Dissertation on Optimizing Lubrication for Hot Rolling Machines

This dissertation investigates effective lubrication strategies for hot rolling machines, crucial equipment in industries reshaping metals and non-metals. It addresses the lubrication challenges, particularly in vertical rollers, and aims to identify optimal lubricant components. The research analyzes various lubricants, including oil, water emulsions, and nano-particle-based additives, considering their physical properties and the metal surfaces' characteristics at different temperatures and roughness levels. Through primary data collection using external measurement tools to monitor temperature and lubricant effectiveness, the study concludes that a mixture of oil, Al2O2 nano-particles, and water demonstrates the best potential as an effective lubricant, reducing thermal changes, frictional force, and rolling force, thereby enhancing the mechanical efficiency of the rolling machine. The dissertation includes a literature review, research methodology, data presentation, analysis, and a conclusion linking findings with research objectives and future scope.

Running head: DISSERTATION
Dissertation: Effective Lubrication in HOT Rolling machine
Name of the Student
Name of the University
Author note:

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Abstract
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. 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. At the same time, the lubrication dilemma is a major issue in the vertical rollers in
rolling machines.
The chief goal of this study is to gain awareness of the most effective components,
which can be used as a lubricant for hot rolling machine. The aim of this research is to
analyse several lubricants concerning oil, water and other emulsions as well as the advanced
nano-particle based additives.
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. 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.
As per this study, it has been found that the mixture of Oil, Al2O2 nano-particles and
water has the optimum potentiality to be an effective lubricant considering the resultant
thermal changes, frictional force and resultant rolling force which imply the mechanical
efficiency of the rolling machine.

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Table of Content
Chapter 1: Introduction..............................................................................................................5
Background:...........................................................................................................................5
Problem Statement:................................................................................................................6
Research Aims:......................................................................................................................7
Research Objectives:..............................................................................................................7
Research Question:.................................................................................................................8
Chapter 2: Literature Review.....................................................................................................8
Introduction:...........................................................................................................................8
Structure of the roller surface and the cause of extreme friction...........................................9
Results of appropriate lubrication........................................................................................10
Conventional use of lubricant..............................................................................................11
Oil based lubricants and its working principles and usage..................................................12
Water based Lubricants and its working principles and usage............................................13
Titanium Oxide Nano-particles as lubricant and usage.......................................................14
Summary:.............................................................................................................................15
Literature Gap:.....................................................................................................................16
Chapter 3: Research Methodology...........................................................................................16
Research philosophy............................................................................................................16
Research design....................................................................................................................17
Research approach...............................................................................................................17

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Data collation Method..........................................................................................................18
Research Tools and materials:.............................................................................................19
Data Analysis Method..........................................................................................................20
Ethical consideration............................................................................................................20
Summary..............................................................................................................................21
Chapter 4: Data presentation and findings...............................................................................22
Chapter 5: Data analysis and discussion..................................................................................30
Analysis................................................................................................................................30
Discussion............................................................................................................................34
Chapter 6: Conclusion..............................................................................................................35
Conclusion............................................................................................................................35
Linking with objectives:.......................................................................................................36
Research Gap and future scope............................................................................................37
References:...............................................................................................................................38

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Chapter 1: Introduction
Background:
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.

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Problem Statement:
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,

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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.
Research Aims:
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.
Research Objectives:
 To learn the physical-chemical properties of Oil as a lubricant
 To learn the physical-chemical properties of water emulsion as a lubricant
 To learn the physical and chemical properties of Titanium Oxide based emulsion as a
lubricant
 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

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 To obtain the best combination of lubricants for Lubrication of Hot Rolling Machine
Research Question:
 What are the physical and chemical properties of Oil as a lubricant?
 What are the physical and chemical properties of water emulsion as a lubricant?
 What are the physical and chemical properties of Titanium Oxide based emulsion as a
lubricant?
 What is the best lubricant that can reduce resultant wear and tear, friction and also
provides a good surface finish for the hot rolling machines?
 What is the best combination of lubricants for Lubrication of Hot Rolling Machine?
Chapter 2: Literature Review
Introduction:
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.

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Structure of the roller surface and the cause of extreme friction
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). These
cylindrical vertical rollers are made with special metallic alloy with higher density metal
which has high-pressure resisting capacity. The exterior curved surface of the rollers has a
significant amount of friction even after frequent polishing. To generate enough power the
electric motor is used that creates the angular momentum in these two vertical cylinders
around their own axis. The metallic sheet or plate are dragged through these two revolving
cylinders where the amount of produced pressure through the revolving rollers creates
enough force to make the metallic object more 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

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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.
Results of appropriate lubrication
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.

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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 use of lubricant
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