Mechanical Contact Stress Analysis of Rollers at Various Hot Rolling Reductions Using Finite Element Approach
DOI:
https://doi.org/10.32497/jrm.v20i3.7190Keywords:
ductile cast iron, fatigue analysis, finite element analysis (FEA), hot rolling, roller stressAbstract
Hot rolling is a fundamental process in metal manufacturing; however, the operational integrity of the rollers is frequently threatened by excessive stress, which can lead to premature fatigue failure. This study aims to quantitatively analyze the effect of the cross-sectional reduction percentage on the distribution and magnitude of equivalent (von Mises) stress in hot rolling rollers. The Finite Element Analysis (FEA) method was employed to simulate the rolling process on rollers made of Ductile Cast Iron and a Structural Steel billet at a temperature of 800°C. Eleven simulation scenarios were executed by varying the reduction from 22% (industry standard) to 44%. The results indicate that the standard 22% reduction yields a very safe stress level (157.36 MPa), which is only 46.5% of the roller material's fatigue strength (338 MPa). It was found that roller stress increases non-linearly with increasing reduction, with a significant stress surge observed after a 41% reduction. The maximum safe operational limit was identified at a 43% reduction, which produced a stress of 275.43 MPa (81.5% of the fatigue limit). At a 44% reduction, the roller stress (369.37 MPa) exceeded the safe limit, indicating a high risk of component failure. This study provides a practical quantitative guide for the industry to optimize production throughput by establishing 43% as the maximum theoretical reduction limit.
References
[1] F. Yilmaz, M. A. Guvenc, and S. Mistikoglu, “Optimization of rolling forces in multi-pass hot rolling using MLR and ABC algorithm for enhanced product quality and energy efficiency,” Int. J. Adv. Manuf. Technol., vol. 139, no. 5–6, pp. 2409–2429, 2025, doi: 10.1007/s00170-025-16008-6.
[2] T. Moser, J. Seitz, E. Alp, and B. Kuhlenkötter, “Identification Of Investigation Procedures To Predict Work Roll Fatigue For Developing Machine Learning Applications – A Systematic Literature Review,” Proc. Conf. Prod. Syst. Logist., vol. 2, pp. 268–281, 2023, doi: 10.15488/15300.
[3] A. S. Siregar, M. Mulyadi, and S. Arief, “Analisis Kegagalan Laminasi Komposit Epoksi/Serat Karbon Pada Sayap Pesawat Tanpa Awak,” Pist. J. Tech. Eng., vol. 5, no. 2, p. 108, 2022, doi: 10.32493/pjte.v5i2.18596.
[4] K. Hu, R. Xue, Q. Shi, W. Han, F. Zhu, and J. Chen, “FEM simulation of thermo-mechanical stress and thermal fatigue life assessment of high-speed steel work rolls during hot strip rolling process,” J. Therm. Stress., vol. 45, no. 7, pp. 538–558, 2022, doi: 10.1080/01495739.2022.2080781.
[5] J. W. Lee, “A Design Study Using Simulation Techniques in Roll Form Production,” Ph.D. dissertation, 2024, [Online]. Available: https://dspace.mit.edu/handle/1721.1/157160
[6] N. laras Agustina, “Metal Rolling by Computation Method : A Brief Review,” HBRP Publ., vol. 2, no. 3, pp. 1–9, 2020, doi: 10.5281/zenodo.3603763.
[7] Y. Yang, B. Zhang, Y. Wang, Z. Jiang, and K. Li, “Mechanical behaviors and constitutive model of structural steel influenced by strain aging,” J. Constr. Steel Res., vol. 192, no. November 2021, p. 107211, 2022, doi: 10.1016/j.jcsr.2022.107211.
[8] T. Pore, S. G. Thorat, and A. A. Nema, “Review of contact modelling in nonlinear finite element analysis,” Mater. Today Proc., vol. 47, no. xxxx, pp. 2436–2440, 2021, doi: 10.1016/j.matpr.2021.04.504.
[9] A. Zabala, E. S. de Argandoña, D. Cañizares, I. Llavori, N. Otegi, and J. Mendiguren, “Numerical study of advanced friction modelling for sheet metal forming: Influence of the die local roughness,” Tribol. Int., vol. 165, no. August 2021, 2022, doi: 10.1016/j.triboint.2021.107259.
[10] João Carlos L. Peixoto, Rafael L. Rangel, and Luiz F. Martha, “Interactive Modeling of NURBS for Isogeometric Analysis,” 2024. doi: 10.55592/cilamce.v6i06.10229.
[11] A. Ojeda-López, M. Botana-Galvín, I. Collado-García, L. González-Rovira, and F. J. Botana, “Finite Element Simulation of Hot Rolling for Large-Scale AISI 430 Ferritic Stainless-Steel Slabs Using Industrial Rolling Schedules—Part 1: Set-Up, Optimization, and Validation of Numerical Model,” Materials (Basel), vol. 18, no. 2, 2025, doi: 10.3390/ma18020383.
[12] P. Odeyar, D. B. Apel, R. Hall, B. Zon, and K. Skrzypkowski, “A Review of Reliability and Fault Analysis Methods for Heavy Equipment and Their Components Used in Mining,” Energies, vol. 15, no. 17, p. 6263, 2022, doi: 10.3390/en15176263.
[13] W. K. Liu, S. Li, and H. S. Park, “Eighty Years of the Finite Element Method: Birth, Evolution, and Future,” Arch. Comput. Methods Eng., vol. 29, no. 6, pp. 4431–4453, 2022, doi: 10.1007/s11831-022-09740-9.
[14] D. Boazu, I. Gavrilescu, and F. Stan, “Analytical and Finite Element Analysis of the Rolling Force for the Three-Roller Cylindrical Bending Process,” Materials (Basel), vol. 17, no. 21, 2024, doi: 10.3390/ma17215230.
[15] H. Liu, J. Zheng, Y. Guo, and L. Zhu, “Residual stresses in high-speed two-dimensional ultrasonic rolling 7050 aluminum alloy with thermal-mechanical coupling,” Int. J. Mech. Sci., vol. 186, no. May, p. 105824, 2020, doi: 10.1016/j.ijmecsci.2020.105824.
[16] U. S. Dixit, Modeling of metal forming: a review. Elsevier Series, 2020. doi: 10.1016/B978-0-12-818232-1.00001-1.
[17] E. Brusa, C. Delprete, and L. Giorio, “Smart Manufacturing in Rolling Process Based on Thermal Safety Monitoring by Fiber Optics Sensors Equipping Mill Bearings,” Appl. Sci., vol. 12, no. 9, 2022, doi: 10.3390/app12094186.
[18] J. Kumar Singh Jadon, R. Singh, and J. Kumar Mahato, “Creep-fatigue interaction behavior of high temperature alloys: A review,” Mater. Today Proc., vol. 62, pp. 5351–5357, 2022, doi: 10.1016/j.matpr.2022.03.487.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 Agung Fauzi Hanafi, Ansor Salim Siregar, Prabuditya Bhisma Wisnu Wardhaanaa, Mega Lazuardi Umar
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
Copyright of articles that appear in Jurnal Rekayasa Mesin belongs exclusively to Penerbit Jurusan Teknik Mesin Politeknik Negeri Semarang. This copyright covers the rights to reproduce the article, including reprints, electronic reproductions, or any other reproductions of similar nature.
