Some trends in roll design for manufacture of long products

Sead Spuzic*1,Dimuthu Hapu Arachchige*2, Zlatko Kovacic**3,

Kazem Abhary*4 and Ramadas Narayanan***5
*University of South Australia, 101 Currie St., Adelaide South Australia 5001
**Open Polytechnic, 3 Cleary St., Waterloo, Lower Hutt 5011, New Zealand
***CQ University, University Drive, Bundaberg QLD 4670, Australia
1
Sead.Spuzic@unisa.edu.au,
2
dimuthu.hapu_arachchige@mymail.unisa.edu.au,3Zlatko.Kovacic@openpolytechnic.ac.n
z., 4Kazem.Abhary@unisa.edu.au,5r.narayanan@cqu.edu.au

Roll design in hot rolling mills is a principal factor that delimits the quality, efficiency and
costs in the relevant fabrication system. The ultimate goal of a roll designer is to ensure
sustainable manufacture of long product with specified morphometric envelope,
microstructure, and mechanical attributes. In this article, diversity of designs used for
products and mills that are both being either similar or identical is addressed along with
concluding that this implies that many of these designs are not optimized sufficiently.
Present data recording, storing, sharing and analysis facilities allow for an
unprecedented outreach in solving roll design tasks. Along with the need to intelligently
structure large industrial databases, there is a prerequisite for overcoming the
communication barriers such as intellectual property and commercial confidentiality. An
outline of roll design strategies is presented with a view to extract logics that permeates
and dominates in this variety.

Key words: Roll design, knowledge discovery in databases

1. INTRODUCTION
Manufacturing by rolling is one of the most widely used industrial methods. The key
aspect in the relevant fabrication system – roll (pass) design (RPD) –is a subject of
continuing research [1-45]. RPD can be defined as a technique that results in producing
the following documentation:

i. Product specification, that is, nominal features and tolerances for morphometry
(geometry and dimensions) and the surface topography, as well as for the
mechanical, chemical, microstructural and other attributes of the product material.
The relevant information is usually available already (by means of international or
national standards), however, sometimes this is a matter for negotiation with the
customers, resulting in the manufacturing norms for the agreed quality.
ii. Specification of the above aspects for a series of transition objects – intermediate
solids, including the initial feed. Manufacturing by rolling includes a number of
discrete stages (sometimes over 50). The initial feed (usually a cuboid) is deformed
gradually, thus undergoing a decrease in cross-sectional area and an increase in the
overall length during each stage (rolling pass). While the chemical composition
does not change, the mechanical, surface and microstructure aspects will be
substantially affected by the specifications of:
- Temperature gradient and its rate within and between each rolling pass;
- Deformation extent, gradient and rate within and between each pass.

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 The relevant information(cross-sectional areas, elongations, rolling speeds, etc.) is
usually summarized in so called „rolling schedules‟ and complemented by means
of technological instructions (documentation).
iii. Deformation zone morphometry for each pass, by means of defining each in the
sequence of roll grooves. This information complements the aspects in the point
(ii), with the „working‟ diameters of the rolls the body of which is cut to create
these grooves. The relevant information is summarized by means of groove
drawings, including the positions of each groove relative to each other.
iv. Tools (rolls) specification, that is, nominal features and tolerances for
morphometry and surface topography, as well as for the mechanical, chemical,
micro structural and other attributes of the tool material. This information includes
the location of each roll in rolling mill, as well as the maximum and the minimum
roll diameters, bearing in mind that each roll is redressed several times during its
life to re-generate the initial groove morphometry. This is usually done after
several rolling campaigns. Additional information includes the method of roll
cooling, and in some cases, lubrication.
v. Complementary documentation, describing the feed preparation and heating
techniques, as well as the finishing operations, after the rolling process itself is
accomplished (such as the product cooling, straightening and cutting to the
delivery lengths). This documentation includes information about the auxiliary
equipment such as rolling tackle (guides and guards) which are necessary for
guiding the rolled solid into each deformation zone.

As mentioned above, (i) is straightforward, and the RPD engineers do not have much, if
any, maneuvering space in deciding the cutting lengths either. The scope of this article is
limited to the stages (ii) to (iv).

The diversity of combinations used across the industries worldwide to define aspects in
(ii), (iii) and (iv) is mind provoking. It is understandable that differing rolling mills use
different RPD systems for manufacturing similar products. This is consequence of
differences in mill layouts, stand configurations and other technical aspects. However, too
often the quite similar mills use radically different RPD systems to manufacture identical
products. It is therefore advisable to compare the performances. Indeed this can be done
on the broad scale [1-3, 7, 9, 27, 28, 30, 33].

Global hindrances, such as the roll propensity to develop large cracks and fractures, as
well as the major corrosion or adhesion, are eliminated by appropriate selection of roll
materials, and operation regimes. The more disguised problem then comes to the surface,
namely hot abrasion combined with its “accomplices”: stress corrosion on the fine scale,
micro-fatigue and micro-adhesion[29]. Therefore, in realization of an RPD project,
designers must have in mind these continuous and progressive changes in the groove
dimensions and geometry, i.e. in the deformation zone morphometry.

Present data recording and analysing facilities allow for extracting relevant knowledge
from industrial records. For this there is a need to intelligently structure large industrial
databases. This can be done by reviewing the variety of approaches that have been
employed in RPD projects worldwide. An outline of roll design strategies is presented
with a view to facilitate extracting the logics that permeates this variety. This overview is

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limited to examples of RPD systems used for manufacturing highly symmetrical rolled
products - so called “rounds”.

2. RPD TRENDS
2.1. Rolling loads

These calculations are made to ensure that the loads are within the safe ranges with regard
to the strength of the rolls and the power of the motors. There is a quite broad range of
models available, and the majority of the modern mills have installed computerized data
acquisition systems connected to the load cells and to the motor drive. Therefore, the
prediction and the control of loads has become a routine exercise, as long as the selected
model is being calibrated (adjusted to measurements) to achieve a reasonable (statistically
defined) fit to rolling of the existing stock.

The following is practical overview of some popular models for load calculations:

1. According to Oduguwa and Roy [17], Ekelund‟s formula[1, 7, 28, 31] is popular
because it contained the essential rolling variables and was considered to be easy
to use. However, this formula is restricted to rolling rectangular cross-sections.
2. Orowan[18]developed a more theoretical approach by considering the coefficient
of friction along the arc of contact and taking into account the inhomogeneity of
stress distribution. Since this theoretical method was quite complicated Orowan
and Pascoe developed an approximate method for calculating roll force[19].
3. Sims [26]derived equations for normal roll pressure, specific roll load and torque
using equations derived by Orowan in combination with von Kármán's equation of
equilibrium.
4. Geleji defined practical calculations [1, 7, 8] which result in predicting analogous
effect of thickness reduction, however, with giving lower quantitative values
compared to the above models.
5. Celikov-Korolev model[1, 7, 8]is based on assumption that sliding, and hence
friction, takes place along the whole deformation zone.
6. Hill‟s[1, 7, 8] model provides calculations for the average specific pressure in the
deformation zone.

All of these models use the concept of the coefficient of friction. Although rolling would
not be possible without friction, the concept of friction coefficient is disputable.
Regardless of the model used, some uncertainties and unknowns will always remain.
Numerous authors [1, 4, 7, 8, 18, 19, 26, 31] have shown that friction depends on
temperature, contacting materials, and sliding velocity – all of which can be measured.
Friction coefficient further depends on the pressure and the characteristics of oxide layers.
The latter are subject to abrupt changes (due to the interaction with roll cooling water),
and the former is supposed to be calculated (which implies circularity). In response to
these difficulties, a number of authors prefer using a frictional shear factor(instead of
friction coefficient) in order to account for shear in the surface layers. In practical RPD
analysis, priority should be given to the entries that can be measured and controlled in
actual processes, and these values should be incorporated in the load models [4, 28, 29].

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2.2. Drawbacks of classical analytical theories

The classical rolling theories were able to predict the plastic deformation system
parameters to a certain extent of accuracy.However, in the real life these theories were too
complicated to be used for solving practical RPD tasks. Furthermore, classical roll theories
aremostly based on flat rolling, whereas the actual rolling process is governed by much
broader range of factors including metallurgical and thermo-mechanical aspects. Due to
the limited number of design variables the results tend to be too unrealistic.

2.3. Empirical RPD without use of advanced modeling and data analysis methods

These “manual” methods are still used frequently in RPD in the industrial practice. The
designer starts new RPD by viewing the closest existing case and changes the variables
one at a time taking into account the empirical (usually individual) knowledge. Further
experimental studies [6, 22-25]have developed enhanced empirical formulas in calculating
RPD parameters thus improving the design guidelines. These applications are successful
after several repetitions but become too costly when new task differs significantly.
Furthermore, this approach varies from designer to designer. In summary, this approach,
which relies mainly on trial and error,is not sustainable any more. In order to overcome
the deficiencies in this “manual” approach, Appleton and Summad[5] introduced a matrix
based method that allows to a team of designers to cooperate in making decisions in
solving RPD problem. This method makes the RPD process more structured. The recent
spread of CAD tools has inspired more designers to incorporate more advanced analysis
such as finite element modeling (FEM) in some RPD context [16].

2.4. Classical algorithmic optimization

Classical algorithmic optimization approaches present improvement when compared to the

“manual” methods. In this approach the values of all design variables are changed at the
same time to achieve a set of objectives while satisfying a set of constraints. Yamada [32]
developed a method to optimize the load distribution among the stands with an optimal
correction algorithm that incorporate mathematical models of temperature and
deformation resistance. Lapovok[15] developed a geometrical tool-form optimization
method for roll pass design. According toOduguwa and Roy[17] these approaches require
the in-depth knowledge of the search space and presume that the involved
mathematicalfunctions are twice differentiable.Still, the complexity of practical RPD
problems in most cases forestalls application of these methods of optimisation.

2.5. Finite element method in RPD

The finite element analysis (FEA) is applied to RPD optimization in various combinations
with other RPD methods. A number of authors[11, 12, 20, 21] predicted successfully the
actual deformation based on rigid-viscoplasticFEA formulation. This approach was
extended tohandling arbitrary roll profiles,including the assumptions of constant shear
friction, as well as the variable sticking and frictionless roll-billet interface. The roll
profile was described as a combination of straight lines and arcs. The simulated results
were validated against the actual data. The possibility of using 3-D FEM code to avoid
forming defects, and to reduce the process development efforts, was explored by
predicting strain distributions and sheet geometry during and after the process. This study

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concluded that dynamic explicit FEM code can be used to simulate the roll forming
process with certain approximations[11].

A coupled thermo-elastoviscoplastic strip deformation and thermo-elastic roll deformation

is modeled by 3-D FEM in [10] for the purpose of predicting profile defects, strain and
stress maps, including residual stresses, in a hot or cold rolled strip. Komori [13] proposed
a simulation model for shape rolling where the deformation of material was analyzed by 3-
D rigid-plastic FEM, including the temperature distribution in the material calculated
using a combination of 3-D FEM and one-dimensional finite-difference method (FDM).
Komori and Koumura in [14] proposed a method for analyzing deformation and
temperatures during H-shape rolling by using conventional 3-D rigid/plastic FEM, while
the temperature was analyzed by combining 3-D, 2-D FEM, and the one-dimensional
FDM. The resulting shape and the surface temperature of the material are found to agree
well with measured values.

Pataro[34]combined the rigid-plastic FEM and the slab method within so called complex
element method capable of analyzing various rolling processes and calculating strain,
stress and contact pressure distributions, rolling load, rolling torque and dimensions of
rolled product. In this method, non-uniform distributions of velocity of transversal cross
sections of the rolled material weretaken into consideration. In [35] a new simplified 3-D
numerical method called finite and slab element method (FSEM) was developed by
combining the slab method and 2-D rigid-plastic FEM used for the generalisedplane-strain
condition. Further, FSEM has been used to develop a computer program called TASKS
which can be used for 3-D analysis of shape-rolling. The square-to-round single pass
rolling TASK simulation confirmed largely improved computational economy[36].

Further improvements in the computational efficiency are achieved by employing an

iterative procedure for updating the billet mesh geometry using sectional sweeping
technique based on the streamline tracing and 3-Dcontact algorithm[37, 38].

The problem with this class of modeling is in that the kinetics of the groove meridians,i.e.
the gradual change of the groove shape during the rolling campaigns due to roll wear, is
not taken in account.However, thesignificance for computationally validating RPD
(previously defined using some other method) is commendable.

2.6. Modern RPD strategies utilizing the information processors

Fuzzy logic was used to determine the sequences of passes for the strip rolling process by
defining the rolling load, accumulated deformation and aimed deformation in linguistic
terms[39].Shivpuri and Kini[40] presented a method for RPD optimization by integrating
empirical knowledge, FEM simulations and fuzzy analysis;authors claim that the fuzzy
incorporated results showed greater improvement overusing empirical rules only.

Expert systems and CAD enable automation for most of the routine and repetitive tasks in
RPD. CAD programs were devolved based on a modular upper-bound analysis to predict
the lateral spread and elongation, as well as the slab method to predict the stresses, roll
separating force, roll torque and the metal flow. The computer predictions were applied to
square passes using a point-by-point direct search method where the parameter values of
stock shape were found by iterative calculations using empirical formulae[41, 42].

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A knowledge-based expert system is proposed for RPD for the section products
usingC++,an object oriented programming technique. A backward chaining algorithm is
developed to determine the manufacturing sequences in reverse order based on design
rules extracted from literature. The rolling sequences determined using this method are
proven to be reasonable compared to those available in RPD practice.Hybrid system for
automatic generation of RPD solutions integrates knowledge based expert system, CAD
and FEM techniques[43, 44].

Intelligent RPD methods allow for automaticminimizing the number of roll passes by
employing artificial intelligence techniques in expert systems and hybrid modeling.
According to the authors the method had permitted automation for geometrical
optimization of roll passes[45].

2.7. Some critical aspectsin contemporary trends

The enormous scale of industry employing rolling technology implies that an immense
volume of RPD records is generated. Figure 1 illustrates the RPD variety for rolling
“round” steel products.

Fig 1: Different sequences for rolling round products [1]

The specialist RPD handbooks summarize empirical experience in the form of guidance
such as illustrated in Fig 2.

a)
b)

Fig 2: Empirically collected guidance for the finishing pass elongation (a) and major
dimensions for the penultimate oval pass (b)

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However, the contemporary information processors allow for analysingthis treasure of
RPD records more propitiously providing that this database is structured intelligently. For
this, the RPD data need to be modeled using appropriate mathematical forms to allow for
extracting useful RPD knowledge which can be incorporated in hybrid models within real
time.In other words, the multitude of the industrially practiced RPD variants, developed
over the years of trials and corrections, obeys to the logical patterns that become visible
when the irrelevant differences are filtered out. Initial steps in this direction are reported
with an increasing frequency[2, 3, 28-30, 33, 43-45].

Figure 3 illustrates approach developed by Abhary et al [2, 3, 30, 33]:

Translation of roll pass data into

START vector with suitable count of
components Regression analysis identifying
Collection of roll pass data from
the groove meridian boundaries
published sources and plant
Minimising the component count
databases
by means of fuzzy logic

Reverse translation of vectors

Full scale operations: roll into pass technical drawings
Semi-industrial trials Process
maintenance monitoring based
control
on supply chain methodology Validation of the design
extremes using lead rolling

Fig 3: Algorithm for RPD based on knowledge extraction

An example of a scheme for intelligent translation of roll grooves for embracing the RPD
aspects shown in Figures 1 to3 is presented in Fig 4.

Fig 4: A scheme for encoding generic RPD information for rolling round products

3. CONCLUSIONS
An increasing volume of data collected during the industrial rolling can be analysed using
scientific methods within the real time due to the advances in computerised information

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processing. These records describing a spectrum of rolling passes present an information
rich sample space.

This information can be translated in knowledge by intelligent structuring RPD database.

A key aspect in this process is introducing a generic analytical function such that changing
its parameters results in reproducing the broadest possible range of groove meridians in
the Cartesian coordinate system.

The discussed spectrum of RPD approaches that have become available today releases the
creative energy of engineers engaged in solving RPD tasks, which in turn enables
improvements in

i. Yield
ii. Productivity
iii. Sustainability
iv. Reliability.

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