Metal Forming Hot Rolling

Manufacturing Processes and Systems Mechanical Engineering University of Colorado

Rolling

Source: http://uk.geocities.com/plinehanuk/management.htm

Hot Rolling

Basic Rolling Process

Heated metal is passes between two rolls The rolls:
Rotate in opposite directions Rotate with a surface velocity higher than the speed of the incoming metal

Friction along the contact surface propels the metal forward

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Ref: W.F. Hosford and R. Caddell Metal Forming 3rd Edition

Friction vs. Position

Calculating Roll Force

= ( + )/ = =

bt and ft = back tension and front tension, respectively

Reducing Roll Force with Small Diameter Rolls

Roll Deflection

Source: http://www.me.gatech.edu/jonathan.colton/me4210/deform.pdf

Defects From Roll Deflection

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Edge Cracking

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Rolling Defects
Defects
Wavy Edges or Center Buckle (shape issues) Edge Cracks
Zipper Cracks

Cause
Roll Deflections

Barreling
Low Ductility

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Yeah, it does happen

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Shape Correction
Roll bending and roll shifting

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Roll Defects
Typically marks that repeat at a distance equal to the working roll circumference

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Flow Stress in Hot Working

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Thermomechanical Processing
Controlled Rolling Accelerated Cooling

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Source: http://www.ipmx.com/html/tour/hotmill.html#lfc

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Al X52_vintage X52_new 0.002 0.017

B <0.0001 <0.0001

C 0.238 0.071

Co 0.004 0.002

Cr 0.014 0.033

Cu 0.085 0.016

Fe 98.48 98.37

H 0.000 1 0.000 6 Ti 0.002 0.038

Mn 0.96 1.06

Mo
X52_vintage X52_new 0.004 0.003

N
0.003 0.004

Nb
0.001 0.026

Ni
0.003 0.004

P
0.011 0.012

S
0.021 0.004

Si
0.064 0.24

V
0.002 0.004

Steel
X52_vintage X52_new

y [MPa std. dev.]

3254 4875

UTS [MPa std. dev.]

5264 5885

Vintage X52 Alloy

New X52 Alloy

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Seamless Tube

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