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Rolling process

Rolling is the process of plastically
deforming metal by passing it between rolls

Most widely used forming process and

provides high production and close control
of final product

As a result of the friction between the rolls

and the metal surface, the metal during the
deformation process is subjected to high
compressive stresses

Rolling process is classified in to Hot and Cold rolling

processes

Hot rolling : The initial breakdown of ingots in to blooms

and billets is generally done by hot rolling. Further hot
rolling is carried out to obtain plates, sheets , rods, bars,
etc.

Cold rolling: Cold rolling is carried out by industries to

obtain sheets, strips, files, bars, etc. with good surface
finishes and close control of product dimensions with
increased mechanical properties

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Terminology
Blooms: It is the product of first breakdown of ingots
(Cross sectional area is > 230 cm2)
Billet: It is the product obtained from a further reduction by hot rolling
(Cross sectional area > 40 x 40 mm2)
Slab: Slab is the hot rolled ingot
(Cross sectional area > 100 cm2 and with ≥ 2x thickness)
Plate: Plate is the product with a thickness > 6 mm
Sheet: is the product with thickness < 6 mm and width > 600 mm
Strip: Strip is the product with thickness < 6 mm and Width < 600 mm

Typical arrangements of rolls for rolling mills

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Typical arrangement of rollers for rolling mills

Continuous rolling

Uses a series of rolling mill

and each set is called a stand

The strip will be moving at

different velocities at each
stage in the mills
A four stand continuous mill or tandom mill

The speed of each set of rolls is synchronized so that the input speed of
each stand is equal to the output of preceding stand

The uncoiler and windup reel not only feed the stock in to the rolls and
coiling up the final product but also provide back tension and front
tension to the strip.

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Shaped rolling or section rolling

A special type of cold rolling in which flat

slab is progressively bent into complex
shapes by passing it through a series of
driven rolls.

No appreciable change in the thickness of
the metal during this process

Suitable for producing moulded sections
such as irregular shaped channels and trim

Mechanics of Rolling process

The direction of friction force (μP) depends on the relative velocity of

the job and work piece.
From the entry to neutral point friction force is directed towards the exit
while from neutral point to exit it is directed towards the roll entrance.

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Considering equilibrium of forces on the element in the x-direction,

Since θ is very small,

Neglecting higher order terms, we get

Re-arranging, we get

------------- eqn(1)

Since friction force is assumed to be small, the principle stresses in

the element can be taken as σx (=σ1) and –p (=σ3)., Negative sign
implies compressive stress.
Since the condition is plain strain, σ2 will be ½(σx – p).
Applying von Mises yield criteria,

or …………….. (eqn. (2)

Eliminating σx, from Equations (1) and (2),

…………….. (eqn. (3)

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Due to the change in the direction of friction force before and after
neutral axis, we can write the above equation as

……….. Eqn (4)

Positive sign is for region before neutral point and negative sign is
for regions after neutral point

When the material undergoes deformation, work hardening takes

place resulting in increase in K. But during deformation, y
decreases. For simplicity, we can assume that the product Ky
remains constant. Hence we can rewrite equation (4) as

……….. Eqn (5)

As θ is small, y can be expressed as

Expanding eqn(5) and substituting for y we obtain

or

Integrating, we get

where C1 is the constant of integration

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or,

C being another constant

………………………………… eqn (6)

where, …………….…… eqn (7)

Applying eqn(2) to the beginning of rolling, i.e.

Where Pi is the roll pressure at the starting point. Using

this equation in (6), we get

where

and C- is the value of the constant C before neutral point is reached .

Hence,

…………………eqn(8)

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For region beyond the neutral point, eqn(6) can be written as

Applying equation (2), at the end of rolling, we get

Where Pf is the roll pressure at the exit. So,

Since the value of θ at the end point is zero, we get,

…………………eqn(9)

Using the value of C- and C+ from equations (8) and (9), respectively,
in equation (6), the equations for the dimensionless roll pressure
(p/2K) in the regions before and after neutral point can be obtained
respectively as,

…………………eqn(10)

…………………eqn(11)

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The pressure at the neutral point can be determined from

either equation (10) or equation (11). The value of λ
corresponding to the neutral point (λn) is obtained by equating
the R.H.S of equations (10) and (11). Thus,

…………………eqn(12)

Location of neutral point (θn) can be obtained using eqn(7) & (12).

The peak pressure at neutral point is normally called the friction hill.
This peak pressure increases with increasing coefficient of friction.

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Roll separating Force

Total force trying to separate the rolls can be obtained by
integrating the vertical component of the force acting at the roll-
strip interface.

Assume the width of the strip is unity.

Since the angle θi is very small, contribution of the roll strip
interface friction is negligible in the vertical direction.

Since θ is small

i.e.,

Driving torque and power

The driving torque is required to overcome the torque exerted on
the roll by the interfacial friction force. The driving toque
corresponding to unit width of the strip , T,

Friction resist the rotation of the roll before the neutral point, whereas
it helps rotation after the neutral point.
The use of above equation is limited due to the numerical error since
the result is the difference between two nearly equal, large numbers.

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Alternative method is to consider the horizontal equilibrium of the

deformation zone of the strip. Figure shows deformation zone along with
the forces acting on it, including an equivalent horizontal force Fe
representing the net frictional interaction between the roll and the strip.
The reaction - Fe of Fe has to be overcome by the roll driving torque T.
Fe can be determined by considering the horizontal equilibrium

The driving power per roll, PR

Ω is the angular speed of roll

The angle α between the entrance

plane and the centre line of the rolls
is called as the angle of contact or
angle of bite.
For the work piece to enter into
the throat of the roll, the horizontal
component of the friction force,
which acts towards the roll gap,
must be ≥ the horizontal
component of the normal force,
which acts away from the rolls

horizontal component of normal force = Pr sinα

horizontal component of Friction force = F cos α

i.e., F cos α ≥ Pr sinα

Since

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Mill rolls

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