Results of experiments investigating the rolling of hollows of pure lead and of a lead— alloy using a laboratory mill, and of hollows of various grades and wall thicknesses of steel using a commercial rolling mill, are presented and discussed. Both mills employ oblique rolls which have clearly defined entry, diameter reduction, and exit zones, and are instrumented for the recording of all relevant forces and moments. Results show a strong dependence of the roll forces on the degree of elongation—the ration of the cross-sectional area of the billet before and after rolling—which affords a convenient means of regulating the process. It is shown that the conditions leading to minimum roll force are not recommended for some grades of steel, owing to the essentially tensile stress state arising in the material between the rolls and the resultant liability to cracking. Based on the findings of the investigation, two improvements were suggested for the process: (i) a modified form of plug was introduce, to alter the pattern of straining of the material being rolled and promote the development of an essentially compressive stress state and (ii) the rolls were aligned with their axes converging, to reduce the degree of twisting imparted to the billet, which latter has been shown to result in the development of tensile stresses and is the cause of numerous defects in the rolling of steel of reduced capacity for plastic strain. By this means it has been possible to roll at much greater degrees of elongation, and at the same time secure improved surface properties in the product and a reduction in the number of rejects.
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