IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison with Single Piece Casing Differential

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 05 Issue: 01 | Jan-2018 www.irjet.net p-ISSN: 2395-0072
© 2018, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 423
DESIGN OPTIMIZATION OF WORK ROLL CHOCK AND BACKUP ROLL
CHOCK IN COLD ROLLING MILL
Tukesh Sahu1, Prof. G.R.Kesheory2
1M.Tech Scholar, Department of Mechanical Engineering, VITS Indore, MP, India
2Assistant Professor, Department of Mechanical Engineering, VITS Indore, MP, India
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Abstract - Rolling is defined as a process in which metal is
formed through a pair of revolving rolls with plain or grooved
barrels. The metal changes its shape gradually during the
period in which it is in contact with the two rolls. Rolling is a
major and a most widely used mechanical working technique.
A Rolling mill is a complex machine for deforming metal in
rotary rolls and performing auxiliary operations such as
transportation of stock to rolls, disposal after rolling, cutting,
cooling, melting. The problem of failure of Rollingmillhousing
was there in industry, which can be efficiently solved by using
CAE.
The present work involves the design optimizationofworkroll
chock and backup Roll chock in cold rolling mill, to controlthe
failure of choke in the cold rolling mill for retain the material
cost and longer life of the roll chock. The roll chock had stress
distribution has been analyses by software ANSYS from which
maximum static stress at critical areas have been calculated.
Structural behavior of Roll chock under the given loading and
boundary conditions using an analytical model are very
difficult. Therefore 3D solid model was chosen in order to
predict the stress and strain response detail.
We have made a prototype of chock of optimized design of
scale so as to verify our results that have been given by the
analysis of work roll chock and backup roll chock on analysis
software.
Key Words: Centeral Burst, Cold Rolling, Design
Methodologies, Housing, PlasticDeformation,Rolls,Split
End
1.INTRODUCTION
Rolling is defined as a process in which metal is formed
through a pair of revolving rolls with plain or grooved
barrels. The metal changes its shape gradually during the
period in which it is in contact with the two rolls. Rolling
is a major and a most widely used mechanical working
technique. A Rolling mill is a complex machinefordeforming
metal in rotary rolls and performing auxiliary operations
such as transportation of stock to rolls, disposal afterrolling,
cutting, cooling and melting.
Chocks are almost invariably the highest stressed
component in a manufactured item, and so are most
susceptible to invariable the financial losses incurred as a
result of chock failure will be far greater than the actual
value of the chock instantiated delivery of chocksbecause of
manufacturing presetting failure could stop a production
failure at the assembly stage is almost certain to halt
production if only one or two chocks out of a large batch
tailback no manufacturer would willingly assemble goods
that are suspecting failure in serviceableness the most
catastrophic consequences example failure of cold rolling
mill chock is very likely to result in the complete destruction
of the cold rolling mill. Failure of chocksin a cold rolling mill
is basically because of higher stressedgeneratedduringstart
up and shut down condition of rolling mill so for a design of
chocks for a cold rolling mill it is essential to know the
maximum load acting on a chock to prevent from a failure
fatigue failure beachwear of cyclic loading is also acriteriaof
chocksdesign. Second most important functionoftoworkas
an isolator case of cold Rollin mill also it ha s to perform this
function .so design chock hold have a required stiffness to
transmit a vibration from a source to receiver.
So while designing a chock for cold rolling mill two factorsis
very important Ice. strength of chock to sustain a maximum
load and stiffness of a chock to transmit lesser vibration.
Over the course of time, finite element models have gained
significant importance, and research has been ongoing to
establish supportive results to candor software calculation.
Computer models have been develop to provide trimly and
economical simulations for results of a component under
extremely Sever loading conditionals simulations can be
used to target sensitive parameters that affect the overall
design, cost and safety.
1.1 MODELING OF ROLL CHOCK
The Roll Chocks were modeled in 3D Modeling Software
“Solid Works2009” for better visualization and interference
checking. 3D Modelsare also requiredforStructuralAnalysis
and Optimization; therefore accurate modeling of Roll
Chokes is required.
The Order of the Models is according to their placement;
from top to bottom; in the Rolling Mill:-
1) Top Back Up Roll Chock
2) Top Work Roll Chock
3) Bottom Work Roll Chock
4) Bottom Back Up Roll Chock

Fig 1.1 Top Back up Roll Chock
Fig.1.2 Top Work Roll Chock
Fig.1.3 Bottom Work Roll Chock
Fig.1.4 Bottom Back up Roll Chock
1.2 Model Analysis
Sample Modal Analysis is done to find out the Natural
Frequency of the Top Roll Choke and to check if the natural
frequency of the machine does not match the natural
frequency of the Top Roll Choke to avoid resonance.
1) Material
Material Used – Fe 410
a. Young’s Modulus – 200GPa
b. Poisson’s Ratio – 0.3
2) Element
a. Element Used – Solid 10 Node Tetrahedral
(Solid 187)
b. Element Size – 30
3) Constraint
a. The bottom surfaces of the Top Roll Choke
were constrained as shown in figure 1.1
Table 1.1 Von Misses Contour Plot for Top Roll Chock
Mode Frequency (Hz.)
1 7.0637
2 8.2337
3 13.896
4 24.336
5 27.757
6 28.280
7 29.517
8 30.709
9 40.672
10 43.793
Also, the deformation for various Modes was plotted as
shown in Figure 2.2
2. STRUCTURAL & MODEL ANALYSIS OF TOP BACK
UP ROLL CHOCK
1) Material
Material Used – Fe 410
a. Young’s Modulus – 200GPa
b. Poisson’s Ratio – 0.3
2) Element
a. Element Used – Solid 10 Node Tetrahedral
(Solid 187)
b. Element Size – The appropriate Element
Size was found out by using an Initial
Element Edge Length to be 50 and then
gradually reducing Element Size until the
Stress remained constant even if the
Element Size reduced. The Table1.1clearly
indicates the above
Table 2.1 Element Size vs. Deformation
Sr. No. Element Size (mm) Deformation (mm)
1 50 0.197729
2 35 0.198522
3 30 0.198749
Therefore, Element Size 30 can be considered to be the ideal
Element Size for the Following Analysis. Also, the Computer
Available would require additional hardware to solve the
number of equations for Element Size less than 30 is a
constraint.
3) Forces
a. The Forces Acting on the Top Roll Choke is the Force
of the Hydraulic Cylinder transferred through the
Bottom Rolls through the material to be rolled and
through the top work roll.

b. The Top Roll Choke is constrained at the top of the
Rolling Mills by an adjustable Power Screw
Mechanism.
c. The Reaction force is considered as the actual force
acting on the choke and the bottom surfaces are
considered to be constrained as shown in the figure
2.1
d. Therefore, the cylinder pressure is converted to force
and applied on the particular area as shown in the
figure 2.1
4) Constraint
a) The bottom surfaces of the Top Roll Choke were
constrained as shown in figure 2.1
Fig. 2.1 Meshing Diagram for Top Roll Chock
Fig. 2.2 Total Deformation Contour Plot for Top Roll
Chock
Fig. 2.3 Misses Contour Plot for Top Roll Chock
3. OPTIMIZATION OF TOP BACK UP ROLL CHOCK
The Top Roll Choke is optimized to a minimum size with
Stress Constraints, Bearing Size Constraints. The Initial
Stress Contour Plots Obtained in Chapter 2 was observed
and studied. It was found out that parts of the roll choke had
very little stress induced in them and could be removed.
The Following Iterations were carried out on the Roll Choke
and a considerable weight reduction and thus cost savings
was obtained.
Iteration 1:-
Fig. 3.1 3D Model of 1st Iteration of Optimization of Top
Back up Roll Chock
Fig. 3.2 Deformation Contour of 1st Iteration of
Optimization of Top Back up Roll Chock

Fig. 3.3 Von Misses Stress Contour of 1st Iteration of
Table 3.1 Comparison of 1st Iteration and Existing Roll
Chock
Sr. No. Item Old New
1 Weight 1816.49 1693.79
2 Deformation 0.198596 0.204209
3 Von Misses Stress 78.444 84.507
2nd Iteration: -
Fig. 3.4 3D Model of 2nd Iteration of Optimization of Top
Back up Roll Chock
Fig. 3.5 Deformation Contour of 1st Iteration of
Fig. 3.6 Von Misses Stress Contour of 2nd Iteration of
Table 3.2 Comparison of 1st Iteration and 2nd Iteration
Roll Chock
Sr. No. Item 1st Iteration 2nd Iteration
1 Weight 1693.79 1633.4
2 Deformation 0.204209 0.207976
3 Von Misses Stress 84.507 84.933
Thus a considerable weight saving is obtained as given
below:-
Weight of Existing Roll Choke – 1816.49 kgs
Weight of Optimized Roll Choke - 1633.4 kgs
Cost Savings – Wt. Reduced x Rs. 50
183.495 x 50
Rs. 9154.5
Modal Analysis of Optimized Roll Choke
The Modes and their frequencies are given in Table 3.3:-
Mode Frequency (Hz.) Deformation (mm.)
1 7.5964 0.048917
2 7.6924 0.035799
3 15.710 0.051504
4 22.976 0.05069
5 24.667 0.060074
6 29.020 0.043498
7 29.047 0.071935
8 32.248 0.038319
9 37.795 0.043885
10 43.152 0.077078
4. CONCLUSIONS
This is the totally new concept introduces by me in the
company where we r going to save the cost and time by
giving more life to roll chock. By simulation of the actual
chock model on the software it was revealed that the

chock of the machine experienced higher stresses at the
place where the holding of work role and back role occur. In
the company there is failure of chock occurs during the
process of operation so we designed the new chock for
rolling machine by improving the all over safety factor. The
new chocks have good life compare to failure one and from
that chock company daily saving. Design Optimizations of
Critical Component Roll Chocks in Cold Rolling Mill is really
good project where designs of roll chock is totally new part.
REFERENCES
[1] G. P. Steven, “Multicriteria optimization that minimizes
maximum stress and maximizesstiffness”,Computers&
Structures Volume 80, Issues 27-30 , November 2002,
Pages 2433-2448.
[2] J. H. Rong, “An improved method for evolutionary
structural optimization against Buckling” Computers&
Structures, Volume 79, Issue 3, January2001,Pages253-
263.
[3] Kurt Maute, ‘an interactive method for the selection of
design criteria and the formulation of optimization
problems in computer aided optimal design”,
Computers Volume 82, Issue 1 , January 2004, Pages71-
79.
[4] Theodore G. ToRidis, “Computer analysisofrigidframes,
Computers”,Volume 1, Issues 1-2, August 1971, Pages
193-221.
[5] William Prager , “Conditions for structural optimality”,
Computers & Structures’,Volume 2, Issues 5-6, 1972,
Pages 833-840.
[6] Rafael Febres, “Modeling of local buckling in tubular
steel frames subjected to cyclic Loading”, Computers &
Structures, Volume 81, Issues 22-23, September 2003.
[7] A.I. Tseliko and V.V. Smirnov, M.H.T. Alford (1965),
Rolling Mills.
[8] William L.Roberts (1938), “Manufacturing engineering
and materials processing/2”,ColdRolling Of Steel.
[9] A.G.Davenport, “The application of statistical conceptto
the wind loading of structure”, proc.Inst.Civil Engg.
London 19(1961)449-472.
[10] Ginzburg Vladimir B.”High-Quality Steel RollingTheory
and practice [M].Newyork”, USA,Marcel Deker
Inc.(1993).
[11] Guide and Principal, Mechanical Department, VITS
Indore, M.P India.

IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison with Single Piece Casing Differential

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IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison with Single Piece Casing Differential