1.

INTRODUCTION

1.1. GENERAL

Steel is initially produced in 20 cm thick slabs. Steel in this form is usually processed

further before being sold to customers. This generally involves rolling it into thinner

sheets (and sometimes forming it into tubes). This steel is now conveniently shaped, but is

prone to rusting so for applications where it is exposed to the weather it is often galvanized

(and sometimes painted as well) to prevent corrosion.

Step 1 - Hot Rolling

In the hot rolling process, slabs are reheated and fed into the rough rolling mill where it is reduced
from 210mm to 25mm thickness. The thin sheets are then wound onto spools to

make 'coils' of rolled steel.

Step 2 - Cold Rolling

Hot rolled coils are welded into continuous sheets, and the iron oxides that have formed in

hot rolling removed with hydrochloric acid:

Fe2O3⋅xH2O + 6HCl → 2FeCl3 + (x+3)H2O

The sheets are then oiled to prevent further corrosion and rolled. This rolling further

reduces the thickness of the sheets and gives them a smoother surface.

Step 3 - Galvanising

Hot alkali solutions are used to remove the remaining grease, then the steel is treated with

acid to clean and etch the surface. The steel is repeatedly heated and cooled to strengthen

it and then galvanised by dipping it in zinc. The steel can then be used as is for roofing, or

further processed.
Step 4 - Paint Coating

The steel is again cleaned and then coated with primer. Solvent in the primer is evaporated
by a hot air jet and the paint baked on. Finish coat is then applied, baked and

cured on top of the primer coating. Different grades of finishing paint are used for

different applications.

1.1.2. Deformation Processes

Deformation processes transform solid materials from one shape into another as per the roll pass
design. A sequence of such processes is generally used to form material progressively from a simple
geometry in to a complex shape, whereby the tools represent the desired geometry and impart
compressive or tensile stresses to the deforming material through the two roll -material interface, as
illustrated in Figure 1.9. Deformation processes are frequently used in conjunction with other unit
operations, such as casting, machining, grinding, and heat treating, to complete the transformation from
raw material to finished and assembly-ready discrete parts. Deformation processes, along with
machining, have been at the core of modem mass production, because they involve primarily metal flow
and do not depend on long-term metallurgical rate processes.

Figure1.9 Rolling Parameters [34]

1.2. Statement of the problems [21, 23, 24, 25, 26]

Interms of availability

Interms of cost

Interms of design and operation complexity

1.3.Objective
1.3.1. General objective The General objective of this thesis is to determine :

Our project objective:

This rolling machine is used to roll the sheet metals with splines and to improve
the strength of the sheet metals. Rolling machine is device which used for rolling the
sheet metal. The sheet metals can be easily rolled. Even an unskilled technician can use
them,With these features, we sincerely hope that our project serve as a valuable project.
Welcome the correction, comments based on our project.
1.3.2. Specific Objective The specific goal of the thesis are :-

The followings are some of the benefits: a) Minimize production cost by apply proper deformation and
reduce the occurrence of loss of billets (cobbles) and having proper mounting and dismounting period as
per the design. b) By improving the production capacity then Meeting delivery schedule and time to
market.

1.4. Scope and limitation of the paper This work will be concerned mainly with the brief presentation of
various parameters that affect the rolling process and also with some of the major theories that have
been presented by recent re searchers on the subject. However the research outputs on this area is
limited. Emphasis will be laid more on the mechanics of bar rolling with a critical appraisal of the various
theories available on the subject, from the point of view of suitability of use for the establishment of
parameters leading to the design for a specific process. The scope of this paper is to perform parametric
study to investigate the effect of reduction in one pass, the temperature field in the billet and the rolls
and loading condition contact stress in roll (not rollers in hot rolling terminology) and billets (raw
material) according to the roll pass design.
To minimize computational time as per the recommendation of researcher’s specially for the first pass
of roughing mill deformation is used two rolls without contour(grooves) for the analysis in FEM
However, due to the limited availability of time, materials, etc. it is difficult to cover the whole portion
in this thesis work. The following are the limitations of the study:
 An important parameter in the operation of hot rolling mill is the cooling
mechanism of work roll. The determination of the best geometry of the cooling system, therefore, plays
an important role in obtaining the highest heat transfer
coefficient and in avoiding lateral water splashes. This analysis was not considered in the current study.
But consideration of such things will give better result.

CHATER TWO
2.1 DEFINITIONS

Definition of Rolling : The process of plastically deforming metal by passing it between rolls. Rolling is
the most widely used forming process, which provides high production and close control of final
product. The metal is subjected to high compressive stresses as a result of the friction between the rolls
and the Rolling process metal surface.

2.2 TYPES OF ROLLING AND ROLLING PROCESS

2.2.1 TYPES OF ROLLING

2.2.1.1 HOT ROLLING

Hot rolling as illustrated in Fig. 2 involves the metal working
process that occurs when the metal pieces are heated above recrystallization temperature. This is
considered to have the most tonnage from all metal processes, in which the material grain
deformation maintains an equiaxed microstructure which prevents the metal from work hardening [9].
The ‘raw material’ such
as large metal from unfinished casting; billets, slabs and booms
are processed and heated to a high temperature to permit manoeuvring before being fed into the
rollers, where additional heat is
introduced, mostly above room temperature and increased in small
increments. Heating of large material has been actualized through
soaking the workpiece in oil pits for effective heating process, however, smaller workpieces achieve
their temperature by induction
heating [10]. Various advantages arise from the above practices,
which includes reduction in cost of energy, in a fast and effective
manner. Thus, improving process performance, while preventing
cracks and other defects causative challenges. Regardless, the heating process before rolling may lead to
the deterioration of tensile
properties in the thickness direction. Moreover, the tendency of
residual stresses caused by uneven cooling may negatively impact
the microstructural and mechanical properties of the metallic
material. Hot rolled materials find applications in automotive rims,
wheels and clutches, agricultural and food processing industries
and guard railways for streets and highways.

2.2.1.2 COLD ROLLING

Cold rolling process is a technique which is mostly applied for
the production of smaller sized products with high strength, these
products are achieved by including cluster mills as shown in Fig. 3,
it does not reduce the thickness as much as hot rolling [11]. The
considerations are met, when the metal pieces are ‘‘worked” at
temperature below its recrystallisation. Cold rolling is applied to
induce ductility in steel, achieved through annealing of the steel
in a process called ‘‘the Cold Rolled and Closed Annealed” [12]. A
more special process of cold rolling is known as skin-rolling and
has the least reduction percentage level. Skin-rolling produces a
smooth finish surface and a uniform thickness while reducing
the yield point phenomenon by restricting what is known as ‘‘Luders bands” from occurring in later
processes. To restrict ‘‘Luders
bands”, dislocations are locked at the surface reducing the possibility, and also creating sufficient
unpinned dislocations by density in
a ferrite-matrix [13]. The cold rolling process is essential where
increased strength and excellent surface finish in a material which
meets tight tolerance is a vital factor. Nonetheless, a cold rolled
Fig. 1. Basic of Rolling operation [8].
Fig. 2. Illustration of hot rolling operation.
Fig. 3. Illustration of cold rolling operation.
O.M. Ikumapayi et al. / Materials Today: Proceedings 26 (2020) 1644–1649 1645
metal has weak buckling and torsional resistance, and finds use in
the manufacture of bars, strips, rods, and sheet metals etc.
2.2.2 TYPES OF ROLLING PROCESS :

2.2.2.1Roll bending

fig 5. Roll bending

Roll bending produces a cylindrical shaped product from plate or steel metal.
2.2.2.2 Roll forming

fig 6. Roll forming

Roll forming is a continuous bending operation in which a long strip of metal (typically coiled steel) is
passed through consecutive sets of rolls, or stands, each performing only an incremental part of the
bend, until the desired cross-section profile is obtained. Roll forming is ideal for producing parts with
long lengths or in large quantities. There are mainly 3 main processes, 4 rollers, 3 rollers and 2 rollers,
and have different advantages according to the specifications of the plate (thickness length and
diameter) and the shapes.

Also call roll bending or plate rolling process this is used in many fields, Exhaust pipes, Trucks brakes,
Pressure Vessel Tanks Gaz tanks, Components for airbags, Fire extinguishers, Hot water boilers, Drawer
rails, Filter housings, Fittings, Fuel filters, Gear components, Gear selector forks, Multi diameter Shells,
Pressurized containers, Pumps' shells, Rear axles, Sink mountings, Spinning compatible tubes, Washing
drumbs.

2.2.2.3 Flat rolling

The most predominant type of rolling is the flat rolling operation. This technique allows feeding material
in between two rollers
rotating in opposite directions as depicted in Fig. 4, with the spacing between the rollers designed
smaller than the thickness of the
initial material to compressed it into the desired thickness [14].
The deformation process causes elongation of the material. It is
worthy of note that this deformation activity is dependent on the
friction between the rollers and the material been deformed. If
the required thickness is too small compared to the initial thickness of the material, then the rollers may
slip on the surface of
the material without causing any change to it [15]. Hence, the need
to consider the required factors, temperature of the roller, lubricant requirement, speed of the process
and physical and mechanical properties of the material. The process is tedious and laborious
especially in cases of rolling bulky materials. However, nowadays,
its use has been limited to metal sheet forming and other small
handy mechanical equipment [11].

2.2.2.4 Foil rolling

Foil rolling is a specialized type of flat rolling, specifically used to produce foil, which is sheet metal with
a thickness less than 200 µm (0.0079 in). The rolling is done in a cluster mill because the small thickness
requires a small diameter rolls. To reduce the need for small rolls pack rolling is used, which rolls
multiple sheets together to increase the effective starting thickness. As the foil sheets come through the
rollers, they are trimmed and slitted with circular or razor-like knives. Trimming refers to the edges of
the foil, while slitting involves cutting it into several sheets. Aluminum foil is the most commonly
produced product via pack rolling. This is evident from the two different surface finishes; the shiny side
is on the roll side and the dull side is against the other sheet of foil.

2.2.2.5 Ring rolling

fig 7. A schematic of ring rolling

Ring rolling is a specialized type of hot rolling that increases the diameter of a ring. The starting material
is a thick-walled ring. This workpiece is placed between two rolls an idler roll, while another roll, called
the driven roll, presses the ring from the outside. As the rolling occurs the wall thickness decreases as
the diameter increases. The rolls may be shaped to form various cross-sectional shapes. The resulting
grain structure is circumferential, which gives better mechanical properties. Diameters can be as large as
8 m (26 ft) and face heights as tall as 2 m (79 in). Common applications include rockets, turbines,
airplanes, pipes, and pressure vessels.

2.2.2.6 Structural shape rolling

fig 8. Cross-sections of continuously rolled structural shapes, showing the change induced by each
rolling mill.

2.2.2.7 Controlled rolling

Controlled rolling is a type of thermomechanical processing which integrates controlled deformation and
heat treating. The heat which brings the workpiece above the recrystallization temperature is also used
to perform the heat treatments so that any subsequent heat treating is unnecessary. Types of heat
treatments include the production of a fine grain structure; controlling the nature, size, and distribution
of various transformation products (such as ferrite, austenite, pearlite, bainite, and martensite in steel)
inducing precipitation hardening and, controlling the toughness. In order to achieve the entire process
must be closely monitored and controlled. Common variables in controlled rolling include the starting
material composition and structure, deformation levels, temperatures at various stages, and cool-down
conditions. The benefits of controlled rolling include better mechanical properties and energy savings.

2.3 Principle of rolling

Rolling is a process used to shape metal into a thin long layer by
passing it through a gap of two rollers rotating in different directions (clockwise and anti-clockwise) [5].
The gap between the
two rollers is supposed to be smaller than the thickness of the
working piece of material to be formed. When the metal piece is
put between the rollers, it experiences a force of friction and compression from the rollers compressing
it to be thin and elongated,
or longer than its original length (Fig. 1). When the piece completes
its way through the gap between rollers, it must have less thickness than the original one with an
increased length and width
[6]. This decrease in thickness is referred to draft and the increase
in length and width is called an absolute elongation and spread
respectively [7]. The process of rolling is a specialized form of
metal forming for shaping large bulk material into more detailed
parts and large length cross sectional materials, as well. The different types of rolling process that leads
to increased operational performance and production flow is discussed based on the different
techniques. The rolling operation must conform to the work component geometry being rolled, to
ensure uniformity of the material
and the change in property due to the deformation process.

2.4. Rolling & its Parameters [34]

The parameters are: • Roll diameter

• Friction between rolls and work piece

• Deformation resistance of the metal as influenced by metallurgy, temperature

and strain rate Presence of roll tensions

Roll Diameter:
Rolling load increases with roll diameter at a rate greater than D1/2 *We know Rolling load P =
p.b.√R.∆t but R=D/2 Therefore P = p.b.√D/2.∆t or P α√D *As roll diameter decreases both rolling load
and length of arc of contact decreases. *Small diameter rolls supported by large back up rolls can
produce greater reduction and keep the work flat.

Friction:

Frictional force is needed to pull the metal into the rolls.*Large fraction of rolling load comes from the
frictional force.*Friction varies from point to point along the arc of contact of the roll, it will be acting
from entry to neutral point long the direction of roll rotation and from neutral point to exit point it
will be opposing the direction of roll rotation. High friction results in high rolling load and a steep
friction hill will be realized. *Since it is very difficult to measure the variation in coefficient of friction
‘µ’ it is assumed that ‘µ’ is constant. For cold rolling it is taken as 0.05-0.1 and for hot rolling it is taken
as >= 0.2.*Coeff.of friction is inversely proportional to the rolling speed. As µ decreases rolling speed
increases. From F= µ/N µ = F/N Thinner gage sheet can be produced in cold rolling as coeff.of friction
is smaller.
Deformation resistance of metal:

Deformation resistance indicate how much a given metal offers resistance to deformation.
Deformation resistance is the resistance offered by the metal for external load. Higher the
deformation resistance higher is the difficulty to deform. Coarser grains in the metal offer less
resistance for deformation and vice versa. Higher the dislocation density higher is the deformation
resistance. Higher the working temperature lesser is the deformation resistance.

Strip Tension:

The presence of tension in the plane of the sheet can reduce the rolling load. Front tension can be
controlled by the coiler where as back tension can be created by controlling the speed of the uncoiler
relative to the roll speed.

Tension reduces wear of the rolls. Improves flatness in the sheet, induces uniform thickness across the
width of the sheet. Tension is used to shift the neutral point towards the exit plane.

Pressure Distribution in Rolling:

The roll pressure ’p’ increases continuously from the entry to the neutral point there after it
decreases continuously.*The peak pressure at the neutral point is normally called as the “Friction
Hill”*This peak pressure increases with increasing coefficient of friction. It can be concluded that as
the roll tension is increased at the front and back the roll pressure can be reduced along the arc of
contact. *Peak pressure is reduced and shifted towards the entry side. *As a result the load required
for rolling gets reduced.