Manufacturing Processes I · Metal Forming · 2 marks · Numerical answer
A 3.5 mm sheet is plane-strain rolled in a two-high mill. Both rolls have diameter 500 mm and speed 200 rpm. Friction coefficient is 0.08; roll elastic deflection is negligible; mean sheet flow strength is 400 MPa. Find minimum exit thickness in one pass, in mm to two decimals.
Maximum draft for biting is $\Delta h_{max}=\mu^2R=0.08^2(250)=1.60$ mm. Minimum exit thickness is 3.50−1.60 = **1.90 mm**. Speed and flow strength affect other rolling quantities but not this ideal biting limit.
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