Department of Materials and Metallurgical Engineering

Bangladesh University of Engineering and Technology, Dhaka

MME458 Metal Forming Sessional

Roll Pass design for hot flat rolling of plain

carbon steel

Submitted to

Dr. Mamun Al Rashed

Assistant Professor

Department of Materials and Metallurgical Engineering

Bangladesh University of Engineering and Technology
Dhaka-1000, Bangladesh

By

Md. Tariqul Islam

STUDENT ID: 1111030
LEVEL: 4 TERM : 2
DEP: MME
Abstract
Flat rolling basically involves pushing a metal work piece into the gap between two rotating rolls
which then simultaneously draw the work piece into the rolls and compress it to reduce the
thickness and increase the length. The primal target of the experiment is to make a roll pass
design for hot flat rolling. Roll pass design methods includes determining the dimensions, shape,
number and type of arrangement of rolling mill passes. Necessary calculations are done to
determine rolling load, torque and power by using the data. This experiment also acquaints us
with different types of roll passes like diamond pass, box pass, round pass, oval pass by using
neat sketches and solidworks drawing software.

1. Introduction
Metal forming is the backbone of modern manufacturing industry besides being a major
industry in itself. Throughout the world hundreds of million tons of metals go through metal
forming processes every year. As much as 15–20% of GDP of industrialized nations comes from
metal forming industry.

1.1. Roll pass design

It is a set of methods for determining the dimensions, shape, number and type of arrangement of rolling
mill passes. It also includes the calculation of pressing forces and their distribution on the roll passes. Roll
pass design is based on the characteristics of initial input (weight of billet/bloom, steel grade, and steel
temperature before and during course of rolling), characteristics of of finished rolled product (dimension
of section, tolerances and specification concerning to mechanical properties and surface finish of rolled
product), and characteristics of rolling mill (number of stand, roll diameter, strength of rolls, rolling speed,
available power of the drive motor and available mill equipment). Other factors which are of important
considerations for good roll pass design are rolling load, draft, strain and rate of heat transfer which do
affect the condition of plastic flow of steel in the roll gap. Flat rolling of plates and sheets is essentially a
plain-strain compression.
1.2. Roll Pass design for steel
The cross sectional area is reduced in each pass and the form and size of the stock gradually
approach the desired profile. Here the thickness of the metal being rolled is reduced in each pass
by decreasing the distance between the rolls. The subsequent passes in rolling section steel are
called roughing passes. In addition to reducing the cross section, these passes change the form so
that it gradually approaches the final profile required. The starting point in roll pass design is to
draw up the pass schedule which indicates the forms of the passes required to obtain the given
profile. At the same time, the number of passes is established, as are the draught for each pass, the
sequence and number of turns, distribution of the passes among the mill stands etc.

1.3. Objective of roll pass design

The primary objective of the roll pass design is to ensure production of a product of correct profile within
the tolerance limits, free of defects, with good surface quality and the required mechanical properties. In
addition, economic condition must be achieved while rolling the product, for example, maximum
productivity at the lowest cost, optimum energy utilization, easy working conditions for the rolling crew
and minimum roll wear. The roll passes are designed to avoid excessive stresses in the steel being rolled
since such stresses can lead to the formation of cracks and other flaws.

2. Data collection
Size of rolls: Roller dia = 25.2 cm

Length = 29.4 cm

Maximum and minimum draft:

Maximum draft: 40 mm

Minimum draft : 0.1 mm

Roll Speed: 400mm/s

Motor capacity : Motor rpm : 50 Hz

Power : 30 KW

Speed : 980

Roller rpm : 77 rev/min

2.1. Roll Pass sketches:

2.2. Questions and answers

a. What are the differences between sheet and strip?

Ans. Strip has thickness less than or equal to 4.76 mm and width less than 24 inches. Sheet has thickness
less than or equal to 4.76 mm and width more than 24 inches.

b. Differentiate among ingot, bloom, billet and pencil ingot.

Ans. Ingot is a mass of metal cast in a convenient form for shaping, remelting or refining. There are no
specific standard dimensions for ingot. Blooms and billets are smaller in size. Billets have a cross section
of 150 mm X 150 mm and that of blooms are greater than 150 mm X 150 mm. Pencil ingots are small
ingots in kilograms produced in mini steel plants.

c. Determine the location of neutral point for flat rolling.

Ans. Neutral point is the point along the contact length where velocity of the strip equals velocity of the
roll. µ = tan α →α = tan-1(µ ) = tan-1 . = . ⁰. The neutral point is located at . ⁰ angle.

d. Calculate roll load for flat rolling.

Ans. Roll load, L = average flow stress (Yf) x initial width x contact length (L)
= 200 x 0.6 x 8.69 = 1.04 MN
e. Calculate power required for this schedule.
Ans. Power, P = 2� rev/sec x roll load x contact length L x λ

= *π*√ Rʹ*Δh * λ *P*n and Rʹ/R = + C*P / W* Δh

= 2� x 1.3 x 1.04 x 0.5 x8.69 x 10 3 = 37 kW
f. Calculate torque for this schedule.

Ans. Torque, T = 0.5 x roll load x L = 0.5 x 1.04 x 10^6 x 8.69 x 10-3 = 4518 N-m

Roll Pass Design:

For ASTM A615:2004 75 grade steel bar size 7, the information that are available are given below:

Elongation, λ = . %

Initial Square Cross section = 100*100 mm^2

Yield strength = 85789 psi

Tensile strength = 117100 psi

Nominal Dia of final deformed rebar = 22.225 mm

Nominal area of final deformed rebar = 388 mm^2

Now, as volume remains same before and after rolling, λ* * = 1

Where,

λ = co-efficient of elongation = exit length/entry length = 112.4/100 = 1.124 (for 12.8 % elongation)

= co-efficient of spread = 1 (assuming negligible change in width)

= co-efficient of reduction = / λ* ) = 1/ (1*1.124) = 0.887

It means, if the entry thickness is 100, the thickness after exit is 88.7. So 11.3 % reduction occurs.

Change in Roughing Pass:

For 5 roughing passes and 11.1 % reduction in each pass, the area after each pass is calculated below –

Initial area = 100 *100 mm^2 = 10000 mm^2

After first pass = 10000 – 10000*0.113 = 8890 mm^2

After second pass = 7903 mm^2

After third pass = 7025 mm^2

After 4th pass = 6245 mm^2

After 5th pass = 5551 mm^2

Change in Intermediate pass:

Assuming 7 intermediate passes and 11.1% reduction in each pass, the area after each pass if calculated
below –

Before first pass, area = 5551 mm^2

After first pass, area = 5551-5551*0.111 = 4934 mm^2

After 2nd pass = 4386 mm^2

After 3rd pass = 3899 mm^2

After 4th pass = 3466 mm^2

After 5th pass = 3081 mm^2

After 6th pass = 22739 mm^2

After 7th pass = 2434 mm^2

Change in Finishing Pass:

Assuming the billet is slit into 4 bars before entering finishing passes. Assuming 7 finishing passes, the
area after each pass is calculated below –

Area before first pass = 2434/4 = 609 mm^2

After first pass, area = 566 mm^2 (taking 7% reduction)

After second pass, area = 477 mm^2 (taking 7% reduction)

After 3rd pass = 448 mm^2 (taking 6% reduction)

After 4th pass = 421 mm^2 (taking 6% reduction)

After 5th pass = 400 mm^2 (taking 5% reduction)

After 6th pass = 390 mm^2 (taking 2.5% reduction)

After 7th pass = 386 mm^2 (taking 1% reduction)

So, final dimension of ribbed rebar = 386 mm^2 and final dia = 22.16 mm
3. Conclusion:
Roll pass design not only aims to improve the size, shape and mechanical properties of the rolled products
but also it seeks to optimize the roll pass process itself. Although roll pass design for section rolling is
usually based on the empirical knowledge of human experts, most of the empirical formulae only give
good results within a limited range of applications. Section rolling has always represented the most
complicated rolling process for optimization. A good roll pass design must ensure a profile with a smooth
surface and correct dimensions within the limits specified in the concerned standard .It must ensure
minimum specific consumption of energy, power and roll and give deformation to the rolling stock in such
a way and at stages so as to have minimum internal stresses in the finished product. It also should optimize
the number of passes required for rolling to reduce the total rolling time cycle, with minimum time spent
for changing and adjustment of rolls.