SpringerLink
Log in

Modeling and Optimization of Process Parameters during Grooved Hot Rolling of SAE 1541 Steel

  • Technical Article
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

SAE 1541 grade steel bars are widely used in automobile sector, mining, ship** and forging industry due to their affordability and adaptability. Steel industries have been striving for productivity and better yield of hot-rolled bar products. The roll separating force, driving torque, end crop length and drive energy are the important response parameters to be controlled for quality production, maximization of yield, safety of mill and reduction in energy consumption. These response parameters depend on several process parameters–rolling speed, billet temperature, reduction ratio, billet cross-sectional area, roll diameter. This paper presents a study on the effect of the process parameters on the response parameters during rolling of SAE 1541 steel. Simulation of the rolling process has been attempted using FORGE® NxT 1.1. The simulated results so obtained have been validated through experimental results obtained in a rolling mill, following statistical tests. Regression models showing relationship between the process parameters and the response parameters have been developed. Significant model terms have been obtained using ANOVA. The optimum rolling conditions for minimization of the response parameters have been obtained.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price includes VAT (Germany)

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. M. Bagheripoor and H. Bisadi, Application of Artificial Neural Networks for the Prediction of roll Force and Roll Torque in Hot Strip Rolling Process, App. Math. Model., 2013, 37, p 4593–4607.

    Article  Google Scholar 

  2. M. Bagheripoor and H. Bisadi, An Investigation on the Roll Force and Torque Fluctuations During Hot Strip Rolling Process, Prod. Mfg. Res., 2014, 2(1), p 128–141.

    Google Scholar 

  3. L.S. Bayoumi and Y. Lee, Effect of Inter-Stand Tension on Roll Load, Torque and Work Piece Deformation in the Rod Rolling Process, J. Mat. P. Tech., 145: 7–13 (2004)

  4. T.E. Bitar, M.E. Meligy and E. Shenawy E, Prediction of roll separating force in a roll pass design of micro-alloyed steel rods, WIT Transact. Built. Envi., 2014, 137, p 67–79.

    Article  Google Scholar 

  5. S.M. Byon, Numerical and Experimental Approach to Investigate Plane-view Shape and Crop Loss in Multistage Plate Rolling, K. Soc. Mech. Eng., 2013, 37(9), p 1117–1125.

    Google Scholar 

  6. W. Chan, A. Wang, and J.M. Shoup, Real Time Torque Measurement of Rolling Mill Drive, IEEE. 0-7803-5589-X/99: 557-564 (1999)

  7. M.S. Chun and Y.H. Moon, Optimization of the Amount of Edging to Increase Rolling Yields in a Plate Mill, J. Mat. P. Tech. 104, 11–16 (2000)

  8. A. Grajcar, Researches and Simulations in Steel Rolling, Metals, 2021, 11, p 560.

    Article  Google Scholar 

  9. U. Hanoglu and B. Sarler, Multi-Pass Hot-Rolling Simulation Using a Mesh Less Method, Comp. Strs., 2018, 194, p 1–14.

    Article  Google Scholar 

  10. S.M. Hwang and S. Kobayashi, Preform Design in Plane-Strain Rolling by the Finite-Element Method, Int. J. Mach. Tool Des. Res., 1984, 24(4), p 253–266.

    Article  Google Scholar 

  11. L.E. Klosterman, R.T. Richter, M.D. Crowley, and A. Maslanka (2002). Method for Reducing Crop Losses during ingot rolling, US Patent No. 6453712 B1.

  12. W.J. Kwak, Y.H. Kim, J.H. Lee and S.M. Hwang, A Precision On-Line Model for the Prediction of Roll Force and Roll Power in Hot-Strip Rolling, Met. Mat. Trans., 2002, 33A, p 3255.

    Article  CAS  Google Scholar 

  13. H.B. Lim, H.I. Yang and C.W. Kim, Analysis of the Roll Hunting Force Due to Hardness in a Hot Rolling Process, J. Mech. Sci. Tech., 2019, 33(8), p 3783–3793.

    Article  Google Scholar 

  14. M.K. Majumder, P.R. More, S. Chatterjee, P.S. Mandley and S.K. Pal, Roll Separating force in Hot Rolling Under Grooved Rolls–a Finite Element Analysis and Experimental Validation, Ind. J. Engg. Mat. Sci., 2016, 23, p 267–273.

    Google Scholar 

  15. C.H. Moon and Y. Lee, An Approximate Model for Local Strain Variation Over Material Thickness and its Applications to Thick Plate Rolling Process, ISIJ Int., 2009, 49(3), p 402–407.

    Article  CAS  Google Scholar 

  16. K. Mori, K. Osakada and T. Oda, Simulation of Plane-Strain Rolling by the Rigid-Plastic Finite Element Method, Int. J. Mech. Sci., 1982, 24(9), p 519–527.

    Article  Google Scholar 

  17. R.S. Nalawade, V.R. Marje, G. Balachandran and V. Balasubramanian, Effect of Pass Schedule and Groove Design on the Metal Deformation of 38MnVS6 in the Initial Passes of Hot Rolling, Sadhana, 2016, 41(1), p 111–124.

    Article  CAS  Google Scholar 

  18. R.S. Nalawade, K.N. Mahadik, V. Balasubramanian, R.K. Singh, V. Satish, K. Cheekatla and P.P. Date, A Novel Method to Reduce End Crop Loss in Rolled Bars, Steel Tech., 2012, 6(4), p 57–66.

    Google Scholar 

  19. A.R. Ragab and S.N. Samy, Evaluation of Estimates of Roll Separating Force in Bar Rolling, Transaction of the ASME, J. Mfg. Sci. Engg., 2006, 128, p 34–45.

    Google Scholar 

  20. S. Rath, Computer Simulation of Hot Rolling of Flat Products, Soft. Engg., 2016, 4(6), p 75–81.

    Google Scholar 

  21. N.A. Razani, B.M. Dariani and M. Soltanpour, Microstructure and Mechanical Property Improvement of X70 in Asymmetrical Thermo-Mechanical Rolling, Int. J. Adv. Mfg. Tech., 2018, 97, p 3981–3997.

    Article  Google Scholar 

  22. R. Rentsch and C. Prinz (2012). Finite element analysis of the hot rolling process on the origins of in homogeneities related to steel bar distortion, Mat.-wiss. u.Werkstofftech. 43:1–2.

  23. A. Said, J.G. Lenard, A.R. Ragab, and M.A. Elkhier, The Temperature, Roll Force and Roll Torque During Hot Bar Rolling, J. Mat. P. Tech., 88: 147–153 (1999)

  24. A. Samuel and K.N. Prabhu, Residual Stress and Distortion during Quench Hardening of Steels: A Review. J. Mater. Eng. Perform. 1–28 (2022)

  25. S. Sarwito and S.A. Semin, Analysis of Three Phases Asynchronous Slip Ring Motor Performance Feedback Type 243, Int. J. Marine Eng Inn. Res., 2017, 2, p 1–7.

    Google Scholar 

  26. G. Singh, P.K. Singh, Effect of process parameters on roll separating force driving torque and end crop length during grooved hot rolling of SAE 1020 steel, J. Mfg. P. 79, 1003–1016 (2022)

  27. G. Singh and P. K. Singh, Effect of process parameters on performance of grooved hot rolling of SAE 4340 steel bars. Mater. Manuf. Process., 1–14 (2022).

  28. U. Stahlberg and A. Goransson, Heavy Reductions by Means of “Non-Bite” Rolling, Including Some Observations on Work Piece Shape, J. of Mech. Working Tech., 1986, 12, p 373–384.

    Article  Google Scholar 

  29. U. Stahlberg, J.O. Soderberg and A. Wallero, Overlap at the Back and Front End in Slab Ingot Rolling, Int. J. Mech. Sci., 1981, 23, p 243–252.

    Article  Google Scholar 

  30. X. Wang, K. Chandrashekhara, S.A. Rummel, S. Lekakh, D.C. Van Aken and R.J. O’Malley, Modeling of Mass Flow Behavior of Hot Rolled Low Alloy Steel Based on Combined Johnson-Cook and Zerilli-Armstrong Model, J. Mater. Sci., 2017, 52, p 2800–2815.

    Article  CAS  Google Scholar 

  31. F. Weidlich, A.P.V. Braga, L.G.D.B. da Slilva Lima, M.B. Junior and R.M. Souza, The influence of Rolling Mill Process Parameters on Roll Thermal Fatigue, Int. J. Adv. Mfg. Tech., 2019, 102, p 2159–2171.

    Article  Google Scholar 

  32. Z. Wusatowski Fundamentals of Rolling 1st ed., Pergamon Press, pp. 25–150 (1969)

  33. L.I. Xu, W. Hongyu, D. **gguo, X. Jiu**g and Z. Dianhua, Analysis and Prediction of Fishtail During V-H Hot Rolling Process, J. Cen. South Uni., 2015, 22, p 1184–1190.

    Article  Google Scholar 

  34. S.H. Zhang, D.W. Zhao and C.R. Gao, The Calculation of Roll Torque and Roll Separating Force for Broadside Rolling by Stream Function Method, Int. J. of Mech. Sci., 2012, 57, p 74–78.

    Article  CAS  Google Scholar 

Download references

Acknowledgments

The authors are thankful to Mr. Raminderpal Singh (MD), Mr. S Paul (CEO), Mr. Ajay Jayale, (Plant Manager) and their entire team at Arora Iron & Steel Rolling Mills Pvt. Ltd. Ludhiana (India) for their support and motivation to carry out this work at their premises. Authors are also grateful to Dr. Sehijpal Singh, Professor, and the TEQIP Cell at Guru Nanak Dev Engineering College, Ludhiana (India), for their valuable suggestions and cooperation.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Guru Nanak Dev Engineering College, Ludhiana, 141006, India

    Gulvir Singh

  2. Department of Mechanical Engineering, Sant Longowal Institute of Engineering & Technology, Longowal, 148106, India

    Pradeep K. Singh

Authors
  1. Gulvir Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Pradeep K. Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Pradeep K. Singh.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Singh, G., Singh, P.K. Modeling and Optimization of Process Parameters during Grooved Hot Rolling of SAE 1541 Steel. J. of Materi Eng and Perform 32, 10128–10140 (2023). https://doi.org/10.1007/s11665-023-07860-2

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-023-07860-2

Keywords

Search

Navigation