Module 3- Important Topics

• Hot & Cold rolling • Mechanics of flat rolling

• Types of rolling mills/rolls • Roll pressure distribution
• Tube Rolling/Roll Piercing • front and back tension
• Ring rolling • Friction in rolling
• Thread rolling • Deflection and flattening
• Rolling defects • Spreading
• Tresca & Von Mises yield • Roll forces in rolling
criteria • Numerical Problems

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 Hot Rolling

• Hot rolling is the process of rolling a metal above its

recrystallization temperature.
• As a result of squeezing, the grains are elongated in the
direction of rolling and after crossing the stress zone, grains
start refining.

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Cold Rolling
• Cold Rolling is a process of rolling
metals and alloys below their
recrystallization temperatures.
Generally they are worked at room
temperatures.

• In Cold Rolling, the grains tend to retain

the shape acquired during rolling.

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SL.No Hot Working Cold Working

Metal heated above its Metal heated below its

1.
recrystallization temperature. recrystallization temperature.
No strain hardening.(ie.
2. Recrystallization takes pace with strain hardening(work hardening).
deformation)
Co-efficient of friction between rolls
3. Lesser.
and work is higher.
Heavy reduction in area can be Heavy reduction in area cannot be
4.
obtained. obtained.
Mechanical properties are improved. Hardness increases. Brittleness
5.
Less decrease in ductility. increases. Ductility decreases.
Blow-holes and other similar defects Excessive cold rolling generates
6.
are removed. cracks.

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 Types of Rolling Mills
• Two High Mill
• Three High Mill
• Four High Mill
• Cluster Mill
• Tandem Mill
• Planetary Rolling Mill

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 Two High Mill
Reversing • This is the simplest and most
common type of rolling.
• These are further classified as
reversing and non reversing mills.
• In non reversing mills, rolls of
equal size are rotated only in one
direction.
• In two high reversing mill the work
can be passed to and fro through
Non the rolls by reversing their
Reversing direction of rotation.
• The space between the rolls can
be adjusted by raising or lowering
the upper roll.
• Used for breaking down of ingots.

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Three High Mill
• This consists of three rolls of
equal size one above the other.
• In the upper and lower rolls are
power driven, while the middle
roll rotates by friction.
• The direction of upper and
lower rolls are the same.
• Used for the production of
steel shapes such as I-beams,
angles, channels etc

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Four High Mill
• This consists of two small diameter working
rolls and two large diameter backup rolls
placed one above the other.
• The larger diameter called as Backup rolls
and its function is to prevent the deflection
of small rolls.
• The smaller rolls are called as Working rolls.
• Less power needed as less friction due to
less contact area.
• Generally used for sheet rolling.
• Used for slab production

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Cluster Mill

• Each of the work rolls (which are Power

driven) are supported by two backing
rolls.
• Used for the production of thin sheet

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Tandem Mill

In this, a series of rolling

mills are after the other, to
facilitate high production
each stand.

Each set of rolls is called

stand.

Since different reduction

takes place at each stand,
the strip will be moving at
different velocities.

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 Planetary rolling mills
• In this type of rolling machine,
a large backup roller is
surrounded by various
numbers of planetary working
rollers
• Each planetary roll gives
constant reduction. It is used
to reduce large thickness in
single pass of steel strip.
• Its rolling capacity is more
than cluster machine but less
than tandem rolling machine.

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Seamless Pipes (Tube Rolling or Roll
Piercing)
– Heated billet is pierced using a punch to create a
hole of predetermined depth (operation called
Punch Piercing).
– A mandrel is placed inside the workpiece and is
placed between conical shaped roller dies and is
rolled.
– Diameter of the mandrel controls the inner
diameter of the tube to be produced.

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Seamless Pipes (Tube Rolling or Roll
Piercing)

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 Ring rolling

A thick walled ring of smaller diameter is rolled into a thin walled ring
of larger diameter

ADVANTAGES
1. No metal removal
2. Can be carried out at room temperature
3. Short production time
4. Close dimensional tolerance
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Thread Rolling

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 Various Rolling Processes and Mills
Shape Rolling
• Straight and long structural shapes (such as
channels, I-beams, railroad rails, and solid
bars) are formed at elevated temperatures by
shape rolling (profile rolling),
• in which the stock goes through a set of
specially designed rolls

Steps in the shape rolling of an I-beam part.

Various other structural sections, such as channels and
rails, also are rolled by this kind of process.

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Defects in Rolling

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 Rolling defects
 Wavy Edges
-Due to bending of rolls, the edges of strip will be compressed more
than at the centre. Cambering of rolls can prevent defect
 Zipper Cracks
-Occur at centre of sheet due to poor material ductility at rolling
temperature
 Edge Cracks
-Due to non homogeneous plastic deformation of metal across the
width
 Alligatoring
-Opening up at the free end of the rolled sheet. Due to friction
between roll surface and the upper or lower work piece surface
 Surface Defects- scaling, scratches, cracks on surface
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 Rolling defects
1. Centreline wrinkling 3. Alligatoring

2. Edge cracking Alligatoring is a complex phenomenon and may

be caused by non uniform deformation during
rolling or by the presence of defects in the
original cast billet

4. Wavy edges
Thicker edges than the centre means the centre
would be plastically elongated more than the edges,
resulting in lateral
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PRINCIPLE OF ROLLING

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 Principle (mechanism) of rolling
• Rolling basically consists of passing the metal piece through
two rolls rotating in opposite directions. The space between
the rolls is adjusted to the desired thickness of the rolled
section.
• The rolls are in contact with passing metal piece over a
sufficient distance represented by the arc AB in the diagram.
• The angle AOB is called Angle of Contact or the Maximum
angle of Bite.
• The friction between metal piece and rolls provide sufficient
grip for the rolls to move the metal piece through the rolls.
• The reduction in thickness increases with coefficient of
friction.
• The line representing the maximum pressure is called Neutral
or No Slip Line and the point C is known as No Slip Point or
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Forward Slip = (Vf – Vr)/ Vr
where Vr- roll velocity (surface speed of roll)

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Roll Force

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Equations for Reference

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 Roll Pressure Distribution
• Pressure rises to a
maximum at the neutral
point and then falls off
• Pressure distribution
does not come to a
sharp peak at the neutral
point which indicates
that the neutral point is
not really a line on the
roll surface but an area

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Front and back tensions

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 Front and back tensions
• Roll force can be reduced by applying a tensile force to the
strip
• Tension in rolling can be applied either at the entry (back
tension) or at the exit (front tension) of the strip or at the
both
• Front tension leads to shift of the neutral point forward
whereas the application of back tension shifts the neutral
point backward
• Roll force, torque and power for rolling get reduced

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 Roll deflection and roll flattening
• As a result of roll bending, the rolled strip tends to be thicker at
its center than at its edges (crown).
• The usual method of avoiding this problem is to grind the rolls in
such a way that their diameter at the center is slightly larger than
at their edges. This is called cambering of rolls.
• Thus, when the roll bends, the strip being rolled now has a
constant thickness along its width
• Roll forces also tend to flatten the rolls elastically, producing an
effect much like the flattening of automobile tires under load.
• This increase in radius of curvature of rolls due to the roll
pressure causes elastic deformation of rolls. This is known as roll
flattening
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Roll deflection and roll flattening

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 Spreading
• In rolling plates and sheets with high
width-to-thickness ratios, the width of
the strip remains effectively constant
during rolling.
• However, with smaller ratios (such as a
strip with a square cross section), its
width increases significantly as it
passes through the rolls. This increase
in width is called spreading
• Spreading can be avoided by increasing
width to thickness ratio, increasing
friction, increasing ratio of roll radius to
strip thickness and also by using
additional vertical rolls
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 Elastic and plastic deformation of Metals

• Deformation is the change in dimensions or form of a material under the action of any
applied force or load.

The deformation can be (i) elastic or (ii) plastic.

• Elastic deformation disappears completely when load is removed.
• Plastic deformation is a permanent deformation without failure and takes place when
elastic range of the deformation has been exceeded.
• The plastic deformation does not disappear when load is removed

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 Stress Strain Relationship

• Hooke’s Law states that the strain of the material is proportional to the applied
stress within the elastic limit of that material.

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 YIELD CRITERIA

• Yield: The yield strength or yield point of a

material is defined as the stress at which a
material begins to deform plastically
• For loading less than yield point, the material will
deform elastically and it will return to original
shape when the loading is removed.
• Once the yield point is passed, some fraction of the
deformation will be permanent and non-reversible.
• The two most commonly used and successful yield
criteria for metallic materials are the
 Tresca Yield criteria
 Von Mises Yield criteria

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 Tresca Criterion
• It states that yielding occurs when the maximum shear stress within an element is equal to or exceeds a critical value

• This theory states that the plastic deformation occurs when the maximum shear stress induced in the system reaches
the value of maximum shear stress developed at yielding in an axial tensile or compressive test on the material

• It is also known as maximum shear stress criterion

• τmax ≥ k where k is the critical value of the shear stress

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 Von Mises Criterion
• Also known as distortion energy criterion
• The theory states that plastic deformation of a material will occur when the total shear strain
energy per unit volume in the strained body reaches a value equal to the strain energy per unit
volume at the elastic limit in uniaxial tension.
• It states that yielding occurs when the relationship between the principal stresses and uniaxial
yield stress of the material is as follows

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 Von-Mises criterion
• The strain energy per unit volume (U) is:

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Tresca and Von Mises Criterion

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 Tresca Von Mises

Plastic flow occurs when the maximum shear Plastic flow occurs when strain energy reaches a
stresses reaches a particular value particular value at elastic point in uni-axial tension
test

Simple to use Not Simple

Less accurate More accurate as principal stresses σ1, σ2 and σ3

are considered

More conservative Less conservative

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