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Principles and Applications of Metal Rolling 1st Edition
Siddhartha Ray Digital Instant Download
Author(s): Siddhartha Ray
ISBN(s): 9781107076099, 1107076099
Edition: 1
File Details: PDF, 20.45 MB
Year: 2016
Language: english
Principles and Applications of Metal Rolling
This is a book written by a practitioner. It is somewhat different from a normal textbook
involving machines and equipment in the field of Mechanical Engineering. Generally
stress is given to the theories and principles involved and processes are explained in
great detail. There is no doubt that these are essential for an engineer. But it is equally
important for an engineer to know the basic design, working principle and operation of
various machines/equipment used for conversion of raw materials into desired products.
The introduction of laboratories, workshops and industrial tours help fill this void to
some degree. Yet, engineering curriculum retains the deficiency.
Meant for undergraduate and graduate students, this book attempts to fill the
void in the sub-field ‘Rolling Process’. It also intends serving as a reference book for
practicing engineers. It begins with comprehensive coverage of rolling processes and the
mechanics of rolling, which is the theoretical content of the subject. This is followed
by a chapter on ‘rolling practices’ that highlights plant level procedures and practices
employed by the rollers for producing desired products. The book concludes with the
description, operation and design principles of various equipment, mechanisms and
systems used inside a rolling plant.

Siddhartha Ray is professor in the Mechanical Engineering Department and Dean

(UG Programmes) at Heritage Institute of Technology, Kolkata. Earlier he taught,
for a decade, at the National Institute of Technical Teachers’ Training & Research,
Kolkata, where he also served as the Director for about two and half years. Before
joining the academia in 2001 Ray spent more than thirty years in various industries,
designing and developing machines and systems for rolling mills and other kinds of
material handling plants. He has published a number of technical and research papers,
and he also holds two patents. Besides teaching and research, he enjoys writing popular
science books and articles in Bengali.
Principles and Applications of
Metal Rolling

Siddhartha Ray
4843/24, 2nd Floor, Ansari Road, Daryaganj, Delhi - 110002, India
Cambridge University Press is part of the University of Cambridge.
It furthers the University’s mission by disseminating knowledge in the pursuit of
education, learning and research at the highest international levels of excellence.
www.cambridge.org
Information on this title: www.cambridge.org/9781107076099
© Siddhartha Ray 2015
This publication is in copyright. Subject to statutory exception
and to the provisions of relevant collective licensing agreements,
no reproduction of any part may take place without the written
permission of Cambridge University Press.
First published 2015
Printed in India
A catalogue record for this publication is available from the British Library
Library of Congress Cataloging-in-Publication Data
Ray, Siddhartha.
Principles and applications of metal rolling / Siddhartha Ray.
pages cm
Includes bibliographical references and index.
Summary: “Discusses the entire gamut of rolling process and the practices followed in rolling
industry and operation and use of various rolling mill equipment and systems”-- Provided by
publisher.
ISBN 978-1-107-07609-9 (hardback)
1. Rolling (Metal-work) I. Title.
TS340.R39 2015
671.3’2--dc23
2015004528
ISBN 978-1-107-07609-9 Hardback
Cambridge University Press has no responsibility for the persistence or accuracy of
URLs for external or third-party internet websites referred to in this publication,
and does not guarantee that any content on such websites is, or will remain,
accurate or appropriate.
 This book is dedicated to the memory of my mother
Sadhana Roy
She remains the main source of inspiration in my life.
Contents

List of Figures x
List of Tables xviii
List of Symbols xix
Preface xxi
Acknowledgments xxiii

1. Introduction to Rolling Process 1

1.1 Definition of Rolling Process 1
1.2 Hot and Cold Rolling Processes 2
1.2.1 Hot rolling 2
1.2.2 Cold rolling 3
1.3 Brief History of Rolling 5
1.3.1 The early history 5
1.3.2 Modern steel rolling plants 6
1.3.3 Modern non-ferrous rolling plants 7
1.3.4 Modern cold rolling facilities 8
1.4 Deformation of Materials 9
1.4.1 Elastic and plastic deformation 9
1.4.2 Size effect and strain hardening 12
1.4.3 Mechanical working and recrystallization 14
1.4.4 Hot and cold rolling and recrystallization 15
1.5 Classification of Rolling Mills and Rolling Stands 17
1.5.1 Classification 17
1.5.2 Rolling mill stands 20
1.5.3 Roll arrangement in mill stands 20
2. Mechanics of Rolling 30
2.1 Characteristics of Rolling 30
2.1.1 Draught and reduction 31
2.1.2 Elongation 31
2.1.3 Spread 32
viii Contents

2.1.4 Contact angle, angle of bite and area of contact 33

2.1.5 Rolling friction 34
2.1.6 Neutral point and forward slip 35
2.1.7 Forward slip and effective working diameter in grooved rolls 36
2.1.8 Pitch line and rolling line 38
2.1.9 Grooved rolls and passes 39
2.1.10 Spread in section rolling 42
2.1.11 Elastic deformation of components vis-à-vis set roll gap 46
2.1.12 Roll flattening 47
2.1.13 Dark mode rolling 49
2.1.14 Roll bending and roll camber 49
2.1.15 Pass schedule 50
2.2 Stresses in Rolling 52
2.2.1 Distribution of stress and strain across rolled strip thickness 52
2.2.2 Contact stresses in two-dimensional deformation 54
2.2.3 Specific pressure in the case of slip with a constant 60
coefficient of friction (dry friction)
2.2.4 Contact stress under alternative theories of contact friction 72
2.3 Rolling Force 75
2.3.1 Direction of forces in simple rolling 75
2.3.2 Determination of roll separating force 78
2.3.3 Formulae for calculation of mean rolling pressure 93
2.4 Rolling Torque and Power 98
2.4.1 Lever arm method 98
2.4.2 Rolling power calculation 101
3. Rolling Practices 104
3.1 Layout of Stands 105
3.1.1 Single stand 105
3.1.2 Multi stands side by side 105
3.1.3 Looping train 106
3.1.4 Two-stand tandem mill 107
3.1.5 Stepped trains of side by side stands 107
3.1.6 Tandem continuous stands 107
3.1.7 Semi-continuous mill layout 109
3.1.8 Cross-country mill layout 109
3.1.9 Chequerboard mill layout 109
3.2 Rolling Applications 110
3.2.1 Introduction 110
3.2.2 Rolling of steel blooms, slabs and billets 110
 Contents ix

3.2.3 Rolling of plates 122

3.2.4 Rolling of bars and rods 126
3.2.5 Rolling heavy sections 137
3.2.6 Rolling of non-ferrous metals and alloys 143
3.2.7 Cold rolling of sheet, strip and foil 146
4. Rolling Equipment and Systems 168
4.1 Mill Stand Components and Mechanisms 168
4.1.1 Rolling mill rolls 169
4.1.2 Roll neck bearings 186
4.1.3 Roll chocks 197
4.1.4 Mill housings 201
4.1.5 Mechanisms for roll adjustment and roll balance 205
4.1.6 Roll change device 217
4.1.7 Sendzimir cluster mills 220
4.1.8 Guides and repeaters 223
4.1.9 Guide tables and loopers 228
4.2 Mill Drive 229
4.2.1 Mill couplings 229
4.2.2 Gear box and pinion stand 232
4.2.3 Spindles 237
4.2.4 Rolling mill electrics 241
4.3 Auxiliary Equipment and Systems 252
4.3.1 Shears and saws 252
4.3.2 Straightening and leveling machines 259
4.3.3 Coilers and decoilers 263
4.3.4 Roller table 271
4.3.5 Miscellaneous equipment 276
4.3.6 Automatic gauge and shape control system 277
4.3.7 Roll lubrication and cooling system 283
Suggested Readings 291
Index 292
List of Figures

1.1 Products produced by hot rolling 3

1.2  Schematic flowchart for the production of various finished and 4
semi-finished steel products which pass through rolling process
1.3 Variation of net interatomic force with interatomic distance 9
1.4 Scheme of plastic deformation in perfect crystal 10
1.5 Mechanics of slip in perfect crystal 11
1.6 Crystal deformation through movement of edge dislocation 12
1.7 Carpet analogy 12
1.8 Strain hardening effect 13
1.9 Effect of grain size on strength and ductility of annealed brass 14
1.10 Effects of mechanical working 15
1.11 Schematic representation of the hot-rolling process, showing 17
the deformation and recrystallization of the grains of metal
being rolled
1.12 Comparison of conventional and prestressed mill stand 28
for 10.75″ & 18″×18″ mill
1.13 4-Hi hydraulic stand with roll load cylinder 29
2.1 Simple rolling process with rectangular stock 31
2.2 Deformation of billet in rolling 32
2.3 Entry of material into the roll gap 34
2.4 Position of neutral point 35
2.5 Initial and final contact conditions-oval-round 37
2.6 Position of effective roll dia. for an oval groove 38
2.7 Underdraught and overdraught in rolling 39
2.8 Grooved roll drawing showing collars and collar holes 40
2.9 Open and closed passes 41
2.10 Causes of end thrust 41
2.11 Common types of passes 42
2.12 Equivalent rectangle method 43
2.13 The Ekelund spread nomogram 45
 List of Figures xi

2.14 Effect of elastic deformation on final stock thickness 47

2.15 Roll flattening phenomenon 48
2.16 Dark mode rolling 49
2.17 Horizontal projection of the peripheral roll velocity 53
2.18 Above: diagram showing the velocity of a rolled strip at different 54
points in its cross-section as it passes through the deformation zone.
Below: diagram showing the velocity distribution for different
cross-sectional depths
2.19 The variation of velocity with depth in the rolled strip shown at 54
various points along its length, with hm:l > 2 and D cos α > hn
where D = roll diameter and hn is strip thickness at neutral zone
2.20 Elementary forces acting on the rolled metal in the zone of 55
backward slip
h
2.21 Determination of x and x 61
2
2.22 The distribution of the specific pressure along the arc of contact 65
during slipping with dry friction τ =µpx
2.23 Theoretical distribution curves of the specific pressure along 68
the arc of contact (with τ =µpx) for two-dimensional rolling with
different coefficients of friction with other rolling parameters of:
reduction = 30%; α = 5°40′ and D = 86.
h1
2.24 Theoretical distribution curves of the specific pressure over the 69
arc of contact (with τ = µpx ) for two-dimensional rolling with
different reductions (Dh/h0 = 0.1, 0.2, 0.3 and 0.5) and keeping
output thickness constant (d/h1 = 200), other conditions are
identical, work hardening effect is neglected, and µ = 0.2
2.25 Theoretical distribution curves of the specific pressure along
the arc of contact (with τ = µpx) for two-dimensional rolling
with rolls of different diameters:D/h1= 100, 200, 350; reduction
of 30% and µ=0.3 70
2.26 Theoretical distribution curves of the specific pressure along 71
the arc of contact (with τ = µpx) in the case of two-dimensional
rolling with different tension
2.27 Theoretical distribution curves of the specific pressure along 71
the arc of contact (with τ =µpx) in the case of two-dimensional
rolling with different arcs of contact but with the same horizontal
projection of the arc of contact: Curve 1: tanφx < µ along the
entire arc of contact; Curve 2: tan φx > µ at the beginning of
the arc of contact
xii List of Figures

2.28 The distribution of specific pressure and specific friction 73

forces along the arc of contact during two-dimensional rolling
according to different theories: dry friction (Von Karman),
constant friction force (Siebel), and viscous friction (Nadai)
2.29 Variation of the specific pressure and specific friction forces 74
along the arc of contact for two-dimensional rolling with different
l: hm ratios: (a) l:hm > 5; (b) l:hm (2–5; (c) l:hm ( 0.5–2;
(d) l:hm <0.5
2.30 Resultants of the elementary forces exerted by the roll on the 75
rolled metal
2.31 Direction of overall resultant forces exerted by the roll on the 76
rolled metal in a simple rolling process
2.32 Direction of the resultant forces applied to the rolls in a simple 77
rolling process
2.33 Forces acting on the roll 78
2.34 Types of reduction effected by rolling: (a) a rhombus from 82
a rhombus; (b) an oval from a square; (c) a square from an oval;
(d) a circle from an oval
2.35 The effect of the reduction during cold rolling on the yield 86
point of steel (0.1% C), copper, and zinc
2.36 Variation of the ultimate strength of mild steel with strain
rate at various temperatures in °C (A. Nandai and M. Manjone) 87
2.37 Variation of yield stress of mild steel with 0.15% C with the 88
h
strain rate when log e 0 = 0.3 for various temperature
h1
2.38 Variation of the coefficient, n′s, which determines the effect 91
of external friction on contact pressure, depending on δ at
various Dh/h0
2.39 The effect of back and front tensions on the decrease in the 92
specific pressure during the cold rolling of steel strip at reduction
of 20%, 30%, and 40%
2.40 Variation of the value of the coefficient C in formula 2.66 with 95
ratio ld/h (A. Geleji)
2.41 Variation with temperature of kf of a plain carbon steels 96
(C < 0.6%; Si < 0.5% and Mn < 0.8%), characterized by
ultimate strengths of 40, 60, 80, and 100 kg/mm2 in the
cold state (A.Geleji)
2.42 Variation of the ratio pm/2k with reduction for various ratio 97
r / h1 according to the formula of Sims
2.43 Diagram illustrating the meaning of lever arm and torque 98
 List of Figures xiii

3.1 Single stand layout 105

3.2 Three stands side by side 105
3.3 (a) Alternate 2-Hi looping train 106
3.3 (b) 2-Hi offset stands looping train 106
3.4 Two stand tandem mill 107
3.5 Stepped open train 107
3.6 Continuous stands with (a) group drive and (b) individual drive 108
3.7 Semi-continuous mill layout 108
3.8 Cross-country mill layout 109
3.9 Chequerboard mill layout 110
3.10 Layout of a 730/530 mm 12 stands continuous billet mill 111
3.11 Prevention of laps due to overfilling in bloom rolling 112
3.12 2-Hi blooming rolls and pass sequence- using a bullhead 114
3.13 Blooming rolls and pass sequence- using grooved passes 115
3.14 Roll of a slabbing mill 116
3.15 Billet mills of different types 118
3.16 Diamond–square pass sequence for a billet mill 121
3.17 Layout of a plate mill 125
3.18 Schematic layout of rolling equipment and shears in a 350 mm 126
diameter continuous section mill
3.19 Layout of a bar and wire rod mill 128
3.20 Layout of a bar and wire–rod mill 129
3.21 Single plug method of cutting finishing pass for rounds 130
3.22 Determination of leading ovals 132
3.23 Comparison of square–oval and slug–oval method 134
3.24 Square–oval and oval square reduction– normal and gothic square 135
3.25 A typical oval–slug sequence of rolling rounds 136
3.26 Rolling of rounds by the oval–round method: 3/4 in. rounds 137
from 4 in. billets in 12 passes
3.27 Layout of rolling stands and equipment in a rail and structural mill 138
3.28 Types of passes for rolling rails 138
3.29 Two types of rail rolling sequence (passes numbered in the 139
order of rolling)
3.30 Basic type of passes for joist rolling 140
3.31 Pass sequences for beam rolling 141
3.32 Types of passes for rolling channels 142
3.33 Elevation of a three stand tandem cold strip mill 147
3.34 Stress curve- aluminum (pure and common alloys) 165
3.35 Stress curve- aluminum (strong alloys) 165
3.36 Roll pressure function – f3 166
xiv List of Figures

3.37 Torque function – f5 166

3.38 Values of R1/R for reduction stress P/∆h as per Hitchcock’s formula 167
4.1 Plain roll 169
4.2 Grooved roll 170
4.3 Evenly distributed load centrally placed in the rolls 180
4.4 Determination of stress magnification factors 181
4.5 Dependence of the coefficient of friction of textolite bearings, 188
with water lubrication, on sliding speed at various specific
pressures.
4.6 Arrangement of linings in open bearing in two-high and three- 188
high mills
4.7 Fabric bearing 189
4.8 Radial thrust oil–film bearing for back-up roll of 2500 mm 189
wide continuous cold rolling mill
4.9 Diagram of boring of sleeve-lining of bearing 190
4.10 Double row spherical roller bearing arrangement on the roll 192
neck of a medium section mill
4.11 Back-up roll neck of a four-high hot mill fitted with four 193
row cylindrical roller bearing and double acting taper roller
thrust bearing.
4.12 Cut sectional view of a four-row taper roller tapered bore bearing 194
assembly fitted on a back-up roll neck of a 4-Hi mill
4.13 Hydraulic mounting of a bearing using a hydraulic nut 195
4.14 Arrangement of work roll and backup roll chocks within window gap 198
4.15 Dimensions of a 2-Hi work roll chock 199
4.16 Dimensions of a 2-Hi back-up roll chock 200
4.17 Approximate minimum work roll chock sections of a four 200
high mill. These values are subject to change by the mill
equipment designer to suit specific mill
4.18 Stand housings 201
4.19 Housing under tension 202
4.20 Various cross-sections of housing posts 203
4.21 General view of the housing assembly of a 1000 mm blooming 204
mill. Weight of one housing 62 t, material-graded cast steel
4.22 General view of the housing assembly of 500 and 1200 × 2500 mm 205
four-high stand in a tandem cold rolling mill. Weight of one
housing 111 T
4.23 Schemes of manual top roll adjusting mechanisms 207
4.24 Stand of 1000 mm blooming mill (lateral cross-section) 209
 List of Figures xv

4.25 Kinematic diagram of drive for screw-downs in 1000 mm 210

blooming mill
4.26 Stand of a 1100 mm blooming mill with hydraulic top roll balancing 211
4.27 Diagram of top roll adjusting mechanism with spring 211
counterbalance arrangement in a three-high plate mill
4.28 Diagram of screw-down drive in a four-high 500and1250×1700 212
reversing cold rolling mill. Gear ratio from motor to screw-down
is 1080
4.29 Diagram of hydraulic roll balancing in four-high 610 and 213
1240×1680 stand
4.30 Safety devices: (a) safety sleeve, (b) wedge. 214
4.31 Axial adjustment of rolls rarely moved 215
4.32 Axial adjustment of rolls moved frequently 215
4.33 Axial fixing of plain roll mounted in roller or oil–film bearings 216
by triangular fixing strips
4.34 Diagram of axial fixing of rolls in four-high mill by hinged pawl 216
4.35 Diagram of roll change with crane 218
4.36 Diagram of rack and pinion mechanism for changing roll with 219
roll box
4.37 Diagram of sliding trolley mechanism for changing back-up 220
rolls in a four-high mill
4.38 Roll arrangement of type 1-2-3-4 Sendzimir mill 221
4.39 Pressure saddles supporting backing bearing assembly in 222
Sendizimir mill
4.40 Lateral adjustment of 1st intermediate rolls 223
4.41 Guides 224
4.42 Outside fastening of cramp bar by bolts 224
4.43 Fastening of side guide on cramp bar 225
4.44 Non-twist entry guide consisting of a box and side guides 225
4.45 Roller entry guide for ovals 226
4.46 Roller twist guide fixed at mill exit 227
4.47 Repeater with open looping trough 227
4.48 Scheme of a looper in skelp mill 229
4.49 Geared coupling 230
4.50 Improved shape of teeth in a geared coupling with barreling 230
(elliptical cross-section)
4.51 Flexible coupling with spiral springs (Bibby) showing 231
deformation of springs under loads
4.52 Diagram of 1, 2 and 3 stage reduction gear 232
4.53 Diagram of group reduction gears 233
xvi List of Figures

4.54 Dimensioned drawing of a reduction gear box with gear ratio 235
i = 6.35, maximum torque on slow-speed shaft 8.73 tm
4.55 Arrangement of pinions of different pinion stands 236
4.56 Sectional elevation view of a 2-Hi pinion stand 237
4.57 Diagram of arrangement of universal spindles 238
4.58 Wobbler coupling 238
4.59 Wobbler connection of breakdown 500 mm three-high section mill 239
4.60 Palm joint of universal spindle 240
4.61 Mill spindle with two half gear couplings at two ends 240
4.62 Spring balancing of spindles with arrangement of springs on 241
one side
4.63 DC motor connection with series field required for high 242
starting torque
4.64 DC motor connection with shunt field required for normal 243
starting torque but speed increase with field weakening beyond
base speed
4.65 DC motor connection with compound field. Best for high 243
starting torque but good speed control
4.66 AC slip ring motor with rotor resistance control, suitable for 244
controlled starting torque and current
4.67 3-phase synchronous motor with separate excitation 244
4.68 Three functions of a tyristor converter 245
4.69 AC VVVF drive 245
4.70 Torque control scheme 246
4.71 Large synchronous motors with variable frequency converter 248
used for tandem hot strip mills
4.72 Typical electrical scheme for 6-stand tandem hot strip mill 248
4.73 (a) Mill DC motor control with thyristor converter. Both 250
armature and field by DC voltage control with six pulse controller.
A two quadrant operation
4.73 (b) Thyristor Converter with 12-pulse controller 250
4.74 Drive and control for a 4-High reversing cold rolling strip mill 251
4.75 Arrangement of shear blades 253
4.76 Motor operated shear with 1000 t shearing force for shearing blooms 254
4.77 Dimensioned drawing of a Multi-knife rotary shear with side 256
scrap cutter for cold shearing of maximum 6 mm strips /
sheets up to 1500 mm wide
4.78 Drum shear with feed rollers 1 and shear 2 257
4.79 Diagram of the movement of knives in two-drum flying 257
shears operating from stationary position
 List of Figures xvii

4.80 Sliding frame circular saw 258

4.81 The most common type of saw tooth for hot cutting of steel 259
4.82 500 T straightening press 260
4.83 Arrangement of rolls in a straightening machine 260
4.84 Chequerboard arrangement of backup rolls in relation to 261
bending roll
4.85 8-roll heavy section straightening machine side view 261
4.86 8-roll heavy section straightening machine front view 262
4.87 Diagram of rotation straightening machines with rolls set 263
obliquely (driven rolls have rotary arrow; rolls taking part in
the straightening process have vertical force arrows.)
4.88 Arrangement of tension coiling drums in a reversing cold 264
rolling mill
4.89 (a) General view of coiler with overhung expanding mandrel 265
4.89 (b) Sectional view of an expanding /collapsing mandrel of a coiler 266
4.90 Roll type coiler with three wrapping rolls (upcoiler). 267
4.91 Diagram of multi-roll down coiler 268
4.92 Roll and drum machine for coiling strip up to 1550 mm wide 268
4.93 Diagram of laying rod reel, Edenborn type 269
4.94 General view of pay-off with overhung drum and slipping brake 270
4.95 Operation of double cone decoiler 271
4.96 Typical group driven receiving table of 1150 blooming mill 273
4.97 A typical dimensioned drawing of a Roller with separate drive 273
by flanged motor through gear coupling
4.98 Diagram of light tilting table with balancing arrangements 274
by weight
4.99 Diagram of roller drives for tilting tables 275
4.100 Diagram of primary mill manipulator with drive located on side 276
4.101 Diagram of a bobbin-type manipulator 276
4.102 4-Hi stand with roll load cylinder and hydraulic roll balancing 278
arrangement
4.103 HAG control scheme 279
4.104 Tension measuring sensor roll 282
4.105 Schematic diagram of a re-circulating type roll coolant system 288
List of Tables

1.1 Lowest recrystallization temperature of common metals 16

1.2 Classification of rolling mills by function 18
1.3 Roll arrangement and use of stands with horizontal rolls 20
1.4 Diagram of stands with vertical rolls and universal stands 25
1.5 Mill stands with inclined rolls 27
2.1 The coefficient of friction during hot rolling of non-ferrous 89
metals at the instant of gripping
2.2 Coefficient of friction under cold rolling of different materials 90
under different conditions
2.3 Average values of λ for all results determined by Ford 99
2.4 Average values of λ′ for all results determined by Ford 100
2.5 Values of the coefficient of friction for various types of 102
roll-neck bearings
3.1 Typical slabbing mill pass schedule 117
3.2 Specifications of Sendzimir 20-Hi cold rolling mills 148
3.3 Recommended maximum pass reduction and maximum 152
cumulative reduction in cold rolling of different metals and alloys
4.1 Maximum permitted angles of bite and ∆h/D 171
4.2 Roll neck dimensions 173
4.3 Hardness figures, tensile strengths and approx. shear strength 178
for steel rolls
4.4 Basic properties of textolite, lignofol, lignoston and bronze 187
4.5 Clearance between chock and window 199
List of Symbols

x,y,z three rectangular coordinates

F force
FR repulsive force
F­A attractive force
ro inter-atomic distance
τo ultimate shear stress
G modulus of rigidity
Hi abbreviation of “High”, signifying number of rolls in a mill stand
h thickness of stock/workpiece
h1 input thickness
h 2 , h0 output thickness after deformation through rolling
hn thickness at neutral axis
w,b width of stock/workpiece
w1,b1 Input width
w2,b2 output width after deformation
w m,bm mean width
A1 cross sectional area of stock/material at input
A2 cross sectional area of output after deformation
L1 length of stock/workpiece at input
L2 length of stock at output after deformation
α contact angle or angle of bite/contact
∆h,(h1-h 2), δ draught or reduction in height/thickness
E′ elongation factor
∆w, ∆bm, (b2-b1) spread
R,r roll radius
D roll diameter
l projected length of arc of contact
µ coefficient of friction
N neutral point
αn, γ neutral point angle
v1 stock velocity at entry
v2 stock velocity at output
xx List of Symbols

hg set roll gap

γ poisson ratio
E Young’s modulus
∆f mill stretch
R′,r′ Deformed roll radius
hm mean thickness of stock/workpiece
v n, v r roll surface velocity
vx roll surface velocity in the direction ‘x’
φ angle subtended by a point on roll surface within roll bite
φx Angle subtended by a point on roll surface at a distance x from
roll axis.
σx, σy, σz normal stresses
k, τs shear yield stress
τx contact shear stress
σ1, σ2, σ3 principal normal stresses
τxy, τyz, τzx Shear stresses
τ1, τ2, τ3 principal shear stresses
σ yield stress
σa actual resistance to deformation (tensile yield stress)
σt ultimate strength
σA tensile stress due to back tension
σB tensile stress due to front tension
η coefficient of viscosity
F horizontal projection of contact area
σs tensile yield stress of annealed metal
T absolute temperature
s specific heat of metal
t rolling temperature, 0c
∆t time interval, seconds
A energy required to deform metal
W weight of metal in kg
u, e. strain rate, sec-1
e Strain
p contact pressure between roll and stock,
a Length of lever arm
λ lever arm coefficient
T Torque
kw Kilo-watt
HP horse power
HAGC Hydraulic automatic gauge control
EDC Edge drop control
Preface

Organization of this book is somewhat different from a normal textbook involving

machines and equipment, in the field of mechanical engineering. Generally, stress
is given to the theories and principles involved and the processes are explained to
a great detail. There is no doubt that these are essential for an engineer. But it is
equally important for an engineer to know the basic design, working principles and
operations of the various machines and equipment which are used in the practical
field for conversion of the raw materials into desired products. Baring the subject
of ‘Machine Tools’, in most other fields of manufacturing processes, available
textbooks seem to be rather miserly in thorough discussions on the description,
design, working principles of various machines and systems involved and practices
followed in actual operation.
An attempt has been made to bridge this gap by introducing laboratory exercises
and workshops along with industry visits, in the engineering curricula. More often
than not these prove to be inadequate. It is next to impossible that an equipment
or machine like a turbine, an extrusion press or a rolling mill can be installed in an
academic institution. By observing the operation of a machine or system during a
visit to an industrial plant, definitely a lot can be learned about the manufacturing
process, but seldom can it give an idea about the working principles of the various
mechanisms, their design details or about the intricacies of operational practices.
While teaching ‘Manufacturing Technology’ to MTech students at the National
Institute of Technical Teachers’ Training and Research (NITTTR), Kolkata, I
observed this shortcoming in my students and cherished the desire to bridge
the gap as soon as possible. With 30 years’ experience in the industry in design,
development and commissioning to operation plant and machinery (out of which
more than half the period was in the field of Rolling Mills), I decided to write this
book titled Principles and Applications of Metal Rolling.
This book is intended to cover undergraduate and postgraduate engineering
curricula for ‘Rolling Technology’ in India and in other countries. It is also meant
to be a reference book for practicing engineers working in the field of rolling
mills. The first two chapters cover the rolling process and mechanics of rolling
xxii Preface

comprehensively, which is the theoretical content of the process of rolling. The

third chapter on ‘Rolling Practices’ highlights plant level procedures and practices
employed by the rollers for producing desired products. The whole of the fourth
chapter on ‘Rolling Equipment and Systems’ is devoted to the description, operation
and design principles of various equipment, mechanisms and systems used in a
rolling plant.
In preparing the book, help has been taken from some specialized books
written and edited by experts and from the literature of equipment manufacturers.
Acknowledgement and references to such books and literature have been made at
appropriate places.
Suggestions and comments on the organization and contents of the book are
welcome and may kindly be sent to the publisher or the author.
Acknowledgments

While writing this book I have received help, suggestions and encouragement from
many of my ex-colleagues, friends and well wishers, which I gratefully acknowledge.
At the very outset I would like to express my appreciation to my MTech
students of Manufacturing Technology course offered by the National Institute of
Technical Teachers’ Training and Research (NITTTR), Kolkata. While teaching
and discussing the subject of Rolling Technology with them, I got impetus to write
the present book. I am indeed thankful to them.
During the writing of this book I have drawn upon the knowledge and experience
I received while working with M/s Davy Ashmore India Ltd., in close contact with
their collaborators in the UK – Davy Lowey Ltd. and Loewy Robertson Engineering
Company of the UK, and later with M/s Tata Construction and Projects Limited. I
would like to acknowledge my deep sense of gratitude to the following persons, who
gave me the opportunity to work in the field of design and operation of Rolling Mills
and also gave me all possible help and cooperation during the writing of this book:
Late P. Sen, Ex.-M. D. of Davy Ashmore India Ltd. and my ex-colleagues
P. K. Bera and A. K. Mitra. I am particularly indebted to S. Bhattacharya from the
same organization, who advised me while writing the topic on Mill Electrics.
I am also grateful to friends from the Davy Group of companies in the UK,
namely: T. Shiemeld, T. Smith, A. F. Uff, D. Fretwell and others who helped me
with information and material on the subject as and when I needed them. I am
thankful to S. Majumdar, Ex President of Hindalco and colleagues at NITTTR,
Kolkata and Heritage Institute of Technology, Kolkata for advising and encouraging
me during the preparation of the book.
My thanks are also due to T. K. Dutta, an ex-colleague of Davy Ashmore, who
joined later M/s. SMS Demag, India, for giving me valuable suggestions on Roll
Lubrication and Cooling System.
I am thankful to Kingshuk Ghosh, the DTP operator of my department at
NITTTR, who untiringly finished the entire manuscript, working beyond his
working hours. My thanks go to G. Patra for preparing some of the diagrams
using CAD.
xxiv Acknowledgments

I am grateful to my wife Dipali Ray and other family members for their constant
encouragement and sacrifices during the preparation of the book.
Finally, my thanks are to the Cambridge University Press for readily accepting
to publish the book.
 Introduction to Rolling Process 1

CHAPTER 1

Introduction to Rolling Process

1.1 Definition of Rolling Process

Rolling is the most important metal forming process. More than 95% of ferrous and
non-ferrous metals and alloys are processed to their usable shapes by rolling. Usable
shapes of rolled metals are plate, sheet, strip, foil, different sections like rail, beam,
channel, angle, bar, rod, and seamless pipe, etc., as shown in Fig. 1.1 and Fig. 1.2.
In the rolling process, permanent deformation is achieved by subjecting the
material to high compressive stress by allowing the material to pass through the
gap between two rotating cylindrical rolls.
The rolls may be flat or grooved, and are kept at a fixed distance apart from
each other. The rolls are rotated in opposite direction by means of electrical drive
system (motor, gearbox, spindle and couplings).
Depending on the direction of rotation of the rolls, the input material enters
the gap between the rolls from one end and comes out from the other end with a
reduced cross-section, the roll gap area being kept less than the cross-sectional area
of the input material (rolling stock). For obtaining the desired final shape of rolled
material, it is generally necessary to pass the material through the rotating rolls
several times. During each of the passes, the roll gap is adjusted by bringing the
two rolls closer to each other, or by allowing the material to pass through different
set of roll gaps with diminishing cross sectional area.
The entire assembly of the rolls mounted on bearings is held in bearing blocks
(called chocks), which in turn are held between the gaps of two cast frames (called
housings), complete with roll gap adjustment facilities and roll driving arrangement.
The entire set up is called a rolling mill stand. One or more number of rolling stands
in combination with other necessary and related equipment to obtain finished
rolled products from one or similar group of input materials is called a rolling mill
or rolling plant.
Rolling process can be classified based on various conditions/methods employed
in rolling. These are:
(i) Temperature of the material- thus we can have hot rolling (temperature
above the recrystallization temperature), warm rolling and cold rolling.
2 Principles and Applications of Metal Rolling

(ii) Shape of the rolled product- flat, sections or hollow sections rolling.
(iii) Direction of rolling- lengthwise, transverse, and skew rolling.
(iv) Mode of rolling mill operation- continuous (unidirectional), and reverse
rolling, where direction of rotation of rolls are reversed.
When two rolls of equal diameter and with axis lying in same plane rotate in
opposite direction with same rotational speed, and the material being rolled is
homogeneous in its mechanical properties and is acted upon only by the forces
from the rolls, the process is called simple rolling.

1.2 Hot and Cold Rolling Processes

From metallurgical point of view, rolling process can be classified under two broad
categories, namely (i) hot rolling and (ii) cold rolling.

1.2.1 Hot rolling

In hot rolling the material is rolled at a temperature higher than its recrystallization
temperature. The advantage of hot rolling is twofold. First, at elevated temperature
the strength of any metal or alloy is reduced. Thus the compressive force required
for deformation is comparatively less and therefore smaller capacity rolling stand
can be used for rolling operation . The second advantage of rolling a material at
a temperature higher than its recrystallization temperature is that a large amount
of plastic deformation can be imparted without getting it strain hardened . With
strain hardening, the deformation stress increases as more and more deformation
takes place rendering the material hard and brittle. As a result, the material becomes
more and more difficult to be deformed, and beyond limit, deformation leads to
various faults or defects.
The ferrous raw material for rolling various shapes is the ingot which is cast out
of molten metal. In case of low carbon steels the ingot is quite large. It is first rolled
into blooms. The blooms are rolled into smaller sizes, called billets. Large structural
sections such as rails, beams, girders, channels, angle sections, and plates are rolled
out of blooms, while billets are rolled into smaller structural sections, bars, plates,
and strips. Alloy steel and stainless steel, produced in mini steel plants, are generally
cast into smaller sizes of ingots. Non-ferrous metals like aluminum are cast into
wide slabs, from which plates, sheets, and strips are obtained.
The above practice still goes on in older plants. However, the present trend is to
install continuous casting units to cast smaller sections directly from liquid metal
and thus eliminate bloom rolling. In some continuous casting plants, billets of small
cross sections may also be continuously cast, thus eliminating even the billet rolling
mill. Installation of continuous casting results in substantial saving in capital cost
 Introduction to Rolling Process 3

of the rolling plant as well as rolling process cost. Non-ferrous alloys of aluminum,
brass, nickel-silver, etc., are continuously cast in bar or strip form.
Rolling of ingots to blooms and blooms to billets, and further rolling of blooms
and billets to different usable products like structural sections, bars, plates, and
strips are all rolled through hot rolling. Some of the products produced through
hot rolling process are illustrated in Fig. 1.1.

Fig. 1.1 Products produced by hot rolling

1.2.2 Cold rolling

When rolling of a material is done at room temperature or below the recrystallization
temperature of the material, it is called cold rolling. Obviously, the advantages of hot
rolling is absent in cold rolling. The resistance to deformation is more. Furthermore,
during rolling, strain hardening takes place, i.e., the strength of the material
progressively increases with increase in degree of deformation in the original material.
However, there are a few advantages also. The first one is about controlling the
grain size and thereby achieving the desired mechanical properties of the finished
rolled material. When the input material is cold rolled, the grains of the input
material get elongated along the direction of rolling. Thus the effective grain size
is reduced, as the surface area of each grain increases whereas their volume remains
the same. With subsequent passes of rolling, the elongated grains break and the
grain size becomes progressively smaller and the material gets harder and harder.
After a certain percentage of volumetric deformation, the cold rolled material
becomes too hard and brittle to be rolled further profitability. At this stage, the cold
rolled material is annealed, which is nothing but heating the material in a neutral
atmosphere (heating in presence of oxygen is avoided to prevent oxidation) above its
4 Principles and Applications of Metal Rolling

recrystallization temperature. By adjusting the time for which the rolled material is
kept at this higher temperature (soaking time), the size of the newly formed grains
of the annealed material can be closely controlled.
Cold rolling is generally done to produce flat rolled products like sheet, plate,
strip, and foil. When the length of the rolled product is too large, the material is
wound and used in the coil form.
In cold rolling, since the degree of deformation, i.e., reduction in thickness
of the flat product in any rolling pass, is kept low to avoid high roll separating
force, several rolling passes are generally required along with requisite number of
intermediate annealing. A number of rolling passes with grain deformation in the
same direction gives a directional bias to the various mechanical properties of cold
rolled products. Such directional bias (anisotropy) often remains even after annealing
after final pass of rolling. This directionality of properties has to be taken care of
during subsequent processing of cold-rolled material.

Fig. 1.2 
Schematic flowchart for the production of various finished and semi-finished
steel products which pass through rolling process
 Introduction to Rolling Process 5

During cold rolling of flat products, the material is passed between two flat
cylindrical rolls of the mill stand. Furthermore, various advanced techniques and
systems are employed to keep the rolled material flat and the thickness of the
finished product within close tolerance throughout the length and width of the
product. These advanced techniques and systems have been discussed in Chapter
3 and 4 respectively.

1.3 Brief History of Rolling

1.3.1 The early history
It is a characteristic feature of engineering and technology that developments
and innovations in different fields of engineering and technology are often not
attributable to any single person, or a specific date, or even a single place, or
country. Engineering and technological developments are induced by social needs,
and are often result of many pioneers over a period of time and places. History of
development of rolling technology is no different.
Rolling of soft metals like gold, silver and perhaps lead was first performed by
goldsmiths for making jewelry. Hand driven rolls of about ½ inches (12.5 mm)
in diameter were in use during the fourteenth century. However, the concept of a
true rolling mill is first found as a sketch in the notebook of Leonardo da Vinci.
There is no evidence that this was ever built.
Before the end of the sixteenth century, at least two mills incorporating basic
ideas of rolling are known to have been in operation. In 1553, a Frenchman named
Brulier, rolled sheets of gold and silver of uniform thickness for making coins. In
1578, a man called Bevis Bulmer, received a patent for operation of a two spindles
slitting mill with series of disc cutters to slit flats into narrow strips.
As per record available, rolling of iron into thin flats was first done in Bristol, the
UK in 1666. As per a pamphlet on ‘British Iron Trade’ published in 1725, all bars were
made by hammering even at that date. By 1682, large rolling mills for hot rolling of
ferrous materials were in operation near Newcastle, the UK. These mills were used
for rolling bars into sheets, which were cut into square rods in slitting machines.
Hot rolling of ferrous material into thin sheets was practiced in many continental
countries, but was monopolized by Germany from the beginning of the seventeenth
century until Major Hanbury started production in Pontypool works in the UK
sometime around 1720[1].
In 1728, a patent was issued to John Payne in England for producing different
rolled shapes using grooved roll. However, there is no proof to support that such
an idea was put to practice.
In 1766, John Purnell of England received a patent for grooved rolls and
arrangement of driving both rolls in unison through use of coupling boxes and nut
pinions. Until this time, rolls were driven individually by water mill.
6 Principles and Applications of Metal Rolling

During this period, the hot mills were evolving to the modern form. William
Playfield’s English patent filed in 1783[2] shows use for cast housings and one
screw on each window for screw down.
By the middle of the eighteenth century, pack rolling came into practice for
producing thin plates for tinning.
The eighteenth century also saw the advent of tandem mill in which metal is
rolled in successive stands. Richard Ford’s English patent in 1766 is the first record
of a true hot tandem mill for producing wire rods. James Cockshutt and Richard
Crawshay, about 1790, built a four-high tandem mill near Sheffield, the UK, with
a capacity of 1 – 2 tons per day. Patents were obtained for tandem mill for rolling
of plates and sheets.
The earliest record of a true continuous wide-strip rolling mill is that built in
1892 at Teplitz in Czechoslovakia[3] (then an Austrian territory) consisting of two
three-high roughing stands and a finishing train consisting of five number two
high continuous finishing stands. The two three-high train and the continuous
five stand train was driven by 1000 H.P. steam engine each. Starting with 8″ (200
mm) thick steel slabs, the mill was reported to be producing sheets up to 50″ (1270
mm) wide strip of thickness between 0.08″ – 0.12″ (2 mm to 3 mm) and in length
up to 60′ (18.29 m).
History of metalworking in the United States began with the arrival of colonists
from Europe. The first American rolling mill was built in 1751 in Massachusetts.
This was used for rolling 3″ (75 mm) wide and 3/4″(19 mm) thick hammered bar
to 1/4″(6 mm) thickness suitable for slitting into nail rods, in 4 passes. In 1793
Isaac Pennoch established a rolling mill which by 1810 was rolling plates in mills
with 16″ – 18″ diameter and 3 – 4 feet long rolls. In same plant around 1820, boiler
plates were rolled by Dr. Charles Lukens (Pennoch’s son-in-law).
The first rolling mill in America to have been powered by a 70 H.P. steam
engine was built by Christopher Cowan in western Pennsylvania. In 1819, the first
angle iron rolled in the US was produced at the Union Rolling Mill in Pittsburg.
By 1825 five rolling mills were in operation in Pittsburg which eventually became
focal point of metalworking industry. Rolling of corrugated plates was patented in
1850. After civil war ended in 1865, rapid expansion of railways gave a tremendous
impetus to the American iron and steel making and rolling industry.

1.3.2 Modern steel rolling plants

Since the early twentieth century, rolling industry saw a continuous string of
developments in terms of size and production capacity, new design of mill stands
and ancillary equipment, increased working efficiency, greater instrumentation and
automation for quality at higher mill speed.
 Introduction to Rolling Process 7

The pioneering effort of Tredegar Iron and Coal Company of South Wales is
worth mentioning. In 1905 Whitehead[4] decided to modernize the continuous
hot mill operation. In one 8-hr shift, the mill could produce 103 tons of 8″ wide ×
0.03″ (0.75 mm) thick material. The plant had continuous furnaces, electric cranes,
flying shears to cut strip coming out from the mill at a speed of 3000 fpm (∼900
mpm), specially designed coilers to coil at fast speed, and many other novel features.
Another milestone in continuous rolling of wide strip was achieved in the Butler
plant established at the Columbia Steel Company of America, which went into
production in 1926, designed and developed by Townsend and Naugle for over a
period of 10 years. This plant[5] included, among others, annealing furnaces, long
continuous pickling line, welding arrangement for joining coils for continuous
operation, and other processing auxiliaries.
After successful operation of the Butler plant, a number of such integrated plants
were erected in the UK and elsewhere. As per data on wide strip mills published
by Davy and United Engineering[6] of the UK in 1960, the largest width capacity
mill was a 108″ (2740 mm) mill in Voroshilov Works in Russia.

1.3.3 Modern non-ferrous rolling plants

Credit goes to the Revere Copper and Brass Company[7] of America for beginning
to roll copper strip in a so-called continuous mill in 1926. In this plant 5″ thick ×
up to 36″ width copper ingot was hot rolled in a two-high reversing mill to about
3/16″ (4.75 mm) thick strip. This strip, after suitable pickling and cleaning was
cold rolled in a 4 stand four-high continuous mill. The plant gradually introduced
mechanized sheet conveying system. In Britain, Imperial Chemical Industries that
has been rolling brass and copper even before the American company, put a highly
mechanized plant in Birmingham in 1933. In 1949, the Scovill Manufacturing
Company[8] in the USA erected one of the most modern brass-rolling plants in
which continuous casting of brass ingots of 2.5″ (63.5 mm) thick and 29.5″(750
mm) wide and more than one ton weight were produced. The ingots were initially
cold rolled to 0.415″ (10.54 mm) in eight passes with two inter-anneals in a massive
two-high mill. The mill stand was equipped with quick roll changing facility and
vacuum cup type stock lifting arrangement was introduced.
The first four-high mill[9] was installed and operated in the UK, in the nickel
and nickel alloy rolling plant of Henry Wiggin and Co. by around 1932 for cold
rolling of these strips.
With gradual increase in consumption of aluminum alloys from the third decade
of twentieth century and specially during and after the World War II, a number of
large and high speed hot and cold aluminum rolling mills were established.
Pioneer of aluminum rolling in Britain was the British Aluminium Company
formed in 1894. By mid 1940s, they laid out a modern aluminum rolling plant at
8 Principles and Applications of Metal Rolling

Falkirk,[10] which included continuous casting units. Thickness of 8″(200 mm) and
about one ton weight slabs were sawed, which were hot rolled, edge trimmed then
coiled for annealing and further cold rolled in both two-high and four-high mills.
The four-high stands using 20″ (508 mm) diameter work roll and 49″ (1245 mm)
back-up rolls and driven by 1500 HP variable speed motor, and rolling 6′ (1829
mm) wide coils at 450 fpm (136 mpm) were built by Robertson of Bedford. This
mill manufacturer, later known as Lowey Robertson’s Engg. Company, played a
significant role in the development of large and high speed aluminum strip and foil
rolling mills with various modern features and quality control systems. The South
Wales Rogerstone works of the Northen Aluminium Co. (Alcan Industries) installed
one of the most modern plants operating in Europe in 1950. This plant included a
three-stand, four-high cold tandem mill. In this mill, coil weighing 1.75 tons could
be rolled to a maximum width of 54″ (1370 mm) and a reduction in thickness of
90% was achieved in one pass through the three stands. The speed of strip from the
last stand was greater than 23 miles per hour (2024 fpm or 613 mpm). Similar mills
with similar production methods and parameters were also established in America.

1.3.4 Modern cold rolling facilities

From 1930’s, cold rolling of hot rolled steel strips became a process of prime
importance. A comparative picture of width and thickness of strip that was cold
rolled between 1923 and 1937 will make the point clear:

Year 1923 1937

Strip width 22″ (560 mm) 10″ (254 mm) 90″ (2290 mm) 35″ (890 mm)
Minimum 0.14″ (3.55 mm) 0.05″ (1.27 mm) 0.038″ (0.96 mm) .01″(0.25 mm)
thickness

Typical strip mills built in the 1930’s are three-stand 84″ wide tandem mill with
about 20½″ diameter work roll, 56″ diameter back-up roll and driven by motors
totaling 6850 HP rolling at speeds up to 540 fpm. Just before and after the World
War II, four-stand tandem mills came into operation. However, since 1960’s five-
stand tandem cold strip mill for rolling ferrous alloys has become the industry norm.
Although most of the tandem mills employ conventional four-high stands, a
unique tandem mill designed for rolling of stainless steel strips up to 50″ (1270
mm) wide commissioned in 1969 by Nisshin Steel Corporation at the Shunan
Works[11] located in Nanyo, Japan, utilizes a train of 6 stands, whose first and last
is two-high stand while the intermediate stands are multi-roll Sendzimir mills.
With limited market of stainless steel, silicon steel, and foil gauge copper alloys,
single stand Sendzimir mills proved to be quite popular for rolling these materials.
 Introduction to Rolling Process 9

In order to meet the demands of high strip quality along with high productivity
(i.e., high rolling speed), substantial improvement has been achieved since 1960’s
in the mill instrumentation, controls and auxiliaries like introduction of Automatic
Gauge Control, Flatness Control and improved Roll Coolant systems.

1.4 Deformation of Materials

1.4.1 Elastic and plastic deformation
Metals are crystalline solids in which atoms are arranged in a well-oriented
pattern. In the absence of any external force in a metal crystal, let the distance
between a pair of atoms be ro. The equilibrium interatomic distance ro is that
distance at which the attractive and the repulsive forces are equal in magnitude.
The slope of the repulsive force curve is always more than that of the attractive
force curve at the point of intersection of the curve. Therefore the equilibrium is
of stable nature. The net inter-atomic force varies with the atomic spacing in a
manner shown in Fig. 1.3, the positive side signifying attractive force. Under the
application of an external tensile force, the interatomic distance increases beyond
ro to maintain the equilibrium. If the external tensile force is of magnitude F,
then the interatomic distance should be ra so that the net interatomic force is
an attractive force of magnitude F, to balance the external force. If ra is not very
much different (of the order of 5%) from ro, when the external force is removed,
the atoms attain their original positions. A similar behavior is also observed with
an external compressive force (when ra < ro). This behavior is called the elastic
behavior of a solid material, and the associated deformation is termed as elastic
deformation.

Fig. 1.3 Variation of net interatomic force with interatomic distance

10 Principles and Applications of Metal Rolling

This phenomenon described for a pair of atoms is also true for normal solids
on a macroscopic scale. It may be noted from Fig. 1.3 that the tangent to the
curve at the point ro coincides with the curve over a small range on either side of
point ro. This indicates that the external force is proportional to the change in the
interatomic distance. Hence, within this elastic range, most solids follow a linear
force deformation rule, and are thus called linear elastic solids.
Now, let us consider a crystal lattice of a solid material with regularly spaced
atoms as shown in Fig. 1.4a. Under the externally applied shear force, the upper
layers of atoms will move to the right and the lower layers will move to the left.
When the applied shear stress reaches beyond a sufficiently high value called the
shear yield stress of the material, the crystal lattice takes the shape as in Fig. 1.4b.
Here, all the atoms are again in equilibrium and will remain so if the external stress
is removed. Thus, a permanent deformation is produced in the crystal lattice. This
permanent deformation is termed as plastic deformation and cannot be recovered
by withdrawing of the external stress.

(a) Original position of atoms (b) Position of atoms after slipping through
distance ‘a’
Fig. 1.4 Scheme of plastic deformation in perfect crystal

The amount of shear stress to cause the deformation between two layers of atoms
in a perfect crystal can be estimated. Referring to Fig. 1.5(a), the shear stress, τ, and
the amount of displacement of the top layer, x, may be approximated by the relation:

τ = τ 0sin 2 πx 1.1
a
This variation is shown in Fig. 1.5(b). For small values of x/a, sin 2πx may
a
be approximated as 2πx . Hence, the foregoing relation can be rewritten
a
approximately as
τ ≈ τ 0 2 πx , where t0 is the ultimate shear stress
a
 Introduction to Rolling Process 11

(a) Atomic arrangement for slip through x (b) Variation of τ with slip

Fig. 1.5 Mechanics of slip in perfect crystal

Now, by definition, shear strain produced is ‘x/b’. Using linear stress–strain

relationship, we can write

τ = τ 0 2 πx = G x 1.2
a b
where the constant G is known as the shear modulus or modulus of rigidity. Thus,
the ultimate shear stress necessary to cause the permanent shear deformation is,

τ0 = G a 1.3
2π b
In a metallic crystal structure, the values of a and b are of the same order, and
as a rough approximation, we can take a ≈ b. Then

τ0 ≅ G 1.4
2π
However, the ultimate shear stresses for different solids and alloys, obtained
through experimentation have always been found to be much less (in the order
of 100 times) than the value of τo as obtained above. This large difference can
be explained only by considering the imperfections that generally always exist
in an actual crystal structure (like point defects, dislocations, interfacial / grain
boundaries, etc.).
Figure 1.6 explains how the movement of an edge dislocation rather than the
movement of a whole plane of atoms can cause a slip by application of less shear
stress (which also means by application of less energy). Here the material is deformed
by breaking and reforming one row of bonds at a time as the dislocation moves
along the plane of slip.
This phenomenon can be appreciated form the following analogy of progressive
movement of a carpet wave.
12 Principles and Applications of Metal Rolling

Fig. 1.6 Crystal deformation through movement of edge dislocation

Let us consider a thick, heavy carpet lying on a floor, which has to be moved
through a distance δ (Fig. 1.7). It can immediately be visualized that a very large
force will be needed if the whole carpet has to be bodily moved over the distance
δ. The same effect, however, can be realized very easily if first a hump is made at
one end of the carpet by moving that end by the distance δ and then this hump is
moved the entire carpet length.

Fig. 1.7 Carpet analogy

1.4.2 Size effect and strain hardening

It has been seen that crystal imperfection like dislocation helps slip. Therefore, if a
very small crystal of a solid that has got very little imperfection, is taken, it will be
difficult to cause slip. Thus strength of a crystal decreases with its increase of size
having more dislocations. This phenomenon is called size effect. However, when a
 Introduction to Rolling Process 13

material is deformed, more and more dislocations take place which interact with
each other. These interactions have the tendency to block movement of various
dislocations and as a result more and more force is required for further deformations,
i.e., the strength of material increases. This gradual increase of strength with
deformation of the material, caused due to interaction and immobility of dislocations
is known as strain hardening or work hardening.
The effect of strain hardening can be understood clearly from a simple tension
test curve, as shown in Fig. 1.8.

Fig. 1.8 Strain hardening effect

If the test piece is loaded beyond the yield point up to P, and then unloaded,
the elastic deformation will recover via the unloading curve PR, which is more or
less parallel to original loading line OA. Out of the total strain OS, the portion
RS is the elastic strain which is recovered. OR is the plastic strain of the test piece
which is not recovered.
If the test piece is again loaded, it will approximately follow the line RP, with
a small deviation due to hysteresis. This indicates that the Young’s modulus of
the material does not change due to plastic deformation. It is interesting to note
that with increased loading, the test piece will start yielding at point P, and will
follow the same stress–strain curve, PEF, which would have been obtained without
unloading, at point P.
Thus the yield point of the test piece after plastic deformation increases from
σ01 to σ02 corresponding to point B and P, respectively, in the figure.
Metals and their alloys are polycrystalline solids. Small, continuous volumes
of solid are known as grains of crystal, and the surfaces that separate the grains
are known as grain boundaries. In a polycrystalline solid, the grain boundaries
also interact with and impede movement of dislocation. In a definite volume of
material, smaller is the size of grains, larger will be the boundary areas causing more
14 Principles and Applications of Metal Rolling

impediments to dislocation movement, resulting in higher strength to deformation.

Similarly, larger grain size with smaller boundary areas results in lower strength.

1.4.3 Mechanical working and recrystallization

Metals do not always posses all the properties required out of it. The material
properties, mainly the mechanical properties, can, however, be changed and
controlled to a large extent by various methods to make the material suitable for a
given application. These methods include (i) alloying, (ii) heat treatment, and (iii)
mechanical working and recrystallization.
As mentioned, the mechanical properties, e.g., strength and hardness of a
polycrystalline material are also governed by the grain size of the material. Figure
1.9 shows the nature of variation of two mechanical properties with the average grain
size. The grain size can be controlled by mechanical working and recrystallization.
In the rolling process, mechanical working and recrystallization are involved. These
processes are discussed briefly below.
When a near spherical grain is deformed into an elongated shape, its volume
remains constant whereas its grain boundary surface area increases. Similarly, if
a large grain of near spherical shape is broken down into a few pieces of smaller
near spherical shapes, then also the volume to surface area ratio reduces. Both these
cases are known as reduction of effective grain size. Different mechanical working
processes deform and thereby reduce the grain size of parent material.

Fig. 1.9 Effect of grain size on strength and ductility of annealed brass

It is possible to restore the original grain geometry by heating the material

above a temperature where the new fine grains are formed. This process is called
recrystallization and the temperature needed to achieve this is known as the
recrystallization temperature. If the material is kept for a considerable period of
time at this temperature, the newly formed fine grains grow in size. If materials
are worked below recrystallization temperature, which is known as cold working,
Exploring the Variety of Random
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John Jasper: The unmatched Negro philosopher
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Title: John Jasper: The unmatched Negro philosopher and

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1908

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*** START OF THE PROJECT GUTENBERG EBOOK JOHN

JASPER: THE UNMATCHED NEGRO PHILOSOPHER AND
PREACHER ***
 Transcriber’s Note:

Obvious typographic errors have been

corrected.
JOHN JASPER
 JOHN JASPER

The Unmatched Negro

Philosopher and Preacher

By
WILLIAM E. HATCHER, LL. D.

New York Chicago Toronto

Fleming H. Revell Company
London and Edinburgh

Copyright, 1908, by
FLEMING H. REVELL COMPANY

New York: 158 Fifth Avenue

Chicago: 17 North Wabash Ave.
London: 21 Paternoster Square
Edinburgh: 75 Princes Street
 CONTENTS
Introduction 7
I. Jasper Presented 15
II. Jasper Has a Thrilling Conversion 23
III. How Jasper Got His Schooling 30
IV. The Slave Preacher 36
V. “Whar Sin Kum Frum?” 47
VI. Jasper Set Free 58
VII. The Picture-Maker 65
VIII. Jasper’s Star Witness 72
IX. Jasper’s Sermon on “Dem Sebun Wimmin” 89
X. Jasper Glimpsed Under Various Lights 94
XI. Sermon:—The Stone Cut Out of the Mountain 108
XII. Facts Concerning the Sermon on the Sun 121
XIII. The Sun Do Move 133
XIV. One Jasper Day in the Spring Time of 1878 150
XV. Jasper’s Picture of Heaven 174
 INTRODUCTION
Reader; stay a moment. A word with you before you begin to sample
this book. We will tell you some things in advance, which may help
you to decide whether it is worth while to read any further. These
pages deal with a negro, and are not designed either to help or to
hurt the negro race. They have only to do with one man. He was one
of a class,—without pedigree, and really without successors, except
that he was so dominant and infectious that numbers of people
affected his ways and dreamed that they were one of his sort. As a
fact, they were simply of another and of a baser sort.
The man in question was a negro, and if you cannot appreciate
greatness in a black skin you would do well to turn your thoughts into
some other channel. Moreover, he was a negro covered over with
ante bellum habits and ways of doing. He lived forty years before the
war and for about forty years after it. He grew wonderfully as a
freeman; but he never grew away from the tastes, dialects, and
manners of the bondage times. He was a man left over from the old
régime and never got infected with the new order. The air of the
educated negro preacher didn’t set well upon him. The raw
scholarship of the new “ish,” as he called it, was sounding brass to
him. As a fact, the new generation of negro preachers sent out by
the schools drew back from this man. They branded him as an
anachronism, and felt that his presence in the pulpit was a shock to
religion and an offense to the ministry; and yet not one of them ever
attained the celebrity or achieved the results which came to this
unlettered and grievously ungrammatical son of Africa.
But do not be afraid that you are to be fooled into the fanatical camp.
This story comes from the pen of a Virginian who claims no
exemption from Southern prejudices and feels no call to sound the
praises of the negro race. Indeed, he never intended to write what is
contained within the covers of this book. It grew up spontaneously
and most of the contents were written before the book was thought
of.
It is, perhaps, too much to expect that the meddlers with books will
take the ipse dixit of an unaccredited stranger. They ought not to do
it: they are not asked to do it. They can go on about their business, if
they prefer; but if they do, they will miss the story of the
incomparable negro of the South. This is said with sobriety and after
a half century spent in close observation of the negro race.
More than that, the writer of this never had any intention of bothering
with this man when he first loomed up into notoriety. He got drawn in
unexpectedly. He heard that there was a marvel of a man “over in
Africa,” a not too savoury portion of Richmond, Virginia,—and one
Sunday afternoon in company with a Scot-Irishman, who was a
scholar and a critic, with a strong leaning towards ridicule, he went to
hear him preach. Shades of our Anglo-Saxon fathers! Did mortal lips
ever gush with such torrents of horrible English! Hardly a word came
out clothed and in its right mind. And gestures! He circled around the
pulpit with his ankle in his hand; and laughed and sang and shouted
and acted about a dozen characters within the space of three
minutes. Meanwhile, in spite of these things, he was pouring out a
gospel sermon, red hot, full of love, full of invective, full of
tenderness, full of bitterness, full of tears, full of every passion that
ever flamed in the human breast. He was a theatre within himself,
with the stage crowded with actors. He was a battle-field;—himself
the general, the staff, the officers, the common soldiery, the
thundering artillery and the rattling musketry. He was the preacher;
likewise the church and the choir and the deacons and the
congregation. The Scot-Irishman surrendered in fifteen minutes after
the affair commenced, but the other man was hard-hearted and
stubborn and refused to commit himself. He preferred to wait until he
got out of doors and let the wind blow on him and see what was left.
He determined to go again; and he went and kept going, off and on,
for twenty years. That was before the negro became a national
figure. It was before he startled his race with his philosophy as to the
rotation of the sun. It was before he became a lecturer and a
sensation, sought after from all parts of the country. Then it was that
he captured the Scot-Irish and the other man also. What is written
here constitutes the gatherings of nearly a quarter of a century, and,
frankly speaking, is a tribute to the brother in black,—the one
unmatched, unapproachable, and wonderful brother.
But possibly the reader is of the practical sort. He would like to get
the worldly view of this African genius and to find out of what stuff he
was made. Very well; he will be gratified! Newspapers are
heartlessly practical. They are grudging of editorial commendation,
and in Richmond, at the period, they were sparing of references of
any kind to negroes. You could hardly expect them to say anything
commendatory of a negro, if he was a negro, with odd and
impossible notions. Now this man was of that very sort. He got it into
his big skull that the earth was flat, and that the sun rotated;—a
scientific absurdity! But you see he proved it by the Bible. He
ransacked the whole book and got up ever so many passages. He
took them just as he found them. It never occurred to him that the
Bible was not dealing with natural science, and that it was written in
an age and country when astronomy was unknown and therefore
written in the language of the time. Intelligent people understand this
very well, but this miracle of his race was behind his era. He took the
Bible literally, and, with it in hand, he fought his battles about the
sun. Literally, but not scientifically, he proved his position, and he
gave some of his devout antagonists a world of botheration by the
tenacity with which he held to his views and the power with which he
stated his case. Scientifically, he was one of the ancients, but that
did not interfere with his piety and did not at all eclipse his views. His
perfect honesty was most apparent in all of his contentions; and,
while some laughed at what they called his vagaries, those who
knew him best respected him none the less, but rather the more, for
his astronomical combat. There was something in his love of the
Bible, his faith in every letter of it, and his courage, that drew to him
the good will and lofty respect of uncounted thousands and,
probably, it might be said, of uncounted millions.
Now when this man died it was as the fall of a tower. It was a crash,
heard and felt farther than was the collapse of the famous tower at
Venice. If the dubious, undecided reader has not broken down on the
road but has come this far, he is invited to look at the subjoined
editorial from The Richmond Dispatch, the leading morning paper of
Richmond, Va., which published at the time an article on this lofty
figure, now national in its proportions and imperishable in its fame,
when it bowed to the solemn edict of death.

(From The Richmond Dispatch)

“It is a sad coincidence that the destruction of the Jefferson
Hotel and the death of the Rev. John Jasper should have fallen
upon the same day. John Jasper was a Richmond Institution, as
surely so as was Major Ginter’s fine hotel. He was a national
character, and he and his philosophy were known from one end
of the land to the other. Some people have the impression that
John Jasper was famous simply because he flew in the face of
the scientists and declared that the sun moved. In one sense,
that is true, but it is also true that his fame was due, in great
measure, to a strong personality, to a deep, earnest conviction,
as well as to a devout Christian character. Some preachers
might have made this assertion about the sun’s motion without
having attracted any special attention. The people would have
laughed over it, and the incident would have passed by as a
summer breeze. But John Jasper made an impression upon his
generation, because he was sincerely and deeply in earnest in
all that he said. No man could talk with him in private, or listen to
him from the pulpit, without being thoroughly convinced of that
fact. His implicit trust in the Bible and everything in it, was
beautiful and impressive. He had no other lamp by which his
feet were guided. He had no other science, no other philosophy.
He took the Bible in its literal significance; he accepted it as the
inspired word of God; he trusted it with all his heart and soul and
mind; he believed nothing that was in conflict with the teachings
of the Bible—scientists and philosophers and theologians to the
contrary notwithstanding.
“‘They tried to make it appear,’ said he, in the last talk we had
with him on the subject, ‘that John Jasper was a fool and a liar
when he said that the sun moved. I paid no attention to it at first,
because I did not believe that the so-called scientists were in
earnest. I did not think that there was any man in the world fool
enough to believe that the sun did not move, for everybody had
seen it move. But when I found that these so-called scientists
were in earnest I took down my old Bible and proved that they,
and not John Jasper, were the fools and the liars.’ And there
was no more doubt in his mind on that subject than there was of
his existence. John Jasper had the faith that removed
mountains. He knew the literal Bible as well as Bible scholars
did. He did not understand it from the scientific point of view, but
he knew its teachings and understood its spirit, and he believed
in it. He accepted it as the true word of God, and he preached it
with unction and with power.
“John Jasper became famous by accident, but he was a most
interesting man apart from his solar theory. He was a man of
deep convictions, a man with a purpose in life, a man who
earnestly desired to save souls for heaven. He followed his
divine calling with faithfulness, with a determination, as far as he
could, to make the ways of his God known unto men, His saving
health among all nations. And the Lord poured upon His
servant, Jasper, ‘the continual dew of His blessing.’”
 I
JASPER PRESENTED

John Jasper, the negro preacher of Richmond, Virginia, stands

preëminent among the preachers of the negro race in the South. He
was for fifty years a slave, and a preacher during twenty-five years of
his slavery, and distinctly of the old plantation type. Freedom came
full-handed to him, but it did not in any notable degree change him in
his style, language, or manner of preaching. He was the ante bellum
preacher until eighty-nine years of age, when he preached his last
sermon on “Regeneration,” and with quiet dignity laid off his mortal
coil and entered the world invisible. He was the last of his type, and
we shall not look upon his like again. It has been my cherished
purpose for some time to embalm the memory of this extraordinary
genius in some form that would preserve it from oblivion. I would
give to the American people a picture of the God-made preacher
who was great in his bondage and became immortal in his freedom.
This is not to be done in biographic form, but rather in vagrant
articles which find their kinship only in the fact that they present
some distinct view of a man, hampered by early limitations, denied
the graces of culture, and cut off even from the advantages of a
common education, but who was munificently endowed by nature,
filled with vigour and self-reliance, and who achieved greatness in
spite of almost limitless adversities. I account him genuinely great
among the sons of men, but I am quite sure that the public can never
apprehend the force and gist of his rare manhood without first being
made acquainted with certain facts appertaining to his early life.
Jasper was born a slave. He grew up on a plantation and was a
toiler in the fields up to his manhood. When he came to Richmond,
now grown to a man, he was untutored, full of dangerous energies,
almost gigantic in his muscle, set on pleasure, and without the fear
of God before his eyes. From his own account of himself, he was
fond of display, a gay coxcomb among the women of his race, a fun-
maker by nature, with a self-assertion that made him a leader within
the circles of his freedom.
We meet him first as one of the “hands” in the tobacco factory of Mr.
Samuel Hargrove, an enterprising and prosperous manufacturer in
the city of Richmond. Jasper occupied the obscure position of “a
stemmer,”—which means that his part was to take the well-cured
tobacco leaf and eliminate the stem, with a view to preparing what
was left to be worked into “the plug” which is the glory of the
tobacco-chewer. This position had one advantage for this quick-
witted and alert young slave. It threw him into contact with a
multitude of his own race, and as nature had made him a lover of his
kind his social qualities found ample scope for exercise. In his early
days he went at a perilous pace and found in the path of the sinful
many fountains of common joy. Indeed, he made evil things fearfully
fascinating by the zestful and remorseless way in which he indulged
them.
It was always a joy renewed for him to tell the story of his
conversion. As described by him, his initial religious experiences,
while awfully mystical and solemn to him, were grotesque and
ludicrous enough. They partook of the extravagances of the times,
yet were so honest in their nature, and so soundly Scriptural in their
doctrines, and so reverential in their tone, that not even the most
captious sceptic could hear him tell of them, in his moments of
exalted inspiration, without feeling profoundly moved by them.
It ought to be borne in mind that this odd and forcible man was a
preacher in Richmond for a half century, and that during all that time,
whether in slavery or in freedom, he lived up to his religion,
maintaining his integrity, defying the unscrupulous efforts of jealous
foes to destroy him, and walking the high path of spotless and
incorruptible honour. Not that he was always popular among his
race. He was too decided, too aggressive, too intolerant towards
meanness, and too unpitying in his castigation of vice, to be popular.
His life, in the nature of the case, had to be a warfare, and it may be
truly said that he slept with his sword buckled on.
Emancipation did not turn his head. He was the same high-minded,
isolated, thoughtful Jasper. His way of preaching became an offense
to the “edicated” preachers of the new order, and with their new
sense of power these double-breasted, Prince-Albert-coated, high
hat and kid-gloved clergymen needed telescopes to look as far down
as Jasper was, to get a sight of him. They verily thought that it would
be a simple process to transfix him with their sneers, and flaunt their
new grandeurs before him, in order to annihilate him. Many of these
new-fledged preachers, who came from the schools to be pastors in
Richmond, resented Jasper’s prominence and fame. They felt that
he was a reproach to the race, and they did not fail to fling at him
their flippant sneers.
But Jasper’s mountain stood strong. He looked this new tribe of his
adversaries over and marked them as a calcimined and fictitious
type of culture. To him they were shop-made and unworthy of
respect. They called forth the storm of his indignant wrath. He
opened his batteries upon them, and, for quite a while, the thunder of
his guns fairly shook the steeples on the other negro churches of
Richmond. And yet it will never do to think of him as the incarnation
of a vindictive and malevolent spirit. He dealt terrific blows, and it is
hardly too much to say that many of his adversaries found it
necessary to get out of the range of his guns. But, after all, there was
a predominant good nature about him. His humour was
inexhaustible, and irresistible as well. If by his fiery denunciations he
made his people ready to “fight Philip,” he was quite apt before he
finished to let fly some of his odd comparisons, his laughable stories,
or his humorous mimicries. He could laugh off his own grievances,
and could make his own people “take the same medicine.”
Jasper was something of a hermit, given to seclusion, imperturbably
calm in his manner, quite ascetic in his tastes, and a cormorant in his
devouring study of the Bible. Naturally, Jasper was as proud as
Lucifer,—too proud to be egotistic and too candid and self-assertive
to affect a humility which he did not feel. He walked heights where
company was scarce, and seemed to love his solitude. Jasper was
as brave as a lion and possibly not a little proud of his bravery. He
fought in the open and set no traps for his adversaries. He believed
in himself,—felt the dignity of his position, and never let himself down
to what was little or unseemly.
The most remarkable fact in Jasper’s history is connected with his
extraordinary performances in connection with his tersely expressed
theory,—THE SUN DO MOVE! We would think in advance that any man
who would come forward to champion that view would be hooted out
of court. It was not so with Jasper. His bearing through all that
excitement was so dignified, so sincere, so consistent and heroic,
that he actually did win the rank of a true philosopher. This result, so
surprising, is possibly the most handsome tribute to his inherent
excellence and nobility of character. One could not fail to see that his
fight on a technical question was so manifestly devout, so filled with
zeal for the honour of religion, and so courageous in the presence of
overwhelming odds, that those who did not agree with him learned to
love and honour him.
The sensation which he awakened fairly flew around the country. It is
said that he preached the sermon 250 times, and it would be hard to
estimate how many thousands of people heard him. The papers,
religious and secular, had much to say about him. Many of them
published his sermons, some of them at first plying him with derision,
but about all of them rounding up with the admission of a good deal
of faith in Jasper. So vast was his popularity that a mercenary
syndicate once undertook to traffic on his popularity by sending him
forth as a public lecturer. The movement proved weak on its feet,
and after a little travel he hobbled back richer in experience than in
purse.
As seen in the pulpit or in the street Jasper was an odd picture to
look upon. His figure was uncouth; he was rather loosely put
together; his limbs were fearfully long and his body strikingly short,—
a sort of nexus to hold his head and limbs in place. He was black,
but his face saved him. It was open, luminous, thoughtful, and in
moments of animation it glowed with a radiance and exultation that
was most attractive.
Jasper’s career as a preacher after the war was a poem. The story is
found later on and marks him as a man of rare originality, and of
patience born of a better world. He left a church almost entirely the
creation of his own productive life, that holds a high rank in
Richmond and that time will find it hard to estrange from his spirit
and influence. For quite a while he was hardly on coöperative terms
with the neighbouring churches, and it is possible that he ought to
share somewhat in the responsibility for the estrangement which so
long existed;—though it might be safely said that if they had left
Jasper alone he would not have bothered them. Let it be said that
the animosities of those days gradually gave away to the gracious
and softening influence of time, and, when his end came, all the
churches and ministers of the city most cordially and lovingly united
in honouring his memory.
It may betoken the regard in which Jasper was held by the white
people if I should be frank enough to say that I was the pastor of the
Grace Street Baptist Church, one of the largest ecclesiastical bodies
in the city at the time of Jasper’s death, and the simple
announcement in the morning papers that I would deliver an address
in honour of this negro preacher who had been carried to his grave
during the previous week brought together a representative and
deeply sympathetic audience which overflowed the largest church
auditorium in the city. With the utmost affection and warmth I put
forth my lofty appreciation of this wonderful prince of his tribe, and so
far as known there was never an adverse criticism offered as to the
propriety or justice of the tribute which was paid him.
It is of this unusual man, this prodigy of his race, and this eminent
type of the Christian negro, that the somewhat random articles of this
volume are to treat. His life jumped the common grooves and ran on
heights not often trod. His life went by bounds and gave surprises
with each succeeding leap.
 II
JASPER HAS A THRILLING CONVERSION

Let us bear in mind that at the time of his conversion John Jasper
was a slave, illiterate and working in a tobacco factory in Richmond.
It need hardly be said that he shared the superstitions and indulged
in the extravagances of his race, and these in many cases have
been so blatant and unreasonable that they have caused some to
doubt the negro’s capacity for true religion. But from the beginning
Jasper’s religious experiences showed forth the Lord Jesus as their
source and centre. His thoughts went to the Cross. His hope was
founded on the sacrificial blood, and his noisy and rhapsodic
demonstrations sounded a distinct note in honour of his Redeemer.
Jasper’s conviction as to his call to the ministry was clear-cut and
intense. He believed that his call came straight from God. His boast
and glory was that he was a God-made preacher. In his fierce
warfares with the educated preachers of his race—“the new issue,”
as he contemptuously called them—he rested his claim on the
ground that God had put him into the ministry; and so reverential, so
full of noble assertion and so irresistibly eloquent was he in setting
forth his ministerial authority that even his most sceptical critics were
constrained to admit that, like John the Baptist, he was “a man sent
from God.”
And yet Jasper knew the human side of his call. It was a part of his
greatness that he could see truth in its relations and completeness,
and while often he presented one side of a truth, as if it were all of it,
he also saw the other side. With him a paradox was not a
contradiction. He gratefully recognized the human influences which
helped him to enter the ministry. While preaching one Sunday
afternoon Jasper suddenly stopped, his face lighted as with a vision,
a rich laugh rippled from his lips while his eyes flashed with soulful
fire. He then said, in a manner never to be reported: “Mars Sam
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