etal Forming Tech. (MU Sem-Mech) _ (Rolling). Pagg phe es Bi ee 1 Forming Tech. (MU - Sem ig © The Fig. 221 ig 221 shows the s cr sir “sage ey 5 decrease in thickness is called nl termed. a6 absolute elongatig Fig. 2.1.1: Operation of rolling absolute spread Ne © The two cylindrical rollers are supported on bearings and are dive, powerful motor. * The opening between the rolls can be adjusted as required. This a normally referred to as roll gap or regulated opening. + The work piece is subjected to compressive forces and is deform, plastically. * The cross section decreases and length gets elongated whereas the volume It is the main metal working process and offers itself to te production, © ‘Two other terms are the re * — Close control of the final product is possible. Rotating rolls will Soe, A De given as follows: the workpiece inducing direct compressive stiess in it. Fists dominates the process. : Rolling of the workpiece can be carried out in hot or cold condition ‘Cae a Components produced through rolling have higher mectanii Properties than cast products, * Slabs, Sheets, Bars, Rods, Structural Fig.2.2 Relative draft (¢| Since the volume of the ) components like I, U, L ete, Jong lengths can be produced easily. where, Rh, = ogi by = orig hy = fina , asthe ¥8 @ Process which consists of passing the metal throvst! by = fina ee et rollers rotating in opposite directions, This gap is sma = he than the thickness ofthe part being worked. : = <= * Therefore, the rollers compress the metal while simultaneously shifi# it forward because ‘ict 4 eee , Of the friction at the roller-metal interfaces. Whe? workpiece complete) 4 above Equation Y Passes through the gap between the rollers, * is i coats folly worked. As a result, the thickness of the work oe Seg sce ee ao aa Width increases, However, the increase in Wi Se proport 'enificant and ig y, sually neglected, work.Matal Forming Tech. (MU - Sem.6-Mech) __(Rolling)....Page no, 2 Metal Forming Tech. () > .5-- Planetary is Planetary Mill E the circumferen «A number of th high roll mill « The arrangeme planetary mill. © In fact the sms big roll acts as possible in on + The mill proy same time. . © There will be Fig. 2.3.3 : Four high mill piece to the > 4. Cluster Mills oe ot) arrangement * Here the main rolls are small and are backed up by two sets of roll, outlet. on each side. | * Themillisn * Higher rigidity and stability is imparted to the mill. Higher reductions are possible. Better, deformation will take place. Backup rolls ; bag Tandem! © A series | Fig. 2.3.4 + Cluster Mi) 4 workpiece(RK) Flat Rolling @ Metal Forming Tech. (MI em.6-Mech) _ (Rolling)... ming Te e of the forces acy metal FO! y of the rolls duit rne oefon ling be id the eli rolling, If the elastic modulus of the roll material is high, then & compositio roll deflection would be smaller. ‘ are the con Compared to its edges, the rolled strip tends to be thicker at 4 Better mec center, We can avoid this problem by grinding the rolls in such controlled ‘way that their diameter at the center is slightly larger than at thy edges. This is the most basic form of rolling in which the starting and eng material both have a rectangular cross-section. ‘The material is fed in between two rollers that rotate in opposig 1. The arc of con directio 2, The coefficie seal ~ ; ies along t The two rollers in flat rolling are called working rolls. The gap varies along yor Fundamental between the two rolls is less than the thickness of the starting 3. The metal is ¢ material, which causes the deformity of it. 4, The volume ¢ The material, which is pushed through due to the friction at the volume migh interfece between the material and the rolls, even elongates due t) 5, The velocity the decrease in material thickness. 6. The metal o1 However, the friction between the rolls limits the amount of width of the deformation possible in a single pass. 7. The cross se The rolls just slip over the material and do not draw it in if the change in thickness is too great. Controlled Rolling a achieve this, ly monitored and controlled, ® It's a type of thermo-mechanical processing which combines heat treating and controlled deformation, i a setpiee is brought above the recrystallization temperature a 1p of heat, which performs the heat i treati any subsequent heat treating, es “7 Controlling the nature, size, transformation Products; producti controlling the toughness; induci Some of the types of heat treatments The entire process Must be clos and distribution of _yariou’ Ing precipitation hardening a 8s included, 4 4 : | | | | : ses— = cae al comming Tech. iM (Rolling)....Page no. (2. u - Sem.6-Mech) fe) Metal Forming Tesh. (MI Calculate the rolling 40 mm-thick slab using 4 760 mm wide. Assume ue 140 MPa at entrance and 200 MPa at 1 easing velocity: hot roll To tre ser roll. The sa % jond if steel sheet 1S 4900 mm-diame' 10.30, The plane-strain OW stress he exit from the rolj w Ex. 2.5.1: due to the iner © soin.: under very! under 10 C=2.16% A, J soln: ho thy (40) + 28) para 34mm. 2 9 = Hea uslkah CoOysoe™ SOX _ 565 h ae 34 = re a Where € = 16 ( — _ Segpee * Gass _ 140+ 2 s % = : = 1404200 _ 170 MPa roll radius. From Equation (10) TOG RX a fe —1) >VRat | We know use ] of RY 0.65 - 1) 76) V0.45 x oar | Ps v70[ bed) ey Keane Continuing the analogy with compression in plane str: 1B li By with c si plane strain From Equation (8), ? Stoy P the cal, Ape— Metal Forming Tech. (MU - Sem.6-Mech) _(Rolling) _.-Page no. (3. wo © Defects in the Final Product of Mechanically worked metal may by, originated from any one or a combination of the following «The ingot used for MW may contain defects (pores, a ie setae) win cony remain 5 such oF get ARETAVGIOE cangg working operation, © Operational Parameters Localit (not following the proper practice): © Defects in Rolled Products 1. General 2. Operational > 1. General The defects may arise due to (i) Surface irregularities zed to a particular type of MW proces, © The ingot or the raw material may be having irregularities due t scaling which will get trapped in the metal and remain inside th: metal surface as laps. This needs to be removed by grinding ani there will be metal loss. : * If the defect is deep and severe the product may get rejected. (i) Non-metallic inclusions * The inclusions may result from oxides or nitrides or silicates ett especially in steels, These are present in the molten metal durisg the preparation, If less in volume may cause small cracks in the metal and if mot in ait will result in severe cracks called crocodile erat Separating the product into two halves, et sate! onmins eo 42 nat Pores .g Tech. (MI phere MAY be pe ike hydrogen, 0} yf too much gass the product may place res ting | ) Barrel Due to fr place. Surface j the cent work thi surfaces (b) Non uniforn ‘When { the wo The ct shown The n surfac metal Surfa of th (©) Alligator . If thi ga8e23= ach. (MU_~ Sem.6-Mech) ning ToS 2 on2. 295 (Rolling) Page no. (2-27) pores a ~ pores in the product d : pee ny be P in the p cs eae . pyarogens OYE 5 os ike DY is al may hayg h g muclt gasses are present leads to elongation of the pores and 7 s i an 2 ot oduct May become weaker. Sometimes separation —— nicrie = 9 beoa ‘ . sa ee resulting 10 cracks. ated during ’ | Barrel j (a! we to friction at the edges of the product b: A AW process Dt Cee place. surface in contact experiences severe friction as compated to the center of the work. Hence, with heavy reduction in the work the center tends to expand laterally more than the outer surfaces in contact with the dies and produces barreled edges. ig) Non uniform deformation: ‘When the rolling conditions are such that only the surface of the work piece is deformed. «The cross section of the slab is deformed into the shape as jes due to shown. inside the « The middle portion is less deformed as compared to the outer ding and surface. This may be due to variation in temperature in the metal. * Surface temperature being more than the inside temperature of the slab. (ce) Alligator Cracks * Ifthere is any metallurgical weakness in the metal (due to the presence of inclusions) along the centerline of the slab, fracture will occur. * This results in the separation of the layer giving rise to the opening of the slab which looks like an alligator mouth in the pening position. Hence, the name.= —- Metal Forming Tech, (MU-Semé-Mech) (Rolling) ee ning otal SS without a Barreling Page no, jigator Cra eo mei ubibore Alligator cracks ~ During) deformation leading | Fig. 2.6.1 a I a cee path of cracks Alligat ; © During preparation of the melt in the furnace several gag, towel try to get into the melt. «Greate * Ont of this Hydrogen gas diffuses into the melt to a lay materi extent and is retained in the solid metal. . Cae © Due the presence of hydrogen in excess internal cry alliga appear through the cross section during rolling and cannoy, By a used. It is a major problem with alloy steels especially. z ae (©) Non metallic inclusion defle: * Inclusions are non metallics appearing in the metal as a of entrapment. “ © Saree ‘* During the preparation of the molten metal non metallic jy "GON oxides, nitrides, silicates enter the melt and remain as such} ae the solid metal. These are discontinuities in the metal a ne reduce the properties of the metal. def * On rolling they may result in cracks which may reach, = critical value and make the product rejectable, — jie © The wa) (@) Edge Cracks def * During both hot and cold rolling, the metal might show soo = cracks on the edges This Phenomenon occurs ft @) Zipper = Stresses induced at the workpiece surfact’ a - pe fe result from factors such as uneven heatill sh oe mF 8 OF excess quenching. eM SST mowsie cess ame velin . » hee ig Under tension might work against & in leSS =Sem.6-Mech) (Rolling) Cambering of tolls has proven ef Page no, Q. fective When it com, * Preventing zipper cracks 4 . Provides a slightly larger diameter at the cente, ‘on the edges, ty CHAPTER 3 This defect occurs due to the self-equilibrating te, : Stresses that result from the rolling process. ‘a Duting center buckling, fibers at the center of the meta} Pigg are longer than those at the edges. In an event where hot or cold mills have too much coy mills roll out atthe center. Sideways deflection of a struct, member perfectly explains center buckling. * Using crowned rolls is a solution to center buckling. * The roll’s parabolic curvature is sufficient to cover ty problems of material, temperature, and deformation. Introduction and processes and Die Forging P) Forged Product © Forging is an for which ac The parts are blacksmith ar hammers. Thus forging temperatures 2 forces exert Zigzag cracks in the TS, di center of Tt consi, the flat rolling maneSS =Sem.6-Mech) (Rolling) Cambering of tolls has proven ef Page no, Q. fective When it com, * Preventing zipper cracks 4 . Provides a slightly larger diameter at the cente, ‘on the edges, ty CHAPTER 3 This defect occurs due to the self-equilibrating te, : Stresses that result from the rolling process. ‘a Duting center buckling, fibers at the center of the meta} Pigg are longer than those at the edges. In an event where hot or cold mills have too much coy mills roll out atthe center. Sideways deflection of a struct, member perfectly explains center buckling. * Using crowned rolls is a solution to center buckling. * The roll’s parabolic curvature is sufficient to cover ty problems of material, temperature, and deformation. Introduction and processes and Die Forging P) Forged Product © Forging is an for which ac The parts are blacksmith ar hammers. Thus forging temperatures 2 forces exert Zigzag cracks in the TS, di center of Tt consi, the flat rolling mane