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02-Oct-14

Lesson Objectives:
Todays lesson objectives:
Introduction to forming and shaping
processes for metal
Principles of rolling process
Parameters involved in rolling process

BMM 2643

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02-Oct-14

Introduction
Metal forming is a shape production

process that uses fundamental of


deformation processes.
These processes is designed to exploit a
property of engineering materials
(mostly metals) known as plasticity, the
ability to flow as solids without
deterioration of their properties.
Since all processing is done in the solid
state, there is no need to handle molten
materials.
BMM 2643

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Introduction (cont.)
The amount of waste is reduced

substantially unlike cutting away


operations.
But, the forces required are often high.
Machinery and tooling can be expensive
and it is suitable for mass production.

BMM 2643

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02-Oct-14

Classification of Metal Forming


Processes
workpiece temperature can be one of

most important process variables.


an increase in temperature brings about
a decrease in strength, an increase in
ductility, and a decrease in the rate of
strain hardening the effects that
would tend to promote the ease of
deformation.
.

BMM 2643

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Classification of Metal Forming


Processes (cont.)
Therefore, forming processes can be

classified based on working


temperature
It can be classified as hot working, cold
working or warm working.

BMM 2643

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02-Oct-14

Hot Working
The plastic deformation of metals at a

temperature above the recrystallization


temperature.
About 0.6 times the melting point of the
material on absolute temperature scale (Kelvin
or Rankine)
the recrystallization temperature varies greatly
with different materials.
e.g. Tin is near hot-working conditions at room
temperature, Steels require temperatures near
1093C, Tungsten has hot working temperature
about 2204C.
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BMM 2643

Cold Working
Cold working is the plastic deformation

of metals below the recrystallization


temperature.
Usually less than 0.3 times the
workpiece melting temperatures.
Normally it is performed at room
temperature, but mildly elevated
temperature may be used to provide
increased ductility and reduced
strength.
BMM 2643

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02-Oct-14

Advantages of Cold Forming vs.


Hot Working
From a manufacturing viewpoint, cold

working has a number of distinct


advantages from hot working include:
No heating is required
Better surface finish
Better accuracy and flatness
Better reproducibility
Strength, fatigue and wear properties
are improved
Contamination problems are minimized
BMM 2643

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Disadvantages of Cold Forming vs.


Hot Working
Some disadvantages associated with

cold working:
Higher forces are required
Heavier and more powerful of
equipments
Less ductility
Undesirable residual stresses
Metal surfaces must be clean
BMM 2643

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02-Oct-14

Warm Working
Deformation produced at temperatures

intermediate to hot and cold working.


temperatures above room temperature but
below recrystallization temperature
0.3Tm < T < 0.6Tm where Tm = melting
point (absolute temperature) for metal

BMM 2643

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Advantages of Warm Working


Lower forces and power than in cold

working
More intricate work geometries possible
Need for annealing may be reduced or
eliminated- coz less residual stresses

BMM 2643

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02-Oct-14

Classification of Metal Forming


Processes
Example of hot working processes:
Forging ,Rolling, Extrusion
Forming of tubes and pipes, etc.

Examples of cold working processes:


Sheet metal working Piercing, Drawing,
Embossing, etc.

BMM 2643

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Rolling of Metals

02-Oct-14

Rolling
Rolling is the process of reducing thickness

(changing the cross section) of a long


workpiece by compressive forces applied
through a set of rolls.
The basic operation is flat rolling, where the
rolled products are flat plate and sheet.
Plates - thickness greater than 6mm
Sheets thickness less than 6 mm thick.

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BMM 2643

Flat- and Shape-Rolling Processes

flat

Schematic outline of
various flat- and
shape-rolling
processes. Source:
American Iron and
Steel Institute.

shape

casting

BMM 2643

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02-Oct-14

The Rolls
The 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 cross section

BMM 2643

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Types of Rolling
By geometry of work:
Flat rolling - used to reduce thickness of a
rectangular cross-section
Shape rolling - a square cross-section is
formed into a shape such as an I-beam

By temperature of work:
Hot Rolling most common due to the
large amount of deformation required
Cold rolling produces finished sheet and
plate stock
BMM 2643

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02-Oct-14

Rolling
Rolling is first carried out at elevated

temperatures (hot rolling)


During this phase, the coarse-grained,
brittle and porous structure of cast metal
is broken down into a wrought structure
having finer grain size and enhanced
properties.
Followed by Cold rolling at room
temperature for finishing.
BMM 2643

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Grain Structure During


Hot Rolling
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 casting are converted to a
wrought structure by hot working.

BMM 2643

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02-Oct-14

Flat Rolling
A strip of thickness h0 enters the roll

gap and is reduced to thickness hf by a


pair of rotating rolls.
Each roll being powered through its
own shaft by electric motors.

BMM 2643

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Flat-Rolling

(a) Schematic illustration of the flat-rolling process. (b) Friction


forces acting on strip surfaces. (c) The roll force, F, and the torque
acting on the rolls. The width w of the strip usually increases
during rolling, as is shown in Figure above.
BMM 2643

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02-Oct-14

The Flat-Rolling Process


Roll force, F (N) = LwYavg
L = roll-strip contact length
w = width of the strip
Yavg = average true stress
This calculation is for a frictionless situation,

actual force maybe 20% more.


Power (for 2 rolls), P (kW) = 2FLN / 60000
N = rpm of the roll

Torque = Fa
a = L/2
BMM 2643

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The Flat-Rolling Process (cont.)


Example

An annealed copper strip, 250 mm wide


and 25 mm thick, is rolled to a
thickness of 20 mm in one pass. The
roll radius is 300 mm, and the rolls
rotate at 100 rpm. Calculate the roll
force and the power required in this
operation.
BMM 2643

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02-Oct-14

The Flat-Rolling Process (cont.)


Example
An annealed copper strip, 250 mm wide
and 25 mm thick, is rolled to a
thickness of 20 mm in one pass. The
roll radius is 300 mm, and the rolls
rotate at 100 rpm. Calculate the roll
force and the power required in this
operation.

F LwYavg

38.7 250

180 MPa 1.74 MN


1000 1000

2 FLN
38.7
100
2 1.74 106

60,000
1000 60,000
705 kW

Power

BMM 2643

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The Flat-Rolling Process


(cont.)

BMM 2643

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02-Oct-14

The Flat-Rolling Process


(cont.)

BMM 2643

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The Flat-Rolling Process


Solution The roll force is determined from Eq.
(13.2) in which L is the roll-strip contact length.
It can be shown from simple geometry that this
length is given approximately by

The average true stress for annealed copper


is determined as follows. First note that the
absolute value of the true strain that the strip
undergoes in this operation is

BMM 2643

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02-Oct-14

The Flat-Rolling Process


(cont.)

BMM 2643

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The Flat-Rolling Process


Referring to Figure, note that annealed
copper has a true stress of about 80 MPa in
the unstrained condition, and at a true strain
of 0.223, the true stress is 280 MPa. Thus,
the average true stress is (80+280)/2=180
MPa. We can now define the roll force as
F LwYavg

38.7 250

180 MPa 1.74 MN


1000 1000

The total power is calculated from Eq. (13.3),


noting that N = 100 rpm. Thus,
2 FLN
38.7
100
2 1.74 106

60,000
1000 60,000
705 kW

Power

BMM 2643

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02-Oct-14

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