Mechanical Working of Metals

Rolling
 Working Processes
Mechanical
Working

Cold Working Hot Working

Done at temp < Trec Done at temp > Trec

Recrystallization temperature :
• temperature at which recrystallization occurs
• 0.3 to 0.6 Tm
The Effect of Temperature on
Working Processes
Cold Working Hot Working
• metal strain hardens • metal recrystallizes
after deformation after deformation
• metal ‘hardens’ • metal stays ‘soft’
• needs high stress to • needs little stress to
deform metal deform metal
• very good surface • forms ‘SCALES’ at
finish the skin
• very good • poor dimensional
dimensional tolerance tolerance
 Rolling
“Process of reducing the thickness of
metals by allowing it to pass through a
pair of rotating rolls”

“More metal is rolled

than the total of all the
other working processes”
Products of Rolling
 Rolling Load Calculation

• Ideal Rolling Load

– No friction involved
• Actual Rolling Load
– Friction involved
– Friction normally increases the required
load
Terminologies used in Rolling
Rolling Load Analysis

h = draft = ho - hf

Vo = entry speed
Vf = exit speed
R = roll radius

 = angle of bite
= angle between
entrance plane and
centerline
 Ideal Rolling Load

Pressure = Load
Area

Rolling Load = Roll Pressure x Area

RL = Rolling Load
y = flow stress (yield stress)

RL =  yW Rh W = Width
R = Roll Radius
h = draft
 Considerations on
Actual Rolling Load
At any point in
the arc of contact,
2 forces act on
the metal:
Pr = Rolling Load
F = Friction Load
and F = Pr

For unaided entry: Fcos = Prsin

 = tan
Maximum Reduction Possible

 = tan

Rh h
tan  = =
h R
R−
2

(h)max = 2R
 Sample Problem
• Determine the maximum possible
reduction for cold-rolling a 300 mm-thick
slab when μ = 0.08 and the roll diameter
is 600 mm. What is the maximum
reduction on the same mill for hot rolling
when μ = 0.5?
 Sample Problem

Determine the maximum reduction possible

on a piece of steel 250 mm thick during cold
rolling when  = 0.1 and during hot rolling
when  = 0.6. What would be the effect on
the maximum draft if the roll diameter was
changed from 500 mm to 1.0 m?
 Observations in Actual Rolling
• Exit speed, Vf > Entry speed, Vo
Assuming constant volume passing through
one point at any given time
Vf

Vroll

Neutral Point
Vo or No-Slip
point

A B
 Friction Hill

At the Neutral
Point, there is no
slipping between
the metal and the
Rolls

N At the Neutral
Point, Friction is
at a maximum!
 Actual Rolling Load
 Rh
RLActual =  yW Rh  1 +
 h 
2h1 − 
 2 
Condition  Condition 
Plain Strain 1.155 < 0.5 
Slipping Friction

Homogenous 1.0 > 0.5 1/2

Deformation Sticking Friction

Plane Strain W Slipping Friction Sticking Friction

5 is found in cold is found in hot
when Rh working working
 Sample Problem
• A. Calculate the rolling load if steel sheet
is rolled 30% from a 40 mm-thick slab
using a 900 mm-diameter roll. The slab is
760 mm wide. Assume µ = 0.30. The
plain-strain flow stress is 140 MPa at
entrance and 200 MPa at the exit from
the roll gap due to the increasing velocity.
 Sample Problem
B. What would be the rolling load if sticking
friction occurs?
 Quiz
Calculate the rolling load required to reduce
steel 600 mm wide and 30 mm thick by
20%. The roll diameter used is 800 mm, 
= 0.15 and flow stress of steel is 150 MPa.
 Sample Problem
Explain the Design of Cluster Mill.