Effect of process parameters on roll separating force, driving torque, and end crop length during grooved hot rolling of SAE 1541 steel

Abstract

The medium carbon steel bars are widely used in automobile sector, mining, shipping, and forging industry. The use of SAE 1541 grade bars is quite common due to their affordability and adaptability. Basic production process of the metal bar involves heating the billet in reheating furnace up to 1200–1210 °C followed by passing it through a pair of grooved rolls in a rolling mill. The steel industries have been striving for productivity and better yield of hot rolled bar products. The roll separating force (RSF), driving torque (DT), and end crop length (ECL) are the important issues to be controlled for quality production, maximization of yield, minimization of rolled bar process scrap, safety of mill, and reduction in energy consumption. The response parameters depend on several process parameters – rolling speed, billet temperature, reduction ratio (strain), billet size (cross section area), roll diameter, etc. This paper presents a study on the effect of process parameters on these 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.