Module SM1: Forming Technology

Part SM1-2: Bulk Forming

Lecture 02: Rolling

2020-21

Prof. Dr.-Ing. habil. Sami Chatti

Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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 Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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Rolling of a Broad-Flange Girder

in a Forming Steel Line

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 Rolled Products

Semi-finished Finished products

product
Form steel Bar steel Sheets Cold strip

Beam blank > 120

Thin sheets
a ≤ 3mm

normal profiles a ≤ 3mm

Billet > 120 Web height > 80mm
Tubes
Heavy sheets
a ≥ 3mm
Plate a > 40 mm
Web height < 80mm
Roofing Profiles

Rails

Hot strip a ≥ 1.2mm Channels Wire

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Classification of rolling processes according

to DIN 8583

Tool kinematics: Longitudinal, cross and skewed rolling

Tool geometry: Flat and profile rolling

Workpiece geometry: Solid and hollow body

Longitudinal rolling Cross rolling Skewed rolling

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 8
7
Flat-Longitudinal rolling
Flat-

2020-21

2020-21
of solid products

Roll
Longitudinal
Flat-Longitudinal rolling rolling
of hollow products

Rolling stock
to DIN 8583

Profile-Longitudinal
rolling of solid products Profile-
Longtidunal rolling

Longitudinal
Profile-Longitudinal rolling

Source: Lange Vol. I – (DIN 8583)

rolling of hollow
products

Process principle

within its thickness and it is

Roll gap

The rolling stock is compressed

Flat-Cross rolling

elongated in longitudinal direction

Product
of solid products
Flat-
Flat-Cross rolling
Cross rolling
of hollow products

Sami Chatti

Sami Chatti
Principles of longitudinal rolling

Upper roll
Rolling

Profile-Cross rolling
Cross rolling

of solid products
Profile-
Profile-Cross rolling
Cross rolling
BF L02 Rolling

BF L02 Rolling
of hollow products
Classification of rolling processes according

Lower roll
Flat-Skewed rolling
of solid products
Flat-

Profile
Profile roll
Rolling stock
Skewed rolling
Flat-Skewed rolling
of hollow products

Flat rolling

Profile rolling
Profile-Skewed rolling
of solid products
Skewed rolling

Profile-
Skewed rolling

Roll design for longitudinal shapes

Profile-Skewed rolling
of hollow products
2.7

2.8

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 Video: Rolling of different products

( youtube)
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From Ore to Steel (1)

Continuous casting Hot forming Cold forming Surface refinement Finished products

( According to VDE )
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 From Ore to Steel (2)

Continuous casting Hot forming Cold forming Surface refinement Finished products

From Tube welding

secondary Tube rolling mills
metallurgy Drawing, Precisions tubes
Billet beam „Pilger“ procedure
blank casting beam blanks Shaped steel line
Shaped steel, heavy profiles
billets -beams, rails, sheet piling
profile blanks profiles

Bar steel line Drawing, peelling, grinding Bright steel

Light profiles, bar steel

Rolled wire
Wire line
Block casting Extrusion press Complicated profiles

Machining Forgings
Open die forge
Pre-linel Drop forge
Cast steel Machining Castings

Liquid crude steel Hot formed steel Coated steel

Firm, "red -hot" steel Cold formed steel

( According to VDE )
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Five-Stand Tandem Cold Mill

( A. – K. Bolbrinker )
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 Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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Flat-longitudinal rolling
Thickness change
 Thickness reduction ∆h
∆h = h0 - h1
 Relative thickness change εh:
εh = (h1 - h0) / h0 = ∆h / h0
 Compression ratio γ:
γ = h1 / h0 (γ < 1)

Width change
 Mean width 𝑏𝑚 =
 Spreading ratio β:
β = b1 / b0 (β ≥ 1)

Reduction per pass ∆A

∆A = A0 - A1

Equivalent strain (von Mises)

𝜑 = 𝑙𝑛 (Plane strain)

Source: Kopp
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 Deformation zone of the flat-longitudinal rolling

α0: Rolling angle

x: Horizontal coordinate in roll gap
(0 < x < ld)
ld: Compressed length (length of roll gap
in rolling direction)
h 2
l d  r  h   r  h
4

h(α), h(x) Local plate thickness in roll gap

h   h1  r   2
x2
h x   h1 
r
hm Mid plate thickness hm = 0.5 (h0+h1)
ld / hm Roll gap ratio (also ld / h0)
Ad: Compressed area (projection of the
contact area on xy-plane)
Source: Kopp
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Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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 Velocity field for the flat-longitudinal rolling
(Slab method)

Volume constancy
(for plane deformation):

h0  v0  h1  v1  h x   v x  x 
h0 h
vx  x   v0   v1  1
h x  h x 

2
with h x   h1  x follows:
r
h0 h1 v1
vx  x   v0  2
 v1  2
 Rolling stock velocity
x x x2 in roll gap
h1  h1  1
r r h1  r with: 0  x  ld
Source: Lange, Kopp
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Velocity increase
Example: Cold rolling-tandem mill

Quadro mills

h1
v2  v1
h2
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 Velocity field for the flat-longitudinal rolling
(Slab method)

Increase of the rolling stock velocity in roll gap from v0 to v1

Components of rolling circumferential velocity in rolling direction remains nearly

constant:

vux  vu  cos( )  vu
with cos   1

Source: Kopp
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Relationship between velocities of rolling stock and

rolls
BSZ: Backward slip zone
FSZ: Forward slip zone
vx: Rolling stock velocity
vux: Rolling stock circumferential
velocity component in rolling
direction

At the so-called neutral point (x = xF) the rolling stock and the rolling
circumferential velocity are equal: vx = vux
Relative velocity before and after the neutral point:
Backward slip zone: vrel = vx – vux < 0
Forward slip zone: vrel = vx – vux > 0
h1  v1 
Location of neutral point (volume constancy): xF  ld   1
h  r   
Source: Kopp
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 Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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BF Interactive

Question: Is rolling without friction possible?

Answer options: 0,9

0,8
A) Yes
0,7

0,6
B) No
0,5

0,4

0,3

0,2

0,1

0
A B

Reset Vote ID = sami.chatti@udo.edu

0 votes

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 Bite and deformation conditions

Bite condition:   FN  cos  0  FN  sin  0

  tan  0

Approximations:
with tan  0   0
h
follows:    0 or:  
r
 hmax   2  r
(max. possible thickness reduction)

Deformation condition:
 Assumption: Normal and friction force acting in the middle of the roll gap (at α0/2)

0 1 h
  tan 
 For the deformation condition (analog to the bite condition): 2 2 r
 hmax  4   r
2

→ Friction coefficients for bite and deformation condition can be different!

Source: Kopp
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Example 1: Longitudinal rolling (1)

Forming Geometry in Longitudinal Rolling

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 Example 1: Longitudinal rolling (2)

Parameters
d: Roll diameter
h 0: Sheet thickness before the pass
h 1: Sheet thickness after the pass
h(α), h(x): Local sheet thickness in roll gap
Δh: Thinning: Difference in thickness before and after the pass
ld : Compressed length: Length of roll gap in rolling direction
r: Roll radius
v 0: Initial sheet velocity
v 1: Sheet velocity after the pass (roll velocity)
x: Horizontal component in roll gap (0<x<ld)
α: Angle coordinate in roll gap (0 < a < a0) ; corresponds to
the length coordinate x
α0 : Rolling angle: Angle between Radius vectors to entrance
and exit planes
α0,max : Grip angle: Maximal rolling angle in which the grip condition
is just fulfilled
μ: Friction value

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Example 1: Longitudinal rolling (3)

Problem
For the hot rolling of a slab with following process parameters
h0 = 250 mm, h1 = 190 mm, d = 800 mm, µ = 0.5

Calculate:
1) the local slab height h in the rolling gap in dependence of α and x,
2) the decrease in height Δh in the rolling gap in dependence of α0,
3) the rolling angle α0 and
4) the length pressed ld

5) Check if the slab can be “gripped” in its first contact with the rolls!

Use for calculations following simplifications:

cos α ≈ 1 – α²/2 (power series)

(1−x²/r²) ≈ 1 – x²/2r² (binomial series)
(sin α)²+ (cos α)² = 1 (trigonometry)
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 Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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Calculation of rolling force and torque

Rolling force F
F    z dA
Ad

Estimation: F  Ad  k w  bm r  h  k w 𝜔

kw = mid σz (empirical value)

Rolling moment Md for a roll

ld

M d  b    z  x  dx
0

Estimation:
Md  F a
In which a = m ∙ ld and m ≈ 0.45
𝜔

Rolling power P
P  2  M d 

Source: Kopp
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 Compression stress distribution in rolling gap
during flat rolling (measured)
Along the rolling direction similar to the stress
state according to SIEBEL:
Strong increase up to neutral point, then drop z
toward the exit

Along the width b: largest stress is present in

the middle because of prevented flow of
material in the width direction

Source: Hoff and Dahl

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Example 2: Position of neutral point

Consider the process of Flat-Longitudinal Rolling given below:

Calculate the position of the neutral point xF in dependence of h1, v1, and r.
Respect following assumptions and simplifications:
- No widening of the sheet.
- Uniform speed distribution
- Plane sections remain plane
- ℎ x ≈ℎ +

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 Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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Quality failure: Crowning

Crowning: Plate is thicker in the central area than at the edge

Reasons:

Counteractive measures:
 Pre-stressing of the rolls and roll housing
 Working rolls supported by the back-up rolls
 Crowned grinding of rolls (camber)
 Specific cooling
Source: J. Ihlefeldt
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 Measure 1: Pre-bending of work rolls

Positive Negative
bending bending
Positive bending
of the working rolls

Positive pre-bending of working rolls counteracts the

negative bending from the band
(bending up in the roll gap)
Negative bending
of the working rolls

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Measure 2: Additional back up rolls

Additional support rolls prevent bending of the working rolls

a) Duo-Gerüst b) Quarto-Umkehrgerüst c) 20-Rollen-Gerüst

a) Two-high mill b) Four-high mill c) 20-high mill
(Duo) (Quadro) (Sendzimir design)

Driven rolls
Angetriebene Walzen
Non-driven
Nicht rolls Walzen
angetriebene

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 Consequences of a too weak roll crown

Source: Hosford & Caddel

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Consequences of a too strong roll crown

Source: Hosford & Caddel

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 BF Interactive

Question: Which curvature behavior of the emerging sheet is to be

expected with the roller misalignment shown?

Answer options:

A) Right curve

B) Left curve

Reset
Start Vote
Vote ID = sami.chatti@udo.edu
27 votes
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Videoclip: Hot rolling – Process steps

Process flow:

Block heating

Scale washer

Roughing train

Cropping shear

Finishing train

Strip cooling

Coiler
Source: https://www.youtube.com/watch?v=LWM6b8P0r3E
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 Videoclip: Hot rolled strip

Source: https://www.youtube.com/watch?v=AuuP8L-WppI
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Influence of rolling temperature

Hot Rolling
• Recrystallization
• Low deformation energy
• Surface scale
• Low strength
• Low residual stresses
Static
100 µm
Recrystallization
Hot rolled: S235 – Re > 235 MPa;
Grain growth A = 25 %

Dynamic
Cold Rolling Recrystallization
• No recrystallization
• High deformation energy
• High surface quality
• Work hardening
• Anisotropy
50 µm
• Residual stresses
Cold rolled: DC06 – Rp 0,2 > 120 MPa;
Source: ThyssenKrupp, Worldsteel Association
Rm > 270 MPa; r90 > 1,6
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 Content

L02 – Rolling

Introduction
Flat-longitudinal rolling
Fundamentals
Kinematics
Bite and deformation conditions
Stress state

Product properties
Process variants

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Profile-longitudinal rolling:
Hot rolling of steel profiles
Hot rolling of steel profiles generally with multiple calibers or passes
Adapted pass sequence for the gradual forming of the rectangular cross-section
to the final shape
Risk of high internal stresses at inapproriate pass sequence

Hot rolling process Profile rolling Pass sequence

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 Profile-longitudinal rolling of tubes:
Pilgrim step process

Pilger roll

Mandrel

Workpiece

Pilgrim step process (Mannesmann process)

Production of thin-walled seamless tubes
Gradual forming by stretching the thicker tube wall over a mandrel
Conical calibrated rolls are operated contrary to the rolling direction
Uniform wall thickness and circularity of the tube is obtained by repeatedly
rolling over each tube region

Source: DIN 8583-2:2003-09

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Cold pilger mill rolling process for seamless

steel tubes

Source: https://www.youtube.com/watch?v=rCg04bDqaSE
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 Profile-longitudinal rolling

carrier
Torsion bar flange

Cold rolling of spline shafts of

Cold reduction of solid material solid material

Disc
carrier

Cold rolling of thin-walled, cylindrical

hollow parts
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State of the Art: Rolling of Shapes -

Grob-Procedure
Process principle: Grob-Procedure:

Workpiece clamping

Adjustment of rolls

Rolls create compressive

stresses

Shape is make

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 Flat-cross rolling of hollow bodies:
Ring rolling

Ring rotates between main roll and mandrel roll

Thickness and diameter of the ring are determined by the
radial adjustment of the mandrel roll
Production of the outside circular contour by centering rolls
Second pair of rolls (axial rolls) for simultaneous rolling of
the front faces of the ring

Source: E. Dittrich und J. Teutrine

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Skewed rolling – procedure I

Roll

Workpiece

Thread rolling is a continuous Skewed rolling of parts

process (ex. Bearing balls)

Source: Fritz and Schulze, DIN 8583-2:2003-09

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 Skewed rolling – procedure II
Video: Manufacturing of seamless pipe

Roll

Plug bar

Workpiece

Plug

Skewed rolling for piercing

with barrel rolls
(Mannesmann process)

Source: Fritz and Schulze, DIN 8583-2:2003-09

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Hot Rolling of Toothed Wheels

a) Slug (forging) b) After pre-rolling with smooth rolls

c) After blooming-down of the toothing Workpiece

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 Rolled and Toothed Workpieces

(PEE-WEE)
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Production of Spur-Gears and Thread

by Cross Rolling

Two rolls profile (thread/gear) rolling

Roto-Flo process
WPM process
( According to D. Schmoeckel / youtube)
(Poland)
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 Flexible rolling „Tailor Rolling“

Product designed for various loading along the component

Variable profile thickness in longitudinal rolling direction

Product: Tailor Rolled Blanks

Automobile cross member

(tailor rolled blank)

Source: RWTH Aachen

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Integrated tube production at Sandvik

Source: https://www.youtube.com/watch?v=7ITgMXtuMv0

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 Appendix: English for Production Engineers

English Français English Français

Rolling Laminage Forward slip Zone de glissement
zone en avant
Rolling stock Produit laminé Neutral point Surface neutre
d’écoulement
Roll gap Emprise cylindre Bite condition Condition
d‘engagement
Roll pass Passe de Crown / Camber Bombé
laminage
Roll stand Cage de laminoir Ring rolling Laminage circulaire

Rolling Direction de Profile rolling Laminage de profilés

direction laminage
Backward slip Zone de Thread rolling Roulage de filets
zone glissement arrière
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