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Development of dull finish
on 301L SS
Development of Dull Finish on 301L SS
Manufacturing
Development of dull finish on 301L SS
• Why is dull finish specified for Metro car exterior
panel (ROTEM, Korea)?
• It is not a scratched finish like 2J, No.4 etc or
random dimples as in bead blasting
• The finish is impregnated on the sheet
• It is non-directional facilitating easier fabrication
• It is more resistant to corrosion from external
atmosphere.
What is the specification?
• En 10088.2-2F
• Cold rolled heat-treated skin passed on roughened rolls
• Uniform non-reflective matt finish
• NISSHIN
• Emboss (provided with irregularities on one side by cold rolling)
• JIS/ASIM
• Nil
• IS-6911
• Any finish mutually agreed
• BEML-Original spec(ROTEM) cold rolling with etched roll
• 26-28% gloss at 60° standard
• 1.27-1.29 Ra
• BEML-Revised
• Glossiness (GU)-35±5 with 60° reflective standard
• Ra-4.5±0.5
Development of dull finish
on 301L SS
• Why is BEML not moving from DF to 2J or No 4
(used by ALSTOM and ALSTOM bombardier)
• BEML supplies to Bangalore metro
• All cars to have the same finish
• Even for the order for CRRC, China, Bangalore
metro insist on DF
• But Delhi metro had requested 2J finish for BEML
supply to Mumbai. This, as I understand, was
spearheaded by JSL.
How do we produce scratched rolls
for DF rolling?
• Rolls can be made by
• Chemical photo etching
• EDT
• LASER
• Bead blasting
Rolling process for DF
Rolling process for DF
Option 1:20 Hi-Mill
Rolling process for DF
Option 2: 4Hi/2Hi-SkinPassMill
Rolling process for DF
Option 1: 20 Hi-Mill
Advantages
• Small diameter work roll -- Less cost for etching
• Uniform loading -- Better finish quality all over width
• Lubrication during boiling -- Less heat on strip
Rolling process for DF
Option 1: 20 Hi-Mill
Disadvantages
• Higher reduction needed – To prevent slippage
• Rolling speed to be less – Contact area is less
• Load/Tension to be less – To prevent slippage
• Lubricant usage – Extra operation of De-oiling
• Defect repeat in strip – More
Rolling process for DF
Option 2: 4Hi/2Hi-SkinPassMill
Advantages
• Larger diameter rolls – Larger contact area
– No slippage
• Lower reduction – better finish
• Dry process – No additional process
• Roll life – higher
• Defect repeat in strip – Less
Rolling process for DF
Option 2: 4Hi/2Hi-SkinPassMill
Disadvantage
Large diameter rolls – cost of etching is high
Removal of rough edges(burr) – Air blow required
Roll texturing process
• Chemical etching with photo film
• Bead blasting
• Electro discharge
• LASER
Chemical etching with photo film
Advantage
• Cheaper
Disadvantage
• Control on roughness not possible
• Acid usage for etching
• Discontinuity of finish if film gets damaged
• Joint line matching
Bead blasting
Advantage
• Faster
• Cheaper
• Simple process
Disadvantage
• No control on roughness
• Discontinuity
Electro discharge process
Advantage
• Uniformity of texture
• Control of roughness
• Reproducible
• Automatic
Disadvantage
• Costly
LASER texturing
Advantage
• Uniformity on finish
• Control of roughness
• Reproducible
• Automatic
Disadvantage
• Costly
Application of textured roll in cold rolling
• Mainly used for CR coils used for Autobody, white
goods
• Helps in corrosion protection treatment and final
painting
• Other than for BEML Metro panel application
• DF can be promoted in Rail coach panel sheets
• This can avoid Grit blasting and other surface preparations
• Now carried out on Rail coach shell
Facilities for DF rolls in India
EDT machines in
• JSW, Tornagalu
• Tata (Bushan), Sahibabad
• SAIL (Bokaro)
• Urjaa Metalics, Haryana, Riwari
LASER texturing in
• Noida
Etching in
• Delhi
• Ahmedabad
• Mumbai
Development of Dull finish on 301L SS
Single side Embossing line - China
Embossing rolls-4Hi
Single side Embossing Machine- China
Relationship of Roughness transfer
ratio and Rolling/Compressive force
Roll roughness to sheet roughness DF
Roll roughness to sheet roughness DF
Roll texturing methods
Picture of DF
Presently procured by BEML indigenously
DF development in 2009
DF trial in 2009
DF trial in 2009
DF trials in 2017
DF trials in 2017
Bead blasted DF trials in Rolling Mill
at Hisar
• Two rolls bead blasted at Jodhpur
• Tried in 20Hi-Mill
• The impression on the roll gave way
• Possible reasons:
• Depth of Bead blast - low
• Load and reduction – on higher side
Let us debate

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Development of dull finish on 301L SS.pptx

  • 1. Development of dull finish on 301L SS
  • 2. Development of Dull Finish on 301L SS Manufacturing
  • 3. Development of dull finish on 301L SS • Why is dull finish specified for Metro car exterior panel (ROTEM, Korea)? • It is not a scratched finish like 2J, No.4 etc or random dimples as in bead blasting • The finish is impregnated on the sheet • It is non-directional facilitating easier fabrication • It is more resistant to corrosion from external atmosphere.
  • 4. What is the specification? • En 10088.2-2F • Cold rolled heat-treated skin passed on roughened rolls • Uniform non-reflective matt finish • NISSHIN • Emboss (provided with irregularities on one side by cold rolling) • JIS/ASIM • Nil • IS-6911 • Any finish mutually agreed • BEML-Original spec(ROTEM) cold rolling with etched roll • 26-28% gloss at 60° standard • 1.27-1.29 Ra • BEML-Revised • Glossiness (GU)-35±5 with 60° reflective standard • Ra-4.5±0.5
  • 5. Development of dull finish on 301L SS • Why is BEML not moving from DF to 2J or No 4 (used by ALSTOM and ALSTOM bombardier) • BEML supplies to Bangalore metro • All cars to have the same finish • Even for the order for CRRC, China, Bangalore metro insist on DF • But Delhi metro had requested 2J finish for BEML supply to Mumbai. This, as I understand, was spearheaded by JSL.
  • 6. How do we produce scratched rolls for DF rolling? • Rolls can be made by • Chemical photo etching • EDT • LASER • Bead blasting
  • 8. Rolling process for DF Option 1:20 Hi-Mill
  • 9. Rolling process for DF Option 2: 4Hi/2Hi-SkinPassMill
  • 10. Rolling process for DF Option 1: 20 Hi-Mill Advantages • Small diameter work roll -- Less cost for etching • Uniform loading -- Better finish quality all over width • Lubrication during boiling -- Less heat on strip
  • 11. Rolling process for DF Option 1: 20 Hi-Mill Disadvantages • Higher reduction needed – To prevent slippage • Rolling speed to be less – Contact area is less • Load/Tension to be less – To prevent slippage • Lubricant usage – Extra operation of De-oiling • Defect repeat in strip – More
  • 12. Rolling process for DF Option 2: 4Hi/2Hi-SkinPassMill Advantages • Larger diameter rolls – Larger contact area – No slippage • Lower reduction – better finish • Dry process – No additional process • Roll life – higher • Defect repeat in strip – Less
  • 13. Rolling process for DF Option 2: 4Hi/2Hi-SkinPassMill Disadvantage Large diameter rolls – cost of etching is high Removal of rough edges(burr) – Air blow required
  • 14. Roll texturing process • Chemical etching with photo film • Bead blasting • Electro discharge • LASER
  • 15. Chemical etching with photo film Advantage • Cheaper Disadvantage • Control on roughness not possible • Acid usage for etching • Discontinuity of finish if film gets damaged • Joint line matching
  • 16. Bead blasting Advantage • Faster • Cheaper • Simple process Disadvantage • No control on roughness • Discontinuity
  • 17. Electro discharge process Advantage • Uniformity of texture • Control of roughness • Reproducible • Automatic Disadvantage • Costly
  • 18. LASER texturing Advantage • Uniformity on finish • Control of roughness • Reproducible • Automatic Disadvantage • Costly
  • 19. Application of textured roll in cold rolling • Mainly used for CR coils used for Autobody, white goods • Helps in corrosion protection treatment and final painting • Other than for BEML Metro panel application • DF can be promoted in Rail coach panel sheets • This can avoid Grit blasting and other surface preparations • Now carried out on Rail coach shell
  • 20. Facilities for DF rolls in India EDT machines in • JSW, Tornagalu • Tata (Bushan), Sahibabad • SAIL (Bokaro) • Urjaa Metalics, Haryana, Riwari LASER texturing in • Noida Etching in • Delhi • Ahmedabad • Mumbai
  • 21. Development of Dull finish on 301L SS
  • 22. Single side Embossing line - China Embossing rolls-4Hi
  • 23. Single side Embossing Machine- China
  • 24. Relationship of Roughness transfer ratio and Rolling/Compressive force
  • 25. Roll roughness to sheet roughness DF Roll roughness to sheet roughness DF
  • 27. Picture of DF Presently procured by BEML indigenously
  • 29. DF trial in 2009
  • 30. DF trial in 2009
  • 31. DF trials in 2017
  • 32. DF trials in 2017
  • 33. Bead blasted DF trials in Rolling Mill at Hisar • Two rolls bead blasted at Jodhpur • Tried in 20Hi-Mill • The impression on the roll gave way • Possible reasons: • Depth of Bead blast - low • Load and reduction – on higher side