Ribbon Fatigue Spalling of a Forged Work Roll Used at a Cold Rolling Mill

Ghosh, Subrata; Sinha, Pankhuri; Indimath, Shivanandan; Mukhopadhyay, Goutam; Bhattacharya, Sandip

doi:10.1007/s11668-014-9885-4

Cited by 7 publications

(4 citation statements)

References 6 publications

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“…It is important to note that the analysis presented herein is also valid in the case of normal operation of rolls with insufficient depth of the hardened case (see e.g. [17][18][19]), either due to technological/manufacturing error or unsuitable design.…”

Section: Discussionmentioning

confidence: 93%

Effects of local overloads on cold rolling mill work rolls

Vinogradov

Knyazhansky

Tsun

2017

International Journal of Mechanical Sciences

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Newcastle University ePrints -eprint.ncl.ac.uk Vinogradov V, Knyazhansky M, Tsun A. Effects of local overloads on cold rolling mill work rolls. AbstractLocal overloading is one of the most common reasons for premature failures of cold rolling mill work rolls. Case-hardened rolls demonstrate spatial variation of the material hardness and yield strength with a decreasing profile with depth and belong to the class of so-called plastically graded materials. Contact overloads cause formation of subsurface closed-shape plastic zones, accompanied by a significant perturbation in the stress field. In the present paper the effect of an overload on a case-hardened roll is numerically modelled using finite element, when the parameters of the contact loads are chosen to represent a common situation when an accidentally formed strip fold enters the roll bite. It is shown that plastic deformations in the graded layer originate at depths, which significantly exceed the depth of the maximum effective stresses, determined by the elastic solution. During the contact overload, tensile stresses develop at the upper boundary between the elastic and plastic zones. Tensile stresses at the free surface in the vicinity of the contact zone increase up to ten times due to formation of the subsurface plastic zone. Residual stresses with a very large tensile hydrostatic component are shown to appear in the unloaded material. These tensile stresses, both operational and residual, can cause premature spalling in the contact surface during either the overloading or further operation of the roll. It is shown that an increase in the depth of the hardened case and increase in the roll core hardness allows to reduce plastic deformations during overloads, reduce both operational and residual stresses in the graded layer and shift formation of the plastic zone deeper from the surface and the contact zone, which decreases the chances of premature spalling.

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Section: Discussionmentioning

confidence: 93%

Effects of local overloads on cold rolling mill work rolls

Vinogradov

Knyazhansky

Tsun

2017

International Journal of Mechanical Sciences

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“…For particular application of bearing or gear claimed that a spall cavity was formed from a surface crack undertaking four stages of growth: small angle growth down, large angle growth down, parallel growth and fast growth towards the surface. However, many literatures have been reviewed regarding to rolling dies, in the study of spalling mechanism . No single case could traced the origin of a spalling to the large surface cracks.…”

Section: Modeling Spalling Crack Growth For Rolling Diementioning

confidence: 99%

“…All damage mechanisms may take place simultaneously and compete with each other. Due to the fact that each mechanisms has own scale and origination of the damage depth . If this is the case, among of these damage mechanisms, which one is predominated that caused by fatigue?…”

Section: Introductionmentioning

confidence: 99%

“…However, the earliest systematic study of RCF was reported by previous studies who were interested in RCF as general which are not applicable for rolling die. In fact, rolling die contact fatigue (RDCF) in metal forming has not been recognized for more than a century, but recent years have seen a revival of interest because of the recognition that there was an increasing problem in the phenomenons …”

Section: Introductionmentioning

confidence: 99%

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Modeling fatigue crack and spalling for rolling die under hot milling

Tolcha

Altenbach

Tibba

2019

Fatigue Fract Eng Mat Struct

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In hot milling process, rolling die is subjected to nonsteady conditions which can rise the combinations of fatigue and spalling damage mechanism. An understanding about the failure mechanism of the rolling die is essential under hot rolling process. Fatigue crack growth and spalling process are governed by highly concentrated strain and stress in the crack tip region. Based on the theory of elastic‐plastic fracture mechanics, an analytical model are presented in this paper to determine the elliptical crack growth rate and spalling damage mechanism. The model includes new proposed constitutive equations for fatigue and spalling crack growth. To verify the models, finite element simulation and experimental data are considered. The results show good agreement with finite element simulation and experimental data.

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On the Crucial Role of the On-Site and Visual Observations in Failure Analysis and Prevention

Kishore

2021

J Fail. Anal. and Preven.

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Ribbon Fatigue Spalling of a Forged Work Roll Used at a Cold Rolling Mill

Cited by 7 publications

References 6 publications

Effects of local overloads on cold rolling mill work rolls

Effects of local overloads on cold rolling mill work rolls

Modeling fatigue crack and spalling for rolling die under hot milling

On the Crucial Role of the On-Site and Visual Observations in Failure Analysis and Prevention

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