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GATE 2021 ME (ME1) – Question 50

Casting, Forming and Joining Processes · Bulk forming and sheet forming, estimation of load · 2 marks · Numerical answer

A 200 mm wide plate having a thickness of 20 mm is fed through a rolling mill with two rolls. The radius of each roll is 300 mm. The plate thickness is to be reduced to 18 mm in one pass using a roll speed of 50 rpm. The strength coefficient ($K$) of the work material flow curve is 300 MPa and the strain hardening exponent, $n$ is 0.2. The coefficient of friction between the rolls and the plate is 0.1. If the friction is sufficient to permit the rolling operation then the roll force will be _____ kN (round off to the nearest integer).

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Correct answer: 781

Explanation

True strain is $\varepsilon=\ln(20/18)=0.105361$. Mean flow stress is $\bar\sigma=K\varepsilon^n/(n+1)=159.40$ MPa. Contact length is $\sqrt{R\Delta h}=\sqrt{300(2)}=24.4949$ mm.

The basic rolling-load estimate is $F=\bar\sigma bL=780874$ N, giving **781 kN**. Bite is feasible since μ²R=3 mm exceeds the 2 mm draft.