PREDICTION OF ROLL PRESSURE AND

PLASTIC STRAIN IN ROLLING OF

TITANIUM ALLOY
The project report submitted in partial fulfilment of the requirements

for the award of the degree of

Bachelor of Technology

By

1. T. YASHWANTH 188W1A0351
2. G. ARUN KUMAR 188W1A0317
3. G. KAMAL KUMAR 198W5A0304
4. N. GEORGE NIKHIL 188W1A0337
5. Y. BHANU SAI PRAKASH 188W1A0354

Under the guidance of

[Link]

DEPARTMENT OF MECHANICAL ENGINEERING

V.R. SIDDHARTHA ENGINEERING COLLEGE
(AUTONOMOUS)
VIJAYAWADA – 520007, INDIA
MAY – 2022
 DEPARTMENT OF MECHANICAL ENGINEERING

V.R. SIDDHARTHA ENGINEERING COLLEGE

CERTIFICATE

This is to certify that the thesis entitled “PREDICTION OF ROLL PRESSURE AND
PLASTIC STRAIN IN ROLLING OF TITANIUM ALLOY” submitted by

1. T. YASHWANTH 188W1A0351
2. G. ARUN KUMAR 188W1A0317
3. G. KAMAL KUMAR 198W5A0304
4. N. GEORGE NIKHIL 188W1A0337
5. Y. BHANU SAI PRAKASH 188W1A0354

to V.R. SIDDHARTHA ENGINEERING COLLEGE, VIJAYAWADA under the

jurisdiction of JNTU Kakinada in partial fulfillment of the requirements for the award of the

degree of Bachelor of Technology is a record of bonafide research work carried out by them

under my supervision and guidance. This work has been submitted elsewhere for the award

of any degree.

Dr. CH. NAGARAJU Dr. N. VIJAYA

SAI
Professor Professor & Head of the
Department
Department of Mechanical Engineering, Department of Mechanical
Engineering,
V.R. Siddhartha Engineering College, V.R. Siddhartha Engineering
College,
Vijayawada-520007. Vijayawada-520007.

ACKNOWLEDGEMENT

We would like to express our deepest gratitude and appreciation to our

supervisor [Link] who inspired, encouraged and supported us at all levels

of this study.

We would like to thank the Scrutiny Members of the Mechanical Engineering

Department, Dr. CH. NAGARAJU, Professor, Department of Mechanical Engineering,

V. R. Siddhartha Engineering College and Dr. N. VIJAYA SAI, Professor & HOD,

Department of Mechanical Engineering, V.R. Siddhartha Engineering College,

Vijayawada for their support and suggestions during the reviews.

We would like to thank to our beloved parents for their continuous support and

we wish to appreciate and heartfelt thanks to our classmates for their support for carrying

out this project.

Finally, we thank one and all who have directly or indirectly contributed for

the successful completion of this research work.

1. T. YASHWANTH 188W1A0351
2. G. ARUN KUMAR 188W1A0317
3. G. KAMAL KUMAR 198W5A0304
4. N. GEORGE NIKHIL 188W1A0337
5. Y. BHANU SAI PRAKASH 188W1A0354
 APPROVAL SHEET

This thesis entitled “PREDICTION OF ROLL PRESSURE AND PLASTIC STRAIN IN

ROLLING OF TITANIUM ALLOY” by

1. T. YASHWANTH 188W1A0351
2. G. ARUN KUMAR 188W1A0317
3. G. KAMAL KUMAR 198W5A0304
4. N. GEORGE NIKHIL 188W1A0337
5. Y. BHANU SAI PRAKASH 188W1A0354

is approved for the degree of Bachelor of Technology

External Examiner

[Link]

Professor, Department of Mechanical Engineering, V.R. Siddhartha Engineering College

Dr.N. VIJAYA SAI

Professor & Head of the Department of Mechanical Engineering, V.R. Siddhartha

Engineering College

Internal Examiner

Date:
 CONTENTS

Section No Description Page No

Title Page

Certificate

Acknowledgement i

Approval sheet ii

Contents iii

Abstract v

List of Figures vi

List of Tables viii

Nomenclature ix

Chapter 1 Introduction 1

1.1 Rolling process 1

1.1.1 Hot rolling 2

1.1.2 Cold rolling 3

1.2 Rolled products terminology 4

1.3 Rolling mills 5

1.3.1 Two high rolling mills 5

1.3.2 Three high rolling mills 6

1.3.3 Four high rolling mills 7

1.3.4 Tandem rolling mills 8

1.3.5 Cluster rolling mills 9

1.4 Types of other rolling processes 10

1.4.1 Flat rolling 10

 1.4.2 Shape rolling 11

1.4.3 Ring rolling 11

1.4.4 Thread rolling 12

1.5 Ti-6Al-4V 13

1.5.1 Physical and mechanical properties 14

of Ti-6Al-4V
1.5.2 Applications of Ti-6Al-4V 15

Chapter 2 Literature survey 16

Chapter 3 Finite Element Analysis 21

Chapter 4 Results and discussions 31

4.1 Influence of rollers’ speed on 31

maximum equivalent stress
4.2 Influence of coefficient of friction 32
on maximum equivalent stress
4.3 Influence of billet velocity on 33
maximum equivalent stress
4.4 Influence of coefficient of friction 34
on maximum equivalent plastic
strain
4.5 Influence of billet velocity on 35
maximum equivalent plastic strain
Chapter 5 Conclusions 39

Chapter 6 Scope for future work 40

Chapter 7 References 41
 ABSTRACT

Cold rolling is the most widely used metal forming process in which the metal sheet

is passed in between a set of rolls. Roll pressure is the major parameter that influences

thickness reduction. In the present work, explicit dynamic analysis was performed using

Finite Element (FE) models to simulate the cold rolling process. Plasticity of a material is

important in forming, shaping and extruding operations on metals. Aim of this project is to

identify the roll pressure and plastic strain by simulating rolling operation on the sheets made

of titanium alloys, which are corrosion resistant and fatigue and fracture resistant. In the

present work the influence of coefficient of friction, roll speed and billet velocity on roll

pressure and plastic strain is to be investigated.

 FIGURES

SI. No Fig No Captions Page

No

1 1.1 Flow diagram showing Rolling of different products 4

2 1.2 Two high non-reversing mill 5

3 1.3 Two high reversing mill 6

4 1.4 Three high rolling mill 7

5 1.5 Four high rolling mill 8

6 1.6 Tandem rolling mill 9

7 1.7 Cluster rolling mill 9

8 1.8 Flat rolling process 10

9 1.9 Stages in shape rolling of H-section part 11

10 1.10 Ring rolling process 12

11 1.11 Thread rolling process 12

12 1.12 Titanium Ti-6Al-4v alloy 15

13 3.1 Flat rolling model 22

14 3.2 Stress-strain curve of Ti-6Al-4V alloy 23

15 3.3 XY plane sketch view of the roller and billet 25

16 3.4 Isometric view of roller and billet assembly 25

17 3.5 Meshed cold rolling model 26

18 3.6 Frictional contact between the roller 1 and billet surface 26

19 3.7 Frictional contact between the roller 2 and billet surface 27

20 3.8 Assignment of billet velocity 27

21 3.9 Assignment of rollers’ speed 28

22 3.10 Displacement assignment for the billet 29

23 3.11 Remote displacement assignment for both the rollers 29

24 3.12 Equivalent(von-mises) stress for billet 30

25 3.13 Equivalent plastic strain for billet 30

26 4.1 Roller speed vs maximum equivalent stress 31

27 4.2 Coefficient of friction vs maximum equivalent stress 32

28 4.3 Billet velocity vs maximum equivalent stress 33

29 4.4 Coefficient of friction vs maximum equivalent plastic 34

strain
30 4.5 Billet velocity vs maximum equivalent plastic strain 35

31 6.1 Neural network model 40

 TABLES

S. No Table No. Captions Page

1 1.1 Properties of Ti-6Al-4V 14

2 3.1 Roller and billet dimensions 19

3 3.2 Roller and billet materials 2

4 3.3 Mechanical properties of roller and billet materials 21

5 4.1 FEM generated data set-1 37

6 4.2 FEM generated data set-2 38

 NOMENCLATURE

symbol Caption

µ Coefficient of friction

ho Initial thickness of plate

hf Final thickness of plate

R Radius of the roller

σy Yield stress

σu Ultimate stress

∈ strain

FEM Finite element method

ANN Artificial neural network