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Chapter 13
Introduction
This chapter describes
Flat rolling
Shape rolling
Production of seamless tubing & pipe
Flat Rolling
Flat Rolling Process
Frictional Forces
Flat-Rolling Practice
Hot rolling
The initial break down of an ingot
Continuously cast slab
Structure may be brittle
Converts the cast structure to a wrought structure
Finer grains
Enhanced ductility
Reduction in defects
Continuous Casting
Is replacing traditional methods
Faster & better
Product of the first hot-rolling operation - Bloom or slab
Square cross section of 150mm (6in) on one side
Processed father by shape rolling
I-beams
Railroad rails
Billets smaller than blooms and rolled into bars and rods
Cold rolling
carried out at room temperature
Produces sheet and strip metal
Better surface finish less scale
Pack rolling when two or more layers of metal are rolled together
Changes in grain structure during hot-rolling
Undesirable
Degrade surface appearance
Adversely affect the strength
Sheet metal defects include:
Scale, Rust, Scratches, Gouges, Pits, & Cracks
May be caused by impurities and inclusions
Wavy edges result of roll bending
Alligatoring complex phenomenon
Other Characteristics
Residual stresses produces:
Compressive residual stresses on the surfaces
Tensile stresses in the middle
Tolerances
Cold-rolled sheets: (+/- ) 0.1mm 0.35mm
Tolerances much greater for hot-rolled plates
Surface roughness
Cold rolling can produce a very fine finish
Hot rolling & sand have the same range of surface finish
Gauge numbers the thickness of a sheet is identified by a
gauge number
Shape-Rolling Operations
Various shapes can be produced by shape rolling
Bars
Channels
I-beams
Railroad rails
Roll-pass design requires considerable experience in order
to avoid external and internal defects
Ring Rolling
A thick ring is expanded into a large diameter ring
The ring is placed between the two rolls
One of which is driven
The thickness is reduced by bringing the rolls together
The ring shaped blank my be produced by:\
Cutting from plate
Piercing
Cutting from a thick walled pipe
Various shapes can be produced by shaped rolls
Typical applications of ring rolling:
Large rings for rockets
Gearwheel rims
Ball-bearing and roller-bearing races
Can be carried out at room temperature
Has short production time
Close dimensional tolerances
RING ROLLING
Thread Rolling
Cold-forming process
Straight or tapered threads are formed on round rods by passing the pipe
though dies
Typical products include
Screws
Bolts
Continuous casting
Advantages
Highly automated
Reduces product cost
Companies are converting over to this type of casting
THE END