A

Report on
rolling process and mills”
Submitted by
Tanvesh Tushar Patil
(2130331612012)
S. Y. B. TECH MECHANICAL ENGINEERING

Dr. Babasaheb Ambedkar Technological University, Lonere Raigad

 INDEX
Chapter Page No.
1)Abstract 2

2) Introduction 2

3) Rolling process 3

4) Working principle 4

5) Types of rolling processes 5-6

a) Thread or gear rolling
b) Shape rolling
c) Ring rolling
d) Tube piercing
e) Skew rolling
f) Transverse rolling

6) Type of rolling mills 7-8

a) Two high rolling mill
b) Three high rolling mill
c) Four high rolling mill
d) Tandem rolling mill
e) Cluster rolling mill
f) Planetary rolling mill

7)Thickness changes along length 9

8)Flatness and shape 10

9)Profile 10

10)Flatness 10

11)The different classifications for flatness defects 11

12)Surface defect types 11

13)Surface defect remediation 11

14)Conclusion 12

15)Referral 12
 1)Abstract
Rolling process is a very common and conventional process which is used in
finishing shaping and designing of flat stripes, angles, rods, etc. In this process the
product which is to be machined is passed through a set of heavy rollers which are
rotating at some speed usually constant due to this rotation of roller the material
which is to be machined gets shrinked and takes the shape as of that of the rotating
rollers through which it is passed. Generally rolling process is having two types: - 1)
Hot Rolling 2) Cold Rolling The present research deals with the various Rolling
Procedure, Terminologies use in rolling process & defect in rolling processes. The
reason for selecting this Paper among the various problems present in the industry in
Rolling processes we want to save the industry from huge lose in the breakdown
period which generally occurs in such industries because of roller break down &
amp; also to save operators, operating the rollers from any harm when roller break
down.

Key Words: - Ignots, Billets, Roller, Hot Rolling, Cold Rolling, Cracks, Fatigue,
Re-rolling mills etc.

2) Introduction
Rolling is a major manufacturing process of sheets and other cross sections of large
length like I beam, railroads etc. It is one of a metal forming process in which the
metal work piece is compressed between a set of rolls where it reduces its
crosssection area and increases its length. This process gives high production rate,
surface finish and grain structure which make it a most suitable metal forming
process for large length same cross section work pieces but high set up cost of
rolling machine makes it as an alternative process. Rolling process is most common
industrial process used for making large length cross section like sheets and plates
of steel and aluminum for structure and other works. Rolling mills are used to
perform rolling process. These machines are available in different shapes and size
according to requirement of the process and due to technical issues. Every rolling
mill consist minimum two rolls. These numbers can extend according to the process
requirement
 3) Rolling process
Terminology:
The most common terminologies used in rolling process are given below.

I. Ingot:
It is casted structure with porosity and blowholes. Ingot is same as used in forging.
This ingot is rolled out at hot temperature of about 1200 degree centigrade into
blooms. This ingot may have any size according to the rolling requirement.

II. Blooms:
It is first rolled product making by rolling ingot at high temperature. It has cross
section area more than or equal to 230 square centimeters. This bloom is further
rolled to make I section, billet, channel, railroad etc.

III. Slab:
Slab is made by hot rolling of ingot. It has crosssection area greater than or equal to
100 centimeters square and its width is greater than or equal to three times of its
thickness. Slabs are used to form plates, sheets, strips etc.

IV. Billets:
Billets are product of hot rolling of blooms. It has greater than or equal to 40 square
centimeters cross section area. Billets are used to roll into pipes, bars, wire etc.

V. Plate:
Plate is product of further rolling of slab. It has greater than 6 mm thickness.

VI. Sheet:
Sheet has less than 6 mm thickness and width greater than 60 cm.

VII. Strip:
Strip is same as sheet but have width less than 60cm.
 4) Working Principle
Rolling works on same as any other metal forming process. When a compressive
force applied by a set of rolls on ingot or any other product like blooms or billets,
plastic deformation takes place which decrease its cross section area and convert it
into required shape. These rolls are designed according to the final product
requirement. They are cylindrical in shape and fitted with the die of the required
shape which to be rolled on blooms or billets. Rolling can be done in both hot and
cold way.

Hot rolling is done at above recrystallization temperature. It is used to large

deformation. It gives residual stresses free product but gives poor dimension
accuracy and surface finish due to scale formation.

Cold rolling is another method witch is done at below recrystallization temperature. It

is done to get final product. This process gives high mechanical strength, dimension
accuracy and surface finish.
 5)Types of Rolling Processes
a)Thread or Gear Rolling:
This process is used to cut threads or gear on cylindrical blank. In this process
threaded dies are fitted on cylindrical rollers of rolling machine. This threaded roller
pressed against cylindrical blank and roll against the faces which displace the
material and form threads on cylindrical blank. This process gives high strength and
surface finish and used to mass production of screw, bolts etc.

b) Shape Rolling:
Shape rolling is used to cut various shapes on metal work piece. It does not involve
appreciable change in thickness. It is used to rolled I section, T section, railroads etc.
c) Ring Rolling:
Ring rolling is another method of rolling which is used to rolled rings of large
bearings, turbines etc. In this process, two rollers (Main Roller and Idler Roller) are
arranged as shown in figure and rotate in same direction to each other. The ring
rotates due to rotation of roller and the rollers start move closer to each other. This
will increase the diameter of rings. A pair of edge rollers is used to maintain the
height of ring which does not allow to metal flow in the direction of height. This
process gives high accuracy and material finish

d) Tube Piercing:
It is another rolling process in which a stationary mandrel is used at the center of
tube and cavity form due to tensile stress in a cylindrical rod when subjected to
external compressive stress. In this process two opposite rolls are rotate in opposite
direction which com press the tube and feed it against mandrel which create hollow
cavity in it. This process is used to making seamless hollow tubes of thick wall.

e) Skew Rolling:
Skew rolling is used to make balls of ball bearing. In this process round bar or wire is
fed directly into special designed rollers which continuously form spherical balls by
rolling action. This process is used for mass production of small size spherical balls.
f) Transverse Rolling:
Transverse rolling is another type of rolling which is used to make tapper shaft , leaf
springs etc. in this process both rollers rolls are fitted with special kind of tapped
section which used to form tapped cavity of cylindrical work piece.

6) Types of Rolling Mills

According to the number and arrangement of rolls, this machine can be classified
into following types.

a) Two High Rolling Mill:

This mill consist two rollers arranged as shown in figure. Both the rollers rotate in
opposite direction for desire movement of work piece. Work piece is feed between
the rollers which apply a compressive force and tends to plastically deform work
piece and convert it into desire shape.
This machine can further classified into two types. The first one is two high non
reversible machine in which the rollers can rotate in only one direction (Either
clockwise or anticlockwise) and thus work piece can feed only in one direction
(Either left to right or right to left). One big problem arises in this machine is that
every time the work piece carried back over the front side of mill to feed again for
reduction in thickness.
The other one is two high reversible machine in which both the rollers can be rotate
in both directions. In this machine no need to carry work piece at front side. We have
to just change the direction of rotation of rollers to again pass the work piece through
rollers for decrease thickness.
 b) Three High Rolling Mill:
This type of rolling mill consist three rollers arrange parallel to each other. In this
machine the middle roller rotate in opposite direction of other two rollers. This
machine is used to reduce two times thickness in one pass. In this machine, the
work piece is feed between bottom and middle roller in one direction and top and
middle rollers in opposite direction. This machine can handle two work pieces in
single run.

c) Four High Rolling Mill:

These machine consist four rollers (two small and two big). These rollers are
arranged as shown in figure. Small rollers are in direct contact with work piece and
rotate in opposite direction. Big rollers works as backup rolls and they also rotates in
opposite direction with each other and also with contact roller.

d) Tandem Rolling Mill:

Tandem rolling is also known as continuous rolling in which two or more set of four
high rolling mill arranged in a series in which each set is called stand. These stands
are arranged so they can roll the work piece in decreasing cross section. It is used
for rolling thick work piece in single pass.
 e) Cluster Rolling Mill:
In this type of rolling mill, each of working roller is backup by two or more of larger
backup roller. These rollers are arrange as shown in figure. This machine is used for
rolling hard material.

f) Planetary Rolling Mill:

In this type of rolling machine, a large backup roller is surrounded by various
numbers of planetary working rollers as shown in figure. Each planetary roll gives
constant reduction. It is used to reduce large thickness in single pass of steel strip.
Its rolling capacity is more than cluster machine but less than tandem rolling
machine.

7) Thickness changes along length

In hot rolling, if the temperature of the workpiece is not uniform the flow of the
material will occur more in the warmer parts and less in the cooler. If the temperature
difference is great enough cracking and tearing can occur. The cooler sections are,
among other things, a result of the supports in the re-heat furnace.
When cold rolling, virtually all of the strip thickness variation is the result of the
eccentricity and out-of-roundness of the Back-up Rolls from about Stand 3 of the Hot
Strip Mill through to the Finished Product.
The Back-up Roll eccentricity can be up to 100 μm in magnitude per stack. The
eccentricity can be measured off-line by plotting the force variation against time with
the Mill on creep, no strip present, and the Mill Stand below face.
A modified Fourier analysis was employed by the 5 Stand Cold Mill at Bluescope
Steel, Port Kembla from 1986 until that Cold Mill ceased production in 2009. Within
each coil, the exit thickness deviation times 10 for every meter of strip was stored in
a file. This file was analyzed separately for each frequency/wavelength from 5 m to
60 m in steps of 0.1 m. To improve the accuracy, care was taken to use a full
multiple of each wavelength (100*). The calculate amplitudes were plotted against
the wavelength, so that the spikes could be compared to the expected wavelengths
created by the Backup Rolls of each Stand.
If a Mill Stand is fitted with Hydraulic Pistons in series with, or instead of the
electrically driven Mechanical Screws, then it is possible to eliminate the effect of
that Stands Back-up Roll eccentricity. While rolling, the eccentricity of each Back-up
Roll is determined by sampling the roll force and assigning it to the corresponding
portion of each Back-up Roll’s rotational position. These recordings are then used to
operate the Hydraulic Piston so as to neutralize the eccentricities.

8) Flatness and shape

In a flat metal workpiece, the flatness is a descriptive attribute characterizing the
extent of the geometric deviation from a reference plane. The deviation from
complete flatness is the direct result of the workpiece relaxation after hot or cold
rolling, due to the internal stress pattern caused by the non-uniform transversal
compressive action of the rolls and the uneven geometrical properties of the entry
material. The transverse distribution of differential strain/elongation-induced stress
with respect to the material's average applied stress is commonly referenced to as
shape. Due to the strict relationship between shape and flatness, these terms can be
used in an interchangeable manner. In the case of metal strips and sheets, the
flatness reflects the differential fiber elongation across the width of the workpiece.
This property must be subject to an accurate feedback-based control in order to
guarantee the machinability of the metal sheets in the final transformation processes.
Some technological details about the feedback control of flatness are given in.
 9) Profile
Profile is made up of the measurements of crown and wedge. Crown is the thickness
in the center as compared to the average thickness at the edges of the workpiece.
Wedge is a measure of the thickness at one edge as opposed to the other edge.
Both may be expressed as absolute measurements or as relative measurements.
For instance, one could have 2 mil of crown (the center of the workpiece is 2 mil
thicker than the edges), or one could have 2% crown (the center of the workpiece is
2% thicker than the edges).

10) Flatness
It is typically desirable to have some crown in the workpiece as this will cause the
workpiece to tend to pull to the center of the mill, and thus will run with higher
stability.
Maintaining a uniform gap between the rolls is difficult because the rolls deflect under the load
required to deform the workpiece. The deflection causes the workpiece to be thinner on the
edges and thicker in the middle. This can be overcome by using a crowned roller (parabolic
crown), however the crowned roller will only compensate for one set of conditions, specifically
the material, temperature, and amount of deformation.
Other methods of compensating for roll deformation include continual varying crown (CVC), pair
cross rolling, and work roll bending. CVC was developed by SMS-Siemag AG and involves
grinding a third order polynomial curve into the work rolls and then shifting the work rolls laterally,
equally, and opposite to each other. The effect is that the rolls will have a gap between them that
is parabolic in shape, and will vary with lateral shift, thus allowing for control of the crown of the
rolls dynamically. Pair cross rolling involves using either flat or parabolically crowned rolls, but
shifting the ends at an angle so that the gap between the edges of the rolls will increase or
decrease, thus allowing for dynamic crown control. Work roll bending involves using hydraulic
cylinders at the ends of the rolls to counteract roll deflection.
Another way to overcome deflection issues is by decreasing the load on the rolls, which can be
done by applying a longitudinal force; this is essentially drawing. Other method of decreasing roll
deflection include increasing the elastic modulus of the roll material and adding back-up supports
to the rolls.

11) The different classifications for flatness defects

 Symmetrical edge wave - the edges on both sides of the workpiece are "wavy" due
to the material at the edges being longer than the material in the center.
 Asymmetrical edge wave - one edge is "wavy" due to the material at one side being
longer than the other side.
 Center buckle - The center of the strip is "wavy" due to the strip in the center being
longer than the strip at the edges.
 Quarter buckle - This is a rare defect where the fibers are elongated in the quarter
regions (the portion of the strip between the center and the edge). This is normally
attributed to using excessive roll bending force since the bending force may not
compensate for the roll deflection across the entire length of the roll.
It is important to note that one could have a flatness defect even with the workpiece having the
same thickness across the width. Also, one could have fairly high crown or wedge, but still
produce material that is flat. In order to produce flat material, the material must be reduced by the
same percentage across the width. This is important because mass flow of the material must be
preserved, and the more a material is reduced, the more it is elongated. If a material is elongated
in the same manner across the width, then the flatness coming into the mill will be preserved at
the exit of the mill.

12) Surface defect types

There are six types of surface defects:
Lap
This type of defect occurs when a corner or fin is folded over and rolled but not welded into the
metal. They appear as seams across the surface of the metal.
Mill-shearing
These defects occur as a feather-like lap.
Rolled-in scale
This occurs when mill scale is rolled into metal.
Scabs
These are long patches of loose metal that have been rolled into the surface of the metal.
Seams
They are open, broken lines that run along the length of the metal and caused by the presence of
scale as well as due to pass roughness of Roughing mill.
Slivers
Prominent surface ruptures.

13) Surface defect remediation

Many surface defects can be scarfed off the surface of semi-finished rolled products before
further rolling. Methods of scarfing have included hand-chipping with chisels (18th and 19th
centuries); powered chipping and grinding with air chisels and grinders; burning with an oxy-
fuel torch, whose gas pressure blows away the metal or slag melted by the flame; and laser
scarfing.

14) Conclusion
Steel rolling is recognised as one of the most important industrial processes. Rolling
using grooved rolls (as a category different from groove-less rolling) is the most
common practice in production of steel sections. Key tools in this process are the
rolls that contribute up to 15 % of production costs. A main cause of roll consumption
is due to continuous wear, complex process where mechanical and thermal fatigue
combines with impact, abrasion, and corrosion. The necessity to compensate for the
non-uniform wear during machining is an additional aspect of roll consumption. An
area of specific interest is concerned with abrasive wear within the environment of
rolling in grooves, where the nature of the deformation zone can accelerate roll
surface deterioration.
 15)References
V.B. Ginzburg, Steel Rolling Technology; Theory and Practice, Marcel Dekker Inc.,
New York, 1989

R. V. Williams, and G.M. Boxall, Journal of The Iron Steel Institute, Volume 203
(1965) p. 369

R. E. Beynon, Roll Design and Mill Layout, Association of Iron & Steel Engineers,
Pittsburgh, 1956

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