JTKP/ BETP1323/ 1

FAKULTI TEKNOLOGI KEJURUTERAAN

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING PROCESS
BETP 1323

SEMESTER 2

SESI 2014/2015

ROLLING AND SPOT WELDING

1.1 OBJECTIVES
The objectives of this laboratory are;
1.
2.
3.

Explain the characteristics of joining in term of process, equipment, setup and their
applications.
Practice the rolling and spot welding joining processes using to make variety of
joints.
Apply the soft skills such as communication skills, critical thinking and spirit of
teamwork

1.2 INTRODUCTION
Rolling process is a plastic deforming of metal by passing it between rolls. Rolling is common
application used in the production of tanks, boilers, and pressure vessels. The metal that needs to
be rolled is run through two metal rolls that are adjustable in width and height depending on the
thickness of the material.Rolling is the most widely used in forming process, which provides
high production and close control of final product. The metal is subjected to high compressive
stresses as a result of the friction between the rolls and the metal surface.
Rolling processes can be mainly divided into hot rolling and cold rolling. In hot rolling, the
initial breakdown of ingots into blooms and billets is generally done by hot rolling. This
followed by further hot rolling into plate, sheet, rod, bar, pipe, rail and etc. On the contrary, cold
rolling process is done in ambient temperature. The cold rolling of metals has played a major
role in industry by providing sheet, strip, foil with good surface finishes and increased
mechanical strength with close control of product dimensions.
Terminology in rolling;
Semi-finished products: Bloom is the product of first breakdown of ingot (cross sectional area > 230 cm2).
Billet is the product obtained from a further reduction by hot rolling (cross sectional area
>40x40 mm2).
Slab is the hot rolled ingot(cross sectional area > 100 cm2 and with a width 2 x
thickness)
Mill products: Plate is the product with a thickness > 6 mm.
Sheet is the product with a thickness < 6 mm and width > 600 mm.
1

JTKP/ BETP1323/ 1
FAKULTI TEKNOLOGI KEJURUTERAAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING PROCESS
BETP 1323

SEMESTER 2

SESI 2014/2015

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

Rolling process
Spot welding is a process in which contacting metal surfaces are joined by the heat obtained
from resistance to electric current.
Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in
the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped copper alloy
electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the
sheets together. Forcing a large current through the spot will melt the metal and form the weld.
The attractive feature of spot welding is that a lot of energy can be delivered to the spot in a very
short time (approximately 10100 milliseconds). That permits the welding to occur without
excessive heating of the remainder of the sheet.

JTKP/ BETP1323/ 1
FAKULTI TEKNOLOGI KEJURUTERAAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING PROCESS
BETP 1323

SEMESTER 2

SESI 2014/2015

The amount of heat (energy) delivered to the spot is determined by the resistance between the
electrodes and the magnitude and duration of the current. The amount of energy is chosen to
match the sheet's material properties, its thickness, and type of electrodes. Applying too little
energy will not melt the metal or will make a poor weld. Applying too much energy will melt too
much metal, eject molten material, and make a hole rather than a weld. Another feature of spot
welding is that the energy delivered to the spot can be controlled to produce reliable welds.

Spot Welding
1.3 EXPERIMENTAL PROCEDURE
In this project, you are divided into groups of 3 or 4 people. Cut the galvanized sheet into
specific dimensions as in drawing attached. Use rolling process to form the sheet into a
cylindrical shape. Then take the parts to the welding lab and joint them together using spot
welding technique.
1.4

EQUIPMENTS

1.
2.
3.
4.
5.
6.

Galvanized Plates thickness 0.5 mm

Plate cutter
Steel Ruler
Math Compass
Cylindrical rolling machine
Spot welding machine
3

JTKP/ BETP1323/ 1
FAKULTI TEKNOLOGI KEJURUTERAAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING PROCESS
BETP 1323

SEMESTER 2

SESI 2014/2015

1.5 SAFETY PROCEDURES

1.
2.
3.
4.

1.6

Always keep safety in mind.

Wear lab coat and safety shoes at all times.
Do not wear neckties, wristwatches, rings jewellery, etc. when operating the machine. Long
sleeve shirts will be rolled above the elbows.
The area surround the machine should be free of oil or coolant spills (avoid a slippery
floor) and as free as possible from obstruction. Keep the area clean at all times.
PROJECT EVALUATION

The project will be evaluated based on;

1.
2.
3.
4.

Quality of rolling (30%)

Welding (30%)
Finishing (creativity) (10%)
Report 30%