BULK

DEFORMATION
PROCESSES
ROLLING
I.Rajkumar
Kalasalingam university
irajkumarilango@gmail.com
i.rajkumar@klu.ac.in

INTRODUCTION

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kalasalingam university

CLASSIFICATION
PRIMARY WORKING operations are those that

take a solid piece of metal (generally in form

of ingot) & break it down successively into
shapes such as slabs, billets & plates.
Traditionally this includes processes like
forging, rolling & extrusion.
SECONDARY WORKING operations involve
further processing of the products from
primary working in to final products like bolts,
sheet metal parts & wires.
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kalasalingam university

CLASSIFICATION
BULK DEFORMATION is the processing of work

pieces whose surface area-to-volume ratio (or

surface area-to-thickness ratio) is relatively small.
In bulk forming processes there is always a change
in thickness or cross-section of work piece.
Includes: rolling, forging, extrusion & drawing of rod
& wire.
SHEET-FORMING operations the surface area-tothickness ratio is relatively high. In general the
material is subjected to shape changes. No
thickness changes.
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kalasalingam university

ROLLING
This is the process of reducing the thickness

or changing the cross-section of a work-piece

by compressive forces exerted by a pair of
rotating rolls.
The products are flat products, like: plates &
sheets.
Plates are used for structural applications
like bridges, ships & nuclear vessels.
Sheets (generally 6mm or less in thickness)
are used for automotive, beverage cans, office
& kitchen equipment.
i.rajkumar@klu.ac.in

kalasalingam university

i.rajkumar@klu.ac.in

kalasalingam university

i.rajkumar@klu.ac.in

kalasalingam university

ROLLING
Hot rolling is a hot working process where large pieces of

metal, such as slabs or billets, are heated above their

recrystallization temperature and then deformed between
rollers to form thinner cross sections.
While cold rolling increases the hardness and strength of
a metal, it also results in a large decrease in ductility. Thus
metals strengthened by cold rolling are more sensitive to
the presence of cracks and are prone to brittle fracture.
Recrystallization temperature The minimum
temperature at which complete recrystallization occurs in.

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kalasalingam university

i.rajkumar@klu.ac.in

kalasalingam university

HOT ROLLING
Hot rolling produces thinner cross sections than

cold rolling processes with the same number of

stages. Hot rolling, due to recrystallization, will
reduce the average grain size of a metal while
maintaining a certain soft microstructure, where as
cold rolling will produce a hardened microstructure.
Hot rolling is primarily concerned with
manipulating material shape and geometry rather
than mechanical properties.
Primary working is always hot rolling.
Recrystallization & Annealing temperatures.
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ROLLING
Ingots

Billets/blooms/slabs
wires, nails, pipes, sheets,

bars/rods
plates
Bloom: square cross-section
Slab: rectangular
Billets: A billet is a bar of steel with a square
cross-section whose dimensions are usually
less than about 6 inches (15 cm) by 6 inches
(15 cm).
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i.rajkumar@klu.ac.in

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Making barbed wire

A steel ingot is heated until it is about 2192F (1200C), then

rolled between grooved rolls until it has reached the proper

size. Giant shears cut the billet to the desired length; then it is
allowed to cool.
The steel billet is again heated and rolled until it has been
shaped into a round bar 0.2 inch (5.6 mm) in diameter, known
as a wire rod. The wire rod is rolled into a coil weighing as
much as 3,969 pounds (1,800 kg), which is shipped to the wire
manufacturer.

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Hot rolling Advantages :

1. Larger deformation can be accomplished and
more rapidly by hot working since the metal is
in plastic state.
2. Porosity of the metal is considerably
minimised.
3. Concentrated impurities, if any in the metal
are disintegrated and distributed throughout
the metal.
4. Grain structure of the metal is refined and
physical properties improved.
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kalasalingam university

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Hot rolling Disadvantages :

1. Due to high temperature a rapid oxidation or scale
formation takes place on the metal surface, leading to poor
surface finish and loss of metal.
2. On account of the lost of carbon from the surface of the
steel piece being worked the surface layer loses its strength,
which is a disadvantage when the part is put to service.
3. This weakening of the surface layer may give rise to crack
which may ultimately result in fatigue failure of the part.
4. Close tolerances cannot be maintained.
5. It involves excessive expenditure on account of high cost of
tooling. This, however, is compensated by the high
production rate and better quality of products

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Cold Rolling
Quarter Hard, Half Hard, Full Hard stock have

higher amounts of reduction. This increases the

i) yield point;
ii) grain orientation and
iii) material properties assume
iv) ductility decreases.
)Quarter Hard material can be bent (perpendicular
to the direction of rolling) on itself without
fracturing.
)Half hard material can be bent 90; full hard can
be bent 45.
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Cold rolling advantages and

limitations
1.Better dimensional control than hot working is possible
because the reduction in size is not much.
2.Surface finish of the component is better because no
oxidation takes place during the process.
3.Strength and hardness of the metal are increased.
4.It is an ideal method for increasing hardness of those
metals which do not respond to the heat treatment.
5.Only ductile metals can be shaped through cold working.
6.Over-working of metal results in brittleness and it has to
be annealed to remove the same.
7. Subsequent heat treatment is mostly needed to remove
the residual stresses set up during cold working.
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