When going from a cast object/ingot you need to do some forging
before you go to the rolling mill. This will help align the structure
of the grain and “toughen it up” so to speak. You could flatten out
the button by forging, but I would think that you would have to do a
lot of forging with the average button just to get it to fit between
the average mill. As well the parallel surfaces of the ingot will
allow a more consistant amount of deformation. With the button, the
center tends to get more deformation than the edges, leaving an
uneven and inconsistant sheet density that can lead to cracking.
Another advantage of the ingot is that it has a square shape which, I
find, leads to more usable space. Button tend to come out more
One thing to keep in mind when rolling sheet is that there is a lot
more surface area in contact with the roller than with wire. The
amount of force needed to roll down the ingot is therefore greater.
Make sure your rolling mill is secured to the floor! You’ll find it
much easier, and safer.
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