Assignment 2 Materials and Manufacturing 2011

Due date: 5.00pm Friday, April 15, 2011

1. A continuous hot rolling mill has two stands. Thickness of the starting plate
= 25 mm and width = 300 mm. Final thickness is to be 13 mm. Roll radius at
each stand = 250 mm. Rotational speed at the first stand = 20 rev/min.
Equal drafts of 6 mm are to be taken at each stand. Assume that there is no
increase in width. As it is only at the neutral point that the roll speed and the
work material speed are the same a term called forward slip is defined for
the difference in speed of the work material before and after the neutral
point. The forward slip (s) is defined in terms of the roll surface speed (vr)
and the work material exit speed (vf) as

S = (Vf – Vr)/Vr

Under the assumption that the forward slip is equal at each stand,
determine the following:
(a) The speed vr at each stand (Hint: Does the volume change with each
pass?).
(3 marks)
(b) The forward slip s.
(2 marks)
(c) The exiting speeds at each rolling stand, if the entering speed at the first
stand = 26 m/min.
(2 marks)
(d) Why it can be assumed that there is no increase in width.
(1 mark)
(e) Any difference between the roll forces at the two stands.
(1 mark)

2. Explain why spreading in flat rolling increases with

(a) decreasing width-to thickness ratio of the entering material
(b) increasing friction,
(c) and decreasing ratio of the roll radius to the strip thickness.
(3 marks)

3.
a. How can you produce compressive stresses in the surface of a
rolled product?
b. If you remove the top compressive layer by, say, grinding, will the
strip remain flat? If not, which way will it curve and why?
(2 marks)
4. An alloy used for casting is a mixture of lead and tin (commonly called
pewter). If the composition of the pewter is 30wt% Pb and 70wt% Sn
explain with the aid of the phase diagram below:
(a) Why the alloy does not freeze at a single temperature but over a
temperature range instead?
(b) What is temperature at which it starts to solidify and at what
temperature is solidification complete?
(c) What phases are present at room temperature?
(d) What is the proportion of these phases?
(e) Is this a hypoeutectic alloy? Why?
(f) What are the compositions of the phases at room temperature in
weight percent?
(g) What are the proportions of alpha and beta in the eutectic?
(h) What is the primary phase present?
(i) What is the proportion of the primary constituent?
(j) Why are the grains cored? Explain with the aid of the phase diagram.

(10 marks)

5. Using dot points explain why the following strengthening mechanisms

may or may not be used to harden the alloy in Question 4
a. Grain size strengthening
b. Strain hardening
c. Alloying (solid solution strengthening)
d. Precipitation (or age) hardening
e. Dispersion strengthening
f. Transformation strengthening
(6 marks)