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Advances in Metal Rolling Process: Modelling, Analysis, and Application

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 May 2026 | Viewed by 2305

Special Issue Editors


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Guest Editor
Department of Mechanical Engineering, Chung-Ang University, Seoul 06974, Republic of Korea
Interests: rolling; roll pass design; dynamic fracture; residual stress
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Department of mechanical Engineering, Dong-A University, Pusan, Republic of Korea
Interests: plasticity; finite element analysis; hot strip rolling; cold strip rolling

Special Issue Information

Dear Colleagues,

Advances in Metal Rolling Process: Modelling, Analysis, and Application focuses on various innovations, including:

  1. Material Flow Models: These predict metal behavior during deformation, such as elongation, grain refinement, and phase transformations, especially in hot rolling.
  2. Machine Learning Models: AI techniques, like machine learning, are used to predict rolling process outcomes based on large sets of experimental or simulation data, aiding in optimization and quality control.
  3. Innovative Process Analysis: Studying factors like roll force, temperature management, friction, advanced lubrication and residual stresses enhances process control and product quality, and reduce defects and energy consumption.
  4. Advanced Materials: These include rolling advanced high-strength steels (AHSS), titanium alloys, and other specialty materials used in high-performance industries such as aerospace, defense, and energy.
  5. Automation and Smart Rolling Mills: The integration of automation and real-time data acquisition enables continuous process monitoring and adjustments, leading to improved product consistency and reduced waste.

This field combines advanced modeling, real-time data, and material science to advance the limits of metal rolling.

Prof. Dr. Youngseog Lee
Dr. Sangmin Byon
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • smart mills
  • automation
  • machine learning
  • energy efficiency
  • process optimization
  • surface quality
  • advanced materials
  • material flow

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Published Papers (2 papers)

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Research

13 pages, 2474 KB  
Article
The Influence of Process Parameters in Radial Ring Rolling on Steel Ring Ovalization
by Piotr Surdacki and Andrzej Piotr Gontarz
Materials 2026, 19(3), 484; https://doi.org/10.3390/ma19030484 - 26 Jan 2026
Viewed by 443
Abstract
Rolling steel rings is a key manufacturing process for producing components with high strength and dimensional accuracy, used, among others, in the automotive, aerospace, and energy industries. The quality of the products depends on the process parameters that affect their mechanical and geometric [...] Read more.
Rolling steel rings is a key manufacturing process for producing components with high strength and dimensional accuracy, used, among others, in the automotive, aerospace, and energy industries. The quality of the products depends on the process parameters that affect their mechanical and geometric properties. One significant quality issue is ovalization, i.e., deviation from the ideal circular shape, which can complicate further processing or assembly. Therefore, analyzing the influence of rolling parameters on ovalization is crucial for ensuring high product quality and minimizing material losses. The aim of the research presented in this article was to determine the influence of the most important parameters of the ring rolling process—namely, billet temperature, forming tool speed, and the position of the calibrating rollers—on the ovalization of the rings produced. The results indicate that, among the parameters studied, the position of the calibrating roller engaged by the rolled ring has the greatest impact on ovality. Ovalization of the forging decreases with an increase in feed speed and a decrease in billet temperature. Higher feed speeds provide a more stable rolling process, which promotes the achievement of a more circular ring geometry. Lower billet temperatures are associated with better material strength properties, making it less susceptible to deformation under inertial forces compared to higher initial billet temperatures. The study of the influence of calibrating roller positions on ovalization showed that it is possible to determine an optimal configuration in which deviation from the ideal circular shape is minimized. Determining the optimal process parameters allows for producing components without the need for large-dimensional tolerances. Based on the results obtained, conclusions were formulated regarding the influence of the investigated process parameters on the ovalization of the finished ring. Full article
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15 pages, 5619 KB  
Article
Material Flow Control and Process Design in Constraint Ring Rolling of Thin-Walled Conical Cylinders with Three Ring Ribs
by Duanyang Tian, Xinghui Han, Zhuwei Lu, Wuhao Zhuang, Zhaosen Zhang, Zushen Deng and Lin Hua
Materials 2025, 18(6), 1262; https://doi.org/10.3390/ma18061262 - 13 Mar 2025
Cited by 2 | Viewed by 1157
Abstract
Thin-walled conical cylinders with three ring ribs (TWCCTRR) are the critical bearing-load components of aerospace equipment, and now the high-performance fabrication of TWCCTRR is confronting great challenges. Constraint ring rolling (CRR) is a new plastic-forming technique that shows great potential in forming high-performance [...] Read more.
Thin-walled conical cylinders with three ring ribs (TWCCTRR) are the critical bearing-load components of aerospace equipment, and now the high-performance fabrication of TWCCTRR is confronting great challenges. Constraint ring rolling (CRR) is a new plastic-forming technique that shows great potential in forming high-performance TWCCTRR. However, unreasonable material flow (UMF) is prone to occur in the CRR of TWCCTRR, which weakens its performance. Therefore, the problem of UMF in the CRR of TWCCTRR is investigated in this work. Through finite element (FE) simulation, it is found that UMF occurs at the bottom of the middle rib in single-pass CRR of TWCCTRR because the rib at the middle part is the earliest among the three ribs to be completely filled. Therefore, the double-pass CRR process is proposed for forming TWCCTRR without UMF, which makes the three ribs fully fill simultaneously to avoid UMF. Based on the FE simulation, in contrast to the single-pass CRR, the deformation homogeneity of TWCCTRR obviously improved, and meanwhile, the maximum radial forming force is approximately reduced by 15% in double-pass CRR due to the variation in material flow mode. Investigation results offer theoretical guidance for the CRR of high-performance TWCCTRR. Full article
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