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Rolling Lecture PDF

Rolling is a metal forming process that reduces the thickness of metal workpieces. There are three main types of rolling based on temperature: hot, warm, and cold rolling. Flat rolling is used to produce sheets and plates less than 6mm thick. Shape rolling is used to modify the profile of a workpiece. The rolling process involves passing metal between rolls to plastically deform it. Key factors include the bite angle, reduction ratio, rolling load, power required, and maintaining a constant volume of metal. Guiding systems are used to direct workpieces between rolls and passes for shape control and safety.

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Jojo Hany
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Download as PDF, TXT or read online on Scribd
368 views

Rolling Lecture PDF

Rolling is a metal forming process that reduces the thickness of metal workpieces. There are three main types of rolling based on temperature: hot, warm, and cold rolling. Flat rolling is used to produce sheets and plates less than 6mm thick. Shape rolling is used to modify the profile of a workpiece. The rolling process involves passing metal between rolls to plastically deform it. Key factors include the bite angle, reduction ratio, rolling load, power required, and maintaining a constant volume of metal. Guiding systems are used to direct workpieces between rolls and passes for shape control and safety.

Uploaded by

Jojo Hany
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Rolling of

Metals
Introduction

This lecture describes


Flat rolling
Shape rolling

Rolling process of reducing the thickness


of a long work piece
Plates having thickness greater than
6mm
Sheets generally less than 6mm thick
Rolling definition

The process of plastically deforming metal


by passing it between rolls to reduce its
section with or without modifying its
profile.
Classification of rolling processes
according to temperature range
There are three temperature ranges.
cold working
warm working
hot working

o T is the work metal melting temperature


m

o T is the ambient (room) temperature


A
1-Hot rolling Tm >
Tr
In hot-rolling steel, the billet are heated initially at
1100-1200 oC. The temperature in the last finishing
stand varies from 700 - 900 oC, but should be above
the upper critical temperature to produce uniform
equiaxed ferrite grains.

Low power consumption


Used with hard material
Use for complex shape
High reduction ratio.
Change in grain structure
2-Cold rolling Tm <
Tr
The temperature of the material lower than the
recristlization temperature.

increased the mechanical strength


Used with ductile material
Use for simple shape
Good surface finish.
Low reduction ratio.
3- Types of Rolls
Two high mill
Three high mill
Four high mill
Cluster mill
Several stands of continuous mill
Planetary mill
Flat and shape rolling processes
Basic Relationships In Rolling

Some definition in rolling.


Fundamental concept of metal rolling.
Volume flow rate.
Roll bite conditions.
The maximum reduction.
Load and Pressure distribution in rolling.
Simplified analysis of rolling load.
Effect of front and back tension.
Some definitions in rolling

Deformation zone
Elongation: L
Spread.
Draught:(h)
Biting angle:()
Neutral point.
Slipping and Friction
Deformation zone
the area between the contact arc of upper roll and contact arc
of lower roll or the area between entrance and exit plan.

Elongation: (L)
Is the increase in bar length after being
drafted.
Draft
Draft = amount of thickness reduction:
d = Do - Df
Reduction = draft expressed as a fraction of starting
stock
thickness: r = d/Do
Biting angle:()
The angle between the center line of the rolls and the
entrance plane is called the angle of contact or the angle of
bite
Neutral point
If the surface velocity of the roll vr equal to the velocity of the
material, this point is called neutral point or no-slip point. For example,
point N.
At only one point along the surface of contact between the roll and the
sheet, two forces act on the metal:
1) a radial force Pr and
2) a tangential frictional force F.

Between the entrance plane (xx)and the neutral point the sheet is
moving slower than the roll surface.
the tangential frictional force, act in the direction (see Fig) to draw the
metal into the roll.

On the exit side (yy) of the neutral point, the sheet moves faster than
the roll surface.
The direction of the frictional fore is then reversed and oppose the
delivery of the sheet from the rolls .
Parameter of Friction coefficient:
1-Temperature
2-Type of rolling metal
3-Type of roller
4-Surface finish of roller
5-Rolling speed
Fundamental concept of metal rolling
1) The arc of contact between the rolls and the
metal is a part of a circle.
2) The coefficient of friction, , is constant in
theory, but in reality varies along the arc of
contact.
3) The metal is considered to deform
plastically during rolling.
4) The volume of metal is constant before and
after rolling. In practical the volume might
decrease a little bit due to close-up of pores.
5) The velocity of the rolls is assumed to be
constant.
6) The metal only extends in the rolling direction
and no extension in the width of the
material.
7) The cross sectional area normal to the
rolling direction is not distorted.
Volume flow rate
A metal sheet with a thickness ho enters the rolls at the entrance
plane xx with velocity vo.
It passes through the roll gap and leaves the exit plane yy with a
v.
reduced thickness hf and at a velocity f

Since there is no change in metal volume at a


given point per unit time throughout the
process, therefore

Ao vo = Av = Af vf
The roll bite condition.
For the workpiece to enter the throat of the roll, the
component of the friction force must be equal to or
greater than the horizontal component of the
normal force.

But we know

Therefore
Definition
Forward Slip
If a piece of hot steel is placed in a press and
reduced in height, it spreads in the other two
dimensions. Similarly when a hot bar is worked
between two rolls, it spreads in the pass filling
the pass and it pushes out in the direction of
rolling ( forward slip )and backwards in the
direction of the incoming stock (backward slip).
This phenomenon is also called the extrusion
effect. Forward slip must be added to the bar
speed to calculate roll speed for tension free
rolling at high speeds in rods.
Separating Force
The deformation process in the roll gap creates
a force that pushes the rolls apart. This is called
the separating force or rolling load.
Factors influencing the magnitude of this force
include the material being rolled, its
temperature, the rate at which the material is
being compressed, the diameter of the rolls,
and the reduction taken in the pass.
There are two methods of calculating the
separating force. One starts with the resistance
of the material to deformation. The second
starts with the power required at the main mill
drive motor.
The maximum reduction.
From triangle ABC, we have

As a is much smaller than R, we can then ignore a2.


Where h = ho hf = 2a
Load and Pressure distribution in rolling.
At only one point along the surface of contact between the roll and
the sheet, two forces act on the metal:
1) radial force Pr and
2) tangential frictional force F.

Between the entrance plane (xx)


and the neutral point the sheet is
moving slower than the roll surface,
and the tangential frictional force,
F, act in the direction (see Fig) to
draw the metal into the roll.

On the exit side (yy) of the neutral


point, the sheet moves faster than
the roll surface. The direction of the
frictional fore is then reversed and
oppose the delivery of the sheet
from the rolls.
The distribution of roll pressure
along the arc of contact shows that the
pressure rises to a maximum at the
neutral point and then falls off.

The pressure distribution does not


come to a sharp peak at the neutral
point, which indicates that the neutral
point is not really a line on the roll
surface but an area.

The area under the curve is


proportional to the rolling load.

The area in shade represents the


force required to overcome
frictional forces between the roll
and the sheet.
The area under the dashed line
AB represents the force required to
deform the metal in plane
homogeneous compression.
Torque and power.
Torque is the measure of the force applied to a member to
produce
rotational motion.

Power is applied to a rolling mill by applying a


torque to the rolls.
The power is spent principally in four ways:-
1) The energy needed to deform the metal.
2) The energy needed to overcome the frictional force.
3) The power lost in the pinions and power-transmission
system.
4) Electrical losses in the various motors and generators.
The torque MT is equal to
the total rolling
load P multiplied by the
effective moment
arm a. Since there are two
work rolls, the
torque is given by
Guiding
Principles
Guiding Principles
Guiding Principles
Directing the bar into the first pass and
from pass to pass was originally
accomplished by catchers using tongs. As
shown in figure 13 - 1, this was a
dangerous, hot, and unrewarding
occupation. Hand mills gradually adopted
guides mounted on rest bars to strip the
bar from the pass and direct the bar onto
tables. This practice was called guide
rolling. With advent of continuous mills
and increasing speeds, guides were
Shape of exit metal
Shape of exit metal

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