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Introduction to Manufacturing Processes (College of Engineering Arkansas State University)

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ME 4563
Introduction to Manufacturing
Processes
Fall 2005
College of Engineering
Arkansas State University

(10.06.2005)
ME 4563 Fall ’05

Dr. S. Haran

1

Bulk Deformation

ME 4563 Fall ’05

Dr. S. Haran

2

1

Rolling

ME 4563 Fall ’05

Dr. S. Haran

3

What is Rolling ?
A process of reducing the thickness
(or changing the cross-section of long
work-piece
By applying compressive forces
through a set of rolls

ME 4563 Fall ’05

Dr. S. Haran

4

2

Some Rolling Facts …
Process developed in late 1500’s
1500’
Accounts for over 90% of all metals produced by
metalworking process by volume
Various cross-sectional shapes are achieved
crossMajor metal that is rolled is Steel, followed by
Aluminum
Can be carried out Hot or Cold
Machinery for Rolling (called “Mills”) have a variety
Mills”
of configurations
Several parameters to be considered in practice, in
the design and selection of machines
ME 4563 Fall ’05 Dr. S. Haran

5

Rolling

Schematic outline of
various flat- and
flatshape-rolling
shapeprocesses. Source:
Source:
American Iron and
Steel Institute.
ME 4563 Fall ’05

Dr. S. Haran

6

3

Rolling – Products include
• Plates
• Sheets
• Rods
• Foil
• Pipes and tubes
• Shape rolled products such as channel, I, L, T,
etc.
• Other structural shapes also made

ME 4563 Fall ’05

Dr. S. Haran

7

Rolling
Major Metals that are Rolled include:

•
•
•
•

Steel
Aluminum
Others like Copper, Brass, Lead, etc.

Special applications – Titanium and
other exotic metals

ME 4563 Fall ’05

Dr. S. Haran

8

4

Rolling
Direct Applications where rolled
plates/sheets are used

•
•
•
•
•
•

Indirect Applications where rolled plates/sheets
are used after further
processing
• Locomotives

Aircraft bodies

•
•
•

Reactor vessel
walls
Boilers
Bridges
Tanks, etc.

ME 4563 Fall ’05

Automobiles

•
•

Ship hulls

Office equipment,

Appliances
Food/Beverage
containers
Construction, etc. etc.

Dr. S. Haran

9

Rolling
Classifications of Rolling Material
Rolling material is separated into classifications based
on the material's cross-sectional dimensions
cross-

Bloom
Billet
Slab
Plate

Cross-Section
CrossSquare

Thickness
> 6 in.

Width
< 2 * thickness

Square or Circular
Rectangular

< 6 in.

< 2 * thickness
> 2 * thickness

0.25 in. < x < 12 in.
0.008 in. < x < 0.25 in.

Sheets
Foil

ME 4563 Fall ’05

<0.008 in.

Dr. S. Haran

10

5

Rolling
What kind of Thickness are we talking about ?
When Manufactured:
Rolled Plates: normally > 6mm
Rolled Sheets: normally < 6mm
And the range of appl...
1
1
ME 4563 Fall ’05 Dr. S. Haran
(10.06.2005)
(10.06.2005)
(10.06.2005)
Fall 2005
College of Engineering
Arkansas State University
Fall 2005
Fall 2005
College of Engineering
College of Engineering
Arkansas State University
Arkansas State University
Introduction to Manufacturing
Processes
Introduction to Manufacturing
Introduction to Manufacturing
Processes
Processes
ME 4563
ME 4563
ME 4563
2
ME 4563 Fall ’05 Dr. S. Haran
Bulk Deformation
Bulk Deformation
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