ROLLING R: Roll Radius ω : rotational speed of the roll

hb: Initial sheet thickness Vb: velocity of the sheet at the entry
ha: Final sheet thickness Va: velocity of the sheet at the entry
N: Neutral point
θ: Angle of bite
θ
R b: Width of the work-piece
ω θ

hb ha
b

ω
p µp
N
µp a
According to continuity:
vb. hb. b = va. ha. B
vb. < va (assuming the width remains constant)

Lagging zone (between point b and N): vb < ω.R

Friction force acts point “b” towards the point “N”
Percentage of slip = [(vb – ω.R)/ ω.R x 100] %

Outstripping zone (between point a and N): va > ω.R

Friction force acts from point “a” towards the point “N”
Percentage of slip = [(va – ω.R)/ ω.R x 100] %
Maximum angle of bite
Max. angle of bite:
θ Maximum contact angle (θ) for which no external back
force or pushing force is required for rolling

b
Also from geometry,
θ
θ
p µp 2R (1 – cosθ) = hb – ha
a 4Rsin2(θ/2) = hb – ha

For unaided rolling: No back force Sin(θ/2) = [(hb – ha )/4R]0.5

µp cosθ ≥ p sinθ (θ/2) = (1/2). [(hb – ha )/R]0.5 (θ is very samll)

µ ≥ tanθ
µ ≥ θ [θ is very small] Max angle of bite
θmax = [(hb – ha)/R]0.5

µ ≥ [(hb – ha)/R]0.5

Problem:
8 mm thick Al alloy strip is rolled to5 mm thickness. Roll radius 125 mm. Find out the following:
I. Minimum co-efficient of friction for unaided rolling
II. Maximum angle of bite
Different types of Rolling
Two high roll mill:
Three high roll mill:
Two step
process
Higher
reduction
These two techniques are mainly used
for hot working process, where the
required load is comparatively less
Tandem rolling mill: Series of four high roll mill
Back-up roll
No. of stands depends on
the reduction
If no. of stand is one it is
called four high roll mill
Function of back-up roll is to
provide rigidity to the main
rollers (smaller rollers)
Back-up roll
Cluster rolling mill: Higher number of back-up roll
Back-up rolls
No. of back-up roll depends on
the loading
Hard materials need higher
back-up roll
These techniques are mainly used
for cold working process: required
load is comparatively high
Back-up rolls