Rolling of Metals

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Rolling of Metals

• Rolling is a process of reducing the thickness of a long

workpiece by compressive forces applied through a set of
rolls.
• Hot rolling breaks down the coarse-grained, brittle and
porous structure of the ingot or continuously cast metal into
wrought structure having finer grain size and enhanced
properties.
• Porosity, Cavity, Blow Holes occurred in the cast ingot will be
closed up during the Rolling process.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Flat-Rolling
and Shape-
Rolling
Processes
Figure:
Schematic
outline of
various flat-
rolling and
shape-rolling
processes.
Source:
After the
American
Iron and
Steel
Institute.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Bulk Deformation Processes

• (a) Rolling and (b) forging

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Flat-Rolling Process

Figure 13.2 (a) Schematic illustration of the flat-rolling process. (b) Friction forces acting on
strip surfaces. (c) Roll force, F, and the torque, T, acting on the rolls. The width of the strip,
w, usually increases during rolling, as shown later in Fig. 13.5.
At one point along the contact length ‘L’, called the neutral point or no-slip-point, the velocity
of the strip is the same as that of the roll.
Higher the friction and larger the roll radius,
the greater the maximum possible draft becomes.
Draft, reduction in thickness = ho-hf
An annealed copper strip 228 mm
wide and 25 mm thick, is rolled into
thickness of 20 mm. The roll radius
is 300 mm, and the rolls rotate at
100 rpm. Calculate the roll force,
torque and power required in this
operation. Yavg = 180 Mpa.
R=300 mm, w =228 mm, ho=25
mm, hf =20mm.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Rolling Force

• Roll forces can be reduced by

– Reducing friction
– Using smaller-diameter rolls to reduce contact area
– Taking smaller reductions per pass, to reduce the contact area
– Rolling at elevated temperatures to lower the strength of the
material
Geometric considerations of Rolls
Thermal camber – barrelling of rolls.
Providing camber at centre (max camber point is generally
0.25mm)
Rollling forces tend to flatten the rolls elastically, results in larger
contact area for the same draft.
Roll force incrases with increased flattening.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Problems in Rolling
• An annealed copper strip 228 mm wide and 25 mm thick, is rolled into thickness of 20
mm. The roll radius is 300 mm, and the rolls rotate at 100 rpm. Calculate the roll
force, torque and power required in this operation. Yavg = 180 Mpa.
• R=300 mm, w =228 mm, ho=25 mm, hf =20mm.
Problems in Rolling
A single stand rolling mill used to roll a
strip height from 25 mm to 22 mm.
Given roll diameter of 500 mm, having
a width of 300 mm and driven at rolling
angular speed of n=50 rpm. Determine
Rolling force, Torque and Power. Given
strength coefficient K =275, strain
hardening exponent, n =0.15.
 Problems in Rolling
•
 Problems in Rolling
• A single stand rolling mill used to roll a strip height from 25 mm to 22 mm. Given
roll diameter of 500 mm, and driven at rolling angular speed of n=50 rpm.
Determine Rolling force, Torque and Power. Given strength coefficient K =275,
strain hardening exponent, n =0.15.
•
 Assignment 2 Problems.

• 1) A single stand rolling mill used to roll a strip height from ho to hf. Given roll
diameter of 500 mm (i.e. R=250 mm), and driven at rolling angular speed of n=60
rpm. If roll width (i.e. strip width w=1800 mm), calculate the Rolling force from
ho=1.5 mm to hf =1.0 mm and power required? Given material follow stress σ
=150 (ε)0.25 N /mm2 .
• 2) A rolling stand has a power of 24 KW, driven at angular speed of 100 rpm. Given
roll diameter is 300 mm, and initial strip thickness is 3 mm and strip-width 280
mm. (Material follow stress σ =120 N /mm2 ). Calculate the maximum reduction
in strip thickness based on given rolling power ?

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Roll Arrangements

Figure 13.3 Schematic illustration of various roll arrangements: (a) four-high

rolling mill showing various features. The stiffness of the housing, the rolls, and the
roll bearings are all important in controlling and maintaining the thickness of the
rolled strip; (b) two-hill mill; (c) three-high mill; and (d) cluster (or Sendzimir) mill.
 Spreading in Flat Rolling

Figure 13.5 Increase in strip width (spreading) in flat rolling. Note that
similar spreading can be observed when dough is rolled with a rolling pin.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Effects of Hot Rolling

Figure 13.6 Changes in the grain structure of cast or of large-grain wrought

metals during hot rolling. Hot rolling is an effective way to reduce grain size
in metals for improved strength and ductility. Cast structures of ingots or
continuous castings are converted to a wrought structure by hot working.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Roller Leveling

Figure 13.7 (a) A method of roller leveling to flatten rolled sheets. (b) Roller leveling to
straighten drawn bars.

Mild steel, when stretched during sheet metal operations, undergoes yield-point elongation,
a phenomenon that causes surface irregularities called stretcher stains or Lueder’s bands.
To correct this sheet metal is subjected to a final pass of 0.5% -1.5% reduction, known as
temper rolling or skin pass.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
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Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Defects in Rolled Plates and sheets
• Surface defects
– Scale, rust, scratches, gouges, pits and cracks
– Caused by inclusions and impurities in the original cast
material or by various other conditions related to material
preparation and to the rolling operation.
• Internal structural defects
– Wavy edges
– Alligatoring
– Central buckling

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Defects in Flat Rolling

Figure 13.8 Schematic

illustration of typical
defects in flat rolling: (a)
wavy edges; (b) zipper
cracks in the center of the
strip; (c) edge cracks; and
(d) alligatoring.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Residual Stresses Developed in Rolling

Figure 13.9 (a) Residual stresses developed in rolling with small-diameter rolls or at small
reductions in thickness per pass. (b) Residual stresses developed in rolling with large-
diameter rolls or at high reductions per pass. Note the reversal of the residual stress patterns.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Bending of Rolls

Figure 13.4 (a) Bending of

straight cylindrical rolls caused by
roll forces. (b) Bending of rolls
ground with camber, producing a
strip with uniform thickness
through the strip width.
Deflections have been
exaggerated for clarity.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Rolling Mill

Figure 13.10 A general view of a rolling mill. Source: Courtesy of Ispat Inland.
 Tandem-Rolling

Figure 13.11 An example of a tandem-rolling operation.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Shape-Rolling Operations
• Various shapes, such as channels, I-beams, and
rail roads are rolled by passing through a set of
specially designed rolls.
• Design of rolls is called as Roll-pass design
• Structural shape rolling
• Ring rolling
• Thread rolling
• Rotary tube piercing
• Roll forging
• Skew rolling

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Shape Rolling of an H-section part

Figure 13.12 Steps in the

shape rolling of an H-
section part. Various other
structural sections, such as
channels and I-beams, also
are rolled by this kind of
process.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Roll-Forging

Figure 13.13 Two examples of the roll-forging operation, also known as cross-rolling.
Tapered leaf springs and knives can be made by this process. Source: After J. Holub.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Production of Steel Balls

Figure 13.14 (a) Production of steel balls by the skew-rolling process. (b) Production of
steel balls by upsetting a cylindrical blank. Note the formation of flash. The balls made by
these processes subsequently are ground and polished for use in ball bearings.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Ring-Rolling

Figure 13.15 (a) Schematic illustration of a ring-rolling operation. Thickness reduction

results in an increase in the part diameter. (b-d) Examples of cross-sections that can be
formed by ring-rolling.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Thread-Rolling Processes

Figure 13.16 Thread-rolling processes: (a) and (c) reciprocating flat dies; (b) two-roller dies.
(d) Threaded fasteners, such as bolts, are made economically by these processes at high
rates of production. Source: Courtesy of Central Rolled Thread Die Co.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Machined and Rolled Threads

Figure 13.17 (a) Features of a machined or rolled thread. Grain flow in (b) machined and
(c) rolled threads. Unlike machining, which cuts through the grains of the metal, the rolling
of threads imparts improved strength because of cold working and favorable grain flow.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Cavity Formation in Bar

Figure 13.18 Cavity formation in a solid, round bar and its utilization in the rotary tube-
piercing process for making seamless pipe and tubing. (see also Fig. 2.9.)

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•

Pilger rolling
•Cold pilger rolling is a metalworking process where a tube blank
is repeatedly compressed between a stationary mandrel and two
rotating dies (or rollers) to reduce its diameter and wall thickness.

•A mandrel, a tapered cylindrical rod, is inserted into the tube to

maintain the inner diameter.
•The tube is then passed through the dies (or rollers) which
compress the outside of the tube to form the desired outer
diameter.
•The process is repeated multiple times to achieve the desired
dimensions.
Benefits:

•High-quality tubes: Pilger rolling produces seamless tubes with a high degree
of dimensional accuracy and surface finish.
•Improved material properties: The process can improve the grain structure and
mechanical properties of the material.
•Suitable for various materials: It can be used for a wide range of metals, including
stainless steel, titanium, and zirconium alloys.
•Cost-effective and faster than other methods: Compared to cold drawing and flow f
orming, pilgering is generally faster and more cost-effective.
•Applications:
•Pilger rolling is used in the production of tubes for various industries,
including automotive, oil and gas, and aerospace.
•It's particularly well-suited for producing high-strength and corrosion-resistant tubes.
•
 Various Tube-Rolling Processes

Figure 13.19 Schematic illustration of various tube-rolling processes: (a) with a

fixed mandrel; (b) with a floating mandrel; (c) without a mandrel; and (d)
pilger rolling over a mandrel and a pair of shaped rolls. Tube diameters and
thicknesses also can be changed by other processes, such as drawing,
extrusion, and spinning.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Forming of Solid Rocket Casings

Figure 13.20 The Space Shuttle U.S.S.

Atlantis is launched by two strapped-on solid-
rocket boosters. Source: Courtesy of NASA.

Figure 13.21 The forming

processes involved in the
manufacture of solid rocket
casings for the Space
Shuttles.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.