Edge Cracks

During both hot and cold rolling, the metal might show
some cracks on the edges. This phenomenon occurs
from secondary tensile stresses induced at the
workpiece surfaces. These cracks result from factors
such as uneven heating, uneven rolling, or excess
quenching.
What is the Remedy for Edge Cracks?
A trimming operation can remove edge cracks. Also,
stretch and roller leveling under tension might work
against edge cracks. Using edge rolls might help in
achieving uniform rolls without any cracks.
• Many metals tend to develop edge cracks
during hot and cold rolling. Edge cracks need
to be removed by a trimming operation, and
they may cause rupture of the sheet in the
rolling mill. Hence, there is a strong motivation
to understand the mechanisms of edge crack
formation and to develop predictive tools for
controlling the phenomenon.
 Alligator Cracks

During rolling, layers of the metal stock might separate, leading to

the opening of slabs resembling alligator cracks. The sheet metal
adheres to the rolled surface and follows the path of respective rolls
causing sheets to appear on the in the plane.
Alligator cracking is majorly due to the non-homogeneous flow of
materials across the sheet thickness. Greater spreading of materials
occurs at the center of the material, thus metallurgical weakness.

How Do You Resolve Alligator Cracking?

Cambering of rolls is one of the most common solutions to alligator
cracking. By applying the camber on rolls in the opposite direction,
the surface in contact with the sheet becomes flat after a deflection.
 Alligatoring
The formed sheet metal will adhere to rolled
surface and to follow the path of their
respective rolls, sheet will shear in the plane and
defect is called as alligatoring.
 Wavy Edges

One of the most common rolling defects is the occurrence of fibers at

the edge, which are longer than those at the center. This occurs when
concave rolls bend leading to elastic deformations. Thickness at the
center implies that the edges are more elongated.

• How Can You Prevent Wavy Edges?

The use of hydraulic jacks works well in instances where wavy edges
occur. These jacks control the elastic deformation of rolls as per the
requirements. Also, the use of small diameter rolls works efficiently.
•

•
Variation in the work across the width in sheet
rolling occurs because the roll gap is not perfectly
parallel (a).
Since width and volume are constant and
thickness is varying, the edges elongate more
than the center (b).
But the sheet is a continuous body; the strains
readjust to maintain continuity. Thus the center
portion is in tension and the edges are in
compression (c).
The result is a wavy edge (d).
 Zipper Cracks
The occurrence of small cracks in the middle of the
metal sheet explains this phenomenon. Mostly, zipper
cracks occur due to the bending of rolls under the high
rolling pressure. It causes compressive stress in the
edges and tensile stress in the center. It’s this tensile
stresses induced at the workpiece by homogeneous
deformation that leads to the formation of zipper
cracks.
How Can You Deal With Zipper Cracks?
Cambering of rolls has proven effective when it comes
to preventing zipper cracks. Camber provides a slightly
large diameter at the center than on the edges.
 Center Buckling

This defect occurs due to the self-equilibrating residual stresses

that result from the rolling process. During center buckling,
fibers at the center of the metal piece are longer than those at
the edges. In an event where hot or cold mills have too much
crown, mills roll out at the center. Sideways deflection of a
structural member perfectly explains center buckling.

• Dealing with Center Buckling

Use crowned rolls is a solution to center buckling. The roll’s
parabolic curvature is sufficient to cover the problems of
material, temperature, and deformation.