GROUP C

TOPICS – ROLLING, CLASSIFICATION, POWER

CALCULATION OF ROLLING LOAD AND POWER

AAMIQ THOKAN
PARIMAL KUMAR
GUGULOTHU THARUN
VISWANATH B
BHARGAB DHUNGEL
DUNNA SUJITH
INTRODUCTION
ROLLING IS A FUNDAMENTAL PROCESS IN THE MANUFACTURING
INDUSTRY, SHAPING RAW METAL MATERIALS INTO VARIOUS FORMS
THAT SERVE AS BUILDING BLOCKS FOR COUNTLESS PRODUCTS WE
ENCOUNTER IN OUR DAILY LIVES.

FROM THE SLEEK CURVES OF AUTOMOTIVE BODY PANELS TO THE

STURDY BEAMS SUPPORTING OUR INFRASTRUCTURE, ROLLING PLAYS
A PIVOTAL ROLE IN TRANSFORMING METAL INGOTS INTO
FUNCTIONAL COMPONENTS.
DEFINITION
ROLLING IS A METALWORKING PROCESS THAT INVOLVES
PASSING A METAL BILLET OR INGOT BETWEEN ROLLERS
TO REDUCE ITS CROSS-SECTION.

THIS DEFORMATION PROCESS IS ACHIEVED THROUGH THE

APPLICATION OF COMPRESSIVE FORCES, RESULTING IN
THE ELONGATION AND REFINEMENT OF THE METAL'S
GRAIN STRUCTURE.
EQUIPMENT USED FOR ROLLING:
CENTRAL TO THE ROLLING PROCESS ARE ROLLING MILLS - MACHINES
EQUIPPED WITH A SERIES OF ROLLERS THAT EXERT CONTROLLED
PRESSURE ON THE METAL WORKPIECE.
THESE ROLLERS MAY VARY IN

CONFIGURATION, RANGING FROM

TWO-HIGH MILLS SUITABLE FOR

SIMPLE FLAT ROLLING TO MORE

COMPLEX FOUR-HIGH AND

CLUSTER MILLS CAPABLE OF

PRODUCING INTRICATE SHAPES

WITH PRECISION.
APPLICATIONS OF ROLLING:
IN THE AUTOMOTIVE SECTOR, ROLLING IS EMPLOYED FOR FABRICATING CHASSIS COMPONENTS,
ENGINE PARTS, AND BODY PANELS, CONTRIBUTING TO THE DURABILITY, SAFETY, AND
AESTHETIC APPEAL OF VEHICLES.
IN THE CONSTRUCTION INDUSTRY, ROLLED STEEL BEAMS AND PROFILES FORM THE
BACKBONE OF STRUCTURAL FRAMEWORKS, OFFERING STRENGTH AND VERSATILITY IN
ARCHITECTURAL DESIGN.
MOREOVER, ROLLING FINDS APPLICATION IN AEROSPACE, MANUFACTURING, AND CONSUMER
GOODS SECTORS, HIGHLIGHTING ITS VERSATILITY AND ADAPTABILITY TO VARIOUS
PRODUCTION NEEDS.
 HOT
ROLLING

AND

COLD ROLLING
 INTRODUCTION:HOT ROLLING
THE INITIAL BREAKDOWN OF INGOTS INTO BLOOMS AND BILLETS IS
GENERALLY DONE BY HOT-ROLLING.THIS IS FOLLOWED BY FURTHER HOT-
ROLLING INTO PLATE,SHEET,ROD,BAR,ETC.
HOT ROLLING IS A METALWORKING PROCESS WHERE METAL IS SHAPED AT
TEMPERATURES ABOVE ITS RECRYSTALLIZATION POINT.

IT INVOLVES PASSING METAL THROUGH ROLLERS TO REDUCE THICKNESS

AND INCREASE LENGTH.

TEMPERATURE RANGE TYPICALLY FALLS BETWEEN 1100°C TO 1300°C FOR

STEEL.

THE PROCESS IMPROVES MECHANICAL PROPERTIES LIKE STRENGTH AND

DUCTILITY.

ENHANCES MATERIAL QUALITY BY ELIMINATING INTERNAL STRESSES AND

IMPROVING HOMOGENEITY.
THE FIRST HOT-WORKING OPERATION FOR MOST STEEL PRODUCTS IS DONE
ON THE PRIMARY ROUGHING MILL(BLOOMING,SLABBING OR COGGING MILLS).

BLOOMING INVOLVES THE INITIAL BREAKDOWN OF INGOT STRUCTURES.

TO ACHIEVE THE REQUIRED BILLET SIZE FOR SMALLER FINISHING MILLS,

BLOOMS ARE OFTEN REROLLED ON THREE-HIGH OR CONTINUOUS BILLET
MILLS.
BILLETS CAN BE FURTHER ROLLED INTO VARIOUS SHAPES SUCH AS ROUND
BARS, HEXAGONS, SPECIAL SHAPES, OR FLATS ON DIFFERENT TYPES OF
FINISHING MILLS.

UNIVERSAL MILL: CONSISTS OF TWO ROLLING MILLS - ONE WITH TWO

HORIZONTAL ROLLS AND THE OTHER WITH FOUR VERTICAL ROLLS, CAPABLE OF
ROLLING INGOTS DIRECTLY INTO PLATES WITH STRAIGHT EDGES, BUT MAY
RESULT IN LOWER TRANSVERSE DUCTILITY.

NONFERROUS HOT-ROLLING EQUIPMENT TENDS TO BE MORE VERSATILE AND

LESS SPECIALIZED COMPARED TO STEEL ROLLING EQUIPMENT DUE TO THE
DIVERSE PRODUCT MIX IN THE NONFERROUS INDUSTRY.
 COLD
ROLLING
 INTRODUCTION : COLD ROLLING

THE COLD-ROLLING OF METALS HAS

PLAYED A MAJOR ROLE IN INDUSTRY
BY PROVIDING SHEET,STRIP,FOIL WITH
GOOD SURFACE FINISHES AND
INCREASED MECHANICAL STRENGTH
WITH CLOSE CONTROL OF PRODUCT
DIMENSIONS.
COLD ROLLING IN METALLURGY REFERS TO THE METALWORKING PROCESS OF
SHAPING METAL AT ROOM TEMPERATURE OR SLIGHTLY ABOVE, USUALLY BELOW
ITS RECRYSTALLIZATION TEMPERATURE.

THICKNESS REDUCTION: COLD ROLLING IS PRIMARILY AIMED AT REDUCING

THE THICKNESS OF METAL SHEETS OR STRIPS.

INCREASED HARDNESS AND STRENGTH: THE PROCESS INDUCES STRAIN

HARDENING IN THE MATERIAL, LEADING TO INCREASED HARDNESS,
STRENGTH, AND IMPROVED MECHANICAL PROPERTIES.

SURFACE FINISH ENHANCEMENT: COLD ROLLING RESULTS IN SMOOTHER

SURFACE FINISHES COMPARED TO HOT ROLLING, MAKING IT IDEAL FOR
APPLICATIONS REQUIRING HIGH-QUALITY SURFACE FINISHES.
IMPROVED SURFACE FLATNESS: COLD ROLLING HELPS TO IMPROVE THE FLATNESS
OF METAL SHEETS OR STRIPS, REDUCING THE NEED FOR FURTHER PROCESSING
AND ENHANCING THEIR SUITABILITY FOR SUBSEQUENT MANUFACTURING
PROCESSES.

WORK HARDENING EFFECT: THE REPEATED DEFORMATION DURING COLD ROLLING

CAUSES WORK HARDENING, WHICH IMPROVES THE MATERIAL'S STRENGTH AND
HARDNESS BUT MAY ALSO LEAD TO INCREASED BRITTLENESS.

VERSATILITY: COLD ROLLING IS VERSATILE AND CAN BE APPLIED TO VARIOUS

METALS INCLUDING STEEL, ALUMINUM, COPPER, AND ALLOYS, CATERING TO A
WIDE RANGE OF INDUSTRIAL APPLICATIONS.
ENERGY EFFICIENCY: COLD ROLLING CONSUMES LESS ENERGY COMPARED TO
HOT ROLLING SINCE IT DOES NOT REQUIRE HEATING THE METAL TO HIGH
TEMPERATURES, MAKING IT A MORE ENVIRONMENTALLY FRIENDLY PROCESS.

COLD ROLLING
COLD ROLLING
MACHINE
DIFFERENCES BETWEEN HOT ROLLING AND COLD ROLLING
 Calculations
VR

VF

V0

WHAT CAN WE SAY ABOUT THE VELOCITES V0 VR AND VF ?

 VR
CONSERVATION OF MASS
VF

H0 HF MASS FLOWING IN = MASS FLOWING OUT

V0.T * H0 * W = VF.T * HF * W

V0 V0 * H0 = VF * HF CLEARLY HF < H0

V0 < VF
V0 < VR < VF
 VR

VF FORWARD SLIP = (VF-VR)/VR

H0 HF
LOWER FORWARD SLIP IS PREFFERED
FOR BETTER SURFACE FINISH

V0
 VR

WHAT IS THE VALUE OF HF-H0 ?

VF

HF-H0 IS CALLED DRAFT

H0 HF

V0
 AREA CALCULATION

VR

VF

H0 HF

V0
 STRESS CALCULATION

VR

VF

H0 HF

V0
FORCE CALCULATION
POWER CALCULATION
DEFORMATION IN ROLLING
->WHILE THE LATERAL SPREAD IS USUALLY OF LITTLE IMPORTANCE IN
ROLLING SHEET AND STRIP, IN THE ROLLING OF BARS AND SHAPES THIS
CAN RESULT IN THE FORMATION OF FLASH, WHICH PRODUCES SURFACE
DEFECTS.

->THE AMOUNT OF LATERAL SPREAD DEPENDS ON SUCH FACTORS AS THE

DIAMETER AND CONDITION OF THE ROLLS, THE FLOW PROPERTIES OF THE
METAL, AND THE AMOUNT OF REDUCTION.

->IN COMPARISON WITH OTHER METAL WORKING PROCESSES THE

DEFORMATION PRODUCED BY ROLLING IS RELATIVELY UNIFORM.
 DEFECTS IN ROLLING PRODUCTS

WHAT ARE THE REASONS FOR THESE DEFECTS ?

 -> Surface defects: These are imperfections on the surface of the rolled product, such as
scratches, pits, scabs, and rolled-in scale. These defects can be caused by foreign materials on
the surface of the metal billet, imperfections in the rolls, or improper lubrication.

->Edge defects: These are defects that occur at the edges of the rolled product, such as
cracks, waves, and tears. They can be caused by uneven rolling pressure, improper roll
alignment, or excessive rolling reduction.

->Dimensional defects: These are deviations from the desired thickness, width, or
length of the rolled product. They can be caused by uneven rolling pressure,
improper roll settings, or temperature variations.
RESIDUAL STRESSES
Residual stresses are the system of stresses which can exist
in a body when it is free from external forces. They are
sometimes referred to as internal stresses, or locked-in
stresses.

REASONS FOR RESIDUAL STRESS

Mechanical: Differential deformation
Thermal: Differential thermal expansion and contraction
Phase change: Difference in phase transformation inside a
volume

NOTE: The deep hole-drilling (DHD) method is used to

measure residual stress in isotropic materials
 CONCLUSION
Rolling offers a cost-effective solution for shaping certain materials, particularly those with complex bends or precise angles.
While many materials can be used for roll forming, it's important to note that only some materials are suitable for this process

While mild steel may be the most

common raw material for roll forming,
any ductile metal can be used for this Brittle materials cannot be used since they
process: Galvanized and galvannealed would fracture immediately.
steel, Stainless steel, Aluminum, Copper,
Brass, and Bronze

NON-METAL ATTEMPTS AT ROLLING:

Foam rubber Plastic Cardboard

-Subject to certain conditions

 APPLICATIONS OF ROLLING PROCESS

MANUFACTURING OF SHAFTS, RODS, TUBES,

AXLES, AND SPINDLES. PRODUCING WORKPIECES WITH DESIRED CROSS- GEAR MANUFACTURING FROM GEAR BLANKS
SECTIONS.

MANUFACTURING OF METAL SHEETS, PLATES,

AND PANELS MANUFACTURING OF AUTOMOBILE BODY PRODUCTION OF BEARINGS
 ADVANTAGES OF ROLLING PROCESS

SPEED AND TIME EFFICIENCY! GREAT FOR MASS PRODUCTION! EFFICIENCY..BUT IN WHAT??

ABILITY TO PRODUCE COMPLEX SHAPES! GREAT PRECISION AND UNIFORMITY!

 DISADVANTAGES OF ROLLING PROCESS

HIGH INITIAL COSTS LESS REFINED SURFACE FINISH CANNOT BE USED FOR SMALL PRODUCTION

PRECAUTIONS TO BE FOLLOWED IN ROLLING PROCESS

USE PERSONAL PROTECTIVE EQUIPMENT (PPE)
SAFE WORKING DISTANCE
SAFE AND CLEAN SURROUNDINGS TO BE MAINTAINED