Rolling: Metal Working Process
Rolling: Metal Working Process
Rolling: Metal Working Process
Metal Working Process: Hot and cold working of Metals: Basic Principles of hot and cold working of metals. Rolling: Types of Rolling, Rolling equipments hot and cold rolling, General deformation pattern, Pressure and forces in rolling.
ROLLING
The process of plastically deforming metal by passing it between the rolls is known as rolling. The work is subjected to high compressive stresses from squeezing action of rolls. The frictional force between metal and rolls is responsible for drawing the metal into the rolls. Classification of Rolling Process i) Hot Rolling ii) Cold Rolling iii) Powder Rolling
Hot Rolling:
Hot working ---- above the re-crystallization temperature It is employed where large reduction in cross-sectional area is required. Hot rolling refine the grain structure. Used for bars, rods, rails etc.
Cold Rolling:
Cold working ---- below the re-crystallization temperature Employed for finishing the metal to given specification of sizes and surface quality. Cold rolling distorts the grain structure. Produces sheets, strips and foils with good surface finish and increased mechanical strength.
Powder Rolling:
Metal powder is introduced between the rolls and turned into a green strip which is subsequently sintered to high density. This produces a tough sheet with very fine grain size or minimum of preferred orientation.
ROLLED PRODUCTS
i) Bloom: First breakdown product of ingots with a minimum crosssectional area of 36 in2. Generally, square in cross-section. ii) Billet: Further reduction of bloom by rolling results in a billet. Cross-sectional area 1.5 in. X 1.5 in. iii) Slab: A hot rolled ingot with a width to thickness ratio of 2:1 at least. Cross-sectional area over 16 sq. in.
**Blooms, billets and slabs are known as semi-finished products because they are subsequently formed into other mill products.
iv) Plate: It has thickness greater than in. v) Sheet and Strip: Generally have thickness lesser than in.
Rolling Process:
In the process of rolling the billet is fed from one side into the rolls and reduces in thickness according to the section and gap between the rolls. The reduction ratios have maximum allowable values for different metals beyond which reduction is not practicable in a single process. Rolling sets in series may be employed. ** There are fundamentally two types of rolls: i) Supporting rolls ii) Driving rolls ** the rolls must be rigid or the rolled material will have a loop like shape.
ROLLING MILLS: A rolling mill consists basically of rolls, bearings, a housing for containing these parts, and a drive for applying power to the rolls and controlling there speeds. Rolling mills can be conventionally classified with respect to the number and arrangement of the rolls. Classification of rolling mills: i) Two-high mills ii) Two-high reversing mills iii) Three-high mills iv) Four-high mills v) Cluster mills vi) Continuous mills vii)Planetary mills
Continuous rolling
Use 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 mill. The speed of each set of rolls is synchronized so that the input speed of each stand is equal to the output speed of preceding stand. The uncoiler and windup reel not only feed the stock into the rolls and coiling up the final product but also provide back tension and front tension to the strip.
Ring Rolling
Plate rolling
The area under the curve is proportional to the rolling load. The area in shade represents the force required to overcome frictional forces between the roll and the sheet. The area under the dashed line AB represents the force required to deform the metal in plane homogeneous compression.
Where
1) No friction situation
In the case of no friction situation, the rolling load (P) is given by the roll pressure (p) times the area of contact between the metal and the rolls (bLp).
Where the roll pressure (p) is the yield stress in plane strain when there is no change in the width (b) of the sheet.
Where Q = Lp/h h = the mean thickness between entry and exit from the rolls.
Where
Roll diameter
Rolling load
Before
After
20
Porosity, cavity, blow hole occurred in the cast ingot will be closed up during the rolling process. Longitudinal stringers of non-metallic inclusions or pearlite are related to melting and solidification practices. In severe cases, these defects can lead to laminations which drastically reduce the strength in the thickness direction.
There are two aspects to the problem of the shape of a sheet. 1) Uniform thickness over the width and thickness can be precisely controlled with modern gage control system.
Under high rolling forces, the rolls flatten and bend, and the entire mill is elastically distorted. Mill spring causes the thickness of the sheet exiting from the rolling mill to be greater than the roll gap set
Flatness
The roll gap must be perfectly parallel to produce sheets/plates with equal thickness at both ends. The rolling speed is very sensitive to flatness. A difference in elongation of one part in 10,000 between different locations in the sheet can cause waviness.
Rolling direction
Perfectly flat
Rolling Defects
Edge Buckling
Because of inhomogeneous deformation in thick slab, the center portion of the sheet is stretched in tension and the edges are compressed in the rolling direction. The result is a wavy edge or edge buckle. The reverse load condition zipper breaks are formed
If the lubrication breaks down so that the flow stress increases because the temperature decreases, the plastic curve will be raised. The rolling load will be increased from P1 to P2 and the final thickness will be increased from hf1 to hf2.
Rolling Torque
Power
Effect of cold working on tensile strength, hardness, ductility and grain size. (The curve below ductility represents the change in grain size)
END OF ROLLING
Figure 18.5 (a) Effect of strain rate on flow stress at an elevated work temperature. (b) Same relationship plotted on log-log coordinates.
where C = strength constant (similar but not equal to strength coefficient in flow curve equation), and m = strain-rate sensitivity exponent
Flow Stress
For most metals at room temperature, strength increases when deformed due to strain hardening Flow stress = instantaneous value of stress required to continue deforming the material
Yf K n
where Yf = flow stress, that is, the yield strength as a function of strain
Cold Working
Performed at room temperature or slightly above Many cold forming processes are important mass production operations Minimum or no machining usually required
These operations are near net shape or net shape processes
Forging: The workpiece is compressed between two opposing dies so that the die shapes
are imparted to the work.
Extrusion: The work material is forced to flow through a die opening taking its shape
Drawing: The diameter of a wire or bar is reduced by pulling it through a die opening (bar
drawing) or a series of die openings (wire drawing)
Warm Working
Performed at temperatures above room temperature but below recrystallization temperature Dividing line between cold working and warm working often expressed in terms of melting point:
0.3Tm, where Tm = melting point (absolute temperature) for metal
Hot Working
Deformation at temperatures above the recrystallization temperature Recrystallization temperature = about one-half of melting point on absolute scale
In practice, hot working usually performed somewhat above 0.5Tm Metal continues to soften as temperature increases above 0.5Tm, enhancing advantage of hot working above this level
Strain rate can reach 1000 s-1 or more for some metal forming operations