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Rolling mill redirects here. For mills that use rollers to known as cold rolling. In terms of usage, hot rolling procrush grain or stone, see roller mill.
cesses more tonnage than any other manufacturing proIn metalworking, rolling is a metal forming process in cess, and cold rolling processes the most tonnage out of
all cold working processes.[1][2] 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-nished casting products into nished products.
There are many types of rolling processes, including ring
rolling, roll bending, roll forming, prole rolling, and controlled rolling.
1 History
1.1 Iron and steel
The invention of the rolling mill is attributed from
Leonardo da Vinci.[3] Earliest rolling mills were slitting
mills, which were introduced from what is now Belgium
to England in 1590. These passed at bars between rolls
to form a plate of iron, which was then passed between
grooved rolls (slitters) to produce rods of iron.[4] The rst
experiments at rolling iron for tinplate took place about
1670. In 1697, Major John Hanbury erected a mill at
Pontypool to roll 'Pontypool platesblackplate. Later
this began to be rerolled and tinned to make tinplate. The
earlier production of plate iron in Europe had been in
forges, not rolling mills.
A rolling schematic
The slitting mill was adapted to producing hoops (for barrels) and iron with a half-round or other sections by means
that were the subject of two patents of c. 1679.,
Some of the earliest literature on rolling mills can be
traced back to Christopher Polhem in 1761 in Patriotista
Testamente, where he mentions rolling mills for both plate
Rolling visualization. (Click on image to view animation.)
and bar iron.[5] He also explains how rolling mills can save
which metal stock is passed through one or more pairs on time and labor because a rolling mill can produce 10
of rolls to reduce the thickness and to make the thick- to 20 or more bars at the same time.
ness uniform. The concept is similar to the rolling of A patent was granted to Thomas Blockley of England in
dough. Rolling is classied according to the temperature 1759 for the polishing and rolling of metals. Another
of the metal rolled. If the temperature of the metal is patent was granted in 1766 to Richard Ford of England
above its recrystallization temperature, then the process for the rst tandem mill.[6] A tandem mill is one in which
is known as hot rolling. If the temperature of the metal the metal is rolled in successive stands; Fords tandem mill
is below its recrystallization temperature, the process is was for hot rolling of wire rods.
1
Modern rolling practice can be attributed to the pioneering eorts of Henry Cort of Funtley Iron Mills, near Fareham, England. In 1783 a patent was issued to Henry Cort
for his use of grooved rolls for rolling iron bars.[7] With
this new design mills were able to produce 15 times the
output per day than with a hammer.[8] Although Cort was
not the rst to use grooved rolls, he was rst to combine
the use of many of the best features of various ironmaking
and shaping processes known at the time. Thus modern
writers have called him father of modern rolling.
The rst rail rolling mill was established by John Birkenshaw in 1820, where he produced sh bellied wrought
iron rails in lengths of 15 to 18 feet.[8] With the advancement of technology in rolling mills the size of rolling mills
grew rapidly along with the size products being rolled.
Example of this was at The Great Exhibition in 1851 a
plate 20 feet long, 3 feet wide, and 7/16 of inch thick,
1.2
Other metals
1.3
Modern rolling
3
curs in shapes that have a non-uniform cross-section, such
as I-beams. While the nished product is of good quality, the surface is covered in mill scale, which is an oxide
that forms at high-temperatures. It is usually removed
via pickling or the smooth clean surface process, which
reveals a smooth surface.[10] Dimensional tolerances are
usually 2 to 5% of the overall dimension.[11]
If processed by a blacksmith, the smoother, more consistent, and lower levels of carbon encapsulated in the steel
makes it easier to process, but at the cost of being more
expensive.[14]
2.2
Processes
Roll bending
Cold rolling
Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature),
which increases the strength via strain hardening up to
20%. It also improves the surface nish and holds
tighter tolerances. Commonly cold-rolled products include sheets, strips, bars, and rods; these products are
usually smaller than the same products that are hot rolled.
Because of the smaller size of the workpieces and their
greater strength, as compared to hot rolled stock, fourhigh or cluster mills are used.[2] Cold rolling cannot reduce the thickness of a workpiece as much as hot rolling Roll bending
in a single pass.
Cold-rolled sheets and strips come in various conditions:
full-hard, half-hard, quarter-hard, and skin-rolled. Fullhard rolling reduces the thickness by 50%, while the others involve less of a reduction.Skin-rolling, also known
as a skin-pass, involves the least amount of reduction:
0.5-1%. It is used to produce a smooth surface, a uniform thickness, and reduce the yield point phenomenon
(by preventing Lders bands from forming in later processing). It locks dislocations at the surface and thereby
reduces the possibility of formation of Lders bands. To
avoid the formation of Lders bands it is necessary to create substantial density of unpinned dislocations in ferrite
matrix. It is also used to breakup the spangles in galvanized steel. Skin-rolled stock is usually used in subsequent cold-working processes where good ductility is
required.
Other shapes can be cold-rolled if the cross-section is relatively uniform and the transverse dimension is relatively
small. Cold rolling shapes requires a series of shaping
operations, usually along the lines of sizing, breakdown,
roughing, semi-roughing, semi-nishing, and nishing.
PROCESSES
Roll forming
3.3
Flat rolling
Ring rolling is a specialized type of hot rolling that increases the diameter of a ring. The starting material is a
thick-walled ring. This workpiece is placed between two
rolls an idler roll, while another roll, called the driven roll,
presses the ring from the outside. As the rolling occurs
the wall thickness decreases as the diameter increases.
The rolls may be shaped to form various cross-sectional
shapes. The resulting grain structure is circumferential,
which gives better mechanical properties. Diameters can
be as large as 8 m (26 ft) and face heights as tall as 2 m
(79 in). Common applications include rockets, turbines,
airplanes, pipes, and pressure vessels.[10]
Foil rolling
Foil rolling is a specialized type of at rolling, specically used to produce foil, which is sheet metal with a
thickness less than 200 m (0.0079 in). The rolling is
done in a cluster mill because the small thickness requires
a small diameter rolls.[9] To reduce the need for small
rolls pack rolling is used, which rolls multiple sheets together to increase the eective starting thickness. As the
foil sheets come through the rollers, they are trimmed and Cross-sections of continuously rolled structural shapes, showing
slitted with circular or razor-like knives. Trimming refers the change induced by each rolling mill.
to the edges of the foil, while slitting involves cutting it
into several sheets.[17] Aluminum foil is the most com- Main article: Structural shape rolling
monly produced product via pack rolling. This is evident
4.1
3.6
Congurations
Controlled rolling
Controlled rolling is a type of thermomechanical processing which integrates controlled deformation and heat
treating. The heat which brings the workpiece above the
recrystallization temperature is also used to perform the
heat treatments so that any subsequent heat treating is unnecessary. Types of heat treatments include the production of a ne grain structure; controlling the nature, size,
and distribution of various transformation products (such
as ferrite, austenite, pearlite, bainite, and martensite in
steel); inducing precipitation hardening; and, controlling
the toughness. In order to achieve this the entire process
must be closely monitored and controlled. Common variables in controlled rolling include the starting material
composition and structure, deformation levels, temperatures at various stages, and cool-down conditions. The
benets of controlled rolling include better mechanical
properties and energy savings.[11]
Mills
Rolling mill for cold rolling metal sheet like this piece of brass
sheet
Rolling mills
Work rolls
Backup rolls - are intended to provide rigid support
required by the working rolls to prevent bending under the rolling load
Rolling balance system - to ensure that the upper Slabs are the feed material for hot strip mills or plate mills
work and back up rolls are maintained in proper po- and blooms are rolled to billets in a billet mill or large
sition relative to lower rolls
sections in a structural mill. The output from a strip mill
Roll changing devices - use of an overhead crane and is coiled and, subsequently, used as the feed for a cold
a unit designed to attach to the neck of the roll to be rolling mill or used directly by fabricators. Billets, for rerolling, are subsequently rolled in either a merchant, bar
removed from or inserted into the mill.
or rod mill. Merchant or bar mills produce a variety of
Mill protection devices - to ensure that forces ap- shaped products such as angles, channels, beams, rounds
plied to the backup roll chocks are not of such a (long or coiled) and hexagons.
5 DEFECTS
to 42 inches in diameter.
Billet mills, three-high, rolls from 24 to 32 inches in
diameter, used for the further reduction of blooms
down to 1.5x1.5-inch billets, being the preparatory
mills for the bar and rod
Various rolling congurations. Key: A. 2-high B. 3-high C. 4high D. 6-high E&F. Cluster
4.1
Congurations
5.1
warmer parts and less in the cooler. If the temperature dierence is great enough cracking and tearing can
occur.[9]
ROLL
FORCE
WORKPIECE
5.1
In a at metal workpiece, the atness is a descriptive attribute characterizing the extent of the geometric deviation from a reference plane. The deviation from complete
atness is the direct result of the workpiece relaxation after hot or cold rolling, due to the internal stress pattern
caused by the non-uniform transversal compressive action of the rolls and the uneven geometrical properties of
the entry material. The transverse distribution of dierential strain/elongation-induced stress with respect to the
materials average applied stress is commonly referenced
to as shape. Due to the strict relationship between shape
and atness, these terms can be used in an interchangeable manner. In the case of metal strips and sheets, the
atness reects the dierential ber elongation across the
width of the workpiece. This property must be subject to
an accurate feedback-based control in order to guarantee
the machinability of the metal sheets in the nal transformation processes. Some technological details about the
feedback control of atness are given in.[21]
STRAIGHT ROLLS
CROWNED ROLLS
Roll deection
Siemag AG and involves grinding a third order polynomial curve into the work rolls and then shifting the work
rolls laterally, equally, and opposite to each other. The
eect is that the rolls will have a gap between them that
is parabolic in shape, and will vary with lateral shift, thus
allowing for control of the crown of the rolls dynamically.
Pair cross rolling involves using either at or parabolically
crowned rolls, but shifting the ends at an angle so that the
gap between the edges of the rolls will increase or de5.1.1 Prole
crease, thus allowing for dynamic crown control. Work
roll bending involves using hydraulic cylinders at the ends
Prole is made up of the measurements of crown and of the rolls to counteract roll deection.
wedge. Crown is the thickness in the center as compared
to the average thickness at the edges of the workpiece. Another way to overcome deection issues is by decreasWedge is a measure of the thickness at one edge as op- ing the load on the rolls, which can be done by applyposed to the other edge. Both may be expressed as abso- ing a longitudinal force; this is essentially drawing. Other
lute measurements or as relative measurements. For in- method of decreasing roll deection include increasing
roll material and adding backstance, one could have 2 mil of crown (the center of the the elastic modulus of the
[11]
up
supports
to
the
rolls.
workpiece is 2 mil thicker than the edges), or one could
have 2% crown (the center of the workpiece is 2% thicker The dierent classications for atness defects are:
than the edges).
It is typically desirable to have some crown in the workpiece as this will cause the workpiece to tend to pull to the
center of the mill, and thus will run with higher stability.
5.1.2
Flatness
7 NOTES
It is important to note that one could have a atness defect even with the workpiece having the same thickness
across the width. Also, one could have fairly high crown
or wedge, but still produce material that is at. In order
to produce at material, the material must be reduced by
the same percentage across the width. This is important
because mass ow of the material must be preserved, and
the more a material is reduced, the more it is elongated.
If a material is elongated in the same manner across the
width, then the atness coming into the mill will be preserved at the exit of the mill.
5.2
Draft
7 Notes
[1] Degarmo, Black & Kohser 2003, p. 384.
[2] Degarmo, Black & Kohser 2003, p. 408.
[3] http://www.mostredileonardo.com/site.asp?idSito=1&
idLingua=10&idPagina=246
[4] Landes, David. S. (1969). The Unbound Prometheus:
Technological Change and Industrial Development in
Western Europe from 1750 to the Present. Cambridge,
New York: Press Syndicate of the University of Cambridge. p. 91. ISBN 0-521-09418-6.
[5] Swank, James M.,History of the Manufacturers of Iron in
All Ages, Published by Burt Franklin 1892, p.91
[6] Roberts 1978, p. 5.
[7] R. A. Mott (ed. P. Singer), Henry Cort: the great ner
(Metals Society, London 1983), 31-36; English patents,
nos. 1351 and 1420.
[8] Roberts 1978, p. 6.
[9] Degarmo, Black & Kohser 2003, p. 385.
5.3
Surface defects
[12] http://metalsforasteel.com
[13] Hot Rolled Steel. Retrieved 31 March 2014.
[14] http://spaco.org/hrvscr.htm
[17] http://www.enotes.com/how-products-encyclopedia/
aluminum-foil
Scabs These are long patches of loose metal that have [18] Degarmo, Black & Kohser 2003, p. 386
been rolled into the surface of the metal.
[19] Roberts 1978, p. 64.
Seams They are open, broken lines that run along the [20] Kindl, F. H. (1913), The Rolling Mill Industry, Penton
length of the metal and caused by the presence of
Publishing, pp. 1319.
scale.
Slivers Prominent surface ruptures.
See also
[21] G Pin, V Francesconi, FA Cuzzola and T Parisini. Adaptive task-space metal strip-atness control in cold multiroll mill stands. Journal of Process Control, 2012. http:
//dx.doi.org/10.1016/j.jprocont.2012.08.008
Bernard Lauth
[22] Denition of standard mill terms, archived from the original on 03-04-2010, retrieved 03-04-2010. Check date
values in: |archivedate=, |accessdate= (help)
John B. Tytus
7.1
Bibliography
Further reading
Roberts, William L. (1983), Hot Rolling of Steel,
CRC Press, ISBN 978-0-8247-1345-4.
Ginzburg, Vladimir B.; Ballas, Robert (2000), Flat
Rolling Fundamentals, CRC Press, ISBN 978-08247-8894-0.
Lee, Youngseog (2004), Rod and bar rolling, CRC
Press, ISBN 978-0-8247-5649-9.
Swank, James M. (1965), History of the Manufacture of Iron in All Ages (2nd ed.), Ayer Publishing,
ISBN 978-0-8337-3463-1.
Reed-Hill, Robert, et al. Physical Metallurgy Principles, 3rd Edition, PWS publishing, Boston, 1991.
ISBN 978-0-534-92173-6.
Callister Jr., William D., Materials Science and Engineering - an Introduction, 6th Edition, John Wiley
& Sons, New York, NY, 2003. ISBN 0-471-135763
External links
How Liners Achieve the Desired Quality of the
Product Being Rolled
History of Rolling Mills
Key to metals: Steel Rolling
Typical gauge distribution: Hot Rolled Steel
Stockiest, Slitters & Distributors of Cold Rolled
Steel
Steel Rolling Mill Machines
Hot Rolled Steel
10
10
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10.1
10.2
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