[TheForge] Bedtime reading

[David E. Smucker]

Andy,  Just my point -- what used to be an "art" and the use of "experience 
based rules of thumb" is today being handle by computer models of the 
process.  Development of these models has been very active since the early 
1970's and they have gotten better and better.  Many of the models have been 
very closely held "trade secrets" for sometime by various companies.  This 
is true of not just rolling both shape and flat rolling but also close die 
forging.  One of the areas that remains the hardest to model is the friction 
between the metal and rolls or dies.  In many cases models still depend on 
experience based data models for the friction factors.

Dave Smucker
----- Original Message ----- 
From: "Andrew Vida" <osan at netlabs.net>
To: "Sponsored by ABANA" <theforge at mailman.qth.net>
Sent: Saturday, February 12, 2005 12:06 AM
Subject: Re: [TheForge] Bedtime reading


>
>
> David E. Smucker wrote:
>> Andy,  You may already know this but the use of round to oval to round to 
>> oval etc. etc. has been the standard method of hot rolling rounds for may 
>> years.  The older mills used to use guides to rotate the rod 90 degrees 
>> between each pass or mill stand.  New mills are called "no twist" because 
>> the rolls are arranged 90 degrees from each other.  I worked on a mill in 
>> the 70's that had been built before WWII that started with a 6 inch 
>> square and ended with 3/8 inch diameter round.  It had 22 stands, that is 
>> it made 22 reductions.  Below the 3/8 dia. round the material went to 
>> drawing dies to make wire.  The design of the rolling passes and the 
>> shape of the rolls used to be an "art", now it is done with math and 
>> computers.  I never did either, but work rather on the mill hardware at 
>> the time.
>
> Yes I am aware, but this article was addressing a new method of modeling 
> the process in favor of finite element analysis in order to predict 
> precise outcomes of a given process on a given size input stock and a 
> given deformation.
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