Design and Evaluation of a Simplified Rolling Mill with Simple Drive Mechanism

A rolling mill design is a difficult undertaking that calls for both a solid process understanding and the capacity to make sound decisions in order to balance a number of competing objectives. The aim of this study, is to design and evaluation a simplified rolling mill with simple drive mechanism. A feasibility study was conducted to determine the suitability of the machine. Design considerations were drawn and conceptual design generated based on the consideration. The best concept was selected using a decision matrix. The materials were created using standard fabrication techniques in accordance with the features that were designed. A Lincoln 6010, φ2.5mm, low hydrogen electrode was used to penetrate the prepared joints, and a 7018, φ4mm, low hydrogen electrode was utilized for filling and capping with a 500Amps Kaleida DC welding machine, in order to assure high integrity of the welded joints, particularly the roll carrier portions. Test evaluations were conducted using an Al-6061 alloy with width and thickness of 500 mm and 95 mm, respectively. It was found that the medium rolling mill torque and force were 1670.22 Nm and 422536.98 N. Furthermore, a rolling power of 7 hp and a solid roll shaft diameter of 80 mm were determined. After rolling, the final thickness was between 102.11 and 102.13 mm. Likewise, the actual draft varied from 7.11 to 7.13 mm. Also, 500 mm, 7.118 mm, 88.975%, 95 mm, and 102.118 mm, respectively were determined as the average width, average actual draft, average efficiency, average original thickness, and average final thickness of Al-6061 alloy. The Al-6061 alloy's final thickness of 102.118 mm and efficiency of 88.975% show how well the medium rolling mill performs.