6 High Reversible Cold Rolling Mill

1. 1. CRM Complex6 High Reversible Cold Rolling Mill Training Manual0

2. 2. LINE VIEW 1
3. 3. SCHEMATIC DIAGRAM OF 6 HIGH ROLLING MILLS Hydraulic jack Back Up roll Back up
rolls Intermediate Pinch rolls Pinch Rolls rolls Pinch rolls Shear Shear Work rolls Uncoiler
Uncoiler Recoiler Bottom foundation 2
4. 4. INTRODUCTION When sheet is entered between a pair of rolls and any kind of force
applied to that sheet, like that generated when making a reduction, the rolls, since they are
supported at the roll ends, will bend around the sheet. This will tend to make the sheet
relatively thick in the middle and thin on the edges. On thin sheet, this will be seen as wavy
edges. The phenomenon of rolls bending around the sheet is often called Roll deflection. 3
5. 5. LINE SPECIFICATIONS CRM - I Min thickness rolled : 0.15 mm Max. rolling speed : 1200
MPM Max. reduction / pass : 38 % Max. No. of passes : 5 Capacity : 0.2 MTPA Load for
reduction Thickness tolerances : 0.8 X width of sheet In rolled sheet : + 0.03 mm Max. front
tension : 12.2 MT Max. back tension : 8.5 Mt Max. width rolled : 1270 mm Min. width rolled :
700 mm 4
6. 6. Technical information about the six high mill Roughness Freq. Of roll Diameter (mm) Ra
(micron) change Work roll 425 (max) 380 (min) 0.5 0.6 500 tonnes Intermediate rolls 490
(max) 440 (min) 0.6 0.7 1000 tonnes Back up rolls 1250 (max) 1050 (min) 0.6 0.8 10000
tonnes 5
7. 7. EQUIPMENT DETAILS CRM-1 CONSISTS FOLLOWING EQUIPMENTS : 1. COIL
STORAGE SADDLE 2. COIL CAR 1, 2 & 3 3. PAY OFF REEL 4. THREE ROLL FEEDER
ASSY. 5. ENTRY TENSION REEL 6. 6 HIGH REVERSIBLE MILL 7. DELIVERY TENSION
REEL 8. BELT WRAPPER 9. ROLL CHANGING CAR (RCC) 6
8. 8. PAY OFF REEL SNUBBER ROLL MENDREL 7
9. 9. THREE ROLL FEEDER ASSY. ROLLS 8
10. 10. ENTRY TENSION REEL SNUBBER MENDREL OUT BOARD BEARING SUPPORT 9
11. 11. 6 HIGH REVERSIBLE MILL TOP BACK UP ROLL TOP INTERMEDIATE ROLL TOP
WORK ROLL BOTTOM WORK ROLL BOTTOM INTERMEDIATE ROLL BOTTOM BACK UP
ROLL 10
12. 12. DELIVERY TENSION REEL BELT WRAPPER OILER ROLL OUT BOARD BEARING
GUARD SUPPORT 11
13. 13. ROLL CHANGING CAR (RCC) FRONT VIEW REAR VIEWThis Assy. is used to change
rolls of 6 High rolling mill USED ROLLS 12
14. 14. SIDE VIEW OF 6 HIGH REVERSIBLE MILL 13
15. 15. OPERATIONAL INSTRUCTIONS A rolling mill should operate at its maximum power
or maximum speed. It becomes obvious that poor shape prevents productivity, by reducing
speed. A double hit is taken on thin gauges as poor shape can cause strip breaks with
often associated mechanical damage and consequential downtime. The use of tension,
particularly the application of rewind tension as a means of producing flat sheet on a rolling
mill is not good practice. Although this visibly appears to work, the shape defects are still
there and some other effects are present as well. These can range from high forward slip
 values causing poor roll life and a tendency for the mill to chatter, to residual stress problems
that manifest themselves as coil set, transverse bow, poor formability etc. 14
16. 16. FUNDAMENTALS OF SHEET SHAPE Very often, the only practical way to achieve
anything that resembles flat shape is to hand the problem over to some form of an automatic
shape sensing device and control system. There are two reasons for this: The first is that
the operator is incapable of detecting bad shape and the Second is that he/she cannot
adjust the sprays quickly enough to achieve the required level of control. High reductions
contribute more to the ROLLS BENDING AROUND THE SHEET EFFECT. To counteract
this, it is necessary to develop more heat in the rolls to generate more thermal roll growth or
crown. Now, this mechanism leads to a situation where the rolls are much hotter in the centre
of the sheet than out near the sheet edges, in fact, there will probably be quite a temperature
gradient in the interface zone between reduction and no reduction taking place on the rolls.
What this means is that this temperature gradient will be transferred into the sheet. This is
bad. 15
17. 17. VARIOUS LOAD CONDITION 16
18. 18. FUNDAMENTALS OF SHEET SHAPE A solution to this problem is presented by the six
high mill. In this case, a set of intermediate rolls is inserted between the work rolls and the
backup rolls. These rolls are placed asymmetrically in the mill so that the edge of the
intermediate roll is close to the strip edge. By adjusting the side shift on these rolls, the
fulcrum points for roll bending and roll deflection are changed and it is reported that buckles
may not only be changed but eliminated. The adjusting the intermediate rolls on a six high
mill is an adjustment of mechanical crown. A simple roll coolant system is then used to
satisfy the lubrication and cooling requirements. Recently, the concept has been further
developed with intermediate rolls taking on coke bottle shapes. Originally, these mills were
designed to be without shape control, as it was thought that the mechanical crown
adjustments would suffice, however, modern quality and productivity requirements have
meant that successfully operated mills do possess sophisticated shape control systems. 17
19. 19. SHAPE DEFINITION Strip shape is defined as the length distribution across the strip
width.Length is chosen because very small non-uniform changes in thickness may resultin
large shape errors. These changes are immeasurable by current thicknessmeasurement
devices, but the changes in strip length may be either directlymeasured off-line or by means
of tension distribution on-line. According to ourdefinition of shape, a device is required that
will enable the length differencesacross the sheet, (or web), width. If the sheet were not
subject to tension forces, it would be possible tomeasure any buckles optically. When cold
rolling, sufficient tension forces areapplied to make the sheet appear to be optically flat.
Tension distribution is usuallyused as a means of obtaining a measurement of strip shape.
The tension distribution is measured using some form of sensing roll, overwhich the strip
wraps. This roll is either an existing deflector, or pass line, roll or anextra roll. A popular
sensor is the Plenicim Roll. 18
20. 20. TYPES OF SHEET SHAPE 19
21. 21. TYPICAL PLENICIM ROLL DISPLAY 20
22. 22. CR DEFECTS21
23. 23. RUST DEFINITION: CORROSION PRODUCTS OF IRON, APPEARS IN THE FORM OF
REDDISH YELLOW TO BLACK PATCHES ON THE STRIP. CAUSE OF FORMATION:
PRESENCE OF AQUEOUS LIQUIDS ON THE METAL SURFACE, PROMOTED BY
TEMPERATURE FLUCTUATIONS, HIGH AIR HUMIDITY AND LONG STORAGE TIMES. 22
24. 24. COOLANT PATCH DEFINITION: THESE ARE PERMANENT STAINS THAT APPEAR
ON THE STRIP AFTER COLD ROLLING CAUSE OF FORMATION: COOLANTS USED
DURING ROLLING ARE NOT REMOVED COMPLETELY. 23
25. 25. SLIVER DEFINITION: LINE TYPE SURFACE DEFECTS OFTEN WITH TWO PARALLEL
LINES DISTRIBUTED SPARSLY ACROSS THE STRIP WIDTH AND THROUGHOUT THE
COIL LENGTH. CAUSE OF FORMATION: DEFECT CONTAINS FINE OXIDES AND OTHER
METALLIC OXIDES FORMED DUE TO OXIDES BEING TRAPPED AND SUBJECTED TO
HIGH TEMPERATURES. 24
26. 26. ROLLED IN SCALE DEFINITION: SCALES WHICH ARE NOT REMOVED DURING
PICKLING AND IS ROLLED INTO THE SURFACE DURING COLD ROLLING OPERATIONS
CAUSE OF FORMATION: INADEQUATE PRELIMINARY DE- SCALING OR PICKLING OF
HOT STRIP. 25
27. 27. ROLL MARKS DEFINITION: THEY ARE INDENTATIONS OR DEPRESSIONS ON THE
STRIP OF REGULAR FORM WHICH OCCUR PERIODICALLY. CAUSE OF FORMATION:
FOREIGN BODIES ON THE WORK ROLLS CAUSE THEM. 26
28. 28. CENTER BUCKLING DEFINITION: UNDULATIONS AT THE CENTRE OF THE STRIP
RUNNING PARALLEL TO THE DIRECTION OF ROLLING. CAUSE OF FORMATION:
EXCESS LOAD AT THE CENTRE DURING ROLLING OPERATION. 27
29. 29. EDGE WAVY DEFINITION: UNDULATIONS AT THE EDGES IN THE FORM OF
WAVES. CAUSE OF FORMATION: EXCESS LOAD AT THE EDGES DURING ROLLING
OPERATION. 28
30. 30. CROSS BOW DEFINITION: CROWN OR CAMBER RUNNING TRANSVERSE TO THE
DIRECTION OF ROLLING. CAUSE OF FORMATION: DIFFERENTIAL FRICTION
BETWEEN THE STRIP AND THE UPPER AND LOWER WORK ROLLS 29
31. 31. COIL SET DEFINITION: LONGITUDINAL CAMBER OF THE STRIP IN THE ROLLING
DIRECTION. CAUSE OF FORMATION: DEFLECTION AROUND SMALL GUIDE ROLL
DIAMETER 30
32. 32. PINCH MARKS DEFINITION: LINEAR MARKINGS ON THE STRIP OF SINGLE OR
PERIODIC OCCURRENCE. CAUSE OF FORMATION: LACK OF STRIP FLATNESS 31
33. 33. SCRATCH LINE DEFINITION: GROOVES, GOUGES AND DEEP SCRATCHES WHICH
OCCUR DURING OR AFTER COLD ROLLING. CAUSE OF FORMATION: PRIMARILY
CAUSED BY FRICTION BETWEEN THE STOCK AND PARTS OF THE EQUIPMENT DUE
TO RELATIVE MOVEMENTS. 32
34. 34. IMULSION MARKS DEFINITION: CRACKED EMULSION RESIDUES ON THE STRIP
SURFACE. CAUSE OF FORMATION INADEQUATE WIPING OR BLOWING TO REMOVE
EXCESS EMULSION. 33
35. 35. HOLES DEFINITION: DISCONTINUITIES IN THE MATERIAL WHICH EXTEND
THROUGH RIGHT FROM TOP TO THE BOTTOM SURFACE CAUSE OF FORMATION:
 LOCAL WEAKNESS SUCH AS BLOW HOLES, COARSE INCLUSIONS, ROLLED IN SCALE
OR SEVERE MECHANICAL DAMAGE. 34
36. 36. SAW EDGES DEFINITION: HACKSAW LIKE PROFILE OF THE EDGES OF THE STRIP
OFTEN RUNNING THROUGHOUT THE LENGTH OF THE COIL. CAUSE OF FORMATION:
IMPROPER TRIMMING AT THE EDGES PRIOR TO ROLLING. 35
37. 37. EDGE CUT DEFINITION: BLACKISH BANDS ON THE SURFACE OF THE STRIP
RUNNING PARALLEL TO THE ROLLING DIRECTION. CAUSE OF FORMATION:
IMPROPER COOLING OF THE STRIP DUE TO WIPING NOZZLE CHOKING. 36
38. 38. HEAT BAND DEFINITION: BLACKISH BANDS ON THE SURFACE OF THE STRIP
RUNNING PARALLEL TO THE ROLLING DIRECTION. CAUSE OF FORMATION:
IMPROPER COOLING OF THE STRIP DUE TO WIPING NOZZLE CHOKING. 37
39. 39. Thank you Compiled by : Rajiv Arora