Study on Spalling of Hot Strip Mill Backup Roll

Ohkomori, Yoshihiro; Kitagawa, Ikuziro; Shinozuka, Keigo; Miyamoto, Ritsuzo; Yazaki, Seiichi; Inoue, Mutsuhiko

doi:10.2355/tetsutohagane1955.73.6_691

Cited by 11 publications

(8 citation statements)

References 2 publications

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“…In this article, this internal fatigue failure caused by

σ_{normalr}

will be studied as the previous papers only focused on the surface spalling in backup rolls. [ 21–29 ] This surface failure starts from several mm inside from the surface caused by the shear stress under rolling fatigue is very different from the failures in Figure 6 caused by

σ_{normalr}

in Figure 5.…”

Section: Residual Stress Generated In the Bimetallic Work Roll Is Used As An Initial Condition To The Rolling Stress Analysismentioning

confidence: 84%

“…The previous roll failure studies mainly focused on surface failure, so‐called spalling, which is mainly caused by the shearing stress due to the rolling contact fatigue at several mm depth from the roll surface. [ 21–29 ] Compared with the spalling at the roll surface, few studies are available for the HSS/DCI boundary failure in the inner layer of work rolls. Some studies discussed the fatigue crack initiation at the internal layer without discussing the rolling normal stress

σ_{normalr}

causing this boundary failure.…”

Section: Introductionmentioning

confidence: 99%

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Fatigue Failure Analysis for Bimetallic Work Roll in Hot Strip Mills

Aridi

Noda

Sano

et al. 2021

steel research int.

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In hot rolling of steels, bimetallic rolls consisting of high‐speed steel and ductile casting iron are extensively used because of their excellent hardness and wear resistance although the fatigue failure study is not available. To extend the roll life service, herein, a 3D finite element method is applied to investigate the residual stress and the rolling stress of the bimetallic work roll in the four‐high rolling mill. The residual stress is analyzed by considering preheating, quenching, and tempering. Using the results as an initial condition, the rolling stress analysis is carried out consecutively. Then, the fatigue failure risk is discussed focusing on several critical points subjected to the largest stress amplitude inside of the work roll. The accuracy of the simple superposition method is also discussed to evaluate the risk conveniently.

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“…In this article, this internal fatigue failure caused by

σ_{normalr}

σ_{normalr}

in Figure 5.…”

Section: Residual Stress Generated In the Bimetallic Work Roll Is Used As An Initial Condition To The Rolling Stress Analysismentioning

confidence: 84%

σ_{normalr}

causing this boundary failure.…”

Section: Introductionmentioning

confidence: 99%

Fatigue Failure Analysis for Bimetallic Work Roll in Hot Strip Mills

Aridi

Noda

Sano

et al. 2021

steel research int.

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“…Then it is propagated along the path parallel to the surface which will let the crack to propagate along a relatively long path and eventually leading to large chunks peeled off from the surface. The whole process can be described by the sketch shown in Figure 6 [7][8][9].…”

Section: Pit and Spallmentioning

confidence: 99%

Contact Strength of Material

Qin¹

2020

Strength of Materials

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Contact is one of the common positions for relationship existing between surfaces of mechanical components with line or point shape, which lead to different stress condition between them. Classic Hertz theory solved the stress distribution of two components with different contact form. The different stress form of contact components will result in different failure modes, and different strength requirement is needed in design. For those works under conditions like classic Hertz contact, obvious plastic deformation should be avoided and the maximum stress should be smaller than the allowed limit stress which is usually equal to yield stress of material. While for the ones enduring load by extrusion of two contact surface, the crushing of two contact surface should be avoided and the maximum contact stress should be smaller than the ultimate strength of the material. But for those works under varying stresses, fatigue and wear are common failure modes. The typical failure form resulted from contact fatigue is pitting and spalling; the previous one usually results in small peeling of materials from surface and lots of small shallow pits will formed, while the spalling usually leads to lager part of material drop off from the surface and scrap of mechanical components. Wear is another failure form of components works under contact conditions, which is actually can be seen as the accumulation of pitting of asperities. Comparing the classic static strength theory and fatigue strength theory of material, the static contact strength is actually the limit condition of contact fatigue strength with the one circle stress loaded in the whole life. With the development of fatigue theory, lots of models were proposed to study the contact strength of material from the fracture mechanics view. The most popular ones are critical plane method and Dang Van multi-axial fatigue criterion, which are used to assess the crack initiation of materials works under contact load.

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“…Therefore, if a permanent residual roll deflection occurs during the operation, the sleeve constructed rolls cannot be used anymore. In the previous study [6][7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22][23], the residual deflection was investigated experimentally for small rolls. However, the residual deflection was not compared with the deflection due to the standard load and therefore the deflection mechanisms has not been sufficiently clarified.…”

Section: Introductionmentioning

confidence: 99%

Quasi-Equilibrium Stress Zone with Residual Displacement Causing Permanent Slippage in Shrink-Fitted Sleeve Rolls

Noda¹,

Sakai²,

Sano³

et al. 2018

Metals

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Rolling back-up rolls require high fracture toughness, particularly in the shaft portion, and high-hardness in the sleeve portion. The rolls are classified into two types; one is an integrated type and the other is a shrink-fitted type consisting of a sleeve and a shaft. The shrink-fitted roll has several advantages, for example, suitable materials can be chosen and the shaft can be reused by replacing the damaged sleeve. However, during use if the residual permanent deflection occurs, the roll cannot be used anymore. In this paper, an elastic-contact finite element method FEM analysis is performed to explain the residual permanent deflection mechanism. It is found that the quasi-equilibrium stress zone with the residual displacement causes the permanent slippage in the axial direction. In a similar way, the interface creep in the circumferential direction can be also explained from the quasi-equilibrium stress zone with the residual displacement.

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Study on Spalling of Hot Strip Mill Backup Roll

Cited by 11 publications

References 2 publications

Fatigue Failure Analysis for Bimetallic Work Roll in Hot Strip Mills

Fatigue Failure Analysis for Bimetallic Work Roll in Hot Strip Mills

Contact Strength of Material

Quasi-Equilibrium Stress Zone with Residual Displacement Causing Permanent Slippage in Shrink-Fitted Sleeve Rolls

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