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Shaping Metals With Mill Rolls

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Shaping Metals With Mill Rolls 2015-10-01

Mill rolls are carefully constructed tubular metal components used to feed and shape other metals. By placing one above another and counter rotating them they allow metal tubes, bars, sheets and wire to be fed through, molding the product as it goes. Historically this type of machinery was used in steel mills to shape the forged steel into forms which can be sold for particular uses. These machines are now used in light and heavy industrial processes. These range from the large scale process of manufacturing parts for aircraft and space vehicles to the small scale manufacture of jewelers. Regardless of the scale, a high level of accuracy is crucial.

When mill rolls(reverse cold rollingmill)are manufactured they need to conform to the exact specifications required by the process they will be used for. Amongst the tests that take place on mill rolls as they are manufactured, ultrasound is used to check for any flaws which may exist in the rolls and the tensile strength and hardness is extensively tested to provide a guarantee of the stresses they can withstand during operation.

There are two main categories for processes involving mill rolls(cold rolling mill manufacturers). Hot rolling is normally used at an early stage of metal production which shapes heated metal into general forms which can then be used in cold rolling mills. Cold rolling allows metal to be very accurately formed into shapes which can then be used for specific tasks. Cold rolling mills can be found in foundries but they are also used in other factories where there is a need to shape metals into specific forms before it is made into an end product.

Foundries normally provide their metals in the following basic forms:

Sheet

This form is used in construction, transport and aerospace. After being further refined, these sheets could be used anything from aircraft components to joists for construction.

Plate

This form is generally thinner than the sheet form but used in similar applications. Most notably this form is extensively used in the automotive industry.

Foil

This form is extremely thin and flexible making it ideal for use in packaging. The electronics sector also uses this form for shielding. It is also used in printing for foil stamping.

Foundries and other factories then take these general forms and convert them into sectional forms. The reason these processes take place after the metal is cast as opposed to casting the metal straight into the final form is the existence of 'blow holes'. These gases trapped in steel and iron ingots make their properties inconsistent. As they normally occur at the head of the ingot this section is removed before undergoing hot rolling. This ensures a level of consistency throughout the metal once it has cooled(6 hi cold rolling mill).

Mill rolls are also incorporated into more complex systems that also bend and cut the metal. This is known as roll forming. As metal is fed into these machines it passes through several stages of processing. The resulting product is rolled, bent and cut to specification.