MIN586: Metal Forming

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Dr. Shamik Basak

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Dr

Assistant Professor

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Department of Mechanical and Industrial Engineering

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Indian Institute of Technology Roorkee, India
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IIT
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Email id: shamik.basak@me.iitr.ac.in

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Metal Forming
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 Reference books

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1. “Plasticity of Mechanical Engineers” by W.Jhonson and

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P.B.Meller, Van Nostrand.

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2. “Manufacturing Science” by A.Ghosh and A.K.Mallik.

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3. “Metal Forming Mechanics and Metallurgy” by W.F.Hosford

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and R.M.Caddll.

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4. “The Mathematical Theory of Plasticity” by R.Hill.

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Metal Forming
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 Forming

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Powder

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Bulk Sheet

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Metal

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Forming Forming

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Forming

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• Deep drawing • Powder forging

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• Rolling • Stretch forming • Powder extrusion

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• Forging • Bending • Powder injection

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• Extrusion • Shearing molding etc.

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• Drawing etc. • Punching etc.

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Apart from these conventional forming processes also non-conventional of high energy rate
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forming processes (HERF) are also there

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Metal Forming 3
 Rolling

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Rolling is a metal forming process in which the thickness of the work is reduced by

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compressive forces exerted by two rolls rotating in opposite direction. Flat rolling is

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shown in figure.

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Metal Forming
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 Different types of rolling

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• Blooms are rolled into structural shapes like rails for railroad tracks.

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• Billets are rolled into bars, rods. They become raw materials for machining, wire drawing, forging,

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extrusion etc.
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• Slabs are rolled into plates, sheets, and strips. Hot rolled plates are generally used in shipbuilding,
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bridges, boilers, welded structures for various heavy machines, and many other products.

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 Salient features

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• The material to be rolled is drawn by means of friction into

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the two revolving roll gap

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• The compressive forces applied by the rolls reduce the

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thickness of the material or changes its cross sectional

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area

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• The geometry of the product depend on the contour of the

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roll gap

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• Roll materials are cast iron, cast steel and forged steel

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because of high strength and wear resistance

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requirements

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 Change in grains structure in rolling

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In rolling the crystals get elongated in the rolling direction. In cold rolling crystal
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more or less retain the elongated shape but in hot rolling they start reforming after
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coming out from the deformation zone IIT

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Metal Forming
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 Roll passes to get a 12 mm rod
from 100 x 100 mm billet

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 De Dr
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Flat strip rolling : Slip

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Metal Forming
 Flat strip rolling

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• The peripheral velocity of rolls at entry exceeds that of the

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strip, which is dragged in if the interface friction is high

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enough.

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• In the deformation zone the thickness of the strip gets

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reduced and it elongates. This increases the linear speed of

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the at the exit.

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• Thus there exist a neutral point where roll speed and strip
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speeds are equal. At this point the direction of the friction

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reverses.

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• Roll torque, power etc. increase with increase in roll work
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contact length or roll radius

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Metal Forming
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 Flat strip rolling

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Roll velocity = VR = w R = constant

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Bite point : Point at which material is gripped by roll

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(Vm)i
At bite point: (Vm)i < VR

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(Vm)f

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At exit point: (Vm)f > VR

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So, somewhere in between arc of contact : (Vm)i = VR (Neutral point)

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This point is called neutral point. Over the neutral point direction of the friction
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force changes. there is one point or zone along the contact arc where work
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velocity equals roll velocity. This is called the no-slip point, or neutral point.
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Metal Forming
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 De Dr
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Some important equations

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Metal Forming
 Mathematical formulation for maximum draft

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A 𝜃

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𝜃
p
hb/2

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C ha/2

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μp

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Symmetric line
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 Mathematical formulation for maximum draft

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A 𝜃

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𝜃
p
hb/2

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C ha/2

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μp

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Symmetric line
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 Rolling mills

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Two high rolling mill This type of rolling mill consists of two rolls rotating in opposite directions.

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• Non-reversing mill: rolls rotate only in one direction, and the

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slab always move from entry to exit side.

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• Reversing mill: direction of roll rotation is reversed, after each

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pass, so that the slab can be passed through in both the

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directions. This permits a continuous reductions to be made

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through the same pairs of rolls.

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Three high rolling mill • Three working rolls

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• At a time, for single pass, two rolls will be used.

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• The roll direction will not be changed in this case.
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• The top two rolls will be used for first reduction and the sheet is
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shifted to the bottom two rolls and further reduction is done.
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• This cycle is continued till actual reduction is attained.

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Disadvantage: automated mechanism is required to shift the slab

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 Rolling mills

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Four high rolling mill

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• Two working roll + Two backup rolls

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• This consists of two small rolls for thickness reduction and two

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large backing rolls to support the small rolls.

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• The small rolls will reduce the roll force required as the roll-

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sheet contact area will be reduced.

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• The large backing rolls are required to reduce the elastic

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• Two-high and three-high mills are generally used for initial and intermediate passes during hot
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rolling, while four-high and cluster mills are used for final passes.

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• Last two arrangements are preferred for cold rolling because roll in these configurations are

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supported by back-up rolls which minimize the deflections and produce better tolerances.
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 Rolling mills
Cluster rolling mill

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• This uses smaller rolls for rolling

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• Two backup rolls for each working roll.

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Tandem rolling mill
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• This consists of series of rolling stations of the order of 8 to 10.
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• In each station, thickness reduction is given to the sheet.
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• With each rolling station, the work velocity increases.

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• This is fully used in industry practice, along with continuous casting operation.
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• This results in reduction in floor space, shorter manufacturing lead time.

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 Rolling mills

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Planetary rolling mill

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• Very large reduction is possible here as much as 95% in a single pass.

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• The process is generally very slow and installed near to the furnace

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• Complete system consists of 1. Furnace 2. feed-roll stand 3. planetary rolling stand 4.

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planishing rolling stand

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• Feed roll to push material into the planetary rolls
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• Roll stock are generally not plat hence use the last arrangement for removing undulation
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problems

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 Other deformation processes related to rolling

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Thread rolling

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• Thread rolling is a cold-forming process by which straight or tapered threads are formed on

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round rods or wire.

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• The threads are formed on the rod or wire with each stroke of a pair of flat reciprocating dies

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(Fig. 1). In another method, threads are formed with rotary dies (Fig. 2),

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• The thread-rolling process has the advantages of generating threads with good strength (due to
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cold working) and without any loss of material (scrap).

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• The surface finish produced is very smooth, and the process induces compressive residual
stresses on the work piece surfaces, thus improving fatigue life.
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• It is used for mass production of external threaded parts like bolts and screws
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Metal Forming
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 Other deformation processes related to rolling

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Ring rolling

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• Ring rolling is a forming process in which a thick walled ring part of smaller diameter is rolled into a

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thin walled ring of larger diameter.

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• The ring is placed between two rolls, one of which is driven while the other is idle.

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• Its thickness is reduced by bringing the rolls closer together as they rotate.
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• Since the volume of the ring material remains constant during plastic deformation (volume
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constancy), the reduction in ring thickness results in an increase in its diameter.
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Application: ball and roller bearing races, steel tires for railroad wheels, rings for pipes, pressure
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vessels, and rotating machinery

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 Other deformation processes related to rolling

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Transverse rolling or roll forging

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• Transverse rolling or Roll forging in this operation (also called cross rolling), the cross section of

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a round bar is shaped by passing it through a pair of rolls with profiled grooves.

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• Roll forging typically is used to produce tapered shafts and leaf springs, table knives, and hand

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tools; it also may be used as a preliminary forming operation, to be followed by other forging
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processes IIT
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Metal Forming
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 Other deformation processes related to rolling

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Skew rolling

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• A process similar to roll forging is skew rolling, typically used for making ball bearings.

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• Round wire or rod is fed into the roll gap, and roughly spherical blanks are formed continuously by

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the action of the rotating rolls.

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 Rolling pressure distribution

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Assumptions

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• Rigid rolls

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• Plane strain deformation

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• Yield strength (Y) is constant

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i – n ------ Lagging zone Vm < VR

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n - f ------ Outstripping zone Vm > VR
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n ---- Neutral point Vm = VR

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No widening take place take place in width direction as we take

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plane strain deformation configuration.

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 Rolling pressure distribution

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Element at outstripping zone
Pr

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μPr

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dh/2

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σx

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σx+dσx
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μPr

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 Rolling pressure distribution

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Element at lagging zone
Pr

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μPr

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dh/2

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σx

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σx+dσx
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μPr

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 De Dr
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Rolling pressure distribution

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Metal Forming
 dh/2
Rdα

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R
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dα α

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Rolling pressure distribution

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Metal Forming
 Rolling pressure distribution

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hb ha

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Rdα

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dh/2
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 De Dr
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Rolling pressure distribution

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Metal Forming
 De Dr
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Rolling pressure distribution

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Metal Forming
 De Dr
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Rolling pressure distribution

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Metal Forming
 Rolling pressure distribution

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2K 2K

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The pressure distribution curve is often known as FRICTION HILL. For no tension, the pressure

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distribution curves look like this.

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Area under the curve = Load in the rolling mill

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 De Dr
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Rolling pressure distribution

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Metal Forming
 Rolling pressure distribution

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• For more front tension, back tension decreases and neutral point moves backwards
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• If back tension increases, front tension decreases and neutral point moves towards front

Metal Forming
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 Effect of forward and backward tension on rolling load

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The effect of back tension as well as

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that of forward tension is to reduce the

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roll pressures at all the points of

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contact area.

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The total load on the mill reduces

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Metal Forming
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Effect of coefficient of friction on rolling load

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Higher values of the roll pressure are higher at

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all points of contact area except at entry and

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exit points,

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The total load on the mill increases

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.S • In cold rolling the value of coefficient of friction

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is around 0.1
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• In warm working it is around 0.2.
• In hot rolling it is around 0.4. In hot rolling

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ha sticking friction condition is also seen and

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then friction coefficient is observed up to 0.7.
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• In sticking the hot wok surface adheres to roll
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and thus the central part of the strip
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undergoes with a severe deformation
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 De Dr
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Effect of roll diameter on rolling load

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Metal Forming
 Procedure to reduce the rolling load

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(1) using hot rolling rather than cold rolling to reduce strength and strain

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hardening (K and n) of the work material;

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(2) reducing the draft in each pass;

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(3) using a smaller roll radius R to reduce contact area and then reduce the

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force;

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(4) using a lower rolling speed N to reduce power
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(5) Using front and back tension force

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Metal Forming
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 Rolling force, torque and power requirements

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T The rolls apply pressure on the flat strip in order to reduce its

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thickness, resulting in a roll force, F, as shown in Fig

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 Rolling force, torque and power requirements

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 De Dr
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.o ha
fM m
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IIT nd
Thank you!

Ro In
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