Manufacturing Lecture

Manufacturing Technology I
ME 303
Chapter 19

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
BULK DEFORMATION PROCESSES
IN METALWORKING
1. Rolling
2. Other Deformation Processes Related to
Rolling
3. Forging
4. Other Deformation Processes Related to
Forging
5. Extrusion
6. Wire and Bar Drawing
Bulk Deformation
Metal forming operations which cause significant
shape change by deforming metal parts whose
initial form is bulk rather than sheet
Starting forms:
Cylindrical bars and billets,
Rectangular billets and slabs, and similar
shapes
These processes stress metal sufficiently to
cause plastic flow into desired shape
Performed as cold, warm, and hot working
operations
Importance of Bulk Deformation
In hot working, significant shape change can
be accomplished
In cold working, strength is increased during
shape change
Little or no waste - some operations are near
net shape or net shape processes
The parts require little or no subsequent
machining
Four Basic Bulk Deformation Processes
1. Rolling slab or plate is squeezed between
opposing rolls
2. Forging work is squeezed and shaped
between opposing dies
3. Extrusion work is squeezed through a die
opening, thereby taking the shape of the
opening
4. Wire and bar drawing diameter of wire or bar
is reduced by pulling it through a die opening
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Rolling of Metals
Deformation process in which work thickness is
reduced by compressive forces exerted by
two opposing rolls
Figure 19.1 The rolling process (specifically, flat rolling).
Rolling
The Rolls
Rotating rolls perform two main functions:
Pull the work into the gap between them by
friction between workpart and rolls
Simultaneously squeeze the work to reduce its
cross section
Types of Rolling
Based on workpiece geometry :
Flat rolling - used to reduce thickness of
a rectangular cross section
Shape rolling - square cross section is
formed into a shape such as an I-beam
Based on work temperature :
Hot Rolling most common due to the
large amount of deformation required
Cold rolling produces finished sheet
and plate stock
Flat-Rolling and
Shape-Rolling
Processes
Figure 13.1 Schematic outline
of various flat-rolling and
shape-rolling processes.
Source: After the American
Iron and Steel Institute.
Figure 19.2 Some of the steel products made in a rolling mill.
Rolled Products Made of Steel
Hot Rolling
Based on workpiece geometry :
Flat rolling - used to reduce thickness of
a rectangular cross section
Shape rolling - square cross section is
formed into a shape such as an I-beam
Based on work temperature :
Hot Rolling most common due to the
large amount of deformation required
Cold rolling produces finished sheet
and plate stock
Flat-Rolling Process
Figure 13.2 (a) Schematic illustration of the flat-rolling process. (b) Friction forces acting on strip surfaces. (c) Roll
force, F, and the torque, T, acting on the rolls. The width of the strip, w, usually increases during rolling, as shown
later in Fig. 13.5.
Figure 19.3 Side view of flat rolling, indicating before and after
thicknesses, work velocities, angle of contact with rolls, and other
features.
Diagram of Flat Rolling
Flat Rolling Terminology
Draft = amount of thickness reduction
d=t
o
t
f
where d = draft; t
o
= starting thickness;
and t
f
= final thickness
Flat Rolling Terminology
Reduction = draft expressed as a fraction of
starting stock thickness:
r=
d
t
o
where r = reduction
When a series of rolling operations are
used, reduction is taken as the sum of the
drafts divided by the original thickness.

Spreading in Flat Rolling
Figure 13.5 Increase in strip width (spreading) in flat rolling. Note that similar spreading
can be observed when dough is rolled with a rolling pin.
Spreading tends to be most pronounced with low
width-to-thickness ratios and low coefficients of
friction.
Conservation of matter is preserved, so the
volume of metal exiting the rolls equals the
volume entering
t
o
w
o
L
o
= t
f
w
f
L
f
Similarly, before and after volume rates of
material flow must be the same, so the before
and after velocities can be related:
t
o
w
o
v
o
= t
f
w
f
v
f

Since the metal flow is continuous, there is a
gradual change in velocity of the work between
the rolls.
However, there is one point along the arc where
work velocity equals roll velocity. This is called the
no-slip point, also known as the neutral point.
On either side of this point, slipping and friction
occur between roll and work.
The amount of slip between the rolls and the work
the forward slip:

s=
v
f
v
r
v
r
The true strain experienced by the work in rolling
is :

The average flow stress :

The average flow stress is used to compute
estimates of force and power in rolling.

n +
K
=
n
f
1

Y

f
o
t
t
=ln
On entrance side of no-slip point, friction force
is in one direction, and on the other side it is in
the opposite direction.
However, the two forces are not equal.
The friction force on the entrance side is
greater, so that the net force pulls the work
through the rolls, else, rolling would not be
possible.
maximum possible draft that can be
accomplished with a given c.o.f, is defined by:
d
max
=
2
R
if friction were zero, draft would be zero, and
therefore no rolling operation.
Coefficient of friction in Rolling
Coefficient of friction in rolling depends on:
1.lubrication,
2.work material, and
3.working temperature.
Typical values of c.o.f are:
cold rolling 0.1
warm working 0.2
hot rolling 0.4
Sticking (hot rolling) 0.7
Rolling Force
The roll force F required to maintain separation between the
two rolls can be computed by integrating the unit roll
pressure p over the roll-work contact area.

where F = rolling force, N; w = the width of the work being
rolled, mm; p = roll pressure, MPa ; and L = length of contact
between rolls and work, mm.
An approximation of the above eq. can be calculated based
on the average flow stress:
F = Y
f
w L
Rolling Force
FIGURE 19.4 Typical variation in pressure
along the contact length in flat rolling. The
peak pressure is located at the neutral point.
The area beneath the curve, representing the
integration in Eq. (19.9), is the roll force F.
FLAT ROLLING AND ITS ANALYSIS
Example 19.1
A 300-mm-wide strip 25-mm thick is fed through a
rolling mill with two powered rolls each of
radius = 250 mm. The work thickness is to be
reduced to 22 mm in one pass at a roll speed
of 50 rev/min. The work material has a flow
curve defined by K = 275 MPa and n = 0.15,
and the coefficient of friction between the rolls
and the work is assumed to be 0.12. Determine
if the friction is sufficient to permit the rolling
operation to be accomplished. If so, calculate
the roll force, torque, and horsepower.
Force / Power in Rolling
Force and/or power to roll a strip of a given width
and work material can be reduced by:
1. using hot rolling rather than cold rolling to
reduce strength and strain hardening (K and n)
of the work material;
2. reducing the draft in each pass;
3. using a smaller roll radius R to reduce force;
and
4. using a lower rolling speed N to reduce power.

Shape Rolling
Work is deformed into a contoured cross section
rather than flat (rectangular)
Accomplished by passing work through rolls
that have the reverse of desired shape
Products include:
Construction shapes such as I-beams,
L-beams, and U-channels
Rails for railroad tracks
Round and square bars and rods
Fig 3.37 Passes for reducing billet to round bar
After Manufacturing Science. By A. Ghosh and A.K. Mallik. 1986 by ELLIS HORWOOD
LIMITED
A rolling mill for hot
flat rolling. The
steel plate is seen
as the glowing
strip in lower left
corner (photo
courtesy of
Bethlehem Steel).
Rolling Mill
Figure 13.10 A general view of a rolling mill. Source: Courtesy of Ispat Inland.
Rolling Mills
Equipment is massive and expensive
Rolling mill configurations:
Two-high two opposing rolls
Three-high work passes through rolls in
both directions
Four-high backing rolls support smaller
work rolls
Cluster mill multiple backing rolls on
smaller rolls
Tandem rolling mill sequence of two-high
mills
Figure 19.5 Various configurations of rolling mills: (a) 2-high
rolling mill.
Two-High Rolling Mill
Figure 19.5 Various configurations of rolling mills: (b) 3-high
rolling mill.
Three-High Rolling Mill
Figure 19.5 Various configurations of rolling mills: (c) four-high
rolling mill.
Four-High Rolling Mill
Multiple backing rolls allow even smaller roll diameters
Figure 19.5 Various configurations of rolling mills: (d) cluster mill
Cluster Mill
A series of rolling stands in sequence
Figure 19.5 Various configurations of rolling mills: (e)
tandem rolling mill.
Tandem Rolling Mill
Tandem-Rolling
Figure 13.11 An example of a tandem-rolling operation.
Roll Arrangements
Figure 13.3 Schematic illustration of various roll arrangements: (a) four-high rolling mill showing
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; (b) two-hill mill; (c) three-high mill; and (d)
cluster (or Sendzimir) mill.
Bending of Rolls
Figure 13.4 (a) Bending of straight
cylindrical rolls caused by roll forces. (b)
Bending of rolls ground with camber,
producing a strip with uniform thickness
through the strip width. Deflections have
been exaggerated for clarity.
Effects of Hot Rolling
Figure 13.6 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 castings are converted to a wrought structure
by hot working.
Roller Leveling
Figure 13.7 (a) A method of roller leveling to flatten rolled sheets. (b) Roller
leveling to straighten drawn bars.
Defects in Flat Rolling
Figure 13.8 Schematic
illustration of typical defects in
flat rolling: (a) wavy edges; (b)
zipper cracks in the center of the
strip; (c) edge cracks; and (d)
alligatoring.
Thread Rolling
Bulk deformation process used to form threads
on cylindrical parts by rolling them between
two dies
Important commercial process for mass
producing bolts and screws
Performed by cold working in thread rolling
machines
Advantages over thread cutting (machining):
Higher production rates
Better material utilization
Stronger threads and better fatigue
resistance due to work hardening
Figure 19.6 Thread rolling with flat dies: (1) start of cycle, and
(2) end of cycle.
Thread Rolling
Thread-Rolling Processes
Figure 13.16 Thread-rolling processes: (a) and (c) reciprocating flat dies; (b) two-roller dies. (d) Threaded
fasteners, such as bolts, are made economically by these processes at high rates of production. Source:
Courtesy of Central Rolled Thread Die Co.
Machined and Rolled Threads
Figure 13.17 (a) Features of a machined or rolled thread. Grain flow in (b) machined and (c) rolled threads.
Unlike machining, which cuts through the grains of the metal, the rolling of threads imparts improved strength
because of cold working and favorable grain flow.
Ring Rolling
Deformation process in which a thick-walled ring of
smaller diameter is rolled into a thin-walled ring of
larger diameter
As thick-walled ring is compressed, deformed metal
elongates, causing diameter of ring to be enlarged
Hot working process for large rings and cold working
process for smaller rings
Applications: ball and roller bearing races, steel tires
for railroad wheels, and rings for pipes, pressure
vessels, and rotating machinery
Advantages: material savings, ideal grain orientation,
strengthening through cold working
Figure 19.7 Ring rolling used to reduce the wall thickness and increase
the diameter of a ring: (1) start, and (2) completion of process.
Ring Rolling
Ring-Rolling
Figure 13.15 (a) Schematic illustration of a ring-rolling operation. Thickness reduction results in an increase in
the part diameter. (b-d) Examples of cross-sections that can be formed by ring-rolling.
Roll Piercing
Fig 19.8 Roll piercing: (a) formation of internal stresses
and cavity by compression of cylindrical part; and (b)
setup of Mannesmann roll mill for producing seamless
tubing
Cavity Formation in Bar
Figure 13.18 Cavity formation in a solid, round bar and its utilization in the rotary tube-piercing process for
making seamless pipe and tubing. (see also Fig. 2.9.)
Various Tube-Rolling Processes
Figure 13.19 Schematic illustration of various tube-rolling processes: (a) with a fixed mandrel; (b) with
a floating mandrel; (c) without a mandrel; and (d) pilger rolling over a mandrel and a pair of shaped
rolls. Tube diameters and thicknesses also can be changed by other processes, such as drawing,
extrusion, and spinning.
Forming of Solid Rocket Casings
Figure 13.20 The Space Shuttle U.S.S. Atlantis is
launched by two strapped-on solid-rocket boosters.
Source: Courtesy of NASA.
Figure 13.21 The forming
processes involved in the
manufacture of solid rocket
casings for the Space Shuttles.

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