Mansoura University

Faculty of Engineering
Mechanical Power Engineering

Defects in Rolled Plates & Sheets

Prepared by:
Mahmoud Mohammed Mohammed Samaha

SAC: 8

To:
Prof. Mona Abu El Eaz
Summary:
In the report, I will discuss the metal rolling defects and I will briefly talk about the principles of metal
rolling and defects in metal rolling. After that, discuss the defects from different points) Structural
defects, surface defects.(
Introduction:

Principles of Metal Rolling: Most metal rolling operations are similar in that
compressive forces between two constantly spinning rolls plastically deform the
work material. These forces act to reduce the thickness of the metal and affect its
grain structure. The reduction in thickness can be measured by the difference in
thickness before and after the reduction, this value is called the draft. In addition to
reducing the thickness of the work, the rolls also act to feed the material as they
spin in opposite directions to each other. Friction is therefore a necessary part of
the rolling operation, but too much friction can be detrimental for a variety of
reasons. It is essential that in a metal rolling process the level of friction between
the rolls and work material is controlled, lubricants can help with this. A basic flat
rolling operation is shown in figure: 130, this manufacturing process is being used to
reduce the thickness of a work piece.

The second thing is the Defects in Metal Rolling, which is a wide variety of defects, are
possible in metal rolling manufacture. Surface defects commonly occur due to
impurities in the material, scale, rust, or dirt. Adequate surface preparation prior to
the metal rolling operation can help avoid these. Most serious internal defects are
caused by improper material distribution in the final product. Defects such as edge
cracks, center cracks, and wavy edges, are all common with this method of metal
manufacturing.
 Rolling defects:

Two types:

1- Surface defects
2- Structural defects

 Surface defects: surface defects include ( laps, mill shearing , scales , scabs and sliver,
scratches and cooling cracks).

 Structural defects:
These defects include the following:

(i) Edge cracking

(ii) Alliatoring
(iii) Wavy edge
(iv) Barrel
(v) Residual stress in rolling
(vi) Centre split
(vii) Folds
Surface defects:

a) Laps: these appear in the form of seams across the surface and are due to the folding of a
corner or a film during rolling because of improper welding.

b) Mill shearing: this appear as feather like laps. Flakes appear in coarse grained ingots which
leads to decrease in ductility.

c) Scales: the oxide scales so formed during hot rolling of a particular metal can result into
penetration of the scales inside the surface due to the surface deformation. Seams may also form
due to the presence of the scales on the surface.

d) Scabs: these are rolled in long patches of the loose metal. This may lead to the scenario of
surface lamination .

e) Sliver, scratches and cooling cracks: slivers are the major surface ruptures. The scratches may
come into picture due to improper machining operations. Cooling cracks along the edges are a
result of non- uniformity in the cooling temperature.
Structure defects:

a) Edge Cracking

Small thickness sheets are more sensitive to roll gap defects leading to greater defects. Thin strips
are more likely to undergo waviness or buckling. These defects are corrected by doing roller
leveling or stretch leveling under tension. Stretch leveling is carried out between roller leveler
rolls.
During rolling the sheet will have a tendency to deform in lateral direction. Friction is high at the centre.
Therefore, spread is the least at the centre. This leads to rounding of ends of the sheet. The edges of the sheet are
subjected to tensile deformation . This leads to edge cracks. If the center of the sheet is severely restrained and
subjected to excess tensile stress, center split may happen.

b) Alligatoring

Non-homogeneous material deformation across the thickness leads to high secondary

tensile stress along edge. This leads to edge cracks. Secondary tensile stresses is due to
bulging of free surface. Edge cracks can be avoided by using edge rolls. Due to non-
homogeneous flow of material across the thickness of the sheet, another defect called
allegatoring occurs. This is because the surface is subjected to tensile deformation and
centre to compressive deformation. This is because greater spread of material occurs at
center.
c) Wavy edges:

Roll elastic deformation may result in uneven sheet thickness across. Roll material should
have high elastic modulus for reducing the roll deformation. For producing very thin gage
sheets like foils, small diameter rolls are used.
They are supported with larger rolls. We can say the minimum thickness of rolled sheets
achieved is directly proportional to roll radius, friction, flow stress. Flatness of rolled sheets
depends on the roll deflection. Sheets become wavy as roll deflection occurs.
If rolls are elastically deflected, the rolled sheets become thin along the edge, whereas at
Centre, the thickness is higher. Similarly, deflected rolls result in longer edges than the
centre. Edges of the sheet elongate more than the centre. Due to continuity of the sheet, we
could say that the centre is subjected to tension, while edges are subjected to compression.
This leads to waviness along edges. Along the centre zipper cracks occur due to high tensile,
stress there. Cambering of rolls can prevent such defects. However, one camber works out
only for a particular roll force.

d) Barrel :

Due to friction at the edges of the product barrel action takes place. Surface in contact
experience severe friction as compared to center of the work. Hence, with heavy reduction in
the work the center tends to expand laterally more than the outer surfaces in contact with the
dies and produces barreled edged.
 e) Residual stress in rolling:
Compressive stress is induced on the surface of rolled product if small diameter rolls are used
or if smaller reductions are affected during rolling. Stress in the bulk of the strip is tensile in
the above case. Larger reductions or rolling using large diameter rolls leads to tensile stress on
the skin and compressive stress in the bulk of the metal. Stress relieving operation can be
used to relieve the residual stresses of rolled products.

Surface cracking (also called hot shortness)

•If temperature, friction or speed is too high, intergranular cracks occur
•Common in aluminum, magnesium, and zinc alloys
•Bamboo defects are periodic surface cracks that develop due to the extruded
Product sticking to the die land

Internal cracking (also called center burst, chevron cracking)

•Due to hydrostatic tensile stress at centerline of deformation zone
(Similar to necking in a tensile test specimen)
•Increases with increased die angle, impurities
•Decreases with increased extrusion ratio and friction
List of figures:
References:

https://techminy.com/rolling-defects/

https://thelibraryofmanufacturing.com/metal_rolling.html

http://rprasadmechanical.blogspot.com/2016/03/defect-in-rolling-drawing-extrusion.html?m=1