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Rolling operation

Useful for MPR 312313 .

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kharodsanket
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8 views

Rolling operation

Useful for MPR 312313 .

Uploaded by

kharodsanket
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Rolling Process

 The Rolling Process involves passing the metal through a pair of rotating rolls to reduce
its thickness and change its cross-sectional shape.
 The rolling process is a deformation method wherein metal is passed between two
opposing rollers. This compression process reduces the metal's thickness as the rollers
roll around it and squeeze it between them.

 This process is capable of producing a wide range of metal products, such as sheets,
plates, bars, and structural shapes, With precise dimensions and surface finishes.
 Rolling offers advantages, including improved material properties, enhanced grain
structure, and the ability to produce large quantities of metal products with consistent
quality.
 Principle of Rolling: Compressing the metal between two opposite rotating
rolls for reducing its thickness - flat strip rolling. High compressive force is exerted
on the work piece by the squeezing action of the rolls. The metal is taken into rolls by
friction. It is most widely used due to higher productivity at low cost. It is hot working
process unless specifically mentioned as cold rolling but it is done both hot and cold.

 Hot Rolling: The hot plastic state metal is passed between rolls. Rolling
carried out above the recrystallization temperature. The crystals are elongated in
the direction of rolling. Best suited for large amount of deformation. Hot rolled
metal is generally free of residual stress and its properties are isotropic.

 Cold rolling: The rolling process employed to finish bars, rods, sheets and
strips at room temperature. It provides good surface finish, better dimensional
accuracy and improved physical properties.
 Types of rolling mills:

1. Two high rolling mill [irreversible]


2. Three high rolling
3. Four high rolling
4. Cluster rolling
5. Planetary rolling.

It has two rolls which rotate in same direction about the horizontal axes. Typical two high
rolling mill consists of a roller conveyor, rolls with a stand and power drive. The upper roller
can be raised or lowered to change the distance between rolls.
The direction of rotation of each rolls remains unchanged. Stock is passed through the either
side of the rolls. It is raised and lowered after each pass using lifting mechanism. The top and
bottom rolls are drive rolls. Intermediate roll rotates by friction. These mills are employed as
blooming mills, billet rolling and finish rolling .More complicated due to lifting mechanism.

Four High Rolling Mill is Similar to two high rolling, but additional two rollers are
added. These extra two rollers are smaller in diameter. Thus the bigger roller will act as
backup rollers behind smaller rollers. The arc of contact is minimised by using smaller
rollers. The backup rolls are provided to avoid bending of rolls due to their low strength and
rigidity.
Cluster Roll mill features two working rollers and two or more backup rollers. The
number of backup rollers depends on the required support for working. It is primarily used in
cold rolling operations.

Advantages of Rolling Process

The rolling process offers several advantages, including:

 Speed and Time Efficiency: It is a fast and time-saving manufacturing process,


allowing for higher production rates.
 Mass Production: Well-suited for mass production, making it ideal for large-
scale manufacturing.
 High Efficiency: Provides high efficiency in material utilisation and energy
consumption.
 Complex Profile Production: Capable of easily producing workpieces with
intricate cross-section profiles.
 Precise Tolerances: Rolling processes can be designed to achieve workpieces
with very close tolerances, ensuring accuracy and consistency.

Disadvantages of Rolling Process

The rolling process has certain drawbacks, including:

 High Initial Cost: The initial cost and investment required for setting up
rolling operations can be significant.
 Surface Finish: The rolled workpiece may have a less refined surface finish,
necessitating additional finishing processes.
 Mass Production Suitability: It is most suitable for mass-production scenarios,
making it less efficient for smaller-scale productions.
Applications of Rolling Process

The rolling process is extensively used in various industrial applications, such as:

 Manufacturing of Shafts, Rods, Tubes, Axles, and Spindles.


 Producing Workpieces with Desired Cross-Sections.
 Gear Manufacturing from Gear Blanks.
 Thread Rolling for Threaded Parts, Bolts, and Screws.
 Production of Bearings and Turbine Rings through Ring Rolling.
 Wide Applications in the Automotive Industry.
 Manufacturing of Metal Sheets, Plates, and Panels.

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