ROLLING PROCESS

A typical product
Powder Shaped Drawn Cold-rolled
metal Moulded tube for
Forged wind shield dash board Sheet metal
filters antenna or
valves
Ceramic Reinforced plastic
Spark plugs For body

Stamped
license
plates
Stamped Injection-
Wheel moulded
covers Stamped Blow-moulded Tail light lens
oil pan Windshield Springs
Washer fluid Fuel tank
tank Compression
Moulded tires

Fig. 1
Formed and shaped parts in a typical automobile
 Rolling
Hot strip Picking and Cold strip
coiling

Welded pipe
Skelp

Plate
Slab
Steel plates
Continuous casting Cold drawn bars
or
ingots Hot-rolled bars

Billet Wire and wire

Rods products

Tube rounds

s Seamless pipe
sfft Bloom
g ---------------
Structural shapes

Rails
Fig.2
Schematic outline of various flat-and shape-rolling processes
A few products of the rolling process

Fig. 2a
A typical rolling process

Fig. 2b
 Flat rolling process
Top roll removed

Wo
Va R
Vr F
ho Roll
Work piece No-roll
Vf Point a
Vo Vf
Wf Work piece Friction forces
Roll
Vr Roll Exit
hf Entry
Gap L zone Torque
zone

Fig. 3b
Fig. 3a Fig. 3c
Friction forces acting Roll force F and torque
Schematic illustration of
on strip surfaces
the flat-rolling processes Acting on the rolls
Note:
The width of the strip usually increases during rolling
 Roll deflections
Rolls

Strip thicker Strip with

at entrance Uniform thickness

Fig.4a Fig. 4b
Bending of straight cylindrical Bending of rolls ground with
rolls caused by the roll force Camber, producing a strip with
uniform thickness
 Four-high rolling-mill stand
Screw or Hydraulic mechanism

Housing

Back-up
rolls

Chocks Work rolls

Back-up
rolls

Fig.5
Schematic illustration of a four-high rolling-mill stand, showing its
various features. The stiffness of the housing, rolls, and roll bearings are
important in controlling and maintaining the thickness of the rolling strip.
 Rolling

Fig. 5a
Schematic illustration of rolling process with axis of roller in vertical
 Rolling

Fig. 5b
Schematic illustration of rolling process with axis of roller in horizontal
A rolling Machine

Fig. 5c
 Spreading

Side
view

Top
view

Fig. 6
Increase in width (Spreading) of a strip in flat rolling.
Spreading can be similarly observed when dough is rolled
with two rolling pin.
 Hot rolling
Deformed
Elongated
grains New grains
Hot growing
rolling New grains
forming
Recrystallization
complete

Wrought
Ingot Wrought Product with
With nonuniform Product with Small, uniform
grains Large grains grains

Fig.7
Change in the grain structure of cast or large-grain wrought metals during
hot rolling. Hot rolling is an effective way to reduce grain size in metals
for improved strength and ductility. Cast structures of ingots or continuous
castings are converted to a wrought structure by hot working.
 Leveling

Sheet

Leveling rolls
Fig. 8
A method of roller leveling to flatten rolled sheets
 Defects in Flat rolling

Fig. 9a Fig. 9b
Wavy edges Zipper cracks in the center of the strip

Fig.9c Fig. 9d
Edge cracks alligatoring
 Residual stresses

Sheet
thickness

Tension Compression Tension Compression

Fig.10a
Residual stresses developed in Fig. 10b
rolling with small rolls or at small Residual stresses developed in
small reductions in thickness per pass rolling with large rolls or at
high reductions per pass
Note: The reversal of the residual stress patterns.
 Surface roughness
Roughness (Ra)

Process
Sand casting
Average application
Hot rolling
Less frequent application
Forging
Permanent mould casting
Investment casting
Extruding
Cold rolling, drawing
Die casting

Fig. 11
Surface roughness in various metal working and casting process.
Note: The large difference in hot and cold rolling
 Rolling mills

Fig.12a Fig.12c
Two-high Fig.12b four-high
three-high
Fig.12d
Cluster (sendzimir) mill

Schematic illustration of various roll arrangements

 A tandem rolling operation

Stand 1 2 3 4 5
30 17.7 10.7 6.6 4.1 m/s

Take-up Pay-off
reel reel

0.26 0.34 0.56 0.90 1.45 2.25 mm

Fig. 13
 Shape-Rolling operations
Stage 1 Stage 2 Stage 3

Blooming rolls Edging rolls Roughing horizontal and vertical rolls

Stage 4 Stage 5 Stage 6

Intermediate horizontal Edging rolls Finishing horizontal

and vertical rolls and vertical rolls
Fig. 14
Stages in shape rolling of an H-section part. Various other structural
sections, such as channels and I-beams, are also rolled by this process
 Ring rolling
Idler roll

Work piece

Fig.15b
Examples of cross sections that
Main roll can be formed by ring rolling
(driven)
Edging roll

Fig. 15a
Schematic illustration of a
ring rolling operation
Note: Thickness reduction results in an increase in the part diameter
A typical ring rolling process

Fig. 15c
 Production of tapered ring

Step 4 Step 5
Step 1 Step 2 Step 3

Punched and Ring rolled

Sheared to Pancaked Prepunched
and restruck
length
preformed

Fig 16
Stages in the production of a tapered ring, using a combination of
Forming process. The sequence shown in steps 2-4 is a common
method of producing holes in relatively small parts.
 Thread rolling

Moving die

Threaded part
Blank
Stationary
die
Fig. 17a
Stationary Cylindrical
Work Moving
die cylindrical
Fig. 17c
die
Force

Work rest
Fig. 17b
Fig. 17a &17c reciprocating flat dies
Fig. 17b two-roller dies
Note: Threaded fasteners, such as bolts, are made economically
By these processes at high rates of production.
 Thread rolling
Diameter of bar Diameter of blank

Minar Major
diameter diameter

Machined thread Rolled thread

Fig.18a
Differences in the diameters of machined and rolled threads

Machined thread Rolled thread

Fig.18b
Grain flow in machined and rolled threads. Unlike machining, which cuts
through the grains of the metal, rolled threads have improved strength
because of cold working and favourable grain flow.
 Production of seamless tubing and pipe
Rolls

Mandrel

Tube

Solid
bar
Fig. 19
Cavity formation in a solid round bar and its utilization in the rotary tube
Piercing process for making seamless pipe and tubing
Fig. (a) round bar is subjected to radial compressive forces
Fig. (b) a cavity begins to form at the center of the bar
Fig. (c) rotary tube pierzing is carried out using an arrangement of
rotating rolls.
 Tube rolling processes
Roll
Roll
Mandrel Work piece

Rod
Work piece Mandrel rod
Fig. 20a fixed mandrel Fig. 20b moving mandrel
Pilger roll
Roll
Mandrel

Work piece
Work piece
Fig. 20c rolling without mandrel Fig. 20d
Note: tube diameters and thickness pilger rolling over a mandrel and
Can also be changed by other processes a pair of shaped rolls
Such as drawing, extrusion & spinning
Direct casting of sheet and plate steel
Tundish Tundish

Substrate
Argon
hood

Water jets Mould plate

Tundish Block Tundish

Side dams

Fig.21 Knife

Examples of direct casting techniques under development for

economical production of plate and sheet
 Spray casting
Induction –heated
ladle

Atomizer
(nitrogen gas)
Recipient
substrate

Tube

Deposition
chamber

Fig. 22
Spray casting (osprey process) in which molten metal is spayed
Over a rotating mandrel to produce seamless tubing and pipe.
Thank you