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Material and Geometry of cutting tool

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Flat- and Shape-Rolling Processes

Schematic outline of various flatand shaperolling processes.

Rolled Products Made of Steel

Shape Rolling

Stages in the shape rolling of an H-section part. Various other structural sections, such as channels and Ibeams, are also rolled by this kind of process.

Flowchart of Rolling Operations

Figure 1 Flow chart for the production of various finished and semi-finished steel shapes. Note the abundance of rolling operations.

Rolling Process

Flat-Rolling

(a) Schematic illustration of the flat-rolling process. (b) Friction forces acting on strip surfaces. (c) The roll force, F, and the torque acting on the rolls. The width w of the strip usually increases during rolling,

Four-High Rolling Mill

Schematic illustration of a four-high rolling-mill stand, showing its various features. The stiffness of the housing, the rolls, and the roll bearings are all important in controlling and maintaining the thickness of the rolled strip.

Backing Roll Arrangements

Schematic illustration of various roll arrangements (a) two-high; (b) three- high; (c) four-high; (d) cluster (Sendzimir) mill.

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Grain Structure During Hot Rolling

Changes in the grain structure of cast or of large-grain wrought metals during hot rolling. Hot rolling is an effective way to reduce grain size in metals, for improved strength and ductility. Cast structures of ingots or continuous casting are converted to a wrought structure by hot working.

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Tandem Rolling

A tandem rolling operation.

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Cold Working
ADVANTAGES

No heating is required Strength, fatigue and wear properties are improved through strain hardening Superior dimensional control is achieved, so little, if any, secondary machining is required

Better surface finish is obtained Products possess better reproducibility and interchangeability Directional properties can be imparted Contamination problems are minimized

Cold Working
DISADVANTAGES

Higher forces are required to initiate and complete the deformation Less ductility is available Intermediate annealing may be required to compensate for the loss of ductility that accompanies strain hardening

Heavier and more powerful equipment is required

Metal surfaces must clean and scale-free

imparted directional properties may be detrimental

be

Undesirable residual stresses may be produced

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Diagram of Flat Rolling

Draft = thickness reduction:

d t o t f

Conservation of Volume:

t o wo L o t f w f L f

t o wo v o t f w f v f

Diagram of Flat Rolling

There is a point on the roll where the work velocity equals the roll velocity, this is the no-slip point. Friction is in opposite directions on either side of this point.v fForward slip: v DN vr
s
r

vr

where,

N rev / min

Maximum draft:
Roll force:

d max 2 R
R(t o t f )
coefficient of friction

F Y f wLcontact Y f w f

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Ring-Rolling

(a) Schematic illustration of a ring-rolling operation. Thickness reduction results in an increase in the part diameter. (b) Examples of cross-sections that can be formed by ring rolling.

Ring Rolling

One roll is placed through the hole of a thick-walled ring and a second roll presses on the outside Produces seamless rings

Circumferential grain orientation and is used in rockets, turbines, airplanes, pressure vessels, and pipelines

Figure 6 Schematic of horizontal ring rolling operation. As the thickness of the ring is reduced, its diameter will increase.