Bangladesh University of Engineering and Technology

Exp. No: 04
Name of Exp.: Effect of Deformation Behaviour on Microstructure and Mechanical Properties of
Plain Carbon Steel

Submitted By
Md. Kamal Uddin
S.ID. 1811005
Course No: MME 458
Contents
Abstract ...................................................................................................................................... 2

Introduction ................................................................................................................................ 2

Types of rolling ...................................................................................................................... 3

Hot rolling .......................................................................................................................... 3

Cold rolling ........................................................................................................................ 4

Procedure ................................................................................................................................... 5

Result and Discussion: ............................................................................................................... 5

Conclusion ............................................................................................................................... 10

References ................................................................................................................................ 10

1
Abstract

From an economic perspective, rolling stands out as a pivotal technique in metalworking and
shaping. Employed for approximately five centuries, rolling has been instrumental in shaping
flat sections and sheet metal. It is crucial to note that distinct rolling methods impart varied
mechanical properties to the final product. In this experimental study, we aim to assess the
influence of both cold rolling and hot rolling on the microstructure and hardness of samples
having differing thicknesses. Through chemical analysis and metallographic examination, we
try to find the forming operations applied to the two distinct samples having different thickness.
Our investigation involves the impact of rolling types on microstructure and hardness and
surface appearances, additionally exploring how thickness influences the selection of rolling
temperature.

Introduction
Rolling is a fundamental metal forming process widely used in industries for shaping metals
into desired forms. It involves passing a metal workpiece between rollers to reduce its thickness
or change its cross-sectional area. It is an indirect compression process. Normally the only
force or stress applied is the radial pressure from the rolls, Fig.1[1].

Figure 1. Applied compressive load on workpiece in rolling process.

2
Types of rolling

Hot rolling
Hot rolling is performed at elevated temperatures, typically above the recrystallization
temperature of the metal. The recrystallization temperature varies with the materials. For
example, for steel, it is considered as 0.4 Tm (Tm= melting temperature of steel). In general, it
raises as melting temperature raises [1].

Figure 2. Schematic of Hot rolling

Advantages:

 Enhanced formability: The ductility of metals increases at higher temperatures,

allowing for easier shaping.
 Improved mechanical properties: Hot rolling refines the grain structure of the metal,
resulting in enhanced mechanical properties such as strength and toughness.
 Cost-effectiveness: Hot rolling requires lower forces compared to cold rolling, reducing
energy consumption and production costs.

Disadvantages:

 Surface oxidation: Exposure to high temperatures can cause surface oxidation, leading
to the formation of scale, which may require additional processing steps for removal.
 Limited dimensional accuracy: Hot rolling may result in less precise dimensions
compared to cold rolling due to the higher degree of thermal expansion.

Commercial Example of hot rolling:

 Automotive structural parts such as frames.

 Tabular products such as pipe and gas cylinders.

3
  Machine structures such as saws and springs.
 Agriculture equipment.
 Metal buildings.
 Guard rails.

Cold rolling
When rolling is done at a temperature below the recrystallization temperature, it is known as
cold rolling. It is conducted at room temperature or slightly elevated temperature [2].

Figure 3. Schematic of cold rolling

Advantages of cold rolling:

 No heating is required
 Better surface finish is obtained
 Better dimensional control is achieved.
 Better strength, fatigue and wear properties of material.
 Contamination problems are almost negligible.

Disadvantages of cold rolling:

 Higher energy consumption: Cold rolling requires more energy compared to hot rolling
due to the absence of thermal assistance in the deformation process.
 Limited formability: Cold rolling may induce greater internal stresses in the metal,
reducing its ductility and formability compared to hot rolling.

4
Commercial example of cold rolling:

The production of aluminum foil for packaging purposes often involves cold rolling. This
process yields thin foils with precise thickness control and excellent surface finish, meeting the
stringent requirements of the packaging industry.

Procedure

 Two plain carbon steel (thin and tick) samples were collected.
 Thickness of the samples was measured.
 Chemical composition of the samples were determined by OES.
 Microstructure of the two sample was observed under optical microscope.
 Hardness test was carried out in HRB.

Result and Discussion:

Identification of the type of rolling performed in given samples

Identification from surface appearance:

Thick sample (plate) has a blackish appearance, indicating the presence of oxide. This gives us
indication that plate is hot rolled.

Figure 4. Given Plate Figure 5. Given Sheet

Identification from microstructure:

We know that presence of elongated grain is an indication of cold rolling. Again, hot rolled
samples are consisted of equiaxed grains.

now, microstructure of Thick sample show that it is consisted of elongated grains and also large
equiaxed grain. Here, we take the microstructure of the cross section. For revealing the cross
section, we used electric hand grinder. This generate heat during cutting. This heat may cause
elongation of some grain into the direction of rolling or other preferable direction of grain.

5
Again, this heat may cause grain growth. That’s why some large grain is also observed.
However, grain growth may be occurred during hot rolling (we do not know exact history of
the given sample). Therefore, we can say the sample was hot rolled but grinding operation
causes the appearance of some elongated grain (it is not an indication of cold rolling)

However, microstructure of cold rolled sample do not fully reveal the appearance of elongated
grain. Because in most of the cases annealing heat treatment is done after cold rolling or other
fabrication process for removal of residual stress or lowering the effect of strain hardening or
making equaixed grain by holding for longer time at relatively lower temperature. However,
some ferrite grain shows aligning to a single direction but most of the grains are small compared
large grain in the plate. This small grain indicates that not so much heat is provided to the
sample. Thus, we can make an educated guess that thin sheet is actually cold rolled.

Identification from the OES data:

Plate or thick sample (0.34 %) has higher %C compared to thin sample ( 0.17%). Higher carbon
percentage increasing the strain hardening effect and making it difficult to form by cold rolling.
From this observation we can make an educated guess from economical point of view, the thin
sample was cold rolled since it has lower carbon percentage.

Identification from the hardness data:

Thick sample show higher hardness because of higher percentage of carbon. If the composition
remain same, in that case cold rolled sample should show high hardness. Here, although cold
rolled sample has carbon percentage half of the hot rolled sample, it does not show very low
hardness compared to thick sample. So, this comparatively high hardness of thin sample come
mainly due to cold rolling.

So, my conclusion is that:

Thick sample /plate : Hot rolled

Thin sample / sheet: Cold rolled

6
How to Distinguish between Plate and Sheet Materials?

Plate Sheet
It has a thickness greater than 6 mm Thickness is less than 6 mm
Surface appearance is not so good compared Very good surface finish and appearance
to sheet
In general , they have large ferrite and They have smaller grain or elongated grain
pearlite grain

Microstructural study of hot rolled and cold rolled materials

In general,

 Hot rolled: large equiaxed grain

 Cold rolled: small grain or elongated grain

Since hot rolling is done above the recrystallization temperature, new recrystallized grain
appears and they become larger. On the other hand, cold rolling impose anisotropy in the
microstructure, but annealing after the cold rolling result in equiaxed grain.

Microstructural comparison of hot rolling and cold rolling is given below[3]:

Figure 6. Comparison of hot rolling and cold rolling

7
Our observed microstructure of hot rolled plate (thick sample) (Left) and cold rolled (right)
sample:

Figure 8. Microstructure of plate (500x) Figure 7. Microstructure of sheet (500x)

Comparison of Mechanical Properties of Hot Rolled and Cold Rolled Materials

Property Hot rolled Cold rolled

Toughness More toughness due to Lower compared to hot
higher grain boundary area rolled
Ductility Increases Decreases
Strength Decreases if grain growth Increases due to strain
occurs hardening

Obtained hardness value of our sample:

Plate Sheet
Average in HRB= 81.74 Average in HRB= 76.37

8
Impact of Sample Dimensions on Choosing an Appropriate Rolling Schedule in terms of
Temperature.

Cold rolling / rolling at relatively lower temperature is done for thin sample, since they have
high surface area and prone to more oxidation. That’s why for sheet, to maintain better
dimensional accuracy and to avoid scale formation they should be formed by cold rolling

However, for thick sample hot rolling should be done. Because they require higher forces for
reducing the thickness. That why, using cold rolling will not cost efficient. Rather deformation
of thick sample at higher temperature becomes easy and hence less energy consumption.

What is the effect of method of processing and sample extraction of the plate and sheet
on its surface appearance and microstructures? Justify with proper microscopic and
photographic images as well as mechanical tests, if required

Since, for plate hot rolling is done, oxide or scale is formed on the surface of the plate. As a
result, surface appearance becomes bad. Again, microstructure consist of equiaxed grain since
recrystallization occurs during hot rolling.

On the other hand, cold rolling of sheet gives better surface appearance since there is no
problem of scale or oxide formation. It gives better dimensional accuracy. Cold rolling causes
alignment of the grain toward the longitudinal direction compared to transverse direction.
However, annealing after the cold rolling eliminate that effect.

Figure 10. Schematics of hot rolling Figure 9. Schematics of cold rolling

9
Conclusion

In conclusion, sheet having lower carbon percentage should be cold rolled and plate having
higher carbon should be hot rolled. The relatively higher hardness of sheet come from cold
drawing and much higher hardness of plate come from higher carbon percentage. Again, proper
rolling scheduling depends on the thickness of the material. For low thickness material or
having high surface area cold rolling should be done. Furthermore, metallographic analysis
give an idea about the forming process that is done for a given sample.

References
[1] Professor Dr. Md. Aminul Islam, Mechanical Metallurgy and Industrial Metal Working
Processes.
[2] S. Kamarudin, “Engineering Materials - Hot Rolling & Cold Rolling”, Accessed:
Feb. 12, 2024. [Online]. Available:
https://www.academia.edu/20062786/Engineering_Materials_Hot_Rolling_and_Cold_Ro
lling
[3] “Hot Rolling vs Cold Rolling - Difference Between Hot rolling and cold rolling.”
Accessed: Feb. 12, 2024. [Online]. Available: https://learnmech.com/hot-rolling-vs-cold-
rolling-difference-between-hot-rolling-and-cold-rolling/

10