ME310

Manufacturing Processes
Rahul Panat

School of Mechanical and Materials Engineering

Washington State University
1

Deformation Processes - II
Week 6

OUTLINE
Rolling Processes
Different Rolling Operations
Mechanics of Rolling
Slab Analysis for Rolling
Pressure Distribution in Rolling
Defects in Rolling

ROLLING

The process of reducing thickness or changing cross-section of

a long work-piece by compressive forces applied through a set
of rolls.
Often the first process that is used to convert material into a
finished wrought product
Thick stock can be rolled into blooms, billets, or slabs

Blooms have a square or rectangular cross section (>36 sq. in.)

Billets are usually smaller than a bloom and can have a square or
circular cross sections.

Slabs are a rectangular solid with a width greater than twice the
thickness.

Can be further rolled into structural shapes

Can be used to produce plates, sheets, or strips

Rolling accounts for 90% of all metalworking!!!

DIFFERENT ROLLING OPERATIONS

Flat rolling
Shape rolling

Videos:
https://www.youtube.com/watch?v=
AuuP8L-WppI -0-1.5min

http://www.youtube.com/watch?ann
otation_id=annotation_280168&feat
ure=iv&src_vid=AuuP8LWppI&v=k6iODHla6qY 0-1min
http://www.youtube.com/watch?v=6xnKmt_gsLs

BASIC ROLLING PROCESS

Metal is passed between two rolls that rotate in opposite
directions
Friction acts to propel the material forward
Metal is squeezed and elongates to compensate for the
decrease in cross-sectional area

MECHANICS OF ROLLING
Friction is important
Neutral point
Vr=Vworkpiece (no slip
point)
Direction of friction is
different across the
neutral point
Desired to be close to exit
R

Forward slip:

Draft, h0 hf =

m2R

http://www.youtube.com/watch?v=Kg1FIIaEwEE

Frictional forces

SLAB ANALYSIS OF ROLLING

L: Roll strip contact length

w = Width of the strip
Yavg = Average true stress
of the strip in the roll gap

Stresses acting on an element in rolling:

(a) entry zone and (b) exit zone
Rolling pressure increases with
Strength of material
Coefficient of friction
R/hf ratio
Thickness reduction

N: Revolutions per minute of the rolls

PRESSURE DISTRIBUTION IN ROLLING

Pressure distribution in the roll

gap as a function of the
coefficient of friction. Note that
as friction increases, the
neutral point shifts toward the
entry. Without friction, the
rolls will slip, and the neutral
point shifts completely to the
exit.

Pressure distribution in the

roll gap as a function of
reduction in thickness. Note
the increase in the area
under
the
curves
with
increasing reduction, thus
increasing the roll force.

Pressure distribution as a
function of front and back
tension in rolling. Note the
shifting of the neutral point
and the reduction in the
area under the curves
(hence reduction in the roll
force) as tensions
increase.

CONTROL OF ROLLING THICKNESS

DEFECTS IN ROLLING

Wavy edges
Zipper cracks in the
center of strip
Edge cracks
Alligatoring
Residual stress

The effect of roll radius on the type

of residual stresses developed in
flat rolling: (a) small rolls and/or
small reduction in thickness; and
(b)
large
rolls
and/or
large
reduction in thickness.

ROLLING PROCESSES
Skew Rolling

Roll Forging

Thread Rolling

QUESTIONS?

REVIEW QUESTIONS
Rolling is a bulk deformation process in which the thickness of
the work is reduced by compressive forces exerted by two
opposing rolls:
(a) true
(b) false

REVIEW QUESTIONS
The maximum possible draft in a rolling operation depends on
which of the following parameters (two correct answers):
(a) coefficient of friction between roll and work,
(b) roll diameter,
(c) roll velocity,
(d) stock thickness,
(e) strength coefficient of the work metal

Draft, h0 hf = m2R

EXTRUSION
Metal is compressed and forced to flow through a shaped die to
form a product with a constant cross section
May be performed hot or cold
A ram advances from one end of the die and causes the metal to
flow plastically through the die
Commonly extruded metals: aluminum, magnesium, copper, and
lead

RAM

TYPES OF EXTRUSION

Direct Extrusion

Indirect Extrusion

Hydrostatic extrusion

Impact extrusion

ADVANTAGES OF EXTRUSION
Many shapes can be produced that are not possible with rolling
Amount of reduction in a single step is only limited by the
equipment, not the material or the design
Dies are relatively inexpensive
Small quantities of a desired shape can be produced
economically
Video Time!
Direct Extrusion
http://www.youtube.com/watch?v=9MqzKihSrFI
Impact Extrusio
http://www.youtube.com/watch?v=zMhVPId-pRA

EXTRUSION OF HOLLOW SHAPES

Mandrels may be used to produce hollow shapes or

shapes with multiple longitudinal cavities

(a) the mandrel and ram have independent motions;

(b) they move as a single unit.

http://www.youtube.com/watch?v=MfMXwhs0gTk 2-4 min

EXTRUDED PRODUCTS

(a)-(c) Examples of extrusions and products made by sectioning them.

Source: Kaiser Aluminum. (d) Examples of extruded cross-sections. Source:
(d) Courtesy of Plymouth Extruded Shapes.

FORCES IN EXTRUSION PRESSURE

Lubrication is important to reduce
friction and act as a heat barrier
p Y (a b ln

A0
)
Af

a 0.8, b 1.2 1.5

Metal flow in extrusion

Flow can be complex
Surface cracks, interior cracks and
flow-related cracks need to be
monitored
Process control is important

Diagram of the ram force versus ram

position for both direct and indirect
extrusion of the same product. The area
under the curve corresponds to the amount
of work (force x distance) performed. The
difference between the two curves is
attributed to billet-chamber friction.

ROD OR WIRE DRAWING

A process in which the cross-sectional area of a bar or tube

is reduced or changed in shape by pulling it through a
converging die.

Tube drawing animation

http://www.youtube.com/watch?v=QKAg1yMZIpY

Tube cold drawing process

http://www.youtube.com/watch?v=zlueIHudt4k

A
m
2
d Y [(1 ) ln( 0 ) ]

Af
3

TUBE DRAWING OPERATION

Examples of tube-drawing operations, with and without an internal mandrel.

Note that a variety of diameters and wall thicknesses can be produced from
the same tube stock (that has been produced by other processes, such as
extrusion

ROTARY SWAGING
A process in which a rod or tube is reduced in diameter by the reciprocating
radial movement of two or four dies (external hammers)

Reduce diameter
Produce taper or add point

Usually limited to a diameter of 2 in.

(a) Schematic of rotary-swaging process. (b) Forming internal profiles in

a tubular workpiece by swaging.

SWAGING OPERATIONS
Swaging process animation

o http://www.youtube.com/watch?v=ilL8ViUDUKc

Reduction of outer and inner diameters of tubes by swaging. (a) Free sinking
without a mandrel. The ends of solid bars and wire are tapered (pointing) by
this process in order to feed the material into the conical die. (b) Sinking on a
mandrel. Coaxial tubes of different materials can also be swaged in one
operation.

SWAGED PRODUCTS

(a) Typical cross-sections produced by swaging tubular blanks with a

constant wall thickness on shaped mandrels. Rifling of small gun
barrels also can be made by swaging. (b) Typical parts made by
swaging. Source: Courtesy of J. Richard Industries.

SUMMARY
There are a variety of bulk deformation processes
The main processes are
Rolling, forging, extrusion, and drawing

Each process has its limits and advantages as to capabilities

The correct process depends on the desired shape, surface
finish, quantity, etc.
Therefore, its important to understand each process
- Operation principles
- Mechanics fundamentals
- Limits and advantages