Introduction to Rolling

Rolling is a bulk deformation process in which the

thickness of the work is reduced by compressive forces
exerted by two opposing rolls. The rolls rotate to pull
and simultaneously squeeze the work between them.

Two High Rolling Mill

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The basic process shown in the previous figure is Flat
Rolling, used to reduce the thickness of a rectangular cross
section. A closely related process is shape rolling, in
which a square cross section is formed into a shape such as
an I-beam.
Shape Rolling
Flat Rolling
Shape Rolling

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After casting, ingots are rolled into one of three intermediate shapes
called blooms, billets, and slabs:
Blooms have square cross section 6 x 6 or larger. They are rolled
into structural shapes.

Billets have square cross section 1.5 x 1.5 or larger. they are rolled
into bars and rods.

 Slabs have rectangular cross section 10 x 1.5 or larger. They are

rolled into plates, sheets and strips.

Plate is the product with a thickness > 6 mm.

Sheet is the product with a thickness < 6 mm
and width > 600 mm.
Strip is the product with a thickness < 6 mm
and width < 600 mm.

Types of Rolling
Based on work piece geometry :
Flat rolling - used to reduce thickness of a rectangular
cross section
Shape rolling - square cross section is formed into a
shape such as an Ibeam
Based on work temperature :
Hot Rolling most common due to the large amount
of deformation required
Cold rolling produces finished sheet and plate stock
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Roll configurations in rolling mills

Two High Rolling Mill.

Three High Rolling Mill

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Cluster Rolling Mill.

Tandem Rolling Mill.

Hot rolling
Hot rolling is a metalworking process that occurs above the
recrystallization temperature of the material.
Hot rolled metals generally have little directionality in their
mechanical properties and deformation induced residual
stresses.
However, in certain instances non-metallic inclusions will
impart some directionality
Hot rolling is used mainly to produce sheet metal or simple
cross sections, such as rail tracks.

Cold rolling
Cold rolling occurs with the metal below its recrystallization
temperature (usually at room temperature).
Due to smaller size of the work pieces and their greater strength
than hot rolled stock, four-high or cluster mills are used.
Commonly cold-rolled products include sheets, strips and rods;
products being smaller than the same products that are hot rolled.

Types of rolling processes

Continuous
Transverse
Section or shape
Ring
Continuous casting and hot rolling
Thread

Continuous
The objective is to decrease the thickness of the metal with an
increase in length and with little increase in width.

Transverse
Using circular wedge rolls.
Heated bar is cropped to length and
fed in transversely between rolls.
Rolls are revolved in one direction.

SECTION or SHAPE
Flat slap is progressively bent into complex shapes.
Suitable for producing moulded sections such as irregular
shaped channels and trim.

Ring
A specialized type of hot rolling that increases the diameter
of a ring.
The resulting grain structure is circumferential, which gives
better mechanical properties.

Continuous casting and hot rolling

Metal is melted, cast and hot rolled continuously through a
series of rolling mills within the same process.

Thread
Rolled threads are produced in a single pass at speeds far in excess
of those used to cut threads. Dies are pressed against the surface of
cylindrical blank. As the blank rolls against the in feeding die
faces, the material is displaced to form the roots of the thread, and
the displaced material flows radially outward to form the thread's
crest.

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