Unit4(Class11)Rolling

Whatwaslearntinthelastclass
1 IntroductiontoRolling
2 ConceptofRolling.
3 Stepsinrollingprocess
4 Classificationofrollingprocess
basedontemperature,roll
arrangementandproduct.
TodaysPortion
1 Classificationbasedontheproductsrolled.
2 DifferencebetweenHotrollingandColdrolling.
3 MetalFlowPatterninRolling.
4 NecessaryconditionforRolling.
5 GeometricRelationshipinRolling.
6 Expressionforangleofbite.
7 LengthofDeformationZone.
8 Max.DraftorReductioninRolling.
9 RollSeparatingForces.
10 RollCamber.
iii)Basedontheproduct
BloomingMillHereonlybloomsareproducedfromtheIngot.Bloomswillhave
adimensionofapprox.150x150mm.
BilletMillHereBilletsareproducedfromBlooms.Billetwillhaveadimension
ofapprox.100x100mm.
Rod/BarMillHerebarsorrodsareproducedfrombillets.Barwillhave
adimensionof40x40mm.
SlabMillHereslabisproducedfromthebloom.t>bandb=100mm
PlateMillHereplateisproducedfromtheslab.t>4mm.
SheetMillHeresheetisproducedfromplate.t<4mm.
StructuralMillHerestructuralshapeslikeI,U,Lorchannelsectionsareproduced.
MetalflowpatterninRolling
Whenthemetalisrolleditisseenthattheoutersurfaceofthemetalisdeformedtoagreater
extent.Thisisduetothefactthatthemetalwillbeindirectcontactwiththerollsurface.The
frictionalforceswillbedraggingitinthedirectionofrolling.Thecenterportionofthemetal
isnotatalldeformedasitisfreefromanycontactwiththerollsurface.
Tostudytheeffectofrollingonthedeformationprocessgridmarkingsaremadeinthevertical

andhorizontaldirections.Thedeformationpatternisobservedafterrolling.Itisobservedthat

distancebetweenthehorizontalgridsdecreasesandtheycomecloser.Thedistancebetweenthe
verticalgridsincreasesandarebentforwardinthedirectionofrolling.
Thevelocityoftheworkpieceasitleavestherollsisgreaterthanthecircumferentialvelocity
oftherollsduetostretchingofthelayers.
Thicknessoftheworkpieceisreducedandthelengthisincreasedasitpassesoutoftherollgap.

DifferencebetweenHotrollingandColdrolling.
HotRolling

ColdRolling

IsCarriedoutaboveRCT

IsCarriedoutbelowRCT

Grainwillbeuniformevenafterrolling.

Grainswillbeelongatedafterrolling.

Surfacefinishwillbepoor.

Surfacefinishwillbegood.

SemifinishedproductslikeBlooms,Billetsare
produced.Structuralshapesarealso
produced.

Finisheditemslikeplates,flats,sheetsand
foilsareproduced.

Loadrequiredfordeformationisless.

Loadrequiredfordeformationismore.

DifferencebetweenHotrollingandColdrolling.
Geometric

RelationshipsinRolling

V1>V0.

NNBB
istheleadingzone
Asthemetalisdrawnbetweentherolls,itiscompressedverticallyduetofriction,startingat
AA.Thisistranslatedintoelongationinthedirectionofrolling.
Thereexistsrelativeslidingbetweentherollsurfaceandtheworkpiece.
Volumerateofthemetalflowisconstant.ie.,thevolumeofthemetalpassingthroughapointis
constantperunittime.
Sincethereisnolateralspreadb=constant
V0t0b=V1t1b
V1=V0{t0/t1}
ThereforeV1is>V0ast0>t1

SimilarlyVn>V0andV1>Vn>V0

PhenomenonofSlip
Duetothevariationinthevelocitiesofrollsurfaceandworksurfacetherewillberelative
motionbetweenthem.
Thisrelativemotionbetweentherollandtheworkpieceisreferredtoasslip.
Therewillbethissliptakingplaceatthefrontandthebackoftherolls.Theyare;
Backwardslip=(VnV0)/Vn
Forwardslip=(V1Vn)/V1
Thevelocityoftheworkpieceincreasessteadilyfromentrancetotheexit.
Atonepointalongthecontactsurfaceoftherollandwork,thesurfacevelocityoftherollwill
beequaltothevelocityofthework.
ThispointisreferredtoasNeutralpointorNoSlipPoint.
Volumerateof
Deformation =(Volumeofwork)/(Timetaken
fordeformation)
={b(t0t1)Lp}/T
Where b=Widthofthework
(t0t1)=thicknessofmetal
deformedLp=Lengthofwork
T=timetakenfordeformation
ExpressionforAngleofbite

LengthofDeformationZone

MaximumDraft