Tech Tip #1: Slip in Flat Rolling
You would think from intuition that the
workpiece and roll in flat rolling move
at the same speed. They do not.
In any process where cross-sectional
area is reduced, the velocity of the
workpiece must increase as it passes
through the deformation zone.
The roll moves faster than the work-
piece at the inlet and slower at the
exit.
There is a point called the neutral point
or neutral zone where the tangential
velocity of the rolls and workpiece are
the same (red arrow in figure). This is
also the point of highest interface pres-
sure in flat rolling.
To either side of the neutral point there
is slip, referred to as forward slip and
backward slip. These create opposing
friction forces that play tug-of-war with
the surfaces.
The friction force at the inlet must be
greater than at the outlet in order to
draw the piece into the contact.
Forward slip is defined as the difference
between the velocities of the workpiece
and roll as the workpiece exits the neu-
tral zone, expressed as a percentage.
Backward slip, which is greater than for-
ward slip, is calculated in the same
way.
Forward slip is factored into roll pass
design.
The workpiece does not change speed.
Relative to the roll surface, however, it
decelerates and then accelerates before
T i p
T e c h
leaving the contact. This happens over
a distance of a few millimeters in half a
millisecond (0.0005 sec).
R i c h a r d s A p e x
Example: A workpiece enters the roll
gap at 9.8 m/s and exits at 14.0 m/s.
The difference, 4.2 m/s, is in the form
of slip, assuming no excess slip.
In reality, the position of the neutral
point and the balance between for-
ward and backward slip is governed by
friction in the contact. Lower friction
= less forward slip.
Think of it this way: In the limit of no
traction, the stock would remain sta-
tionary and the roll would spin. For-
ward slip would be negative, and the
entire surface of the stock would be
subject to reverse shear.
It is easy to see why controlling friction
is important—enough to draw the rod
into the bite but not so much as to in-
crease slip velocity and wear.
Slip in rod rolling will be the subject of
our next Tech Tip.