In this paper, the top spindle, end coupling and slipper metal are main components of the hot roll process and used for transmission of rotational power with heavy duty load. The top spindle connected with the motor and end coupling connected with the roller are combined with the slipper metal act as a bearing and joint. The contact surface between end coupling and slipper metal is occurred stress concentration, and life cycles of slipper metal is reduced. This study aims to increase the slipper metal thickness for increment of replacement period. The derivation of load condition is conducted for hot rolling process under slipper metal combination types and operation situations. The structural analysis is performed by applying mechanical characteristics, combination type, and rotational boundary condition: top spindle, end coupling, slipper metal. the shape design of hot mill spindle assembly is carried out by using the response surface methodology.
1) The results of this study shows the contact discrepancy between the slipper metal and coupling was the major reason of fracture of slipper metal. The deviation of maximum stress applied to the initial slipper metal was about five times higher than modified model according to the contact condition between slipper metal and coupling.
2) Regression equation of the stress of the power transmission components has been generated. The error rate of regression equation was evaluated below 3% compare to the finite element method. The maximum stress applied to the power transmission components can be predicted using this regression equation.
3) The maximum stress of the power transmission components can be derived from regression equation according to the thickness of slipper metal. The shape design of the power transmission components had been developed consideration of the predicted maximum and safety stress using regression equation.
4) The maximum stress of coupling and spindle of modified model had been decreased 5.1% and 29% respectively compare to the initial model. Replacement period of slipper metal had been increased by five times with increasing the minimum thickness by 9mm and coinciding the contact surface.
Assessment of structural integrity of the power transmission components can be predicted using the regression equation which was derived from finite element and statistical method. Also, this regression equation can be used to modify the design according to the requirement of rolling process for power transmission components.