Rolling

overview

Rolling
Rolling is a process of forming metal
to the required shape by passing it
between rotating rolls.

Salient features of rolling

Rolling is the most extensively used
metal forming process and its share is
roughly 90%.
The material to be rolled is drawn by
means of friction into the two revolving
roll gap.
The compressive forces applied by the
rolls reduce the thickness of the material
or changes its cross sectional area.
The geometry of the product depend on
the contour of the roll gap.

 Roller material - cast iron, cast steel

,forged
steel
- high strength &
wear resistance
Roll torque, power etc. increase with
increase in roll work contact length or
roll radius.
Rolling types Hot rolling
- Cold rolling

Rolling

Change in grain structure in

rolling

 Absolute draft (t) = ti tf

where,
ti - Initial thickness of work piece
tf Final thickness of work piece
Absolute elongation (t) = lf li
where,
li - Initial length of work piece
lf Final length of work piece

 Relative draft (Rt) = t / ti

= ((ti - tf)/ ti) x 100
Elongation co-efficient () = (lf / li)
Angle of bite () = 1 / tan ()
where,
- max. bite angle (or)angle of contact
co-efficient of friction between metal
and roll surfaces

 The usual values of biting angles () are :

2- 10

------- For cold rolling of oiled

sheet and strip

15- 20 -------

For hot rolling of oiled

sheet and strip

24- 30 -------- For hot rolling of

heavy billets
and blooms

 Roll force, (F) = L w Yavg

where,
L - roll strip contact length
w - Width of strip
Yavg - Average true stress
Power (P) = (2FLN)/60000
kw
where,
F Force in N
N - Speed of the roll in RPM

 Roll strip contact length, (L) :

L = (R (ti - tf))
= R (t)
where ,
R roll radius
t - absolute draft

Roll passes to get a 12mm rod from

100 x100 mm billet

Types of rolls

Planetary Roll

Cluster Mill

 Two-high and three-high mills are

generally
used
for
initial
and
intermediate passes during hot rolling.
Four-high and cluster mills are used for
final passes.
Last two arrangements are preferred
for cold working .
Because roll in these configurations are
supported by back-up rolls which
minimize the deflections and produce
better tolerances.

Process variables in rolling

process

Diameter of roll
Angle of bite
Speed of rolling
Strength of working material
Roll gap (or) draft
Temperature
Co-efficient of friction
Dimensions of sheet

Shape Rolling
In shape rolling process, the various
shapes can be produced.
Examples : I beams, channels, rail
road rails
Types :
1. Ring rolling
2. Thread rolling

Shape Rolling

Ring rolling

Ring rolling
This process depend upon:
- The size
- Strength
- Ductility of material
The process carried out at room
temperature.
Advantages:
Short production time.
Close tolerances
Material savings

Thread rolling

 Advantages :
Generating threads with less
wastage of
material.
- The surface finish is very good.
- The fatigue life is high.
Applications :
- Bolts
- Spur and helical gears can be
made by cold rolling process similar
to thread rolling

Defects in rolling
Surface defects:
These defects may result from:
- impurities in the materials
- scale, rust, dirt
- roll marks

 Structural defects:
1.
2.
3.
4.

Wavy edges
Zipper cracks
Edge cracks
Alligatoring