Failure analysis of rolls with grooves

The failure analysis of rolls with grooves on a 3-high-roughing mill stand for hot rolling is presented. A detailed analysis of all the elements which influenced failure was carried out, namely, the cause of all failures was determined and all fracture surfaces are described; the rolling forces were determined by analytical and experimental methods; numerical analysis of the local stresses due to rolling forces was performed with the finite element method; stress time history of the individual local stress and stress spectrum were obtained from service loads; properties of the roll material (strength, hardness, toughness and ductility) were determined by experimental testing. Based on the results of investigation, the main causes of the failures are presented.