Abstract:It is important to monitor the roll bite interface during metal rolling to maintain the product size and homogeneity so as to minimize the material wastage. However, the harsh nature of cold rolling makes installation of sensors in metal roll for industrial applications difficult. The present study used a novel ultrasonic measurement technique whereby an ultrasonic signal went through an external sensor layout arrangement to study the metal-roll interface. The reflection coefficient obtained from the roll-stri… Show more
“…Figure 14 shows the variation between the oil-film thicknesses obtained using the theoretical approach as explained in Adeyemi's report [27] and the experimental value of the oil-film thickness obtained in this research. Figure 14 Experimental and theoretical oil-film thickness obtained at different rolling loads.…”
Section: Resultsmentioning
confidence: 85%
“…Adeyemi et al [16,17] utilised a pitch-catch ultrasonic technique to investigate conditions in the metal-roll interface during metal rolling. Normal and oblique ultrasonic reflections from externally mounted piezoelectric sensors on the modified metal roll were used to model and experimentally study the effect of angle of incidence wave on the reflection coefficient at metal-roll interface during metal rolling operation [16]. They further explored the oblique ultrasonic reflections to estimate rolled strip thickness and roll-bite length in metal rolling [17].…”
Lubrication is essential in metal cold rolling operation to regulate friction at the metal-roll interface, reduce energy loss and improve the product surface finish. A novel non-intrusive pitch-catch technique, based on the reflection of ultrasound, was employed on a pilot mill to evaluate oil-film thickness at the metal-roll interface during the metal cold rolling operation. During the metal rolling process, oil-film thickness was measured under varying rolling load and rolling speed. The oil-film thickness increases as the roll speed increases and reduces as the rolling load increases. The values of oil-film thickness obtained from this non-intrusive ultrasonic technique agree with theoretical values. This study is a proof of concept and has shown promising results. If further developed, the technique could be employed for in situ monitoring of lubricant during rolling operation in metal rolling industries.
“…Figure 14 shows the variation between the oil-film thicknesses obtained using the theoretical approach as explained in Adeyemi's report [27] and the experimental value of the oil-film thickness obtained in this research. Figure 14 Experimental and theoretical oil-film thickness obtained at different rolling loads.…”
Section: Resultsmentioning
confidence: 85%
“…Adeyemi et al [16,17] utilised a pitch-catch ultrasonic technique to investigate conditions in the metal-roll interface during metal rolling. Normal and oblique ultrasonic reflections from externally mounted piezoelectric sensors on the modified metal roll were used to model and experimentally study the effect of angle of incidence wave on the reflection coefficient at metal-roll interface during metal rolling operation [16]. They further explored the oblique ultrasonic reflections to estimate rolled strip thickness and roll-bite length in metal rolling [17].…”
Lubrication is essential in metal cold rolling operation to regulate friction at the metal-roll interface, reduce energy loss and improve the product surface finish. A novel non-intrusive pitch-catch technique, based on the reflection of ultrasound, was employed on a pilot mill to evaluate oil-film thickness at the metal-roll interface during the metal cold rolling operation. During the metal rolling process, oil-film thickness was measured under varying rolling load and rolling speed. The oil-film thickness increases as the roll speed increases and reduces as the rolling load increases. The values of oil-film thickness obtained from this non-intrusive ultrasonic technique agree with theoretical values. This study is a proof of concept and has shown promising results. If further developed, the technique could be employed for in situ monitoring of lubricant during rolling operation in metal rolling industries.
“…Since then, it has been used for measuring lubricant film thickness [3][4][5], lubricant viscosity [6], thermoelastic compliance [7], contact forces [8], friction [9,10], contact dimensions [11], contact surface roughness [2], among other relevant information about tribological contacts. In addition to a number of works under laboratory conditions, this technique has been adapted to a range of real applications, varying from typical engineering applications such as the piston/liner system in engines [3,7,12,13], sliding bearings [14][15][16][17], roller bearings [18,19], and metal-forming applications [11,20], to a much broader realm of applications, such as measuring the thickness of leaves in tree canopies [21].…”
The principle of reflection of ultrasonic waves at lubricated interfaces has been widely studied in recent years using different models. In this work, two different models (the spring model and the resonance model) were used to verify the influence of the acoustic properties of four different lubricating oils. A simple three-layer configuration was used, where carefully prepared, well-controlled gaps between stainless steel plates were established to accommodate a drop of oil. Optical measurements showed that the gaps formed were: gap 1 = 11 µm, gap 2 = 85 µm, gap 3 = 100 µm, and gap 4 = 170 µm. The smaller gap (11 µm) was found to be in the limit measurement range using the spring model for the sensor used in this work (14 MHz), whereas the resonance method was used for the thicker gaps. For the resonance model, the use of the phase spectra helped the identification of the resonance frequencies. The results showed good agreement between the measured thicknesses and the nominal gap values. There was little effect of the acoustic properties of the oils on the measured values, with the largest discrepancies found for the oil with the highest speed of sound (PAO4). This new way to characterize oil properties in a thin gap, where the material and geometry of the contact are fully characterized, enables us to compare different measurement methods and understand their sensitivity when testing similar materials of the same class of lubricants, as small deviations are crucial in real-life applications.
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