EDPT 604

Metal Forming Processes and Machines

Lecture 2
Rolling Process

Dr. Mohamed Harraz

Rolling Process
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 Rolling Process
Rolling is a process of reduction of the cross-sectional area or shaping a metal piece
through the deformation caused by a pair of rotating in opposite directions metal rolls.

The gap between the rotating rolls is less than the thickness of the entering bar H0 therefore
a friction force is necessary in order to bite the bar and to pull it through the rolls.
A metal bar passing through the rotating rolls is squeezed, and it elongates while its cross
section area decreases.
Dr. Mohamed Harraz
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Rolling Process

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Rolling Mill

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Flat Rolling Processes

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 Basic Technique
A machine used for rolling metal is called rolling mill.
A typical rolling mill consists of a pair of rolls driven by an electric motor
transmitting a torque through a gear and pair of cardan shaft. The rolls are
equipped with bearings and mounted in a stand with a screw-down mechanism.
A force applied to the rolls in vertical direction is called roll separating force.
However such rolls are susceptible to bending and causing non-uniform
widthwise strip thickness distribution (convex crown). See next slides figures.
Hot rolling is a rolling operation carried out at a temperature exceeding the
recrystallization temperature and permitting large amount of deformation.

Cold rolling is a rolling operation carried out at room temperature. Cold

rolling is commonly conducted after hot rolling when good surface quality and
low thickness tolerance are needed. Cold rolling causes material strengthening
and may be followed by annealing.

Dr. Mohamed Harraz

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Driving Cardan Shafts

Pair of cardan shafts used to drive two vertical mills

Dr. Mohamed Harraz

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 convex crown
The elastic deflection of the work rolls results in an uneven widthwise
distribution of the work-piece thickness in such a way where the thickness is
greater at the center of the width and smaller at the edges.

Dr. Mohamed Harraz

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 Configuration of rolling mills
Complex rolling mill designs employing back-up rolls are used to diminish
the bending effect:

Dr. Mohamed Harraz

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Geometrical Considerations
d

Strip with
uniform
thickness

Roll gap geometry.

(a) Unloaded rolls.
(b) Loaded cold rolls.
(c) Unloaded hot rolls
(d) Loaded hot rolls
(Cambered work Roll)
Dr. Mohamed Harraz
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Reducing Roll Force

Dr. Mohamed Harraz

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Defects in Rolling
Lack of camber or insufficient cambering of the work rolls results in
producing a work-piece that has a thicker center than the edge. The thicker
center implies that the edges are plastically elongated more than the center.
This induces a residual stress pattern of compression at the edges and tension
along the centerline of the work-piece (Figure a). The consequences of this
uneven distribution of stress within the work-piece can be centerline cracking
(Figure b), warping (Figure c) or edge wrinkling (Figure d) of the final metal
sheet.

Dr. Mohamed Harraz

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 Defects in Rolling
In the case where the work rolls are over-cambered, the edges of the work-
piece will be thicker than the center and the residual stress pattern is exactly
the opposite of that of insufficient cambering, i.e. tension at the edges and
compression along the centerline (Figure e). Possible undesirable results of
the work-piece being produced in such a manner are edge cracking (Figure f),
splitting (Figure g) or centerline wrinkling (Figure h).

Dr. Mohamed Harraz

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Typical coil defects

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Flat Rolling Practice

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 Rolling products

Coils, plates Structural Bars and Rods

And sheets shapes

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Rolling Products

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 Different rolling orientations
a)Two-high mill,
b) three-high mill,
c) four-high mill,
d) tandem mill,
e) four-high with work rolls
and support rolls,
f) six-high with work rolls
and support rolls,
g) cluster mill and
h) planetary (orbital) mill

Dr. Mohamed Harraz

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cross rolling process

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Shape Rolling

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Bend Rolling

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Steps for I beam rolling

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Ring Rolling

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Ring Rolling

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Tube rolling

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Tube rolling (seamless)

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Tube rolling (seamless)

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Other Characteristics of rolled metal

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 Calculations
The amount of deformation R achieved in a flat rolling operation (thickness
reduction) is determined by the relationship:
R = 100% * (H H0)/H0

Dr. Mohamed Harraz

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