I'm working as a mechanical design intern at a rolling mill and have been asked to design a roll turning device for the finish stands. The purpose of this device is to be able to set the roll gap in the roll shop instead of out in the mill after the rolls have been changed out. The way the roll gap is set, initially, is by taking a 0.25" piece of aluminum wire (round), and in some instances a 0.375" piece of steel wire (round), and running it through the pinch rolls and then measuring the flattened wire. The wire rod is effectively used as plastigage and is run through the pinch rolls on the shoulder at a relatively slow speed. They just jog the stand in order to hand feed this piece of wire through.
I need to calculate the necessary torque to be applied at the rolls in order to successfully crush this material. I know there are standard fomulas for this as this is one of the basic (relative term here) rolling calculations considered when designing or setting up a stand for rolling a given material.
The rolls are turning on what can be considered frictionless bearings since there is very little resistance here and the amount the test wie is crushed is as follows:
0.25" aluminum flattened to 0.025" 90% reduction
0.375" steel flattend to 0.200" ~46.6% reduction
I need formulas including and relating reduction in area, separtion forces, as well as the mechanical properties of the material being crushed. I think. Thats why I'm asking. I'm a student of Mechanical Design/Engineering and do not have textbooks (yet) that cover this topic. Any help on this would be greatly appreciated and please let me know if any of this is unclear or you would like additional info.
Torque Required at Pinch Roll to Flatten Wire Rod
Re: Torque Required at Pinch Roll to Flatten Wire Rod
