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Introduction To Manufacturing: Chapter 13: Rolling

The document discusses the rolling process which uses compressive forces to reduce the thickness or change the cross-sectional area of a long workpiece. Rolling accounts for about 90% of all metals produced and produces continuous products unlike forging which produces discrete parts. The document describes different types of rolling mills, rolling terminology, defects that can occur, and various rolling processes including flat rolling, shape rolling, ring rolling, thread rolling, and rotary tube piercing.

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Lue ni
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106 views19 pages

Introduction To Manufacturing: Chapter 13: Rolling

The document discusses the rolling process which uses compressive forces to reduce the thickness or change the cross-sectional area of a long workpiece. Rolling accounts for about 90% of all metals produced and produces continuous products unlike forging which produces discrete parts. The document describes different types of rolling mills, rolling terminology, defects that can occur, and various rolling processes including flat rolling, shape rolling, ring rolling, thread rolling, and rotary tube piercing.

Uploaded by

Lue ni
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Introduction to Manufacturing

Chapter 13: Rolling


Rolling
• Process of reducing the thickness or
changing the cross-section area of a
long work piece by compressive forces.
• accounts for about 90% of all metals
produced by metalworking processes.

 forging operations produce discrete parts,


where rolling operations produce
continuous products.

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Rolling

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Rolling Rolls

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Rolled Texture

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Unrolling and Straightening of
Rolls (Maytag)

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Roll Loading

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Rolling Process
• Terminology (raw material)
• Bloom: square cross section of at least 6"
on the side. (sheets)
• Billets: square cross section, smaller than
bloom. (rod, pipe)
• Slab: rectangular in shape, rolled into
plates and sheet. (rails, I-beams)

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Rolling Mills
• Two-high
• primary roughing (cogging mills).

• Three-high
• primary roughing (reversing mill).

• Four High & Cluster


• principal (small diameter) rolls lower the roll forces
and power requirements, but must be supported in
order to reduce deflection.

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Rolling Mills

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Rolling Mills
• Tandem Rolling
• strip is rolled continuously through a
number of strands (set of rolls with its own
separate housing and controls) to smaller
gauges with each pass.

• Group of Strands = train

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Roll Deflections
• Rolling forces cause deflection and roll
flattening.
• Crown: thicker in the center than the
edges.
• Chamber: thicker in the edges than
center.
• Spreading: increase of width after rolled.

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Roll Deflections
• Forces can be reduced by:
• reducing friction.
• reducing contact area.
• smaller reductions per pass.
• rolling at elevated temperatures to reduce
strength of material.

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Roll Materials

• Cast iron

• Cast steel

• Forged steel

• Aluminum Alloys

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Rolling Processes
• Flat-rolling
• hot or cold work (slabs, blooms, billets, or sheet
metal).
• 3000 °F for refractory alloys.
• 2300 °F for alloy steels.
• 850 °F for aluminum alloys.

• Pack Rolling: two or more layers of metal rolled


together (Al foil example)

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Flat-rolling (Cont.)
• Defects (P. 327)
• wavy edges
• zipper cracks
• edge cracks
• alligatoring

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Rolling Processes
• Shape Rolling (P. 331)
• structural shapes (I-beam, rails, etc.)
• requires specially designed rolls

• Ring Rolling (P. 332)


• ring (which is the part) placed between two rolls,
to increase diameter.
• large rings for rockets, gearwheel rims, ball
bearing and roller- bearing races, flanges,
reinforcing rings for pipes, etc.

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Rolling Processes
• Thread rolling (P. 333)
• cold-forming process where threads are formed
on round rods by use of flat reciprocating dies
which pass the part between them.
• no material loss.
• no cutting through grain line flow improves
strength.

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Rolling Processes
• Rotary Tube Piercing (P. 334)
• hot working process for making long, thick
walled seamless tubing/pipe.
• round bar subjected to radial compressive
forces causing tensile stresses toward the
center of the bar.
• cavity forms from cyclic compressive
stresses.

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