Beruflich Dokumente
Kultur Dokumente
Rolling of Metals
13.1 Introduction
• The rolls pull the material into the roll gap through a
net frictional force on the material which must be to
the right.
• The max possible draft: difference between the initial
and final thickness, (ho – hf), is a function of the
coefficient of friction, m, and the roll radius, R:
ho – hf = m2R
• The higher the friction and the larger the roll radius,
the greater the max draft.
Flat rolling – Roll Force and Power Requirement
L R (ho hf )
• This equation is used for a frictionless situation.
• The higher the coefficient of friction is between the rolls and the
strip, the greater the divergence, and the formula predicts
lower roll force than the actual force.
• The power required per roll can be estimated by assuming that
the force F acts in the middle of the arc of contact: a = L/2
2 FLN
power kW
60000
EXAMPLE |3.l Calculation of Roll Force and
Torque in Flat-rolling
• An annealed copper strip 250 mm wide and 25 mm thick is rolled to a thickness of 20
mm in one pass. The roll radius is 300 mm, and the rolls rotate at 100 rpm. Calculate
the roll force and the power required in this operation.
Solution:
• The average true stress, Yavg, for annealed copper is determined as follows: First note
that the absolute value of the true strain that the strip undergoes in this operation is
EXAMPLE |3.l Calculation of Roll Force and
Torque in Flat-rolling
• Referring to figure 2.6
the annealed copper
has true unstrained
stress 80 MPa and at
0.223 true strain, the
true stress is 280 MPa,
then the average true
stress is 180 MPa.
Flat rolling – Reducing Roll Force
Figure 13.7 (a) A method of roller leveling to flatten rolled sheets. (b)
Roller leveling to straighten drawn bars.
Flat rolling practice - Defects
• Scale, rust, scratches, and cracks may
be caused by inclusions and impurities in
the original cast material, or due to
surface and material conditions
• Wavy edges are the results of roll
bending: the strip is thinner along its
edges than at its centers (F13.3a).
Because the edges elongate more than
the center, they buckle because they are
restrained from expanding freely in the
long. direction.
• cracks shown in F13.8b and c are due to
poor material ductility at the rolling temp.
• Alligatoring (F13.8d): caused by non-
uniform deformation or by the presence
of defects in the original cast billet. Figure 13.8 Schematic illustration of
typical defects in flat rolling: (a) wavy
• Edge defects are removed by shearing edges; (b) zipper cracks in the center of
and slitting operations. the strip; (c) edge cracks; and (d)
alligatoring.
Flat rolling practice – residual stresses
• Because of non-uniform
deformation of the material in
the roll gap, residual stresses
may develop.
• Small diameter rolls or small
reductions per pass tend to
deform the metal plastically at
its surfaces (F13.9a)
• Large diam rolls & high
reductions tend to deform the
bulk more than the surfaces
(F13.9b). This is due to the
frictional constraint at the
surfaces along the arc of
contact Figure 13.9 (a) Residual stresses developed in rolling
with small-diameter rolls or at small reductions in
thickness per pass. (b) Residual stresses developed in
rolling with large-diameter rolls or at high reductions per
pass. Note the reversal of the residual stress patterns.
Rolling Mills
• Width of rolled products: up to
5m and be as thin as
0.0025mm.
• Rolling speeds: up to 25m/s for
CR.
• 2-high or 3-high mills are used
for HR in initial breakdown
passes on cast ingots or in
continuous casting, with roll
diam range from 0.6m to 1.4m.
• 4-high mills and cluster mills are
based on the principle that small
diameter rolls lower roll forces &
power req. and reduce
spreading.
• Also, when worn or broken,
small rolls can be replaced at
less cost than large rolls.
Figure 13.13 Two examples of the roll-forging operation, also known as cross-rolling.
Tapered leaf springs and knives can be made by this process. Source: After J. Holub.
Production of Steel Balls
Figure 13.14 (a) Production of steel balls by the skew-rolling process. (b) Production of
steel balls by upsetting a cylindrical blank. Note the formation of flash. The balls made by
these processes subsequently are ground and polished for use in ball bearings.
Shape Rolling Operations – Thread Rolling
• Threads are formed
on rod or wire with
each stroke of a pair
of flat reciprocating
dies (F13.15a)
• Another method
uses rotary dies
(F13.15b) at prod
rates as high as 80
pieces per sec.
Figure 13.16 Thread-rolling processes: (a) and (c) reciprocating flat dies; (b) two-roller dies.
(d) Threaded fasteners, such as bolts, are made economically by these processes at high
rates of production. Source: Courtesy of Central Rolled Thread Die Co.
Shape Rolling Operations – Thread Rolling
Figure 13.17 (a) Features of a machined or rolled thread. Grain flow in (b) machined and
(c) rolled threads. Unlike machining, which cuts through the grains of the metal, the rolling
of threads imparts improved strength because of cold working and favorable grain flow.
Production of Seamless Pipe and Tubing
Figure 13.18 Cavity formation in a solid, round bar and its utilization in the rotary tube-
piercing process for making seamless pipe and tubing. (see also Fig. 2.9.)
Production of Seamless Pipe and Tubing
• Rotary tube piercing is
carried out using an
arrangement of rotating
rolls (F13.17c).
• Axis of rolls are skewed,
in order to pull the round
bar through the rolls by
axial comp of the rotary
motion.
• An internal mandrel
assists the operation by
expanding the hole and
sizing the inside
diameter of the tube.
• The diameter &
thickness of tubes and
pipes can be reduced
by tube rolling (F13.18)
Continuous casting and rolling: integrated
mills and minimills