Reducing production loss by prolonging service life of rolling mill shear pin with ultrasonic nanocrystal surface modification technology
Premature failure at the shear pin of stainless hot rolling mill caused by increasing productivity and fluctuation of roll torque raises significant downtime cost. To reduce downtime cost, UNSM (Ultrasonic Nanocrystal Surface Modification) treatment is applied to the neck groove of shear pin as the...
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| Published in | International journal of precision engineering and manufacturing Vol. 14; no. 11; pp. 2027 - 2032 |
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| Main Authors | , , , , , , |
| Format | Journal Article |
| Language | English |
| Published |
Berlin/Heidelberg
Springer Berlin Heidelberg
01.11.2013
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| Subjects | |
| Online Access | Get full text |
| ISSN | 2234-7593 2005-4602 |
| DOI | 10.1007/s12541-013-0276-7 |
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| Abstract | Premature failure at the shear pin of stainless hot rolling mill caused by increasing productivity and fluctuation of roll torque raises significant downtime cost. To reduce downtime cost, UNSM (Ultrasonic Nanocrystal Surface Modification) treatment is applied to the neck groove of shear pin as the alternative to existing solutions. This treatment prevents premature failure, increases service life and reduces the number of replacements. Proper process variables of UNSM technology which give the strongest fatigue strength are determined by comparing with S-N curve of rotary bending test result. Surface roughness, hardness and compressive residual stress on three kinds of test specimens are analyzed together with SEM analysis of fracture surface. Real shear pins are produced by the property of highest fatigue strength and installed to the hot mill stand for validation. They come to pass as twice as the original operation cycle. |
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| AbstractList | Premature failure at the shear pin of stainless hot rolling mill caused by increasing productivity and fluctuation of roll torque raises significant downtime cost. To reduce downtime cost, UNSM (Ultrasonic Nanocrystal Surface Modification) treatment is applied to the neck groove of shear pin as the alternative to existing solutions. This treatment prevents premature failure, increases service life and reduces the number of replacements. Proper process variables of UNSM technology which give the strongest fatigue strength are determined by comparing with S-N curve of rotary bending test result. Surface roughness, hardness and compressive residual stress on three kinds of test specimens are analyzed together with SEM analysis of fracture surface. Real shear pins are produced by the property of highest fatigue strength and installed to the hot mill stand for validation. They come to pass as twice as the original operation cycle. |
| Author | Rogers, Josh Kayumov, Ravil Pyun, Young Sik Cho, In Ho Park, Jin Suh, Chang Min Murakami, Riichi |
| Author_xml | – sequence: 1 givenname: Young Sik surname: Pyun fullname: Pyun, Young Sik organization: Sun Moon University, DesignMecha Co. Ltd – sequence: 2 givenname: In Ho surname: Cho fullname: Cho, In Ho organization: DesignMecha Co. Ltd – sequence: 3 givenname: Chang Min surname: Suh fullname: Suh, Chang Min organization: Kyungpook University – sequence: 4 givenname: Jin surname: Park fullname: Park, Jin organization: DesignMecha Co. Ltd – sequence: 5 givenname: Josh surname: Rogers fullname: Rogers, Josh organization: North American Stainless – sequence: 6 givenname: Ravil surname: Kayumov fullname: Kayumov, Ravil email: rkayumov@yandex.ru organization: Sun Moon University – sequence: 7 givenname: Riichi surname: Murakami fullname: Murakami, Riichi organization: University of Tokushima |
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| Keywords | Service life Fatigue Ultrasonic nanocrystal surface modification (UNSM) Compressive residual stress AISI1045 |
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| References | Li, Chen, Xu (CR4) 2009; 255 Suh, Lee, Pyoun (CR1) 2008 Dai, Shaw (CR6) 2008; 30 Roland, Retraint, Lu, Lu (CR5) 2006; 54 Shan, Qin, Liu, Liu (CR12) 2012; 13 Ting, Dongpo, Gang, Baoming, Ningxia (CR8) 2008; 255 Wu, Wang, Pyoun, Zhang, Murakami (CR2) 2012; 213 CR11 Takahashi, Shikama, Yoshihara, Aiura, Noguchi (CR10) 2012; 60 Suresh (CR9) 1992 Park, Kwon, Kim, Min, Park, Sung (CR13) 2009; 10 Suh, Song, Suh, Pyoun (CR3) 2007; 443 Tian, Villegas, Yuan, Fielden, Shaw, Liaw, Klarstrom (CR7) 2007; 468-470 C M Suh (276_CR3) 2007; 443 C W Park (276_CR13) 2009; 10 B Wu (276_CR2) 2012; 213 W Ting (276_CR8) 2008; 255 D Li (276_CR4) 2009; 255 276_CR11 K Dai (276_CR6) 2008; 30 J W Tian (276_CR7) 2007; 468-470 Z Shan (276_CR12) 2012; 13 T Roland (276_CR5) 2006; 54 C M Suh (276_CR1) 2008 S Suresh (276_CR9) 1992 Y Takahashi (276_CR10) 2012; 60 |
| References_xml | – volume: 468-470 start-page: 164 year: 2007 end-page: 170 ident: CR7 article-title: A study of the effect of nanostructured surface layers on the fatigue behaviors of a C-2000 superalloy publication-title: Materials Science and Engineering: A doi: 10.1016/j.msea.2006.10.150 – volume: 30 start-page: 1398 issue: 8 year: 2008 end-page: 1408 ident: CR6 article-title: Analysis of fatigue resistance improvements via surface severe plastic deformation publication-title: International Journal of Fatigue doi: 10.1016/j.ijfatigue.2007.10.010 – start-page: 12 year: 1992 ident: CR9 article-title: Fatigue of materials publication-title: Cambridge University Press – year: 2008 ident: CR1 article-title: Improvement of fatigue characteristics of engineering materials by UNSM (Ultrasonic Nanocrystal Surface Modification) technology publication-title: Proc. of 5th International Conference on Advanced Materials Development and Performance – volume: 213 start-page: 271 year: 2012 end-page: 277 ident: CR2 article-title: Effect of ultrasonic nanocrystal surface modification on the fatigue behaviors of plasma-nitrided S45C steel publication-title: Surface and Coatings Technology doi: 10.1016/j.surfcoat.2012.10.063 – volume: 54 start-page: 1949 issue: 11 year: 2006 end-page: 1954 ident: CR5 article-title: Fatigue life improvement through surface nanostructuring of stainless steel by means of surface mechanical attrition treatment publication-title: Scripta Materialia doi: 10.1016/j.scriptamat.2006.01.049 – volume: 13 start-page: 1095 issue: 7 year: 2012 end-page: 1100 ident: CR12 article-title: Key manufacturing technology & equipment for energy saving and emissions reduction in mechanical equipment industry publication-title: Int. J. Precis. Eng. Manuf. doi: 10.1007/s12541-012-0143-y – volume: 255 start-page: 1824 issue: 5 year: 2008 end-page: 1829 ident: CR8 article-title: Investigations on the nanocrystallization of 40Cr using ultrasonic surface rolling processing publication-title: Applied Surface Science doi: 10.1016/j.apsusc.2008.06.034 – ident: CR11 – volume: 443 start-page: 101 issue: 1–2 year: 2007 end-page: 106 ident: CR3 article-title: Fatigue and mechanical characteristics of nano-structured tool steel by ultrasonic cold forging technology publication-title: Materials Science and Engineering: A doi: 10.1016/j.msea.2006.08.066 – volume: 10 start-page: 151 issue: 5 year: 2009 end-page: 173 ident: CR13 article-title: Energy consumption reduction technology in manufacturing — A selective review of policies, standards, and research publication-title: Int. J. Precis. Eng. Manuf. doi: 10.1007/s12541-009-0107-z – volume: 255 start-page: 3811 issue: 6 year: 2009 end-page: 3816 ident: CR4 article-title: The effect of nanostructured surface layer on the fatigue behaviors of a carbon steel publication-title: Applied Surface Science doi: 10.1016/j.apsusc.2008.10.037 – volume: 60 start-page: 2554 issue: 6-7 year: 2012 end-page: 2567 ident: CR10 article-title: Study on dominant mechanism of high-cycle fatigue life in 6061-t6 aluminum alloy through microanalyses of microstructurally small cracks publication-title: Acta Materialia doi: 10.1016/j.actamat.2012.01.023 – volume: 60 start-page: 2554 issue: 6-7 year: 2012 ident: 276_CR10 publication-title: Acta Materialia doi: 10.1016/j.actamat.2012.01.023 – ident: 276_CR11 – start-page: 12 volume-title: Cambridge University Press year: 1992 ident: 276_CR9 – volume: 468-470 start-page: 164 year: 2007 ident: 276_CR7 publication-title: Materials Science and Engineering: A doi: 10.1016/j.msea.2006.10.150 – volume: 30 start-page: 1398 issue: 8 year: 2008 ident: 276_CR6 publication-title: International Journal of Fatigue doi: 10.1016/j.ijfatigue.2007.10.010 – volume: 443 start-page: 101 issue: 1–2 year: 2007 ident: 276_CR3 publication-title: Materials Science and Engineering: A doi: 10.1016/j.msea.2006.08.066 – volume: 54 start-page: 1949 issue: 11 year: 2006 ident: 276_CR5 publication-title: Scripta Materialia doi: 10.1016/j.scriptamat.2006.01.049 – volume: 255 start-page: 3811 issue: 6 year: 2009 ident: 276_CR4 publication-title: Applied Surface Science doi: 10.1016/j.apsusc.2008.10.037 – volume: 213 start-page: 271 year: 2012 ident: 276_CR2 publication-title: Surface and Coatings Technology doi: 10.1016/j.surfcoat.2012.10.063 – volume: 255 start-page: 1824 issue: 5 year: 2008 ident: 276_CR8 publication-title: Applied Surface Science doi: 10.1016/j.apsusc.2008.06.034 – volume: 13 start-page: 1095 issue: 7 year: 2012 ident: 276_CR12 publication-title: Int. J. Precis. Eng. Manuf. doi: 10.1007/s12541-012-0143-y – volume: 10 start-page: 151 issue: 5 year: 2009 ident: 276_CR13 publication-title: Int. J. Precis. Eng. Manuf. doi: 10.1007/s12541-009-0107-z – volume-title: Proc. of 5th International Conference on Advanced Materials Development and Performance year: 2008 ident: 276_CR1 |
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| Title | Reducing production loss by prolonging service life of rolling mill shear pin with ultrasonic nanocrystal surface modification technology |
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