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History
 Manufactured by FALCI in ITALY.
 There are only four mills of this type in all over the world.
 In India, Profile mill generally comes into the picture after
1995.
 And it is brought to India in 1996.
Introduction
 The Profile Rolling Mill is a new concept in India and has some unique features.
 It has a state of the art manufacturing facility for producing 6000 MT per annum of
hot rolled & cold drawn solid steel sections with close dimensional tolerances.
 The uniqueness of this latest technology lies in the fact that the profiles are rolled
from wire rods that are continuously heated on-line with electrical resistance heaters,
unlike from billets that are heated in fuel fired furnaces in conventional rolling mills.


Introduction
 Unlike extrusion, where molten metal is pushed
through a die to obtain the required shape, the hot
rolling process involves shaping of the heated billets
or wire rods by passing through a set of rolls that are
rotating in opposite direction.
 The rolls have groves cut in it as per the specific roll
pass design and each roll has a different set of
groves. These profiles or sections have the same
shape or cross section throughout the length.
General specification
 Manufacturing : FALCI, Italy
 Mill capacity : 6000 MT/annum
 Connected electric load : 1000 KVA, 380 volts
 Raw material : Hot rolled wire rod
 Rolling speed : Rod entry speed 4 to 14 m/min
 Steel grade : Mild Steel, Medium Carbon
steel, High Carbon steel, Alloy
steel, Stainless steel
Profile hot rolling process
 The profile hot rolling process is divided in to two
processes.
• Manufacturing of the rolls
• Process on rolling mill
Manufacturing of rolls
 This process is considered as pre-rolling process.
 The complicate profile shape is grooved first on rolls
and afterward by pressing steel rod between rolls, the
required profile is obtained.
 This process contains other processes like,
• Template making
• Profiling of Grinding wheel
• Profiling of Rolls
PROCESS ON ROLLING MILL
 Uncoiler
 Straightner
 Chain puller
 De-scaler
 Heating zone
 Mill stand
 Pinch roll drive
 Shear cutter
 Colling bed
 Pusher blade
PROCESS ON ROLLING MILL
Pinch
Heating zone roll Shear
Mill stand drive cutter
Uncoiler Straightner
Cooling bed
Uncoiler
 Also called raw material
holding equipment.
 The raw material of hot
rolled wire in its coiled
form loaded on
uncoiler.
 used for uncoiling the
raw material.
Straightner
 Converts uneven shape in to the straight form.
 It carries total 18 rollers. First nine rollers straight the
raw material vertically and remaining nine
horizontally.
 Raw material has one line passage to pass.
 The coil end is pulled up to straightening machine by
the chain of the bar gripper on the winch drum,
provided on the straightening machine.
Heating zone
 The temperature of rod is increased.
 Three heating elements, which are called heating
zone 1, 2 & 3.
 Each heating zone is connected with electric load of
1000 KVA and 380 Volts. The current is passed in
increasing order through each zone.
 The heating zone 3 has maximum current about 800
to 1000 amp. , which differs with the different raw
materials.
 At zone 3 the raw material rod becomes red hot.
Mill stand

 Each mill stand has a


pair of rolling assembly,
which contains one top
roll and one bottom roll.
 These rolls revolving at
same speed but in
opposite direction.
Mill stand
 By passing the red hot material between the rolls
and applying tremendous amount of pressure on it,
we get required shape of profile.
Pinch roll drive & Shear cutter
 Used to grip this hot profile in such a way that the
shape of profile doesn’t change. Then after it draws
the profile to the shear carefully.
 After rolling profile is cut in required length & for
cutting purpose shear is used.
 Cutter has sharp edge, which cuts profile rapidly only
in one pass.
Cooling bed & Pusher blade
 For cooling of hot profile cooling bed is required,
which has length same that of profile which is
required.
 Pusher blade is used to push profile from cooling
bed to collection bed.
 At collection bed profiles are cooled at atmospheric
temperature by natural heat transfer.
Profile Specification
 Specific Weight of Profiles : 0.2 Kg / meter to 4.5 Kg / meter
 Width of Profiles : 8 mm to 55 mm.
 Thickness of Profiles : 3 mm minimum.
 Length of Profiles : 3000 mm to 11000 mm
 Weight of Profiled Coils : 500 Kg. maximum
 Tolerance : On thickness  +/- 0.2 to +/- 0.5 mm.
On width  +/- 0.2 to +/- 0.5 mm.
Applications
 We can design any type of complicated profile shape to
suit any specified requirement.
 Its range finds wide application in a variety of sectors
such as the electronic, mechanical, automobile and
electrical industries, etc. The list is end less and
growing fast.
 In different industries or sectors, which type of
complicated profile shapes are used and in which
manner are described as follow:
Agriculture sector
 Sickles
 Coffee Choppers
 They have
conventionally been
manufactured by village
smiths.
• No uniform section
• Uneven wearing
• Needs re-sharpning
Automobile industries
 Door Hinges
 Pole Shoes
 Lock Rings / Flanges /
Side Rings / Advance
Bands
 Flywheel Ring Gears
 Serrated Angles
 Special T
Construction industries
 Ornamental Grills
 Hand Railings
 Gratings
 T for joining
chequered plate
 Serrated T's
 Chamfers
 Half Ovals
Construction industries
 It can manufacture hot rolled sections for various
architectural applications such as ornamental grills, hand
railings, gratings, T sections for joining chequered plates,
serrated Ts for staircases etc.
 In the construction industry, chamfers are fitted into the
corners to obtain a chamfered edge along the length of
the pre-cast column or beam. On account of such
chamfered edges, the question of corner breakage does
not arise.
 Half oval section is used to obtain flutes on decorative
pillars.
Cutting tools
 Wood Chisel. Paring
Tools, Rasp & Planer
 Engineers' Steel Files
& Rasps
 Hot rolled preshapes
for Clicking knives
Earth moving vehicle
 Grouser Bars / Lug
Bars for rebuilding
track shoes
Horse shoe & Gun barrel
 Horse shoe

 Gun barrel
Textile machinery
 Nore bar/Apron bar
for ring frame
machines
 Condenser support
bar
 Lappet rail
 Balance weight
 D bars
 Rod weighing bars
Miscellaneous
 Springs
 Taper washers
 Locks and Keys
 Sliding rails for partitions
 Machine tool guide ways
 Linear motion guide
ways
 Steam turbine blades
 Gear shifting sliding keys
Advantages

• Better dimensional tolerances.


 Consistency in dimensions due to continuous
rolling.
 Reduced material wastage on account of
better tolerances.
 Reduced cost of machining operations and
saving in time.
Disadvantages
 More care should be taken during whole
operation, because whole process is gone
through at very high temperature.
 Primary cost is high.
 Occupy large floor area.
 Whole process would be done accurately,
because small error in dimension makes high
material waste.
Limitations
 Hollow profiles can not be manufactured.
 The profiles of more than 50 mm width can
not be rolled.
Conclusion

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