ROOT CAUSE OF MILL DEFECTS AND ITS REMEDIES

GUIDED BY:Mr. I Mukherjee (AGM) Mr. S.K. Malik (Ast. Mgr) Mr. Rajeev Ganer (Ast. Mgr)

Presented By:

Soumyo Broto Das (4687) U.S. N Raju (4691) Sushil Kumar Patel (4688) Nitesh Chand (4692)

6th Batch

Group R2

What is Quality ?


Quality in business, engineering and manufacturing has a interpretation as the non-inferiority or superiority of something. Quality is a perceptual, conditional and somewhat subjective attribute and may be understood differently by different people. Quality may be defined as the products fitness for consumption/use.

Definition of Quality!
Definitions  The common element of the business definitions is that the quality of a product or service refers to the perception of the degree to which the product or service meets the customer's expectations. Quality has no specific meaning unless related to a specific function and/or object. Quality is a perceptual, conditional and somewhat subjective attribute.

Quality from Customer point of view



Customer may focus on the specification quality of a product/service, or how it compares to competitors in the marketplace.

Quality from Manufacturer point of view



Manufacturer might measure the conformance quality, or degree to which the product/service was produced correctly.

Quality Mantra Right specifications, Right Time, Right Price

Customers Needs
Stated Implied Design as per customers requirements

Manufacturing Supply

On right Time

Of right specifications

At right Price

EVERY TIME - FIRST TIME

Definition of Customer Customer is one who uses our product or services

Types of Customer 1.Internal Customer Next User 1.Intermediate Customer Next dept/Other plant/sister concern 1.External Customer End User
To satisfy all these customers is our first & foremost objective

Packing & Dispatch

CUSTOMER

Quality Control

Marketing

Production

Quality Loop

Technical Support

Store

Marketing

Purchase

Design /Engineering

Customer Process Route.

CUSTOMER

Drawing

Forging

Cold Forging

Machining

Heat Treatment

JNIL Process Chart

PINCH ROLL

GCPR-1 GARRET COILER-1

GCPR-2 GARRET COILER-2

SLAT CONVEYOR TRANSFER DEVICE SLAT CONVEYOR CAPSTAN SHIPING YARD

Defects Undesirable By Customer

         

Fins Laps Roughness Seams Dent Scratches Stick Scales Fire Cracks Transfer Marks Roll Marks Surface Decarburation

Dimensional Problem Upset Problem

Forging Problem Poor Surface Finish Deterioration in Mechanical Properties

FINS
Fins are narrow beads running longitudinally. Occurrence : Several fins uniformly distributed at the periphery of the wire rod can be caused if the finishing pass is overfilled because of improper roll adjustment. When material is rolled in multi stand continuous mills, fins can not be avoided at the ends of the coil because of the tension effect. Root Cause of Fins Over filling because of improper roll adjustment.

Detection Of Fins Fins can easily be detected by naked eyes generally.

LAPS


This type of defect occurs when a corner or fin is folded over and rolled but not welded into the metal. They appear across the surface of the metal. Root Cause Pass overfilling is the most frequent cause of laps, when material which is forced out into the roll gap folds over and is rolled into the rod surface during subsequent passes. Passes are overfilled when too large reduction is attempted or the wrong pass design is used.

Detection Of Laps Generally Laps can easily be detected by naked eyes. Laps can usually be distinguished from cracks by the typical configuration and arrangement of the defect, such as parallel double lines or discontinuities in the material distributed uniformly over the section and following the circumference.

ROUGHNESS


Continuously recurring, irregular depressions and elevations on the surface of wire rod are known as roughness. Root Cause A rough wire rod surface is usually caused by severe roll groove wear, particularly in the last two forming stands. Surface roughness can also caused by corrosion if the rod stored for lengthy periods in a damp or corrosive atmosphere.

Detection Of Roughness
Generally Roughness can easily be detected by naked eyes. Further roughness can also be detected under microscopic test. Roughness can also felt and observed, if naked hand is gently rubbed over the surface of the wire rod.

SCALE


Scale is the oxide layer on the surface of wire rod. This oxide layer of varying thickness and colouring may cling loosely or adhere firmly. It can have an adverse effect if its condition or constitution is unsuitable for the further processing of the rod and if it adheres so tightly to the base material that it is difficult to remove. The constitution and thickness of the oxide layer (layer of scale) depend on temperature and the rate of cooling.

Root Cause


Detection Of Scale


Thickness and constitution of the scale and thus the suitability of the material for further processing can be established by pickling and bend tests, by weighing before and after descaling and by microexamination.

SCRATCHES
Scratches are furrow-like depressions which always run longitudinally. The form and the size of the scratches vary considerably according to the source of the defect. Scratches are mechanical marks occurred during Rolling. Root Cause Scratches are caused by scoring of the stock by sharp or pointed objects. The defect may, for instance, be caused by the uneven surface of guide parts on which scale or particles of the rolled product have built up.

Detection Of Scratches
Scratches ca be detected with the naked eyes or with low magnification, even in the scaled condition, though more easily in the descaled state. Unlike laps, scratches seldom opens up during upsetting test.

ROLL MARKS
Roll marks are embossed elevations or depressions usually recurring periodically and varying greatly in shape and size

Root Cause
Roll marks occurs due to depressions of various kinds in the rolls themselves or in the pinch rolls.

Detection Of Roughness
The defects can usually be detected with naked eyes or with a low magnification on the scaled or descaled specimen.

Rolled in matter in guide roller Roll mark defects

Mark from upper roller

Mark from lower roller

FIRE CRACK TRANSFER MARKS

Fire Crack transfer marks are patterns of elevations that recur periodically and run at right angles to the direction of rolling.


Root Cause

During hot rolling, surface of the roll is continuously heating and quenching & because of this cracks occurs on surface of hot metal. Detection Because of their characteristic form, fire crack transfer marks can easily be detected with the naked eye or with a low magnification.

SEAMS
These are the discontinuous scratches occurred due to non metallic inclusion embedded in steel.

Root Cause


During the production processes, the stock comes into contact with metallic and non-metallic materials. Parts of the surface regions of the stock. Sometimes, metallic foreign bodies can become welded to the stock. These defects may also be caused by parts of guides which come loose or are broken or torn off.

Detection


Seams can be detected with naked eye or with a low magnification. Micro-examination or chemical analysis of the foreign body will indicated the origin of the defect.

SURFACE DECARBURATION


Surface Decarburisation is a loss of carbon, on furnace due to interaction with the gases in the reheating furnace. Decarburization is the decrease of the carbon content of (the surface of) a steel due to interactions with the environment at elevated temperatures. Carbon has a large influence on the mechanical properties of the steel. The decreasing carbon content causes a degradation of these properties, as the hardness as well as the strength decrease.

SURFACE DECARBURATION


Root Cause
If the steel is heated for too long period at a high temperature or if there is only a slight reaction between the furnace atmosphere and the iron itself but a distinct reaction with carbon, there is a loss of carbon in the surface region of the rolled product. Slight reaction between the oxidizing furnace atmosphere.

Detection This defect can be observed under microscope.