sheet rolling machine

8/11/2019 Sheet Rolling Machine

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CONTENTS

Sl.No NAME OF THE CONTENT PAGE NO.

1 SYNOPSIS 4

2 INTRODUCTION 6

3 PROJECT PLANNING 11

4 FABRICATION DETAILS 19

5MECHANISM SHEET ROLLING

PROCESS22

6 LIST OF MATERIAL 24

7 COST ESTIMATION 26

8 DC MOTOR DRIVE DETAILS 28

9 DRAWING 41

10 CONCLUSION 43

11 BIBILIOGRAPHY 46

12 PARTS OF DIAGRAM 48

13 ASSEMBLY OF DIAGRAM 50


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SYNOPSIS

This sheet rolling machine is used to roll the flat strip in order to make the

cylindrical shape container. The required diameter of cylinder is first cut from the

main sheet in the form of strip of length equal to 3.14x Dia and the height of the

cylinder is marked to breath wise dimension in the sheet. This sheet is feed in to

the roller which is driven by the spur gear arrangement. This machine have Three

rollers. Two rollers are used for feeding the work and the third roller is used to give

pressure in order to make cylinder.


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INTRODUCTION

This is a selfassessment test on the part of the students to assess his competency

in creativity.

During the course of study, the student is put on a sound theoretical

foundation of various mechanical engineering subjects and of course, to a

satisfactory extent. Opportunities are made available to him to work on different

kinds of machines, so that he is exposed to various kinds of manufacturing process.

As a students learn more and more his hold on production technology

becomes stronger. He attains a stage of perfection, when he himself is able to

design and fabricate a device.

This is the project work. That is the testimony for the strenuous training,

which the student had in the institute. This assures that he is no more a student, he

is an engineer.

This report discuses the necessity of the project and various aspects of

planning , design, selection of materials, fabrication, erection, estimation and

testing.

INTRODUCTION

In metalworking, rolling is a metal formingprocess in which metal stock is

passed through a pair of rolls. Rolling is classified according to the temperature of
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the metal rolled. If the temperature of the metal is above its recrystallization

temperature, then the process is termed as hot rolling. If the temperature of the

metal is below its recrystallization temperature, the process is termed as cold

rolling. In terms of usage, hot rolling processes more tonnage than any other

manufacturing process and cold rolling processes the most tonnage out of all cold

workingprocesses.[1][2]

There are many types of rolling processes, including flat rolling, foil rolling, ring

rolling, roll bending, roll forming,profile rolling, and controlled rolling.

Hot rolling

A coil of hot-rolled steel

Hot rolling is a metalworking process that occurs above the recrystallization

temperature of the material. After the grains deform during processing, they

recrystallize, which maintains an equiaxed microstructure and prevents the metal

from work hardening. The starting material is usually large pieces of metal, like

semi-finished casting products,such as slabs, blooms, and billets. If these products

came from acontinuous casting operation the products are
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usually fed directly into the rolling mills at the proper temperature. In smaller

operations the material starts at room temperature and must be heated. This is done

in a gas- or oil-firedsoaking pit for larger workpieces and for smaller workpieces

induction heating is used. As the material is worked the temperature must be

monitored to make sure it remains above the recrystallization temperature. To

maintain a safety factor a finishing temperature is defined above the

recrystallization temperature; this is usually 50 to 100 C (122 to 212 F) above the

recrystallization temperature. If the temperature does drop below this temperature

the material must be re-heated before more hot rolling.[3]

Hot rolled metals generally have little directionality in their mechanical properties

and deformation induced residual stresses. However, in certain instances non-

metallic inclusions will impart some directionality and workpieces less than 20 mm

(0.79 in) thick often have some directional properties. Also, non-uniformed cooling

will induce a lot of residual stresses, which usually occurs in shapes that have a

non-uniform cross-section, such as I-beams and H-beams. While the finished

product is of good quality, the surface is covered in mill scale,which is anoxide

that forms at high-temperatures. It is usually removed via pickling or the smooth

clean surface process, which reveals a smooth surface.[4] Dimensional tolerances

are usually 2 to 5% of the overall dimension.[5]
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Hot rolling is used mainly to produce sheet metal or simple cross sections, such as

rail tracks.

Cold rolling

A coil of cold-rolled steel

Cold rolling occurs with the metal below its recrystallization temperature (usuallyat room temperature), which increases thestrength viastrain hardening up to 20%.

It also improves the surface finish and holds tighter tolerances.Commonly cold-

rolled products include sheets, strips, bars, and rods; these products are usually

smaller than the same products that are hot rolled. Because of the smaller size of

the workpieces and their greater strength, as compared to hot rolled stock, four-

high or cluster mills are used.[2] Cold rolling cannot reduce the thickness of a

workpiece as much as hot rolling in a single pass.

Cold-rolled sheets and strips come in various conditions: full-hard, half-hard,

quarter-hard, and skin-rolled. Full-hard rolling reduces the thickness by 50%,

while the others involve less of a reduction. Quarter-hard is defined by its
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ability to bebentback onto itself along thegrain boundary without breaking. Half-

hard can be bent 90, while full-hard can only be bent 45, with the bend radius

approximately equal to the material thickness. Skin-rolling, also known as a skin-

pass, involves the least amount of reduction: 0.5-1%. It is used to produce a

smooth surface, a uniform thickness, and reduce the yield-point phenomenon (by

preventing Luder bands from forming in later processing).[6] It is also used to

breakup the spangles in galvanized steel.[citation needed]Skin-rolled stock is usually

used in subsequent cold-working processes where good ductility is required.[2]

Other shapes can be cold-rolled if the cross-section is relatively uniform and the

transverse dimension is relatively small; approximately less than 50 mm (2.0 in).

This may be a cost-effective alternative toextruding or machining the profile if the

volume is in the several tons or more. Cold rolling shapes requires a series of

shaping operations, usually along the lines of: sizing, breakdown, roughing, semi-

roughing, semi-finishing, and finishing.[2]

Processes

Flat rolling

Flat rolling is the most basic form of rolling with the starting and ending material

having a rectangular cross-section. The material is fed in between two rollers,

called working rolls, that rotate in opposite directions. The gap between the two

rolls is less than the thickness of the starting material, which causes it to deform.

The decrease in material thickness causes the material to elongate. Thefriction at

the interface between the material and the rolls causes the material to be pushed
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through. The amount of deformation possible in a single pass is limited by the

friction between the rolls; if the change in thickness is too great

the rolls just slip over the material and do not draw it in.[1]The final product is

either sheet or plate, with the former being less than 6 mm (0.24 in) thick and the

latter greater than; however, heavy plates tend to be formed using apress,which is

termedforming, rather than rolling.[citation needed]

Oftentimes the rolls are heated to assist in the workability of the metal. Lubrication

is often used to keep the workpiece from sticking to the rolls.[citation needed]To fine

tune the process the speed of the rolls and the temperature of the rollers are

adjusted.[7]

Foil rolling

Foil rollingis a specialized type of flat rolling, specifically used to produce foil,

which is sheet metal with a thickness less than 200 m (0.0079 in). [citation needed]The

rolling is done in a cluster mill because the small thickness requires a small

diameter rolls.[3]To reduce the need for small rollspack rollingis used, which rolls

multiple sheets together to increase the effective starting thickness. As the foil

sheets come through the rollers, they are trimmed and slitted with circular or razor-

likeknives.Trimming refers to the edges of the foil, while slitting involves cutting
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it into several sheets.[7]Aluminum foil is the most commonly produced product via

pack rolling. This is evident from the two different surface finishes; the shiny side

is on the roll side and the dull side is against the other sheet of foil.[8]

Ring rolling

A schematic of ring rolling

Ring rolling is a specialized type of hot rolling that increases the diameter of a

ring. The starting material is a thick-walled ring. This workpiece is placed on an

idler roll, while another roll, called the driven roll, presses the ring from the

outside. As the rolling occurs the wall thickness decreases as the diameter

increases. The rolls may be shaped to form various cross-sectional shapes. The

resulting grain structure is circumferential, which gives better mechanical

properties. Diameters can be as large as 8 m (26 ft) and face heights as tall as 2 m

(79 in). Common applications include rockets, turbines, airplanes,pipes, and

pressure vessels.[4]

Roll bending
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Roll bending

Roll bending produces a cylindrical shaped product from plate or steel metal.[9]

Roll forming

Roll forming

Roll forming is a continuous bending operation in which a long strip of metal

(typically coiled steel) is passed through consecutive sets of rolls, or stands, each

performing only an incremental part of the bend, until the desired cross-section

profile is obtained. Roll forming is ideal for producing parts with long lengths or in

large quantities.
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Structural shape rolling

Cross-sections of continuously rolled structural shapes, showing the change

induced by each rolling mill.

Main article:Structural shape rolling

Controlled rolling

Controlled rolling is a type of thermomechanical processing which integrates

controlled deformation and heat treating. The heat which brings the workpiece

above the recrystallization temperature is also used to perform the heat treatments

so that any subsequent heat treating is unnecessary. Types of heat treatments

include the production of a fine grain structure; controlling the nature, size, anddistribution of various transformation products (such as ferrite,austenite,pearlite,

bainite,and martensite in steel); inducingprecipitation hardening;and, controlling

thetoughness.In order to achieve this the entire process must be closely monitored

and controlled. Common variables in controlled rolling include the starting
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material composition and structure, deformation levels, temperatures at various

stages, and cool-down conditions. The benefits of controlled rolling include better

mechanical properties and energy savings.[5]

.
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PRECAUTION BEFORE SELECTION OF THE PROJECT

Before rushing out of buy the material for the component first determine the

Size of material required for the sheet to be rolled. Obviously the first thing to

look at is Whether rolling having an enough provisions to roll the maximum size

of height required for the cylinder.

PROJECT PLANNING

CONCEPT OF THE PROJECTBefore starting every project its planning is to be done. In planning

functions are life the functions of nerves in our body. planning a project is a very

important task and should be taken up with great care as the efficiency of the

whole project largely depends upon its planning, while planning a project each and

every details should be worked out in anticipation should be carefully considered

with all the relative provisions aspects.

PROJECT CAPACITY

The capacity of the project must be decided considering the amount of

money which can be invested. The availability of material and machines and

usefulness of the project.

DESIGN AND DRAWING

Having decided about the project to be manufactured at must be designed.

Design work should be done very considering all the relevant factors.


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After design the project detailed drawing are prepared. Detailed

Specification for raw material and finished products should be decided Carefully

along with the specification of the machine required for the manufacture.

MATERIAL REQUIREMENTS

The list of material required for manufacture is prepared from the

drawing. The list is known as Bill of materials. Availability of these materials

is surveyed and purchased from the market.

OPERATION PLANNINGNext work of planning is to select the best method manufacture the

product, so that the wastage of materials, labour, machines and time can be

eliminated by considering various methods. The best method is to be selected for

fabrication and other works.

The proper method and proper person and the purposes of operation,

Necessity operation, proper machine planning. The best method is the

Developed and is applied to fabricate the project.

MACHINE LOADING

While planning proper care should be taken to find the machining time for the

operation as correct as possible. So that arrangement of full useof machines can be

made and the machine loading program can be decided.


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PURCHASE CONSIDERATION

It is difficult to manufacture all the components needed for the project in the

machine shop. In each case, we should decide whether to make or buy about a

particular item. It is decided during the planning after making a complete study of

relative merits and demerits.

EQUIPMENT PROCEDURE

Results obtained from operation planning and machine loading help

in calculating the equipment require specification of the equipment should be laid

down by considering then drawings. Drawings will also help in deciding the

necessary requirement of tools and accessories.


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FABRICATION

DETAILS

FABRICATION OF PARTS DETAILS


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. A sheet hot rolling method comprising: disposing a pair of work rolls respectively having

different diameters between upper and lower backup rolls; and driving only a large-diameter

work roll of the pair of work rolls for hot rolling to produce a sheet; wherein a small-diameterwork roll of the pair of work rolls is disposed so that a rotational axis of the small-diameter work

roll is positioned on a mill center, the mill center corresponding to a plane including center axes

of the upper and lower backup rolls, or a downstream side with respect to the mill center in arolling direction, and the large-diameter work roll is disposed so that a rotational axis of thelarge-diameter work roll is positioned on a downstream side with respect to the rotational axis of

the small-diameter work roll in the rolling direction.

2. The sheet rolling method according to claim 1, wherein an offset e 1by which the rotational

axis of the small-diameter work roll is shifted in the rolling direction from the mill center, and an

offset e2 by which the rotational axis of the large-diameter work roll is shifted in the rolling

direction from the rotational axis of the small-diameter work roll meet inequalities:

0 mme1 and 0 mm


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BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to a rolling mill provided with a pair of work rolls having different

diameters, and a sheet rolling method employing the same rolling mill.

2. Description of Related Art

A conventional rolling mill is provided with upper and lower work rolls respectively having

different diameters and supported by upper and lower backup rolls. In this type of rolling mill,

the larger work roll, i.e., the work roll having a larger diameter, is driven by a motor or the like

to roll a sheet. A rolling mill provided with work rolls having different diameters, sometimescalled a differential rolling mill (as compared with ordinary rolling mills provided with work

rolls of the same diameter) is able to roll a sheet at a high draft by a low rolling force, which is

advantageous in manufacturing steel sheets by rolling. Since only a small rolling force is

necessary, edge drop resulting from the flattening of the rolls can be suppressed and hence steelsheets having a small thickness deviation can be manufactured.

Generally, as shown in FIG. 8, working rolls 11 and 12 included in most rolling mills are

shifted downstream by an offset e with respect to backup rolls 13 and 14. The work rolls are

thus shifted downstream with respect to the backup rolls because a rolling mill in which workrolls are shifted downstream with respect to backup rolls is able to stabilize loading conditions

for loading a rolled sheet more effectively than a rolling mill in which work rolls are shifted

upstream with respect to backup rolls.

A related art is disclosed in JP-B No. 47421/1976.

Recently, hot rolling techniques for hot-rolling sheets are required to be capable of rolling sheets

in a greater rolling width, i.e., the width of the rolled sheet, and in smaller thickness, and of

rolling sheets at higher drafts. However, the diameter of the smaller work roll of the differential

rolling mill is smaller and the mechanical strength of the smaller work roll is insufficient to meetthe foregoing requirements. More specifically, a high stress is induced in necks, including

stepped parts, at the joints of the body, which is used for rolling, of the smaller work roller and

the journals, supported in bearings, of the smaller work roll.

Thus, the upper limit of the rolling width of steel sheets hot-rolled by differential rolling mills

has been 4 ft (about 1200 mm). Even the differential rolling mill that needs a relatively low

rolling force requires a high rolling force exceeding 3000 tons (3000 tf=2.94107

N) when therolling width exceeds 4 ft. An excessively high stress unbearable by the mechanical strength of

the smaller work roll is thus induced in the necks of the smaller work roll.

The present invention is intended to meet the foregoing requirements required of rolling mills for

hot-rolling sheets, including capability of rolling sheets in an increased width exceeding 4 ft byreducing mechanical load on work rolls.


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According to an exemplary embodiment of the invention, the small-diameter and the large-

diameter work rolls are disposed such that the offset of the axis of the large-diameter work roll

with respect to the mill center plane is greater than the offset which could be zero in some casesof the small-diameter work roll with respect to the mill center plane. This arrangement provides

for the horizontal component (SB1) of the vertical force exerted by the large-diameter work roll

on the small-diameter work roll and used to determine the horizontal force (P mt, the force c)) tobe directed upstream with respect to the rolling direction. Consequently, the horizontal force(Pmt, the force c)) is reduced. Since the direction of the horizontal component (SB1) is opposite to

the rolling direction, the horizontal force that acts on the small-diameter work roll, i.e., the

resultant force acting on the small-diameter work roll, i.e., the sum of the horizontal force (SR1,the force a)) and the horizontal component (SB1), is reduced. When the horizontal force is

reduced, the mechanical load on the small-diameter work roll is reduced accordingly even if the

vertical force, such as the force b), does not change. Consequently, a sheet having a big width

and a small thickness can be produced and draft at which the sheet can be rolled by one rollingmill can be increased.

In the sheet rolling method according to the first aspect of the present invention, it is preferablethat an offset e1by which the rotational axis of the small-diameter work roll is shifted from the

mill center plane, and an offset e2by which the rotational axis of the large-diameter work roll isshifted from the rotational axis of the small-diameter work roll (refer to FIG. 1 for e1 and e2)meet inequalities:

0 mme1 and 0 mm


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the possibility of increasing rolling width. Accordingly, the offsets e1 and e2 must satisfy

inequalities:

0e1 and 0 mm


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FIG. 7 is a typical view of a sheet rolling mill for hot-rolling sheets; and

FIG. 8 is a typical view of a conventional rolling mill.


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DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1 to 7 show a preferred embodiment of the present invention. FIG. 1 is a typical sideelevation of one of three downstream mills 10in a back stage (downstream side) of a rolling line

1shown in FIG. 7.

The rolling line 1for hot-rolling a steel sheet x is a tandem rolling line having six rolling mills 5and 10as shown in FIG. 7. The three front rolling mills 5 in a front stage (upstream side) are

ordinary four-high mills each having two work rolls 6and 7of the same diameter disposed one

on top of the other, and upper and lower backup rolls 8and 9supporting the work rolls 6and 7.The three back rolling mills 10 in the back stage are so-called differential rolling mills each

having an upper backup roll 13, a lower backup roll 14 and a pair of work rolls 11 and 12

respectively having different diameters and disposed between the backup rolls 13and 14. Both

the two work rolls 6and 7of each of the three front rolling mills 5are driven for rotation, whileonly the lower work roll 12of each of the three back rolling mills 10in the back stage is driven

for rotation because the required torque of the back rolling mills 10is not high.

Referring to FIG. 1 showing the back rolling mill 10, the diameter DW1 of the small-diameter

work roll 11 is 450 mm, the diameter DW2 of the large-diameter work-roll 12 is 590 mm, the

diameters DB of the backup rolls 13 and 14 are 1300 mm, Unless otherwise specified, thediameter of a roll is that of a part of the roll that comes into contact with the steel sheet x and the

body of the adjacent roll. In the back rolling stand 10, an offset e1 of the rotational axis of the

small-diameter work roll 11from the mill center plane, i.e., the plane including the center axes ofthe backup rolls 13and 14, and an offset e2 of the rotational axis of the large-diameter work roll

12from the rotational axis of the small-diameter roll 11are variable. In this embodiment,

e1=6 mm and e2=4 mm.

The rolling line 1hot-rolls a hot-rolled soft steel plate (SPHC, JIS) of 25 mm in thickness into asteel sheet of 1.2 mm in thickness and 1550 mm in width. The rolling line 1operates on a pass

schedule setting the thicknesses of the sheet at the respective exits of the front rolling mills 5and

the back rolling mills 10to, for example, 10.97 mm, 5.12 mm, 3.46 mm, 2.22 mm, 1.49 mm and

1.17 mm, respectively. A roll bender force of 80 ton (PB1 and PB2) is exerted on each of chockssupporting the work rolls 11and 12of the rolling mills 5and 10to control the shape of the steel

sheet x.

Generally, the rolling mills 5and 10need to exert considerably high rolling forces on the steel

sheet when the rolling width is big. Mechanical measures must be incorporated into the back

rolling mills 10 provided with the small-diameter work roll 11 in which an excessively highstress is liable to be induced when a high rolling force is used. Elaborate measures to withstandstress must be taken particularly for the fourth rolling mill 10that uses a high rolling force higher

than those used by the rest of the back rolling mills 10, i.e., the uppermost one among the three

back rolling mills 10in the back stage. In the rolling line 1shown in FIG. 7, the fourth rollingmill 10uses a rolling force as high as 3000 tons. The offsets e1 and e2 in the fourth rolling mill

10, i.e., a differential rolling mill, are determined so that an excessively high stress may not be


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induced in the small-diameter work roll 11 even a high rolling force is exerted to the small-

diameter work roll 11.

In a rolling mill in a comparative example,

e1=6 mm and e2=0 mm.

The rolling mill 10and the rolling mill in the comparative example will be compared, and theresults of mechanical examination of the work rolls 11and 12will be explained hereinafter.

Stresses that may be induced in the small-diameter work roll 11and the large-diameter work roll

12are calculated in the following manner. Forces exerted on the work rolls 11and 12include:

a) horizontal forces SR1 and SR2 acting on the work rolls 11and 13in directions shown in FIG.3, respectively, by the steel sheet x when only the large-diameter work roll 12 is driven for

rotation,

b) roll bender forces PB1 and PB2 (80 tons, not indicated) acting on the work rolls 11and 12in a

vertical plane perpendicular to the rolling direction, and

c) horizontal forces PmT and PmB acting on the work rolls 11and 12, respectively, when a rolling

force (3000 tons for the fourth rolling mill 10) is exerted on the work rolls 11and 12through the

backup rolls 13and 14in contact with the work rolls 11and 12, respectively.

Vertical forces acting on the work rolls 11and 12do not need to be considered because forces

exerted on the working rolls 11 and 12 by the backup rolls 13and 14 are balanced by forcesexerted on the work rolls 11and 12by the steel sheet x. Referring to FIG. 6 showing the small-

diameter work roll 11, the forces a) to c) exerted on a body 11b included in the small-diameterwork roll 11are counterbalanced by reaction forces exerted by bearings, not shown, on journals

11c. The magnitudes of the forces a) to c) will be examined supposing that forces acting in the

rolling direction, i.e., the direction of the blank arrows in FIGS. 2 and 3, are positive forces.

SR1=PRtan(/s) (1)

SR2=SR1(2)

where PR is rolling force, and is center angle corresponding to a part, in contact with the steel

sheet x, of the circumference of the small-diameter work roll 11expressed by:

=cos1

[{DW12DW2H/(DW1+DW2)}/DW1]

where H is the difference (1.24 mm) between the thickness H1(3.46 mm) of the steel sheet x at

the entrance of the fourth rolling mill 10, and the thickness H2(2.22 mm) of the steel sheet x atthe exit of the fourth rolling mill 10. In both the rolling mill 10in the embodiment and the rolling

mill in the comparative example, =4.53 from H=1.24 mm, and hence, using Expressions (1)

and (2),


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SR1=118.7 tons, and

SR2=118.7 tons.

The forces c) shown in FIG. 2 are:

PmT=SB=1SD1(3)

PmB=SD2+SB1(4)

where

SB1=PRtan[sin1

{2e2/(DW1+DW2)}]

SD1=PRtan[sin1

{2e1/(DB+DW1)}]

SD2=PRtan[sin

1

{2(e1+e2)/(DB+DW2)}]

Since e1=6 mm and e2=4 mm in the rolling mill 10in the embodiment, horizontal forces PmT and

PmB are calculated by using Expressions (3) and (4).

PmT=SB1SD1=23.120.6=2.5 (tons)

PmB=SD2+SB1=31.7+23.1=54.8 (tons)

Since e1=6 mm and e2=0 mm in the rolling mill in the comparative example,

PmT=SB1SD

1=020.6=20.6 (tons)

PmB=SD2+SB1=10.0+0=19.0 (tons)

Total forces (the sum of the forces a) to c)) F1 and F2 that act, respectively, on the work rolls 11

and 12are:

F1={(SR1PmT)2+PB1

2}

1/2

F2={(SR2+PmB)2+PB2

2}

1/2

Thus, reaction forces corresponding to the forces F1 and F2 act on the journals 11c of the small-diameter work roll 11, and those of the large-diameter work roll 12. The values of the total forcesF1 and F2 are converted into those in kgf (1 kgf=9.8 N) as follows.

F1 and F2 for the embodiment are:

F1=141,100 (kgf) and F2=102,400 (kgf).


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F1 and F2 for the comparative example are:

F1=160,600 (kgf) and F2=127,800 (kgf).

Whereas the forces SR1 and PB1 of the total force F1 acting on the small-diameter work roll 11are

always positive, the force PmT=SB1SD1 is negative and the total force F1 can be reduced when

2e2/(DW1+DW2)>2e1/(DB+DW1).


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The rolling mill in the comparative example, in which e1=6 mm and e2=0 mm, is unable to

satisfy this inequality, and hence the total force F1 is high.

Since forces respectively corresponding to the total forces F1 and F2 are exerted on the necks 11n

(FIG. 6) of the small-diameter work roll 11and those of the large-diameter work roll 12, bending

moments M1 and M2proportional to the lengths L1 and L2between the necks and the centers ofthe corresponding journals are produced at the necks 11n of the small-diameter work roll 11and

those of the large-diameter work roll 12. Consequently, bending stresses 1 and 2 are induced in

the necks of the work rolls 11and 12according to the respective section moduli Z1 and Z2 of thework rolls 11 and 12 and a stress concentration factor at the neck. Generally, M=FL,

Z=D3/32 and =M/Z, where D is diameter. L1=265 mm and D (diameter of the neck)=270

mm in the small-diameter work roll 11, L1=265 mm and D (diameter of the neck)=270 mm in the

large-diameter work roll 12, and is about 1.8. Therefore, in the rolling mill 10 in theembodiment, in which e1=6 mm and e2=4 mm,

1=34.8 kgf/mm2, and

2=15.9 kgf/mm2,

and in the rolling mill in the comparative example, in which e1=6 mm and e2=0 mm,

1=39.7 kgf/mm2, and

2=19.9 kgf/mm2

(1 kgf/mm2=9.810

6Pa).

FIGS. 4 and 5 are graphs showing the variation with the offset e 2 of the total forces F1 and F2acting on the work rolls 11 and 12and bending stresses 1 and 2 induced in the necks of the

work rolls 11and 12when e1 is 6 mm. The total force F1 and the bending stress 1 decreases asthe offset e2 increases in both the work rolls 11and 12.

As obvious from FIG. 5, the stress 1 induced in the small-diameter work roll 11 exceeds 40

kgf/mm2

when e20.

If e2>7 mm, bowing of the steel sheet x, i.e., upward warping of the leading edge of the steel

sheet x passed between the small-diameter work roll 11 and the large-diameter work roll 12

occurs and smooth rolling is impossible.

Therefore, the offset e2 must meet an inequality:

0


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The present invention is applicable to rolling of sheets using a rolling mill provided with a pair

of work rolls respectively having different diameters.

This invention relates in general to an improved sheet metal rolling machine adapted to roll sheetmetal to impart a radius thereto as is done in the manufacture of stove pipes, tubular ventilation

ducts, and the like.

One object of the present invention is to provide a sheet metal rolling machine which is designed

so that the intended curvature is imparted to a sheet of metal with one pass through the machine,the machine being operative to curve the sheet from edge to edge thereof leaving no unbent

portion, along either edge, requiring subsequent bending.

Another object of the invention is to provide a sheet metal rolling machine which is adjustable,

readily and quickly, to roll sheet metal to different radii, and such machine is also adjustable to

accommodate metal sheets of different gauges.

A further object of the invention is to provide a sheet metal rolling machine which comprises a

novel combination of a work supporting bed, an idler roller, and a cooperating driven feed roller;said elements of the machine being arranged so that the sheet of metal is worked by the

cooperating rollers at a point closely adjacent the delivery 2 end of the table which permits of

proper support of the work and bending thereof from edge to edge without leaving any materialunbent portion along either edge.

A further object of the invention is to provide 3 a sheet metal rolling machine which is practicaland effective for the purpose for which it is designed.

These objects are accomplished by means of such structure and relative arrangement of parts 3 aswill fully appear by a perusal of the following specification and claims.

In the drawings: Fig. 1 is a side elevation of the improved sheet metal rolling machine. 4 Fig. 2 isa fragmentary transverse elevation, mainly in section, of the adjustable roller assembly.

Fig. 3 is a cross section taken through the work supporting bed. 4 Fig. 4 is an enlarged,

fragmentary cross section illustrating the roller assembly and the adjacent or delivery end portion

of the work supporting bed; the drive roller being shown in fully retracted position. Pig. 5 is a

similar view, but shows the drive roller and bed as fully advanced.

Referring now more particularly to the characters of reference on the drawings, the improved

sheet metal rolling machine comprises a rigid, upstanding table or main frame I fitted on top witha work supporting bed 2 which is mounted for longitudinal adjustment by means of guide

channels 3 on the bed which cooperatively engage with longitudinal tongues 4 on the main frame

I. 0O The work supporting bed 2 may be adjusted lengthwise by any suitable means. At one endthe bed 2 includes a relatively thin, outwardly projecting delivery lip 5.


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At the end of the main frame I adjacent the delivery lips 5, the machine includes a pair of

transverse cooperating sheet metal rollers disposed one above the other in parallel relationship;

the upper roller 6 being an idler, while the lower roller 7 is driven. The mounting and operationof the rollers 6 and 7 is described in detail hereinafter.

The working face of the driven lower roller 7 is serrated, as shown, and is normally disposed inperipheral working contact with the upper, idler roller 6; the delivery lip 5 of the work

supporting bSd 2 terminating at its outer edge in very close relationship to said point of

peripheral working contact of the lower roller with the upper roller. The main frame I is fitted,beyond opposite ends of the rollers 6 and 7, with rigid, upstanding heads 8, each of which is

provided, on the outside, with a vertically adjustable slide 9 carried in vertical guide channels 10

on opposite sides of !5 said heads. The slides 9 are adjustable by screws I which extend upwardly

through outwardly projecting flanges 12 on the lower ends of the heads 8. The screws 11 areused not only to level the upper, idler roller 6 but to adjust said 0 roller relative to the plane of

the delivery lip 5, as is necessary for working in connection with sheet metal of different gauges.

The upper, idler roller 6 is supported at opposite ends by bearings, indicated at 13 and 14, re5spectively; the bearing 13 being hinged, as at 15, in connection with the corresponding slide 9,

for swinging movement in a vertical plane. The other bearing 14 is releasably held inengagement with the corresponding slide 9 by a removable 0 hold-down yoke 16 actuated by an

off-center type latch 17 mounted on said corresponding slide.

It will be seen that with release and removal of the hold-down yoke 16 from the bearing 14, that

the upper, idler roller 6 may swing upwardly 5 about the pivot 15 so as to move clear of the

lower, drive roller 7, and as is necessary to permit removal of tubular work from said idler roller

6. as will subsequently appear. As the upper, idler roller 6 is relatively heavy, the shaft 18 ofSsaid roller is extended at one end and connected by a rotary collar unit 19 with a tensioned

counterbalancing spring 20 which connects at its lower end to a suitable point on the main frame.

This arrangement makes it much easier for the operator to lift the upper, idler roller 6 for

removal of the work.

The lower, drive roller 7 is supported, at opposite ends, by bearings 2 carried on the free ends of

inwardly projecting legs 22 of bellcranks, indicated generally at 23; such belleranks eachineluding an elongated, depending leg 24 disposed outwardly of the adjacent end of the

upstanding main frame 1.

The pivot for these bellcranks 23 comprises, in each thereof, an eccentric circular cam 25 fixedon a transverse shaft 26 which is adjustably supported, at its ends, on ears 21 which project

outwardly from the head 8. The adjustable shaft 26 includes a square end for the placement of a

wrench thereon and is normally held -against l rotation by locking nuts, as shown. Eachbellcrank 23 includes an eccentric strap 28 which encircles the corresponding cam 25. Each

depending leg 24 is normally urge nary tod inwardly toward the upstanding main frame I by a

tension spring 29 connected between the lower end of such leg and the frame, there being anadjustable stop 30 for each leg 24 to limit the extent of such swinging motion of said

corresponding leg.


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The lower, drive roller 1 is driven at one end by an endless chain and sprocket unit 31 from a

reduction unit 32 driven by a motor mounted in the upstanding main frame I. A chain tightener

34 cooperates with the chain to maintain the same under proper tension regardless of the positionof adjustment of the lower, drive roller 7.

The lower, drive roller 7 is adjustable from its fully retracted position, as shown in Fig. 4, to itsfully advanced position, as shown ini Fig. 5, by rotation of the shaft 26 and the cams 25; the

springs 29 maintaining said lower roller in working engagement with the upper roller in all

positions of adjustment of said lower roller.

When the upper andoweaer rollers are in direct vertical alinement, as in Fig. 4, no bending of a

sheet of metal passed therebetween would result, and the extent of the bend or the radius of thebend is controlled by the advanced position of adjustment of the lower, drive roller 7. As the

lower, drive roller 7 is advanced by adjustment thereof, the point of peripheral working contact

of said drive roller with the idler roller is elevated-onsi the side ofthe idler roller opposite the

work supporting bed-relative to said bed so that the radius of the bend which will be imparted to

sheet metal work passing therethrough is progressively reduced.

In operation of the emachine, the lower, drive roller 7 is first adjusted to produce a bend ofdesired radius in the work, and thereafter the work supporting bed 2 is adjusted so that the

delivery lip 5 is disposed closely adjacent said point of peripheral working contact. At all times

the bed is substantially tangential to the -idler roller at the low point of the latter.

Thereafter, the lower roller roe is driven in the direction indicated and the sheet metal work fed

from the bed 2 off the delivery lip 5 and between the rollers at the point of peripheral workingcontact thereof, which point is indicated, for example, -at 35 in Fig. 5. With continued rotation of

the lower, drive roller the work feeds upwardly and has the desired curvature or bend imparted

thereto. As the delivery lip 5 .is close to the point of peripheral working contact, the bend isimparted to the sheet to substantially the trailing edge thereof, thus completing the entire -bendon the work with one pass through the machine.

As each piece of work is .rolled to -tubular form. the machine is stopped, the upper, 'idler roller f

released and elevated at one end, as previoussl. described, and the work slipped therefrom.

With -the described sheet metal rolling machine tubular work can be rolled from fiat stock

rapidly effectively, and economically; the machine beinm simple and practical in its

construction, operation and adjustment.

From the foregoing description it will be readily seen that there has been produced such a device

as substantially fulfills the objects of the invention, as set forth herein.

While this specification sets forth in detail the present and preferred construction of the device,

nstill in .practice such deviations from such detail .0 may be resorted to as do not form adeparture from the spirit of the invention, as defined by the ,appended claims.


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Having thus described the invention, the following is claimed as new and useful and upon which

Letters Patent are desired: 1. A sheet metal rolling machin mcie comprising an upstanding

.frame, a work supporting bed on the frame, said bed having a delivery end, a pair of transverse,cooperating rollers, means mounting the rollers on the frame one above the other and directly

beyond the delivery end of the bed, said delivery end of the bed being closely adjacent and

substantially tangential to the upper roller at the low point thereof, the lower roller beingmounted for adjustment to alter the peripheral working point thereof circumferentially of theupper roller on the side of the latter opposite the bed and above said low point, and means

operative to drive a roller of the pair in a direction turning away from the bed at such peripheral

working point; the lower roller mounting means comprising a pair of upstanding parallel bellcrank levers, the lower roller being journaled at its ends on corresponding legs of the bell crank

;35 *levers, means pivotally mounting said levers internmediate their ends in connection with the

frame for swinging lengthwise of the latter and for adjustment in the same direction, and

yieldable means connected to the bell crank levers and acting thereon in a direction to urge thelower roller toward the upper roller.

2. A sheet metal rolling machine, as in claim 1 in which the bell crank lever mounting meanscomprises a transverse shaft, said shaft being .normally non-rotatable but rotatably adjustably

mounted, circular eccentric cams on the shaft, and an eccentric strap on each bell crank leverintermediate its ends surrounding one of said cams -in cooperative.relation.

3. A .sheet metal rolling machine comprising a frame, a work supporting bed on the frame, a

roller journaled on the frame forwardly of and above the bed, an adjustable cam shaft mountedon the frame, cams on the shaft, straps surround5 ing the cams, projecting arms on the straps, a

roller journaled in the outer ends of the arms and held in peripheral engagement with the first

roller, and means to idrive 'one of said rollers in a direction turning away from the forward edgeG0 of the work -supporting bed


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WORKING PRINCIPLE

This sheet rolling machine is used to roll the flat strip in order to make the

cylindrical shape container. The required diameter of cylinder is first cut from the

main sheet in the form of strip of length equal to 3.14x Dia and the height of the

cylinder is marked to breath wise dimension in the sheet. This sheet is feed in to

the roller which is driven by the spur gear arrangement. This machine have Three

rollers. Two rollers are used for feeding the work and the third roller is used to give

pressure in order to make cylinder.

The sheet to be rolled is feed into the rollers . The sheet is slightly bend in

curve shape after passing into the rollers.Now both the screw rods are turned to

reduce the gap inorder to give the bend force apply on the work sheet. By

increasing the bend force through the screw rods , the sheet becomes rolled to

cylinder shape.


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SAFTY, CARE AND MAINTENANCE

Before starting the machine, the user should wear the gloves .

Protective guards for gear box should be provided in the machine..

Alignment of the gear wheel and roller mechanism should be maintained

periodically.

Clean the rollers before starting the rolling process .

Always maintain the smooth engagement of gears for long

running life of machine.

Oil should be added periodically to maintain the lubrication ..


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ADVANTAGES

1.

Cylindrical shaped sheet metal can be easily done with this machine.

2. Rate of production increased.

3. Single person is enough to operate this efficiently to operate this machine.

4.

Easy and efficient handling of this unit without wastage or damage to the

sheet, machine and to any other parts.

5. Low maintenance cost and life of equipment also increased..

6. Least maintenance of the equipment. .


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CONCLUSION

At present this attachment is purely operated and controller by means of

mechanical . The present made can eliminate the rescue work of the operator and

make away to semi-skilled operator can also perform the cylinder making

operation and at the same time increase the productivity of the same machine.

We present out idea for mechanism in manual assisted or operated type

attachment. We have decided an equipment namely SHEET ROLLING

MACHINE has been completed successfully to our entire satisfaction. While

processing his project, we happen to visit number of libraries, browsing net notes

and industries to collect information. We got an opportunity to meet a few

experienced person in his field.

This experience have also enriched our knowledge both theoretically and

practically creating confidence which would be useful in my future span of life.


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BIBLIOGRAPHY

www.google.co.in

WORKSHOP : W.J. CHAPMAN

PRODUCTION TECHNOLOGY : R.K. JAIN

PRODUCTION TECHNOLOGY : R.K. JAIN & S.C. QUPTA

METAL FORMING PROCESS : R.S. KURMI

MANUFACTURING PROCESS : K. RAMACHANDRAN

MACHINE SHOP TECHNOLOGY : S.S.MANIAN &

RAJAGOPAL

G. BALAJI SINGH

DESIGN OF MACHINE ELEMENTS : RAMACHANDRAN

DESIGN DATA BOOK : P.S.G. COLLEGE OF

TECHNOLOGY
http://www.google.co.in/http://www.google.co.in/http://www.google.co.in/


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sheet rolling machine

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