Rolling is a process of reduction of the cross-

sectional area or shaping a metal piece

through the deformation caused by a pair of
metal rolls rotating in opposite directions.

Rolling is the plastic deformation of materials caused by

compressive force applied through a set of rolls.
 The gap between rolls <
thickness of entering bar
 Friction force necessary to
bite the bar and to pull it
through the rolls
 Metal bar gets squeezed,
and elongated while its c/s
a machine rolling:
area decreases ROLLING MILL
 The most important In a typical rolling mill:
industrial metal forming  A pair of rolls is driven
operations by an electric motor which
transmits torque through
gear
 Rolls are mounted in a
stand with a screw-down
mechanism.
TYPES - based on  Hot rolling results in residual
stress-free product.
work temperature:  Scaling is a major problem,
due to which dimensional
– Hot Rolling: accuracy is not maintained.
most common due to  Cold rolling of sheets, foils etc
the large amount of is gaining importance, due to
deformation required high accuracy and lack of oxide
scaling.
– Cold rolling:  Commonly conducted after
hot rolling when good surface
produces finished quality and low thickness
sheet and plate stock tolerance are needed.
 Cold rolling also strengthens
the product due to work
hardening.
TYPES -based
on work-piece
geometry:

– Flat rolling:
used to reduce
thickness of a
rectangular cross
section

– Shape rolling:
square cross
section is formed
into a shape.
Microscopic View:
 Coarse grain
becomes finer in size
 Gets elongated
along the direction of
rolling
 In order to refine
the grains, heat
treatment performed APPLICATION:
Hot rolling: rails, sheets,
immediately after structural sections(I-beams, L-
rolling, which results beams, and U-channels), round and
in recrystallization square bars and rods, plates etc.
after rolling
Cold Rolling: Sheet metal work
Analysis:
DRAFT:
R=roll
amount radius of thickness
L=contact
reduction,arc length
d=to-tf
Lp=projected arc length
hf= strip final thickness
Too much & too little??
Vr=velocity of the roll
Vf=velocity
REDUCTION : strip at roll
of the
exit
draft expressed as a
ho=strip initial thickness
fraction of starting
N=neutral point
stock
α=angle thickness,
of bite r= d/
to
Vo=velocity of strip at entrance
to roll Side view of flat rolling, indicating
CONTACT ARC LENGTH: before and after thicknesses, work
Smaller rollers have velocities, angle of contact with
small length of contact rolls, and other features.
MILLS & EQUIPMENTS

Driving Power per Roll: T=FXR/2

PR = T x w
MILLS & EQUIPMENTS
Points to remember:
 Two horizontal rolls
revolving at the same
speed but in opposite
direction
 Rolls are supported on
bearings housed in
sturdy upright side
frames called stands
 Space between the
rolls can be adjusted by
raising or 1owering the
upper roll.
MILLS & EQUIPMENTS

Points to remember:

 Three parallel rolls,

arranged one above the
other
 It is used for rolling of
two continuous passes in
a rolling sequence
 This results in a higher
rate of production than
the two-high rolling mill.

MILLS & EQUIPMENTS
..\TEACHING\SUBJECTS\Manufacturing\FORMING\Video\2-3-4 high
Points to remember:
 It is essentially a two-
high rolling mill
 Two middle rolls are
smaller in size than the
top and bottom rolls
 Smaller size rolls
(working rolls)
concentrate the total
rolling pressure over the
workpiece.
 The larger (back-up
rolls) prevents the
deflection of the smaller
rolls
Two high would result in
wavy rolled plates or
sheets unevenly thick
MILLS & EQUIPMENTS
Points to remember:
 Two smaller working
rolls are backed up by
two or more of the larger
back-up rolls.
 For rolling hard thin
materials, work rolls of
very small diameter and
considerable length
needed.
 This type of mill is
generally used for cold
rolling work
MILLS & EQUIPMENTS

It is suitable for continuous & mass production

 ..\TEACHING\SUBJECTS\Manufacturing\FORMING\Video\Thread Rolling

PROCESSES & APPLICATIONS

Thread and gear
rolling:

 Forms threads on cylindrical parts by rolling them between

two dies
 Commercial process for mass producing bolts and screws
because of higher production rates & stronger threads
 Performed by cold working in thread rolling machines
 PROCESSES & APPLICATIONS
Shape Rolling:

 Blooms are usually taken as raw materials for shape rolling

 Multiple steps are required in shape rolling
 Structural sections such as I-sections, rails, channels can
be rolled using set of shaped rolls
 PROCESSES & APPLICATIONS
Ring Rolling:

Applications: ball and roller bearing races,

steel tires for railroad wheels, and rings
for pipes, pressure vessels, and rotating
machinery

Deformation process in which a thick-walled ring of smaller

diameter is rolled into a thin-walled ring of larger diameter
 Two circular rolls, (idler roll and driven roll )are used, they
move closer to each other, thereby reducing the thickness of
ring and increasing its diameter
 A pair of edging rollers are used for maintaining the height
constant.
..\TEACHING\SUBJECTS\Manufacturing\FORMING\Video\Ring Rolling.mp4
 PROCESSES & APPLICATIONS
Tube piercing or, seamless tubing: :
..\TEACHING\SUBJECTS\Manufacturing\FORMING\Video\Hot piercing billet process.mp4

Rotary tube piercing is used for producing long thick walled

tubes.
 A pair of skewed rolls are used for drawing the work piece
inside the rolls.
 A mandrel is used for expanding the central hole, and sizing
the inner diameter.