Professional Documents
Culture Documents
Submitted to Submitted by
Dr. V.K.Sharma Basitti Hitesh
2017PMT5094
Early equipment for metal rolling
The equipment that followed to create sheet products proved
to be of very simple design.
It is not known who created the first rolling mill. However, one
of the earliest drawings is by Leonardo da Vinci. It even shows
the need for larger diameter backup rolls to support longer,
smaller diameter work rolls as shown in the fig.
The work can be passed back and forth through the rolls
by reversing their direction of rotation.
Typical arrangement of rollers for rolling mills
However, small rolls deflect more under roll forces and have to be
supported by other rolls.
Very thin sheet can be rolled to very close tolerances with small
diameter work rolls.
Typical arrangement of rollers for rolling mills
Typical arrangement of rollers for rolling mills
• Here, uses a series of rolling mill and each set is called a stand.
• The strip will be moving at different velocity at each stage in the mill.
The uncoiler and wind up reel not only feed the stock into the rolls and coiling up the final
product but also provide back tension and front tension to the strip.
Typical arrangement of rollers for rolling mills
Planetary rolling mill
• 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 operation requires feed rolls to introduce the slab into the mill, and a
pair of planishing rolls on the exit to improve the surface finish.
Types of Planetary Rolling Mill
Rolling Processes (according to the shape of products)
• Continuous Rolling
• Transverse Rolling
• Shaped Rolling or Section Rolling
• Ring Rolling
• Powder Rolling
• Continuous Casting and Hot Rolling
• Thread Rolling
Continuous Rolling (Conventional Hot or Cold Rolling)
Advantages
• Cut down the initial hot ingot breakdown step.
• Economical
• Minimize contamination in hot rolling.
• Provide fine grain size with a minimum of preferred
orientation.
Continuous casting and Hot Rolling
Low Capital investment for main equipment in case of green field units.
Low Operational cost of rolled steel depending on unit costs
Low inventory and working-capital requirements
Reduced requirements of personnel / manpower.
Reduced civil works and infrastructure costs.
Reduced energy consumption.
Smooth mill operation due to consistent temperature of the input stock.
Higher product yield& consistent quality product.
Low CO2 emissions.
Saving of space.
Production of finished rolled products from scrap in lesser time.
Thread Rolling
Dies are pressed against the surface of cylindrical blank. As the
blank rolls against the in-feeding die faces, the material is displaced
to form the roots of the thread, and the displaced material flows
radially outward to form the thread’s crest.
Rolled threads are produced in a single pass at speeds far in excess of those
used to cut threads.
Assumptions
1. The arc of contact between the rolls and the metal is a part of a
circle.
2. The co-efficient of friction, ‘μ’ is constant in theory, but in reality ‘μ’
varies along the arc of contact.
3. The metal is considered to deform plastically during rolling.
4. The volume of metal is constant before and after rolling. In practical,
the volume might decrease a little bit due to close-up of pores.
5. The velocity of the rolls is assumed to be constant.
6. The metal only extends in the rolling direction and no extension in
the width of the material.
7. The cross sectional area normal to the rolling direction is not
distorted.
Since, there is no change in metal volume at a given pt.
per unit time throughout the process.
To the left of this pt., the roll moves faster than the strip,
to the, to the right of this pt., the strip moves faster than
the roll.
Because the surface speed of the rigid roll is
constant, there is relative sliding between the roll
and the strip along the arc of contact in the roll
gap.
The amount of slip between the rolls and the work can
be measured by means of the forward slip, a term
used in rolling that is defined:
For the workpiece 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.
But we know,
Therefore,
Where ∆h=2a
The distribution of roll pressure along the arc of contact shows that the
pressure rises to a maximum at the neutral point and then falls off.
The pressure distribution does not come to a sharp peak at the neutral point,
which indicates that the neutral point is not really a line on the roll surface
but an area.
The area in shade represents the force required to overcome frictional forces
between the roll and the sheet.
The area under the dashed line AB represents the force required to
deform the metal in plane homogeneous compression.
The specific roll pressure, ‘p’ is the rolling load divided by the contact area.
Roll force Calculation
Note that this force appears in the figure as perpendicular to the plane of the strip,
rather than at an angle. This is because, in practice, the arc of contact is very small
compared with the roll radius, so we can assume that the roll force is perpendicular to
the strip without causing significant error in calculations. The roll force in flat rolling
can be estimated from the formula
Where = average flow stress, MPa (lb/in2); and the product (wL) is the roll-
work contact area, mm2 (in2).
The main variables in rolling are:
• The roll diameter.
• The deformation resistance of the metal as influenced by metallurgy, temperature and strain rate.
• The friction between the rolls and the workpiece.
• The presence of the front tension and/or back tension in the plane of the sheet.
Where the roll pressure (p) is the yield stress in plane strain
when there is no change in the width (b) of the sheet.
Normal friction situation
In the normal case of friction situation in plane strain, the average pressure ‘p’ can be calculated as.
Where Q = μLp/h
h = the mean thickness between entry and exit from the rolls.
We have,
Therefore the rolling load P increases with the roll radius √R, depending on the
contribution from the friction hill.
• The rolling load also increases as the sheet entering the rolls becomes thinner (due
to the term eQ).
• Small-diameter rolls which are properly stiffened against deflection by backup rolls
can produce a greater reduction before roll flattening become significant and no
further reduction of the sheet is possible.
And,
Torque, and Power requirements
The torque in rolling can be estimated by assuming that the roll force is
centered on the work as it passes between the rolls, and that it acts with a
moment arm of one-half the contact length L. Thus, torque for each roll is
T=0.5FL
The power required per roll can be estimated by assuming that (F) acts in the
middle of the arc of contact; thus, in Fig. (5-4), a = L/2. Therefore, the total
power (for two rolls), in S.I. units, is
Roll Bending
Possible effects of insufficient camber (a) : edge wrinkling (b), warping (c), centerline cracking (d), and (e) residual stresses.
Over camber
Effects of over-cambering(a): residual stresses(b), edge cracking (c), centerline splitting (d), and (e). wavy center
Classification of Defects
AZ91 Mg Alloy
As cast condition: T.S: 250MPa el.: 5-10%
Conventional process: T.S: <~350 MPa el.:<~15%
HPR process: T.S: 371MPa el.:23%
The Mg-9Al-1Zn (AZ91) plates processed by HPR consist of coarse grains of 30–60 μm, exhibiting a typical basal
texture, fine grains of 1–5 μm and ultrafine (sub) grains of 200–500 nm, both of the latter two having a weakened
texture.
The superior properties should be mainly attributed to the cooperation effect of the multimodal grain structure and
weakened texture, where the former facilitates a strong work hardening while the latter promotes the basal slip.
Differential Speed Rolling (DSR) process
Hydrostatic SPD methods such as cyclic extrusion compression (CEC), equal-channel angular pressing (ECAP), and
high-pressure torsion (HPT).
In SPD processes, the material is subjected to a very large plastic deformation (true strain ε is even greater than 80)
usually being conducted under a hydrostatic pressure and room temperature conditions.
These SPD methods also exhibit some serious disadvantages, e.g., a poor process efficiency, small dimensions of
produced (semi-) products, or a necessity of using specialized machines and tools.
DSR (cont.)
The neutral point associated with the slow roll is shifted toward the
entrance of the roll gap, while the neutral point associated with the
fast roll is moved toward the exit of the roll gap.
Kim et al. reported that in oxygen-free copper, submicron grain size of 820 nm is obtained after the 65 % thickness
reduction in a single rolling pass by the DSR method (the R = 3). This processing also leads to a formation of a large
fraction of high-angle grain boundaries (HAGBs) (~60 %) and maintaining a high electrical conductivity (that proves a low
level of structure defects).
Jiang et al. [22] on pure aluminum subjected to the DSR process. The authors found that the cold rolling (with the R = 3)
of commercially pure aluminum to 90 % of thickness reduction leads to a formation of microstructure composed of
submicron-equiaxed grains and a high fraction of HAGBs (~50 %).
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