IE 3130 Material Processing

Module 3: Forming and Shaping

Rolling Processes and Equipment
 Metal Bulk Deformation Processes

Objective of this module

Upon completion of class activity, lecture, and homework, student should be able to do
the following:
1. Sketch and describe an open-die forging with simple tools and complex process
sequences.
2. Describe Impression and closed-die forging with complex tools and simple process
sequences.
3. Sketch and describe extrusion and drawing of wire, tube and shaped sections.
4. Estimate die pressure, force, and power requirement of forging, extrusion,
drawing, and rolling processes.
5. List different processes of cutting parts for further working or immediate
assembly.
6. Sketch and describe bending on presses or roll-forming lines.
 Rolling
Of all bulk deformation processes, rolling occupies the most
important position. Over 90% of all materials that are ever
deformed are subjected to rolling.

Flat Rolling is the process of reducing the thickness of a slab to

produce a thinner and longer but only slightly wider product. It is
the most important primary deformation process.

The process of flat rolling looks deceptively simple. Two driven rolls
of cylindrical shape (work rolls) reduce the flat workpiece to a
thinner gage. The rolls are supported in housings, and the roll gap
can be adjusted by mechanical or hydraulic means
FIGURE 13.1 Schematic outline of various flat-rolling and shape-rolling processes. Source:
After American Iron and Steel Institute.
 Rolling Applications
➢Large quantities of steel are rolled to around 0.7 mm for
automotive and appliance bodies and down to 0.15 mm for food and
beverage containers (cans)
➢Copper is rolled to various gages for roofing, containers, cooking
vessels, and down to 0.04 mm for radiator fin stock.
➢Aluminum alloy sheet, of around 1.0-mm thickness, is extensively
used in aircraft fuselages, automotive components, and in trailer
construction.
➢Aluminum foil is rolled down to 8 µm gage at speeds up to 60 m/s
and used in large quantities for packaging.
➢Foils of thicknesses down to 3 µm are produced on special mills
(among them Sendzimir mills) in all materials.
➢Cost of rolling goes up as the gage decreases, especially if thinner
gage necessitates extra passes through a single-stand or tandem mill.
 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-high mill; (c) three-high mill; and (d) cluster (or Sendzimir) mill.
There are many types of rolling:
1. Flat rolling
2. Shape rolling
3. Ring rolling
4. Transverse rolling
 ho + h1
h=
2
L = R (ho − h1 ) = Rh
 = Entry Angle

Rolling
FIGURE 13.2 (a) Schematic illustration of the flat-rolling process. (b) Friction forces
acting on strip surfaces. (c) Roll force, F, and torque, T, acting on the rolls. The
width of the strip, w, usually increases during rolling, as shown later in Fig. 13.5.
 Process Parameters
ho v
 = ln ;  = 
h1 L
tan   
Process Limits
max reduction = (ho − h1 ) max =  R
2
Forces and Power Requirements
ho
1.  = ln
h1
v
2.  = 
L
K   n +1 
 fm (cold) =  
3.   n + 1 
v
 fm (hot) = Cave
m
; ave = 
L
4. Check h/L :
h  1 → Qi Inhomogeneous Deformation
L
h  1 → Qp Plane Strain Deformation
L
5. Rolling Force :
Pr = (1.15)(Lw)(Qσ fm )
w = width, L is contact rolling length
Torque = M T = Pr L

Power = (M T v)
R
2Pr LN Pr Lv
Power (in kW) = = where N = rpm
60000 R
Power (HP) = Torque (lb.in) x Speed (RPM) / 63,025
Torque (N.m) = 9.5488 x Power (kW) / Speed (RPM)
Power (kW) = Torque (N.m) x Speed (RPM) / 9.5488
 Pi
Qi =
f
 Rolling Process Analysis
An AISI 1015 steel slab of ho = 300 mm thickness and w0 = 1000 mm
width is hot rolled at 1000 ºC on a mill with rolls of 600-mm
diameter. The presence of scale reduces friction to  = 0.3. A
reduction of 27 mm is taken. Roll speed is 1.2 m/s. Calculate roll
force and power requirement.
Known Condition:
Hot Rolling of 1015 Steel, From Table 8.2, C = 120 Mpa, m = 0.1
Roll Radius = 300 mm, velocity = 1200 mm/s,  = 0.3
wo = 1000 mm, ho = 300 mm
First pass = h1 = 273 mm

max reduction = (ho − h1 ) max =  2 R = 0.32 * 300mm = 27mm

ho + h1 300 + 273
have = = = 286.5mm
2 2
L = R(ho − h1 ) = 300mm(27mm) = 90mm
ho 300 v 1200mm / s
 = ln = ln = 0.094;  =  = 0.094 = 1.2574s −1
h1 273 L 90mm
 Rolling Process Analysis Continued

 f = C m = 120Mpa(1.2574) 0.1 = 122.78 N / mm 2

h / L = 286.5mm / 90mm = 3.12
Qi from Figure 9 - 9 = 1.50
Roll pressure, p r = Qi *1.15 f = 1.5 *1.15 *122.78 N / mm 2 = 212 N / mm 2

Area of contact zone, A = L * w 0 = 90mm *1000mm = 90000mm 2

Roll Force, Pr = p r * A
212 N / mm 2 (90000mm 2 ) = 19062 KN

2Pr LN Pr Lv
Roll Power = =
60 R
(19062 KN )(90mm)(1200mm / s )
= 6862 KW
300mm
Reducing Roll Force
1. Reducing friction at the roll-workpiece interface
2. Using smaller diameter rolls to reduce the contact area
3. Taking smaller reductions per pass to reduce the contact area
4. Rolling at elevated temperatures to lower the strength of the
material
5. Applying front and/or back tensions to the strip
tan    max reduction = (ho − h1 ) max =  2 R
Defects in Rolled Plates and Sheets
1. Wavy Edges: results from roll bending. The strip is thinner
along its edges than its center, thus the edges elongate more than
the center.
2. Zipper cracks: result of poor material ductility at the rolling
temperature.
3. Edge cracks: result of poor material ductility at the rolling
temperature.
4. Alligatoring: complex phenomenon that is typically caused by
nonuniform bulk deformation of the billet during rolling or by
the presence of defects in the original cast material.
Because the quality of the edges of the sheet may affect sheet
metal forming operations, edge defects in rolled sheets often are
removed by shearing and slitting operations.
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.
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.
Rolling Mills
1. Two-high rolling mills
2. Four-high rolling mills
3. Tandem mills
4. Cluster or Sendzimir mill
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-high mill; (c) three-high mill; and (d) cluster (or Sendzimir) mill.
The finished product must have a uniform thickness in length and width,
a flat shape, a controlled and uniform surface finish, and reproducible
mechanical properties. Satisfying these requirements taxes the ingenuity
of the production engineer, equipment designer, control specialist and
theoretician and makes an apparently simple process into one of the most
complex ones ( Consider holding tolerance of ± 0.002 mm on kilometers
of 0.04 mm thick strip while rolling at a speed of 40 m/s!)
FIGURE 13.11 An example of a tandem-rolling operation.
 Rolling Process Analysis
An AISI 1015 steel slab of ho = 300 mm thickness and w0 = 1000 mm
width is hot rolled at 1000 ºC on a mill with rolls of 600-mm
diameter. The presence of scale reduces friction to  = 0.3. A
reduction of 27 mm is taken. Roll speed is 1.2 m/s. Calculate roll
force and power requirement.
Known Condition:
Hot Rolling of 1015 Steel, From Table 8.2, C = 120 Mpa, m = 0.1
Roll Radius = 300 mm, velocity = 1200 mm/s,  = 0.3
wo = 1000 mm, ho = 300 mm
First pass = h1 = 273 mm

max reduction = (ho − h1 ) max =  2 R = 0.32 * 300mm = 27mm

ho + h1 300 + 273
have = = = 286.5mm
2 2
L = R(ho − h1 ) = 300mm(27mm) = 90mm
ho 300 v 1200mm / s
 = ln = ln = 0.094;  =  = 0.094 = 1.2574s −1
h1 273 L 90mm
 Rolling Process Analysis Continued

 f = C m = 120Mpa(1.2574) 0.1 = 122.78 N / mm 2

h / L = 286.5mm / 90mm = 3.12
Qi from Figure 9 - 9 = 1.50
Roll pressure, p r = Qi *1.15 f = 1.5 *1.15 *122.78 N / mm 2 = 212 N / mm 2

Area of contact zone, A = L * w 0 = 90mm *1000mm = 90000mm 2

Roll Force, Pr = p r * A
212 N / mm 2 (90000mm 2 ) = 19062 KN

2Pr LN Pr Lv
Roll Power = =
60 R
(19062 KN )(90mm)(1200mm / s )
= 6862 KW
300mm