In today’s industry rolling machine is considered to be extensively used equipment. This machine is generally used in industries where solid as well as Semi solid metals and non-metals are reshaped. The process involved extensive pressure both from the counter purse and the Rolling machine. In this process, the exterior surface of the Rolling machine receives the maximum pressure (Askeland 2013). It can be clearly understood that the layer of friction takes place into separate segments namely the apparel And the Rolling material as well as the lower role and the Rolling material. in both the cases a good amount of energy weight loss due to wear here as well as fictional erosion at an intensive level. Apart from that in rolling machines with high temperature this type of friction results in additional heat as well as enhancement in temperature that Infosys impact on the operational efficiency as well as durability of the production material. Not only has this it also imposed an adverse effect on the strength and sustainability of the Rolling machine. Due to extensive pressure and friction, the rulers of the Rolling machine often develop several cracks as well as microscopic holes. In order to prevent search erosion of the Rolling machine generally, welding machines are made with the help of non-elastic alloy in order to enhance their survival capacity as well as durability even under continuous and extreme fluctuation of the surface temperature (Biresaw 2016). In spite of all these measures, rear and tear of the rollers take place since the material of which they are made up of process highest capacity for having balanced expansion as well as contraction. Once the specific threshold limit gets crossed, the roller material usually gains extreme tear and wear and even visible cracks on the exterior surface.
In these industrial rolling machine the effective utilisation of lubricant substances is notably useful for the rolling device as well as for the manufacturing products. Throughout the last decade, several lubricants are being used in order to lower the frictional erosion on the exterior floor of the rolling device. However, all of these lubricants are pretty elastic and possess lower chance to be dispensed over the operational floor. Therefore, to enhance the efficiency it requires additional maintenance as well as repeated oiling in the operating rollers and inner gears (DellaCorte et al. 2012). This repeated oiling procedure increases the cauterisation process of this lubricant. The cauterisation results in a non-homogeneous distribution of emulsion and frictional imbalance. Therefore, the capability and excellence of the produced material get reduced considerably. In order to resolve this issue, the conventional lubrication methods need to be analysed. Along with that, the ideal requirement for greater fee powerful lubrication method must be recognized. At the equal time, the manufacturing and upkeep efficiency also are relatively dependent on the rate for the lubrication manner in any mechanical industry. The thermodynamical drawback results in extra power loss that also will increase the operational cost of this rolling device.
The lubrication dilemma is a major issue in the vertical rollers in rolling machines. These sorts of rolling machines are specifically utilised in a paper production, metallic sheet manufacturing enterprises. In this mechanical method, the significant disadvantage is the gravitational pull that enhances the lubricant concentration inside the lower edge of the roller. At the same time, the top position of the vertical roller give up the lubricants without from the outer surface due to gravitational pull. This unequal distribution also reasons operational anomaly. Therefore, the rolling material generally passes through the lower part of the roll more without problems than the higher a part of the rolling machine (Hashmi 2015). This operational dilemma affects the general productiveness of the rolling machine. Therefore, besides the ineffective frictional issue, an ideal lubricant must also have the efficient Ven Der Walls pressure to stay connected with the surface of the rolling machine with appropriate distribution.
The chief aim of this research is to gain awareness of the most effective components, which can be used as a lubricant for high temperature rolling machine. Rolling device requires the lubricant in order to enhance the quality of production as well as expanded durability. The goal of this research is to analyse the conventional lubricants concerning oil, water and other emulsions. Through this examination, the most potential method of developing effective lubrication materials can be decided. Apart from that, the study also aims to decide the maximum appropriate utility field of the lubricant in addition to the further evaluation process. According to researchers, the more efficient is the lubricant may be the less amount of energy the machine will take to function. Therefore, finding out the thermodynamical significance of the recognised lubricant materials is another crucial aim of the research.
In this literature review section, several valuable articles and research journals, books n industrial mechanics, research in surface have been reviewed to develop a secondary database on this particular topic of lubrication. The literature review section the structure of the rolling machine and the use of conventional lubricants have been discussed comparing with the advanced utilisation of the various lubrication methods. The water-based, oil-based and the Titanium Nanoparticle lubricants have been examined with their all possible emulsion formation and their advantages and disadvantages. The purpose of this literature review is to collect all the essential secondary data and information that can help the research to formulate the procedure as well as to compare the viability of the outcomes.
The rolling machines are mainly used for making paper and metal sheet, oil paint mixture, plastic roll, rubber production and other industrial infrastructures. The basic principles of the rolling machine are to convert the angular momentum into perpendicular force in order to generate the appropriate pressure on a particular solid or Semi-solid materials. The structure of the rolling machine can comprise with several metallic heavy solid cylinders, however the force acted on the rolled material is generated by 2 parallel closely situated roller cylinders. Hence, the exterior surfaces of these two cylinders are the contact points with or without the processing object (Jamaati, Toroghinejad, and Edris 2014). Most of this time these cylindrical rollers are made by special metallic alloy with higher density with high-pressure resisting capacity. The exterior curved surface of the rollers has a significant amount of friction even after frequent polishing. The electric motor is used to generate enough power to create an angular motion in these two cylinders around their own axis. When the metallic sheet or the solid material are dragged through these two revolving cylinders the amount of pressure produced in that machine creates enormous pressure to make the material flat and thin. As per Dowson and Higginson 2014, to reshape the solid and semisolid materials between the two cylinders require a high force that causes additional effective frictional force within these two rollers.
As per the operational structure of the rolling materials, it is clear that the points of friction are two considering the friction plane between upper roller and the upper surface of the rolled material and the friction plane between the lower roller and the lower plane of the rolled material (Kalpakjian, Vijai Sekar and Schmid 2014). This situation causes both thermal energy radiation and resistance frictional force against the applied force on the roller. The roughness of the rollers is directly proportional to the resultant frictional force and thermal energy. At the same time, the greater speed comes from more torque that subsequently is transferred to greater frictional force and greater resultant thermal energy. If the applied power on the roller is P, the resultant frictional force is F and the resultant thermal emission is T therefore it can be deduced that:
P α F and P α T, which means P α FT
At the same time, we can consider that the resultant temperature is caused by remitted thermal energy, which implies that if the increased temperature is t therefore: T α t
As per the principle of the frictional force, the resultant frictional force directly results from the average roughness of the cylinder which is indicated by Ra. Therefore, from the above to consideration it can be found that P α Ra and P α t (Armstrong-Helouvry 2012)
Therefore, appropriate additional of semi-liquid materials that can decrease the resultant friction of the rolling machine can reduce the resultant thermal energy generation while increasing the mechanical efficiency of the machine.
The mechanical efficiency is the driver of the lubrication process. The mechanical efficiency of the rolling machine depends on how efficiently the machine can convert the applied power in the machine to the effective rolling force. In this operation, friction acts both as a resistance and as a generator of the additional thermal sink (Kamimura, Mor and Idemitsu Kosan Co Ltd 2012). The lubricant can cover the microscopic gap of the outer surface of the rollers. In this situation, both viscosity and surface elasticity of the lubricant allows to make a proper grip on the external surface. At the same time, the resulting temperature caused by the frictional force of the rolling operation can be reduced by reducing the roughness. The molecular structure of the lubricant has huge contribution to developing the smoothness in the outer surface of the roller.
As opined by Holmberg et al. 2013 One of the major disadvantages of using the lubrication is that sometimes these lubricants trap the head within the exterior surface of the metallic rollers while increasing the overall temperature. Consequently, this situation leads to decreasing mechanical efficiency. Hence, a huge amount of applied power on the rolling machine is leaked by the resultant temperature caused by the trapped heat of the lubricant and reduced friction level. For these, the utilisation of the lubricants depends on the operating speed of the rolling machine. The friction control and temperature trapping properties of each lubricant has the specific bandwidth for optimum outcomes
The conventional lubrication is a significant issue in the history of industrial revelation throughout the globe. In different industrial operations, the conventional lubrication procedures have been evolved significantly throughout the history of mechanical utilisation in industry belt (Taylor 2012). The production and the maintenance cost of the lubrication procedure are considerably high due to regular usage and measured optimisation. The major driver force of this artificial evacuation of lubrication techniques is the cost of the lubrication, effective friction reducing and the resultant heat generation. Both the cold rolling and hot rolling types of machinery use various types of lubricants depending on their optimum operational bandwidth. In lubrication efficiency testing procedure Al- alloy and a low carbon steel are used for cold rolling and hot rolling respectively (Mabuchi, Nakagawa and Nissan Motor Co Ltd 2015). At the same time, Lubricants bearing capacity and the product surface roughness depends on the properties and the molecular structure of the lubricant chemical.
Oil-based lubrication, oil-water emulsions, grease synthetic lubricants are some common example of traditional lubrication procedure. The conventional lubrication procedures do not have any significant differences in terms of their operational efficiency in temperature reduction and effective rolling force. Some conventional lubricant has a low ability to control the “forward slip” and high thermal energy emission properties. Some specific natural refined oil and water emulsion have high-temperature emission power while having low control on “forward slip” that results in a lack of pressure on the rolled material (Mang 2014.). This lack of pressure causes product deformation, which encouraged the researchers to find out more effective lubrication techniques. Corrosion is another significant factor that influences the development of a new lubricant additive. The physical properties of lubricants also influence the corrosion of the metal used to build the rollers of the rolling machine. At the same time, this kind of additives is unsatisfactory in commercial application due to their pungent odour.
Oil-based lubrication is a very commonly used lubrication procedure that uses for almost all bearing steel. The oil-in-water (O/W) emulsion and the water-glycol based liquid are selected as the base fluids for most of the industrial additives. The effect of molecular chain length, additive concentration and sliding velocity on the water-glycol’s tribological performance is the most effective factor that influences the lubrication efficiency. Three novel xanthate-containing water-soluble triazine derivatives, EXT, BXT and HXT, are synthesized and used as additives in the water-glycol base fluid. It has been found, that the additive that contains samples had no corrosive effect on the cast iron and copper surface within 2.5 wt.% additive (Martin 2014). The tribological tests using a four-ball tribometer showed that STB and STC both improved the PB value, anti-wear and friction-reducing capacities of the Oil base fluid greatly. Therefore, it can be said that the differences in tribological performances of STB and STC samples are due mainly to the differences of the sulfur content and the sulfur activity in additives.
The XPS results indicate that STB-tribofilm mainly contained sulfate, but STC tribofilm contained sulfide as well. Additives had reacted with the contact metal surfaces and formed complex tribofilms composed of iron oxide, iron sulfide and iron sulfate, which may contribute to the reduction of friction coefficient and wear rate of the friction system. O/W emulsion lubrication, if the droplets can be quickly adsorbed into the metal surface, forming an oily layer between the rubbing surfaces, the COF will be reduced. If coupled with the formation of an effective adsorption film and tribofilm by additives, the COF will be further reduced (Padgurskas et al. 2013). For water-glycol lubrication, the differences in the tribological performances are due mainly to the differences of the formed adsorption film and the tribofilm on the rubbing surface, including the forming velocity, strength and thickness and the composition. These change not only with the additives but also with the working conditions.
Synthetic water-based lubricant, used in the cold rolling of an Al- alloy, showed good lubrication capability, better than the mineral oil but worse than the emulsion. The rolled Al- strip finish was found to be finest for the synthetic lubricant followed by the mineral oil and the emulsion. Similar results were obtained from the steel rolling. Here four synthetic lubricants were compared with two mineral oils and one emulsion (Pawelski et al. 2013). The best lubricant was found to be one of the water-based synthetics, showing the lowest value of the friction coefficient and a smooth product surface. Most emulsions are composed of inherently immiscible water (W) and oil (O), and they are classified into two types: the O/W (oil in water type, in which oil droplets are dispersed in a continuous water phase) and the W/O (water in oil type). For example, milk is an O/W type emulsion in which oil fat droplets (butter) are dispersed in water with the aid of casein (a type of protein) emulsifier. It appears that milk and cream (an O/W type emulsion with relatively high oil content) have long been used as lubricants (Riahi et al. 2012). Natural cow’s milk was once employed as a cutting solution for the machining of Ti and other difficult-to-cut materials and as the lubricant for some special plastic working processes (Zhu, Olofsson and Persson 2012). However, natural cow’s milk contains undesired constituents, making secondary washing and waste solution processing necessary. Thus natural milk lubricants have now been replaced by synthetic emulsion lubricants. Even today, butterfat and other natural biological oils are widely used as base oils for emulsions, while synthetic surface activators are commonly used as an emulsifier.
Nano-TiO2 has anti-wear, friction-reducing and cooling properties which can reduce the coefficient of rolling and friction force during the hot rolling process. TiO2 has potential application in the steel rolling process, micro-drilling process, and machine cutting process . the coefficient of performance of a refrigeration system can be improved if a reduction in the work of compression can be achieved by a suitable technique, for a specified heat removal rate. The present study investigates the effect of dispersing a low concentration of TiO2 nanoparticles in the mineral oil-based lubricant, on its viscosity and lubrication characteristics, as well as on the overall performance of a Vapor Compression Refrigeration System using R12 (Dichlorodifluoromethane) as the working fluid (Sabareesh et al. 2012). An enhancement in the COP of the refrigeration system has been observed and the existence of an optimum volume fraction noticed, with low concentrations of nanoparticles suspended in the mineral oil. The physics involved in the interaction of nanoparticles with the base fluid has been further elucidated by estimating the Optical Roughness Index using a Speckle Interferometer, by performing measurements on the pin surface following tests with a Pin-on-Disk tester. The additive used in the mineral oil based lubricant was TiO2 in the nanoparticle form. Fig. 1 shows the SEM image of the TiO2 nanoparticles, which was used in this study. The average size of the nanoparticles had a range of 30e40 nm and was supplied by Sigma Aldrich Limited USA. Mineral oil e TiO2 nano-fluid samples with different volume fractions of TiO2 nanoparticles were prepared using ultrasonic agitation for achieving good dispersion of the particles in the base fluid (Stachowiak 2015). The required weight of the TiO2 nanoparticles corresponding to the volume fraction was accurately measured using a high precision electronic balance.
From the above discussion, it can be said that the conventional lubrication is a significant issue in the history of industrial revelation throughout the globe. In different industrial operations, the conventional lubrication procedures have been evolved significantly throughout the history of mechanical utilisation in industry belt. It has been found that, Oil based lubrication, oil-water emulsions, grease synthetic lubricants are some common example of traditional lubrication procedure. At the same time, the oil-in-water (O/W) emulsion and the water-glycol based liquid are selected as the base fluids for most of the industrial additives. In the case of O/W emulsion lubrication, if the droplets can be quickly adsorbed onto a metal surface, forming an oily layer between the rubbing surfaces, the COF will be reduced. As per the literature, the Synthetic water-based lubricant is used in the cold rolling of an Al- alloy, showed good lubrication capability, better than the mineral oil but worse than the emulsion. They are classified into two types: the O/W (oil in water type, in which oil droplets are dispersed in a continuous water phase) and the W/O (water in oil type). However, the advance Nano-TiO2 has anti-wear, friction-reducing and cooling properties which can reduce the coefficient of rolling and friction force during the hot rolling process.
The primary objective of this literature review was to collect the secondary data regarding the commercial lubrication procedure with scientific and theoretical analysis. The literature review helped to compare the basic operational differences of three types of core lubricant concerning the thermal effect, effective pressure and the resultant frictional force. However, the significance of the corrosion due to the chemical composition of the lubrication and their longtime impact on the rolling machine was not explored properly. The literature review also lacks practical data of industrial usage of the lubricant and their existing and potential benefit as well as cost.
In order to choose the appropriate research philosophy for this research, this study had three options namely the realism, positivism and the interpretivism philosophy. This study is based on the physical properties of the lubricants considering the molecular level structure as well as the physical properties of metal surfaces considering the temperature and roughness. Therefore, to analyse the data this research needed to execute various interpretation of the findings. At the same time, the positivism philosophy is more valuable for social science and the realism philosophy, which is the mixed philosophy of the other two philosophies is more effective on verbal and non-verbal based data collection. In this research, various scientific tools and measurement techniques have been used. Therefore, the realism philosophy has been followed in this research.
The research design helped the research to synchronise all the necessary components of the research as per their utilisation and effectiveness. Presentation style of this research highly depends on the research design. To present and conduct this research the study had three choices namely exploratory research design, explanatory research design and descriptive research design. This research did not have any assumption or predetermined prediction (Takahama et al. 2014). Therefore, the design of this research was planned to explore the physical properties of various lubricants and their effectiveness in different implications on the hot rolling machine. The exploration rather based on numerical outcomes. Therefore, the exploratory research design has been used in this research. At the same time, there was no pre-observation to be described in this research. therefore, the research did not use the descriptive research design either.
The research approach is the pattern of utilising the data collection tools in order to develop a particular group of findings for analysis. In this research, there were three research approaches available to be chosen namely the inductive research approach and the deductive research approach. This research did not have any assumption or predetermined prediction which is also known as a hypothesis to be proven. Therefore, this research focuses on finding the outcomes from an open ended perspective that allowed the research to choose the inductive research approach. Therefore, the approach of this research was planned to explore the physical properties of various lubricants and their effectiveness in different implications on the hot rolling machine.
In this primary data collection, several external measurement tools have been used to monitor the temperature of the rolling machine and the effectiveness of different lubricant. In this data collection method, the major 5 numerical considerations are the temperature of the rolling machine, the roughness of the rolling cylinder’s surface, the speed of the rolling machine and the resultant force from the torque of the rolling cylinders. In these components, the controlled variables are the speed of the rolling machine, the temperature of the rolling machine. The independent or resultant variables are the roughness of the surface, the resultant force of rolling. Other supportive variables are the diameter of distribution of droplets and the thickness differences of the metal sheet.
Initially, the droplet test has been executed to identify the distribution of the lubricants without involving any external pressure or thermal changes. It has helped to identify the properties and tendency of the lubricant on the rolling surface. The metal sheet thickness test has been executed to identify the effective pressure of the rolling machine with regards to the rolling speed. The thermal test has been executed to measure the operating temperatures of the rolling machine because of the thermodynamic properties of the used lubricant emulsions. To collect the readings of rolling machines operational temperature, the speed of the rolling machine was controlled externally. The roughness differences of the metal plate have been also measured through the optical surface roughness measurement technique to find the effectiveness of the rolling machine. During this roughness measurement process, the optimum speed of the rolling machine has been set from the findings from metal sheet thickness test. In this test, multiple lubricant emulsions have been used including Oil-water, Inorganic chemicals-water, Oil-TiO2-water, Oil-Al2O2-water and Oil-graphene oxide-ware mixture. The force test has been executed by using all these lubricants individually.
Research tools are the essential components for any research that help the researchers to collect adequate data set from the data resources through various procedures. This research comprised of many adiabatic and metric measurement system and the tools have been chosen accordingly. To measure the controlled, dependent and independent variables various industry standard tools have been used. Testo 835-T2- High-Temperature Infrared Thermometer with the capability of -50 to 1500 degree Celsius temperature measurement has been used to measure the operating temperature of the rolling machine and the roller surface. Coulter LS 230 Leisure Diffraction tool is used to determine the molecular level distribution of lubricant. The LS230 Leisure Diffraction tool is able to measure the angular diffraction for nanoparticles of 0.4 to 2000 µm. EHD Ultra-thin sheet Measurement System has been selected as the thickness measurement tools for metal film. This EHD system has been mounted internally within the Rolling machine. The research will be conducted on the Low Carbon Sheet Metal sheet with higher resistance and hardiness than other metals of industrial use. A low carbon sheet metal with a yield stress of 345 MPa (Mega Pascal) has been used in this study. The thickness of this sheet was 5mm. The rolling force during hot rolling was detected using two individual load cells assembled at the drive and operation sides in the rolling mill. The data acquisition was conducted by MATLAB xPC technology. The roughness of the metal sheet after and before the rolling has been contact roughness measurement device Roughness Tester PCE-RT 2200-ICA. The used lubricants are:
The research is based on the real time physical measurement system depending on the surface properties and molecular structure. Therefore, the reading of different tools calculated through numerical data analysis. The research had two options to choose namely quantitative and qualitative data analysis. In this research, the quantitative data has been chosen for mathematical and statistical data analysis of the numerical findings from the data collection. Droplet distributions have been collected comparing the diameter of distribution by µm with distribution percentage density of the lubricant on the metal surface. The collected data from the have been controlled by the percentage of lubrication. After the data collection procedure, the tabular and graphical presentation has been used for analysis and finding the outcomes. The roughness differences of the metal sheet before and after the rolling process have been used to develop the effectiveness of the rolling machine on the metal sheet surface. To analyse the spreading ability lubricants are analyses through the radiuses of the droplets distributions. The effectiveness or flattening capacity of the rolling machine due to the utilisations of the lubricants have been analysed from the RA differences of the rolled metal sheet. After that, the findings have been compared side by side through graphical and tabular representation. The data analysis also used the graphical data presentation as strategic use of the visual data analysis technique. It helped the researchers to have a more in-depth and effective view on the outcomes and their significance.
For this research, the ethical consideration is one of the major factors that can ensure the credibility and authentication of the research. The Ethical consideration of this research can be defined from both Safety measures and the Data privacy measures. In the ethical consideration of this study, many moral and ethical factors within the execution of the research methods have been kept in mind. The research procedure ensured that it would not cause any physical damage or hazard to the researchers and the support team members. Before conducting the research the laboratory premises were inspected properly to detect any hazardous situation (Wan et al. 2016). Apart from that all the PPE types of equipment with fire distinguishing arrangement and the emergency first aid system ware present in the research premises during the research. The measurement tools that were used to collect the data are calibrated repeatedly to ensure that the collected data sets are valid and feasible.
This study is based on the physical properties of the lubricants considering the molecular level structure as well as the physical properties of metal surfaces considering the temperature and roughness. Therefore, the realism philosophy has been followed in this research. The design of this research was planned to explore the physical properties of various lubricants. Therefore, the exploratory research design has been used in this research. This research focuses on finding the outcomes from an open-ended perspective that allowed the research to choose the inductive research approach. In this primary data collection, several external measurement tools have been used to monitor the temperature of the rolling machine and the effectiveness of different lubricant. This research comprised of many adiabatic and metric measurement system and the tools have been chosen accordingly. Therefore, the reading of different tools calculated through numerical or quantitative data analysis.
|
Droplet Volume in percentage |
Diameter of Distribution (µm) |
|
0.01 |
0 |
|
0.02 |
1 |
|
0.04 |
3 |
|
0.06 |
6 |
|
0.08 |
12 |
|
0.1 |
24 |
|
0.12 |
12 |
|
0.14 |
6 |
|
0.16 |
3 |
|
0.18 |
1 |
|
0.2 |
0 |
|
Droplet Volume in percentage |
Diameter of Distribution (µm) |
|
0.01 |
0 |
|
0.02 |
1 |
|
0.04 |
5 |
|
0.06 |
3 |
|
0.08 |
10 |
|
0.1 |
8 |
|
0.12 |
12 |
|
0.14 |
7 |
|
0.16 |
3 |
|
0.18 |
2 |
|
0.2 |
1 |
|
Droplet Volume in percentage |
Diameter of Distribution (µm) |
|
0.01 |
0 |
|
0.02 |
1 |
|
0.04 |
6 |
|
0.06 |
3 |
|
0.08 |
10 |
|
0.1 |
18 |
|
0.12 |
12 |
|
0.14 |
5 |
|
0.16 |
8 |
|
0.18 |
2 |
|
0.2 |
0 |
|
0.1 |
400 |
250 |
380 |
|
0.2 |
540 |
400 |
500 |
|
0.3 |
710 |
550 |
620 |
|
0.4 |
820 |
660 |
750 |
|
0.5 |
980 |
750 |
830 |
|
0.6 |
1050 |
820 |
880 |
|
0.7 |
1100 |
880 |
910 |
|
0.8 |
1150 |
950 |
930 |
|
0.9 |
1180 |
980 |
945 |
|
Speed (m/s) |
Change in thickness of metal sheet (nm) |
|
0.1 |
0 |
|
0.25 |
4 |
|
0.5 |
10 |
|
0.75 |
15 |
|
1 |
19 |
|
1.25 |
21 |
|
1.5 |
22 |
|
1.75 |
22 |
|
2 |
22 |
|
2.25 |
21 |
|
2.5 |
19 |
|
2.75 |
19 |
|
3 |
18 |
|
Speed (m/s) |
Change in thickness of metal sheet (nm) |
|
0.1 |
0 |
|
0.25 |
5 |
|
0.5 |
8 |
|
0.75 |
10 |
|
1 |
12 |
|
1.25 |
13 |
|
1.5 |
14 |
|
1.75 |
15 |
|
2 |
16 |
|
2.25 |
16 |
|
2.5 |
17 |
|
2.75 |
17 |
|
3 |
17 |
|
Speed (m/s) |
Change in thickness of metal sheet (nm) |
|
0.1 |
0 |
|
0.25 |
2 |
|
0.5 |
5 |
|
0.75 |
10 |
|
1 |
12 |
|
1.25 |
13 |
|
1.5 |
13 |
|
1.75 |
13 |
|
2 |
15 |
|
2.25 |
18 |
|
2.5 |
18 |
|
2.75 |
18 |
|
3 |
19 |
Lubrication and effective force
|
Percentage of lubrication |
Force (KN) |
||||
|
Oil and Water |
Inorganic chemicals and Water |
Oil, TiO2 nano particles and water |
Oil, Al2O2 nanoparticles and water |
Oil graphene oxide and water |
|
|
Unlubricated |
610 |
610 |
610 |
610 |
610 |
|
30% |
545 |
550 |
580 |
585 |
540 |
|
45% |
530 |
520 |
560 |
570 |
525 |
Lubrication and roughness differences
|
Percentage of lubrication |
Roughness differences RA (µm) |
||||
|
Oil and Water |
Inorganic chemicals and Water |
Oil, TiO2 nano particles and water |
Oil, Al2O2 nanoparticles and water |
Oil graphene oxide and water |
|
|
Unlubricated |
0.8 |
0.8 |
0.8 |
0.8 |
0.8 |
|
30% |
0.5 |
0.4 |
0.7 |
0.6 |
0.8 |
|
45% |
0.8 |
0.7 |
0.9 |
0.7 |
0.1 |
From the droplet distribution test, it can be found that the diameter distribution of each of the emulation showed different measures. From the water-based emulsion with some limited additive of natural oils the viscosity represented very high coefficient. As per the graphical presentation, it is clear that the concentration of this additive is high centralised at the initial position of the droplet. From the droplet distribution test for the oil-based impulsion with various metallic additives it can be found that the diameter distribution is not synchronised properly. The concentration of the distributed liquid reduces significantly after the distance of 0.12 µm from the centre. However, the droplet distribution of the Titanium Oxide based emulsion showed a completely different outcome from the previous two additives. In this In this situation, there was no particular radial distance for the maximised density of the liquid. However, the density of the liquid was dense maximum in 0.1 µm, however other secondary picks of concentrated lubricant are visible at the two corresponding positions, which are at 0.04 µm and 0.16 µm radial distance.
As per the temperature and lubrication test, several temperature variables are found that have a significant individuality of uniqueness. It has been found that the temperature increase of water-based emulsion did not have any considerable stagnant point. This lubricant has approximately stable growth with the increasing speed of the rolling machine. On the other hand, the temperature increase of oil-based emulsion has a minor stagnant point at 0.5 mm per second. However, the overall increment of this oil-based emulsion is significantly high compared to the other emulsions. At the stagnant point of 0.5 mm per second, the temperature of the oil-based lubricant reached almost 1000 degree Celsius. The Titanium oxide-based emulsion, on the other hand, has comparatively stable temperature growth. At the stagnant point of 0.5mm/sec, the temperature of this lubricant was 830 degree Celsius which is higher than the water-based solution and lower than the oil-based solution at this particular speed. Apart from that, the major difference after this speed the temperature increment rate of this nano-particle based lubricant dropped. After the speed of 0.8 mm per second, the resulted temperature became even below than the temperature of the water-based solution at that particular speed.
As per film thickness test, several thickness variables in the metallic plate are found that have a significant individuality of uniqueness. It has been found that the changes of metal sheet thickness after applying the water-based emulsion have a considerable stagnant point at the speed of 1.25 mm per second. After that, at the speed of 2.25, the thickness changes of the metal sheet was decreasing rapidly with the increasing speed of the rollers. This speed can be considered as the critical point for this water-based emulsion. On the other hand, the changes in metal sheet thickness due to the use of oil-based emulsion does not have a critical point like water-based lubricant. However, after the speed of 2.5 mm per second, the thickness changes of the metal sheet became apparently constant. The Titanium oxide-based emulsion, on the other hand, has comparatively unstable changes of the metal sheet thickness. For this nano-particle based lubricant, there were multiple stagnant points where the thickness changes showed a constant value temporarily. However, there was no permanent stagnant point as per the graphical expression. The major difference for this lubricant is, in this case, the resultant changes of metal sheet thickness is continuously increasing even at the speed of 3mm per second.
As per rolling force test and the roughness difference test, several variables of the resultant pressure measurement and the metallic plate roughness were found that have a significant individuality of uniqueness. In this situation, the research should prioritise both the roughness of the output metal sheet and the resultant force. In order to do the following comparison table and graphical presentation has been made for more in-depth analysis an comparison.
|
UnLubricated |
30% Lubrication |
45% Lubrication |
||||
|
SAMPLES |
Rolling Force (KN) |
Roughness Differences (µm) |
Rolling Force (KN) |
Roughness Differences (µm) |
Rolling Force (KN) |
Roughness Differences (µm) |
|
Oil and Water |
610 |
0.8 |
545 |
0.5 |
530 |
0.8 |
|
Inorganic chemicals and Water |
610 |
0.8 |
550 |
0.4 |
520 |
0.7 |
|
Oil, TiO2 nano particles and water |
610 |
0.8 |
580 |
0.7 |
560 |
0.9 |
|
Oil, Al2O2 nanoparticles and water |
610 |
0.8 |
585 |
0.6 |
570 |
0.7 |
|
Oil graphene oxide and water |
610 |
0.8 |
540 |
0.8 |
525 |
1 |
As per the above tabular analysis, it has been found that an unlubricated machine has high rolling force as well as high roughness differences in output metal plate. The mixture of Oil, Al2O2 nanoparticles and water has the second higher resultant force, which is 585KN on the metal plate at the lubrication of 30%. At the lubrication of 45% this lubricant solution had the highest resultant force as well amongst the other lubricants. However, in terms of roughness reduction, this lubricant is far below that the Oil, TiO2 nanoparticles and water mixture. For both 30% and 45% lubrication, the changes in roughness were 0.7 and 0.9 respectively. In terms of roughness difference, Oil graphene oxide and water mixture had the largest value among the lubricants. The following table represents the average lubrication effects of all the lubricants considering the rolling force and the resultant roughness differences.
|
On Average Lubrication |
||
|
Samples |
Rolling Force (KN) |
Roughness Differences (µm) |
|
UnLubricated |
610 |
0.8 |
|
Oil and Water |
535 |
0.65 |
|
Inorganic chemicals and Water |
535 |
0.55 |
|
Oil, TiO2 nano particles and water |
570 |
0.8 |
|
Oil, Al2O2 nanoparticles and water |
577 |
0.65 |
|
Oil graphene oxide and water |
532 |
0.9 |
From the above data analysis, it has been found that as per the droplet distribution the Titanium Oxide nano-particle based lubricant has the appropriate viscosity and surface tension that can allow distributing throughout the exterior surface of the rolling cylinder sequentially. In terms of lubrication and distribution, it is more beneficial than the oil based and water based lubricants. As per the secondary data, it is clear that one of the major boundaries of the lubricants is they are unable to expand homogeneously. Using the Titanium Oxide nano-particle based lubricant can minimise this disadvantage by distributing throughout the upper and lower area of the roller more homogeneously (Wright 2011). As per the thermodynamical properties of all these lubricants, it has been found that After the speed of 0.8 mm per second the resulted temperature became even below than the temperature of the water-based solution at that particular speed, which can be significantly beneficial for the hot rolling machine. This type of thermal effect can be caused by the higher heat conduction or realising capability of the Titanium Oxide Nanoparticles.
The less frictional resistance against the speed of the metal rollers after using the Titanium Oxide nano-particle is the result of the spherical shape of the nanoparticles. This spherical shape of the microscopic particle helps to cover up the depth of the microscopic roughness on the outer layer of the metal cylinder. At the same time, the self-rolling capability of the nanoparticles added more advantage at the touch points of the upper rolling cylinder and the upper surface of the rolled material and the lower rolling cylinder and the lower surface of the rolled material. It also helped to stabilise the force on the particular point of pressure on the rolled metallic sheet (Zhu et al. 2013). As per the average calculation of the rolling force and the roughness differences it has been found though Oil, Al2O2 nano-particles and water has higher pressure, it has lower roughness reduction capability. At the same time, Oil graphene oxide and water have the highest roughness reduction capability while having the low rolling force. Therefore, the mixture of Oil, TiO2 nanoparticles and water has the optimum balance of rolling force and roughness reduction capability. Hence, it can be said that the Titanium Oxide nano-particle based lubricant has the optimum quality of lubrication. It allows the machine to control the temperature while having a larger range of speed. At the same time, it also makes a proper balance of resultant rolling force and the roughness reduction capability.
Chapter 6: Conclusion
Conclusion
As per the above discussion, it has been found that calculation of the rolling force and the roughness differences it has been found though Oil, Al2O2 nano-particles and water has higher pressure, it has lower roughness reduction capability. At the same time, the mixture of Oil, TiO2 nanoparticles and water has the optimum balance of rolling force and roughness reduction capability. Hence, it can be said that the Titanium Oxide nano-particle based lubricant has the optimum quality of lubrication. It allows the machine to control the temperature while having a larger range of speed. At the same time, it also makes a proper balance of resultant rolling force and the roughness reduction capability. This lubricant is needed for acting as a lubricant to resist tear and friction of the metallic surface. It will also help to identify the most effective and cost-efficient process of lubrication in industrialised mechanical usage. As per the lubrication testing, the Identified combination of the lubricant is oil, water and Titanium Oxide nano-particles as a part of emulsion lubricant. This mixture can provide best thermodynamical efficiency as well.
To learn the physical and chemical properties of Oil as a lubricant: Though the literature review and the mechanical testing, it has been found that as lubricant oil has good friction reduction capability, however, the high amount of heat-trapping is the major issue.
To learn the physical and chemical properties of water emulsion as the lubricant: Though the literature review and the mechanical testing, it has been found that as lubricant water-based solution has less frequency reduction capability, however the amount resultant pressure in high.
To learn the physical and chemical properties of Titanium Oxide based emulsion as a lubricant: Though the literature review and the mechanical testing, it has been found that as lubricant Titanium Oxide nano-particle based solution has moderate frequency reduction capability, however the amount resultant pressure in high. Apart from that, this lubricant has also less thermal trapping tendency among others
To obtain the best lubricants that can reduce resultant wear and tear, friction and also provides a good surface finish for the hot rolling machines: After analysing the physical and molecular mechanical properties of the core substances the working principles suggesting that Titanium Oxide nano-particle based lubricant is the optimum solution. This lubricant is needed for acting as a lubricant to resist tear and friction of the metallic surface. It will also help to identify the most effective and cost-efficient process of lubrication in industrialised mechanical usage.
To obtain the best combination of lubricants for Lubrication of Hot Rolling Machine: As per the lubrication testing the Identified combination of the lubricant is oil, water and Titanium Oxide nano-particles as a part of emulsion lubricant. This mixture can provide best thermodynamical efficiency as well.
The major research gap of this research it that the research did not focus properly on the corrosion effect of the chosen lubricants. The conducted data collection techniques were focused on only the resultant force, friction and the thermal efficiency of all the lubricant. However, to become this research more authentic and viable prioritising the oxidation or corrosion effect of the selected lubricants should be also considered. In future, more in-depth analysis of all these lubricants can be done considering the existing variables as well as the corrosion effects on the hot rolling machine. Along with that, the literature review also lacks practical data of industrial usage of the lubricant and their existing and potential benefit as well as cost. Therefore, in further data analysis process the industrial usage of the lubricant and their existing and potential cost-benefit analysis have to be done properly.
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