Rolling

1. Plastically deforming metal by passing in between rolls.

2. It is most widely used metal working process because it lends itself

to high production and close control of the final product.

3. The initial break down is done to produce bloom and billets.

4. These blooms and billets are further subjected to hot rolling to

produce plate, sheet, rod, bar, pipe, rail or structural shapes.

5. Cold rolling produces sheet, strip and foil with good surface finish,
increased mechanical strength and maintains close control over the
dimension of the product.

6. During rolling, the decrease in thickness will result in increase in

length of the material and very little increase in width of the material.
Hence, rolling is known as plane strain deformation. 1
 Terminology for rolled products
Bloom: First break down of the ingot. Here width is equal to thickness
and area of the cross section is more than 230 cm2.

Billet: Cross sectional area is 40X40 mm2.

Slab: Cross sectional area greater than 100 cm2 and width is at least
twice than thickness.

Blooms, billets and slabs are known as the semi-finished products.

Plate: Thickness greater than 6 mm.

Sheet / Strip: Thickness less than 6 mm. The width of strip is less than
600 mm whereas the width of sheet is greater than 600 mm.
Roll forming: Here the strip is progressively bent into complex shapes
by passing it into a series of driven rolls. No thickness reduction occurs.
Thread rolling: Here blank is fed between two grooved die plates to
form the threads. 2
 Classification of rolling
It is based on the number and arrangement of the rolls.

Two high, pull over Two high, Reversing

It is the simplest and most common type.
Rolls of equal size rotated in one direction.
Productivity is more in two high reversing mill because the work can
be passed back and forth by reversing the direction of rotation. 3
Continue…

Three high mill Four high mill Cluster mill

In three high mill, upper and lower rollers are driven by motor and
middle one rotates by friction.
In four high mill, the rolling is done by smaller rolls. Lower power is
required to drive small rolls. Smaller rolls have less strength and
rigidity than larger rolls. Hence, back of rolls of large diameter is
provided in four high mills.
In cluster mill, each work rolls is supported by two backing rolls. The
Sendzimir mill is a modification of cluster mill. Thin foils can be
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produced from high strength alloys.
Continue…

The uncoiler and windup reel accomplish the functions of feeding the
stock to the rolls and coiling the final product. They also provide back
tension and front tension to the strip.
1. Heavy backing rolls surrounded by a large
number of small planetary rolls.
2. In one pass, the slab can be reduced to a strip.
3. The overall reduction is the summation of a
series of small reductions by each pair of rolls in
turn following each other in rapid succession. 5
Continue…
Pendulum mill: It is used for cold rolling. It reduces the slab to thin
sheet.
Contact-bend-stretch rolling: uses four high mill with a small diameter
floating bend roll.

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 Forces and geometrical relationship in rolling
Since equal volumes of metal must pass a given point per unit time,
we can write,
bh0v0 = bhv = bhfvf (1)

where b = width of the sheet and v = velocity at any thickness h

intermediate between h0 and hf

In order that the vertical element in the sheet remains undistorted,

the exit velocity vf must be greater than the entrance velocity v0.

Therefore, the velocity of the sheet must steadily increase from

entrance to exit.

At only one point along the surface of contact between the roll and
the sheet, is the surface velocity of the roll (vr) equal to the velocity of
the sheet. This point is called the neutral point or no-slip point. It is
indicated by point N (see Figure in slide no. 8). 7
Continue…
At any point along the surface
of contact, such as point ‘A’ in
the figure, two forces act on the
metal.
1. Radial force (Pr)
2. Tangential frictional force (F)
Point ‘N’ is Neutral point.
 Roll surface velocity is vr.
Between the entrance plane
and the neutral point: Sheet is
moving slower than the roll
surface. Frictional force helps in
drawn the metal into rolls.
 : Angle of contact On the exit side of the neutral point: Sheet
or angle of bite. moves faster than the roll surface. Frictional
force is reversed and acts to oppose the delivery
of the sheet from the rolls.
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Continue…
The vertical component of Pr is known as the rolling load ‘P’. The
rolling load is also known as the separating force because the metal is
trying to force the rolls apart.

The specific roll pressure ‘P’ is given by P = P/ bLP (1)

𝟏/𝟐
(𝐡𝟎−𝐡𝐟 )𝟐 𝟏/𝟐
where LP = 𝐑 𝐡𝟎 − 𝐡𝐟 − ≈ 𝐑(𝐡𝟎 − 𝐡𝐟 )
𝟒

Overcome
Neutral
frictional force surface

Stress required to deform

under plane strain compression

Friction hill for homogeneous compression

Distribution of roll pressure along of a disk with Coulomb friction 9
the arc of contact
Continue…
Roll pressure rises to the maximum at the neutral point and then falls
off. The neutral point is not a line on the roll surface but an area.

The shaded area represents the force required to overcome frictional

forces between the roll and the sheet.

The area under the dashed line AB represents the force required to
deform the metal in plane homogeneous compression.

For the work piece to enter into the throat of the roll, the horizontal
component of the frictional force (FH) which acts towards the roll gap,
must be equal to or greater than the horizontal component of the
normal force (PH), which acts away from the roll gap.
FH= Fcos and PH = Prsin
The limiting condition for unaided entry of a slab into the rolls is
Fcos  = Prsin or tan = F/Pr
But F = Pr Hence  = tan (2) 10
Continue…
If  = 0, then rolling cannot occur.
The roll surface is grooved to increase the effective value of .

For the same friction conditions, a large diameter roll will permit a
thicker slab to enter into the rolls than a small diameter roll?
Ans:

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 Rolling variables
1. Roll diameter.
2. Deformation resistance of the metal as influenced by metallurgy,
temperature and strain rate.
3. Friction between the rolls and the workpiece.
4. Presence of front/back tension in the plane of the sheet.
1. Roll diameter
The rolling load, P = PbLP = 𝝈𝟎′ b 𝐑∆𝐡 (1)
where 𝝈𝟎′ is the plane strain yield stress because there is no change in
the width of the sheet. Assumption: Neglecting friction. Then the
pressure is the yield stress of the material.
The compressive pressure on a small section of the segment
considering sliding friction prevails during deformation is given by,

(2)
For derivation of eq. (2), please refer to the appendix
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Continue…

The mean pressure is given by

(3)

For the case of rolling, LP = 2a and h = 𝐡ҧ

(4)
Continue…
The rolling load is given by, (use eq. 4 in eq. 1)

P= (5)

Rolling load increases with the roll diameter at a rate greater than D1/2
(Depending on the contribution from friction hill).

Rolling load also increases as the sheet entering the roll becomes
thinner (Due to the eQ term).

Both rolling load and length of the arc of contact decreases with roll
diameter. There rolling by small rolls require backup rolls.

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 2. Deformation resistance of the metal as influenced by metallurgy,
temperature and strain rate
The mean flow stress for a rolling process can be determined directly
from a plane strain compression test. For cold rolling, it does not
depend on strain rate or roll speed. However, in hot rolling, change in
strain rate has significant effect on the flow stress of the material.
3. Friction between the rolls and the work piece
Frictional force is needed to pull the metal into the rolls.

High friction results in high rolling load, a steep friction hill and great
tendency for edge cracking.

Friction varies from point to point along the contact arc of the roll.
Hence, a constant coefficient of friction is assumed in all theories of
rolling.

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4. Presence of front tension / back tension in the plane of the sheet
The presence of tension in the plane of the sheet can materially
reduce the rolling load.
Considering the Von Mises’ criterion in plane strain
𝟐
 1 -  3 = 𝟑 𝛔𝟎
If 1 = P (+ve in compression), 3 = - t
𝟐
Then P = 𝛔𝟎 -  t
𝟑

𝟐
Thus rolling load, P = ( 𝟑
𝛔𝟎 - t)

Thus, the roll pressure is reduced in direct proportion to the tension

in the plane of the sheet.
A study has shown that back tension is about twice as effective I
reducing the rolling load as front tension.

16
Continue…

Effect of strip tension on the distribution of roll pressure

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 Problems
Q 1.

Ans.

Q 2.

Ans.

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Continue…

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 Theories of cold rolling
Assumptions:
1. The arc of contact is circular i.e no elastic deformation of the rolls.

2. The coefficient of friction is constant at all points on the arc of

contact.

3. There is no lateral spread. So, the rolling is under plane strain

condition.

4. The deformation is homogeneous.

5. The peripheral velocity of the rolls is constant.

6. The elastic deformation of the sheet is negligible compared to the

plastic deformation.

7. The distortion energy criterion of yielding, for plane strain, holds.

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Continue…

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Continue…
The radial pressure is Pr and the tangential shear stress  = Pr
The stress x is is assumed to be uniform over the vertical faces of the
element.

The normal force on one end of the element is PrRbd

Horizontal component: PrRbdsin ; Vertical component: PrRbdcos

The tangential frictional force is PrRbd

Horizontal component: PrRbdcos ; Vertical: PrRbdsin

Taking the summation of the horizontal forces

(x + dx)(h+dh)b- xhb+2PrRbdcos -2PrRbdsin =0
𝐝(𝛔 𝐱 𝐡)
The above eq. simplifies to = 2PrR(sin±cos) (1)
𝐝𝛉

+ve sign applies between the exit plane and neutral point, while the –
ve sign applies between the entrance and neutral point, respectively.
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Continue…
Taking the equilibrium of forces along vertical direction results in

P = Pr

P -  x = 𝛔𝟎 ′
Restricting the conditions of cold rolling to low friction and for angles
of contact less than 6o , we can assume sin ≈  and cos = 1
𝐝(𝛔 𝐱 𝐡)
Eq. (1) becomes = 2PrR(±) (2)
𝐝𝛉
Assume Pr ≈ P
Pr - 𝛔𝟎′ = x (3)
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Continue… On integrating eq. (2), we get

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 Theories of hot rolling
The flow stress for hot rolling is a function of both temperature and
strain rate.
The strain rate for hot rolling with sticking friction is given by

Maximum strain rate occurs near the entrance to the rolls.

For equal percentage reduction, thin sheet will undergo much greater
strain rates than thick slab.
The mean strain rate with sticking friction is given by

When slipping friction occurs, the surface velocity of the metal

cannot be assumed equal to peripheral velocity of the rolls. Only at
neutral point, this situation exists.
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Continue…
The strain rate for slipping friction is given by

where  ,  (shown in slide 8) and hn is the metal thickness in the gap

at the neutral point.
A rolling load during hot rolling is given by

where

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Appendix Forging in plane strain

Taking the equilibrium of forces in the x direction

(1)
Von Mises’ yield criterion for a condition of plane strain is given by
(2) 27
Continue…

(3)

Substituting the value of dp/dx = dx/dx in eq. (1)

(4)
Using Coulomb’s law of sliding friction xy = p

(5)
On integrating eq. (5) on both sides

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Continue…

(6)

The mean forging pressure is given by

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 Question

Solution (a) ℎҧ = (3+2.4)/2 = 2.7 mm, L = 150X0.6 = 9.487 mm

P

Q = 0.075x9.487/2.7 = 0.263527

1
ҧ= σҧ′ 0Q e Q − 1 = 200 x 3.794 x (exp0.263527 −1)= 228.82 MPa

(b) ҧ = (200-37.5) x 3.794 x (exp0.263527 −1) = 185.88 MPa

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Assignments

(4)

31
Thank You

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