African Foundries Ltd.

Lagos, Nigeria

Presented by
Rahul Kishore
Basics of Rolling
A rolling mill consist of several, at least two rolls
cylindrical or nearly cylindrical bodies which are
termed as roll and which rest in bearings at their
ends.

The normal and average center distance from the

center of one roll to the center of other determine the
size of mill. Thus 12 inch mill, the distance from center
to center rolls is 12 inch.
Types of pass
According to shape wise
Definite passes those having two equal axes in an x, y
plane (Squares, Rounds)
Types of pass
Intermediate passes those having one axis larger
than the other one (Rectangles box, Diamonds,
Ovals)
Types of pass
According to adjustment of rolls
Open passes The joint between the two rolls is open
or the opening of the pass lies in center.
Types of pass
Closed passes The projection of one roll fits into a
groove of the other roll.
Pass Design and Groove Details
This calculation gives the following parameters
for each pass.
Roll groove dimensions.
Roll gap.
Filled width in pass.
Filled area.
Area reduction.
Bite angle.
Number of passes required
No. of Passes= log of co-eff of elongation/log(1.29)
Thumb rules in rolls pass design
Pass Groove Bottom Relief radius Bottom
angle angle radius

Box pass 8-10 deg 10

Diamond >90 deg 18
pass
Square pass 45 deg Around 90 5
deg
Oval pass 60 deg 30 deg 5

Round pass 60 deg 60 deg 0.2 x Bottom 0.5 x dia

radius
Geometrical relation in Rolling
Geometrical relation in Rolling
A1 x V1 = A2 x V2= A3 x V3.=1
A1,A2,A3.. Area of stand 1, stand 2, stand 3.
V1,V2,V3..Velocity of stand 1, stand 2, stand 3.

Shrinkage factor of steel (1.012 - 1.015)

Thumb rules in rolls pass design
Fittings from oval to round must be 0.3 to 0.7.

For ovals width to height ratio must be less than 3.0.

Spread
When the steel is compressed in the rolls it will
obviously move in the direction of least resistance, so
usually there is not only longitudinal flow but also
some lateral flow. This is called Spread. it is generally
accepted that beyond a ratio width/height = 5, spread
becomes negligible.
Spread calculation in round
Spread calculation in Oval
Spread
The equivalent rectangular approximation into round
oval pass to calculate effective height of the work piece
and the area fraction of work piece and the geometry
of groove.
H0 Effective height of outgoing work piece.
Hi Effective height of incoming work piece.
Hi Height of incoming work piece.
Reff Effective Radius of incoming work piece.
Wi Width of incoming work piece.
Bc Effective Width of work piece.
Spread
Then maximum spread of a work piece at exit Wmax
was then calculated as.
Spread
With original Shinokura procedure, following spread factors for roll pass design is suggested [1]:

Spread
Where y is constant and the value for different pass as
following

Pass y
Square - Oval 0.92
Round - Oval 0.97
Square - Diamond 0.83
Oval - Square 1.06
Oval - Round 0.83
Diamond - Square 0.83
Diamond - Diamond 0.95
Oval - Oval 0.95
Important Formula to Calculate arc
To calculate the radius Given an arc or segment with
known width and height:
The formula for the radius is:
Important Formula to Calculate arc
Where:-
W is the length of the chord defining the base of the
arc .
H is the height measured at the midpoint of the arc's
base.
Important Formula to Calculate arc
Area
Important Formula to Calculate arc
Area
where:
C - is the central angle in DEGREES

R - is the radius of the circle of which the segment is a

part.
Flow Chart to Design Pass For Maximum
Elongation
Important formula to calculate
nominal Weight of bar

Diameter x Diameter
Weight =
162.163
Example
The Weight of 16 mm Re- Bar
16 x 16 =264
264/162.163 = 1.578 kg

The Weight of 25mm Re-Bar

25 x 25 = 625
625/162.163 = 3.854 kg
Important formula to calculate
area
Where Ae = Effective cross-sectional area of bar
L = Length of TMT
W = Weight of TMT
Angle adjustment for twister
guides
Thank You