This document discusses several metal forming processes including sheet rolling, shape rolling, tube rolling, ring rolling, and gear rolling. Sheet rolling is used to reduce the thickness of metal sheets using rotating rolls. Shape rolling reduces thickness while also shaping the cross-section using rolls with grooves. Tube rolling reduces the diameter of tubes using rolls. Ring rolling forms hollow circular blanks into rings using a main roll on the outside and mandrel on the inside. Gear rolling involves rolling a blank between toothed die wheels to form gear teeth. Each process is used to form specific shapes from various metal materials like steels and aluminum alloys.

1. Metal forming processes
‫التاسعة‬ ‫المحاضرة‬

2. Definition: sheet rolling is hot or cold
forming process of metal for
reducing sectional area of the stock
with the use of rotating rolls. In
general, the rolled material elongates
in the direction of rolling with
reduced in cross sectional area.
16- Sheet Rolling

3. Initial thickness
of Plate
Final thickness
of Plate
Rotational Roller

4. Equipment : Two- high rolling mills, four-
high rolling mills, claster rolling mills,
planetary rolling mills.
Materials : Carbon and alloy steels, stainless
steels, aluminum alloys, copper alloys,
titanium alloys, nickel alloys.
Parameters which influences in the process :
initial thickness, reduction ratio, rolls
diameter, roll pressure.
Applications : strip, sheet and plate

5. Definition: Shape rolling is a hot or
cold forming process for reducing as
well as shaping the cross section of
the metal stock by passing it through
a series of rotating sets of rolls with
appropriately shaped grooves .
17- shape Rolling

6. Shape Rolling

7. Equipment : Two- high rolling mills.
Materials : Carbon and alloy steels, tool
steels, stainless steels, titanium, copper and
copper-base alloys
Parameters which influences in the process :
grooves between two rollers, forming
pressure.
Applications : Structural parts, such as T, L
and U sections.

8. Definition: Tube rolling is the process
of reducing the cross section area
and/or the diameter of a tube by
passing it through powered rolls.
18- Tube Rolling

10. Equipment : Two- high rolling mills.
Materials : Carbon and alloy steels, copper
alloys, aluminum alloys.
Parameters which influences in the process
:initial and final tube thickness or diameters.
Applications : Seamless tubes for various
industries

11. Definition: Ring rolling is the forming process of a hollow
circular blank into a ring (cold or hot) . A main roll passes
on the outside diameter of the blank, which is supported
by a mandrel on the inside diameter. Shaped cross sections
are obtained by appropriate contouring of the mandrel
and the roll. The height of the rings controlled by auxiliary
rolls.
19- Ring Rolling
1- Work-piece.
2- Supported mandrel .
3- Auxiliary rolls.
4- Main roll .

12. Equipment : Ring rolling machine or mills.
Materials : Carbon and alloy steels, copper
alloys, aluminum alloys, titanium alloys,
nickel alloys..
Parameters which influences in the process :
thickness and height of ring
Applications : Rings with different diameters,
flanges, wheel bearings,

13. Ring Rolling Products

14. Definition: Gear rolling is the process of
forming gear teeth on a hot or cold blank
by rolling it between driven toothed die
wheels.
20- Gear Rolling
dies
W.P

15. Gear Rolling

16. Gear Rolling

17. Equipment : Gear rolling machines.
Materials : Carbon and alloy steels.
Parameters which influences in the process :
geometry of gear tooth
Applications : Gears manufacturing

18. ‫النهاية‬