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5 Rolling Process

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Pratik Ghosh
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94 views48 pages

5 Rolling Process

Uploaded by

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

Rolling Process
• Rolling is a metal forming process in which the thickness of the work
is reduced by compressive forces exerted by two rolls rotating in
opposite direction.
• The basic process shown in figure is flat rolling (1600), used to
reduce the thickness of a rectangular cross section. A closely related
process is shape rolling (1783), in which a square cross section is
formed into a shape such as an I-beam.
• The rotating rolls perform two main functions: (1) Pull the work into
the gap between them by friction between work part and rolls;
(2) Simultaneously squeeze the work to reduce cross section.
• Most rolling processes are very capital intensive, requiring massive
pieces of equipment, called rolling mills, to perform them.
• Blooms are rolled into structural shapes like rails for railroad tracks.
• Billets are rolled into bars, rods. They become raw materials for
machining, wire drawing, forging, extrusion etc.
• Slabs are rolled into plates, sheets, and strips. Hot rolled plates are
generally used in shipbuilding, bridges, boilers, welded structures for
various heavy machines, and many other products.
Types of Rolling

• By geometry of work:
➢ Flat rolling - used to reduce thickness of a rectangular
cross-section
➢ Shape rolling - a square cross-section is formed into a
shape such as an I-beam

• By temperature of work:
➢ Hot Rolling –most common due to the large amount of
deformation required
➢ Cold rolling –produces finished sheet and plate stock
Roll Configurations

Two-high rolling mills: rolls in these mills have diameters in the range 0.6 to 1.4 m
Roll-work contact length is reduced with a lower roll radius, and this leads
to lower forces, torque, and power.
Roll Configurations
Roll Configurations
Thread and ring rolling

Faster production, (1) better material utilization, (2) stronger threads due to work
hardening, (3) smoother surface, and (4) better fatigue resistance due to compressive
stresses introduced by rolling.

roller bearing races, steel tires for railroad wheels, and rings for pipes, pressure
vessels, and rotating machinery – more complex shapes. Adv. – raw material
savings, ideal grain orientation for the application, and strengthening through 10 cold
working.
Roll process Analysis
Roll Analysis

(Conservation of material) (Continuity of volume flow rate)


Roll Analysis
Roll Analysis
Roll Analysis
Roll Analysis
Roll Analysis
Roll Bite Condition

▪ If 𝒕𝒂𝒏𝜽 > 𝝁, the workpiece cannot be drawn.


▪ If 𝝁 = 𝟎, rolling cannot occur.
Example 1:

Solution:
Example2:
Example 3:
Rolling Mechanics
Rolling Mechanics
40
General:

At neutral point:

Roll pressure in the region before and after the neutral point:

Roll Separating Force:


General:

At neutral point:

Roll pressure in the region before and after the neutral point:

Roll Separating Force:


Self study
forging defects
rolling defects

Thank you

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