Rolling Final
Rolling Final
Rolling Final
Roll milling
In metalworking, 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
roll milling deformation process in which Metal(s) in its semi-finished or finished form is passed between
the two opposing rollers, which reduces the metal’s thickness through the compression process. The
rollers rolls around the metal as it squeezes in between them.
Most rolling mills feature two or more rolls arranged in a symmetrical pattern, with half above the work
and half below the work to be rolled. Typically, the rolls are mounted one above the other and rotate at
the same speed in opposite directions. The metal is passed through the machine multiple times with the
spaces between the cylinders decreasing each time so the metal becomes increasingly thinner.
Cold Rolling
Cold rolling mills pass metals though the rollers at a temperature below its recrystallization temperature.
This process is typically used to decrease the thickness of plate and sheet metal by increasing the metal’s
yield strength and hardness through the introduction of defects to its crystal structure. The defects
produced by cold rolling mills prevent slip and reduce the grain size of the metal, which results in Hall-
Petch hardening.
The deformation mechanism in cold roll-forming is quite complex and the inherent complexity of the
process has often resulted in the adoption of a trial and error approach towards solving many problems
encountered in practice. Despite the appearance of both theoretical and experimental studies in the
literature the approach has remained very empirical.
Principle of Rolling
The Rolling Process consists of two opposing rollers and a metal squeezing in between them. The basic
consideration is that the thickness between the rollers should be less than the Metal’s (Ingot) Initial
Thickness. This consideration will help metal’s forward motion as it passes through the gap between the
Rollers. Rolling Process decreases the Thickness of Metal and Increases its Length and Breadth, Keeping
Overall Volume Constant.
Theory and Working of Cold Rolling
Rolling mills work by using multiple rollers to manipulate the physical properties of sheet metal. In
steelmaking, they offer a uniform thickness and consistency for the steel sheet metal with which they are
used. Rolling mills contain rollers that squeeze and compress sheet metal as it passes through them.
Therefore, the sheet metal may have an inconsistent size or shape beforehand. After passing through the
rollers in a rolling mill, however, the sheet metal will develop a uniform size and shape.
It’s important to note that rolling mills support both cold rolling and hot rolling processes. Cold rolling
means the sheet metal is pressed between the rollers at or near room temperature. Hot rolling, on the
other, means the sheet metal is pressed between the rollers at a temperature above the metal’s
recrystallization point. Cold rolling allows for the production of stronger and more durable steel products,
whereas hot rolling is a faster and easier rolling process that allows for streamlined production activities.
Rolling mills can be used for both cold rolling and hot rolling.
Cold roll-forming is a process of forming metal from sheet, strip or coiled stock into shapes of essentially
uniform cross-section by feeding the strips through successive pairs of rolls arranged in tandem. The
deformation in cold roll-forming is quite complex and due to this inherent complexity of the process, the
roll design and other decision-makings often involve a good deal of trial and error. The "forming angle"
method, which is regarded as reasonably dependable for assisting in determination of the number of roll
stations to form a bend, takes account of it the intermittent deformation under each roll station only in a
crude way. The deformation length under each roll station a priori by minimizing the deformation energy
and assuming the material to be rigid--plastic.
The theoretical results have been verified by roll forming channel sections from mild steel and aluminum
strips and the agreement between the theory and the experiment has been found to be extremely good.
The results also suggest that the deformation length depends on the physical parameters of the produced
channel section but is practically independent of the mechanical properties of the work material for the
situations considered in the present investigation.
Rolled products, i.e. sheet, plate and foil constitute almost 50% of all aluminum alloys used. Sheet is also
used extensively in building for roofing and siding, in transport for airframes, road and rail vehicles, in
marine applications, including offshore platforms, and superstructures and hulls of boats.
Characteristics of Cold Rolling:
Conducting full cooling and increasing reduction greatly increases von Mises effective stress at the bite
region, stress inside the roll is not much affected
Numerical Calculations:
There are five rollers which are used in cold roll milling of Aluminium alloy whose core functions are
mentioned below:
2 x Flat Sheet Rollers (75 x 41mm Ø)
2 x Textured Rollers to create interesting effects
1 x Half round and V shaped wire roller to enable you to create your own wire
To Find Thickness
In passing through the roll gap a strip of constant width w, undergoes a thickness change from ho to hl, or
Ah, and because the deformation has been assumed to be one of plane strain on an incompressible
material the following relationship holds:
W×ho×Vo = whv =wh1 v1
Thus the velocity of the strip increases steadily from entry to exit and the velocity of the rolls must have a
value somewhere vo and v1.
To find Length
Length: The length of the deformation zone (ld) for absolutely solid rolls is calculated using the
following equation:
ld =√ R △ h−¿ ¿
Where
ld= Length of deformation
R= Radius
H= Thickness
To find Position
Position: The position of aluminium sample can be describe by the parameter S which can be define by
the equation
S=△t/t0
Where
△t= distance from the center,
t0= the sheet thickness
References