In hot rolling mills, premature failure of rolls is a major concern as it adversely affects the mill operation and as well as production. Analysis of failed roll materials and actual rolling conditions in service are therefore necessary to understand the roll failure mechanism and thereby improve the wear resistance and extend the service life of rolls.
This work describes two different types of roll failure cases and their analysis which was carried out using destructive as well as non-destructive testing techniques (NDT). The cases are as follows:
Case I: Enhanced ICDP Bottom roll of fifth stand (F#5) which failed from the neck portion.
Case II: Analysis of sub-surface defect of ICDP rolls of the last stand (F#6