Modelling and Optimization of Process Parameters during Grooved Hot Rolling of SAE 1020 Steel

The rolled SAE 1020 steel bars are widely used for production of mechanical components, such as, gears, spindles, camshafts, axles, fasteners, and gudgeon pins etc. Steel industries have been striving for productivity and better yield of hot rolled bar products. The roll separating force (RSF), driving torque (DT), end crop length (ECL), and drive energy (DE) are the important response parameters to be controlled for quality production, maximization of yield (i.e. minimization of rolled bar process scrap), safety of mill and reduction in energy consumption, etc. These response parameters depend on several process parameters – rolling speed, billet temperature, reduction ratio, billet cross-section area, roll diameter, etc. This paper presents a study on the effect of the process parameters on the response parameters during rolling of SAE 1020 steel. Simulation of the rolling process has been attempted using FORGE® NxT 1.1. The simulated results so obtained have been validated through experimental results obtained in a rolling mill, following statistical tests. Regression models showing relationship between the process parameters and the response parameters have been developed. Significant model terms have been obtained using ANOVA. The optimum rolling conditions for minimization of the response parameters have been obtained.