Effect of roller diameter on the production rate in hot rolling process: Mathematical modeling and experimentation approach

Abstract

Metal forming techniques are critical in the industrial sector. Metal forming procedures are used to create components with cross-sections such as conical, elliptical, cylindrical, oval, etc. As mentioned earlier, one of the procedures for forming the shapes is plate bending. The functioning of a plate rolling mill is related to various loading restrictions, while metals are bit with the lateral rollers of a reversed roller stand. Hot rolling is a vital phase in the manufacture and fabrication of steel sheets, resulting in a product with a high degree of flexibility. The paper justifies the experimental model, which verifies the experimental result using a mathematical model for the hot rolling process production rate. The mathematical model was developed using the Buckingham Pi (π) methodology and the dimensional analysis method. In addition, the influence of roller diameter on production rate was calculated at a diameter of 225 mm, 285 mm and 345 mm. The maximum production rate of 46.2 tons, 49.5 tons and 53.0 tons was observed at a roller diameter of 225 mm, 285 mm and 345 mm respectively. The percentage error between experimental and mathematical readings varies from 4.1 to 10.0%, 3.7 to 8.6% and 2.3 to 8.2% at roller diameter of 225 mm, 285 mm and 345 mm respectively. The experimental results are closely related to mathematical a modeling value, which further verifies the developed mathematical model using the Buckingham Pi (π) approach.