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    Cold Rolling

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    poom2007
    The document discusses the process of cold rolling and recrystallization annealing of steel strips. It begins with an overview of how cold rolling is used to attain the required thickness, mechanical properties, and surface finish of steel strips by controlling the microstructure. It then describes the various stages of cold rolling including pickling to remove scale, cold rolling using multi-stand mills, and recrystallization annealing to relieve work hardening and develop suitable microstructures and properties for forming. Key aspects covered are the pickling process to remove scale, parameters of cold rolling like rolling forces and work hardening, and recrystallization annealing to produce a new optimized grain structure.

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    Cold Rolling

    Uploaded by

    poom2007
    263 views8 pages
    The document discusses the process of cold rolling and recrystallization annealing of steel strips. It begins with an overview of how cold rolling is used to attain the required thickness, mechanical properties, and surface finish of steel strips by controlling the microstructure. It then describes the various stages of cold rolling including pickling to remove scale, cold rolling using multi-stand mills, and recrystallization annealing to relieve work hardening and develop suitable microstructures and properties for forming. Key aspects covered are the pickling process to remove scale, parameters of cold rolling like rolling forces and work hardening, and recrystallization annealing to produce a new optimized grain structure.

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    The document discusses the process of cold rolling and recrystallization annealing of steel strips. It begins with an overview of how cold rolling is used to attain the required thickness, mechanical properties, and surface finish of steel strips by controlling the microstructure. It then describes the various stages of cold rolling including pickling to remove scale, cold rolling using multi-stand mills, and recrystallization annealing to relieve work hardening and develop suitable microstructures and properties for forming. Key aspects covered are the pickling process to remove scale, parameters of cold rolling like rolling forces and work hardening, and recrystallization annealing to produce a new optimized grain structure.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    263 views8 pages

    Cold Rolling

    Uploaded by

    poom2007
    The document discusses the process of cold rolling and recrystallization annealing of steel strips. It begins with an overview of how cold rolling is used to attain the required thickness, mechanical properties, and surface finish of steel strips by controlling the microstructure. It then describes the various stages of cold rolling including pickling to remove scale, cold rolling using multi-stand mills, and recrystallization annealing to relieve work hardening and develop suitable microstructures and properties for forming. Key aspects covered are the pickling process to remove scale, parameters of cold rolling like rolling forces and work hardening, and recrystallization annealing to produce a new optimized grain structure.

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    of 8

    Institute of Ferrous Metallurgy

    RWTH Aachen

    10.1 Cold rolling and recrystallization annealing


    Introduction
    Pickling & Cold rolling
    Recrystallization annealing & skin pass
    Cold rolled steels for automotive applications

    Topic 10:
    Metallurgical aspects during cold strip processing
    Dipl.-Ing. Friedrich Luther

    Outline

    10.1 Cold rolling and recrystallization annealing


    Introduction
    Pickling & Cold rolling
    Recrystallization annealing & skin pass
    Cold rolled steels for automotive applications

    Cold rolling mills are supplied with hot rolled coils of various
    grades, depending on the final characteristics to be optained.
    Cold rolling enables:
    Attainment of the required final thickness which is not
    possible to obtain by hot rolling, due to excessive cooling.
    Achievement of the mechanical properties (drawability,
    blankability, strength), by control of the microstructure.
    Definition of the final surface appearance and properties
    (aptitude for surface treatment, brightness, drawability), by
    eliminating oxidized layers and inducing a controlled
    roughness.
    Attainment of the required flatness.

    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Outline

    Function of cold rolling

    Thin strip is the general term used to desribe the coiled sheet
    material used in the automotive industry (bodywork and
    structural parts), domestic appliances, metallic furniture, the
    building industry (sections, walling, etc.), and even in small
    electric motors (low silicon steels).
    These products are generally delivered to the customer in
    thicknesses from 0.5 to 3 mm and in widths up to 1900 mm.
    They are delivered either bare, i.e. protected only by a film of
    oil, or coated.
    The starting material for cold rolling is a coil of hot rolled strip,
    of thickness between 2 and 6 mm.
    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Thin strip

    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Applications for thin strip

    continuous
    casting

    hot rolling

    pickling

    cold rolling

    batch
    annealing

    10.1 Cold rolling and recrystallization annealing


    Introduction
    Pickling & Cold rolling
    Recrystallization annealing & skin pass
    Cold rolled steels for automotive applications

    continuous
    annealing +tr

    temper
    rolling (tr)
    elektrolytic
    strip coating

    hot dip metal


    coating +tr

    plastic
    coating
    arrangement +
    dispatch

    Outline

    Processing of thin strip

    The hot rolled strip is covered with scale, which is incompatible


    with subsequent cold rolling, since it would behave as a
    foreign body between the steel and the rolls.
    The rolling force would mark the strip, or even perforate it, and
    excessive surface roughness would cause a high and irregular
    friction coefficient.
    The scale must therefore be removed, and this is done by
    pickling in an acid bath.

    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    The typical architecture of a pickling plant includes:


    Entry section
    - uncoilers
    - flash welding station
    - strip accumulator/ looping pit
    Central pickling section
    - oxide breaker
    - tension levelers
    - acid tanks
    Exit section
    - exit accumulator
    - edge trimming shear
    - inspection station
    - oiling apparatus
    - coilers
    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Pickling

    Pickling plant layout

    In cold rolling, the pickled strip is fed between very hard rolls,
    with both high roll forces and high tension.

    Pickling line (Neuwied)


    total length
    thickness (hot strip)
    width (hot strip)
    speed (max.)
    etchant
    concentration
    temperature
    input power

    Pickling line (Andernach)


    190 m
    1.5-5.0 m
    610-1630 mm

    entry section
    270 m/min

    pickling section
    160 m/min
    HCl
    20-120 g HCl/l
    65-75 C
    3000 kVA

    total length
    thickness (hot strip)
    width (hot strip)
    speed (max.)
    etchant
    concentration
    temperature
    input power

    207 m
    1.5-3.0 m
    600-1250 mm
    entry section
    610 m/min

    pickling section
    245 m/min
    H2SO4
    15-25 %
    100-105 C
    4800 kVA

    This is performed either in a


    single reversing stand, equipped with an uncoiler and a
    coiler, by making several passes in alternate directions, or
    more often,
    in continuous tandem mills, where the strip is engaged in
    several stands simultaneously, enabling high tension forces to
    be applied. The productivity of continuous mills is much higher
    than for reversing mills.

    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Pickling line

    Cold rolling

    Source: http://www.thyssenkrupp.com/

    Cold rolling mill

    Continuous tandem mill

    The rolling forces are very high, typically 700 to 1200 t/m of width. A mill
    stand is composed of a housing with ring-shaped columns, which transmit
    the rolling load to the rolls via chucks. In modern mills, screwdown is
    obtained with the aid of hydraulic pistons with precise position control (1 to
    2 m). The work rolls must have relatively small diameters and therefore
    tend to bend. This is prevented by the use of large diameter back-up rolls.
    Two types of stand are commonly encountered:
    "Four-high" stands with two 500-600 mm diameter work rolls, which are
    generally driven, supported by two 1400 to 1500 mm diameter back-up
    rolls.
    "Six-high stands, in which intermediate shift rolls are inserted
    between the 300-400 mm diameter work rolls and the back-up rolls,
    enabling the mill to be adapted to the strip width. This configuration
    allows the use of smaller diameter work rolls, and makes it possible to
    change the load distribution on the strip, depending on the position of the
    ends of the intermediate rolls.
    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Mill stands

    In each stand n, the thickness is reduced from the entry value


    en-1 to en at the exit. The reduction in thickness and increase in
    length occur without significant lateral spread.
    If vn-1 is the speed of the strip at the entry to stand n, and vn
    that at the exit, conservation of mass flowrate leads to the
    following relation:

    vn-1 en-1 = vn en
    The strip accelerates as it moves through the mill!
    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Principle

    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Cross section of six-high


    and four-high stands

    The rolling mill must transmit a very high pressure to the strip
    via the rolls. This pressure depends on the flow stress of the
    strip, the front and back tension forces, and the friction
    between the rolls and the strip.
    The rolling force per unit width is the integral of the pressure
    along the contact arc, and will therefore increase with the
    length of the roll bite.
    The length of the roll bite increases with the diameter of the
    work rolls, the strip thickness, the reduction ratio, and the
    extent of roll flattening, which itself depends on the roll
    pressure.
    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Roll bite

    Cold working is accompanied by an increase in the apparent


    yield stress, or flow stress, which therefore rises as the metal
    moves through the roll gap. In parallel, the ductility decreases,
    and the metal tends to become brittle.
    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Variation of rolling pressure and strip flow


    stress with position in the roll bite

    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Variation of metal flow stress due to cold


    work for two steel grades

    In the roll bite, the sheet undergoes cold working, involving the
    creation and displacement of dislocations on preferred crystal
    planes.

    UTS, MPa

    The microstructure is modified by elongation and rotation of


    the grains, which become aligned along the rolling direction,
    with the formation of a substructure of dislocation cells and
    deformation bands.

    ferritic
    ferritic-bainitic
    austenitic
    pearlitic

    The hard second phase particles (cementite and inclusions),


    are unable to deform significantly and break up into strings
    aligned in the rolling direction and separated by microcracks.
    cold reduction, %
    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Structure development in roll bite

    Work hardening of
    different microstructures

    After cold rolling the strain hardened strip is not suitable for
    forming processes.
    10.1 Cold rolling and recrystallization annealing
    Introduction
    Pickling & Cold rolling
    Recrystallization annealing & skin pass
    Cold rolled steels for automotive applications

    The purpose of recrystallization annealing is to produce a new


    grain structure with an optimum grain size, in order to control
    the yield strength, and in the case of steels for drawing
    applications, to develop favorable crystallographic textures
    corresponding to a high strain ratio r.

    Source: Branger, G et al.: The Book of Steel, Lavoisier Publishing, Lavoisier, 1996.

    Outline

    Recrystallization annealing

    The static recrystallization after heavy cold rolling reduction is


    a thermally activated process, which can be characterized by
    an activation energy, usually in the order of magnitude of 125
    kJ/mole for rimmed steels, 160 kJ/mole for aluminium killed
    steels and 350 kJ/mole for microalloyed steels including IF
    steels.
    Activation energies <200 kJ/mole in recrystallization can be
    connected with the self-diffusion of iron, while the high
    activation energies of microalloyed steels indicate
    precipitation, possibly also particle growth as the
    recrystallization controlling factor.

    Source: A.R. Marder, Progress in Materials Science 45 (2000) 191-271.

    Various metallurgical changes take place during the annealing


    process including
    recovery,
    recrystallization and
    grain growth as well as the
    formation, growth or dissolution of precipitates or
    transformation products.
    It is the complex controlled interaction of these changes which
    enables the wide range of combinations of properties to be
    obtained depending on the composition of the steel and the
    processing.
    Source: A.R. Marder, Progress in Materials Science 45 (2000) 191-271.

    Recrystallization

    Metallurgical effects during annealing

    batch annealing process

    1
    5

    2
    6

    3
    7

    Cold rolling mill

    continuous annealing line

    1)
    2)
    3)
    4)

    batch-type annealing furnace


    cooling
    temper rolling mill
    recoiling, trimming, inspection, oiling

    5)
    6)
    7)
    8)
    9)

    cleaning
    annealing
    cooling
    temper milling
    trimming, inspection, oiling

    Source: A.R. Marder, Progress in Materials Science 45 (2000) 191-271.

    Typical recrystallization
    curves for IF steels

    Traditionally, annealing has been usually carried out by batch


    annealing in which several tightly wound coils are stacked on
    top of each other. They are enclosed by a furnace cover which
    contains a protective gas, nitrogen with 5% hydrogen or 100%
    hydrogen, which is circulated to promote heat transfer from the
    cover and into the steel.
    The steel is slowly heated to a temperature between 600 and
    700C, the lower temperature given by the required
    recrystallization, the upper by the danger of sticking. The
    improved heat transfer characteristics of hydrogen in
    combination with improved fans and cooling devices are used
    in high convection batch annealing, leading to shorter
    annealing cycles and more uniform temperature distributions.
    Source: A.R. Marder, Progress in Materials Science 45 (2000) 191-271.

    Batch annealing

    Batch annealing and


    continuous annealing process

    The other commonly used method of annealing is continuous


    annealing, with a total cycle time of up to a few minutes. This
    is carried out either in continuous annealing and processing
    lines for uncoated strip or in hot-dip galvanizing lines.
    The main difference is in the overaging part of the annealing
    cycle. The main problem of continuous annealing is the high
    cooling rate after soaking; by this carbon is supersaturated and
    needs to be precipitated in order to control the aging properties
    of the strip.
    The precipitation behavior is dependent on the cooling and
    overaging conditions applied during continuous annealing
    treatment,
    Source: A.R. Marder, Progress in Materials Science 45 (2000) 191-271.

    Continuous annealing

    batch-type annealing furnace

    continuous annealing line


    700-850C

    ca. 10K/h

    <150C

    ca. 50K/h

    10-100K/s

    temperature, C

    temperature, C

    <720C

    >10 K/s
    300-400C
    1000K/s
    <40C

    <40C
    heating

    soaking

    1. cooling

    2. cooling

    heating soaking 1. cooling 2. cooling


    overaging
    time, <10min

    time, up to 4 days

    T-t-curve, batch annealing


    and continuous annealing

    Metallurgical effects
    during continuous annealing

    Batch annealing:
    Low investment costs
    Use of aluminum-killed steels which do not require vacuum
    refining or stabilizing with titanium or niobium.
    Reliable production of standard grades with reproducible
    mechanical properties and good surface cleanness.
    Continuous annealing:
    Drastic reduction of stocks and lead times.
    Production of high strength steels and "super-drawable"
    grades with small scatter in mechanical properties.
    The production of strip with very high surface cleanness.

    Influence of different annealing cycles


    on cementite distribution

    Steel group
    Unalloyed deep drawing
    steel, batch annealed
    Microalloyed deep
    drawing steel
    Unalloyed d eep drawing
    steel, continuously
    annealed
    Microalloyed. steel for
    cold deformation
    Dual phase steel
    TRIP steel
    QT-steel,
    soft annealed

    Metallographic cold rolled


    microstructure
    ferrite,
    pancake
    ferrite,
    equiaxed

    Standard
    DIN EN 10130

    DIN EN 10130

    Parameter of
    microstructure
    grain size number 7 -8
    extension grade 4:1

    grain size number 8 -9

    ferrite,
    equiaxed, fine grained

    DIN EN 10149

    grain size number 10

    ferrite + martensite

    SEW 097

    5-15 vol% martensite

    ferrite + bainite +
    retained austenite
    ferrite + pearlite,
    spheroidised

    --DIN EN 10083

    40 vol% bainite,
    10 vol% retained austenite
    carbide formation
    (SEP 1520)

    Examples of typical microstructures


    in cold strip

    Comparison between batch and


    continuous annealing

    In steels containing interstitial elements (carbon and nitrogen),


    the metal shows a yield point elongation effect after annealing,
    due to initial pinning of residual dislocations by these species.
    The purpose of skin-pass rolling is to introduce a sufficient
    amount of strain to increase the dislocation density and
    eliminate the yield point elongation, conferring stable
    mechanical properties.
    By appropriately texturing the rolls, it also ensures the
    roughness required for the intended application and improves
    the flatness.

    Skin pass/ temper rolling

    cold reduction, %

    2-stand temper rolling mill

    Influence of cold reduction


    during temper rolling

    10.1 Cold rolling and recrystallization annealing


    Introduction
    Pickling & Cold rolling
    Recrystallization annealing & skin pass
    Cold rolled steels for automotive applications

    Outline

    Cold rolled standard steel


    for autobody sheets (compositions)

    Cold rolled standard steel


    for autobody sheets (properties)

    Cold rolled special steel


    for autobody sheets (properties)

    Cold rolled special steel


    for autobody sheets (compositions)

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