Rolling Process in Manufacturing
The world is changing quickly and getting bigger at a rate that is almost exponential. This fast-paced world has also made more people want manufactured products. Companies in the auto industry have seen their revenues expand by a factor of five or more in the last two decades. This demand has prompted us to embrace innovative methods for quick, easy, and affordable manufacturing. Rolling is one of these techniques and is utilised extensively in numerous industries.
Principle of Rolling Process
In the rolling process, two rollers push against each other and squeeze a piece of metal in between them. The main thing to keep in mind is that the distance between the rollers should be lesser than the initial thickness of the metal (Ingot). When the metal goes through the space between the Rollers, this will help it move forward. The rolling process makes metal thinner and longer and wider while keeping its overall volume the same.
Types of Rolling Mill
Rolling mills have equipment that turns the roller and helps start and finish the rolling process. It has one or more roller stands, a reducing gear, the main drive motor, a stand pinion, a flywheel, and a coupling gear between the units. These parts worked well together to help finish the rolling process.
Rolling mills are put into different groups based on how many rolls are in a stand and how they are set up.
Two High Rolling Mills
It has two tall stands and two rolls that are placed one on top of the other. In this type of Rolling Mill, the Rollers move in opposite directions, and their direction changes after each pass of metal. The Metal (Ingot) is passed over and over again, and it takes about 25–30 passes to turn Ingot into Bloom.
Three High Rolling Mills
It has three high stands and three Rollers, all of which are on the same vertical plane. The top and bottom rollers move in the same direction, while the middle roller moves in the opposite direction. In this type of rolling mill, the drive direction doesn't change between passes. Compared to the two-high rolling mill, it is more efficient and easier to use.
Four High Rolling Mills
It has two backup rollers and two working rollers stacked one on top of the other in the same vertical plane. The backup rollers always have a larger diameter than the working rollers. Most of the time, these rollers are used for Sheet Rolling. Small-diameter working rollers are used to reduce the amount of power needed, but this makes it more likely that the working rollers will bend, which leads to sheets being compressed in different ways. This is why we use Backup rollers to keep Working rollers from getting bent.
Cluster Rolling Mill
It is made up of two working rollers as well as two or more backup rollers. The quantity of support that is required for working determines the number of Backup rollers that are needed. The majority of their applications involve cold rolling processes.
Planetary Rolling Mill
The Planetary Mill is a mill with a medium output that rolls steel strips. Its output is lower than that of continuous mills with a large number of stands, but it is higher than that of reversing two-high or three-high mills. All types of metals can be rolled with this mill, although the ones with the lowest ductility are the ones that benefit the most from its use.
Tandem or Continuous Mill
In rolling mills that operate in a continuous group, vibrations are transmitted from one stand to the next by the bar, strip, etc. As a result, the excitation of vibrations in one stand might create vibrations in all of the other rolling mills that are part of the same continuous group.
Types of Rolling Process
The rolling of metal can be done in a variety of ways, and these methods are utilised differently depending on the application. The quantity of product, the condition of manufacturing, and other factors all play a role in the decision-making process when choosing the type of rolling process to use. Rolling Process can be broken down into the following categories according to these requirements:
Thread and Gear Rolling:
Thread and gear rolling: By rolling over Metal Input with Dies, thread is formed. This method cuts threads and gears.
Shape Rolling:
This rolling process forms metals (Workpieces). Rolls I-Section, H-Section, etc. Metal is shaped with rollers. The ultimate shape determines roller combinations and shapes. It's precise.
Ring-rolling:
This Rolling has a Drive Roller, an Idler roller, and an Axial roller. Drive and Idler rollers revolve in the same direction. Idler rollers rotate inside metal, and as hole diameter increases, they move closer together.
Tube Piercing:
Two Rollers plus a stationary mandrel make up this rolling procedure. Metal slides towards the mandrel as rollers turn it. The mandrel's compressive tension causes Metal to move toward it, creating a hole. It makes thick-walled seamless hollow tubes.
Skew Rolling:
Ball bearings are rolled this way. Metal is run through a specific roller to make bearing balls. It's an easy way to mass-produce ball bearings.
Transverse Rolling:
This rolling creates a tapered surface. Metal is transferred between two rotating rollers. Rollers have a tapered section that causes surface tapering. It is utilised during the production of tapered shafts, leaf springs, etc.
Roll-bending:
This rolling method bends metal. When metal passes through the rollers, it curves along their direction. Roll bending boosts a vehicle's aerodynamic efficiency by bending chassis tubing.
Flat-rolled:
It's the basic rolling method used to make bloom, slab, etc. from ingots. Input flat metal is output with reduced thickness. This technique of rolling reduces metal thickness only at the output.
Controlled Rolling:
As the name suggests, it is one type of rolling process that is done in a controlled way. Industries use it frequently. In steel industries, grain size is predetermined, and rolling is controlled to produce the same grain size.
At Bellclife engineering we will be happy to assist you if you require additional information about your rolling mill or the rolling project. You can contact us by calling, sending an email, or using the inquiry form.
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