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
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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

Start Vote ID = sami.chatti@udo.edu

Vote has not been started yet

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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  2  r

→ 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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