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Rolling of metals
Subjects of interest • Introduction/objectives
• Rolling mills
• Classification of rolling processes
• Hot rolling
• Cold rolling
• Forces and geometry relationships in rolling
• Simplified analysis of rolling load: Rolling variables
• Problems and defects in rolled products
• Rolling-mill control
• Theories of cold rolling
• Theories of hot rolling
• Torque and power
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Objectives
Hot rolling
Cold rolling
Rollforming machine
Mill • Sheet is the product with a thickness < 6 mm and width > 600 mm.
products
• Strip is the product with a thickness < 6 mm and width < 600 mm.
Rolls
Mill rolls
• The speed of each set of rolls is synchronised so that the input speed of
each stand is equal to the output speed of preceding stand.
• The uncoiler and windup reel not only feed the stock into the rolls and coiling up
the final product but also provide back tension and front tension to the strip.
• Continuous rolling
• Transverse rolling
• Shaped rolling or section rolling
• Ring rolling
• Powder rolling
• Continuous casting and hot rolling
• Thread rolling
Applications:
- construction materials,
- partition beam
- ceiling panel
- roofing panels.
- steel pipe
- automotive parts
- household appliances
- metal furniture,
- door and window frames
- other metal products.
www.formtak.com
A variety of rolled sections
Seamless rings
www.qcforge.com
www.rz.rwth-aachen.de
Simulation
of ring
rolling
Advantage :
- Cut down the initial hot-ingot breakdown step (reduced capital investment).
- Economical - metal powder is cheaply produced during the extraction process.
- Minimise contamination in hot-rolling.
- Provide fine grain size with a minimum of preferred orientation.
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Continuous casting and hot rolling
• The objective is to breakdown the cast ingot into blooms or slabs for
subsequent finishing into bars, plate or sheet.
• In hot-rolling steel, the slabs are heated initially at 1100 -1300 oC. The
temperature in the last finishing stand varies from 700 - 900 oC, but should
be above the upper critical temperature to produce uniform equiaxed
ferrite grains.
Plate 12 to 30 mm thick
www.uksteel.org.uk
www.reverecopper.com
Plate rolling
• The total reduction achieved by cold-rolling generally will vary from about
50 to 90%.
• The reduction in each stand should be distributed uniformly without falling
much below the maximum reduction for each pass.
• Generally the lowest percentage reduction is taken place in the last pass
to permit better control of flatness, gage, and surface finish.
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Example for cold strip mill process. www.nzsteel.co.nz
In batches of 9 coils, cold
rolled steel is annealed to
reduce work hardening
results
R bho vo = bh f v f
x y
vo
ho vf hf Given that bo = bf
Lf
x’ y’
vo < vf h Lo
o t =h f t
Then we have
vo ho = v f h f
When ho > hf , we then have vo < vf
vo h f
The velocity of the sheet must steadily increase = …Eq.2
from entrance to exit such that a vertical element vf ho
in the sheet remain undistorted.
• If the surface velocity of the roll vr equal to the velocity of the sheet, this
point is called neutral point or no-slip point. For example, point N.
(ho − h f )
12
2
L p = R(ho − h f ) −
4
[
≈ R (ho − h f ) ]
12
…Eq.4
L p ≈ R∆h
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
• The distribution of roll pressure
along the arc of contact shows that the
pressure rises to a maximum at the
neutral point and then falls off.
R
• The pressure distribution does not
N come to a sharp peak at the neutral
vo
ho hf point, which indicates that the neutral
point is not really a line on the roll
p surface but an area.
• The area under the curve is
A B Friction hill in rolling proportional to the rolling load.
α1>α2 α2
α1
L p ≈ 2 Ra ≈ R∆h …Eq.6
A large diameter roll will permit a
thicker slab to enter the rolls than will
Where ∆h = ho – hf = 2a
a small-diameter roll.
Lp R∆h ∆h
µ = tan α = ≈ ≈ (∆h )max = µ 2 R …Eq.7
R − ∆h / 2 R − ∆h / 2 R
When high forces generated in rolling are transmitted to the workpiece through
the rolls, there are two major types of elastic distortions:
1) The rolls tends to bend along their length because the workpiece tends to
separate them while they are restrained at their ends. thickness
variation.
2) The rolls flatten in the region where they contact the workpiece. The radius
of the curvature is increased R R’. (roll flattening)
CP ' R R‘
R = R 1 +
'
b ( ho − h )
f
Roll flattening
1) No friction condition
2) Normal friction condition
3) Sticky friction condition
Where the roll pressure (p) is the yield stress in plane strain
when there is no change in the width (b) of the sheet.
From Eq.8, _
P = p bL p
1 Q
( )
_
2
We have P= σo e − 1 b R∆h …Eq.10
3 Q
Backup rolls
Example: the rolling of aluminium cooking foil.
Roll diameter < 10 mm with as many as 18
backing rolls.
• High friction results in high rolling load, a steep friction hill and great
tendency for edge cracking.
• The friction varies from point to point along the contact arc of the roll.
However it is very difficult to measure this variation in µ, all theory of
rolling are forced to assume a constant coefficient of friction.
ho − h f _ ho + h f (40) + (28)
x100 = 30% h= = = 34mm
ho 2 2
(40) − (h f ) µL p µ R∆h (0.30) 450 x12
x100 = 30 Q= = = = 0.65
(40) _ _
(34)
h h
h f = 28mm
' σ ' entrance + σ 'exit 140 + 200
∆h = ho − h f = (40) − (28) = 12mm σ = o = = 170 MPa
2 2
From Eq.10 1 Q
P = σ (e − 1)b R∆h
'
o
Q
1
P = 170 ( )
e 0.65 − 1 (0.76) 0.45 x0.012 = 13.4 MN
(0.65)
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
3) Sticky friction situation
What would be the rolling load if sticky friction occurs?
R∆h
P =σ '
+ 1b R∆h
o _
4h
0.45 x0.012
P = 170 + 1(0.76) 0.45 x0.012
4 x0.034
P = 14.6MN
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Example: The previous example neglected the influence of roll flattening
under very high rolling loads. If the deformed radius R’ of a roll under load is given
in Eq.11, using C = 2.16x10-11 Pa-1, P’ =13.4 MPa from previous example.
• Porosity, cavity, blow hole occurred in the cast ingot will be closed up
during the rolling process.
h h
_ '
µR σ o …Eq.12
hmin =
12.8
g n
ll in tio
o
R irec
d
(a) (b)
(a) (b)
(c)
(d)
(e)
(a) (b)
(c)
(d)
(e)
• Thicker edges than the centre means the centre would be plastically
elongated more than the edges, resulting in lateral spread.
•The residual stress pattern is now under compression in the centreline and
tension at the edges (b).
• This may cause edge cracking (c), centre splitting (d), centreline
wrinkling (e).
Material
flow
work rolls
Roller-leveller
• Of all the metal working processes, rolling is the best suited for the
adoption of automatic control because it is an essentially steady-state
process in which the tooling geometry (roll gap) may be changed readily
during the process.
• Automatic control in rolling such as the development of online sensors
to continuously measure sheet thickness. The most widely used
instruments are
1) flying micrometer
2) x-ray or isotope, gauges which measure thickness by monitoring
the amount of radiation transmitted through the sheet.
1 Q
( )
_
2
P= σ o e − 1 b R∆h
3 Q
Example: • If the sheet thickness increases, the plastic curve will move to the
right relative to the elastic curve.
• If the there is an increase in strip tension, the plastic curve will move
to the left.
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Thickness measurement in continuous hot mill
• The error signal is fedback to the rolling mill screws to reposition them
so as to minimise the error.
Assumptions
1) The arc of the contact is circular – no elastic deformation of the roll.
2) The coefficient of friction is constant at all points on the arc of contact.
3) There is no lateral spread, so that rolling can be considered a problem
in plain strain.
4) Plane vertical section remain plane: i.e., the deformation is
homogeneous.
5) The peripheral velocity of the rolls is constant
6) The elastic deformation of the sheet is negligible in comparison with the
plastic deformation.
7) The distortion-energy criterion of yielding, for plane strain, holds.
θ
σx+dσx σx
dθ
µPrsinθ
µPr
µPrcosθ
ho h+dh h hf
Prcosθ
θ Pr
Prsinθ
B R dθ
• At any point of contact between the strip and the roll surface, designated
by the angle θ, the stresses are the radial pressure pr and the
tangential shearing stress τ = µpr. These stresses are resolved into
their horizontal and vertical components (b).
• The stress σx is assumed to be uniformly distributed over the vertical
faces of the element.
Prsinθ Rd
θ
Prcosθ
θ
Pr
Pr
µPrcosθ
µPrsinθ
µPrcosθRdθ θRdθ
Prsinθ θ
σxh
h+dh σx+dσx σx h
(σx+dσx)(h+dh)
µPrsinθ
h
µPr
gt
en
tl
µPrcosθRdθ
ni
µPrcosθ θRdθ
Prsinθ θ
Prcosθ
U
θ Pr
Prsinθ
R dθ
p = p r (1 m µ tan θ ) …Eq.14
2
σ1 − σ 3 = σ o = σ o'
3
p − σ x = σ o' …Eq.15
Where p is the greater of the two compressive principal stresses.
d (σ dx h(σ)h) = 2 p R (θ '± µ )
dθ = 2 p r R (θ ± µ )
x '
r …Eq.16
dθ
σ o' h
σ xb µ ( H − H ) σ xf µH
σ o' h
pr =
1 − ' e …Eq.17 1
pr = 1 − ' e …Eq.18
ho σ 01 h f σ 02
Where R'
1
2 ' 2
1
and σxb = back tension
−1 R θ
H = 2 tan σxf = front tension
h h f
f
θ =α
P = R 'b ∫ pdθ
o
…Eq.19
'
o [
P = σ b R (ho − h f )] 1
2 Qp …Eq.20
ho −1 ∆h R hn2 π
Qp = π tan − ln −
4∆h hf hf ho h f 4
…Eq.21
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Torque and power
Torque is the measure of the force applied to a member to produce
rotational motion.
Remarks: Losses in the windup reel and uncoiler must also be considered.
a a
λ= = …Eq.22 Schematic diagram illustrating roll torque
Lp R∆h
M T = 2 Pa …Eq.23 ho hf
Since power is defined as the rate of doing work, i.e., 1 W = 1 J s-1, the
power (in watts) needed to operated a pair of rolls revolving at N Hz (s-1) in
deforming metal as it flows through the roll gap is given by
W = 4πaPN …Eq.25
From Eq.20
[
P = σ o' b R (ho − h f )] 1
2 Qp
b = 0.3 m, R = 0.5 m, ho = 0.02 m and hf
= 0.015 m, we need to know σ’o and Qp.
20 ε1
ε 1 = ln = 0.288 k ∫ ε n dε
15
kε n +1 ε1 kε 1n Qp can be found
20 − 15 σ o' = o
= =
r= = 0.25 ε1 ε 1 (n + 1) o
n +1 from graph(~1.5)
20
140(0.288) when reduction r and
0.2
R 500
= = 33.3 σ =
'
o = 91MPa R/hf are known.
hf 15 1.2
2
(91)(0.3)[0.5(0.020 − 0.015)] (1.5) = 2.36MN
1
P= 2
3