Metal process Technology

(MEng 5233)

Rolling and ring

rolling
Design of roll passes
in shape rolling
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Material and Geometry of cutting tool

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Flat- and Shape-Rolling

Processes
Schematic
outline of
various flatand shaperolling
processes.

Rolled Products Made of Steel

Shape Rolling

Stages in the shape rolling of an H-section part.

Various other structural sections, such as channels and Ibeams, are also rolled by this kind of process.

Flowchart of Rolling
Operations

Figure 1 Flow chart

for the production of
various finished and
semi-finished
steel
shapes.
Note
the
abundance of rolling
operations.

Rolling Process

Flat-Rolling

(a) Schematic illustration of the flat-rolling process.

(b) Friction forces acting on strip surfaces.
(c) The roll force, F, and the torque acting on the rolls. The
width w of the strip usually increases during rolling,

Four-High Rolling Mill

Schematic illustration of a four-high rolling-mill stand,

showing its various features.
The stiffness of the housing, the rolls, and the roll bearings
are all important in controlling and maintaining the
thickness of the rolled strip.

Backing Roll Arrangements

Schematic illustration of various roll arrangements

(a) two-high;
(b) three- high;
(c) four-high;
(d) cluster (Sendzimir) mill.

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Grain Structure During Hot

Rolling

Changes in the grain structure of cast or of large-grain wrought metals during

hot rolling. Hot rolling is an effective way to reduce grain size in metals, for
improved strength and ductility. Cast structures of ingots or continuous casting
are converted to a wrought structure by hot working.

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Tandem Rolling

A tandem rolling operation.

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Cold Working
ADVANTAGES

No heating is required

Strength, fatigue and

wear properties are
improved through
strain hardening

Superior dimensional
control is achieved, so
little, if any, secondary
machining is required

Better surface finish

is obtained

Products possess better

reproducibility and
interchangeability

Directional properties
can be imparted

Contamination
problems are
minimized

Cold Working
DISADVANTAGES
Higher
forces
are
required to initiate and
complete
the
deformation
Less
ductility
is
available
Intermediate annealing
may be required to
compensate for the
loss of ductility that
accompanies strain
hardening

Heavier and more

powerful equipment
is required

Metal surfaces must be

clean and scale-free

imparted directional
properties may be
detrimental

Undesirable residual
stresses may be
produced

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Diagram of Flat Rolling

Draft = thickness
reduction:

d t o t f

Conservation of Volume:

t o wo L o t f w f L f

t o wo v o t f w f v f

Diagram of Flat Rolling

There is a point on the roll
where the work velocity
equals the roll velocity, this
is the no-slip point.
Friction is in opposite
directions
v f v r on either
v r side
DNof
s point. Forward slip:
this
vr
N rev / min
where,
Roll force:

F Y f wLcontact Y f w f

Maximum draft:
d max 2 R
R (t o t f )

coefficient of friction

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Ring-Rolling

(a) Schematic illustration of a

ring-rolling operation.
Thickness reduction results in
an increase in the part
diameter.
(b) Examples of cross-sections
that can be formed by ring
rolling.

Ring Rolling

One roll is placed through

the hole of a thick-walled
ring and a second roll
presses on the outside

Produces seamless rings

Circumferential grain
orientation and is used in
rockets, turbines,
airplanes, pressure vessels,
and pipelines

Figure 6 Schematic of horizontal ring

rolling operation. As the thickness of the
ring is reduced, its diameter will increase.