Mansoura University

Faculty Of Engineering
Mechanical Power Engineering

Defects In Rolled Plates & Sheets

Prepared By

Mahmoud Mohamed Mohamed Abd El Kader

TO

DR / Mona Abu El Eaz

Conclusion :

That report discusses defects on rolling processes either in

plates or sheets . Briefly , we discussed forming definition .
Then , we discussed the defects ( wavy edges , alligatoring ,
undesirable defects and sheet metal defects ) .
Introduction :

Rolling is a metal forming process in which metal stock is passed through one or

more pairs of rolls to reduce the thickness and to make the thickness uniform. The

concept is similar to the rolling of dough. Rolling is classified according to the

temperature of the metal rolled. If the temperature of the metal is above its

recrystallization temperature, then the process is known as hot rolling. If the

temperature of the metal is below its recrystallization temperature, the process is

known as cold rolling. In terms of usage, hot rolling processes more tonnage than any

other manufacturing process, and cold rolling processes the most tonnage out of all

cold working processes.Roll stands holding pairs of rolls are grouped together into

rolling mills that can quickly process metal, typically steel, into products such as

structural steel (I-beams, angle stock, channel stock, and so on), bar stock, and rails.

Most steel mills have rolling mill divisions that convert the semi-finished casting

products into finished products.

Rolling defects:

Mill spring is a defect in which the rolled sheet is thicker than the required thickness because,

the rolls get deflected by high rolling forces. Elastic deformation of the mill takes place. If we

use stiffer rolls, namely roll material of high stiffness or elastic constant, we could avoid mill

spring. Normally elastic constant for mills may range from 1 to 4 GNm
 Wavy Edges :

Roll elastic deformation may result in uneven sheet thickness across. Roll material should

have high elastic modulus for reducing the roll deformation. For producing very thin gage sheets

like foils, small diameter rolls are used. They are supported with larger rolls. We can say the

minimum thickness of rolled sheets achieved is directly proportional to roll radius, friction, flow

stress. Flatness of rolled sheets depends on the roll deflection. Sheets become wavy as roll

deflection occurs.

If rolls are elastically deflected, the rolled sheets become thin along the edge, whereas at

centre, the thickness is higher. Similarly, deflected rolls result in longer edges than the centre.

Edges of the sheet elongate more than the centre. Due to continuity of the sheet, we could say

that the centre is subjected to tension, while edges are subjected to compression. This leads to

waviness along edges. Along the centre zipper cracks occur due to high tensile stress there.

Cambering of rolls can prevent such defects. However, one camber works out only for a

particular roll force.

Edge Cracks :

Small thickness sheets are more sensitive to roll gap defects leading to greater defects. Thin strips

are more likely to undergo waviness or buckling. These defects are corrected by doing roller leveling or

stretch leveling under tension. Stretch leveling is carried out between roller leveler rolls.

During rolling the sheet will have a tendency to deform in lateral direction. Friction is high at the centre.

Therefore, spread is the least at the centre. This leads to rounding of ends of the sheet. The edges of

the sheet are subjected to tensile deformation . This leads to edge cracks. If the center of the sheet is

severely restrained and subjected to excess tensile stress, center split may happen.
Barrel :

This defect happens when you are rolling material that is thicker then what the rolls are cambered for.

Because the plate is thicker it deflects all of the camber out of the roll while you are bending the plate

causing the rolls to pinch the plate tighter on the outside edges and looser in the middle. The result is a

seam that is closed more on the ends of the plate and is open in the center. To compensate for this you can

try to use a lower pinching pressure so when you pinch the rolls together the lower pinching pressure

deflects the rolls less. The down side to this is that it can require you to leave a longer flat on the pre-bend.

The other option to correct this defect is called shimming. You have to use some type of material (cardboard

for example) and place it along the edge of the plate in the center of the plate. Usually the middle third of the

material. This cardboard (or shim) placed on top of the material essentially changes the camber of the roll

making it bigger in the center so when the roll is deflected during bending you get a straighter seem as the

shim fills in the space left by too much deflection of the roll. The thickness and width of the shim can be

adjusted depending on the severity of the defect.

Alligator Cracks : Non-homogeneous material deformation across the thickness leads to high secondary

tensile stress along edge. This leads to edge cracks. Secondary tensile stresses is due to bulging of free

surface. Edge cracks can be avoided by using edge rolls. Due to non homogeneous flow of material

across the thickness of the sheet, another defect called allegatoring occurs. This is due to the fact that the

surface is subjected to tensile deformation and centre to compressive deformation. This is because

greater spread of material occurs at center.

Residual stress in rolling: Compressive stress is induced on the surface of rolled product if small

diameter rolls are used or if smaller reductions are affected during rolling. Stress in the bulk of the strip is

tensile in the above case. Larger reductions or rolling using large diameter rolls leads to tensile stress on

the skin and compressive stress in the bulk of the metal. Stress relieving operation can be used to relieve

the residual stresses of rolled products.

Surface cracking (also called hot shortness)

•If temperature, friction or speed is too high, intergranular cracks occur
•Common in aluminum, magnesium, and zinc alloys
•Bamboo defects are periodic surface cracks that develop due to the extruded
product sticking to the die land

Internal cracking (also called center burst, chevron cracking)

•Due to hydrostatic tensile stress at centerline of deformation zone
(similar to necking in a tensile test specimen)
•Increases with increased die angle, impurities
•Decreases with increased extrusion ratio and friction
List of figures :
References :

http://rprasadmechanical.blogspot.com/2016/03/defect-in

https://www.slideshare.net/veerendrachaurasiya/design-fo