Damage resistance and roughness retention of work rolls in cold rolling mills

Bolt, P. H.; Batazzi, D.; Belfiore, Nicola Pio; Gaspard, C.; Goiset, L.; Laugier, Maxime; Lemaire, Olivier O.; Matthews, D.T.A.; Mul, S.; Nylen, Tommy; Reuver, K.M.; Stocchi, D.; Stork, F.J.B.; Tensen, J.; Tornicelli, M.; Valle, R.; Elzen, Eva van den; Vergne, Catherine; Williams, Inger M.

doi:10.1051/metal/2010026

Cited by 11 publications

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“…Therefore, in our basis realization of the hardened case, significant decrease in the endurance limit of the material is expected at depths 10-20 mm, where the maximum tensile stresses have magnitudes of 0.8-1 GPa; hence, a higher probability of spalling is expected at these depths. It is interesting to note, that in engineering practice local spalling and delamination in cold rolling mill rolls are often observed at the depth of 10-20 mm [1,[4][5][6].…”

Section: Discussionmentioning

confidence: 99%

“…The situation changes significantly when in some areas of the contact region the operating stress exceeds the local elastic limit and the material transfers into the elastic-plastic state. This not rarely happens in practice due to accidental overloads [4][5][6]. A very common issue in the steel industry is when the rolled strip folds ("pinches") in the roll bite due to strip breakage or non-uniform deformation of the strip across its width (see e.g.…”

Section: Introductionmentioning

confidence: 99%

“…A very common issue in the steel industry is when the rolled strip folds ("pinches") in the roll bite due to strip breakage or non-uniform deformation of the strip across its width (see e.g. [5][6]), which can occur for several technological reasons [7][8][9]. Figure 1 schematically shows the distribution of the yield strength along the depth of hardened zone (curve 1) and the values of the effective stress on the symmetry axis of the loading area (curve 2), corresponding to regular working conditions.…”

Section: Introductionmentioning

confidence: 99%

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Effects of local overloads on cold rolling mill work rolls

Vinogradov

Knyazhansky

Tsun

2017

International Journal of Mechanical Sciences

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Newcastle University ePrints -eprint.ncl.ac.uk Vinogradov V, Knyazhansky M, Tsun A. Effects of local overloads on cold rolling mill work rolls. AbstractLocal overloading is one of the most common reasons for premature failures of cold rolling mill work rolls. Case-hardened rolls demonstrate spatial variation of the material hardness and yield strength with a decreasing profile with depth and belong to the class of so-called plastically graded materials. Contact overloads cause formation of subsurface closed-shape plastic zones, accompanied by a significant perturbation in the stress field. In the present paper the effect of an overload on a case-hardened roll is numerically modelled using finite element, when the parameters of the contact loads are chosen to represent a common situation when an accidentally formed strip fold enters the roll bite. It is shown that plastic deformations in the graded layer originate at depths, which significantly exceed the depth of the maximum effective stresses, determined by the elastic solution. During the contact overload, tensile stresses develop at the upper boundary between the elastic and plastic zones. Tensile stresses at the free surface in the vicinity of the contact zone increase up to ten times due to formation of the subsurface plastic zone. Residual stresses with a very large tensile hydrostatic component are shown to appear in the unloaded material. These tensile stresses, both operational and residual, can cause premature spalling in the contact surface during either the overloading or further operation of the roll. It is shown that an increase in the depth of the hardened case and increase in the roll core hardness allows to reduce plastic deformations during overloads, reduce both operational and residual stresses in the graded layer and shift formation of the plastic zone deeper from the surface and the contact zone, which decreases the chances of premature spalling.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effects of local overloads on cold rolling mill work rolls

Vinogradov

Knyazhansky

Tsun

2017

International Journal of Mechanical Sciences

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“…Then, FL is used to follow the effect of roll roughness loss in avoiding the critical domain. The possible impact on roll campaign length is a more difficult subject when dealing with wear [15,16]. There are two main ways to increase the roll campaign length.…”

Section: Potential Industrial Impact Of Flmentioning

confidence: 99%

Flexible lubrication concept. The future of cold rolling lubrication

Laugier

Tornicelli

Leligois

et al. 2011

Proceedings of the Institution of Mechanical Engineers, Part J:

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For cold rolling systems, in particular for tandem mills that are the major form of the process, conventional lubrication processes appear to have reached their limits. This paper proposes a new advanced lubrication concept called flexible lubrication which adjusts the friction levels at the three process time scales: the rolling campaign, the local scale (coil to coil), and the transient stages within two coils. The proposed approach is expected to increase roll campaign length, energy saving, mill capacity, and flexibility of production programming while at the same time avoiding the detrimental effects created by uncontrolled friction variations such as sudden increases in rolling force and chattering. Showing the conventional lubrication limits through a deep production analysis, this paper is then concerned with the study of the flexible lubrication concept at the laboratory scale and finally, initial results obtained in the first industrial application of this procedure are also reported.

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“…Both experimental and theoretical works have been dedicated to a huge amount of applications. In order to name a few of them, and only those which the authors have been involved into, it is worth noticing how the variety of the applications has been extended to very different fields, such as special transmissions (Belfiore and De Stefani, 2003; Belfiore et al, 2006a), gears (Belfiore, 2004; Belfiore et al, 2006b), metal forming (Belfiore et al, 2007), cold rolling (Bolt et al, 2010), and microsystems (Belfiore et al, 2014). However, more recently, the applications where an electric current is induced to flow through a pair of tribo-elements have received a certain attention in literature.…”

Section: Introductionmentioning

confidence: 99%

An accelerated test stand to assess wear in offshore wind turbines rolling bearings

et al. 2018

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Rolling bearings are universally adopted to serve as revolute joints in almost all mechanisms or machines, because they offer a convenient solution to the problem of minimizing friction and, simultaneously, providing a large load-carrying capacity at any kinematic regime, including slow or alternate rotations. However, in offshore wind turbines not only they reach large dimensions but also they move within strong electromagnetic fields created by the turbine generators. For example, considering the last amplification stadium epicyclic gearbox, they may serve to sustain elements rotating around floating shafts (planetary) which also move around a fixed principal shaft (solar). This article illustrates an original experimental test bench that simulates sliding and rolling contacts through which a test current is flowing. Unexpected and interesting results disclose how this particular field is challenging and how more investigations are still required to achieve an adequate and complete interpretation. The understanding of this phenomenon could give rise to modification to the composition and the microstructure of rollers and rings employed in offshore wind turbines.

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Damage resistance and roughness retention of work rolls in cold rolling mills

Cited by 11 publications

References 0 publications

Effects of local overloads on cold rolling mill work rolls

Effects of local overloads on cold rolling mill work rolls

Flexible lubrication concept. The future of cold rolling lubrication

An accelerated test stand to assess wear in offshore wind turbines rolling bearings

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