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Metal Forming Lect 3

This document discusses metal forming processes with a focus on rolling mechanics and flat rolling. It covers topics such as drafting, reduction ratio, factors that influence the angle of bite, and equations for determining torque and power requirements. Methods for increasing drafting and ways to reduce roll separating forces are also presented.

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e22mecu0009
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17 views

Metal Forming Lect 3

This document discusses metal forming processes with a focus on rolling mechanics and flat rolling. It covers topics such as drafting, reduction ratio, factors that influence the angle of bite, and equations for determining torque and power requirements. Methods for increasing drafting and ways to reduce roll separating forces are also presented.

Uploaded by

e22mecu0009
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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LECTURE 3: METAL FORMING PROCESSES

ROLLING MECHANICS
Flat Rolling

Side view of flat


rolling, indicating
before and after
thicknesses, work
velocities, angle of
contact with rolls, and
other features
Flat Rolling Terminology

Draft = amount of thickness reduction


d = t o −t f

Reduction ratio = draft expressed as a fraction of


starting stock thickness:
d
r =
to

where d = draft; to = starting thickness; tf = final


thickness, and r = reduction ratio
Factors influencing Angle of Bite

1) Rolling temperature (Hot rolling/ cold rolling)

2) Surface roughness of rollers

3) Diameter of rollers
Torque and Power Requirements

Roll Force = Flow stress x length of contact x width of plate

Assuming that the roll force is centered on the work as it passes


through the rolls, and it acts effectively at ½ the contact length,

Torque ‘T’ for each roll = (F x L)/2

Power required to drive each roll = Torque x Angular velocity


P = 2𝝅𝑵𝑭𝑳
Where P = Power in Watt
N = rotational speed , rev/s
F = rolling Force, N
L = contact length, m
Methods to increase the Draft

1) Larger diameter rolls and higher coefficient of


friction allow heavy draft
2) It is possible to roll with greater draft if the work is
pushed between the rolls
3) Radius of the rolls must be small to increase the
length of contact, and subsequently draft
1) If the coefficient of friction for cold rolling is 0.08,
determine the a) contact length b) velocity of the slab at
the exit c) specific roll pressure d) Rolling Torque. Use the
following data; width of slab = 80 mm, roll radius = 800
mm, thickness of the slab = 400 mm, velocity of the slab at
the entry = 200 mm/sec and rolling load = 14 MN
Lc = 64 mm

V2 = 202.63 mm/s
ROLL DEFLECTION / Roll Bending

Flatness and uniform thickness: Strength and rigidity are


important characteristics of the rolls used to form product in
metal rolling. The roll gap must be perfectly parallel to
produce sheets/plates with equal thickness at both ends.

Flatness of rolled sheets depends on the roll deflection. The


thickness of the sheet becomes uneven as roll deflection
occurs.
Roll Deflection: During the rolling process, rolls will be
subjected to some degrees of deflection.

The rolls initially start out flat. During the rolling process great
forces act upon the rolls. It is observed that the work material
exert greater force on the rolls towards the center of the material
than at its edges. This will cause the rolls to deflect at the center.
1. Roll deflection results in uneven sheet thickness across the
length.
2. If rolls are elastically deflected, the rolled sheets become thin
along the edge, whereas at centre the thickness is large.
Thicker centre means the edges would be plastically elongated
more than the centre,
3. Due to continuity of the sheet, the centre is subjected to
tension, while edges are subjected to compression. This leads
to waviness along the length
Ways to reduce the roll separating force

1. For a given reduction in thickness of the work piece the roll


separating force (influencing roll bending) increases linearly
with roll radius. Forces will be set up along the length of the
roll and try to separate the rolls and deflect. Hence to reduce
the deflection due to bending in the rolls, the diameter of the
rolls is to be kept to a minimum. A more economical way to
reduce the deflection is to use back up rolls with larger radius
to increase the rigidity. The radius of the back up rolls ‘R’
will be greater than the radius ‘r’ of drive roll.
2. Roll Camber
Roll Camber

By providing convex contour on the surface of the rolls


along the length, roll deflection can be taken care.
ROLL CAMBER

1. The convex contour provided on the rolls is called


“Roll Camber”.
2. Without Roll Camber the thickness of the work
piece is more at the centre than at the ends. But with
Roll Camber, uniform thickness is maintained across
the width of the work.
Variation of Roll Pressure Vs Length of Arc of contact

• Area under the curve


ABC is proportional to
the rolling load.
• Area under AB
represents force required
to deform the metal in
plane homogeneous
compression.
• Shaded area represents
force required to
overcome the frictional
force between the roll
and the work.
Roll Defects
STRAIN RATE SENSITIVITY
What is Strain Rate?

1. Strain rate in forming is directly related to speed of deformation


v
2. Deformation speed v = velocity of the ram or other movement
of the equipment
3. Strain rate is defined:
v
=
h
where  = true strain rate; v = deformation speed and
h = instantaneous height of workpiece being deformed
Evaluation of Strain Rate

1) In most practical operations, evaluation of strain rate is


complicated by :
• Work part geometry
• Variations in strain rate in different regions of the part
2) Strain rate can reach 1000 s-1 or more for some metal forming
operations
Effect of Strain Rate on Flow Stress

• Flow stress is a function of temperature


• Under hot working temperatures, flow stress also
depends on strain rate
• As strain rate increases, resistance to deformation
increases. This effect is known as strain-rate
sensitivity
Strain Rate Sensitivity

(a) Effect of strain


rate on flow
stress at an
elevated work
temperature

(b) Same
relationship
plotted on
log-log
coordinates
Strain Rate Sensitivity Equation

Yf = Cεm

where C = strength constant (analogous but not equal to strength


coefficient in flow curve equation), and
m = strain-rate sensitivity exponent

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