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Introduction - Definition of Rolling Process

Rolling is a metal forming process that reduces the thickness and makes the thickness uniform by passing metal stock through one or more pairs of rolls. It is classified as hot or cold rolling based on the temperature of the metal. Hot rolling processes above the metal's recrystallization temperature while cold rolling is below. The most common products formed from rolling are structural steel, bar stock, and rails. Rolling mills use groups of roll stands holding roll pairs to quickly process metals like steel.

Uploaded by

Eloisa Nher Hipolito
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Topics covered

  • bloom,
  • dimensional tolerance,
  • gauge control,
  • mass conservation,
  • steel products,
  • continuous rolling,
  • ingot breakdown,
  • rolling mills,
  • material properties,
  • product dimensions
426 views7 pages

Introduction - Definition of Rolling Process

Rolling is a metal forming process that reduces the thickness and makes the thickness uniform by passing metal stock through one or more pairs of rolls. It is classified as hot or cold rolling based on the temperature of the metal. Hot rolling processes above the metal's recrystallization temperature while cold rolling is below. The most common products formed from rolling are structural steel, bar stock, and rails. Rolling mills use groups of roll stands holding roll pairs to quickly process metals like steel.

Uploaded by

Eloisa Nher Hipolito
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

Topics covered

  • bloom,
  • dimensional tolerance,
  • gauge control,
  • mass conservation,
  • steel products,
  • continuous rolling,
  • ingot breakdown,
  • rolling mills,
  • material properties,
  • product dimensions

INTRODUCTION - DEFINITION OF ROLLING PROCESS

In metal working, rolling is a metal forming process in which metal stock is passed
through one or more pairs of rolls to reduce the thickness and to make the thickness uniform.
The concept is similar to the rolling of dough. Rolling is classified according to the temperature
of the metal rolled. If the temperature of the metal is above its recrystallization temperature,
then the process is known as hot rolling. If the temperature of the metal is below its
recrystallization temperature, the process is known as cold rolling. In terms of usage, hot rolling
processes more tonnage than any other manufacturing process, and cold rolling processes the
most tonnage out of all cold working processes. Roll stands holding pairs of rolls are grouped
together into rolling mills that can quickly process metal, typically steel, into products such as
structural steel (I-beams, angle stock, channel stock, and so on), bar stock, and rails. Most steel
mills have rolling mill divisions that convert the semi-finished casting products into finished
products.
Forming, or metal forming, is the metalworking process of fashioning metal parts and
objects through mechanical deformation; the work piece is reshaped without adding or
removing material, and its mass remains unchanged. Forming operates on the materials science
principle of plastic deformation, where the physical shape of a material is permanently
deformed.

Metal forming tends to have more uniform characteristics across its sub processes than its
contemporary processes, cutting and joining.

INTRODUCTION TO HOT ROLLING & COLD ROLLING PROCESS

Hot Rolling : The initial breakdown of ingots


into blooms and billets is generally done by hot-
rolling. This followed by further hot-rolling into
plate, sheet, rod, bar, pipe, rail etc.

Cold Rolling : The cold-rolling of metals has


played a major role in industry by providing
sheet, strip, foil with good surface finishes and
increased mechanical strength with close control
of product dimensions
SHEET ROLLING MACHINES

Rolled strips

Rollforming machine

TERMINOLOGY

 Bloom is the product of first breakdown of ingot (cross


sectional area > 230 cm2). Semi-finished
 Billet is the product obtained from a further reduction products
by hot rolling (cross sectional area > 40x40 mm2).
 Slab is the hot rolled ingot (cross sectional area > 100
cm2 and with a width ≥ 2 x thickness).

Further rolling steps


 Plate is the product with a thickness > 6 mm.
 Sheet is the product with a thickness < 6 mm and width
Mill products
> 600 mm.
 Strip is the product with a thickness < 6 mm and width
< 600 mm.
ROLLS
Mill Rolls

Ring Rolls

Ring rolls are used for tube rolling, ring rolling. Ring rolls are made of spheroidized graphite
bainitic and pearlitic matrix or alloy cast steel base.
TYPICAL ARRANGEMENT OF ROLLERS FOR ROLLING MILLS

 Two-high mill, powder


o The stock is returned to the
entrance for further reduction.

 Two-high mill, reversing


o The work can be passed back and forth
through the rolls by reversing their
direction of rotation.

 Three-high mill
o Consist of upper and lower driven rolls and
a middle roll, which rotates by friction.

 Four-high mill
o Small-diameter rolls (less strength & rigidity) are
supported by larger-diameter backup rolls.

 Cluster mill or Sendzimir mill


o Each of the work rolls is supported by two backing
rolls.

 Continuous rolling
o Use a series of rolling mill and each set is called a
stand. The strip will be moving at each stage in the
mill. The speed of each set of rolls is synchronized
so that the input speed of each stand is equal to
the output speed of preceding stand. The uncoiler
and windup reel not only feed the stock into rolls
and coiling up the final products but also provide
back tension and front tension to the strip.

 Planetary mill
o Consists of a pair of heavy backing rolls
surrounded by a large number of planetary rolls.
Each planetary roll gives an almost constant
reduction to the slab as it sweeps out a circular
path between the backing rolls and the slab.
o As each pair of planetary rolls ceases to have
contact with the work piece, another pair of rolls
makes contact and repeat that reduction.
o The overall reduction is the summation of a series
of small reductions by pair of rolls. Therefore, the
planetary mill can reduces a hot slab directly to
the strip in one pass through the mill.
o The operation requires feed rolls to introduce the
slab into the mill, and a pair of planishing rolls on
the exit to improve the surface finish.
ROLLING MILLS
Rolling mill is a machine or a factory for shaping metal by passing it through rollers. A
rolling mills basically consists of rolls, bearings, a housing for containing these parts and also
a drive (motor) for applying power to the rolls and controlling the speed.
Modern rolling mill requires very rigid construction and large motors to supply enough
power. Successive stands of a large continuous mill will contributes to huge capital
investment in term of skills, engineering design and construction.

CONVENTIONAL HOT OR COLD ROLLING


The objective is to decrease the thickness of the metal with an increase in length and with
little increase in width. The material in the centre of the sheet is constrained in the z-direction
(across the width of the sheet) and the constraints of un-deformed shoulders of material on
each side of the rolls prevent extension of the sheet in the width direction. This condition is
known as plane strain. The material therefore gets longer and not wider. Otherwise, we would
need the width of a football pitch to roll down a steel ingot to make tin plate.

HOT ROLLING
The first hot-working operation for most steel products is done on the primary roughing mill
(blooming, slabbing or cogging mills). These mills are normally two-high reversing mills
with 0.6-1.4 m diameter rolls (designated by size). The process involves heating steel to
above the re-crystallisation temperature and deformed between rollers. Hot rolling makes
shaping and forming much easier, and it is even typically cheaper and quicker to
manufacture.

The objective is to breakdown the cast ingot into blooms or slabs for subsequent finishing
into bars, plate or sheet. In hot-rolling steel, the slabs are heated initially at 1100°C-1300°C.
The temperature in the last finishing stand varies from 700°C-900°C, but should be above the
upper critical temperature to produce uniform equal axed ferrite drains.

• Flat plate of large thickness (10 mm – 50 mm) is passed through different set of
working rolls, while each set consecutively reduces thickness.

• Hot strip is coiled to reduce its increasing length due to a reduction of thickness.
Reducing the complication of controlling strips of different speeds due to different thickness.
(Thinner section moves faster).
COLD ROLLING
Cold rolling is carried out under recrystallization temperature and introduces work hardening.
The starting material for cold-rolled steel sheet is pickled hot-rolled breakdown coil from the
continuous hot-strip mill. The total reduction achieved by col-rolling generally will vary from
about 50% to 90%. The reduction in each stand should be distrusted uniformly without
falling much below the maximum reduction for each pass. Generally the lowest percentage
reduction is taken place in the last pass to permit better control of flatness, gage, and surface
finish.

Cold rolling provide products with superior surface finish (due to low temperature → no
oxide scales). Better dimensional tolerance compared with hot-rolled products due to less
thermal expansion. Cold-rolled nonferrous sheet may be produced from hot-rolled strip, or in
the case of certain copper alloys it is cold-rolled directly from the cast state.
Cold-rolled metals are rated as ‘temper’

 Skin rolled : Metal undergoes the least rolling ̴ 0.5% - 1% harden, still more
workable.
 Quarter hard : Higher amount of deformation. Can be bent normal to rolling direction
without fracturing.
 Half hard : Can be bent up to 90°.
 Full hard : Metal is compressed by 50% with no cracking. Can be bent up to 45°.
Hot Rolling Cold Rolling

Example of HOT strip mill process Example of COLD strip mill process

Common questions

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Hot rolling processes can handle greater tonnage because metals processed above their recrystallization temperature exhibit lower yield strength and greater ductility, making them easier to deform . This reduces the force required, increases processing speeds, and allows for continuous operation without frequent stoppages for equipment or material changes. The larger throughput capacity due to higher efficiency and less material resistance makes hot rolling suitable for mass production of large metal components .

The arrangement of rollers significantly influences the rolling process by determining the material flow, contact area, and force distribution during rolling. For instance, two-high mills allow for simple forward and reverse rolling, while four-high mills use backup rolls to support small-diameter work rolls, enabling precise control and reduced deflection for better surface finish . Cluster and Sendzimir mills offer even greater flexibility and precision by using multiple support rolls for each work roll. Planetary mills allow continuous reduction and improved deformation without needing massive force . Such configurations improve overall control, surface quality, and dimensional accuracy, adapting to various production needs .

Cold rolling improves surface finish and dimensional tolerance by operating at room temperature or below the recrystallization temperature, which minimizes oxidation and thermal expansion that occur during hot rolling . As there is no scale formation, the metal surface remains smoother. The process induces work hardening, which further refines grain structure, enhancing precision in product dimensions and providing a superior surface finish necessary for applications where aesthetics and tight dimensional tolerances are important .

Hot rolling involves processing metal above its recrystallization temperature, which allows the metal to be shaped without strain hardening and results in a final product with less internal stress and better mechanical properties. It is more economical and faster, commonly used for producing large structural components like beams and rails . Cold rolling, conducted below the recrystallization temperature, enhances the mechanical strength and surface finish due to strain hardening. It allows for precise control of dimensions but requires more energy due to increased resistance from hardened metal. Cold rolling is typically used for products requiring a smooth surface and closer dimensional tolerances, like sheets and strips .

In conventional rolling processes, plane strain occurs when the width of metal sheets is constrained to prevent lateral extension while the thickness is reduced during rolling. This results in the sheet elongating only in the length direction, which is constrained by un-deformed material shoulders on either side of the rolls . This concept allows for efficient utilization of space, ensuring that sheet rolling is conducted efficiently without expanding the width excessively, which would require impractical processing spaces .

Ring rolls are crucial for tube and ring rolling processes, forming components by squeezing a metal piece between specialized concave and convex rolls to produce cylindrical shapes . They are characterized by the use of spheroidized graphite bainitic and pearlitic matrix or alloy cast steel, providing necessary durability and wear resistance for continuous operations under high compressive forces. Primarily used for manufacturing seamless rings, tubes, and flanges, ring rolls effectively handle high strain and shear during the rolling process, accommodating diverse industrial applications requiring precise circular dimensions and robustness .

Backup rolls in a four-high rolling mill provide essential support to the smaller work rolls, which have less rigidity and strength. They counteract the bending forces exerted by the rolled material and ensure that the work rolls maintain correct alignment with reduced deflection . This arrangement allows the mill to produce materials with higher precision and better surface quality, as it minimizes roll wear and facilitates higher rolling forces for a given roll size .

The lowest reduction percentage and special attention in the final pass of cold rolling are required to ensure the control of flatness, gauge, and surface finish. This pass is crucial because it refines the final product's dimensions and surface properties, determining the quality and usability of the material for applications where precise thickness and finish are paramount . A higher reduction in earlier passes strains the material, potentially leading to defects, so reducing strain in the final pass minimizes the risk of surface defects and maintains desirable characteristics like dimensional accuracy and surface smoothness .

The planetary mill design contributes to metal rolling efficiency by using a set of heavy backing rolls surrounded by numerous smaller planetary rolls capable of imposing continuous, small incremental reductions on a large slab . This innovative arrangement allows for substantial thickness reduction of the slab into strips in a single pass, minimizing required force for each reduction and optimizing energy usage. Each planetary roll runs in a circular path, successively contacting the workpiece, which reduces the required time for adjustments between passes and increases overall throughput . This design is particularly advantageous for processing large slabs with high efficiency and consistency .

The continuous rolling process is significant for its efficiency in consistently producing long lengths of metal products with uniform mechanical properties and dimensions. It differs from other rolling methods by utilizing a series of synchronized rolling stands where each set's input speed matches the preceding stand's output, ensuring seamless and quicker processing . Unlike batch processing in reversing mills, continuous rolling enhances production rate and quality by maintaining consistent tension and reducing downtime . Additionally, back and front tension control systems increase stability and dimensional accuracy of the final product .

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