Rolling Process

Instructional Design Document

STAM Interactive Solutions

Demo Outline (For reference)

Topic Number

Topic Name

Page Type

Introduction

Animated page

Rolling Process

Animated page

Roll Gap

Animated page

Neutral Point

Animated page

Position of Neutral Point

Animated page

Simulation

Interactive page

Change Log (as per the minutes pdf)

Changes Suggested by Prof. Ramesh Singh

Changes reflected on slide no.

Start with photo of real roll, voiceover to outline the process

Slide 5 Also refer to the notes

section

Follow with schematic diagram listing process

parameters (slide 15 of lecture notes at
me.iitb.ac.in/~ramesh/me649/rolling.pdf)

Slides 6, 7, 8 & 9 Also refer to the

notes section

Show pressure distribution on the schematic (free body diagram /

stresses and forces)
Introduce neutral point
3

Voiceover to introduce objective of instruction feasibility for

reduction / power

Slide 4 Text & Voice over changed

Interactivity / animation
Fix roll radius, back height and rotational speed of roll
Enter hi and obtain maximum permissible hf
Also show power required (using slides 35, 36, 55 and
56 of above cited lecture notes)
Allow switch between 3 values for m: low, high and
medium (use 0.1, 0.2 and 0.4)
Assume steel properties (perfectly plastic)

Slide10 - Also refer to the notes

section

References
Dont cite the wikipedia
Add reference books as suggested

Slide 11

Modify quiz question 1 - Spelling: affect vs. effect

Modify quiz question 4 - All of above should be the correct answer

Slide 12 & 15

Advanced Manufacturing Process I & II

Rolling Process

This demo illustrates the procedure for a 2-high

rolling mill. Calculation of the maximum
reduction that can be achieved and the power
required to drive the rolling mill will be
explained.

Advanced Manufacturing Process I & II

Rolling Process
Introduction

Rolling:
Is the process of plastically deforming metal by passing it between
rolls
Is widely used to convert steel ingots into blooms, billets, and slabs,
and subsequently into plates, sheets and strips

Advantages:
Provides high throughput
Provides good control over the dimensions
of the finished product
In Hot Rolling:
Metal is rolled at a temperature above its
recrystallization temperature
Higher reduction in the cross-section is
achieved
In Cold Rolling:
Metal is rolled at a temperature below its recrystallization
temperature
Better strength and control of dimensions are achieved

Advanced Manufacturing Process I & II

Rolling Process
Rolling Process

Rolls transfer energy to the strip through friction. As the strip is dragged by the rolls into the gap
between them, it decreases in thickness while passing from the entrance to the exit. Meanwhile its speed
gradually increases from the entrance to the exit.

V0 = input velocity
Vf = final or output velocity
R = roll radius
hb = back height
hf = output or final thickness

Advanced Manufacturing Process I & II

Rolling Process
Roll Gap

V0 = input velocity
Vf = final or output velocity
R = roll radius
hb = back height
hf = output or final thickness
= = angle of bite
L = Roll Gap

Advanced Manufacturing Process I & II

Rolling Process
Neutral Point

V0 = input velocity
Vf = final or output velocity
R = roll radius
hb = back height
hf = output or final thickness
= = angle of bite
N-N = neutral point or no-slip
point
L = Roll Gap
To the left of the Neutral Point:
Velocity of the strip < Velocity of the roll
To the right of the Neutral Point:
Velocity of the strip > Velocity of the roll

Advanced Manufacturing Process I & II

Rolling Process
Position of the Neutral Point

As the neutral point reaches the exit, the rolls skid over the strip and the strip will stop moving.
Maximum reduction is given by:

Advanced Manufacturing Process I & II

Rolling Process
Simulation

Back Height (hb):

Neutral
Point

Friction Coefficient ():

Roll

Flow stress of steel (Yflow)

R

Range (0.4mm to 10mm)

0.1

Constant

130 Mpa Constant

Width of the Roller (W):

10 mm

Constant

Roll Radius (R):

75 mm

Constant

Rotational speed of Roll:

hb

2 mm

0.8 m/s Constant

m:

hf

0.1

START
Sheet
Final sheet thickness (hf):
Roll Gap (L):
Force/Roller (F):
Power/Roller (P):

Enter the parameters and click START.

0.2

0.4

Advanced Manufacturing Process I & II

Rolling Process
Resources

Books:

Serope Kalpakjian & Steven R. Schmid, Manufacturing Process for Engineering

Materials, Section 6.3 Rolling Process

Ghosh & Malik, Manufacturing Science

Advanced Manufacturing Process I & II

Rolling Process

The effect of friction on the rolling mill is

always bad since it retards exit of reduced metal

always good since it drags metal into the gap
between the rolls
advantageous before the neutral point
disadvantageous after the neutral point

Advanced Manufacturing Process I & II

Rolling Process

As compared to cold rolling, hot rolling yields

better dimensional control and higher strength

better dimensional control but poorer strength
worse dimensional control and higher strength
better dimensional control and poorer strength

Advanced Manufacturing Process I & II

Rolling Process

Velocity at the exit is

higher than velocity at the entry

lower than velocity at the entry
either equal to or lower than velocity at the entry,
depending on the coefficient of friction
either equal to or higher than velocity at the entry,
depending on the coefficient of friction

Advanced Manufacturing Process I & II

Rolling Process

Power required depends upon

reduction of thickness
width of metal / rolls
coefficient of friction
metal type

Advanced Manufacturing Process I & II

Rolling Process

Reducing the rpm of the rolls

reduces the power required

has no affect on the power required
affects the power required depending on the
coefficient of friction
affects the power required depending on the
properties of the metal