R. V.

COLLEGE OF ENGINEERING,
BANGALORE.







PRODUCTION TECHNOLOGY ASSIGNMENT

ROLLING









By
Avinash Kumar (1RV11ME033)
Basavaraj Devakki (1RV11ME034)
Biswajyothi Dutta (1RV11ME035)
Brian Nikil Quadras (1RV11ME036)
3
rd
Sem A Section
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Contents:

Introduction

Types of rolling
Two high rolling mill
Three high rolling mill
Four high rolling mill
Tandem rolling mill
Cluster rolling mill
Continuous rolling mill
Planetary rolling mill

Defects in rolling
Surface defects
Wavy defects
Edge cracking
Center split
Zipper crack

Flatness and shape
Profile
Draft










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Introduction

Rolling is a process of reduction of the cross-sectional area or shaping a metal
piece through the deformation caused by a pair of rotating in opposite directions
metal rolls.

A scheme of rolling process is shown in the picture:


The gap between the rotating rolls is less than the thickness of the entering
bar H
0
therefore a friction force is necessary in order to bite the bar and to pull it
through the rolls.

A metal bar passing through the rotating rolls is squeezed, and it elongates
while its cross section area decreases. The amount of deformation R achieved in
a flat rolling operation (thickness reduction) is determined by the relationship:
R = 100% * (H H
0
)/H
0


A machine used for rolling metal is called rolling mill.

A typical rolling mill consists of a pair of rolls driven by an electric motor
transmitting a torque through a gear and pair of cardans. The rolls are equipped
with bearings and mounted in a stand with a screw-down mechanism.
A force applied to the rolls in vertical direction is called roll separating force.
A rolling mill is characterized by the maximum values of its roll separating force
and the torque.
The maximum amount of deformation (thickness reduction) which may be
achieved in a single rolling pass is determined by the maximum roll separating
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force, maximum torque, work roll diameter, friction coefficient and mechanical
strength of the rolled material and its width.

Low roll diameter results in low roll contact area and consequently in low
absolute value of the roll separating force and the torque required for achieving a
certain thickness reduction.
However such rolls are susceptible to bending and causing non-uniform
widthwise strip thickness distribution (convex crown).
Complex rolling mill designs employing back-up rolls are used to diminish the
bending effect
Hot rolling is a rolling operation carried out at a temperature exceeding
the recrystallization temperature and permitting large amount of deformation.

Cold rolling is a rolling operation carried out at room temperature. Cold rolling
is commonly conducted after hot rolling when good surface quality and low
thickness tolerance are needed. Cold rolling causes material strengthening and may
be followed by annealing.

Types of Rolling mills

Rolling mills may be classified according to the number and arrangement of
the rolls.

1) Two high rolling mills
2) Three high rolling mills
3) Four high rolling mills
4) Tandem rolling mills
5) Cluster rolling mills


1) Two high rolling mills

Two high rolling mills may further classified as
Reversing mill
Non reversing mill
A two high rolling mill has two rolls only.

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Two high reversing mill

In two high reversing rolling mills the rolls rotate it in one direction and then
in the other, so that rolled metal may pass back and forth through the rolls several
times. This type is used in pluming and slabing mills and for roughing work in
plate, rail, structural and other mills.


These are more expensive compared to the non-reversing rolling mills.
Because of the reversible drive needed.


Two high non reversing mill

In two high non reversing mills as two rolls which revolve continuously in
same direction therefore smaller and less costly motive power can be used.
However every time material is to be carried back over the top of the mill for again
passing in through the rolls. Such an arrangement is used in mills through which
the bar
passes once
and in open
train plate
mill.






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2) Three high rolling mill:

It consists of a roll stand with three parallel rolls one above the other. Adjacent
rolls rotates in opposite direction. So that the material may be passed between the
top and the middle roll in one direction and the bottom and middle rolls in opposite
one.

In three high rolling mills the work piece is rolled on both the forward and
return passes. First of all the work piece passes through the bottom and middle
rolls and the returning between the middle and the top rolls.


So that thickness is reduced at each pass. Mechanically operated lifted tables
are used which move vertically or either side of the stand. So that the work piece
fed automatically into the roll gap.

Since the rolls run in one direction only a much less powerful motor and
transmission system is required. The rolls of a three high rolling mills may be
either plain or grooved to produce plate or sections respectively.


3) Four high rolling mill:

It has a roll stand with four parallel rolls one above the other. The top and the
bottom rolls rotate in opposite direction as do the two middle rolls. The two middle
are smaller in size than the top and bottom rolls which are called backup rolls for
providing the necessary rigidity to the smaller rolls.

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A four high rolling mill is used for the hot rolling of armor and other plates as
well as cold rolling of plates, sheets and strips.


4) Tandem rolling mills:

It is a set of two or three stands of roll set in parallel alignment. So that a
continuous pass may be made through each one successively with change the
direction of material.

5) Cluster rolling mills:

It is a special type of rolling mill in which each of the two working rolls is backup
by two or more of larger backup rolls for rolling hard in materials .It may be
necessary to employ work rolls of very small diameter but considerable length. In
such cases adequate of the working rolls can be obtained using a cluster mill.

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6) Continuous rolling mill
A continuous mill consists of several stands of rolls arranged in a straight line
(in tandem), with each succeeding stand operating with roll surface speed greater
than its predecessor. This type of mill is in very common usage for rolling strip,
sheet, billets, bars, rods, etc. Any part of the workpiece, after pass through the
roughing, intermediate and finish stands, is rolled from initial shape into the finish
one, and emerges from the last roll stand.
7) Planetary rolling mill
This consists of one pair of heavy back up rolls. Each back up roll is
surrounded by a series of small planetary rolls as shown in the figure. The
planetary rolls sweeps out a circular path between the slab and the backup roll as a
result it gives almost a constant reduction to the slab. When one pair of planetary
rolls make contact and the reduction continues. Thus the total reduction undergone
by the workpiece is the summation of the series of small reductions effected by
each pair of rolls
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Defects in Rolling
As with any other manufacturing process, it is extremely difficult roll
products which are totally defect free. To produce quality roll product, rolling
practice requires balancing many factors, including material properties, process
variables and lubrication .The defects observed in rolled products can be broadly
considered as follows.
In hot rolling, if the temperature of the workpiece is not uniform the flow of
the material will occur more in the warmer parts and less in the cooler. If the
temperature difference is great enough cracking and tearing can occur.

1) Surface defects:
These result from inclusions and impurities in the material , scale, rust, dirt, roll
marks, and various other causes related to the prior treatment and working of the
material.

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2) Wavy edges:
This is caused by bending of thee rolls which results in the edge of the strip
being thinner than at the center.



3) Edge cracking:

During rolling inhomogeneity in the deformation is a major problem. The
decrease in thickness at the center of the sheet results in increase in length. In
addition a part of the thickness decrease at the edges results in lateral spread.
Due to continuity between the edges and center the the edges of the sheet are
placed in tension which results in edge cracklings.


4) Center split:
Under severe conditions, the reduction in thickness of the sheet at the center
may result in center split.
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5) Zipper cracks:
These cracks appear at the center of the strip and are usually accused by low
ductility and barreling.


Flatness and Shape:
In a flat metal workpiece, the flatness is a descriptive attribute characterizing the
extent of the geometric deviation from a reference plane. The deviation from
complete flatness is the direct result of the workpiece relaxation after hot or cold
rolling, due to the internal stress pattern caused by the non-uniform transversal
compressive action of the rolls and the uneven geometrical properties of the entry
material. The transverse distribution of differential strain/elongation-induced stress
with respect to the material's average applied stress is commonly referenced to as
shape. Due to the strict relationship between shape and flatness, these terms can be
used in an interchangeable manner. In the case of metal strips and sheets, the
flatness reflects the differential fiber elongation across the width of the workpiece.
This property must be subject to an accurate feedback-based control in order to
guarantee the machinability of the metal sheets in the final transformation
processes.
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Profile:
Profile is made up of the measurements of crown and wedge. Crown is the
thickness in the centre as compared to the average thickness at the edges of the
workpiece. Wedge is a measure of the thickness at one edge as opposed to the
other edge. Both may be expressed as absolute measurements or as relative
measurements. For instance, one could have 2 mil of crown (the centre of the
workpiece is 2 mil thicker than the edges), or one could have 2% crown (the centre
of the workpiece is 2% thicker than the edges).
It is typically desirable to have some crown in the workpiece as this will cause
the workpiece to tend to pull to the centre of the mill, and thus will run with higher
stability.
Draft:
The difference between the thickness of initial and rolled metal piece is called
Draft. Thus if is initial thickness and is final thickness, then the draft is
given by

The maximum draft that can be achieved via rollers of radius with
coefficient of static friction between the roller and the metal surface is given by

This is the case when the frictional force on the metal from inlet contact
matches the negative force from the exit contact.





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Bibliography
Manufacturing technology by P N Rao
http://engineeringhut.blogspot.in
http://www.subtech.com
Image Courtesy: http://www.google.co.in