5. Metal Rolling

Rolled metallic products find wide applications in building construction, the automotive industry, the aerospace industry, the defense sector, and the like. This chapter first introduces metal rolling, including the role of friction in the rolling operation; here, various rolled products of different geometries produced by flat rolling and shape rolling are also illustrated. Rolling mill practices are discussed with reference to 2-high single-pass mill, 2-high reversing mill, 3-high rolling mill, 4-high rolling mill, cluster rolling mill, and tandem rolling mill; here, the advantage of small-sized rolls in power saving is scientifically justified. Engineering analysis of flat rolling is presented with reference to forward slip, reduction, rolling force, rolling torque, rolling power, feasibility of rolling, and the number of passes. Shape rolling is also analyzed, including roll pass design for bar mills. This chapter contains 21 worked numerical examples, 9 diagrams, 23 formulae, 8 problems, and 10 MCQs with their answers provided at the end of the book.