An 1100-0 Aluminum strip 8 inches wide is cold rolled in one pass from 0.075 inch to 0.005 inch in thickness with 6 inch diameter rolls rotating at 0.5 rps. The material is characterized by 26000 0.2 psi. The friction coefficient between the roll and the workpiece is 0.2.

(a) Check if this friction coefficient is high enough to grip the incoming strip.

(b) Estimate the roll separating force and the total horse power required (for both rolls) for this process.

(c) How will you redesign this process (keeping same overall height reduction) to reduce roll separating forces? What are the tradeoffs in your redesign?