Toolox steel mill applications

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This is a presentation that was created for a Toolox information day. Tool is a tool steel that can be flame cut into steel profiles. The present

This is a presentation that was created for a Toolox information day. Tool is a tool steel that can be flame cut into steel profiles. The present

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  • 1. Applications In Steel Mill HE-CK130527
  • 2. Benefits Of Selecting Toolox ✔ Ready to use – no heat treatment required ✔ Easy to machine ✔ Weldable ✔ Possible to gas cut ✔ Perfect for nitriding ✔ Dimensional stability ✔ Wear resistance – even high temperatures ✔ Crack resistance
  • 3. Metallurgy
  • 4. Sliding Shoe PRESSURE POLE
  • 5. Grid Grid Grid Olov Zakrisson - Area Technical Manager provides 2 months of servicel Sliding Shoe
  • 6. Sliding Shoe DESCRIPTION Sliding shoe of pressure pole in coking plant. Pushes ready coke out of the blast furnace oven. Abrasion due to sliding on hot coke on top of a bed of heat resistant bricks. Surrounding temperatures of approximately 1050 °C. Shoe is at temperatures of around 500 °C. Stays in oven 60 seconds per push. Hardox 400 at 25 mm ⫤ 2 MONTHS PROBLEMS High temperature ruins hardness. After service life below 250 HB. Expensive formatting. Require extreme bending forces. Grid Grid Grid Grid Grid Grid Grid Grid Grid Grid Grid Grid Grid Grid High production cost Olov Zakrisson - Area Technical Manager 25mm Hardox 400 provides 2 months of servicelife HX400% Plateprice%Euro%/%ton% 1%500%€% Ext.%forma;ng%cost%/%ton% 2%100%€% Servicelife%/%ton% 360%days% Total'cost'/'day'' 10,0'€' Cost'exkl.'forma9ng' 4,2'€'' 0"€ 2"€ 4"€ 6"€ 8"€ 10"€ 12"€ HX400 Cost /&day Due to the high bendingforce needed external bending capacity must be obtained, rendering a high formating cost.
  • 7. Sliding Shoe What about Toolox? ➠ Toolox 44 ⫤ 8 MONTHS EXPERIENCE Longer service life. Will not back-temper at 500 °C. Less maintenance, less downtime. Lower formatting costs. EN 10 160 (rolled plates) EN 10228-3 (forged bars) with extra demands according to specification SSAB V6 Etching Toolox 44 fulfils the etching requirements of NADCA # 207-2006. Dimensions Toolox 44 is supplied as plate in thicknesses between 5 - 130 mm, or as forged bars in thicknesses between 150 - 300 mm. Delivery condition Quenched and tempered at a minimum temperature of 590 ˚C. Heat treatment Toolox 44 is not intended for further heat treatment. If Toolox 44 is heated above 590˚C after delivery from SSAB Plate no guarantees for the properties of the steel are given. Nitriding/coating Nitriding or surface coating may be carried out if the temperature is below 590 °C. Testing Testing according to EN 10 025 and EN ISO 6506-1. Hardness is measured on a milled surface 0.5 - 2 mm below the original surface. Tolerances Thickness, length, width and flatness tolerances according to “Dimension program and tolerances for new rolling of tool steel plates from SSAB Plate”. Forged bars; According to DIN 7527. Surface finish On delivery from SSAB Plate the plate meets the following specifications: - free from mill scale - not repair welded - surface defects below the nominal ordered thickness are not permitted. Forged bars according to DIN 7527. onic inspection Ultrasonic inspection is carried out according to: EN 10 160 (rolled plates) EN 10228-3 (forged bars) with extra demands according to specification SSAB V6 ng Toolox 44 fulfils the etching requirements of NADCA # 207-2006. nsions Toolox 44 is supplied as plate in thicknesses between 5 - 130 mm, or as forged bars in thicknesses between 150 - 300 mm. ery condition Quenched and tempered at a minimum temperature of 590 ˚C. treatment Toolox 44 is not intended for further heat treatment. If Toolox 44 is heated above 590˚C after delivery from SSAB Plate no guarantees for the properties of the steel are given. ing/coating Nitriding or surface coating may be carried out if the temperature is below 590 °C. g Testing according to EN 10 025 and EN ISO 6506-1. Hardness is measured on a milled surface 0.5 - 2 mm below the original surface. ances Thickness, length, width and flatness tolerances according to “Dimension program and tolerances for new rolling of tool steel plates from SSAB Plate”. Forged bars; According to DIN 7527. ce finish On delivery from SSAB Plate the plate meets the following specifications: - free from mill scale - not repair welded - surface defects below the nominal ordered thickness are not permitted. Forged bars according to DIN 7527.
  • 8. Cable Drum
  • 9. Cable Drum DESCRIPTION Cable drum used for a wagon in coking plant ➠ Toolox 44 EXPERIENCE 220 mm forged block machined with HSS tools to 190 mm. Combination of strength, hardness, and toughness very important. Works perfectly since 2010.
  • 10. Slag Bucket
  • 11. Slag Bucket DESCRIPTION Bucket for handling hot slag. Temperatures up to 1500 °C. Hardox 400, St52, Heat Resistant Steel ⫤ 8 WEEKS ➠ Toolox 33 ⫤ 8 MONTHS EXPERIENCE Toolox offers high temperature wear resistance. Reflected in much longer lifetime of Toolox. Installed January 2011 Photo Taken April 19 2011
  • 12. Crane Wheel
  • 13. Crane Wheel DESCRIPTION Steering wheel in an overhead crane ⌀ 610 mm L 125 mm 35CrNiMo14 INDUCTION HARDENED ➠ Toolox 44 EXPERIENCE Faster manufacturing. Water jet cut and directly machined to final piece. Safer solution due to no heat treatment. Critical component. First test in 2006 and introduced as standard. Wheels typically replaced every 3-4 years.
  • 14. Steering Wheel
  • 15. Steering Wheel DESCRIPTION Steering wheel in an overhead crane ⌀ 250 mm L 86 mm 1.6582 / 34CrNiMo6 ➠ Toolox 44 EXPERIENCE Hardness consistent across material. Crack problems due to hardening avoided. No heat treatment shortens lead time 1.6582 bar – Turn, thread, harden, and machine again. Toolox – Gas cut, turn, thread. Steering wheel and crane wheel used in 10-15 similar applications.
  • 16. Bearing House
  • 17. Bearing House DESCRIPTION Bearing house for rollers in continuous caster ⌀ 230 mm L 60 mm Corrosion and cyclic thermal load ➠ Toolox 33 EXPERIENCE Increased lifetime from 6 months to at least 1 year. Easily gas cut and machined. Rollers surface welded with stainless steel electrodes to protect against corrosion. Since 2006 standard for this application.
  • 18. Support Beams
  • 19. Support Beams
  • 20. Support Beams DESCRIPTION Support beams for rollers in continuous caster All materials pass through continuous caster. 1900 x 200 x 40 mm ➠ Toolox 33 NITRIDED EXPERIENCE Machine easily and to close tolerances. Black nitriding to resist wear and corrosion. High quality control and guaranteed properties. Very important in this sensitive application. Since 2010 solution introduced as standard. More than 125 pieces manufactured.
  • 21. Rolling Mill
  • 22. Slide Rails
  • 23. Slide Rails DESCRIPTION Slide rails to guide and move rollers Rollers slide on rails when moved for regrinding. Each roller weighs 40-50 tonnes. Lengths up to 2500 mm Thicknesses 30, 50.7, 86 mm 1.7225 / 42CrMo4 ➠ Toolox 33 NITRIDED EXPERIENCE Excellent flatness and dimensional stability. Black nitriding to resist wear and corrosion. 64 rails produced, total length 121.7 m. Rails installed 2009, since then running perfectly.
  • 24. Step Plate
  • 25. Step Plate
  • 26. Step Plate DESCRIPTION Step plate to adjust height of rollers in mill 1199 x 850 x 210 mm, 1199 x 1050 x 150 mm 1.6582 INDUCTION HARDENED, 1.2738 HH ➠ Toolox 33 EXPERIENCE Require high strength and toughness. 1.6582 low strength. 1.2728 HH cracked as well as Toolox 44. Forged Toolox cut then machined to final piece Thicker piece gas cut. Thinner piece waterjet cut.
  • 27. Rocker Plate
  • 28. Rocker Plate DESCRIPTION Base plate to support HGC hydraulic cylinder Sits on top of step plate in rolling mill. 2020 x 1490 x 110 mm Require very good flatness. St52-3 / 1.0570 ➠ Toolox 33 EXPERIENCE Machining and welding strips at edges. Dimensional stability and precision allowed for faster manufacturing. Replaced every 2-3 years due to corrosion and wear.
  • 29. Sleeve Bushing
  • 30. Sleeve Bushing DESCRIPTION Sleeve to cover cracked rollers. Replacement roller took over a month to deliver. Rollers ⌀ 950 mm L 1087 mm Sleeve ⌀ 950 mm L 300 mm 17CrNiMo6 CASE HARDENING ➠ Toolox 33 EXPERIENCE 2 rings of thickness 165 mm used Cut, bent, welded, and crimped onto roller Production downtime minimized while waiting for replacement roller.
  • 31. Gear Rack
  • 32. Gear Rack DESCRIPTION Gear rack in rolling mill Sits on ruler arms to guide and center the plates. 2614 x 210 x 66 mm 1.7225 / 42CrMo4 V ➠ Toolox 33 EXPERIENCE Gas cut 70 mm plate and machined. Very happy due to fast machining and high dimensional stability. Since 2007 introduced as standard. Gear racks replaced every 2-3 years due to corrosion and wear.
  • 33. Wear Protection Plate
  • 34. Wear Protection Plate
  • 35. Wear Protection Plate DESCRIPTION Wear protection plate in four-high rolling mill. Used in several different positions. Dimension Example 1285 x 1000 x 38 mm Demanding operating conditions. Sliding forces when rolls lowered towards steel, with 1 million cycles per year. Corrosive atmosphere with grease, scale and water. Previous material uneconomical to produce, risk of cracks, long delivery time. Compound Plate (Soft / 60 HRC) ➠ Toolox 44 NITRIDED
  • 36. Wear Protection Plate Compound Plate (Soft / 60 HRC) ➠ Toolox 44 NITRIDED EXPERIENCE More economical production Gas cut 43 mm, machined, black nitrided. Good performance. Hardness 64-71 HRC ensures wear resistance. Black nitriding also ensures corrosion resistance. Toughness of Toolox ensures crack resistance. Introduced in 2003 and now standard for over 40 similar wear pieces. Some positions corrosion and deformation still play a role, but Toolox 44 the best solution for the application.
  • 37. Chain Gear
  • 38. Chain Gear DESCRIPTION Chain gear in steel plate conveyor Conveyor driving steel plates into a heating furnace. Previously one piece milled from ⌀ 380 mm round. 80% material waste. 1.7218 / 25CrMo4 ➠ Toolox 44 EXPERIENCE New design gives less material cost. Collar in mild steel. Gears in Toolox ⌀ 368 mm L 174 mm Much longer lifetime.
  • 39. Wedge
  • 40. Wedge DESCRIPTION Wedges to optimize space between shear blades. 4600 x 170 x 70 mm Require high flatness and precise tolerances. 1.6582, C45 ➠ Toolox 33 EXPERIENCE Easier machining due dimensional stability. Water cut 84 mm plate, machined, put in use. Toolox 33 now used as standard for this solution.
  • 41. Knife Support
  • 42. Knife Support DESCRIPTION Knife support for steel plate shear in rolling mill. 4000 x 230 x 80 mm Require flatness of 0.1 mm over 4000 mm. Failure due to plastic deformation after 1 year. 1.7218 / 25CrMo4 ➠ Toolox 33 EXPERIENCE Manufacturing much faster. Previous material milled both sides from 104 mm. Toolox milled from one side only. Support now replaced intervals of 2-3 years. Toolox now the standard for this application.
  • 43. Shear Blade
  • 44. Shear Blade DESCRIPTION Shear blade to cut Hardox / Weldox steel plates. Used in different cutting machines. Dimension Example 3700 x 200 x 70 mm 1.2767 HT 50 HRC ➠ Toolox 44 NITRIDED
  • 45. Shear Blade 1.2767 HT 50 HRC ➠ Toolox 44 NITRIDED EXPERIENCE Each corner used until worn out. 8000 cuts / corner and a life of one month. Knife rotated so all 4 corners used. Then short edges of knife remachined and knife put back in use. No need for re-nitriding. Superior performance High strength and wear resistance. Nitriding layer prevents debris sticking to surface
  • 46. Cutting Blade
  • 47. Cutting Blade DESCRIPTION Blades for cutting plates in rolling mill. 300 x 48 x 16 mm ➠ Toolox 44 NITRIDED EXPERIENCE Gas cut, machined, nitrided. Low manufacturing cost for each blade.
  • 48. Hydraulic Cylinder Base
  • 49. Hydraulic Cylinder Base DESCRIPTION ⌀ 292 mm L 99 mm 1.6582 / 34CrNiMo6 ➠ Toolox 33 EXPERIENCE 104 mm gas cut, treated, machined to final piece. Advantages homogeneity and shape stability Very important in hydraulic components.
  • 50. Bearing House
  • 51. Bearing House DESCRIPTION Bearing house for plate leveler 320 x 210 x 110 mm Thin walls around bearing 1.7218 / GS25CrMo4 VII ➠ Toolox 33 EXPERIENCE Gas cut Toolox and machined to final piece. Meets dimensional stability requirement in machining. Bearing houses changed typically every 1-2 years. Since 2007 standard in several similar machines.
  • 52. Finishing & Testing
  • 53. Wheel Hub
  • 54. Wheel Hub DESCRIPTION Wheel hub for heavy duty trucks High forces on the hub with loads up to 40 tonnes. ⌀ 773 mm L 317 mm Replacement hubs take 3 months delivery Cast Material ➠ Toolox 33 EXPERIENCE In-house manufacturing possible 3 rings from 130 mm cut, welded, machined. Works perfectly since 2007.
  • 55. Brake Disc
  • 56. Brake Disc DESCRIPTION Brake disc of large slag transport truck 8 discs on each truck. Elevated temperature during braking. ~ ⌀ 500 mm Cast Material ➠ Toolox 44 EXPERIENCE High temperature properties Faster delivery, lower cost. Discs produced from plates. Cost saving of 550 euro / disc Increased toughness.
  • 57. Rotation Bar
  • 58. Rotation Bar DESCRIPTION Rotation bar in slag transport truck. 2 bars on each truck. ~ ⌀ 300 mm 240 HB Material ➠ Toolox 44 EXPERIENCE Longer lifetime. Previously failure due to wear. Higher strength, hardness, toughness. Forged bar 300 mm of Toolox used.
  • 59. Axles & Axle Trees
  • 60. Axles & Axle Trees
  • 61. Axles & Axle Trees DESCRIPTION Axle and axle trees used in slag transport truck. 42CrMo4 / 1.7225 ➠ Toolox 44 EXPERIENCE Axles made from ⌀ 280 mm bars. Axle trees hard-face welded and milled. Less wear than previous solution. Running since 2010.
  • 62. Sprocket Wheels
  • 63. Sprocket Wheels
  • 64. Sprocket Wheels DESCRIPTION Sprocket wheels in steel plate painting line. Wheels are scrapped when the teeth are worn out. ⌀ 680 mm L 180 mm C 45 ➠ Toolox 33 EXPERIENCE Triplex pinion was made with 3 plates of 80 mm gas cut and machined. Avoided long delivery time of cast material. Better lifetime and high reliability. Running since 2006.
  • 65. Shot Blasting Ramp
  • 66. Shot Blasting Ramp DESCRIPTION Shot blasting ramp in de-scaling system. Water nozzles are positioned in the holes. Entire ramp previously made from cast material. Cast Material ➠ Toolox 44 EXPERIENCE New design gives much longer life. Toolox in most worn part of ramp 3770 mm x 250 mm x 70 mm Flatness requirement and precise tolerances. Easy maintenance with removable part. First time installed 2008, remade in 2013.
  • 67. Pinion
  • 68. Pinion DESCRIPTION Pinion in cutting machine Driving cutting machine by running against gear rack. ⌀ 80 mm L 61 mm 1.6582 / 34CrNiMo6 NITRIDED ➠ Toolox 33 NITRIDED EXPERIENCE Gas cut 70 mm plate, machined, nitrided. Performing perfectly since 2006.
  • 69. Saw Support
  • 70. Saw Support DESCRIPTION Support sitting behind circular saw. 710 x 100 x 40 mm Previous material short lifetime and difficult to achieve small tolerances in manufacturing. ➠ Toolox 44 NITRIDED EXPERIENCE 43 mm gas cut, machined, nitrided. In use since 2006 with perfect result.
  • 71. Boring Tool Support
  • 72. Boring Tool Support DESCRIPTION Tool support for boring large holes. Holes up to 1000 mm diameter. Method gives closer tolerances and better surfaces than normal milling. Used Toolox due to availability. ➠ Toolox 33 EXPERIENCE Component meets dimensional requirements. Good result in usage.
  • 73. Machine Frame
  • 74. Machine Frame DESCRIPTION Machine frame of tensile testing equipment. On average 700 specimens tested weekly. Maximum load force reaches up to 95 ton. C45 HARDENED, St52-2 ➠ Toolox 33 EXPERIENCE Easy machining. Much longer service life. No cracking as compared to C45. More resistant to deformations as compared to St52. Sliding surface deformed only 5/100 mm in Toolox frame after 1 year vs 16/100 mm in St52 after failure.
  • 75. Vices
  • 76. Vices DESCRIPTION Vices to clamp specimen in tensile testing. Previous material failure due to cracking and wear. 1.2358 HT 55 HRC + NITRIDED ➠ Toolox 44 NITRIDED EXPERIENCE First test with Toolox 33. Low lifetime due to plastic deformation. Toolox 44 machined, textured, nitrided. Much longer service life. 1.2358 need 24-28 pieces annually. Toolox 44 need 6-8 pieces annually.
  • 77. Hydraulic Cylinder
  • 78. Hydraulic Cylinder DESCRIPTION Hydraulic cylinder in tensile testing machine. Push shoes locking the steel test specimens. Found in both upper and lower part of machine. High demands on cylinders. Extreme and repetitive forces. C60, C45 HT 63 HRC ➠ Toolox 44 NITRIDED EXPERIENCE Milled, turned, grinded, nitrided. Since 2005 working perfectly. Failure of regular C60 due to low strength. Failure of heat treated C45 due to cracking.
  • 79. Tensile Jaw
  • 80. Tensile Jaw DESCRIPTION Tensile jaws in in tensile testing machine Strong material needed due to high forces ➠ Toolox 44 NITRIDED EXPERIENCE Machined, textured, nitrided. Longer lifetime than original material.
  • 81. Fixture
  • 82. Fixture DESCRIPTION Fixture used to hold and prepare samples. Strong and tough material required. Guarantee tolerances and avoid cracks. ➠ Toolox 44 NITRIDED EXPERIENCE Gas cut, machined, nitrided. Works perfectly since 2007.
  • 83. Fixture
  • 84. Fixture DESCRIPTION Fixture to clamp work-piece in circular saw 100 x 30 x 17.3 mm 1.2311 NITRIDED, Hardox 500 ➠ Toolox 44 NITRIDED EXPERIENCE Gas cut, strips sawed, machined and nitrided. In operation since 2007 with perfect result.
  • 85. Rail Connection
  • 86. Rail Connection DESCRIPTION Rail connection in harbour crane. Every crane wheel pass local deformation. 1000 cycles / day. Previous material lifetime one year. St52-3 / 1.0570 ➠ Toolox 33 EXPERIENCE 70 mm plate cut and machined. Much longer lifetime. Now can replace rail and connection at same time.