Metal Forming

Analytical Modeling of Thermo-Mechanically Induced Residual Stresses of Work Rolls

During Hot Rolling
1) 1) 2) 3) 3)
Matthias Dünckelmeyer , Christian Krempaszky , Ewald Werner , Gerald Hein , Karl Schörkhuber

1)
Christian-Doppler-Laboratory of Material Mechanics of High Performance Alloys, Technische Universität München, Munich / Germany,
duenckelmeyer@wkm.mw.tum.de; 2) Institute for Materials Science and Mechanics of Materials, Technische Universität München, Munich /
Germany; 3) voestalpine Stahl GmbH, Linz / Austria

An analytical model is set up to predict the surface-near thermo-mechanical stresses in work rolls during hot rolling. The quantification of
the temperature distribution and the residual stresses in circumferential direction allow for an optimization of the rolling process in order to
reduce banding. Besides influences of mechanical loading, banding is primarily caused by high temperature differences between the roll's
surface and colder layers underneath the surface. Since a steady-state is not reached in the relevant time domain the model accounts for
the instationary case. Calculated thermally induced residual stresses are related to the mechanical properties of the roll's material. Analyti-
cally calculated temperature distributions on the roll surface are predicted by the model and compared with experimental results. The
influence of the rolling speed and strip temperature are discussed with respect to plastic strains in circumferential direction of the roll.

Keywords: Residual Stress, Banding, Hot rolling, Analytical model, Constitutive law

Introduction since several authors report on significant computational

The performance of work rolls for hot rolling depends on
several degradation phenomena, like mechanical fatigue,
wear, thermal fatigue, and oxidation. Therefore much ef-
fort had been undertaken in order to describe and classify
thermo-mechanically induced roll damage like banding [1].
DEBARBADILLO et al. [2] define banding as the surface dete-
rioration of early finishing stand work rolls brought about
by the tearing out of very small pieces of roll material.
WALMAG et al. [3] described that in a common rolling mill
0.6 % of coils are rejected due to rolled-in work roll scale.
ERICKSON et al. [4] summarized that the thermo-mechanical
fatigue of the roll surface due to temperature cycling and
the resulting mechanical stresses are the main cause of
wear associated with banding. REIP [5] showed, that the
main reason for banding of work rolls is the high tempera-
ture gradient induced in the rolling gap and primarily rolls
in the first stands are susceptible to banding. Several mod-
els were developed in order to predict the temperature
fields and the resulting residual stresses in work rolls dur-
ing hot rolling to analyse and reduce damages like banding
[6]. NARITA et al. [7] proposed a simplified mathematical
model to estimate the temperature history within the strip
and work rolls under transient heat transfer conditions,
dealing with several hundreds of overrollings. TSENG [8, 9]
modelled the hot rolling process with steady state heat
transfer equations and the finite element method. SERA-
JZADEH et al. [10] created a two-dimensional finite element
model to predict the work roll temperature during the con-
tinuous hot slab rolling process. SUN et al. [11] studied the
thermal behaviour and roll life of a work roll during strip
rolling. These models assume stationary heat transfer con-
ditions and are based on numerical approaches which are
computationally intensive and hence cannot be used for
real-time evaluation of the rolling process.
This paper introduces an analytical approach to compute
instationary temperature distributions and circumferential
stresses of a work roll surface, which can be used for fast
real-time evaluation and an optimization of the hot rolling
process. An analytical approach seems to be preferable
efforts to model the problem with standard structural me-
chanics software [5, 8, 10, 12].
Mathematical Model
An analytical model is used to calculate the maximum
surface temperature, the temperature distribution and
strains and stresses in circumferential direction for the
instationary case. It allows the modelling of plastic strains,
which correspond with the damage of the roll surface. The
model consists of three parts: the first sub-model describes
the thermal interaction between work roll and strip and is
used to determine the maximum temperature on the roll
surface [13]. With the second sub-model the temperature
distribution on the roll surface is calculated. With the
knowledge of the temperature distribution it is possible to
calculate strains and stresses via thermo-elastic and consti-
tutive equations with the third sub-model, similar as has
been done in [14, 15]. Figure 1 shows the segmentation of
the work roll according to [12]. The regions are as follows:
α represents the rolling gap, γ and ξ the cooling zones and
β, δ, ζ regions without heat transfer to the environment.
Figure 1. Thermal loading and classification of segments of the
work roll.
Thermal Interaction between Work Roll and Strip. The
maximum temperature is reached after the rolling gap (α,
see Figure 1). The curved contact in the rolling gap is
simplified as follows: Two plane bodies are in contact for
a certain time, whereby heat is transferred according to
[13]. The following simplifying assumptions are made:
Constant thermal material properties, constant contact
Metal Forming
resistance between work-roll and strip, no heat flow per-
pendicular to the contact surface, no slip between strip and
work roll, no geometry change of the strip and no heat
production by plastic deformation of the strip or by fric-
tion. Additionally, a constant initial temperature in the
work roll and the strip before the thermal contact is as-
sumed. This is acceptable since the temperature profile of
the roll is nearly constant when reentering the rolling gap
[5]. The development of the temperature distribution in
depth direction is given by
K 1κ 1−0.5T0   | x | 
Troll = erfc  − e h 2 x+ h22κ 2t erfc  | x | + h2 κ 2 t ,
K1κ 1− 0.5 + K 2κ 2− 0.5 
  2 κ 2 t 
where index 1 denotes the strip and 2 the roll, K1 and K2
are the thermal conductivities, erfc is the complementary
error function, κ1 and κ2 are the thermal diffusivities, t is
the contact time, x is the distance from the roll surface, T0
is the initial temperature of the strip, H is the thermal resis-
tance and the quantity h2 is defined as
H ( K1κ1−0.5 + K 2κ 2−0.5 )
h = . (2)
2 strength in compression of the work roll material [11, 18].
K1 K 2κ 2−0.5
A comparison of the analytical results with measured tem-
peratures on the roll surface [16, 17] shows good agree-
ment and thus justifies the simplifying assumptions.
Surface Temperature Distribution of Work Roll.
FISCHER et al. [12] proposed a plane configuration by repre-
senting the roll as a straightened disk in order to avoid
mathematical difficulties which arise from the use of Bes-
sel functions. This is acceptable since one is mainly inter-
ested in the temperature distribution near the surface due to
the small surface-near heat affected layer. Boundary condi-
tions are selected as follows [12]: Quasi-stationary for one
revolution n, roll as a halfplane with horizontal surface, no
heat conduction in axial direction of the roll and cooling is
so intense, that the roll surface reaches the cooling medium
temperature Tcm at the two points (α+β+γ and
α+β+γ+δ+ε), see Figure 1. The temperature distribution is
schematically shown in Figure 2. Calculated temperature
differences are displayed as overlined quantities, whereas
temperatures are not overlined. The reference temperature
Tζ,n-1 is introduced, since all temperatures within this model
correspond to a certain reference temperature, which is the
start temperature for each revolution. Exemplarily, the
expression for the end temperature is according to [12]:
 2π
Tζ ,n = Tα ,n ⋅  −
2π   2π − (α + β )
−1  − TMaxK1,n  −
2π − (α + β ) 
 α α   γ
 2π − (α + β + γ + δ ) 2π − (α + β + γ + δ ) 
− TMaxK2,n  − −1  .
 ξ ξ 
TMaxK1,n and TMaxK2,n are extreme temperatures correspond-
ing to the two cooling intervals. In order to simulate the
instationary case the last value of Tζ,n becomes the input
value Tζ,n-1 for the next revolution.
Mechanical Loading of Work Roll Material. For a
rough thermo-mechanical analysis in the thin surface layer
of the roll, the total strain (i.e. the sum of thermal, elastic
and plastic strains) in axial and circumferential directions
as well as the normal stress component in radial direction
can be assumed to be zero.
Figure 2. Schematic temperature distribution for one revolution.
 
(1)
  In the linear elastic case the tangential and axial stress
 2 κ 2t 
components can be estimated by
Ea∆T (4)
σ =− ,
1− v
where E, ν and a denote Young’s modulus, Poisson’s ratio
and the coefficient of thermal expansion, respectively. It
can be shown, that the equivalent stress within the rolling
gap at positions near the roll surface exceeds the yield
In this work, plastic deformations are calculated via J2
standard plasticity. According to the assumptions of
FISCHER et al. [12] a plane configuration is considered. The
equivalent v. Mises stress in the plane configuration is
σV = σx2 +σy2 −σxσy +3τxy
2
. (5)
Since the stresses in tangential and axial directions are
equal and an infinitesimal small cube is regarded, it is
valid to introduce polar coordinates into Equation (5),
which then reduces to
σV =σϕ. (6)
Cyclic mechanical tests performed in[19] justify the appli-
cation of a kinematic hardening law according to LEMAITRE
and CHABOCHE [15]. The flow criterion is
(7)
0 = σV − q −Y(T,η),
where q is the backstress and Y is the yield strength as a
function of the temperature T and the loading direction η
(tension: 1, compression: -1) The evolution equation for
the hardening variable q is [15],
C  C (8)
q =η +  q − η  ⋅ exp[−ηb(ε − ε )],
0 p p0
b  b
where C and b are characteristic coefficients for kinematic
hardening describing the gradient and the saturation of the
flow curve, q0 is the initial back stress, εp is the plastic
−1 
strain and εp0 is the accumulated plastic strain, both in
γ  circumferential direction. This approach allows the simula-
(3) tion of the strain-stress hysteresis for materials exhibiting a
Bauschinger effect. Stresses due to the roll pressure are
neglected since they are approximately up to 15 times
smaller than thermally induced stresses [5].
Results
Roll material data are taken from monotonic and cyclic
mechanical tests [5, 19] as well as thermo-physical tests,
measured with the laser flash method [20]. As an example,
typical rolling mill values are taken for kinematical, geo-
metrical and thermo-mechanical data. Material data for a
HSS roll are taken from [5, 18, 19], see Table 1. In the
following the development of the temperature distribution

and of the stress strain distribution will be discussed ex-
emplarily for such a HSS roll. Data for the temperature
dependent compression yield strength are taken from [5],
where indices t denote tension and c compression.
Table 1. Material data of HSS roll [5, 18, 19].
E (GPa) a (1/K) C (GPa) b (−) Yc (MPa) Yt (MPa)
220 1.3 x 10-5 250 800 1700 (20°C)
1100 (500°C)
Development of Temperature Distribution. A combina-
tion of the analytical approaches thermal interaction be-
tween work roll and strip, eq. (1), and surface temperature
distribution of work roll, eq. (3), allow a calculation of the
development of the temperature distribution over several
revolutions. In order to keep the simulation close to reality,
two cooling zones are taken into account, Figure 1. Figure
3 shows a comparison of the simulation with experimental
data of STEVENS et al. [16]. There, temperatures beneath
and at the surface of work rolls were measured via thermo-
couples over several revolutions, however with only one
cooling zone. Therefore – and just in this comparison – our
model is adapted to one cooling zone. Continuous rolling
leads to a heating of the roll until a stationary temperature
distribution is reached, which means that the maximum
temperature approaches a limit asymptotically. Figure 3
shows that the model agrees well with the experimental
findings.
Figure 3. Comparison of analytically calculated temperature
distribution and measurements of Stevens et al. [16] (roll surface).
Development of Stress-Strain Distribution. The tem-
perature distribution is the input parameter for the calcula-
tion of the mechanical loading of work roll material,
whereby stresses and strains (elastic and plastic) can be
determined. The surface heating in the rolling gap leads to
axial and circumferential compressive loads in the roll
material. As the material starts to yield a load reduction
caused by thermal softening with superimposed strain
hardening can be seen. The cooling of the surface leads to
relaxation (the surface becomes cooler than surface near
layers) and by means of this the compressed material is
loaded in tension. In this regard two possible consequences
should be mentioned: the material reaches its tension yield
stress or not. Here, the roll material does not reach its
tension yield stress during the first revolution. Conduction
of heat from the roll interior to the surface after the two
cooling zones (Figure 2) causes compressive stresses
again. After each revolution residual stresses with a certain
displacement remain in the roll surface, which is caused by
the thermal boundary conditions. Figure 4 shows the cal-
culated stress-strain hysteresis loop for 50 revolutions.
Metal Forming
Here, elastic shakedown can be observed after 25 revolu-
tions. Elastic shakedown denotes a steady state of the hys-
teresis loop after several cycles with purely elastic strains
due to strain hardening, which means no further accumula-
tion of plastic strains.
800
Figure 4. Strain-stress hysteresis loop of roll surface for 50 revo-
lutions. Slab temperature 1000 °C, rolling speed 2 m/s.
Parameter study. Thermo-mechanically induced plastic
deformations of surface near regions of a work roll corre-
late with banding [5]. It is coherent to correlate damage
with the plastic deformation in circumferential direction. In
the following the influence of the rolling speed and the
slab temperature on the plastic deformation of the roll
surface are discussed. Separately, both parameters can be
affected by the rolling schedule in the rolling mill. It is
assumed that the roll is new or refinished. The accumu-
lated plastic strain in circumferential direction is calculated
as follows,
Cycles
(9)
~
ε pl ,ϕ = ∑ (ε
1
pl , ϕ , t )
+ ε pl , ϕ , c .
Influence of the rolling speed
Figure 5 shows the accumulated plastic strain in circum-
ferential direction in dependency of the rolling speed for a
fixed slab temperature of T0 = 1000 °C (a typical value for
steel slabs in hot rolling mills when entering the first stand).
Here, it can be seen that a slower rolling speed causes a
steeper increase of the accumulated plastic strain at the
beginning of rolling caused by the higher heat input in the
rolling gap due to a longer contact time. A saturation -
elastic shakedown – can be seen for 2, 4 and 10 m/s (Figu-
re 5). The strain-stress hysteresis loop for 2, 4 and 10 m/s
shows plastic flow due to compression, until the strains
become fully elastic, see Figure 4, exemplarily for 2 m/s.
Figure 5 shows an increase of the accumulated plastic
strain for 1 m/s – plastic shakedown - which is driven by
alternating plastic flow in tension and compression. If
always the first revolution is considered it seems to be
preferable to roll at higher speeds [5]. This conclusion can
be falsified with the following consideration: Although
lower rolling speeds may cause a higher heating of the roll
surface and therefore a higher deformation, it is crucial
that it takes a certain time until a stationary temperature
distribution of the work roll is reached. Until this time is
reached an arbitrary point on the roll surface has under-
gone several revolutions, where the number of revolutions
depends on the rolling speed. Although the increment of
plastic strain as function of number of revolutions is lower
for faster rolling, the total plastic strain is higher (more
revolutions until stationary state is reached), as long as the
speed is not too slow, whereby flow by tension is induced.
It can be assumed that an optimal rolling speed can be
found.
Metal Forming
Figure 5. Accumulated plastic strain in circumferential direction
for different rolling speed, slab temperature 1000 °C.
Influence of the slab temperature
Figure 6 shows the accumulated plastic strains in circum-
ferential direction in dependency of the strip temperature.
High strip temperatures cause an intense increase of plastic
deformation. Here, 1100°C causes an approximately linear
and steep increase. This can be interpreted as ratchetting.
Marginal changes of the temperatures in the range from
1000°C to 1050°C have a strong influence on the me-
chanical response of the roll material. This is comprehen-
sible since the materials are designed for loads near their
collapse load.
Figure 6. Accumulated plastic strain in circumferential direction
for different strip temperatures, rolling speed 2 m/s.
Conclusions
An analytical model was set up in order to estimate the
instationary temperature distribution and residual stresses
in circumferential direction on the surface of a work roll.
Due to its fast algorithms it can be used for online evalua-
tion of the rolling process, unlike computationally inten-
sive numerical approaches. The model takes elastic and
plastic strains (including kinematic hardening) into ac-
count. As a result, it can be seen as an extension of the
FISCHER approach [12], which estimates purely elastic
strains. According to observations of DEBARBADILLO et al.
[2] a correlation between thermo-mechanical loads – plas-
tic strains in circumferential direction - and banding exists.
This allows the use of the accumulated plastic strain in
circumferential direction as an evaluation criterion for
banding. Many authors calculate stresses and strains
(mainly elastic) via a stationary temperature distribution
[5, 8, 11, 22, 23], whereas the instationary temperature
development of this model allows a more accurate calcula-
tion.
The parameter study presented in this work shows:
1. A high rolling speed can cause higher accumulated
plastic deformations and an optimal rolling speed can
be found, specific for the characteristics of a rolling
mill.
2. The strip temperature is the main factor inducing
thermo-mechanical damage. High strip temperatures
may lead to ratchetting of the roll material.
In the next step, the model should take into account the
initial residual stress state of the work roll induced by the
manufacturing process [5, 16, 24], as well as material data
identified in LCF tests performed at elevated temperatures.
Since this model is fully based on analytical solutions it is
fast and suitable for online applications, whereby an opti-
misation of the rolling process regarding the rolling speed
and the strip temperature can be realized.
Acknowledgements
The authors gratefully acknowledge the financial support
of the Christian Doppler Research Society (CDG).
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