Rolling of Metals
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Rolling is a metal fabrication process that uses rotating rolls to reduce the cross-sectional area of metal stock by plastic deformation as it passes between the rolls. There are two main types of rolling: hot rolling, which occurs above the metal's recrystallization temperature, and cold rolling, which occurs below the recrystallization temperature and increases strength through strain hardening. Rolling mills consist of rolls, bearings, and a housing and use large motors to power the rolls. Common mill types include two-high, two-high reversing, three-high reversing, and four-high mills.
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Rolling Process.pdf
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and increase the length. There are two main types:
1) Hot rolling is performed above the metal's recrystallization temperature for lower pressure and improved ductility. It produces coarse grains and no residual stresses.
2) Cold rolling is performed below the recrystallization temperature, requiring higher pressures but improving dimensions, finish and strength through residual stresses and elongated grains.
Rolling mills are classified by the number of rolls used, including two-high, three-high, four-high and cluster/sendzimir mills. Continuous mills use multiple stands to continuously roll sheet metal.
R O L L I N G
This document discusses rolling processes used to shape metals. It describes rolling as a bulk deformation process that reduces thickness or changes cross-section of a workpiece using compressive forces from rotating rolls. Hot rolling involves heating metal above its recrystallization temperature before rolling, allowing larger deformation and grain refinement. Cold rolling increases strength but reduces ductility, so heat treatment is often required after. The document provides details on advantages and limitations of both hot and cold rolling processes.
Rolling process presentation
The document discusses the rolling process used in mechanical engineering. It begins with introductions and terminology for rolling. It then covers classifications of rolling mills like two high, three high, and four high mills. The types of rolling processes discussed include conventional, transverse, shaped, ring, powder, and thread rolling. Hot and cold rolling are also covered. Key aspects of the rolling process like roll bite condition and common rolling defects are defined. The document concludes with potential problems in rolling and sample multiple choice questions.
Rolling of the metals
The document discusses the process of rolling metals. It begins by defining rolling as the plastic deformation of materials caused by compressive force applied through revolving rolls, which reduces the thickness and increases the length of the workpiece. It then discusses hot rolling and cold rolling processes. Hot rolling is performed above the recrystallization temperature and allows for large deformation, while cold rolling is used for finished sheets and plates. The document also covers grain structure changes during rolling, mechanics of rolling including forces, entry conditions, and roll pressure distribution. It concludes with discussing types of rolling mills.
Hot and cold working
1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
Rolling
Rolling is a key metallurgical process that shapes 90% of metal products through the use of rolling mills. It involves heating metal above recrystallization temperatures, between 1200°C to 900°C, then rolling it in 2-high rolling stands. The document discusses factors that influence rolling, including angle of bite, draft, spread, and elongation. It also covers the different types of rolling mills and their characteristics, as well as considerations for roll pass design like shape, sequence, material properties, and process parameters. Finally, it provides details on rolling practices at VSP, including existing and proposed mills with their products and tonnages.
Rolling process
The document discusses the rolling process used in metal forming. It describes rolling as a process where the thickness of metal is reduced by compressive forces from two opposing rolls. Rolling can be used for flat rolling to reduce thickness of rectangular cross-sections or shape rolling to form square cross-sections into shapes like I-beams. The document outlines different types of rolling like hot rolling, cold rolling, continuous rolling and shape rolling and describes the purposes and processes for each type.
Extrusion of metals by Hariprasad
The document discusses the process of extrusion. It begins with an introduction to extrusion, defining it as reducing the cross-section of metal by forcing it to flow through a die under high pressure. It then covers the basic extrusion process using diagrams. The document goes on to classify extrusion processes and describe various types like direct/indirect, hot/cold, lateral, and hydrostatic extrusion. It also covers die design, defects, variables that affect extrusion, and applications of extrusion.
Recommended
Rolling Process.pdf
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and increase the length. There are two main types:
1) Hot rolling is performed above the metal's recrystallization temperature for lower pressure and improved ductility. It produces coarse grains and no residual stresses.
2) Cold rolling is performed below the recrystallization temperature, requiring higher pressures but improving dimensions, finish and strength through residual stresses and elongated grains.
Rolling mills are classified by the number of rolls used, including two-high, three-high, four-high and cluster/sendzimir mills. Continuous mills use multiple stands to continuously roll sheet metal.
R O L L I N G
This document discusses rolling processes used to shape metals. It describes rolling as a bulk deformation process that reduces thickness or changes cross-section of a workpiece using compressive forces from rotating rolls. Hot rolling involves heating metal above its recrystallization temperature before rolling, allowing larger deformation and grain refinement. Cold rolling increases strength but reduces ductility, so heat treatment is often required after. The document provides details on advantages and limitations of both hot and cold rolling processes.
Rolling process presentation
The document discusses the rolling process used in mechanical engineering. It begins with introductions and terminology for rolling. It then covers classifications of rolling mills like two high, three high, and four high mills. The types of rolling processes discussed include conventional, transverse, shaped, ring, powder, and thread rolling. Hot and cold rolling are also covered. Key aspects of the rolling process like roll bite condition and common rolling defects are defined. The document concludes with potential problems in rolling and sample multiple choice questions.
Rolling of the metals
The document discusses the process of rolling metals. It begins by defining rolling as the plastic deformation of materials caused by compressive force applied through revolving rolls, which reduces the thickness and increases the length of the workpiece. It then discusses hot rolling and cold rolling processes. Hot rolling is performed above the recrystallization temperature and allows for large deformation, while cold rolling is used for finished sheets and plates. The document also covers grain structure changes during rolling, mechanics of rolling including forces, entry conditions, and roll pressure distribution. It concludes with discussing types of rolling mills.
Hot and cold working
1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
Rolling
Rolling is a key metallurgical process that shapes 90% of metal products through the use of rolling mills. It involves heating metal above recrystallization temperatures, between 1200°C to 900°C, then rolling it in 2-high rolling stands. The document discusses factors that influence rolling, including angle of bite, draft, spread, and elongation. It also covers the different types of rolling mills and their characteristics, as well as considerations for roll pass design like shape, sequence, material properties, and process parameters. Finally, it provides details on rolling practices at VSP, including existing and proposed mills with their products and tonnages.
Rolling process
The document discusses the rolling process used in metal forming. It describes rolling as a process where the thickness of metal is reduced by compressive forces from two opposing rolls. Rolling can be used for flat rolling to reduce thickness of rectangular cross-sections or shape rolling to form square cross-sections into shapes like I-beams. The document outlines different types of rolling like hot rolling, cold rolling, continuous rolling and shape rolling and describes the purposes and processes for each type.
Extrusion of metals by Hariprasad
The document discusses the process of extrusion. It begins with an introduction to extrusion, defining it as reducing the cross-section of metal by forcing it to flow through a die under high pressure. It then covers the basic extrusion process using diagrams. The document goes on to classify extrusion processes and describe various types like direct/indirect, hot/cold, lateral, and hydrostatic extrusion. It also covers die design, defects, variables that affect extrusion, and applications of extrusion.
Rolling Process
The document summarizes the rolling process. It defines rolling as plastically deforming metal by passing it between rolls. Rolling provides close dimensional control and high production. There are two main types: hot rolling and cold rolling. The document describes various rolling terminologies, mill products, defects, and different rolling processes like hot rolling, cold rolling, shaped rolling, and thread rolling. It also discusses factors like angle of contact, forces involved, and how to control flatness.
Rolling slides
The document discusses the rolling process for metal forming. Rolling is defined as passing metal between rolls to plastically deform it. There are two main types: hot rolling, which is used for initial breakdown of ingots, and cold rolling, which provides closer dimensional tolerances and better surface finishes. Rolling can produce products like plate, sheet, strip, bars, and pipes. The rolling process involves passing metal through sets of rolls under high compressive forces.
Casting
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
Metal Rolling Process
This document summarizes the metal rolling process. It describes how rolling is used to plastically deform metal by passing it between rolls, providing close control of the final product dimensions. It defines various semi-finished products produced from rolling like billets, blooms, slabs, plates, sheets, and strips based on their cross-sectional area and thickness. It also describes hot rolling and cold rolling processes, their applications and equipment used.
Fundamentals of metal forming processes
The document discusses various metal forming processes used to change the shape of metal workpieces through plastic deformation exceeding the metal's yield strength, including bulk deformation techniques like rolling, forging, and extrusion that involve significant shape changes with lower surface area to volume ratios, and sheet metalworking techniques like bending, drawing, and shearing that are performed on metal sheets or strips with higher surface area to volume ratios. Metal forming is an important manufacturing method that allows for net or near-net shape production, high production rates, profitability, and improved material properties.
03 rolling of metals
This document provides information on various metal rolling processes including hot rolling, cold rolling, and other specialized rolling techniques. It discusses the basic components and setup of rolling mills. Key rolling processes are defined, such as continuous rolling, shaped rolling, and ring rolling. The document also examines the differences between hot and cold rolling, and provides examples of typical rolling mill operations. Mathematical approaches for calculating rolling loads are introduced.
shell moulding
Shell moulding is a casting process that uses a sand-resin mixture to form a disposable mould around a reusable pattern. This allows for higher production rates than sand casting while also enabling more complex part geometries. The process involves creating a metal pattern, heating it, applying a sand-resin mixture to form shell halves, joining the shells to create the mould, pouring molten metal, and removing the casting after solidification. Shell moulding provides better dimensional accuracy, higher productivity, and lower labor costs than sand casting for small to medium precision parts.
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Sheet Metal Forming
1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
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The document discusses various topics related to rolling mills and rolling processes. It defines a rolling mill as consisting of at least two cylindrical rolls used to shape or form metal. It describes different types of mill passes based on shape (definite, intermediate) and roll adjustment (open, closed). It provides formulas to calculate parameters for each pass like roll groove dimensions, roll gap, filled width, area reduction, and bite angle. It discusses concepts like number of passes required, spread calculation, and provides thumb rules and flow charts for roll pass design.
METAL FORMING PROCESS
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
Forging processes
Smith forging, also called flat die or open die forging, uses simple flat-faced dies and stock tooling to produce workpieces with less accuracy than impression or closed die forging. Impression die forging uses cavities in specially prepared dies to produce forged shapes in large quantities through drop, press, or machine forging. Closed die forging places a heated workpiece on a lower die while an upper die forces the metal to fill die contours. Hand forging shapes small forgings through hammering heated metal on anvils while power hammers and presses are used to forge larger parts through blows or squeezing.
Metal casting Process
Sand Casting : Sand Mould – Type of patterns - Pattern Materials – Pattern allowances –Moulding sand Properties and testing – Cores –Types and applications – Moulding machines– Types and applications; Melting furnaces : Blast and Cupola Furnaces; Principle of special casting processes : Shell - investment – Ceramic mould – Pressure die casting - Centrifugal Casting - CO2 process – Stir casting; Defects in Sand casting.
Basics of rolling process
This presentation is for academic purpose
Topics:-
1) Metal forming
2) Stress- strain analysis for forming process
3) Hot working and cold working process
4) Rolling process
5) Rolling mill arrangements
6) Rolling defects
7) Ring rolling
8) Thread rolling
9)Seamless Pipe Manufacturing By Rolling Process
10) Production of Steel Balls by Rolling Process
11) Roll-Forging
Advanced casting and welding
Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. The solidified part is known as a casting. Investment casting, also known as lost-wax casting, involves creating a wax pattern, coating it with refractory material to create a ceramic mold, melting away the wax to leave a cavity, and pouring molten metal into the mold cavity. This allows for very intricate parts to be cast with close tolerances and smooth finishes. Investment casting is commonly used for parts that are difficult to machine from difficult to machine alloys like aluminum, copper, and steels.
Roll pass design - Definitions
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Classification of Manufacturing Process
This document classifies manufacturing processes into two categories: by function of process and by quantity of production. By function, processes are classified as casting, forming, fabrication, or metal removal. Casting involves pouring molten metal into molds. Forming modifies shape through processes like rolling, forging, and extrusion. Fabrication joins metals through welding, riveting, brazing or soldering. Metal removal machines excess material via cutting tools. By quantity, production is classified as unit, batch, or mass. Unit production customizes single projects. Batch production groups components in batches. Mass production standardized large quantities on assembly lines.
Metal Forming Process
The document discusses various metal forming processes including rolling, forging, and extrusion. It describes rolling as reducing thickness of metal between opposing rolls. The main types are flat rolling and shape rolling, with hot rolling being most common. Forging involves compressing metal between dies to shape it. The main types are cold forging, hot forging, drop forging, and press forging. Extrusion uses compression to force metal through a die opening to produce parts with uniform cross-sections like rods.
Heat treatment
The document discusses heat treatment processes for metals like steel. It describes the purposes of heat treatment as relieving stress, improving machinability, and changing grain structure. Specific heat treatment processes covered include annealing, normalizing, hardening, and tempering. Annealing involves slowly heating and cooling to soften metals. Normalizing heats above critical temperature and air cools for hardness. Hardening rapidly cools from above critical temperature to form martensite for maximum hardness. Tempering then reheats hardened steel to relieve brittleness.
Rolling
The document discusses the metal forming process of rolling. It involves passing hot or cold metal through heavy rolls to reduce thickness and increase length. There are two main types - hot rolling above the metal's recrystallization temperature and cold rolling at room temperature. The grain structure changes as the metal is compressed and different rolling mill designs are used for different applications, including two-high, three-high, and cluster mills. The rolling process involves reducing thickness through multiple passes to achieve the final shape and dimensions.
Rolling (metal forming) apratim khandelwal.docx
One of the metal forming operation. Rolling- process, variables, geometry and load calculations, hot and cold rolling, rolling defects and remedies.
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The document discusses the rolling process for metal forming. Rolling is defined as passing metal between rolls to plastically deform it. There are two main types: hot rolling, which is used for initial breakdown of ingots, and cold rolling, which provides closer dimensional tolerances and better surface finishes. Rolling can produce products like plate, sheet, strip, bars, and pipes. The rolling process involves passing metal through sets of rolls under high compressive forces.
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Shell moulding is a casting process that uses a sand-resin mixture to form a disposable mould around a reusable pattern. This allows for higher production rates than sand casting while also enabling more complex part geometries. The process involves creating a metal pattern, heating it, applying a sand-resin mixture to form shell halves, joining the shells to create the mould, pouring molten metal, and removing the casting after solidification. Shell moulding provides better dimensional accuracy, higher productivity, and lower labor costs than sand casting for small to medium precision parts.
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1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
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METAL FORMING PROCESS
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
Forging processes
Smith forging, also called flat die or open die forging, uses simple flat-faced dies and stock tooling to produce workpieces with less accuracy than impression or closed die forging. Impression die forging uses cavities in specially prepared dies to produce forged shapes in large quantities through drop, press, or machine forging. Closed die forging places a heated workpiece on a lower die while an upper die forces the metal to fill die contours. Hand forging shapes small forgings through hammering heated metal on anvils while power hammers and presses are used to forge larger parts through blows or squeezing.
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Sand Casting : Sand Mould – Type of patterns - Pattern Materials – Pattern allowances –Moulding sand Properties and testing – Cores –Types and applications – Moulding machines– Types and applications; Melting furnaces : Blast and Cupola Furnaces; Principle of special casting processes : Shell - investment – Ceramic mould – Pressure die casting - Centrifugal Casting - CO2 process – Stir casting; Defects in Sand casting.
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This presentation is for academic purpose
Topics:-
1) Metal forming
2) Stress- strain analysis for forming process
3) Hot working and cold working process
4) Rolling process
5) Rolling mill arrangements
6) Rolling defects
7) Ring rolling
8) Thread rolling
9)Seamless Pipe Manufacturing By Rolling Process
10) Production of Steel Balls by Rolling Process
11) Roll-Forging
Advanced casting and welding
Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. The solidified part is known as a casting. Investment casting, also known as lost-wax casting, involves creating a wax pattern, coating it with refractory material to create a ceramic mold, melting away the wax to leave a cavity, and pouring molten metal into the mold cavity. This allows for very intricate parts to be cast with close tolerances and smooth finishes. Investment casting is commonly used for parts that are difficult to machine from difficult to machine alloys like aluminum, copper, and steels.
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This document provides definitions and concepts related to roll pass design. It discusses what roll pass designers do, such as designing new mills or extending size ranges on existing mills. Key terms defined include draft, elongation, reduction, spread, contact angle, coefficient of friction, separating force, torque, flow stress, and power curves. The document is presented by Ansar Hussain Rizvi and appears to be the first part of multiple parts on the topic of roll pass design.
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Rolling
Rolling is a metal forming process that reduces thickness or changes the cross-section of metal stock by compressive forces from rolls. There are two main types: flat rolling and shape rolling. Rolling can be done hot or cold depending on the temperature of the metal. Key rolling mill configurations include two-high, three-high, and four-high mills. Seamless pipes and tubes are formed through continuous processes without any welds, providing more reliable pressure retention than welded alternatives.
ch13 Metal Rolling pocess.pdf
This document discusses various metal forming and shaping processes, with a focus on rolling processes. It describes how rolling is used to reduce thickness and change the cross-section of metal workpieces. Rolling accounts for about 90% of all metals produced and involves passing metal between rotating rolls. Hot rolling at elevated temperatures is used to break down cast structures into wrought structures with improved properties. Cold rolling at room temperature produces parts with higher strength, hardness and surface finish. The document outlines various rolling processes like flat rolling, shape rolling, ring rolling and their associated equipment and applications in producing parts.
Rolling Process
Rolling is a metal forming process that uses rolls to reduce the thickness and increase the length of metal workpieces. It can be done hot or cold. Hot rolling occurs above the metal's recrystallization temperature and results in a more uniform structure, while cold rolling occurs at room temperature and produces closer tolerances and a better surface finish. The document defines various products of rolling like billets, blooms, slabs, plates, sheets and strips based on their dimensions. It also describes different types of rolling processes like continuous, transverse, shape, ring and thread rolling as well as the types of mills used like two-high, three-high and four-high mills.
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Rolling of Metals
- 2. Metallic materials may be formed into useful shapes in two basic ways: 1. By plastic deformation processes in which the volume and mass of metallic material are conserved and the metallic material is displaced from equilibrium or given shapes into desired shapes. 2. By material removal or machining processes in which material is removed in order to give it the required shape.
- 3. Rolling of metallic materials The process of plastically deforming metallic materials by passing it between the rolls is known as rolling. The work is subjected to high compressive stresses from squeezing action on rolls. The frictional forces between material and rolls is also responsible for drawing the metal into the rolls. A process of reduction in cross sectional area of a material by plastic deformation, by passing it through a pair of rotating (in opposite directions) rolls; is called rolling process.
- 4. The gap between the rotating rolls is less than the thickness of the entering bar (Ho) therefore a friction force is necessary to pull it through the rolls. A metal bar passing through the rotating rolls is squeezed, and it elongates while its cross sectional area decreases. The amount of deformation “R” achieved in a flat rolling operation (thickness reduction) is determined by the relationship; 𝑅 = 𝐻 − 𝐻 𝑜 𝐻 𝑜 ∗ 100 A machine used for rolling process is called rolling mill.
- 5. Hot rolling Rolling is often carried out at elevated temperatures (above the recrystallization temp) first to change coarse grained, brittle and porous ingot structure to finally rolled wrought structures with finer grains and enhanced properties.
- 7. Cold rolling If the rolling is carried out below the recrystallization temperature, it is called cold rolling process. increases the strength via strain hardening up to 20%.
- 8. Rolling mills A rolling mill consists of ○ Rolls ○ Bearings ○ A housing for the these parts ○ A drive for applying power to the rolls and controlling their speeds. Very rigid construction is needed and very large motors are required.
- 10. Types of rolling mill Rolling mill can be classified w.r.t the number and arrangement of rolls. 1. Two high mill Simplest and most common type of rolling mill is the two high mill. Rolls of equal size are rotated only in one direction. The stock is returned to the entrance of the rolls, for further reduction, by hand carrying or by means of a platform which can be raised to pass the work above the rolls.
- 12. 2. Two high reversing mill Improvement in the productivity results from the use of two high reversing mill The direction of rolls’ rotation can be reversed. The work piece can be passed and forth through the rolls by reversing the direction of rotation.
- 14. 3. Three high reversing mill Consists of three rolls. Consists of upper and lower driven rolls. The middle roll rotates by the friction. The disadvantage to this system is the work piece must be lifted and lowered using an elevator.
- 16. 4. Four high mill A small roll diameter is advantageous because area of contact is less in this case. It results in a lower force and power requirement. However, as small diameter rolls have less strength and rigidity than large rolls, small rolls need backup rolls.
- 18. Cluster rolling mill Special type of four rolling mill in which each of the two working rolls is backup by two or more of the larger backup rolls
- 20. Tandem rolling For high production, it is common to install series of rolling mills, one after the other. Each set of rolls is called a strand. Different reduction is carried out at each strand. The strip moves at different velocities at each strand and all velocities are synchronized.
- 22. Shape rolling