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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 05 Issue: 01 | Jan-2018 www.irjet.net p-ISSN: 2395-0072

DESIGN OPTIMIZATION OF WORK ROLL CHOCK AND BACKUP ROLL


CHOCK IN COLD ROLLING MILL
Tukesh Sahu1, Prof. G.R.Kesheory2
1M.Tech Scholar, Department of Mechanical Engineering, VITS Indore, MP, India
2Assistant Professor, Department of Mechanical Engineering, VITS Indore, MP, India
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Abstract - Rolling is defined as a process in which metal is value of the chock instantiated delivery of chocks because of
formed through a pair of revolving rolls with plain or grooved manufacturing presetting failure could stop a production
barrels. The metal changes its shape gradually during the failure at the assembly stage is almost certain to halt
period in which it is in contact with the two rolls. Rolling is a production if only one or two chocks out of a large batch
major and a most widely used mechanical working technique. tailback no manufacturer would willingly assemble goods
A Rolling mill is a complex machine for deforming metal in that are suspecting failure in serviceableness the most
rotary rolls and performing auxiliary operations such as catastrophic consequences example failure of cold rolling
transportation of stock to rolls, disposal after rolling, cutting, mill chock is very likely to result in the complete destruction
cooling, melting. The problem of failure of Rolling mill housing of the cold rolling mill. Failure of chocks in a cold rolling mill
was there in industry, which can be efficiently solved by using is basically because of higher stressed generated during start
CAE. up and shut down condition of rolling mill so for a design of
chocks for a cold rolling mill it is essential to know the
The present work involves the design optimization of work roll maximum load acting on a chock to prevent from a failure
chock and backup Roll chock in cold rolling mill, to control the fatigue failure beachwear of cyclic loading is also a criteria of
failure of choke in the cold rolling mill for retain the material chocks design. Second most important function of to work as
cost and longer life of the roll chock. The roll chock had stress an isolator case of cold Rollin mill also it ha s to perform this
distribution has been analyses by software ANSYS from which function .so design chock hold have a required stiffness to
maximum static stress at critical areas have been calculated. transmit a vibration from a source to receiver.
Structural behavior of Roll chock under the given loading and
boundary conditions using an analytical model are very So while designing a chock for cold rolling mill two factors is
difficult. Therefore 3D solid model was chosen in order to very important Ice. strength of chock to sustain a maximum
predict the stress and strain response detail. load and stiffness of a chock to transmit lesser vibration.

We have made a prototype of chock of optimized design of Over the course of time, finite element models have gained
scale so as to verify our results that have been given by the significant importance, and research has been ongoing to
analysis of work roll chock and backup roll chock on analysis establish supportive results to candor software calculation.
software. Computer models have been develop to provide trimly and
economical simulations for results of a component under
Key Words: Centeral Burst, Cold Rolling, Design extremely Sever loading conditionals simulations can be
Methodologies, Housing, Plastic Deformation, Rolls, Split used to target sensitive parameters that affect the overall
End design, cost and safety.

1.INTRODUCTION 1.1 MODELING OF ROLL CHOCK

Rolling is defined as a process in which metal is formed The Roll Chocks were modeled in 3D Modeling Software
through a pair of revolving rolls with plain or grooved “Solid Works 2009” for better visualization and interference
barrels. The metal changes its shape gradually during the checking. 3D Models are also required for Structural Analysis
period in which it is in contact with the two rolls. Rolling and Optimization; therefore accurate modeling of Roll
is a major and a most widely used mechanical working Chokes is required.
technique. A Rolling mill is a complex machine for deforming
metal in rotary rolls and performing auxiliary operations The Order of the Models is according to their placement;
such as transportation of stock to rolls, disposal after rolling, from top to bottom; in the Rolling Mill:-
cutting, cooling and melting.
1) Top Back Up Roll Chock
Chocks are almost invariably the highest stressed 2) Top Work Roll Chock
component in a manufactured item, and so are most
susceptible to invariable the financial losses incurred as a 3) Bottom Work Roll Chock
result of chock failure will be far greater than the actual 4) Bottom Back Up Roll Chock

© 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 423
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 01 | Jan-2018 www.irjet.net p-ISSN: 2395-0072

Table 1.1 Von Misses Contour Plot for Top Roll Chock

Mode Frequency (Hz.)


1 7.0637
2 8.2337
3 13.896
4 24.336
Fig 1.1 Top Back up Roll Chock 5 27.757
6 28.280
7 29.517
8 30.709
9 40.672
10 43.793

Also, the deformation for various Modes was plotted as


shown in Figure 2.2
Fig.1.2 Top Work Roll Chock
2. STRUCTURAL & MODEL ANALYSIS OF TOP BACK
UP ROLL CHOCK

1) Material
Material Used – Fe 410
a. Young’s Modulus – 200GPa
b. Poisson’s Ratio – 0.3

Fig.1.3 Bottom Work Roll Chock 2) Element


a. Element Used – Solid 10 Node Tetrahedral
(Solid 187)
b. Element Size – The appropriate Element
Size was found out by using an Initial
Element Edge Length to be 50 and then
gradually reducing Element Size until the
Stress remained constant even if the
Element Size reduced. The Table 1.1 clearly
Fig.1.4 Bottom Back up Roll Chock indicates the above

1.2 Model Analysis Table 2.1 Element Size vs. Deformation


Sample Modal Analysis is done to find out the Natural Sr. No. Element Size (mm) Deformation (mm)
Frequency of the Top Roll Choke and to check if the natural
1 50 0.197729
frequency of the machine does not match the natural
2 35 0.198522
frequency of the Top Roll Choke to avoid resonance.
3 30 0.198749
1) Material
Material Used – Fe 410 Therefore, Element Size 30 can be considered to be the ideal
a. Young’s Modulus – 200GPa Element Size for the Following Analysis. Also, the Computer
b. Poisson’s Ratio – 0.3 Available would require additional hardware to solve the
number of equations for Element Size less than 30 is a
2) Element constraint.
a. Element Used – Solid 10 Node Tetrahedral
(Solid 187) 3) Forces
b. Element Size – 30
a. The Forces Acting on the Top Roll Choke is the Force
3) Constraint of the Hydraulic Cylinder transferred through the
a. The bottom surfaces of the Top Roll Choke Bottom Rolls through the material to be rolled and
were constrained as shown in figure 1.1 through the top work roll.

© 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 424
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 01 | Jan-2018 www.irjet.net p-ISSN: 2395-0072

b. The Top Roll Choke is constrained at the top of the


Rolling Mills by an adjustable Power Screw
Mechanism.

c. The Reaction force is considered as the actual force


acting on the choke and the bottom surfaces are
considered to be constrained as shown in the figure
2.1

d. Therefore, the cylinder pressure is converted to force


and applied on the particular area as shown in the
figure 2.1

4) Constraint

a) The bottom surfaces of the Top Roll Choke were


constrained as shown in figure 2.1 Fig. 2.3 Misses Contour Plot for Top Roll Chock

3. OPTIMIZATION OF TOP BACK UP ROLL CHOCK

The Top Roll Choke is optimized to a minimum size with


Stress Constraints, Bearing Size Constraints. The Initial
Stress Contour Plots Obtained in Chapter 2 was observed
and studied. It was found out that parts of the roll choke had
very little stress induced in them and could be removed.

The Following Iterations were carried out on the Roll Choke


and a considerable weight reduction and thus cost savings
was obtained.

Iteration 1:-

Fig. 2.1 Meshing Diagram for Top Roll Chock

Fig. 3.1 3D Model of 1st Iteration of Optimization of Top


Back up Roll Chock

Fig. 2.2 Total Deformation Contour Plot for Top Roll


Chock

Fig. 3.2 Deformation Contour of 1st Iteration of


Optimization of Top Back up Roll Chock

© 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 425
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 01 | Jan-2018 www.irjet.net p-ISSN: 2395-0072

Fig. 3.3 Von Misses Stress Contour of 1st Iteration of Fig. 3.6 Von Misses Stress Contour of 2nd Iteration of
Optimization of Top Back up Roll Chock Optimization of Top Back up Roll Chock

Table 3.1 Comparison of 1st Iteration and Existing Roll Table 3.2 Comparison of 1st Iteration and 2nd Iteration
Chock Roll Chock

Sr. No. Item Old New Sr. No. Item 1st Iteration 2nd Iteration
1 Weight 1816.49 1693.79 1 Weight 1693.79 1633.4
2 Deformation 0.198596 0.204209 2 Deformation 0.204209 0.207976
3 Von Misses Stress 78.444 84.507 3 Von Misses Stress 84.507 84.933

Thus a considerable weight saving is obtained as given


2nd Iteration: - below:-
Weight of Existing Roll Choke – 1816.49 kgs
Weight of Optimized Roll Choke - 1633.4 kgs
Cost Savings – Wt. Reduced x Rs. 50
183.495 x 50
Rs. 9154.5

Modal Analysis of Optimized Roll Choke

The Modes and their frequencies are given in Table 3.3:-

Mode Frequency (Hz.) Deformation (mm.)


Fig. 3.4 3D Model of 2nd Iteration of Optimization of Top 1 7.5964 0.048917
Back up Roll Chock 2 7.6924 0.035799
3 15.710 0.051504
4 22.976 0.05069
5 24.667 0.060074
6 29.020 0.043498
7 29.047 0.071935
8 32.248 0.038319
9 37.795 0.043885
10 43.152 0.077078

4. CONCLUSIONS
Fig. 3.5 Deformation Contour of 1st Iteration of This is the totally new concept introduces by me in the
Optimization of Top Back up Roll Chock company where we r going to save the cost and time by
giving more life to roll chock. By simulation of the actual
chock model on the software it was revealed that the

© 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 426
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 01 | Jan-2018 www.irjet.net p-ISSN: 2395-0072

chock of the machine experienced higher stresses at the


place where the holding of work role and back role occur. In
the company there is failure of chock occurs during the
process of operation so we designed the new chock for
rolling machine by improving the all over safety factor. The
new chocks have good life compare to failure one and from
that chock company daily saving. Design Optimizations of
Critical Component Roll Chocks in Cold Rolling Mill is really
good project where designs of roll chock is totally new part.

REFERENCES

[1] G. P. Steven, “Multicriteria optimization that minimizes


maximum stress and maximizes stiffness”, Computers &
Structures Volume 80, Issues 27-30 , November 2002,
Pages 2433-2448.

[2] J. H. Rong, “An improved method for evolutionary


structural optimization against Buckling” Computers &
Structures, Volume 79, Issue 3, January 2001, Pages 253-
263.

[3] Kurt Maute, ‘an interactive method for the selection of


design criteria and the formulation of optimization
problems in computer aided optimal design”,
Computers Volume 82, Issue 1 , January 2004, Pages 71-
79.

[4] Theodore G. ToRidis, “Computer analysis of rigid frames,


Computers”,Volume 1, Issues 1-2, August 1971, Pages
193-221.

[5] William Prager , “Conditions for structural optimality”,


Computers & Structures’,Volume 2, Issues 5-6, 1972,
Pages 833-840.

[6] Rafael Febres, “Modeling of local buckling in tubular


steel frames subjected to cyclic Loading”, Computers &
Structures, Volume 81, Issues 22-23, September 2003.

[7] A.I. Tseliko and V.V. Smirnov, M.H.T. Alford (1965),


Rolling Mills.

[8] William L.Roberts (1938), “Manufacturing engineering


and materials processing/2”,ColdRolling Of Steel.

[9] A.G.Davenport, “The application of statistical concept to


the wind loading of structure”, proc.Inst.Civil Engg.
London 19(1961)449-472.

[10] Ginzburg Vladimir B.”High-Quality Steel Rolling Theory


and practice [M].Newyork”, USA,Marcel Deker
Inc.(1993).

[11] Guide and Principal, Mechanical Department, VITS


Indore, M.P India.

© 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 427

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