Rolling and Extrusion

Rolling process
❑ Rolling is the process of reducing the thickness of a long workpiece by
compressive forces applied through a set of rolls

❑ Rolling accounts for about 90% of all metals produced by metal working
processes
 Rolled Products Made of Steel
Semifinished casting products

Blooms have square cross sections

Plate thickness > 6 mm

Sheet thickness < 6 mm

Slabs have square cross sections

Billets have square cross sections

 Types of Rolling
❑ Based on work temperature
▪ Hot Rolling
▪ Cold Rolling

❑ Based on workpiece geometry

▪ Flat rolling
▪ Shape rolling
 Hot Rolling
❑ Hot rolling occurs above the recrystallization temperature of the material

❑ The material fed for rolling is usually large pieces of metal, like semi-finished
casting products, such as slabs, billets and bolloms

❑ Equiaxed microstructure could be obtained by hot rolling process

 Cold Rolling
❑ Temperature is below recrystallization temperatures of metal

❑ This increases yield stress and hardness of metals

❑ Thinner sheets could be obtained by cold rolling process

FLAT ROLLING PROCESSES
 ROLL BITE CONDITION
For the work piece to enter the throat of the roll, the component of the friction
force must be equal to or greater than the horizontal component of the normal
force
 SHAPE ROLLING PROCESSES
❑ Various shapes can be produced by shape rolling. (Straight and long structural
shapes, channels, I-beams, railroad rails

a) Ring Rolling
b) Thread Rolling
RING ROLLING
❑ A Thick ring is expanded into a large
diameter ring with a reduced cross-
section

❑ The ring is placed between two rolls

and its thickness is reduced by bringing
the rolls closer together as they rotate
STEPS IN THE RING ROLLING
 THREAD ROLLING
❑ Thread rolling process is a cold forming process by which straight or tapered
threads are formed on round rods, by passing them between dies
Screws, bolts and similar threaded parts
Higher production rates
Better fatigue resistance
 Rolling Mills

❑ Two – high -------Two opposing rolls

❑ Three – high ----- Work passes through rolls in both directions

❑ Four high -------- Backing rolls support smaller work rolls

❑ Cluster mill ------ Multiple backing rolls on smaller rolls

❑ Tandem rolling mill -------- Sequence of two-high mills

Two – High Rolling Mill
Three – High Rolling Mill
Four-High Rolling Mill
Cluster Mill
Tandem Rolling Mill
 Extrusion
❑ In the extrusion process, a billet is forced throuhg a die in a manner similar
to squeezing toothpaste from a tube.

❑ A Material is pushed or drawn through a die of the desired cross-section

❑ This process is used to create objects of a fixed cross sectional profile

 EXTRUSION TYPES

❑ Direct (Forward) Extrusion

❑ Indirect (Backward) Extrusion

❑ Impact Extrusion

❑ Hydrostatic Extrusion
 DIRECT EXTRUSION
❑ Round billet is placed in a chamber and forced through a die opening by
hydraulically-driven ram or pressing.
 INDIRECT EXTRUSION

❑ The die moves toward the billet

 IMPACT EXTRUSION
❑ Impact extrusion is similar to indirect extrusion.
❑The punch descends rapidly on the blank, which is extruded backward
 HYDROSTATIC EXTRUSION
❑ The billet is smaller in diameter than the chamber, which is filled with a fluid,
and the pressure is transmitted to the billet by a ram.
❑ Unlike in direct extrusion, there is no friction to overcome along the
container walls.
METAL FLOW IN EXTRUSION
EXTRUSION DIE DESIGN AND DIE MATERIALS
 DIE MATERIALS

❑ Die materials for hot extrusion are usually hot-work die steels

❑ Coatings such as zirconia may be applied to the dies

❑ Partially-stabilized zirconia dies are also being used for hot extrusion

of tubes and rods