Rolling of Metals

This chapter describes

Flat rolling
Shape rolling
Production of seamless tubing & pipe
Rolling is the process of reducing the
thickness of a long work piece
Plates having thickness greater than 6mm
Sheets generally less than 6mm thick
Introduction
Flat Rolling Process
Flat Rolling
Flat Rolling Process
Metal strip enters the roll gap
The strip is reduced in size by the metal rolls
The velocity of the strip is increased the metal strip is reduced in size
Factors affecting Rolling Process
Frictional Forces
Roll Force and Power Requirement
Frictional Forces
Friction Forces acting on strip forces
Max Draft
h
0
-h
f
= 2R
Roll Force
F= W
0
.L.Y
avg
L= sqrt{R(h
o
-h
f
)}
Strategies available to reduce the roll forces: -
By reducing friction btn rolls and the sheet.
By using small rolls, to reduce contact length.
By planning for a small draft per pass. DRAFT=ho-hf
To plan rolling at elevated temperatures (hot working)
Also by increasing a back tension and front tension, which is given
with this intension.
Effects of Rolling force on the rolls: -
Bending along the roll axis. This is called as camber. The rolled sheet
has an increased thickness upto +0.25mm at the middle.
The roll gets flattened at the point of rolling
Bending effect
Solution, redesign roll with
a camber allowance
Roll flattens at the point of
rolling
Flat Flat- -Rolling Rolling Practice Practice
Hot rolling
The initial break down of an ingot
Continuously cast slab
Structure may be brittle
Converts the cast structure to a wrought structure
Finer grains
Enhanced ductility
Reduction in defects
Continuous Casting
Is replacing traditional methods
Faster & better
Product of the first hot-rolling operation - Bloom or slab
Square cross section of 150mm (6in) on one side
Processed father by shape rolling
I-beams
Railroad rails
Flat-Rolling Practice Cont.d
Billets smaller than blooms and rolled into bars and rods
Cold rolling
carried out at room temperature
Produces sheet and strip metal
Better surface finish less scale
Pack rolling when two or more layers of metal are rolled together
Changes in grain structure during hot-rolling
VARIOUS CONFIGURATIONS OF
ROLLING
Cont..d next
page
Temper rolling: giving one more light pass when nearing
the final thickness, with a 0.5% reduction. This will
remove the surface irregularities like stretch marks.
Pack rolling: finish rolling of two sheets together. Pass
two sheets parallelybetween two rolls. In this case the roll
side surface of the sheet will have a shiny finish and the
sheet to sheet faces will have matt finish.
Matt finish
shiny finish
shiny finish
PACK ROLLING
Smallest thicknessof the sheets that can be made by the rolling process
=0.0025mm
Roll peripheral speeds could be 1500m/min. note that the rolled out
sheet will travel with a speed >this 1500m/min
Materials for Roll:
Common roll material is CI., cast steel, forged steel.
In case of the smaller rolls, even tungsten carbide is used.
Surface finish: The rolls will be ground finish with polishing.
Lubricants: Graphite powder, emulsions, fatty acids
Seamless tubing: can be done by keeping a mandrel, for piercing, when
the rod is being rolled by two rolls. This mandrel will come under the
gap
Defects in Defects in Rolled Plates & Sheets
Undesirable
Degrade surface appearance
Adversely affect the strength
Sheet metal defects include:
Scale, Rust, Scratches, Gouges, Pits, & Cracks
May be caused by impurities and inclusions from the supply bloom:
Wavy edges result of roll bending
Alligatoring complex phenomenon
Wavy edges: Due to
bending of roll;
edges getting thinner.
Zipper cracks: at
the center of sheet:
Due to poor mtl
ductility
Wavy edges: Due to
bending of roll;
edges getting thinner.
Alligatoring: Due to non uniform
deformation during Rolling opn:
Deformations vary across
thickness.
Other Characteristics Other Characteristics
Residual stresses produces:
Compressive residual stresses on the surfaces
Tensile stresses in the middle
Tolerances
Cold-rolled sheets: (+/- ) 0.1mm 0.35mm
Tolerances much greater for hot-rolled plates
Surface roughness
Cold rolling can produce a very fine finish (1.6 3.2..this is
equivalent to .finish)
Hot rolling & sand have the same range of surface finish
Gauge numbers the thickness of a sheet is identified by a
gauge number: Smaller the gage no, thicker is the sheet.
Schematic Illustration of Various Schematic Illustration of Various Roll configurations Roll configurations
Schematic Illustration of various roll arrangements : (a) two-high; (b)
three-high; (c) four-high; (d) cluster mill (Sendzmir mill)
Shape
Shape
-
-
Rolling Operations
Rolling Operations
Various shapes can be produced by shape rolling
Bars
Channels
I-beams
Railroad rails
Roll-pass design requires considerable experience in order
to avoid external and internal defects
Stages in Shape Rolling of an H-section part. Various other structural
sections such as channels and I-beams, are rolled by this kind of process.
Ring Rolling Ring Rolling
A thick ring is expanded into a large diameter ring
The ring is placed between the two rolls
One of which is driven
The thickness is reduced by bringing the rolls together
The ring shaped blank my be produced by:\
Cutting from plate
Piercing
Cutting from a thick walled pipe
Various shapes can be produced by shaped rolls
Typical applications of ring rolling:
Large rings for rockets
Gearwheel rims
Ball-bearing and roller-bearing races
Can be carried out at room temperature
Has short production time
Close dimensional tolerances
RING ROLLING RING ROLLING
(a) Schematic illustration of
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
Thread Rolling Thread Rolling
Cold-forming process
Straight or tapered threads are formed on round rods by passing the pipe
though dies
Typical products include
Screws
Bolts
Thread Rolling Con Thread Rolling Con t t
Threads are rolled in the soft condition
Threads may then be heat treated, and subjected to final machining or grinding
Uncommon or special-purpose threads are machined
Production of Seamless Pipe & Tubing
Rotary tube piercing (Mannesmann process)
Hot-working process
Produces long thick-walled seamless pipe
Carried out by using an arrangement of rotating rolls
Tensile stresses develop at the center of the bar when it is subjected to compressive forces
Continuous Casting & Integrated Mills & Minimills Continuous Casting & Integrated Mills & Minimills
The roll mills are established in the same place where the metal is produced. The final out put of
the metal, i.ethe ingot will be in hot condition.
Instead of heating the billets once again, in another place, thesame hot billet is subjected to
rolling process for sheet metal production.
Such a mill is called the continuous casting and integrated mills.
Continuous casting & Integrated mills.
Advantages
Highly automated
Reduces product cost
Companies are converting over to this type of casting
HOT
Continuous Casting & Integrated Mills & Minimills Con Continuous Casting & Integrated Mills & Minimills Con t t
Integrated Mills utilize everything from the production of hot metal to the casting and
rolling of the finished product
Minimills
Scrap metal is melted
Cast continuously
Rolled directly into specific lines of products
Each minimill produces one kind of rolled product
Rod
Bar
Structural steel
Spray Casting : In spray casting the molten metal is sprayed over a
rotating mandrel to produce seamless tubing and pipe
THE END
THE END