Assignment No.2.

Roll Pass Scheduling- Continuous hot rolling billet Mill

Billet
Billets are the feedstock for long products of the small cross-section. In cases when they are not directly
cast by a continuous caster, they are rolled from blooms by billet mills. One method of rolling billets,
which are usually 75 to 125 mm square, (10 cm x 10 cm) is to use a three-high mill with box passes.
Continuous hot rolling billet Mill
A rolling mill comprises the following sections:
i. Drive mechanisms
ii. Roughing stands
iii. Intermediate stands
iv. Finishing mill
v. Cooling bed
vi. Shearing section/finishing yard
vii. Dispatch yard

It consists of many stands in a row and the stock passes through both sets of stands only in one direction
(uni-direction) and only once. Each stand may have a 2-high or 4-high rolling mill. In 4 -high rolling
mill, the two backup rolls (Ø200 - Ø500mm) are used to vary the gap between the working rolls. For
continuous operation, a wound rotor induction/synchronous /DC shunt motor is used. A continuous
rolling mill 600/4 - 400/4 – 300/2

Rolls of billet mill

1
Shape rolling, the incoming billet undergoes significant shape, dimensional and structural changes
through a multitude of passes at elevated temperatures. Commonly, it follows a two-step design process
consisting of roll sequence and roll pass design phases is adopted. The roll sequence design (RSD)
involves the selection and sequencing of roll passes, while the roll pass design (RPD) concerns with the
prediction of the geometrical characteristics of a rolled product (calibration), the required torque, and the
load on rolls, and involves the determination of the rolling parameters.
Objectives of higher productivity and lower operating cost usually lead to the search for the shortest
feasible rolling sequence ( minimum number of passes). The involved rolling passes determine the
characteristics and the quality of a finished product, i.e., surface finishing, geometrical dimensions,
material structure, presence/absence of internal defects, and in general the feasibility of the pass.
Traditionally, the design of rolling sequences is performed by experts in the field which recur to a trial-
and-error approach based on experience and existing solutions. Nevertheless, such an approach is
significantly expensive and time-consuming and confines the exploration of possible solutions. Roll
sequence design is performed by assuming different breakdown sequences and adjusting the dimensions
of roll calibers with a trial-and-error approach.
It has mainly three groups of stands
 Roughing mill stands (roughing train) to obtain a maximum reduction in size
 Intermediate mill stands
 Finishing mill stands (Finishing train) to obtain final shape and accurate size
During rolling initial passes results in a large reduction of cross-sectional area, while intermediate passes
try to bring the shape closer to the final shape and the final or finishing passes bring the material to the
required shape and size. Plates, bars, rounds, structural shapes, sheets, and strips can be obtained by
rolling. These trains may be together or far apart.

Roughing passes

Intermediate passes

Finishing passes

2
Once the sequence is determined, each pass is designed based on the experience and available
mathematical models allowing the prediction of the degree of fulfillment of roll grooves, the load, and
torque Siebel’s, Ekelund’s, Orowan’s, or more recently Sims’s.

Introductory pass

Drawing pass

Strand pass

Leader pass

Finishing pass

Grooved rolls and passes

Even during hot rolling of thick rectangular stock, to restrict lateral spread, grooved rolls may be used.
Wherever possible dimensions are expressed as diameters rather than radii for the benefit of the roll
turner.

3
4
5
 box pass - groove angle should be 8 to100 and relief radius should be 10 mm

 diamond pass - relief radius should be around 18 mm

 square pass - relief radius should be 5mm.

 The relief radius for the oval should be 5mm.

 The relief radius for rounds is 1/5th of the bottom radius and 1.5 mm for the finish pass.

 The relief radius for rounds in the finish pass should be 1.5.

 Fitting from oval to round should be 0.3 to 0.7.

 For ovals width to height ratio should be < 3.0.

6
7
 (a) SQ-SQ (b) SQ- oval (c) Oval - SQ (d) Oval - round
Passes can be shape passes (round or square) and intermediate (rectangular -box pass, diamond, oval)

8
There are three types of breakdown passes required in the proper sequence to produce the desired shape
nearer to the rolled product: 1. Box Pass Series 2. Diamond-Square Series 3. Oval-Square Series.

Box Pass Series:

Box pass series is shown in Fig. 2.10 (a). Box passes are generally used for medium and large sections of
blooming and billet mills. The rolls used in these series are stronger. The top roller can be adjusted to
different reduction sizes.

Diamond-Square Series:
The Diamond-square series is shown in Fig 2.10 (b). In this, the square produced in a larger roll is turned
over by 90° and passes through the diamond rolls, the output of which is again turned over by 90° and put
through smaller square rolls.
The principle used in designing the diamond square series is that the height of one pass is equal to or less
than the width of the next pass.
The advantages of these series are:
1. Slow cooling of the entire material.
2. Accurate square produced.
3. Larger elongation can be achieved (1.20 to 1.45).
4. Used in finishing passes.
5. Good stability and uniform deformation of the metal.

Oval-Square Series
9
The stock after going through the oval pass is turned over by 90° into the square pass, the output of which
is then turned over by 45° to feed into the next oval pass. A large elongation can be obtained (1.35 to
1.75) compared to the other breakdown passes.
This is a heavy reduction series that is widely used for rolling products from billets but it is not so
common for billet production. However, it may be used if there is a shortage of passes but no shortage of
power.

Open-box passes - The percentage reduction generally lies between 20–30%.

Open square- square sequence the open square with an apex angle of from 91°–98°. A rhombus with an
apex angle greater than this may be considered a diamond. In this sequence, the stock emerging from one
pass is turned up 90° and entered into the next square, the angle being gradually decreased towards the
finishing pass. The open square pass rolls all four sides of the billet but the drafts have to be light as there
is little allowance for spread, and reductions of 20% may lead to overfilling. To obtain higher draughts the
obvious way is to broaden the open square by increasing the apex angle so giving more room for spread.

Diamond–square sequence
The diamond may be from 100° to 125° ( we take 120°) while alternate passes will be squares. The
diamond is usually limited to 125° as it is more difficult to enter into the next square groove due to the
high angle of contact. Reduction up to 28% is possible in the diamond to the square stage. In the reduction
from square to diamond the actual vertical draft is less than the above for a given reduction in area and the
pass is wider so allowing more spread. However, the more open sides impose less restriction on the
spread and 30% is found to be the approximate limit of reduction. These two steps give an overall
reduction from square to square of about 47.5%. If a higher rate of reduction is required a square–oval–
square sequence must be used.
The bottoms of the grooves of both square and diamond are usually filleted or chamfered for ease of
working. The fillet or chamfer ensures the corner is working but it must be of the correct dimensions. The
radius in the passes should be large enough to enable the entering stock to fit torners but must be small
enough to hold the stock stable. The finishing pass will have the radius required on the finished billet and
the earlier passes will be derived from this and form the need to prevent overfilling.

10
Determine the dimensions of the finishing pass and leader pass for rolling an MS bar of 30
× 30 𝐦𝐦𝟐 the cross-section in a rolling mill having a roll diameter of Ø 300 mm.
It considers three pass sequences: square (strand pass) – diamond (leader pass)– square (finishing pass)
Finishing square pass design
ao = aa [1 + α (t o − t a )]
ao = side of the square at operating (elevated) temperature
aa = side of the square at ambient/room temperature
α = linear coefficient of expansion = 12 × 10−6
t 0 = rolling/ operating temperature 0C = 1200 0 C
11
t a = ambient temperature 0C = 30 0C
a3 = ao = side of the square groove in the finishing pass at the working temperature of 1200C.
a3 = 30 × [1 + 12 × 10−6 × (1200 − 30) ]
= 30.4 mm
Taking into account the minus tolerance for wear, a3 = 30.2 mm
b3 = h3 = √2 × a3 = √2 × 30.2 = 42.7 mm
The gap between the rolls c = 0.01 × D = 0.01× 300 = 3 mm
h3 −3 42.7−3
the depth of the groove in each roll = = = 19.85 mm
𝟐 𝟐

r3 = fillet radius = 0.15 a3 = 5 mm

R 3 = corner radius = 0.85 a3 = 25 mm
Designing the diamond groove for the leader pass
λm = 1.18, a3 = 30.4
a1 = λm × a3 = 1.18 × 30.4 = 35.6 mm
A2 = Area of the interposed diamond groove = a1 × a3 = 30.2 × 35.6
= 1075 mm2
h2 = height of the diamond groove
(a1 − a3 ) (a1 − a3 )
=1.35 a3 − [√R (a1 − a3 ) − ]
2 a1 2

(35.6 −30.2) (35.6 −30.2)

= 1.35  30.2 − × [√150 × (35.6 − 30.2) − ]
2 × 35.6 2 × 0.45

= 37 mm
b2 = breadth of the diamond groove
1
Area of the fifth-pass diamond groove = A2 = × b2 × h2
2
1
1075 = × b5 × 37
2

b2 = 58 mm
1 1
a2 = 2 √b22 + h22 = √(37)2 + (58)2
2

= 34.5 mm
Designing the Square groove for the first strand pass:
a1 = side of the square groove of the strand-pass = 35.6 mm

12
b1 = h1 = √2 × a1 = 50.3 mm
gap between the rolls c = 0.01 × D = 0.01× 300 = 3 mm
h3 −3 50.3−3
the depth of the groove in each roll = = = 23.65 mm
𝟐 𝟐

r3 = fillet radius = 0.15 a3 = 5 mm

R 3 = corner radius = 0.85 a3 = 30 mm

You are required to roll a 40  40 mm2 square section from mild steel bar having a cross-
section of 85  85 mm2 , using a continuous mill having specifications of 750/4-500/2. The
rpm of the first stand is 60 and the forward slip is 0.2. The rolling temperature is 1100C
which can be assumed to be the same for all the stands. Find the following:
i) Determine the appropriate rolling sequence and types of roll grooves for all the stands.
ii) Determine the coefficient of elongation for all the stands.
iii) Design and draw neat and dimensioned sketches of leader and preleader pass grooves.
iv) Calculate the rpm for each stand.
Given:
h0 = 85 mm b0 = 85 mm A0 = 85 × 85 mm2
hn = 40 mm bn = 40 mm An = 40 × 40 mm2
The mill specification is 750/4-500/2 i.e. It has two trains, roughing train has 4 stands and the the
finishing train has 2 stands. Thus, six stands are available for rolling i.e. n = 6

As the operating temperature is assumed to remain the same for all the stands, A0 and An can be used to
determine the number of passes and stands required to obtain the desired reduction.

13
 log A0 − log An
n=
log λm
The λm employed for billet mill is between 1.2 to 1.4. Assuming λm for the continuous billet mill = 1.3
log (85 × 85) – log(40 × 40)
n= = 5.75
log(1.3)

≈6 (the even numbers of passings are preferred for continuous billet mill)
The number of passing (i.e. 6) also matches with the number stands available on the given mill 750/4 -
500/2. The roll diameter of the four roughing mill stands is Ø750 mm and the two finishing mill stands
are Ø500 mm. Further diamondsquare pass sequence can be used as it gives fairly good reductions.

Pass No. 0 1 2 3 4 5 6

Groove Square Diamond Square Diamond Square Diamond Square

Cross- section A0 A1 A2 A3 A4 A5 A6

The linear coefficient of expansion is used to determine

ao = aa [1 + α (t o − t a )]
ao = side of the square at operating (elevated) temperature
aa = side of the square at ambient/room temperature
α = linear coefficient of expansion = 12 × 10−6
t 0 = rolling/ operating temperature 0C = 1100 0 C
t a = ambient temperature 0C = 25 0C
a6 = side of the square groove in the sixth and the finishing pass at the working temperature of 1100C.
a6 = 40 × [1 + 12 × 10−6 × (1100 − 25) ]
= 40.5 mm
a0 = input size of the billet to the first pass at the operating temperature of 1100C

14
 = 85 × [1 + 12 × 10−6 × (1100 − 25)]
= 86 mm

Pass No. Groove type b h A λ Side of SQ

0 Square (billet) 7396 86.0

1 Diamond 146.6 70.4 5160 1.43

2 Square 85 85 3600 1.43 60.0

3 Diamond 102 52.5 2670 1.35

4 Square 63 63 1980 1.35 44.5

5 Diamond 67.6 53.3 1802 1.1 43.0

6 Square 57.3 57.3 1640 1.1 40.5

Designing groove for the sixth pass finishing pass (Square groove)
a6 = side of the square groove of the sixth-pass = 40.5 mm.

b6 = h6 = √2 × a6 = 57.3 mm.
r6 = fillet radius = 0.15 a6 = 6 mm.
R 6 = corner radius = 0.85 a6 =34 mm.
Diameter of roll in the finishing stand D = Ø 500 mm
Clearance between the rolls ( 1%) c = 0.01 × D = 0.01× 500 = 5 mm
A6 = cross-sectional area of the sixth pass groove = a26 = 1640 mm2
15
Designing the diamond groove for the fifth (leader) pass:
a6 = side of the square groove of the sixth-pass
A6 = cross-sectional area of the sixth pass groove = a26
a4 = side of the square groove of the fourth-pass
A4 = cross-sectional area of the fourth pass square groove = a24
A5 = cross-sectional area of the fifth pass diamond groove, intermediate between the two square passes
Let λm = (geometric) mean coefficient of elongation of the fifth and sixth passes.
A A4 A5
A4 =  = λ5 × λ6 = λm × λm = λ2m
6 A5 A6

A a 2
 A4 = (a4 ) = λ2m
6 6

a4
( ) = λm
a6
a 4 = λm × a 6
Reduction for finishing passes must be kept to the minimum for reasons of
i) It lowers the roll separating force and thus assures the accuracy of shape and size.
ii) The temperature of the billet decreases from the first pass onward and therefore the resistanace to
deformation increases.
Since m for overall rolling is 1.3, and  for finishing passes is kept lower i.e. λm = 1.1
a
(a4 ) = λm = 1.1
6

 a4 = 1.1 × 40.5 = 44.5 mm

16
.
When a diamond groove is interposed between two square grooves, the design of the diamond groove
follows the following practice
A5 = Area of the fifth-pass diamond groove = a6 × a4 = 44.5× 40.5
= 1802.25 mm2
h5 = height of the diamond groove
(a4 − a6 ) (a4 − a6 )
=1.35 a6 − [√R (a4 − a6 ) − ]
2 a4 2

(44.5 −40.5) (44.5 −40.5)

= 1.35  40.5 − × [√250 × (44.5 − 40.5) − ]
2 × 44.4 2 × 0.45

= 53.3 mm
b5 = breadth of the fifth-pass diamond groove
1
Area of the fifth-pass diamond groove = A5 = × b5 × h5
2
1
1802 = × b5 × 53.5
2

b5 = 67.6 mm
1 1
a5 = 2 √b25 + h25 = √(67.6)2 + (53.3)2
2

= 43 mm
Diameter of the roll in the finishing stand D = Ø 500 mm
Clearance between the rolls = 1% of roll diameter = 0.01 × D = 0.01 × 500 = 5 mm
3. Design of square groove for fourth pass [preleader] pass

17
a4 = side of the square groove of the fourth pass = 44.5 mm

b4 = h4 = √2 a4 = 63 mm
r4 = fillet radius = 0.15 a4 = 6 mm
R 4 = corner radius = 0.85 a4 = 38 mm
Diameter of roll in the roughing stand D = Ø750 mm
Clearance between the rolls = 0.01 × D = 0.01 × 750 = 8 mm.
A4 = cross-sectional area of the fourth pass groove = a24 = 1980.25 mm2
Designing the diamond groove for the third pass
a4 = side of the square groove of the fourth pass = 44.5 mm
a2 = side of the second-pass square groove
A4 = cross-sectional area of the fourth pass square groove = a24
A3 = cross-sectional area of the third pass diamond groove
A2 = cross-sectional area of the second-pass groove = a22
Let λm = (geometric) mean coefficient of elongation of the third and the fourth passes
A A2 A3
 A2 =  = λ3  λ4 = λm  λm = λ2m
4 A3 A4

A a 2
 A2 = (a2 ) = λ2m
4 4

a2
( ) = λm
a4
a 2 = λm a 4

18
The crucial parameter that needs to be selected is the mean coefficient of elongation and it needs to more
than the overall coefficient of elongation i.e., 1.3 which is general. In this case, we take is 1.35 viz.
λm = (geometric) mean coefficient of elongation of
a2 = λm × a4 = 1.35 × 44.5
= 60 mm

When a diamond groove is interposed between two square grooves, the design of the diamond groove
follows the following practice.
A3 = Area of the fifth-pass diamond groove = a2 a4 = 60 × 44.5
= 2670 mm2
h3 = height of the third-pass diamond groove
(a2 − a4 ) (a2 − a4 )
=1.35 a4 − [√R × (a2 − a4 ) − ]
2 a2 2

(60 −44.5) (60− 44.5)

= 1.35  44.5 − [√375 × (60 − 44.5 ) − ]
2  60 2 × 0.45

= 52.5 mm
b3 = breadth of the third-pass diamond groove
1
Area of the fifth-pass diamond groove = A3 = b h3
2 3
1
2670 = × b3 × 52.5
2

b3 = 102 mm.

19
 1 1
a3 = 2 √b23 + h23 = × √(102)2 + (52.5)2
2

= 57.4 mm.
θ b 102
tan 2 = h3 = 52.5
3

θ = 125.50
Diameter of the roll in the finishing stand D = Ø750 mm
Clearance between the rolls = 1% of roll diameter = 0.01 × D = 0.01 × 750 = 8 mm
Designing the second-pass square groove
a2 = side of the square groove of the second pass = 60 mm

b2 = h4 = √2 × a2 = 85 mm.
r2 = fillet radius = 0.15 a2 = 9 mm
R 2 = corner radius = 0.85a2 = 50 mm.
Diameter of roll in the roughing stand D = Ø750 mm
Clearance between the rolls = 0.01  D = 0.01 × 750 = 8 mm.
A2 = cross-sectional area of the second-pass groove = a22 = 3600 mm2
Designing diamond groove for the first pass
The input square size at the operating temperature is 86 × 86 mm i.e.
a0 = side of the input square = 86 mm
a2 = side of the square groove of the second pass = 60 mm

20
 a0 86
λm = = 60 = 1.43
a2

A2 = cross-sectional area of the second-pass square groove = a22 = 3600 mm2

A1 = cross-sectional area of the first-pass diamond groove
A0 = cross-sectional area of the input stock = a20 = 862 = 7396 mm2
A1 = a0 × a2 = 86 × 60 = 5160 mm2
h1 = height of the first-pass diamond groove
(a0 −a2 ) (a0 −a2 )
=1.35 a2 − [√R × ((a0 − a2 ) − ]
2 a0 2

(86 −60) (86−60 )

= 1.35  60 − [√375 × (86 − 60 ) − ]
2  86 2 × 0.45

= 70.4 mm
b1 = breadth of the first-pass diamond groove
1
Area of the first-pass diamond groove = A1 = × b1 × h1
2
1
5160 = × b1 × 70.4
2

b1 = 146.6 mm.
1 1
a1 = 2 √b12 + h12 = × √(146.6)2 + (70.4)2
2

= 81.3 mm.
θ b 146.6
tan 2 = h1 =
1 70.4

θ ≈ 1290 129
Diameter of the roll in the finishing stand D = Ø750 mm

21
Clearance between the rolls = 1% of roll diameter = 0.01  D = 0.01 × 750 =8 mm.
Determination of RPM for all the stands
N1 = rpm of the first-stand = 60 (given)
N2 = rpm of the second-stand
D = Ø nominal roll diameter
De = Ø effective working diameter of the roll
= (D − k)
Area of the groove
Where, k = breadth of groove

In a grooved roll, the surface velocity at the bottom of the groove is less than the surface velocity at the
top of the groove where the roll diameter is larger. Since all the points on the surface of the stock leave
the roll at the same speed, the stock will be faster than the roll speed at the bottom of the grove but slower
than the speed of the roll at the top of the groove. At some point between the speed of the roll and the
speed of the stock at the exit plane will be equal,
The radius of the roll at his point is known as the effective radius and the corresponding diameter is
known as the effective diameter.
The De is different than the nominal roll diameter due to the presence of a deeper groove in the roll. It
depends on the shape and size of the groove.

Sr. No. Groove type Area of groove The breadth of the groove k

1 Box pass (b  h) bh b h

2 Square groove with side “a” a2 a√2 a

√2
1
3 Diamond groove bh b 0.5 h
2

π
4 Circular groove d2 d 0.8 d
4

π
5 Oval groove bh b 0.8 h
4

Xx

Pass De =
Groove type a h k D rpm
No. (D − k)

1 Diamond 70.4 35.2 750 714.8 60 (given)

22
2 Square 60 42.4 750 707.6 72.7

3 Diamond 52.5 26.25 750 723.75 85.3

4 Square 45.5 31.5 750 718.5 103

5 Diamond 53.3 26.7 500 473.3 188

6 Square 40.5 28.6 500 471.4 226

N2 D
= De1  (1 + s) where s = forward slip = 0.2
N1 e2

714.8
 N2 = 60 × 707.6 × 1.2 = 72.7 RPM
De2 707.6
N3 = N2 (1 + s) = 72.7  723.25  1.2 = 85.3 rpm.
De3

De3 723.75
N4 = N3 (1 + s) = 85.3   1.2 = 103 rpm
De4 718.5

De4 718.5
N5 = N4 (1 + s) = 103  473.3  1.2 = 186 rpm.
De5

De5 473.3
N6 = N5 (1 + s) = 188  471.4  1.2 = 226 rpm.
De6

You are required to roll a Ø30mm round of mild steel from a billet of Ø90 mm in a
continuous mill. The initial rolling temperature is 1100C and the finish rolling temperature
is 900C. Assume the value of the average coefficient of elongation between 1.2 to 1.4.
a) Determine the roll -specifications using rolls of the nominal diameter of Ø 800 mm, Ø
720 mm, and Ø 600 mm.
b) Determine the coefficient of elongation for each pass.
c) Determine the rolling sequence and type of groove for all rolling stands.
d) Design and draw a neat sketch of the finishing passing grove.

23
The round sizes of Ø 90 mm and Ø 30 are at room temperature. Hence they must be converted to size at
the corresponding operating temperature of 1100C.
The initial rolling temperature is 1100C. Assuming ambient temperature of 25C and the linear
−6
coefficient of expansion for steel is 12 × 10 and therefore the input stock diameter
ah = ac [1 + α (t 0 − t a )]
α = linear coefficient of expansion = 12 × 10−6
t 0 = rolling/ opertaing temperature 0C = 1100 0C
t a = ambient temperature 0C = 25 0C
d0 = 90 × [1 + 12 × 10−6 × (1100 − 25) ]
= 91.2 mm

A0 = initial cross-sectional area = 4 d20 = 6527 mm2

The finishing stand's rolling temperature is 900C

dn = 30 × [1 + 12 × 10−6 × (900 − 25) ]
= 30.32 mm
π π
An =4 × d2n = × (30.32)2 = 722 mm2
4

The λm employed for billet mill is between 1.2 to 1.4. Assuming λm for continuous billet mill = 1.35
log A0 − log An log (6527) – log(722)
n= = = 7.33
log λm log(1.35)

≈8 (As even numbers of passings are preferred for continuous billet mill)

24
The mill specifications: 800/4 − 600/2 − 400/2. The mill has three trains- roughing, intermediate, and
finishing having 4, 2, and 2 stands respectively.
The number of rolling stand available are 4 + 2 + 2 = 8. As the number of passes available meets the
requirement, it can be used for rolling.
Pass No. 0 1 2 3 4 5 6 7 8

Groove Round Oval Round Oval Round Oval Round Oval Round

Cross-section A0 A1 A2 A3 A4 A5 A6 A7 A8

Rolling sequence:
The finish pass must be round and consequently, the leader pass should be oval. Oval round pass
sequence has been selected because λm required for this rolling is not very high to select oval square
series.
Advantages of an ovalround pass series:
i. Lower stresses involved in this can be explained by smooth shape transition in these passes.
ii. Uniform distribution of temperature across the section.
iii. better conditions for preventing laps and seams for descaling.
The main disadvantage of this ovalround series is a reduced coefficient of elongation [1.3 to 1.5] as
compared to ovalsquare series [1.4 to 1.6]

1. Finishing pass round groove

d8 = Ø30.32 mm
1
c = clearance = 2 % of roll diameter

= 3 mm

A8 = × d28 = 722 mm2
4

2. Leader passSeventh passOval groove.

25
When the finishing pass is round and the leader pass is oval, in that case, the coefficient of elongation is
selected in the range of 1.1 to 1.2.
 = 1.2
A7
= λ = 1.2
A8

A7 = 866 mm.

The thickness of the oval groove is taken about 0.85 times (85%) of the diameter of the subsequent pass
round groove
h7 = 0.85 × d8 = 0.85 × 30.32 =25.8 mm2


A7 = × h7 × b7
4

With A7 = 866 mm2 and h7 = 25.8 mm

b7 = 42.7 mm
Clearance between the rolls = 0.015  D = 0.01  600 = 6 mm
b27 + h27 42.72 + 25.82
R7 = = = 24 mm
4h7 4×25.8

3 Sixth Pass with Round groove

26
 A
Taking λ = 1.3 in A6 = 
7

A6 = 1.3 × A7 = 1.3 × 866 =1126 (with A7 = 866 mm2 )


A6 = 4 d26

1126 = 4 d26
d6 = Ø37.86 mm
c = 3 mm
4 Fifth Pass with oval groove

A6 = 1126 mm2 and chosen λ = 1.35

A5
= λ = 1.35
A6

A5 = λ × A6 = 1.35 × 1126 =1520 mm2

27
The thickness of the oval groove is taken about 0.85 times of the diameter of the subsequent pass round
groove
h5 = 0.85 × d6 = 0.85 × 37.89 = 32 mm.

A5 = 4 h5 b5

1520 = 4 × 32 × b5
b5 = 60.5 mm
Clearance between the rolls = 0.015  D = 0.01 × 600 = 6 mm
b25 + h25 60.52 + 322
R5 = = = 37 mm
4 h5 4×32

Fourth Pass with round grrove groove

A
Taking λ = 1.35 in A4 = λ
5

A4 = 1.35 A5 = 1.35 × 1125 = 2052 mm2


A4 = 4 d24

2052 = 4 d24  d4 = Ø51.1 mm
c = 3 mm
r = 5 mm
Third Pass with oval groove
A4 = 2052 mm2
λ =1.35
A3
= λ = 1.35
A4

 A3 = λ × A4 = 1.35 × 2052 = 2770 mm2

The thickness of the oval groove is taken about 0.85 times the diameter of the subsequent pass round
groove
h3 = 0.85 × d4 = 0.85 × 51.1 = 43.4 mm

A3 = 4 h3 b3

2770 = 4 × 43.4 × b3
 b3 = 81.3 mm
Clearance between the rolls = 0.01 × D = 0.01 × 800 = 8 mm
b23 + h23 43.42 + 81.32
R3 = = = 49 mm
4h3 4×43.4

Second Pass with round groove groove

28
A3 = 2770 mm2 and taking λ = 1.4
A2
= λ
A3

A2 = 1.4 × A3 = 1.4 × 2770 = 3878 mm2


A2 = 4 d22

∴ 3878 = 4 d22 ∴ d2 = Ø70.3 mm
c = 3 mm
r = 5 mm
First Pass with oval groove
A2 = 3878 mm2
λ = 1.4
A1
= λ = 1.4
A2

 A1 = λ × A2 = 1.4 × 3878 = 5430 mm2

The thickness of the oval groove is taken about 0.85 times the diameter of the subsequent pass round
groove
h1 = 0.85 × d2 = 0.85 × 70.3 = 60 mm

A1 = 4 × h1 × b1

5430 = 4 × 60 × b1  b1 = 115 mm
Clearance between the rolls = 0.01 × D = 0.01 × 800 = 8 mm
b21 + h21 1152 + 602
R3 = = = 70 mm.
4h1 4×60

Pass Groove D (mm) d or h k (D – k) rpm

A Groove Area 
No. type mm
0 Round A0 6526
A
1 Oval A1 5430 1.2  1 = A0 800 60 48 752 80
1

A1
2 Round A2 3878 1.4 2 = 800 70.3 56 744 97
A2

3 Oval A2 800 43.4 35 765 113.3

A3 2770 1.4 3 =
A3

A
4 Round 1.35 4 = A 800 51.1 41 759 137
3
A4 2052
4

A
5 Oval 1.35 5 = A 720 32 26 694 180
4
A5 1520
5

A
6 Round 1.35 6 = A 720 37.9 30 690 217.3
5
A6 1126
6

29
 A
7 Oval A7 866 1.3  7 = A6 600 26 21 579 310.8
7

A
8 Round A8 722 1.2  8 = A7 600 30.32 25 575 375.6
8

Area of the groove

Where, k = breadth of groove

= 0.8 h for oval pass

= 0.8 d for round pass
N2 De1
=  (1 + s) where s = forward slip = 0.2
N1 De2
752
N2 = 80  744  1.2 = 97 rpm
De2 744
N3 = N2   (1 + s) = 97   1.2 =113.3 rpm.
De3 765
De 765
N4 = N3  De3  (1 + s) = 113.3  759  1.2 = 137 rpm
4
De4 759
N5 = N4  De  (1 + s) =137  694  1.2 = 180 rpm.
5
De5 694
N6 = N5  De  (1 + s) = 180  690  1.2 = 217.3 rpm.
6
De6 690
N7 = N6  De  (1 + s) = 217.3  579  1.2 = 310.8 rpm.
7
De7 579
N8 = N7  De  (1 + s) = 310.8  575  1.2 = 375.6 rpm.
8

Determine by calculation the initial billet size required at room temperature to roll into a Ø 40 mm
mild in steel (M.S) round using only four passes/stands in a continuous rolling mill. The roll pass
sequence to be followed is  diamond  square  oval round. Assume suitable mill specifications
and other missing data as applicable and state the same clearly. The following information may be
used.
i) Initial rolling temperature is 1200C and finish rolling temperature of 900C.
ii) Initial maximum permissible reduction of the square section in the oval groove is 42% and in all
other passes it is limited to 30%.
You are also required to pre-leaser and leader grooves with complete dimensioning with input stock
profile superimposed on each of these two grooves.
Sol. Mill type  continuous billet mill with 4 stands and have working roll diameter of 700 mm.
Pass sequence: diamond  square  oval  round

30
λm = (geometric) mean coefficient of elongation = 1.3
Determination of initial billetsize at room temperature
d4 c = Ø 40 mm, finished round diameter at room temperature.
d4 = diameter Ø of the round at the rolling temperature of 900C
d4 = d4 c [1 + α (t 0 − t a )]
α = linear coefficient of expansion = 12 × 10−6
t 0 = rolling/ operating temperature 0C = 900 0 C
t a = ambient temperature 0C = 25 0C
d4 = 40 × [1 + 12 × 10−6 × (900 − 25) ]
= 40.42 mm

A4 = cross-sectional area of the fourth pass groove = 4 d24

= 4 × (40.42)2

= 1283 mm2
A0 = initial billet cross-section at the initial rolling temperature of 1200C.
n = 4 (number of passes)
log A0 − log An
n=
log λm

log A0 − log 1283

4 = log(1.3)

A0 = 3664 mm2
Assuming a billet shape as square as the first pass is a diamond pass. Let a0 is a side of the square.
a0 = input size of the billet at an initial temperature of 1200C
A0 = a20 =3664 mm2
∴ a0 = 60.5 mm
Let a0c is the side of the input square at room temperature
Fig
a0 = a0c [1 + α (t 0 − t a )]
t 0 = 1200 0 C ,t a = 25 0C, α = 12 × 10−6
60.5 = a0c × [1 + 12 × 10−6 × (1200 − 25) ]
a0c = 59.7 mm
The initial square billet size required at room temperature is 59.7 mm.

31
1. Fourth (finishing) Pass with the round groove
d4 = (1 +  T)  (d  1)
where 1 = lower tolerance obtainable = 0.5
Fig
d = nominal diameter of the round at room temperature
d4 = [1 + 12 × 106 × (900  25)] (40  0.5)
= Ø 39.91 mm
π
A4 = d24 = 1283 mm2
4

2. Third Pass (Leader pass) with oval groove.

The coefficient of elongation for the oval cross-section is in the range of 1.1 to 1.3 if it feeds the finishing
round.
A3
Taking λ =1.2  =λ
A4

A3 = cross-section of the oval groove = λ × A4

= 1.2 ×1283 = 1540 mm2
Fig
c = clearance between rolls is 1% of roll diameter
= 0.01 D Where D = roll diameter = Ø 700 mm
c = 7 mm
π π
A3 = h3 b3 = × 34.4 × b3
4 4
b3 = 57 mm
b23 + h23
R3 = = 32 mm
4h3

3. Second Pass with square groove [Pre leader pass]

A pass before a leader pass is also known as a strand pass. Enough care should be taken to ensure the
correct and complete filling of the leader oval groove to avoid the possibility of surface defects in the final
round. The side of strand square is obtained in such case [square  oval  round ] by multiplying the
round diameter by 1.1 that giving an overall reduction of 35%.
a2 = 1.1 × d4 =1.1  40.42
= 44.46 mm.
b2 = h2 = √2 a2 = 62.88 mm.
r2 = fillet radius = 0.15 a2 = 7 mm
R 2 = corner radius = 0.85 a2 = 37mm
32
A2 = a22 = (44.46)2 = 1977 mm2
4. First pass with Diamond groove.
A2 = 1977 mm2
A0 = a20 = (60.5)2 = 3664 mm2
A1 = area of the diamond groove = a0 a2 = 60.5 × 44.46
= 2691 mm2
(a0 − a2 ) (a0 − a2 )
h1 = diamond groove breadth =1.37 a2 − [√R. (a0 − a2 ) - ]
2 a0 2

μ = 0.42
(60.5 −44.46) (60.5−44.46)
h1 = 1.37 × 44.46− × [√350 × (60.5 − 44.46) − ]
2 × 60.5 2 × 0.42

= 53 mm
1
A1 = b1 h1
2
1
2691 = 2 × b1 × 53

b1 = 101.5 mm Fig
1 1
a1 = 2 √b12 + h12 = × √(101.5)2 + (53)2
2

= 57.3 mm.
θ b /2 101.5
tan 2 = h1/2 =
1 53

θ = 1250
A summary of computed values is given in the following table:

Cross section
Pass No Groove Size h  b Area  k De rpm
reduction

0  60.5  60.5 3664

1 Diamond 53  101 2691 1.36 26.5 53 647 80

2 Square 62.88  62.88 1977 1.36 26.5 44.545 655 97

3 Oval 34.4  57 1540 1.28 28.3 28 672 120

4 Round 39.91  39.91 1283 1.2 16.6 32 668 144

Determining the RPM of various stand

33
N1 = rpm of the first-stand = 80 (given)
De = effective working roll diameter. It is different than the nominal roll diameter due to the presence of
a groove in the roll and depends on the shape and size of the groove
=D−k
where D = nominal diameter of roll = Ø 700 mm in this case
Area of the groove
k = the breadth of the groove

Sr. Area of
Groove type K
No. groove

1 Box pass (b  h ) bh h

𝑎
2 Square groove with side “a” a2 √2

1
3 Diamond groove having a depth of h bh 0.5h
2

π
4 Circular groove d2 0.8d
4

π
5. Oval groove bh 0.8h
4

N2 De1
= (1 + s) where s = slip = 20% = 0.2
N1 De2
De1 647
N2 = N1 (1 + s) = 80 × 655 × 1.2 = 95 rpm
De2
De2 655
N3 = N2 (1 + s) = 95 × 672 × 1.2 = 111 rpm
De3

De3 672
N4 = N3 (1 + s) = 111 × 668 × 1.2 = 134 rpm
De4

Determine the initial billet size required at room temperature to obtain a square bar of size
𝟖𝟎𝟎 𝟒𝟎𝟎
40  40 mm of mild steel. The rolling mill has six stands and has specifications  .
𝟒 𝟒
The pass sequence to be followed is the diamond  square  oval  square  oval  square.
The following information is also available for use:
The initial rolling temperature =1200 C
The finish-stand rolling temperature = 900C

34
The maximum permissible reduction square oval groove is limited to 40% and in all other passes limited
to 28%.
b) Draw a dimensioned sketch of the first pass diamond groove with the input profile superimposed.
c) Draw a dimensioned sketch of leader pass with input profile superimposed.
800 400
Sol. Mill specification  .
4 4

 Maximum number of passes available are = 4 + 2 = 6.

Pass sequence:
1 2 3 4 5 6
Diamond Square Oval Square Oval Square
The preferable profile of input stock is square as the first pass is diamond.
Hence reduction is from square to square.
ah = ac [1 + α (t 0 − t a )] Fig
a6 = 40 × [1 + 12 × 10−6 × (900 − 25) ]
= 40.42 mm
n= number of passes = 6
A0 = Initial billet cross-section at the operating temperature of 1200 C
An = A6 = a26 = (40.42)2 = 1634 mm2
The available number of stands as per mill specifications is six and hence n=6
log A0 − log An
n= log λm

log A0 −log 1634

6= log(1.3)

A0 = 7887 mm2

a0 = √A0 = 88.8 mm
a0 is a side of the square input billet at the elevated temperature of 1200C. Therefore, the square side at
room temperature of 25C will be
a0 = ac [1 + α (t 0 − t a )]
88.8 = ac × [1 + 12 × 10−6 × (1200 − 25) ]
ac = 87.5 mm
 Initial billet size at room temperature is 87.5 mm square.
The sequence provided is oval  square sequence i.e., oval is interposed between the two square passes.

35
For finishing passes,  must be kept low and hence λ = 1.2
Percent
Pass No. Groove a A 
Reduction

0  88.8 7887

1 Diamond 5683 28.0% 1.39

2 Square 64 4096 28% 1.39

3 Oval 2940 28.2 1.39

4 Square 48.5 2352 20.00 1.25

5 Oval 1900 23.50 1.30

6 Square 40.42 1634 9.1% 1.1

Designing and drawing of leader pass [Oval pass]

A
(A5 ) = λ = 1.2
6

A5 = 1.2 × 1634 = 1960 mm2

For an oval pass
π b
A5 = b5 h5 and h = 2.3
4
π
A5 = × 2.3 × h25 = 1960
4

h5 = 33 mm
b5 = 76 mm
Clearance between two rolls = 0.1 × D = 0.01 × 400 = 4 mm

You are required to roll a 40  40 mm2 square from a square section of 175  175 mm2 of mild steel
𝟗𝟎𝟎 𝟕𝟎𝟎 𝟓𝟎𝟎
using a continuous billet mill having a specification of   . The forward slip for rolling
𝟒 𝟒 𝟐
can be taken as 0.2 and the rpm of the first stand is 20. The rolling temperature for all the stands
can be assumed to same and constant  1100C. Find the following:
i) Appropriate rolling sequence and type of grooves used in all the stands.
ii) Coefficient of elongations.
iii) Design and draw neat and dimensioned sketches of finishing and leader pass grooves.

36
iv) the rpm for each stand.
Solution
A0 = initial billet cross-section = 175 × 175 mm2
An = finished billet cross-section = 40 × 40 mm2
Mill specifications: 900/4 − 700/4 − 500/2
Hence, the available number of stands and passes.
= 4 + 4 + 2 = 10
log A0 − log An
n= log λm

log(175 ×175)−log(40 ×40)

10 = log λm

∴ λm = 1.34
The λm for the diamondsquare series is 1.2 to 1.4 and therefore this series can be selected.

0 1 2 3 4 5 6 7 8 9 10

SQ D S D S D S D S D S

S = square D = Diamond.

Groove type Area a  h k De

0 SQ 31435 177.3

1 D 22162 1.42 155.7 77.85 822.15

2 S 15625 125 1.42 176.8 88.38 811.62

3 D 11250 1.40 110 55.00 845.0

4 S 8100 90 1.40 127.3 63.64 836.36

5 D 5760 1.40 76.83 38.42 711.58

6 S 4096 64 1.40 90.5 45.25 704.75

7 D 3136 1.31 59.6 29.8 720.2

8 S 2401 49 1.31 69.3 34.64 715.35

9 D 1985 1.21 52.0 26.00 474.0

10 S 1460 40.5 1.21 57.3 28.64 471.36

37
a10 = side of the finishing groove i.e. square groove at the working temperature of 1100C
a10 = 40 × [1 + 12 × 10−6 × (1100 − 25) ]
= 40.5 mm
a0 = 175 × [1 + 12 × 10−6 × (1100 − 25) ]
= 177.3 mm
ii) Design for finishing pass:
a10 = 40.5 mm.
h10 = b10 = 40.5  √2
= 57.3 mm
c = 0.01 D = 9 mm Fig
r10 = 0.15 a10 = 6 mm
R10 = 0.85 a10 = 34 mm
Design for Leader pass: Diamond groove (9th pass).
A9 = a10 × a8 = 40.5 × 49 =1985 mm2
(a8 − a10 ) (a8 − a10 )
h9 = 1.35 a10 − [√R (a8 − a10 ) − ]
2 a8 2 

 = 0.4 for hot working

(49 − 40.5) (49 −40.5)
h9 =1.35  40.5 − × [√250 × (49 − 40.5) − ]
2 × 49 2 ×0.4

= 52 mm
1
A9 = b9 h9
2
1
1985 = 2 × b9 × 52

b9 = 76.4 mm
Fig
c = 0.01 D = 0.01 × 500 = 5 mm
1
a9 = √h29 + b29 = 40.4 mm
2
θ b9 76.4
tan (2) = =
h9 52

θ = 1120

38
To find the effective diameter for all the passes, ‘h’ (depth of groove must be known. ‘h’ for square passes
can be found as h = √2 a but for diamond passes, the same has to be calculated using the Bakhtinov
formula.
h for the seventh pass
a8 = 49 mm a6 = 64 mm R =750/2 = 375 mm μ = 0.4
(a6 − a8 ) (a6 − a8 )
h7 = 1.35 a8 − [√R (a6 − a8 ) − ]
2 a6 2 

(64 − 49) (64 − 49)

= 1.35 × 49 − [√375 × (64 − 49) − ]
2 × 64 2 × 0.4

= 59.6 mm
h for the fifth pass
h for the seventh pass:
a4 = 90 mm a6 = 64 mm R =750/2 = 375 mm μ = 0.4
(a4 − a6 ) (a4 − a6 )
h7 = 1.35 a6 − [√R (a4 − a6 ) − ]
2 a4 2 

(90 – 64) (90 – 64)

=1.35 × 64 − [√375 × (90 – 64) − ]
2 × 90 2 × 0.4

= 76.8 mm
h for the third pass
a4 = 90 mm a2 = 125 mm R =900/2 = 450 mm μ = 0.4
(a2 − a4 ) (a2 − a4 )
h3 = 1.35 a4 − [√R (a2 − a4 ) − ]
2 a2 2 

(90 − 64) (90 – 64)

=1.35 × 90 − × [√450 × (90 – 64) − ]
2 × 125 2 × 0.4

= 110 mm
h for the first pass
a0 = 177.3 mm a2 = 125 mm R =900/2 = 450 mm μ = 0.4
(a0 − a2 ) (a0 − a2 )
h1 = 1.35 a2 − [√R (a0 − a2 ) − ]
2 a0 2 

(177.3 − 125) (177.3 − 125)

=1.35 × 125 − × [√450 × (177.3 − 125) − ]
2 × 177.3 2 × 0.4

= 156 mm
rpm calculations for each stand.
N1 = 20 rpm s = forward slip = 0.2
De 822.15
N2 = N1 De1 (1 + s) = 20 × 811.62 × 1.2 = 24.3 rpm
2

39
 De2 811.62
N3 = N2 (1 + s) = 24.3 × × 1.2 = 28 rpm
De3 845

De3 845
N4 = N3 (1 + s) = 28 × 836.36 × 1.2 = 34 rpm
De4
De 836.36
N5 = N4 De4 (1 + s) = 34 × 711.58 × 1.2 = 48 rpm
5

De5 711.58
N6 = N5 (1 + s) = 48 × 704.74 × 1.2= 58 rpm
De6
De6 704.75
N7 = N6 (1 + s) = 58 × × 1.2= 68 rpm
De7 720.2
De7 720.2
N8 = N7 (1 + s) = 68 × 715.35 × 1.2 = 82 rpm
De8

De8 715.35
N9 = N8 (1 + s) = 82 × × 1.2 = 148 rpm
De9 474
De9 822.15
N10 = N9 (1 + s) = 148.5 × 811.62 × 1.2 = 179.8 rpm
De10

Pass 1 2 3 4 5 6 7 8 9 10

Groove D S D S D S D S D S

De 822 812 845 836 712 705 720 715 474 471

rpm 20 24.3 28 34 48 58 68 82 148.5 180

40