materials and manufacturing 3. You own an aluminum processing plant, and want to
ID: 2998151 • Letter: M
Question
materials and manufacturing
3. You own an aluminum processing plant, and want to hot roll aluminum from a billet to a sheet form. The billet is 5m long, 3m wide and 0.25m thick. Your output sheet is to be 0.001m in thickness by 3m width. You configured your plant as a flexible manufacturing line, with an N-stage rolling mill configuration. Your initial feed rate is 0.005m/s.
Assume that the material does not require reheating from start to finish. The maximum reduction of the cross-section from a single roll is 50%, with negligible post-roll bulging. Side rollers maintain the width at 3m. Use Wikipedia for the data on Al, as needed.
A. What is the total mass of aluminum in the billet?
B. How many roller heads will you need to make this material into 0.001m sheets? You cannot
Explanation / Answer
Description:
Aluminium is the ductile material because it is having FCC crystal structure, with 12 (maximum number) slip planes. Hot rolling of aluminium, results in the reduced thickness with retained ductility.
Aluminium billet dimensions:
Thickness = t = 0.25 metres, width= w =3 metres, length = L = 5 metres, N-stages of hot rolling, reduction in the cross sectional area in a single pass- 50%, and it is known that density of the aluminium = D = 2.7 grams per cm3.
The volume of the billet = V = 0.25*5*3 = 3.75 m3 and from density the mass of the billet can be calculated; that is mass of the billet = m = D*V = 10125 Kg
In single pass the reduction in the area is about 50 percent and initial area = IA = 3*0.25 = 0.75 metres square, after 50 percent reduction we get area = 0.375, corresponding thickness = t1 = 0.125 metres, this means after first pass, the thickness gets reduced to 0.125 metres
Followed by same reduction 7 times the final thickness = 0.000975 metres nearly equals to 0.001 metres, this is the final thickness achieved after seven passes with 50 percent reduction each time.
The total reduction in the thickness = ratio of change in the thickness to the original thickness = 93 percent
Since the materials is hot rolled, the rolling action was carried out temperature above the recrystallisation temperature of the aluminium, thus it retains its ductility.
Chromium (free) is most essential element in the stainless steel (SS), because it reacts with the atmospheric oxygen and forms chromium oxide, this is less reactive (less Gibb
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