Metal rolling is one of many methods of forming ferrous and nonferrous metals and alloys. Raw metals are produced in large pieces called ingots, which are rolled into various thinner pieces through hot and cold rolling processes.
Rolling metal changes its shape and physical properties so that it can be made into products ranging from beams and rails to sheets or plates.
Here, we’ll look at the basics of metal rolling, the benefits it imparts to metal products and components, and some examples of products made with rolled metal.
Metal Rolling Explained
Metal rolling forms large pieces of metal and alloys by compression. The metal is fed between sets of paired upper and lower rollers, which apply downward and upper force on the material. Rollers are mounted on a stand that supports the metal as the rollers push it through and out the other side. Different configurations of rollers may be used to achieve different results but in all cases, the resulting metal piece becomes thinner, wider, and longer. Multiple passes through the machine may be used to achieve desired properties and dimensions.
Two general types of metal rolling are hot rolling and cold rolling. Hot and cold rolled metal materials have different levels of hardness and other properties, which makes them suitable for different applications.
In hot rolling, metal ingots are heated to above their recrystallization temperature and fed through rollers. This process creates materials including I-beams, rails, billets, bars, and other components with limited strain hardening. Hot rolling is generally done in steel mills and specialized, large-scale facilities.
Cold rolling is done at room temperature or below the material’s recrystallization temperature. As the metal is rolled, it becomes strain-hardened, which makes it stronger, harder, and more brittle. Materials like strips with specific profiles, flat sheets or plates, and foils are often made with cold rolling. Once cold rolled, the metal can be finished with annealing or other treatments, or fabricated into a variety of products by further rolling to create a desired profile. Cold rolled metal is also used in stamping, bending, welding, laser cutting, and other operations.
Metal Rolling Products Benefits
Rolling offers several benefits compared to other methods of metalworking like extrusion, press braking, or bending:
- Production efficiency: Metal rolling is highly efficient and repeatable, facilitating mass production of uniform components at high speeds.
- Versatility: Metal rolling is used to create a wide range of flat and shaped materials including sheet metal, structural steel components, and highly cosmetic finished pieces.
- Enhanced material properties: Metal rolling can be used to alter material properties including hardness and strength.
- Cost-Effectiveness: Rolling is well-suited to high-volume production. Rolling mills can process 30-100 feet per minute. Tool wear is usually lower in rolling processes, reducing tooling maintenance and replacement costs over time.
- Customizability: Rolling can be used to form complex profiles that meet your exact specifications and tolerances.
- Recyclability: Depending on the type of metal used, many products made through rolling can often be recycled. This helps make manufacturing efforts more sustainable and eco-friendly.
Metal Rolling Products
Many types of products and materials are fabricated with metal rolling processes. Some examples include:
- Structural components: Steel, aluminum, and other metals can be rolled to form parts like angle and channel stock, I-beams, bars, and plates.
- Piping and tubing: Rolled steel is used in manufacturing pipes and tubes of various sizes for the oil and gas, automotive, and construction industries.
- Rails and bar stock: These are made in varying lengths with metal rolling. Depending on the application, hot or cold rolling may be a preferred method for creating these components.
- Strips, sheets, plates, and foils: These are commonly formed with cold rolling processes, and then used to manufacture parts and components for industries like automotive, aerospace, construction, electrical, and appliances.
- Finished Products: Products including shelving, furniture, equipment and appliance cabinets, door panels, and many other finished goods are constructed with rolled metal materials.
Metal Rolling Products from Premier Products of Racine
At Premier Products of Racine, we operate nine roll forming mills and can manufacture parts from 0.010–3/16 inches thick, up to 20 inches wide, and virtually unlimited length. Our material options include, but are not limited to, aluminum and aluminized steel, stainless steel, and titanium. We also offer finishing and in-process capabilities.
For more information, contact us to speak with one of our experts, or request a quote to get started on a custom solution.
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