07 - Guide Training - Key Issues (11052) PDF

Guide and Roll Pass
Training - Guides
June 18 – 21, 2018
Avalon Inn and Conf. Center
Warren, OH
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Guide Training Contents
•Guide Fundamentals and Definitions

•Guide Types
•Basic Theories
•Pass Progression
•Selection Criteria
•Guide Design
•Guide Maintenance and Operation
•Key Guiding Issues
•New & Future Developments
•Questions and Answers
•Conclusion
Restricted © Primetals Technologies 2015 All rights reserved.

Page 2 06.18.2018 Anderson / Industry / USA / MSS
Key Guiding
Issues

Key Guiding Issues
Guide Realities:
1. Guides are for the most part, very
simple pieces of equipment.
2. Guides are an extremely important
part of a successful rolling mill.
3. Due to their simple nature, often less
attention is paid to guides
4. Rolling mills that put more effort into
their guides usually have better
finished product, and less downtime.
5. Most guiding issues are setup
related.
6. The difference between correct and
incorrect guide setup is a matter of
minutes

Key Guiding Issues - Bearings
Bearing failure is the #1 reason for guide failure.
Primary causes for guide bearing failure:

Overuse  not using a preventative maintenance schedule.
Overloading  guide set too tight, impacts, off the hole, etc.
Improper installation  worn spacers, damage, reuse of outer race, too tight, etc.
Lack of lubrication  clogged air/oil, improper grease, etc.
Contamination  rust, water, metal, etc.
The guide builder can control many of these

Key Guiding Issues – Bearing Lubrication
Proper lubrication is critical!
Air / oil or Grease lubrication
• Air / oil is preferred, 0.24cc / cycle (3 min/cycle)
• Contamination can cause significant failures
• Grease specification: Mobilith SHC PM460 or

equivalent.
• Cross drillings and passages must be checked

regularly to ensure proper lubrication.

Key Guiding Issues – Guide not Aligned to Pass Groove
Issue: Guide not aligned properly to the pass groove, i.e. set ‘off the hole’.
Cause: Improper aligning methods, carelessness, mistakes, intentional misalignment.
Results: Cobbles, hooking to opposite side, knuckles, laps, seams, poorly formed section,
premature guide wear.
Solution: Ensure that guides are aligned properly to the pass groove every time  Always
use gauges or optics.

Key Guiding Issues – Worn Entry Inserts
Issue: Worn or oversize receiving guide

static inserts.
Cause: Failing to replace worn inserts, using

incorrect size inserts.
Results: Inconsistent product , delivery guide

cobbles, twist guide failures, hooked and
knuckled head ends, roller pin failures, guide
roller wear, and damage to guide bearings.
Solution: Ensure static receiving inserts are

replaced when worn, and correct size inserts
are being used.

Key Guiding Issues – Incorrect Twist
Issue: Twist out of twist guide incorrect, over or

under twisting.
Cause: Improper guide setting methods, worn twist

guide rollers, carelessness, mistakes, mill stand gap
changes not being fed back to guide setters, mill roll
pass wear, etc.
Result: Rolling section out of following stand, cobbles,

uneven roller wear on following RE guide, heavy RE
impacts, roller guide failure (broken rollers, bearings,
pins, etc)
Solution: Ensure that guides are being set properly to

the actual section size every time. Make sure changes
are fed to guide setters, always use gauges / optics,
setup sheets, etc. Avoid using overly worn twist guide
rollers.

Key Guiding Issues – Incorrect Guide Elevation
Issue: Guide is positioned too low or too high relative to work rolls.
Cause: Restbar elevation incorrect, equipment damage, debris under guide, intentional
misalignment, incorrect mill stand setup.
Results: Premature guide failures, increased guide wear, hooked ends, and cobbles.

Key Guiding Issues – Incorrect Guide Elevation
Solution: Ensure correct guide elevation: proper setup, gauges, etc .

Key Guiding Issues – Guide Set to Wrong Section Size
Issue: Guide not set to actual stock size.
Cause: Improper guide setting methods,

carelessness, mistakes, mill stand gap changes
not being fed back to guide setters, etc.
Result: Guides being set too tight  cobbles,

knuckles, guide roller failure, guide wear, bearing
failure, mounting wear, reduction of stock in
extreme cases. Guides being set too loose 
cobbles, inconsistent product, improperly filled out
sections, laps, seams, uneven guide wear.
Solution: Ensure that guides are being set

properly to the actual section size every time.
Make sure changes are fed to guide setters,
always use gauges / optics, setup sheets, etc.

Key Guiding Issues – Conclusion
Guides are an extremely important part of a effectively operating rolling

mill. They can be both the cause and solution for many rolling mill
issues. The importance of their proper care, maintenance, and
operation cannot be understated.

New and Future
Developments

New and Future Developments
Recent Developments and Future Projects:

• Advanced Optics System
• Bar Height System
• Automated Restbar
• RODS system
• Laser Based Stand Alignment System
• Next Generation Guides
• Guide Usage Analysis System
• High Efficiency Water Headers

New and Future Developments
Industry 4.0
What is the Goal?
Lower costs, higher production/yield and
better quality
How?
SMART – With intelligence
ADAPTIVE – Reacts to current situation
LEARNING – Self Improves for future

Contact
Matthew Anderson The information (including, e.g., figures and

Guides Engineering Manager numbers) provided in this document contains
merely general descriptions or characteristics of
T +1 (774) 849-6347 performance based on estimates and assumptions
which have not been verified.
E matthewanderson@primetals.com
It is no representation, does not constitute and/or
evidence a contract or an offer to enter into a
contract to any extent and is not binding upon the
parties. Any obligation to provide and/or
demonstrate respective characteristics shall only
exist if expressly agreed in the terms of the contract.
These estimates and assumptions have to be

analyzed on a case-to-case basis and might change
as a result of further product development.
Primetals Technologies excludes any liability

whatsoever under or in connection with any
Primetals Technologies provided information, estimates and assumptions.
The provided information, estimates and
50 Prescott Street assumptions shall be without prejudice to any
possible future offer and/or contract.
Worcester, MA 01605
United States Any use of information provided by Primetals
Technologies to the recipient shall be subject to
applicable confidentiality obligations and for the own
convenience of and of the sole risk of the recipient.
primetals.com

THANK YOU
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Guide and Roll Pass

Restricted © Primetals Technologies 2015 All rights reserved. primetals.com

•Guide Fundamentals and Definitions

Restricted © Primetals Technologies 2015 All rights reserved.

Restricted © Primetals Technologies 2015 All rights reserved.

Restricted © Primetals Technologies 2015 All rights reserved.

Bearing failure is the #1 reason for guide failure.

Primary causes for guide bearing failure:

The guide builder can control many of these

Restricted © Primetals Technologies 2015 All rights reserved.

Proper lubrication is critical!

Air / oil or Grease lubrication

• Air / oil is preferred, 0.24cc / cycle (3 min/cycle)

• Contamination can cause significant failures

• Grease specification: Mobilith SHC PM460 or

• Cross drillings and passages must be checked

Restricted © Primetals Technologies 2015 All rights reserved.

Cause: Improper aligning methods, carelessness, mistakes, intentional misalignment.

Restricted © Primetals Technologies 2015 All rights reserved.

Issue: Worn or oversize receiving guide

Cause: Failing to replace worn inserts, using

Results: Inconsistent product , delivery guide

Solution: Ensure static receiving inserts are

Restricted © Primetals Technologies 2015 All rights reserved.

Issue: Twist out of twist guide incorrect, over or

Cause: Improper guide setting methods, worn twist

Result: Rolling section out of following stand, cobbles,

Solution: Ensure that guides are being set properly to

Restricted © Primetals Technologies 2015 All rights reserved.

Restricted © Primetals Technologies 2015 All rights reserved.

Solution: Ensure correct guide elevation: proper setup, gauges, etc .

Restricted © Primetals Technologies 2015 All rights reserved.

Issue: Guide not set to actual stock size.

Cause: Improper guide setting methods,

Result: Guides being set too tight  cobbles,

Solution: Ensure that guides are being set

Restricted © Primetals Technologies 2015 All rights reserved.

Guides are an extremely important part of a effectively operating rolling

Restricted © Primetals Technologies 2015 All rights reserved.

Restricted © Primetals Technologies 2015 All rights reserved.

Recent Developments and Future Projects:

Restricted © Primetals Technologies 2015 All rights reserved.

Restricted © Primetals Technologies 2015 All rights reserved.

Matthew Anderson The information (including, e.g., figures and

These estimates and assumptions have to be

Primetals Technologies excludes any liability

Restricted © Primetals Technologies 2015 All rights reserved.

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