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ROLLING
INTRODUCTION
CLASSIFICATION
PRIMARY WORKING operations are those that
take a solid piece of metal (generally in form of ingot) & break it down successively into shapes such as slabs, billets & plates. Traditionally this includes processes like forging, rolling & extrusion. SECONDARY WORKING operations involve further processing of the products from primary working in to final products like bolts, sheet metal parts & wires.
CLASSIFICATION
BULK DEFORMATION is the processing of work
pieces whose surface area-to-volume ratio (or surface area-to-thickness ratio) is relatively small. In bulk forming processes there is always a change in thickness or cross-section of work piece. Includes: rolling, forging, extrusion & drawing of rod & wire. SHEET-FORMING operations the surface areato-thickness ratio is relatively high. In general the material is subjected to shape changes. No thickness changes.
ROLLING
This is the process of reducing the thickness or
changing the cross-section of a work-piece by compressive forces exerted by a pair of rotating rolls. The products are flat products, like: plates & sheets. Plates are used for structural applications like bridges, ships & nuclear vessels. Sheets (generally 6mm or less in thickness) are used for automotive, beverage cans, office & kitchen equipment.
ROLLING
Hot rolling is a hot working process where large
pieces of metal, such as slabs or billets, are heated above their recrystallization temperature and then deformed between rollers to form thinner cross sections. While cold rolling increases the hardness and strength of a metal, it also results in a large decrease in ductility. Thus metals strengthened by cold rolling are more sensitive to the presence of cracks and are prone to brittle fracture. Recrystallization temperature The minimum temperature at which complete recrystallization occurs in.
HOT ROLLING
Hot rolling produces thinner cross sections than
cold rolling processes with the same number of stages. Hot rolling, due to recrystallization, will reduce the average grain size of a metal while maintaining a certain soft microstructure, where as cold rolling will produce a hardened microstructure. Hot rolling is primarily concerned with manipulating material shape and geometry rather than mechanical properties. Primary working is always hot rolling. Recrystallization & Annealing temperatures.
ROLLING
Ingots
Billets/blooms/slabs bars/rods wires, nails, pipes, sheets, plates Bloom: square cross-section Slab: rectangular Billets: A billet is a bar of steel with a square cross-section whose dimensions are usually less than about 6 inches (15 cm) by 6 inches (15 cm).
(1200C), then rolled between grooved rolls until it has reached the proper size. Giant shears cut the billet to the desired length; then it is allowed to cool. The steel billet is again heated and rolled until it has been shaped into a round bar 0.2 inch (5.6 mm) in diameter, known as a wire rod. The wire rod is rolled into a coil weighing as much as 3,969 pounds (1,800 kg), which is shipped to the wire manufacturer.
Cold Rolling
Quarter Hard, Half Hard, Full Hard stock have
higher amounts of reduction. This increases the i) yield point; ii) grain orientation and iii) material properties assume iv) ductility decreases. Quarter Hard material can be bent (perpendicular to the direction of rolling) on itself without fracturing. Half hard material can be bent 90; full hard can be bent 45.