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Metal Manufacturing Processes and Energy Systems
Published in Swapan Kumar Dutta, Jitendra Saxena, Binoy Krishna Choudhury, Energy Efficiency and Conservation in Metal Industries, 2023
Swapan Kumar Dutta, Binoy Krishna Choudhury
In rolling mills, both hot rolling and cold rolling are used, as per requirement. In the case of hot rolling, steel is heated and passed through heavy rollers to reduce the thickness or provide the desired shape. Hot rolled steels are used primarily for grain orientation and also reduce thickness and smooth surfaces faster than cold rolling. Cold rolling mills are known for better surface finishes and packed grain orientation, which make the product more durable, but consumes more electrical energy and thermal energy is used for pickling, followed by treatment in a tandem mill. The final process involves finishing of the product, whereby annealing and surface treatment are done particularly for the products from hot rolling mills. This principle applies to all metals—both ferrous and non-ferrous.
Aluminum-Manufacturing Methods
Published in Raghu Echempati, Primer on Automotive Lightweighting Technologies, 2021
Rolling is classified into two types: by the geometry of the work and by the temperature of the work. Flat rolling and shape rolling are classified into the geometry category, and hot rolling and cold rolling are classified into the temperature category. Hot rolling is where the raw material is heated to ease deformation and is a common rolling process when large deformations are required. Cold rolling is where the workpiece is rolled under cold conditions described using the equations in Section 4.3.4.
A Morphological Process Model
Published in Leo Alting, Geoffrey Boothroyd, Manufacturing Engineering Processes, 2020
Leo Alting, Geoffrey Boothroyd
Rolling can be characterized as: mass conserving, solid state of material, me chanical primary basic process—plastic deformation. Rolling is extensively used in the manufacturing of plates, sheets, structural beams, and so on. Figure 1.7b shows the rolling of plates or sheets. An ingot is produced in casting and in several stages it is reduced in thickness, usually while hot. Since the width of the work material is kept constant, its length is increased according to the reduc tions. After the last hot-rolling stage, a final stage is carried out cold to improve surface quality and tolerances and to increase strength. In rolling, the profiles of the rolls are designed to produce the desired geometry.
Lattice severe deformation rolling (LSDR) for bimetal laminated composite preparation
Published in Materials and Manufacturing Processes, 2023
Guang Feng, Liang Wang, Haojie Gao
Bimetal laminated composite made from two dissimilar metals is capable of achieving excellent mechanical, electrical, thermal, corrosion-resistant performance and remarkable economic benefits that individual metal fails to provide.[1,2] These plates are widely used in a variety of fields such as aerospace, petrochemical, shipbuilding, nuclear energy, construction and electronic industry.[3–5] The quality of bimetal laminated composite directly affects its service period and determines whether it can be further developed for high-end applications. Many techniques have been explored to prepare such plates, including rolling, explosive bonding, diffusion bonding, extrusion bonding, hot-press bonding, friction-stir welding and cast-roll bonding.[6–8] In particular, rolling is nearly the most commonly used technique in comparison with others and has attracted extensive attention, as it is high-efficiency, low-cost, less pollution and owns the potential capability of mass production.
An investigation of hybrid models FEA coupled with AHP-ELECTRE, RSM-GA, and ANN-GA into the process parameter optimization of high-quality deep-drawn cylindrical copper cups
Published in Mechanics Based Design of Structures and Machines, 2022
S. P. Sundar Singh Sivam, R. Rajendran, N. Harshavardhana
The design of multi-stage forming processes for structural parts is based on the engineer’s current expertise and virtual experiments like FEA to reduce the trial run cost. Therefore, the design quality is compromised, and it takes a longer time for virtual experiment analysis to reduce the cost of determining optimum parameter settings. Rolling/unidirectional rolling (UDR) is one of the conventional thermo-mechanical processes widely used in industries, where sheet metal is passed between two rollers that rotate in opposite directions. Rotation of rollers applies a load on the material, causing deformation that reduces sheet thickness. Rolling enhances material properties like hardness, tensile strength, proof strength, and toughness, whereas ductility decreases during the rolling process. The preferred orientation of the sheet metal grains affects the rolled products’ physical and mechanical properties—the rolled sample results in elongated grains along the rolling direction, which increases anisotropy. The planar anisotropy R relates to the tendency of the sheet to form ears in deep-drawn cups. If R is positive, the ear forms at 0° and 90°; if R is negative, the ear forms at 45° to the rolling direction. For copper sheet metal, rolling results in an increase in anisotropy, and it affects deep-drawing operations.
Monitoring and root-cause diagnostics of high-dimensional data streams
Published in Journal of Quality Technology, 2021
Samaneh Ebrahimi, Chitta Ranjan, Kamran Paynabar
Rolling is a metal-forming process in which metal billets are passed through a sequence of rollers to reduce their thickness and create uniform sheets. Early detection of anomalies at different stages of the process is necessary to avoid damage to the final product. However, as rolling is a high-speed manufacturing process, monitoring and anomaly detection is particularly challenging. To monitor the quality of billets and detect anomalies on their surfaces, an image sensing system is set up to take snapshots of the surface at short time intervals. As each image can be seen as a high-dimensional correlated observation, we show that the PCA-based method can effectively detect anomalies and damages imprinted on a steel bar using the image data. The data set we consider here includes images of size 128 × 512 pixels of the surface of rolled bars collected by a high-speed camera (Yan, Paynabar, and Shi (2017)). Of the 100 images, the first 50 images are in-control. One example of the image of rolling data for in-control vs out-of-control process is shown in Figure 15. Note that, in the out-of-control image, there exists a vertical curved line defect on the left side of the image.