Failure Analysis of a Working Roll Under the Influence of the Stress Field Due to Hot Rolling Process

Abstract

Crack growth leads to roller failure and damages other parts. The three-dimensional modeling of crack growth, the effect of different factors on the fatigue life of roller, and the effect of stress distribution are important factors that should be considered. The purpose of this paper is to investigate the failure and modeling of three-dimensional fatigue crack growth and fatigue life prediction of high chromium steel (HCS) rollers in hot rolling to minimize the failure of rollers by practical solutions. This article uses boundary element method for fatigue crack growth under the influence of stress field. The proposed method allows modeling each of the components involved separately in the contact area. As a result, this method is faster than finite element models with contact components. In this regard, the types and causes of cracks in the roller are analyzed with the effect of residual stresses on the roller. By selecting the HCS roller and sheet, modeling and stress analysis are performed by finite element method. This study includes the effect of crack growth factors such as load ratio, length, and initial crack angle. The results of the numerical model showed a good agreement with the results obtained in the field observations.