Welcome back to The Mechanical post ! Today in this article we will see:
What is Rolling process ? its working, advantages, disadvantages and applications.
What is Rolling process ?
This process mainly deals with the cross-section of the metal which is to be rolled. The main aim of using this process, is to reduce the thickness of the workpiece by increasing its length. However, in this process the breadth or width of the strip/sheet remains the same.
When a metal is loaded beyond its elastic limit it deforms permanently. This property of metals is termed as ‘Plasticity’
- Hot rolled process
- Cold rolled process
Hot rolling process
Advantages of hot rolling process
- Due to heating of metal, it becomes soft and thus easier to be rolled.
- Less effort is required to give the metal workpiece the desired form.
- Application of heat reduces the strain in the material.
limitations of hot rolling process
- Due to less force applied the surface finish of the workpiece suffers.
- Heating element is required for heating of metals.
- Cost of operation is high as compared to cold rolling process.
Cold rolling process
Advantages of Cold rolling process
- Superior surface finish.
- Inexpensive as compared to hot rolling process.
limitations of Cold rolling process
- High amount of force is required to push the metal strip through the rollers.
- Cold rolling process can induce internal stresses in the material.
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Types of Rolling process
- Transverse rolling
- Continuous rolling
- Section or shape rolling
- Ring rolling
- Thread rolling
Transverse rolling is a type of rolling process which is used to make tapered shafts, leaf spring etc.
Section or shape
|Tosaka / CC BY|
Types of defects in rolling
- Wavy structure
- Edge cracks
Due to improper force applied or due to improper arrangement of the rollers, the metal sheet or strip isn’t compressed successfully resulting in wavy shaped workpiece instead of a smooth one.
Advantages of rolling process
- It is a fast and less time consuming manufacturing process.
- Suitable for mass production.
- Has high efficiency.
- Complex cross-section profiles can be produced easily.
- Rolling processes can be designed to produce workpieces with very close tolerances.
Limitations of rolling process
- The initial cost / investment is high.
- The rolled workpiece’s surface finish is not very good, thus it is needed to be subjected to further finishing processes.
- It is ideal for mass production only.
Applications of Rolling process
The rolling process finds many industrial applications like:
- By using rolling process, shafts, rods, tubes, axles, spindle etc can be manufactured.
- Rolling is used to manufacture workpiece with desired cross-section.
- Rolling is used to produce gears on the gear blank.
- By making use of Thread rolling threaded parts, bolts, screws, etc. are manufactured.
- Bearings, Turbines rings are manufactured by ring rolling process.
- The rolling process of manufacturing finds many applications in the automotive industry.
- Metal sheets, plates, panels etc are manufactured by rolling process.
That’s an overview on the rolling process. If you like this post or have any suggestions do let us know in the comments we would love to hear it from you.
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