Rolling

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• Rolling is the process in which the metals and alloys
are plastically deformed into semi finished or
finished condition by passing between circular
cylinders.
• Due to the frictional forces the metal is drawn into
the opening.
• Metal Changes its shape due to high compressive
forces.
• Both hot(for drastic shape changing) and cold
rolling(for finishing) process are there.
• From the start ingot- blooms- billet- slaps which are
further rolled into plat, sheet,
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rod, bar, pipe, rails.
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• The metal contact
each of the roller
along the arc(AB),
which is known as the
“flat strip” arc of
contact.
• This arc corresponds
to the central angle “α”
called angle of contact
or Bite.

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 900

900 - α

Resolving horizontal component forces

If α value is higher than the metal

would not enter the space between the
rolls automatically.
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• It depends on lubrication, work material and also
on the temperature.
• In cold rolling the value of coefficient of friction is
around 0.1 and in warm working it is around 0.2.
• In hot rolling it is around 0.4 In hot rolling sticking
friction condition is also seen and then friction
coefficient is observed up to 0.7.
• In sticking the hot wok surface adheres to roll
and thus the central part of the strip undergoes with
a severe deformation.
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 Strips
ingot Slab

From the start ingot- blooms- billet- slaps

which are further rolled into plat, sheet, rod,
bar, pipe, rails.
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The most important continuous hot working processes
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Roll force
F= contact Length* width of strip * average ture stress
=L * w * True stress average

Power per roll

P= 2*3.14*Force* Length * speed in rpm / 6000

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• Classifications based on number of rolls

• Two high rolling mills

• Three high rolling mills
• Four high rolling mills
• Multi roll rolling mills
• Universal rolling mill
• Planetary rolling mill
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• Two high rolling mills(single
direction)
• Constant direction rolling
• Upper rolls is moveable one to set the distance.
• For single step reduction it is better one.
• If successive reduction is need we have
to change the distance for each operations.
• Least expensive

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• Two high rolling mills(both
direction)
• For successive reduction this is better than single direction
rolling.
• We can set a different distance for each direction.
• Two high reversing mills are often used for the first rolling of
an ingot into blooms and slabs.

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• Three high rolling mills
• Three rolls with constant direction
of rotation are arranged in a single vertical plane.
• Lifting table used to rise or lower
the metal after each pass.
• Both top and bottom rolls
are driver rolls

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• Four high rolling mills
• The bending of the roller is less if the diameter of the roller is
high. At the same time the power consumption and force P
value also very high for big diameter rollers.
• To over come this problem small Diameter rollers with
larger diameter back up rollers are used. This can be used
for both directions.

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• Multiple roll mills
In four high rolling the
diameter of the back up
rolls can not be greater
that 2 to 3 times that of
the work rolls.

• By reducing the work roll diameter will produce

bending effect on the back up rolls.
• So in multiple roll mills a cluster of 6, 12, 20 rolls are
used to manufacturing strips. Form 0.001mm thick
and 2000 mm wide. YoucaN
• Multiple roll
mills

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• Sendzimir mill
• Modified cluster mill
• For thin sheets
• 1 to 5 micron

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• Universal rolling mill
• Metal reduction occurs in both
horizontal and vertical rolls.
• Vertical rolls are mounted either one side
or both sides
• Horizontal rolls may be either two, three
or four high arrangement.
• Used for roll wide strips, sheets, plates
and slabs that requires both rolling
edges and also for rolling of H sectioins.
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• Classifications based on number of rolls

• Planetary roll mills

• Consist of a pair of heavy backing rolls surrounded by a
large number of planetary rolls.
• Each planetary roll gives an almost constant reduction to the
slab as it sweeps out a circular path between the backing rolls
and the slab.
• As each pair of planetary rolls ceases to have contact with the
work piece, another pair of rolls makes contact and repeat that
reduction.
• The overall reduction is the summation of a series of small
reductions by each pair of rolls. Therefore, the planetary mill
can hot reduces a
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slab directly to strip in one pass through the mill.
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• Continuous rolling mills(tandom)
• Arrangement is similar to two- high rolling mill.
• Here the metal work piece passes from one roll pass to
another and we get continuous reduction in size.
• Used for mass production

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• 5. Steelmaking Rolling

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• Various shapes can be produced
• Straight and long structural shapes, solid bars, I-beams,
channels, railroad rails.

• Ring rolling
• Thread rolling

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• Thick ring is expanded into a large diameter ring with a
reduced cross section.
• Ring is placed between two rolls and one of the roll is
driven and the ring thickness is reduced by bringing the
rolls closer together as they rotate.
• The reduction in thickness of the ring is compensated by
an increase in the rings diameter.
• Short production time, close tolerances and material
savings.

Video- 4. Forging, Ring Rolling, Open-Die Forging,

Hammer Forging-Kihlsteel.se
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• Ball and roller bearing races
• Steel tires for railroad wheels
• Rings for pipes
• Pressure vessels
• Rotating machinery

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• It is a cold forming process by which straight or tapered
threads are formed.
• Threads are formed on the rod or on wire with each stroke of
a pair of flat reciprocating dies.
• In the die we have the required thread impressions.
• One die is stationary and another is moveable one.
• The thread is formed by rotating and squeezing the blank
between hardened steel dies.
• The displaced material forms the roots of the thread and,
at the same time it forced radially outward to form the
crests.
• The die penetrated on the work, so this will create the
impressions on workpiece. YoucaN
• Here with out loss of material we can prepare the thread.
• Good surface finish and good fatigue life products
• Machining thread cuts the grain flow lines of the material.
• Rolled threads have a grain flow pattern that improves
the strength of the thread.
• The threads are rolled on metals in the soft conditions
and threaded fastness such as bolts are made by this
process.
• The lubrication is very important in thread rolling process
to minimize the defects.
• Spur and helical gears can be produced by cold rolling
process similar to thread rolling.
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• STEP 1: the billet piercing
• STEP 2: the shell elongation
• STEP 3: the tube sizing
• STEP 4: the tube finishing

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When a round bar is subjected to radial compressive forces,
stresses develop at the center of the bar.
When it is subjected continuously to these cyclic
compressive stresses, the bar begins to develop a small
cavity at its center, which then begins to grow.
The axes of the rolls are skewed in order to pull the round bar
through the rolls by the axial component of the rotary motion.
An internal mandrel assists the operation by expanding the
hole and sizing the inside diameter of the tube.
The mandrel may be held in place by a long rod, or it may be
a floating mandrel without a support.
Because of the severe deformation that the bar undergoes,
the material must be high in quality and free from defects
(since internal defects may propagate rapidly and cause
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premature failure of the part during forming).
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• Surface defects
• Internal structural defects

• Surface Defects:
• Defects such as scale, rust, scratches, cracks etc.
• Due to impurities and inclusions in the original cast
material or various other conditions related to material
preparation and rolling operations.

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• Wavy edges can be caused because of the elastic
deflection of the rolls due to the rolling force acting
on them.
• The edges of the rolled part gets thin and will experience
compressive stresses.
• These compressive stresses cause the rolled sheet to
be wavy at the edges.

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• These are also caused due to the bending of rolls
under the rolling pressure similar to wavy edges.
• Zipped cracks will be seen at the centre due to the
bending deformation of the rolls.

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• Due to the non uniform deformation of metal across the
width.
• The lateral spread is more prominent towards the edges
which will cause the edge cracks.

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• The top and bottom surface of the rolled part expands
less compared to the middle portion of the part. So the
middle portion will tear.
• Due to the Defects in the original cast material also
reason for alligatoring

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