Rolling of Metals : Lecture 12

ROLLING OF METALS
Introduction
This chapter describes
Flat rolling
Shape rolling
Production of seamless tubing & pipe
Rolling process of reducing the thickness

of a long work piece

Plates having thickness greater than
6mm
Sheets generally less than 6mm thick
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Rolling of Metals : Lecture 12

ROLLING OF METALS
Flat Rolling Process

Rolling of Metals : Lecture 12

ROLLING OF METALS

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

Rolling of Metals : Lecture 12

ROLLING OF METALS
Frictional Forces

Friction Forces acting on strip forces

Max Draft
h0-hf = 2R
Roll Force
F= W0.L.Yavg
L== sqrt{R(ho-hf)}

Rolling of Metals : Lecture 12

ROLLING OF METALS

Flat-Rolling 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

Rolling of Metals : Lecture 12

ROLLING OF METALS
Billets smaller than blooms
and rolled into
bars and rods
Flat-Rolling
Practice
Cont
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

Rolling of Metals : Lecture 12

ROLLING OF METALS
Defects
Undesirablein Rolled Plates &
Degrade surface appearance
Sheets
Adversely affect the strength

Sheet metal defects include:

Scale, Rust, Scratches, Gouges, Pits, & Cracks
May be caused by impurities and inclusions

Wavy edges result of roll bending

Alligatoring complex phenomenon

Rolling of Metals : Lecture 12

ROLLING OF METALS
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
Hot rolling & sand have the same range of surface finish

Gauge numbers the thickness of a sheet is identified by a

gauge number
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Rolling of Metals : Lecture 12

ROLLING OF METALS

Schematic Illustration of Various Roll

arrangements

Rolling of Metals : Lecture 12

ROLLING OF METALS
Schematic Illustration of various roll arrangements : (a) twohigh; (b) three-high; (c) four-high; (d) cluster mill

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Rolling of Metals : Lecture 12

ROLLING OF METALS
Shape-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

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Rolling of Metals : Lecture 12

ROLLING OF METALS

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.

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Rolling of Metals : Lecture 12

ROLLING OF METALS

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
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Rolling of Metals : Lecture 12

ROLLING OF METALS
RING ROLLING

(a) Schematic illustration

of Ring-rolling
operation. Thickness
reduction results in an
increase in the part
diameter.
(b) Examples of crosssections that can be
formed by ring-rolling

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Rolling of Metals : Lecture 12

ROLLING OF METALS
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

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Rolling of Metals : Lecture 12

ROLLING OF METALS
Thread
Rolling
Cont
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

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Rolling of Metals : Lecture 12

ROLLING OF METALS
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
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Rolling of Metals : Lecture 12

ROLLING OF METALS

Continuous Casting & Integrated Mills &

Continuous casting
Minimills
Advantages

Highly automated
Reduces product cost
Companies are converting over to this type of casting

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Rolling of Metals : Lecture 12

ROLLING OF METALS
Continuous Casting & Integrated Mills &
Minimills
Cont
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

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Rolling of Metals : Lecture 12

ROLLING OF METALS
Spray Casting : In spray casting the molten metal is
sprayed over a rotating mandrel to produce seamless
tubing and pipe

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