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[01] Definition
ROLLING is the process of reducing the thickness or changing the cross section of a long
work-piece by compressive forces applied through a set of opposed rotating rolls. This
Primary Working operation takes a solid piece of m etal (generally from a cast state, such
as an ingot) and breaks it down successively into shapes such as slabs, plates, and billets.
Rolling is a bulk deform ation process. The term bulk deformation is applied to the
processing of workpieces having a relatively small surface area-to-volume (or surface
area-to-thickness) ratio. In all bulk deform ation processing, the thickness or cross -section
of the workpiece changes. The other three basic bulk-deformation processes for metals
are forging, extrusion, and drawing of rod and wire.
Temperature, size, and shape of the workpiece can group rolling processes. For example,
using temperature as a criterion, the categories would be hot rolling and cold rolling. If we
are interested in size, it is important to note that plates are generally regarded as having a
thickness greater than 6 mm (1/4 in.) whereas sheets are generally less than 6 mm thick.
Flat Rolling, strip rolling, or simply rolling, is the most basic operation, where the rolled
products are flat plates and sheets, and the m ain purpose is to reduce the thickness of the
material. This process results in the production of flat plate, sheet, and foil in long lengths,
at high speeds, and with good surface finish, especially in cold rolling. It requires high
capital investment and low to m oderate labor cost.
Cast structures of ingots of continuous castings are converted to a wrought structure by hot working.
[04] Cold Rolling
Cold rolling is the process of rolling at low temperatures. It is usual applied as finishing
process after hot rolling to enhance strength and hardness, and ensure high surface
quality.
During cold rolling, annealing may take place to facilitate further cold rolling. C old rolling is
the process of rolling at low temperatures. It is usual to roll very large quantities of material
as long uninterrupted coils.
The loads must remain steady, therefore it is common for several rolling mills to work in
tandem, and it is essential that the tension in the strip between mills be held within close
limits to maintain an even gauge. As the thickness of the slab is reduced, its length
increases and the speed of the outgoing strip may reach values up to about 5,000 ft/m in.
One benefit of cold rolling is cold working, which increases the strength of a product.
Mills are classified by descriptive dimensions that indicate the size of the m ill, by the
arrangement of roll stands, and by the type of product that is rolled. The dim ensions used
to indicate size vary depending on the type of mill and the product.
However, there are three principal types of rolling mills, referred to as two-high, three-high,
and four-high mills. This classification, as the names indicate, is based on the way the
rolls are arranged in the housings. A two-high stand consistsof two rolls, one positioned
directly above the other; a three-high mill has three rolls, and a four-high mill has four rolls,
also arranged one on top of the other.
Two-high mills may be either pull-over (drag over) mills or reversing mills. In pull-over-
type mills, the rolls run in only one direction. The workpiece must be returned over the top
of the mill for further Reversing mills em ploy rolls on which the direction of rotation can be
reversed. Rolling then takes place alternately in two opposite directions.
Reversing m ills are am ong the m ost widely used in industry, and can be used to produce
slabs, blooms, plates, billets, rounds, and partially
formed sections suitable for rolling into
finished shapes on other m ills.
Two-high mills
Three-high mills:
In three-high mills, the top and bottom rolls
rotate in the sam e direction, while the m iddle roll
rotates in the opposite direction. This allows the
workpiece to be passed back and forth
alternately through the top and m iddle rolls and
then through the bottom and middle rolls without
reversing the direction of roll rotation.
Four-high mills:
Four-high mills are used for rolling flat
material such as sheet and plate. This type
of mill uses large backup rolls to reinforce
smaller work rolls, thus obtaining fairly large
reductions without excessive amounts of roll
deflection. Four-high mills are used to
produce wide plates and hot rolled or cold-
rolled sheet, as well as strip of uniform
thickness.
Special Mills:
Two other types of mills that are used are
cluster mills and planetary mills.
The most common type of cluster mill
is the Sendzimir m ill. In a typical
Sendzimir mill design (Fig. 22a), each
work roll is supported through its
entire length by two rolls, which in turn
are supported by three rolls. These
rolls transfer roll-separating forces
through four large backup rolls to a
rigid, cast steel housing. Sendzimir
mills are used for the cold rolling of
sheet and foil to precise thicknesses.
[3] Friction
In rolling, although the rolls cannot pull the strip into the roll gap without some friction,
forces and power requirements rise with increasing friction.
In cold rolling, the coefficient of friction m usually ranges between 0.02 and 0.3, depending
on the materials and lubricants used. The low ranges for the coefficient of friction is
obtained with effective lubricants and regim es approaching hydrodynamic lubrication, such
as in cold rolling of aluminum at high speeds.
In hot rolling, the coefficient of friction may range from 0.2, with effective lubrication, to as
high as 0.7, indicating sticking, which usually occurs with steels, stainless steels, and high
temperature alloys.
References:
Lecture notes of Dr. Ahmed Fareed, Ain shams University,2007.