Problem Definition

Rolling machine is widely used equipment in modern industry where solid state as well as semi solid state metals and non-metals are forcefully reshaped. Therefore on the exterior surface of the rolling machine receives the maximum pressure both from counterpart and the rolled materials (Armstrong-Helouvry 2012). Therefore the layer of friction usually works in two separate segments namely upper roll and rolling material, rolling material and lower roll. Both of this friction plane the resultant wear, tear and frictional erosion usually happens in extreme level. Apart from that, in high temperature rolling machine this friction causes additional heat and temperature increase that also regulates the operational efficiency and durability of the production material. Similarly, the material quality of rolling machine is also decreased along with its sustainability of exterior surface tension. Therefore, it causes several cracks and microscopic holes in the rollers (Graney and Starry 2012). Rolling machines are usually made with non-elastic alloy to increase its survival capacity and durability in continuous and extreme fluctuation of surface temperature. However, this material has specific maximum capacity for having sustainable expansion and contraction. After crossing that specific threshold limit the roller material usually gains extreme tear and wear and even visible cracks on the exterior surface (Armstrong-Helouvry 2012).

Lubricants are useful to increase the longevity and durability of the rollers. This is achieved by reducing the friction and the resultant wear and tear to the components of the roller especially to the outer surface of the roller that faces the maximum stress. Conventional lubricants however are not able to spread evenly on the roller surface and extra maintenance is needed to protect the roller surface from additional wear and tear. Strategies such as oiling the parts and changing the gears are the most common used in this aspect (Zhu et al. 2013; Neto, Pimenta and Wriggers 2014). However studies have shown that repeated oiling can adversely affect the quality of the materials being processed due to uneven spreading of lubricant causing frictional misbalance. Thus it is necessary to assess the conventional strategies of lubrication to identify the best approach. In the assessment, both the cost to lubricate the machinery as well as due to efficiency loss caused by frictional damaged needs to be compared and considered, especially in case of vertical rollers where the problem is most significant (Neto, Pimenta and Wriggers 2014; Rovira et al. 2012).

The aim of the study is to find the best components for lubrication, assess the conventional models for lubrication, identify the best approach in the lubrication of rollers, and identify the best fields where the new lubrication strategy can be used and identifying the thermodynamic advantage of the proposed lubrication strategy.

Aims, Objectives and Scope

The objective of the study is to develop an understanding of the physical and chemical properties of oil based lubrication, water emulsion based lubrication and titanium oxide nano particle based lubrication as well as identifying the optimal lubricant for rolling machine and the best combination of lubricants that can be useful for hot rolling machine. The purpose is to find which lubricant can provide the maximum benefit that is protecting the rollers from frictional damage to the maximum extent while preserving the quality of the products.

The scope of the study is based on literature review and analysis of real time data from primary studies.

Through the review of literature, several important information was identified as is discussed below:

The structure comprise of two cylindrical rollers usually made of allow metals and exerts a double sided force to the processed materials. The external surface of the rollers faces high pressure leading to frictional wear and tear. Non elastic alloys can improve the durability of rollers but has its own threshold limit. Lubrication helps to protect the rollers from damage by friction but repeated lubrication can have adverse effects on the efficiency of the machine (Poll and Wang 2012; Sebald et al. 2014; De Laurentis et al. 2016; Askeland 2013).

Mainly uses a mixture of oil, water and grease along with fossil fuels or low friction lubricants. Water in the lubricant helps to dissipate heat caused by friction quickly than oil based lubrication. This is important since heat can increase consumption of power by the machine (Biresaw 2016; Lugt 2012; Hashmi 2015; Martin 2014; Stachowiak, 2015)

Mainly uses blend oil and a mixture of nitrogen hetero-cycle, sulfur and grapheme is used to optimize performance and it helps in asymmetric synthetic alteration of the lubricant to increase efficiency (Wright 2011; Poll and Wang 2012; Ahmadi et al. 2013).

Water supports better adsorption of dissolved particles compared to emulsified lubricants. The tribilogical property of the lubricant helps to reduce friction, while sulfate can increase efficiency of lubricant (Zolfaghari et al. 2016; Mao et al. 2012; Dai et al. 2016; Ooi, Sayuti and Sarhan 2015).

Nanoparticles helps in faster cooling of the machines and thus supports better efficiency especially in case of oil based lubricants containing nanoparticles of titanium oxide (Quinchia et al. 2012; Borugadda and Goud 2014; Zhu et al. 2013; (Pirro, Webster and Daschner 2016)

The research philosophy is based on the positivism theory which implies that knowledge can be based on outcomes and observation of natural phenomenon and their properties and interplay with each other. The design of the study is a descriptive one that supports a descriptive analysis of data. The approach used in the study is an inductive research, where information from other studies is used to inform the study design. The tools used in the research includes: Emulsions of water, oil and titanium dioxide, Experimental Rolling Mill, Infrared Thermometer, Coulter LS 230 Leisure Diffraction tool, EHD Ultra thin sheet Measurement System and Low Carbon Sheet Metal sheet. The data collection strategy used includes primary and secondary data collection. The data analysis strategies include quantitative analysis of primary data and qualitative analysis of primary data. Ethical considerations of the study are: Work health and Safety Act, Non Forceful participation, Authorization from local government and first Aid systems (Greenfield 2016; Shahrom, Yahya and Yusoff, 2013).

Literature Review

The results of the study are shown below:

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

 

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

Performing analysis of the lubricant types and their impact on the rolling machine and operating temperature. Examining the nature in the change in friction using different lubricants

All the studies utilized a fixed range of temperatures to analyze the performance of the lubricants. It is important therefore to consider the temperature related variables for further studies. More secondary data will be collected for secondary analysis and an updated work plan will be developed for secondary data collection, however no change would be needed for evaluation strategy, the existing strategy should suffice the purpose.

Given below is the proposed timeline for the study:

Selection of the topic from 1^st to 3^rd days of the study, developing research design from 4^th to 7^th, Literature review from 4^th to 11^th, selection of the method for research from 8^th to 11^th, collecting primary data from 12^th to 19^th, quantitative data analysis and interpretation from 16^th to 23^rd, secondary data collection 20^th to 27^th, qualitative analysis and interpretation from 24^th to 31^st, summarizing the findings 32^nd to 35^th day, concluding the study from 36^th to 39^th day and submission of the final work between 40^th to 43^rd day.

Conclusion:

Rolling machines are used to reshape metals and non metals using two drum rollers moving against each other between which the processed materials pass. The processed materials experiences high pressure from the rollers to change their shapes. A lot of friction and heat is developed on the rollers while interacting with the materials to be processed. These causes frictional wear and tear of the machine and causes damage, reduces the longevity of the machine and rollers and the problem is most pronounced in case of heat rollers. Lubricants are used to reduce friction between the rollers and minimize damage. Different types of lubrications are used for this such as water based and oil based lubricants, however both has limited efficiencies as they do not spread evenly over the roller surface. In the study the efficiency of these lubricants were compared with titanium oxide nanoparticle based lubrication. The preliminary study shows that titanium oxide lubrications are more promising as lubrication for rollers. However further studies are needed to analyze the temperature related variables and how it affects the performance of the lubricants.

References:

Ahmadi, H., Rashidi, A., Nouralishahi, A. and Mohtasebi, S.S., 2013. Preparation and thermal properties of oil-based nanofluid from multi-walled carbon nanotubes and engine oil as nano-lubricant. International Communications in Heat and Mass Transfer, 46, pp.142-147.

Methodology

Armstrong-Helouvry, B., 2012. Control of machines with friction (Vol. 128). Springer Science & Business Media.

Askeland, D. R., 2013. The Science and Engineering of Materials. 1st ed. Paris: Cengage Learning.

Biresaw, G., 2016. Surfactants in Tribology, Volume 4. 4th ed. London: CRC Press.

Borugadda, V.B. and Goud, V.V., 2014. Epoxidation of castor oil fatty acid methyl esters (COFAME) as a lubricant base stock using heterogeneous ion-exchange resin (IR-120) as a catalyst. Energy Procedia, 54, pp.75-84.

Cao, M., Guo, D., Yu, C., Li, K., Liu, M. and Jiang, L., 2015. Water-repellent properties of superhydrophobic and lubricant-infused “slippery” surfaces: A brief study on the functions and applications. ACS applied materials & interfaces, 8(6), pp.3615-3623.

Carou, D., Rubio, E.M. and Davim, J.P., 2015. A note on the use of the minimum quantity lubrication (MQL) system in turning. Industrial Lubrication and Tribology, 67(3), pp.256-261.

Clauss, F.J. ed., 2012. Solid lubricants and self-lubricating solids. Elsevier.

Dai, W., Kheireddin, B., Gao, H. and Liang, H., 2016. Roles of nanoparticles in oil lubrication. Tribology International, 102, pp.88-98.

De Laurentis, N., Kadiric, A., Lugt, P. and Cann, P., 2016. The influence of bearing grease composition on friction in rolling/sliding concentrated contacts. Tribology international, 94, pp.624-632.

Flick, U., 2015. Introducing research methodology: A beginner’s guide to doing a research project. Sage.

Ghalme, S.G., Mankar, A. and Bhalerao, Y.J., 2013. Effect of lubricant viscosity and surface roughness on coefficient of friction in rolling contact. Tribology in Industry, 35(4), pp.330-336.

Graney, B.P. and Starry, K., 2012. Rolling element bearing analysis. Materials Evaluation, 70(1).

Greenfield, T., 2016. Research methods for postgraduates. John Wiley & Sons.

Hashmi, S., 2015. Comprehensive Materials Processing. 3rd ed. London: Newnes.

Ilie, F. and Covaliu, C., 2016. Tribological properties of the lubricant containing titanium dioxide nanoparticles as an additive. Lubricants, 4(2), p.12.

Lim, G.M., Bae, D.M. and Kim, J.H., 2014. Fault diagnosis of rotating machine by thermography method on support vector machine. Journal of Mechanical Science and Technology, 28(8), pp.2947-2952.

Lugt, P.M., 2012. Grease lubrication in rolling bearings. John Wiley & Sons.

Mang, T., 2014. Encyclopedia of Lubricants and Lubrication. Springer Berlin Heidelberg.

Mao, C., Tang, X., Zou, H., Zhou, Z. and Yin, W., 2012. Experimental investigation of surface quality for minimum quantity oil–water lubrication grinding. The International Journal of Advanced Manufacturing Technology, 59(1-4), pp.93-100.

Martin, J. M., 2014. Nanolubricants. 2nd ed. Chicago: John Wiley & Sons,

Neto, A.G., Pimenta, P.M. and Wriggers, P., 2014. Contact between rolling beams and flat surfaces. International Journal for Numerical Methods in Engineering, 97(9), pp.683-706.

Ooi, M.E., Sayuti, M. and Sarhan, A.A., 2015. Fuzzy logic-based approach to investigate the novel uses of nano suspended lubrication in precise machining of aerospace AL tempered grade 6061. Journal of Cleaner Production, 89, pp.286-295.

Results

Panneerselvam, R., 2014. Research methodology. PHI Learning Pvt. Ltd..

Pirro, D.M., Webster, M. and Daschner, E., 2016. Lubrication Fundamentals, Revised and Expanded. CRC Press.

Poll, G.W.G. and Wang, D., 2012. Fluid rheology, traction/creep relationships and friction in machine elements with rolling contacts. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 226(6), pp.481-500.

Poll, G.W.G. and Wang, D., 2012. Fluid rheology, traction/creep relationships and friction in machine elements with rolling contacts. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 226(6), pp.481-500.

Quinchia, L.A., Delgado, M.A., Franco, J.M., Spikes, H.A. and Gallegos, C., 2012. Low-temperature flow behaviour of vegetable oil-based lubricants. Industrial Crops and Products, 37(1), pp.383-388.

Rovira, A., Roda, A., Lewis, R. and Marshall, M.B., 2012. Application of Fastsim with variable coefficient of friction using twin disc experimental measurements. Wear, 274, pp.109-126.

Rudnick, L.R., 2017. Lubricant additives: chemistry and applications. CRC press.

Sebald, W. and Masur, E., Schaeffler Technologies AG and Co KG, 2014. Bearing arrangement having a double-row roller bearing, turbocharger and method for feeding a lubricant to the rows of rolling bodies of a double-row roller bearing. U.S. Patent 8,668,432.

Shahnazar, S., Bagheri, S. and Hamid, S.B.A., 2016. Enhancing lubricant properties by nanoparticle additives. international journal of hydrogen energy, 41(4), pp.3153-3170.

Shahrom, M.S., Yahya, N.M. and Yusoff, A.R., 2013. Taguchi method approach on effect of lubrication condition on surface roughness in milling operation. Procedia Engineering, 53, pp.594-599.

Stachowiak, G., 2015. Experimental Methods in Tribology. 4th ed. Berlin: Elsevier.

Wang, H., Zhang, S., Wang, G., Yang, S. and Zhu, Y., 2013. Tribological behaviors of hierarchical porous PEEK composites with mesoporous titanium oxide whisker. Wear, 297(1-2), pp.736-741.

Wright, W. J., 2011. Chemical Abstracts, 4th ed. Texas: American Chemical Society.

Zhu, J., Yoon, J.M., He, D., Qu, Y. and Bechhoefer, E., 2013. Lubrication oil condition monitoring and remaining useful life prediction with particle filtering. International Journal of Prognostics and Health Management, 4, pp.124-138.

Zhu, Z.X., Sun, J.L., Wei, H.R., Niu, T.L. and Zhu, Z.L., 2013. Research on lubrication behaviors of nano-TiO2 in water-based hot rolling liquid. In Advanced Materials Research (Vol. 643, pp. 139-143). Trans Tech Publications.

Zolfaghari, R., Fakhru’l-Razi, A., Abdullah, L.C., Elnashaie, S.S. and Pendashteh, A., 2016. Demulsification techniques of water-in-oil and oil-in-water emulsions in petroleum industry. Separation and Purification Technology, 170, pp.377-407.

Boswell, B., Islam, M.N., Davies, I.J., Ginting, Y.R. and Ong, A.K., 2017. A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining. The International Journal of Advanced Manufacturing Technology, 92(1-4), pp.321-340.

Mabuchi, Y. and Nakagawa, A., Nissan Motor Co Ltd, 2015. Nanoparticle-containing lubricating oil compositions. U.S. Patent 9,023,771.

Mordukhovich, G. and Israelachvili, J.N., GM Global Technology Operations LLC, 2013. Tribo-system and method for reducing particle conglomeration therein. U.S. Patent 8,563,485.

Wan, Q., Jin, Y., Sun, P. and Ding, Y., 2014. Rheological and tribological behaviour of lubricating oils containing platelet MoS 2 nanoparticles. Journal of Nanoparticle Research, 16(5), p.2386.