• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.220-226
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• 1995

A study on the spalling causes of work roll for cold rolling was performed in the cold rolling mill. Performance of work roll is dependent to a great extent on spalling sothat both roll manufactures and users show great interest in spalling. So this paper shows that spalling origin on the roll surface. As being well known, spalling mostlyoccurred due to developing fatigue fracture originated a crack on a roll. But such spalling can be prevented by proper roll maintenance, The spalling accidents have sharply decreased since 1981 because of the use of ultrasonic test to detect cracks on a roll.

• Journal of the Korean Society for Precision Engineering
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• v.10 no.3
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• pp.69-80
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• 1993

It is important to prevent roll failure in hot rolling process for reducing maintenance coat and production loss. Roll material and rolling conditions such as the roll force and torque have been intensively investigated to overcome the roll failures. In this study, a computer roll life prediction system under working condition is developed and evaluated on IBM-PC level. The system is composed and fatigue estimation models which are stress analysis, crack propagation, wear and fatigue estimation. Roll damage can be predicted by calculating the stress anplification, crack depth propagation and fatigue level in the roll using this computer model. The developed system is applied to a work roll in actual hot rolling process for reliability evaluation. Roll failures can be diagnosed and the propriety of current working condition can be determined through roll life prediction simulation.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.4
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• pp.819-827
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• 1992

Investigations of the fatigue damage of roughing mill roll and experimentally. By the computer simulation for analysing the stresses on the roll surface and experimental hot rolling, the following results were drawn : The crakcs observed on the roll surface were initiated thermally in the initial stage of the rolling and propagated by repeated thermal and bending stresses. The size of the roll surface cracks smaller than 4.87mm could avoid the occurrence of tiny scab, surface defect of hot steel strip. Since the size of surface cracks observed on the roughing mill roll was very small, the fatigue damage of roll surface was found not to be the major factor for the formation of the scab.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.2
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• pp.58-65
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• 1997

Work rolls used in cold rolling mills must have outstanding wear resistance and very little plastic defor- mation. Thus, these rolls require a higher surface hardness and harding to a greater depth. To meet these requirements, the rolls, in general, have basic chemical composition of 0.7 to 1.0% carbon and 1.0 to 5.0% Cr(chromium), plus a small amounts of special elements, and are subjected to intensive water quenching and tempering at low temperature to provide a surface hardness of over 90 shore. This test results are as follows. Deflection and fracture load of 5% Cr material are than those of 3% Cr material and show flat curve from surface to subsurface. It will be clear that 5% Cr work roll has a superior resisti- bility against wear and abrasion comparing with 3% Cr work roll. The improvement of wear and abrasion in 5% Cr work roll will be achieved by the large amount of wpheroidal carbide. In grindability and polish, 5% Cr work roll will be a little inferior comparing with 3% Cr work roll.

• Journal of Mechanical Science and Technology
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• v.18 no.12
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• pp.2174-2181
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• 2004

The metal processing system usually consists of various components such as motors, work rolls, backup rolls, idle rolls, sensors, etc. Even a simple fault in a single component in the system may cause a serious damage on the final product. It is, therefore, necessary to diagnose the faults of the components to detect and prevent a system failure. Especially, the defects in a work roll are critical to the quality of strip. In this study, a new 3-D diagnosis method was developed for roll shape defects in rolling processes. The new method was induced from analyzing the rolling mechanism by using a rolling force model, a tension model, the Hitchcock's equation, and measurement of the strip thickness, etc. Computer simulation shows that the proposed method is very useful in the diagnosis of the 3-D roll shape.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.04a
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• pp.13-16
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• 2009

In order to investigate the effects of geometry factors such as a roil diameter ratio and backup roll crown of the stress concentration factor on the edge of backup roil end, 3-dimensional FEM analyses of stress at the contact of backup roll and work roll assembled in a 4-high strip mill were carried out, It was made clear that the peak stress at the edge is about 2 to 3 times of that at the longitudinal center of the roll barrel and the peak stress proportionally increase with decreasing the ratio of backup roll diameter to work roll diameter Furthermore a crowning on the backup roll is effective to decrease the maximum edge stress.

• Journal of the Korean Society of Safety
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• v.23 no.6
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• pp.7-13
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• 2008

It is important to prevent roll failure in hot rolling process for reducing maintenance cost and production loss. The relationship between rolling pass schedule and the work roll wear profile will be presented. The roll wear pattern is related with roll catastrophic failure. The irregular and deep roll wear pattern should be removed by On-line Roll Grinder(ORG) for roll failure prevention. In this study, a computer roll wear prediction model under real process working condition is developed and evaluated with hot rolling pass schedule. The method of building wear calculation functions for center portion abrasion and marginal abrasion respectively was used to develop a work roll wear prediction mathematical model. The three type rolling schedule are evaluated by wear prediction model. The optimum roll grinding methods is suggested for schedule tree rolling technique.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.261-264
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• 1999

An integrated finite element-based model is presented for the prediction of the three dimensional tran-sient thermo-mechanical behavior of the work roll in hot strip rolling. The model is comprised of basic finite element models which are incorporated into an iterative solution procedure to deal with the inter-dependence between the thermo-mechanical behavior of the strip and that of the work roll which arises from roll-strip contact as well as with the interdependence between the thermal and mechanical behav-ior Demonstrated is the capability of the model to reveal the detailed aspects of the thermo-mechanical behavior and to reflect the effect of various process parameters.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.229-232
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• 2007

In hot strip rolling, the work roll profile is one of the main factors in predicting and correcting the strip profile. Various studies concerning the wear profile and the thermal crown of work roll have been performed, and the results of these studies have shown that the work roll profile must be predicted accurately so as to efficiently control the strip qualities such as thickness, crown, flatness, and camber. Therefore, a precise prediction model of roll profile is called for in a perfect shape control system. In this paper, a genetic algorithm was applied to improve on the roll profile prediction model in hot strip rolling. In this approach, the optimal design problem is formulated on the basis of a numerical model so as to cover the diverse design variables and objective functions. A genetic algorithm was adopted for conducting design iteration for optimization to determine the coefficient of the numerical model for minimization of errors in the result of the calculated value and the measured data. A comparative analysis showed a satisfactory conformity between them..

• Transactions of Materials Processing
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• v.16 no.4 s.94
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• pp.250-253
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• 2007

In hot strip rolling, the work roll profile is one of the main factors in predicting and correcting the strip profile. Various studies concerning the wear profile and the thermal crown of work roll have been performed, and the results of these studies have shown that the work roll profile must be predicted accurately so as to efficiently control the strip qualities such as thickness, crown, flatness, and camber. Therefore, a precise prediction model of roll profile is called for in a perfect shape control system. In this paper, a genetic algorithm was applied to improve on the roll profile prediction model in hot strip rolling. In this approach, the optimal design problem is formulated on the basis of a numerical model so as to cover the diverse design variables and objective functions. A genetic algorithm was adopted for conducting design iteration for optimization to determine the coefficient of the numerical model for minimization of errors in the result of the calculated value and the measured data. A comparative analysis showed a satisfactory conformity between them.