Design and Analysis of Force, Torque, and Tension of Twin Roll for

Thermomechanical Treatment Process

Tugiman, Farida Ariani, F. Perinta Tarigan, T. Istaula Febrian, H. Alwizar Harahap,

Ivan Tamayo and Abdi M. Manurung

Department of Mechanical Engineering, Faculty of Engineering, Universitas Sumatera Utara,

Padang Bulan, Medan, 20155, Indonesia

Keywords: Roll, Reduction of Thickness, Stress, Bending Stress.

Abstract: The process of roll are promising method to improve mechanical properties of aluminum alloys by modified

of microstructures. A common roll consists of minimum two drums made of hard steel with a small

clearance between drum. The effectiveness and lifetime of the roll machine influenced by many parameters

such as the maximum force, torque, and stress occurred. In this project the twin roll used to reduce thickness

of aluminum plate from 10, 20, 30, 40, and 50% with constant temperature and revolution. The aim of the

present work to analysisthe parameters of rolling introduce in to main components. To solve these problems

some equations in static condition were used to analysis. The results show that the increasing of reduction of

thickness influences some parameters of rolling machine process. The 105 KN, 39.8N.mand 2.63x10

N/m

of force, torque, and bending stress respectively was obtained for 50% of reduction.

1 INTRODUCTION

Roll machine is a common mechanic tools in

engineering field. The principle rolls consist of

minimum two rolls which rotated opposite direction

and pulling a plate to flow into the cavity of roll.

The roll machine have been used in many areas and

material such as rolling on AA8006 aluminum

sheets (Cieslar and Republic, 2014), continuous roll

casting of aluminum (Lela, 2010), carbon steel and

stainless steel (Lindgren, 2007). The advantage of

rolling process could improve the mechanical

properties of aluminum alloys without melting.

S.Roy, et al., reported that the strength improvement

of aluminum by using accumulative roll due to grain

refinement and strain hardening (Roy et al., 2017).

Furthermore, the modification of grain size

increased the hardness in which correspond with hall

pecth equation ( 𝐻𝐻



 𝐾



𝑑







) where H is

hardness, H

is the hardness intercept at d

-1/2

= 0, and

is the hall-pecth slope (Sathiyamoorthi et al.,

2017). It is believed that strain hardening, higher

strength and hardness of alloys could be obtained by

cold work process. Based on work temperature, it

could be divided minimum two main group rolling

process i.e. cold roll (Lindgren, 2007; Mohammad et

al., 2017) and hot rolling (Roy et al., 2017; Sahoo,

2016; Chandramouli, n.d.; Na et al., 2019).Y.S. Lee

et al. (2014) investigated that roll separation force

during twin roll casting influenced by roll speed and

melt temperature (Lee et al., 2014). Furthermore, a

relative rolling velocity results interest and tension

and influences the roll load and torque (Bayoumi

and Lee, 2008). The roll separating forcet end to

decrease with the increases of the roll speed in twin

roll casting process(Sahoo, 2016; Lee et al., 2014).

M. Lindgren (2007) reported that both of force and

torque are two important parameters of rolling

process, they needed for bending in a forming stages

as a function of thickness (Lindgren, 2007) of

materials and an important indicator of optimum

process in production system (Jurkovic et al., 2014).

Front/back tension also is important parameter to

maintain the neutral plane placement of rolling

system (František et al., 2008). Therefore, in the

rolling design is important to consider the analysis

of forces, torque, and tension of twin rolling

parameters to obtain optimum process. Based on

previous work, only a few researchers investigated

these problems in their project.

In the present study, the design and fabrication of

twin rolling have been done for aluminum casting

plates. The analysis of forces, torque, and tension

336

Tugiman, ., Ariani, F., Tarigan, F., Febrian, T., Harahap, H., Tamayo, I. and Manurung, A.

Design and the Analysis of Force, Torque, and Tension of Twin Roll for Thermomechanical Treatment Process.

DOI: 10.5220/0010181400002775

In Proceedings of the 1st International MIPAnet Conference on Science and Mathematics (IMC-SciMath 2019), pages 336-339

ISBN: 978-989-758-556-2

calculated for the main components by using static

equation to estimate the construction of roll

machine.

2 METHODS

Twin roll was designed by using CAD to

determinethe main components, dimension, and

ideal arrangement in its frame.The simplicity in

operation has been a priority of this design, so that

the machine has an ability to serve a rolling process

of aluminum sheet in different thickness.

Furthermore, the parameters of forces, torque, and

tension/stress for different reduction (10, 20, 30, 40,

and 50%).The 1 hp electric motor have been used as

a driving force. Further, roll has 75 kg of mass with

200 mm diameter and 230 mm length. The high of

aluminum plate 11.5, 12.5, 14.2, 16.6 and 20 mm

were used to analyzed parameters in rolling process.

3 RESULTS AND DISCUSSION

3.1 Rolling Machine Design

The design of twin roll machine as shown in Fig. 1,

the main components of the machine consists of two

steel rolls, electrical motor, pulley and frame. These

components arranged as simple as possible to make

it easy movement and handling.

Figure 1: Rolling machine design

The roll components made of steel material (ST

60) are important part to obtain a good dimension

corresponding with reduction of plate thickness. The

roll system completed with a pair of high adjuster to

lift and down of upper roll, see Fig. 2. Furthermore,

the single phase induction motor with 1 HP and 220

of power and voltage respectively were used to drive

this machine.

Figure 2: Portable twin roll machine model.

3.2 Analysis of Force, Tension (Stress),

and Torque of Roll Machine

The analysis of direct compressive forces are

important to understand the capacity of roll machine.

The forces generated compressive stress along

contact point during rolling process, deformation

and reduced a cross section area. In the present

work the analysis have been done. According to the

equation (1) below, the compressive force of

different reduction plate could be calculated.

𝑃

 . .

 .

(1)

The bending stress/tension (σ), inertia (I), length

of roll (L) and plat thickness (h) are important

parameters to determine the pressure force (P). The

inertia is a function of geometry of specimen, by this

data the ability of plate withstand a bending

phenomenon measured. In this research the

specimens has plate form with different thickness

and or dissimilar % reduction. Fig. 3 shows the

inertia for different reduction (10-50%). The

increases of reduction cause the inertia rise linearly,

the maximum inertia 2,2953 x 10

-9

obtained at

50% of plate reduction.

Design and the Analysis of Force, Torque, and Tension of Twin Roll for Thermomechanical Treatment Process

337

Figure 3: The moment inertia for different reduction.

The bending stress could be calculated by equation

(2) below

𝜎





(2)

From the equation we can conclude that the

bending stress influenced by two parameters i.e.

moment (m and cross section modulus (z)

respectively), which is a moment equal to a total

force multiplied by radius of roll. Fig. 4 show the

bending stress in various reduction of plate. It is

clear was observed that the bending stress tend to

decrease linearly with the increase of reduction.

10 20 30 40 50

Bending stress, x10

(N/m

)

Reduction (%)

Figure 4: The bending stress for different reduction area.

The compressive stress is the function of bending,

inertia and geometry, see equation (1). Length of roll

230 mm constant for all reduction. This stress about

105076,6667 N for different reduction. It is believed

that the similarity of stress due to the existence of

bending stress going to low was offset by the

increases inertia as well the constant geometry factor

such as length and diameter of the roll. The force for

plate feeding should be overcome the friction force

friction

)between roll and aluminum plate. The

friction is multipliedfriction and compressive stress,

furthermore, the 49386 N friction forces were

obtained for various reduction. Fig. 5 shows the

distribution of pressure and F

friction

in rolling machine

system. Two roll has similar dimension were

assembled with different direction of revolution

induce the plate flow between roll with dissimilar

reduction. In order to get the roll could operate

properly the thrust must be greater than friction

force.

Figure 5: Scheme of distribution of pressure and F

friction

free body diagram.

4 CONCLUSIONS

The design, analysis of forces, stress, torsion of twin

roll machine were studied in the present work. A

simple design twin roll have been finished

fabricated. The results show a compressive force,

friction

and torque are similar for various reduction.

Conversely, the bending stress decreases with the

increase of reduction. The inertia moment as a

function of geometry show increase linearly with the

increase of % reduction.

ACKNOWLEDGEMENT

The authors would like to gratefully acknowledge

financial support from TALENTA program of the

University of SumateraUtara, Ministry of Research,

Technology, and Higher education of the Republic

5E-10

1E-09

1,5E-09

2E-09

2,5E-09

10 20 30 40 50

Inertia (m

)

Reduction (%)

friction

IMC-SciMath 2019 - The International MIPAnet Conference on Science and Mathematics (IMC-SciMath)

338

of Indonesia under the grant number

87/UN5.2.3.1/PPM/KP-TALENTA USU/2019

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