This document discusses recent technologies in cold rolling mills to improve product quality, as presented by SMS Demag AG. It describes Edge Drop Control systems that help achieve constant strip thickness across the width. It also details the T-roll® process technology package for simulating cold rolling processes. Furthermore, it presents a new lubrication and cleaning concept combining low-quantity lubrication with liquid nitrogen to improve strip surface quality. Online measuring systems are also discussed for documenting product quality parameters.
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
This document discusses time-temperature-transformation (TTT) diagrams and continuous cooling transformation (CCT) diagrams. TTT diagrams show the transformation of austenite at constant temperatures over time, indicating what microstructures form during different cooling rates. CCT diagrams track phase changes during continuous cooling at various cooling rates. Both diagrams are important for selecting processing conditions to achieve desired material properties in steels. The document provides detailed explanations of the various microstructures - pearlite, bainite, martensite - that form during austenite decomposition, and how TTT and CCT diagrams can be used to understand their formation.
The HYL process uses natural gas to directly reduce iron ore into DRI through a gas-based reduction process. It was developed in the 1950s in Mexico. The HYL process uses fixed bed reactors that are heated to reduce iron ore pellets or lumps into sponge iron using a mixture of carbon monoxide and hydrogen produced from the reforming of natural gas. Later developments included moving to a single rotating shaft furnace (HYL III) and allowing production of DRI, HBI, or hot briquetted iron.
This document provides an overview of metal heat treating presented by various individuals. It discusses what metal heat treating is, where it is used, why and how it is done, common heat treating processes and equipment. Specific details covered include commonly heat treated metals, types of heat treating furnaces, importance of protective atmospheres, and different heat treating processes like annealing. The document is intended to educate about key aspects of industrial metal heat treating.
Control of Cooling in Continuous Casting of Thin Steel SlabsBishoy Saeed
This document discusses the development of a digital control system for the secondary cooling process in continuous casting machines used in steel plants. Maintaining the desired temperature is important for optimizing steel quality, as over 96% of steel produced in the US goes through continuous casting. The control system aims to address issues like cracks caused by temperature variations during cooling by setting optimal spray water flow rates, as conventional feedback control cannot rely on temperature sensors. Mathematical models are being developed to predict factors like shell thickness, temperature distribution, and metallurgical length to help with control.
The document provides information on electric arc furnaces used for steelmaking. It describes how arc furnaces use electric arcs to melt scrap metal and discusses their advantages over traditional blast furnaces. Key points include that arc furnaces can be rapidly started and stopped to vary production according to demand, use 100% scrap metal which reduces energy needs compared to primary steelmaking, and mini-mills using arc furnaces can be located near consumer markets. The document also outlines some environmental issues associated with arc furnace operation like noise, dust, and impacts of electricity generation.
The document provides an overview of the process flow for Khopoli Steel Plant, including HR slitting, pickling, and cold rolling mill (CRM). The HR slitting process involves cutting wider hot rolled coils into narrower coils for uniform width and to remove damaged edges. Pickling uses HCL acid to remove impurities from ferrous metals. The CRM uses 6- and 4- high mills to cold roll pickled strips, reducing thickness by up to 90% to strengthen the metal through strain hardening and improve surface finish and tolerances.
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
This document discusses time-temperature-transformation (TTT) diagrams and continuous cooling transformation (CCT) diagrams. TTT diagrams show the transformation of austenite at constant temperatures over time, indicating what microstructures form during different cooling rates. CCT diagrams track phase changes during continuous cooling at various cooling rates. Both diagrams are important for selecting processing conditions to achieve desired material properties in steels. The document provides detailed explanations of the various microstructures - pearlite, bainite, martensite - that form during austenite decomposition, and how TTT and CCT diagrams can be used to understand their formation.
The HYL process uses natural gas to directly reduce iron ore into DRI through a gas-based reduction process. It was developed in the 1950s in Mexico. The HYL process uses fixed bed reactors that are heated to reduce iron ore pellets or lumps into sponge iron using a mixture of carbon monoxide and hydrogen produced from the reforming of natural gas. Later developments included moving to a single rotating shaft furnace (HYL III) and allowing production of DRI, HBI, or hot briquetted iron.
This document provides an overview of metal heat treating presented by various individuals. It discusses what metal heat treating is, where it is used, why and how it is done, common heat treating processes and equipment. Specific details covered include commonly heat treated metals, types of heat treating furnaces, importance of protective atmospheres, and different heat treating processes like annealing. The document is intended to educate about key aspects of industrial metal heat treating.
Control of Cooling in Continuous Casting of Thin Steel SlabsBishoy Saeed
This document discusses the development of a digital control system for the secondary cooling process in continuous casting machines used in steel plants. Maintaining the desired temperature is important for optimizing steel quality, as over 96% of steel produced in the US goes through continuous casting. The control system aims to address issues like cracks caused by temperature variations during cooling by setting optimal spray water flow rates, as conventional feedback control cannot rely on temperature sensors. Mathematical models are being developed to predict factors like shell thickness, temperature distribution, and metallurgical length to help with control.
The document provides information on electric arc furnaces used for steelmaking. It describes how arc furnaces use electric arcs to melt scrap metal and discusses their advantages over traditional blast furnaces. Key points include that arc furnaces can be rapidly started and stopped to vary production according to demand, use 100% scrap metal which reduces energy needs compared to primary steelmaking, and mini-mills using arc furnaces can be located near consumer markets. The document also outlines some environmental issues associated with arc furnace operation like noise, dust, and impacts of electricity generation.
The document provides an overview of the process flow for Khopoli Steel Plant, including HR slitting, pickling, and cold rolling mill (CRM). The HR slitting process involves cutting wider hot rolled coils into narrower coils for uniform width and to remove damaged edges. Pickling uses HCL acid to remove impurities from ferrous metals. The CRM uses 6- and 4- high mills to cold roll pickled strips, reducing thickness by up to 90% to strengthen the metal through strain hardening and improve surface finish and tolerances.
The document is an industrial training report submitted by Abhishek Prajapati to OP Jindal University about his 4-week training at the DRI-1 (Direct Reduced Iron) section of Jindal Steel & Power Limited (JSPL) in Raigarh, Chhattisgarh, India. It provides an overview of the DRI production process, including information on raw materials, the rotary kiln, rotary cooler, and power distribution systems. The student thanks his guides Mr. Vivek Garg and Mr. Shalendra Pratap Singh for enabling his learning experience at the facility.
B.Sc. (Engineering)
Department of Mechanical Engineering
Khulna University of Engineering & Technology
Course - Manufacturing Process
Topic - Welding, Brazing & Soldering
The document discusses various metal casting processes and techniques. It provides an overview of sand casting, describing the key steps of pouring molten metal into a sand mold, allowing it to solidify, breaking up the mold, and cleaning the casting. It also discusses mold materials, gating systems, risers, solidification processes for pure metals and alloys, and shrinkage and directional solidification techniques.
Shell moulding is a casting process that uses a sand-resin mixture to form a disposable mould around a reusable pattern. This allows for higher production rates than sand casting while also enabling more complex part geometries. The process involves creating a metal pattern, heating it, applying a sand-resin mixture to form shell halves, joining the shells to create the mould, pouring molten metal, and removing the casting after solidification. Shell moulding provides better dimensional accuracy, higher productivity, and lower labor costs than sand casting for small to medium precision parts.
Rourkela Steel Plant was the first in Asia to adopt the LD steelmaking process and the first in India to use external desulphurization. It is also the only plant where 100% of slabs are continuously cast. The steelmaking process in SMS involves charging hot metal, scrap, and fluxes into converters where oxygen is blown to remove impurities through oxidation, producing slag. Molten steel is tapped and further processed before continuous casting into slabs. Waste gases are captured and recycled while dust and slag are also recycled in the process.
The document discusses various heat treatment processes including annealing, normalizing, hardening, tempering, and analyzing hardenability. Annealing involves heating material to relieve stresses and improve ductility. Normalizing is similar but involves faster cooling in air to refine grain structure. Hardening increases hardness through rapid quenching from austenitizing temperatures resulting in martensite formation. Tempering improves toughness of hardened steel by reheating to precipitate carbides. Hardenability is measured using the Jominy end quench test and indicates the depth of hardness achieved during quenching.
1) During welding, the material experiences a thermal cycle where it is rapidly heated and more slowly cools. This temperature cycle influences the structure and properties of the material.
2) Analytical equations are presented to describe the temperature distribution and peak temperatures experienced during welding. These equations simplify the complex heat transfer process.
3) The shape and size of the weld pool impacts the solidified weld metal microstructure. Flow within the molten weld pool is driven by surface tension gradients and electromagnetic forces, influencing the weld pool shape.
The document discusses key aspects of blast furnace design and operation, including:
1. Blast furnace productivity depends on optimal gas flow and smooth, rapid burden descent which requires an optimized furnace profile and lines.
2. Effluent gas from the furnace contains 20-30% CO by volume and is cleaned through three stages before use to reduce dust from 7-30 g/m3 to 0.01 g/m3.
3. Stoves are used to heat incoming blast with heat from cleaned furnace gas in a cyclic process, maintaining a steady, preheated blast supply to the furnace.
An electric induction furnace uses electromagnetic induction to melt metals through eddy currents induced in the material. It has several advantages over combustion furnaces like faster startup times, more flexibility, and cleaner melting without byproducts. The document describes the basic principles of electromagnetic induction and joule heating used in induction furnaces. It provides details on the construction, types, advantages, and limitations of induction furnaces.
Tempering is a heat treatment process that reduces the brittleness of hardened steel without significantly lowering its hardness and strength. It involves heating hardened steel to a temperature below the eutectoid temperature and allowing it to cool slowly. This process reduces brittleness by allowing the formation of tempered martensite from martensite and decreasing internal stresses. Tempering may also cause some reduction in hardness. In alloy steels, tempering can result in secondary hardening due to precipitation of alloy carbides that increase hardness even as tempering progresses.
The document discusses various heat treatment processes including annealing, normalizing, quenching, and martensitic transformation. It provides details on the purposes, methods, and applications of each process. Annealing involves heating and slow cooling to relieve stresses and modify properties. Normalizing heats above the transformation temperature and air cools to produce a fine grain structure. Quenching rapidly cools steel above the transformation temperature to form very hard martensite. Martensitic transformation is the formation of acicular needlelike structures during rapid cooling of austenite.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
The document discusses various heat treatment processes used to alter the properties of metals and alloys. It describes processes like normalizing, annealing, hardening, and tempering. Normalizing involves heating above the critical temperature and air cooling to refine grains. Annealing fully softens metals by heating above the critical temperature and slow cooling. Hardening involves heating above the critical temperature and quenching in water or oil to form martensite. Tempering reduces the brittleness of hardened steel by reheating below the critical temperature.
This document provides an overview of various surface hardening techniques including case hardening methods like carburizing, nitriding, and carbonitriding which involve diffusing carbon and/or nitrogen into the surface of steel. It also discusses selective surface hardening techniques like induction hardening where only the surface is heated and quenched to produce a hard martensitic case. Common components that undergo surface hardening are gears, bearings, valves, and machine tool components to improve properties like wear and fatigue resistance. Induction hardening involves inducing current in metal to quickly heat just the surface layer to about 750-850 degrees Celsius before quenching.
The document discusses heat treatment processes for metals like steel. It describes the purposes of heat treatment as relieving stress, improving machinability, and changing grain structure. Specific heat treatment processes covered include annealing, normalizing, hardening, and tempering. Annealing involves slowly heating and cooling to soften metals. Normalizing heats above critical temperature and air cools for hardness. Hardening rapidly cools from above critical temperature to form martensite for maximum hardness. Tempering then reheats hardened steel to relieve brittleness.
The document discusses various types of engineering materials including metals and their classification. It begins by introducing metallic materials and their properties. It then discusses the two main categories of metals - ferrous and non-ferrous metals. Ferrous metals contain iron while non-ferrous metals do not. The document further discusses various ferrous metals like steel and its alloys. It also discusses common non-ferrous metals like aluminum, zinc and copper. The classification of materials into ferrous and non-ferrous is described. Mechanical properties testing methods like tensile testing and hardness testing are also summarized.
The document discusses the structure and properties of metallurgical slags. It states that slags comprise complex compounds of oxides from gangue minerals and sulphides that protect the metal melt. The structure and properties of slags, such as basicity and viscosity, are controlled by their composition. Network forming oxides like SiO2 form stable hexagonal networks, while network breaking oxides like CaO disrupt these networks. The fraction of ionic and covalent bonding in oxides determines their behavior in slags.
SMELTING REDUCTION:AN ALTERNATIVE TO PIG IRON PRODUCTIONNishantKumarMehta
This document summarizes several alternative iron making technologies to the traditional blast furnace process, including direct reduction processes like FINEX and HIsmelt, and smelting reduction processes like Corex and Ausmelt. It describes the basic processes and reactions, advantages like flexibility and lower emissions, and disadvantages such as higher costs. Key alternative processes discussed are FINEX, INRED, ELRED, Ausmelt, HIsmelt, and Corex, with summaries of their process designs and operating principles.
The document discusses optimizing the capacity and surface quality of a pickling line using the Detmaster MPG Pickling Grade Measurement System. In a pickling process, residual scale from hot rolling is removed through chemical reaction in pickling tanks. The system aims to achieve the nominal level of scale removal while maximizing production capacity. It introduces a new highly sensitive technology that can continuously measure residual scale across the entire strip surface with changes below 2% detectable. This provides operators real-time visualization to precisely control line speeds and processing for each steel grade, increasing capacity by an estimated minimum of 5% without other investments.
The document discusses challenges and guidelines for printing solder paste with step stencils. It analyzes how factors like squeegee speed, pressure, angle, and material affect the amount of paste residue near step edges. Testing showed circular apertures near steep step downs had lower transfer efficiency than oblong apertures due to more residue. Guidelines recommend reducing speed, increasing pressure, changing the angle to 45°, and using a polymer squeegee to minimize residue for consistent paste transfer. Apertures far from step edges showed high transfer efficiency regardless of geometry or step height.
The document is an industrial training report submitted by Abhishek Prajapati to OP Jindal University about his 4-week training at the DRI-1 (Direct Reduced Iron) section of Jindal Steel & Power Limited (JSPL) in Raigarh, Chhattisgarh, India. It provides an overview of the DRI production process, including information on raw materials, the rotary kiln, rotary cooler, and power distribution systems. The student thanks his guides Mr. Vivek Garg and Mr. Shalendra Pratap Singh for enabling his learning experience at the facility.
B.Sc. (Engineering)
Department of Mechanical Engineering
Khulna University of Engineering & Technology
Course - Manufacturing Process
Topic - Welding, Brazing & Soldering
The document discusses various metal casting processes and techniques. It provides an overview of sand casting, describing the key steps of pouring molten metal into a sand mold, allowing it to solidify, breaking up the mold, and cleaning the casting. It also discusses mold materials, gating systems, risers, solidification processes for pure metals and alloys, and shrinkage and directional solidification techniques.
Shell moulding is a casting process that uses a sand-resin mixture to form a disposable mould around a reusable pattern. This allows for higher production rates than sand casting while also enabling more complex part geometries. The process involves creating a metal pattern, heating it, applying a sand-resin mixture to form shell halves, joining the shells to create the mould, pouring molten metal, and removing the casting after solidification. Shell moulding provides better dimensional accuracy, higher productivity, and lower labor costs than sand casting for small to medium precision parts.
Rourkela Steel Plant was the first in Asia to adopt the LD steelmaking process and the first in India to use external desulphurization. It is also the only plant where 100% of slabs are continuously cast. The steelmaking process in SMS involves charging hot metal, scrap, and fluxes into converters where oxygen is blown to remove impurities through oxidation, producing slag. Molten steel is tapped and further processed before continuous casting into slabs. Waste gases are captured and recycled while dust and slag are also recycled in the process.
The document discusses various heat treatment processes including annealing, normalizing, hardening, tempering, and analyzing hardenability. Annealing involves heating material to relieve stresses and improve ductility. Normalizing is similar but involves faster cooling in air to refine grain structure. Hardening increases hardness through rapid quenching from austenitizing temperatures resulting in martensite formation. Tempering improves toughness of hardened steel by reheating to precipitate carbides. Hardenability is measured using the Jominy end quench test and indicates the depth of hardness achieved during quenching.
1) During welding, the material experiences a thermal cycle where it is rapidly heated and more slowly cools. This temperature cycle influences the structure and properties of the material.
2) Analytical equations are presented to describe the temperature distribution and peak temperatures experienced during welding. These equations simplify the complex heat transfer process.
3) The shape and size of the weld pool impacts the solidified weld metal microstructure. Flow within the molten weld pool is driven by surface tension gradients and electromagnetic forces, influencing the weld pool shape.
The document discusses key aspects of blast furnace design and operation, including:
1. Blast furnace productivity depends on optimal gas flow and smooth, rapid burden descent which requires an optimized furnace profile and lines.
2. Effluent gas from the furnace contains 20-30% CO by volume and is cleaned through three stages before use to reduce dust from 7-30 g/m3 to 0.01 g/m3.
3. Stoves are used to heat incoming blast with heat from cleaned furnace gas in a cyclic process, maintaining a steady, preheated blast supply to the furnace.
An electric induction furnace uses electromagnetic induction to melt metals through eddy currents induced in the material. It has several advantages over combustion furnaces like faster startup times, more flexibility, and cleaner melting without byproducts. The document describes the basic principles of electromagnetic induction and joule heating used in induction furnaces. It provides details on the construction, types, advantages, and limitations of induction furnaces.
Tempering is a heat treatment process that reduces the brittleness of hardened steel without significantly lowering its hardness and strength. It involves heating hardened steel to a temperature below the eutectoid temperature and allowing it to cool slowly. This process reduces brittleness by allowing the formation of tempered martensite from martensite and decreasing internal stresses. Tempering may also cause some reduction in hardness. In alloy steels, tempering can result in secondary hardening due to precipitation of alloy carbides that increase hardness even as tempering progresses.
The document discusses various heat treatment processes including annealing, normalizing, quenching, and martensitic transformation. It provides details on the purposes, methods, and applications of each process. Annealing involves heating and slow cooling to relieve stresses and modify properties. Normalizing heats above the transformation temperature and air cools to produce a fine grain structure. Quenching rapidly cools steel above the transformation temperature to form very hard martensite. Martensitic transformation is the formation of acicular needlelike structures during rapid cooling of austenite.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
The document discusses various heat treatment processes used to alter the properties of metals and alloys. It describes processes like normalizing, annealing, hardening, and tempering. Normalizing involves heating above the critical temperature and air cooling to refine grains. Annealing fully softens metals by heating above the critical temperature and slow cooling. Hardening involves heating above the critical temperature and quenching in water or oil to form martensite. Tempering reduces the brittleness of hardened steel by reheating below the critical temperature.
This document provides an overview of various surface hardening techniques including case hardening methods like carburizing, nitriding, and carbonitriding which involve diffusing carbon and/or nitrogen into the surface of steel. It also discusses selective surface hardening techniques like induction hardening where only the surface is heated and quenched to produce a hard martensitic case. Common components that undergo surface hardening are gears, bearings, valves, and machine tool components to improve properties like wear and fatigue resistance. Induction hardening involves inducing current in metal to quickly heat just the surface layer to about 750-850 degrees Celsius before quenching.
The document discusses heat treatment processes for metals like steel. It describes the purposes of heat treatment as relieving stress, improving machinability, and changing grain structure. Specific heat treatment processes covered include annealing, normalizing, hardening, and tempering. Annealing involves slowly heating and cooling to soften metals. Normalizing heats above critical temperature and air cools for hardness. Hardening rapidly cools from above critical temperature to form martensite for maximum hardness. Tempering then reheats hardened steel to relieve brittleness.
The document discusses various types of engineering materials including metals and their classification. It begins by introducing metallic materials and their properties. It then discusses the two main categories of metals - ferrous and non-ferrous metals. Ferrous metals contain iron while non-ferrous metals do not. The document further discusses various ferrous metals like steel and its alloys. It also discusses common non-ferrous metals like aluminum, zinc and copper. The classification of materials into ferrous and non-ferrous is described. Mechanical properties testing methods like tensile testing and hardness testing are also summarized.
The document discusses the structure and properties of metallurgical slags. It states that slags comprise complex compounds of oxides from gangue minerals and sulphides that protect the metal melt. The structure and properties of slags, such as basicity and viscosity, are controlled by their composition. Network forming oxides like SiO2 form stable hexagonal networks, while network breaking oxides like CaO disrupt these networks. The fraction of ionic and covalent bonding in oxides determines their behavior in slags.
SMELTING REDUCTION:AN ALTERNATIVE TO PIG IRON PRODUCTIONNishantKumarMehta
This document summarizes several alternative iron making technologies to the traditional blast furnace process, including direct reduction processes like FINEX and HIsmelt, and smelting reduction processes like Corex and Ausmelt. It describes the basic processes and reactions, advantages like flexibility and lower emissions, and disadvantages such as higher costs. Key alternative processes discussed are FINEX, INRED, ELRED, Ausmelt, HIsmelt, and Corex, with summaries of their process designs and operating principles.
The document discusses optimizing the capacity and surface quality of a pickling line using the Detmaster MPG Pickling Grade Measurement System. In a pickling process, residual scale from hot rolling is removed through chemical reaction in pickling tanks. The system aims to achieve the nominal level of scale removal while maximizing production capacity. It introduces a new highly sensitive technology that can continuously measure residual scale across the entire strip surface with changes below 2% detectable. This provides operators real-time visualization to precisely control line speeds and processing for each steel grade, increasing capacity by an estimated minimum of 5% without other investments.
The document discusses challenges and guidelines for printing solder paste with step stencils. It analyzes how factors like squeegee speed, pressure, angle, and material affect the amount of paste residue near step edges. Testing showed circular apertures near steep step downs had lower transfer efficiency than oblong apertures due to more residue. Guidelines recommend reducing speed, increasing pressure, changing the angle to 45°, and using a polymer squeegee to minimize residue for consistent paste transfer. Apertures far from step edges showed high transfer efficiency regardless of geometry or step height.
Design and Fabrication of advanced Abrasive flow machine for superfinishing m...IRJET Journal
This document describes the design and fabrication of an advanced abrasive flow machining (AFM) system for superfinishing machine parts. It discusses the key components of the AFM system including the machine, media, and tooling. The machine components like the piston assembly, media cylinders, fixtures, and hydraulic power pack are designed to operate at pressures up to 10 MPa. Formulas are provided for calculating dimensions of these components to withstand operating pressures. The document also summarizes the sequence of AFM operation and presents surface roughness results indicating the system is capable of achieving a final roughness of 0.120 microns on EN8 steel.
Modern machine-shop-apr-18 centrifugal isofinishing crnakshaftsDave Davidson
See the technical article on Centrifugal Iso-Finishing on surface finish and it's effect on engine components in the Motorsports Industry terms of performance improvement.
Contact D. A. (Dave) Davidson at ddavidson@deburring-tech-group.com for additional information or help with free sample finishing.
This document provides information on the mission, vision, certifications, facilities, machinery, processes, and products of a company that manufactures custom designed heavy commercial vehicle bodies. The company's mission is to become a leading manufacturer in this industry by offering flexible, high-quality products at competitive rates. It aims to create a positive work environment for employees and maintain long-term relationships with vendors and suppliers. The company also strives to contribute to economic growth and environmental preservation in the local community.
Pipelines require strong materials to ensure safety and integrity. Thicker walled steel is increasingly used for pipelines to allow for higher pressures over long distances. Pipe bending machines must be able to handle these stronger steel grades. The article discusses how pipe bending machine specifications need to keep up with modern, higher strength steel pipe specifications in order to safely and properly install pipelines. It focuses on a company that builds powerful pipe bending machines capable of handling today's strongest steel grades to help supply the pipeline industry.
Kerone.com - Manufacturer, Supplier and Exporter of various type of coating machine like as Gravure Coater, Reverse Roll Coating Machine, Knife-Over-Roll Coating Machine,Air Knife coating , Metering Rod (Mayer Rod) Coating Machine, Slot Die Coating Machine, Curtain Coating Machine, Dip Coater, Hot melt Coating Machine, Web Coating Machine, Fabric Coating Machine and Many More Coater in Mumbai, India.
The document discusses hard turning as an alternative to grinding for finishing hardened surfaces. Hard turning offers benefits like shorter cycle times, higher material removal rates, and eliminating multiple setups. However, questions remain about hard turning's ability to meet surface finish and integrity requirements. Tool wear patterns and predictions must also be better understood. The research aims to investigate tool wear behavior in hard turning and develop a wear model to optimize the process and identify ideal conditions.
The document discusses turbo-abrasive machining (TAM) and turbo-polishing processes for deburring and surface finishing of complex metal parts. TAM uses loose abrasive particles to remove burrs and condition surfaces and edges of rotating parts in a continuous flow, addressing challenges with conventional batch processes. TAM can produce refined surfaces rapidly in minutes compared to hours for manual methods. The processes minimize waste streams and facilitate automation. TAM provides a machining-like method for precision finishing that enhances manufacturing flow.
Cape East is a contracting firm that provides industrial services like insulation, coatings, and fire protection. The author's objectives for their 2-month internship included developing office skills, learning cost estimation processes, understanding machinery used, and gaining insight into strategies and health & safety regulations. Key experiences included estimating costs, visiting Cape's workshop, observing machinery like CNC cutting machines, learning about blasting and painting processes, understanding insulation systems, assisting with 5-year strategic planning, and seeing health and safety measures implemented.
IRJET- Investigation of Mechanical Properties of Poly Lactic Acid Embedded Na...IRJET Journal
This document investigates the mechanical properties of structures made using fused deposition modelling that are embedded with natural fibers such as cotton and sheep wool. Samples were made with varying numbers of laminates, infill densities, and raster angles. Tensile and flexural testing was performed according to ASTM standards and the results were statistically analyzed. It was found that maximum tensile and flexural strength occurred with 4 laminates, 100% infill density, and a 90° raster angle. The number of laminates and infill density had a direct proportional relationship with strength, while raster angle was found to be an insignificant parameter.
IRJET- Experimental Investigation of Aluminum 7075 using Dry, Wet and MQL...IRJET Journal
The document experimentally investigates the effect of dry, wet, and minimum quantity lubrication (MQL) conditions on machining aluminum 7075 alloy. Surface roughness and temperature near the cutting zone were analyzed for each condition. MQL machining resulted in lower surface roughness and temperature compared to dry and wet machining. Gray relational analysis determined that for dry machining, a cutting speed of 10000 rpm, feed rate of 600 mm/min, and depth of cut of 0.25 mm provided the best performance across surface roughness and temperature.
dMT SPC® dry surface coatings for the ultimate wear protection on industrial ...dmtgms
The document describes dMT-SPC®, a protective coating system for crane wheels, rails, and other conveying machinery. It consists of self-applying blocks that continually apply a dry protective coating to maintain a constant, optimum coefficient of friction between contacting surfaces. This reduces stress, wear, flaking and increases the lifetime of metal parts by 3-5 times compared to uncoated surfaces. The non-toxic coating bonds strongly without disrupting machinery operation, requiring little maintenance, and providing environmental and performance benefits.
This document describes two grease products, Klüberplex BEM 34-132 and Klüberplex BEM 34-131 N, which are specialty greases for lubricating rolling bearings and linear guides operating under demanding conditions. The greases provide long service intervals, reliable performance, and protection of rolling bearings. They are suitable for lubricating various machinery components including textile machines, spinning machines, paper-making machines, conveyors, electric motors, and automotive components.
This document provides information on Kaltenbach's shotblast and painting systems. It highlights the Sprint, Marathon, and Triathlon series for shotblasting plates, profiles, tubes, and welded constructions. The Sprint is suited for annual shotblasting requirements up to 20,000 tonnes. The Marathon is for higher conveyor speeds, heavier loads, and multiple shifts. The Triathlon is for shotblasting and cleaning welded constructions. The document also briefly outlines painting systems and technical services available from Kaltenbach.
The document discusses advances in abrasive flow machining (AFM) and orbital abrasive flow machining technologies. AFM uses a semisolid abrasive media to deburr, polish, or radius surfaces by flowing it over target areas. Orbital abrasive flow machining combines AFM with an orbital grinding motion to uniformly remove material from complex shapes. Both techniques can process a variety of materials and have applications in aerospace, automotive, and other industries.
IRJET- Controlling the Formation of Rust in the Rocker Panel using Cavity...IRJET Journal
This document discusses a study that aimed to prevent rust formation in the rocker panel of vehicles using cavity wax. The researchers used Deming's PDCA (plan-do-check-act) cycle to guide their methodology. In the plan stage, they selected a vehicle body and cut out the rocker panel. In the do stage, they applied cavity wax to the rocker panel using a pump. In the check stage, they evaluated if the wax was applied evenly. In the act stage, they identified areas for process improvement. The results showed that applying cavity wax to the rocker panel via this process helped prevent rust formation.
This document provides information on pipeheads from KraussMaffei Berstorff for PVC pipe production. It discusses their nine pipehead sizes that cover a broad range of diameters and applications. It also describes benefits like perfect pipe quality, a stable process, tight wall thickness tolerances, and a wide processing window. The document provides details on pipehead models, dimensions, throughputs, applications for pressure classes, and the benefits of multilayer PVC pipe production.
Review on investigation and optimization of turning process parameter in wet ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
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Unlock the Future of Search with MongoDB Atlas_ Vector Search Unleashed.pdfMalak Abu Hammad
Discover how MongoDB Atlas and vector search technology can revolutionize your application's search capabilities. This comprehensive presentation covers:
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#MongoDB #VectorSearch #AI #SemanticSearch #TechInnovation #DataScience #LLM #MachineLearning #SearchTechnology
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Wally s3 e cold_rolling_mills_strip_processing_lines
1. COLD ROLLING MILLS and
STRIP PROCESSING LINES
Session 3
COLD ROLLING MILLS
STRIP PROCESSING LINES
SMS metallurgy Conference 2007
2.
3. Most recent technologies in
cold rolling to improve product
quality
Dr. Hartmut Pawelski
General Manager
Metal Forming and Surface Technology
Dipl.-Ing. Christoph Schwarz
Deputy General Manager
Technical Sales Cold Rolling Mills
Dipl.-Ing. Rüdiger Holz
Execute Vice President
Cold Rolling Mills Division
Dr. Karl Hoen
General Manager Plant Technology
Hot/Cold Rolling Mills Division
SMS Demag AG
Düsseldorf/Hilchenbach, Germany
4.
5. Most recent technologies in cold rolling to improve product quality
Rüdiger Holz, Dr. Karl Hoen, Dr. Hartmut Pawelski, Christoph Schwarz
In recent years, the steel industry world-
wide achieved remarkable growth rates.
It is not only growing in Asia, here espe-
cially in China and India, but also in
Europe and America. At the same time,
its consolidation is going on and the
steel markets become more and more
global.
In such an environment it is important for
mill owners to meet highest quality re-
quirements and at the same time curb
the production costs.
SMS Demag as system supplier for inte-
grated solutions of rolling mill technology
developed a large number of suitable
systems for supporting mill owners in
these efforts. Examples of effective solu-
tions in cold rolling mills for achieving
high quality requirements and highest
economic efficiency are the following:
▬ Equipment for Edge Drop Control to
achieve a constant strip thickness
across the complete width,
▬ the T-roll®
process technology,
▬ an alternative lubrication and clean-
ing concept for an improved strip sur-
face quality and
▬ online measuring systems for the
documentation of product quality and
meeting of narrower tolerances.
Edge Drop Control (EDC®
)
Edge Drop describes the undesired
thickness drop in the edge zone of cold
rolled strips. Reason for it is the chang-
ing roll flattening in the transition from
the loaded to the unloaded rolling sec-
tion. Depending on the intended use of
the strip, this area has to be removed.
For this purpose, the strip is trimmed
what will reduce the plant yield.
For avoiding such losses, SMS Demag
developed Edge Drop Control strategies
for reversing cold mills and tandem cold
mills.
For compensating the thickness drop,
the work roll diameter in the strip edge
area has to be reduced. For this pur-
pose, the work roll barrel is tapered by a
special grind at one end. The principle of
the control is now based on shifting the
taper for so far into the strip edge zone
until a specified edge drop value is set.
The operating results of the CSC revers-
ing mill in Taiwan illustrate the difference
between using and not using an Edge
Drop Control for non-grain-oriented
silicon steel. Application of the Edge
Drop Control was able to reduce the
trimming losses by over 20 mm for each
side. This increases the yield for the
common strip width by more than 3 %.
6. The strategy for a continuously operating
tandem mill is a combination of open-
and closed-loop controls. The drop in
thickness is measured after the first and
the last stand (stand 5). The first mea-
surement is used for controlling the edge
drop in stand 1. At the same time, this
signal is applied for a pilot control of mill
stands 2, 3 and 4. The measurement
after the last stand is introduced to cor-
rect the control command of the pilot
control in mill stands 2, 3 and 4 and that
way the desired edge drop value after
stand 5 is set.
As the operating results show, this strat-
egy is suitable to set a constantly low
value for edge drop over the entire strip
length and thus subsequent trimming
losses are reduced.
T-roll®
process technology
For optimizing the cold rolling process
and for an improved product quality it is
indispensable to understand the physical
processes during cold rolling in a better
way.
Therefore SMS Demag developed
T-roll®
, a technology package including
new and enhanced physical model ap-
proaches for simulating the cold rolling
process. Beside the complete mechani-
cal and thermal description it is above all
the detailed and realistic description of
the tribological processes which open up
new options for process optimization.
The accuracy of the model approaches
becomes apparent in the high coinci-
dence between measurement and simu-
lation. Examples are the accurate simu-
lation of rolling force and strip lead as
well as the transfer of the roll surface
roughness onto the strip surface.
As examples for the efficiency of T-roll®
,
the optimization of a single-stand revers-
ing mill for the production of grain-orient-
ed silicon steel shall be mentioned. In
this project, the lubricant and the appli-
cation of lubricant could be improved in a
well-aimed way by the new way of con-
sidering the tribology in the roll gap. This
enabled a clearly higher rolling speed
and thus a clear improvement of the
plant's output capacity.
A second example is the avoiding of
form waves in cold rolling of brass in a
two-stand tandem mill. It was only
through the analysis of the problem by
means of the T-roll®
technological pack-
age and a test setup in the laboratory
based thereon that it was demonstrated
that the form waves exclusively occur
through insufficient lubrication condi-
tions. By improving the lubricant and di-
rect application of an additive in the first
passes the form waves were avoided.
7. Lubrication and cleaning concept
As a new lubrication and cleaning con-
cept, SMS Demag developed a com-
bination of least quantity lubrication and
the utilization of liquid nitrogen. In skin-
passing, this concept decisively im-
proves the strip surfaces and at the
same time curbs the operating costs.
When using the least quantity lubrication
in the skin-pass stand entry, the lubricant
volume is precisely applied, which is re-
quired for reducing the friction in the roll
gap. This reduces the rolling force and
improves flatness at simultaneously us-
ing a minimum quantity of lubricant. The
liquid nitrogen in the exit covers both the
strip surface and the roll surface. This
method has the following advantages:
▬ clean and dry strip surfaces and thus
clearly lower susceptibility to rust,
▬ clearly reduced efforts in the down-
stream cleaning steps for cleaning
the strip surface and
▬ prolonged work roll service lives.
For assessment of the strip surface qual-
ity, the same material was skin-passed
under different operating conditions. In
the pass with emulsion, clear impres-
sions of the lubricant could be found.
They make the surfaces appear less
bright. The roll abrasion in dry skin-pas-
sing has a similar effect on the surface
quality. Compared to that, the surfaces
are clearly more uniform and thus
brighter when using liquid nitrogen in the
entry or in the entry and exit.
Moreover the operating experience
showed that the use of nitrogen more
than doubled the work roll service lives.
This and the lower refinishing effort on
the strips led at our cooperation partner
C. D. Wälzholz to cutting the process
costs for skin-passing by ca. 20 %.
The most recent reference for this con-
cept is the new inline skin-pass mill
stand for the continuous annealing line
of ThyssenKrupp Steel in Dortmund,
Germany.
Online measuring systems
Efficient production on a high quality lev-
el today requires complete documenta-
tion of the main quality parameters. Only
that way it is possible to demonstrate
quality towards the customer and at the
same time efficiently track down causes
for quality problems in the process line
and to remedy them.
Our new "Rotary Inspect" inline inspec-
tion line sets the record here for safety
and ergonomics in the manual assess-
ment of strip top and bottom sides.
Our patented roughness control system
enables controlling the strip roughness
over the entire length to a constant value
and to perform the roll change only when
it is really needed. For roughness mea-
surement, the SORM 3 plus measuring
system of our cooperation partner EMG
is used.
8. The SMS Demag flatness measuring
roll is the ideal solution for precise and
reliable measurement of strip flatness.
The closed surface of the roll avoids
marks on the strip and can be coated
specifically for each application. The roll
allows simple installation of the sen-
sors which can even be performed on
site. The sensors can be arranged flexi-
bly regarding their distances in accor-
dance with the current and future re-
quirements of the profile and flatness
control system.
Ten references within a short time
demonstrate our customers' high
acceptance of this measuring system.
9. 1SMS metallurgy Conference 2007
Most recent technologies in cold rolling
SMS Demag solutions for improved product quality
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Constant strip thickness
up to the edge
EDC
Closer tolerances and
better documentation
Higher yield and improved
product quality
T-roll®
process technology
Lubrication and
cleaning concepts
Online measurement
systems
A new approach for
perfect surface quality
2SMS metallurgy Conference 2007
Most recent technologies in cold rolling
EDC® Edge Drop Control – constant strip thickness
up to the edge
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
10. 3SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Principle of the Edge Drop Control
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Stripthickness
Principle of work
roll shifting for
Edge Drop Control
Strip width
with EDC
without EDC
Reduced
Edge Drop
Influence of EDC on the
strip edge
transverse
material flow
4SMS metallurgy Conference 2007
Results of Edge Drop Control in a single-stand
reversing mill
Most recent technologies in cold rolling
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Material: Non grain-oriented silicon steel
0 20 40 60 80 100 120
-2.5
-2
-1.5
-1
-0.5
0
0.5
Distance from strip edge
Thicknessdeviation[%]
Edge Drop measurement
Hot strip
After last pass
with EDC
without EDC
Yield increased by approx. 3 % due to by reduced trimming losses►►
11. 5SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Edge Drop Control strategy for a continuous
tandem cold mill
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
AW
Position
AW
Position
AW
Position
S1 S2 S3 S4 S5
EDC
Vorsteuerung
EDC Regelung
G2;G3;G4
AddRef
AddRef
Ref Ref Ref
AW
Position
Ref
AddRef
EDC Regelung
G1
Act
AW
Position
WR
shifting
AW
Position
WR
shifting
AW
Position
WR
shifting
measured
edge drop
edge drop
references
EDC
feed forward control
EDC feedback control
G2;G3;G4
AddRef
AddRef
Ref Ref RefRef Ref Ref
AW
Position
WR
shifting
Ref
AddRef
EDC feedback control
G1
Act
Model
parameter
measured
edge drop
EDC feedback control for S1 EDC feed forward control and feedback control of S2, S3, S4
6SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Results of closed loop Edge Drop Control in a
tandem cold mill
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
position(mm)
Strip length [m]
G1 G2 G3 G4
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
0
20
40
60
80
100
EDC-Position (measured)
Strip length [m]
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
-10
0
20
40
60
80
Edge drop (measured)
Edgedrop[μm]
Edge drop measured
EDC workroll shifting position
Strip length [m]
Edgedrop(μm)
after G1 after G5
Reference value:
after stand 1 20 μm
after stand 5 10 μm
with EDC
Edge drop reduction constant over total strip length►►
12. 7SMS metallurgy Conference 2007
Most recent technologies in cold rolling
T-roll® process technology
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Technology package for the simulation of the cold rolling
processes with advanced models for
▬ mechanical
▬ thermal and
▬ tribological processes
Applications:
▬ thermal and tribological processes
▬ Analysis and optimization of
lubrication and cooling conditions
▬ Selection of adequate lubricants
▬ Development of new rolling strategies
▬ Calculation of pass schedules for
new steel grades
▬ Pre-calculation of strip surface
roughness
More profit due to higher yield and improved product quality►►
8SMS metallurgy Conference 2007
Most recent technologies in cold rolling
T-roll® process technology
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
High capability of new approaches
0
0.5
1
1.5
2
2.5
3
0.0 0.5 1.0 1.5 2.0 2.5
Elongation in %
Roughingofstrip,Rainμm
Measured, top
Measured, bottom
Tribological model
Tribologisches Modell
Rolling Speed [m/min]
Walzkraft [MN]
Walzgeschwindigkeit [m/min]
Tribologisches Modell
Rolling Speed [m/min]
Walzkraft [MN]
Tribological model
Rolling Speed [m/min]
Roll force [MN]
Roll speed [m/min]
Rolling Speed [m/min]
tribological model
Voreilung [%]
Tribologisches Modell
Walzgeschwindigkeit [m/min]
tribological model
Rolling Speed [m/min]
Tribologisches Modell
Voreilung [%]
Walzgeschwindigkeit [m/min]Rolling Speed [m/min]
tribological model
Voreilung [%]
Tribologisches Modell
Walzgeschwindigkeit [m/min]
tribological model
Rolling Speed [m/min]
Tribological model
forward slip [%]
Roll speed [m/min]
▬ High forecast accuracy for
• improved processing and
• higher plant utilization
13. 9SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Cold rolling of high-grain-oriented silicon steel
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
before modernization
after modernization
900 m/min = max. motor speed
5 pass HGO
Share of production approx. 30 %
Max.rollingspeed
[m/min]
900
600
300
0
pass 1 pass 2 pass 3 pass 4 pass 5
Increase of maximum speed by tribological optimization►►
10SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Cold rolling of brass on a tandem cold mill:
elimination of waves
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
SMS Demag solutions:
▬ Optimization of lubricant
▬ Low quantity lubrication for first passes
►►
14. 11SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Combination of low-quantity lubrication and
liquid nitrogen
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Low quantity lubrication Liquid nitrogen
▬ Substantial reduction of
lubrication quantities
▬ Reduction of friction in the
roll gap
• lower rolling force
• improved strip flatness
▬ Improvement of strip surface quality
▬ Better cleaning effect on work rolls
▬ Longer service life of work rolls
Benefits:In cooperation with:
C.D. Wälzholz
►►
12SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Skin-pass rolling with liquid nitrogen
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Valuation of strip surface quality after skin-pass rolling
Target: Ra = 1,0 – 1,8 μm; shining surface
Liquid nitrogen,
entry
Liquid nitrogen,
entry and exit
Emulsion, entry
(height profile: ± 0,8 μm)
100 μm
lubricant impressed
dry
Abrasion of rolls
Improved surface quality
Considerably improved strip surface quality►►
15. 13SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Skin-pass rolling with liquid nitrogen
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
after coil No. 1: 1.4 μm
after coil No. 4: <1.0 μm
Roughness of new work roll: 3 – 3.3 μm
after coil No. 1: 1.7 μm
after coil No. 10: 1.2 μm
Coil No.
Dry (2004-05-03)
3.0
10
1 2 3 4 5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Roughness of new work roll: 3 – 3.3 μm
Coil No.
0.0
0.5
1.0
1.5
2.0
2.5
3.0
1 2 3 4 5 6 7 8 9 10
Liquid nitrogen (exit)
Service life of work rolls increased by more than 100 %
Skin-pass process costs reduced by 20 %
►►
14SMS metallurgy Conference 2007
Most recent technologies in cold rolling
Recent reference:
ThyssenKrupp Steel, Germany
New inline skin-pass mill for continuous annealing line
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Main technical data:
Strip thickness: 0.4 to 2.3 mm
Strip width:: 600 to 1,720 mm
Roll speed range: 0 to 412 m/min
Annual capacity: 780,000 t
Year of commissioning: 2007
Inline-skin pass
Technical features:
▬ Newly developed low-quantity lubrication
system and roll-strip cleaning with liquid nitrogen
▬ SMS Demag shapemeter roll
▬ X-Pact® – electric and automation systems
16. 15SMS metallurgy Conference 2007
►►
Most recent technologies in cold rolling
Online measurement systems to improve product quality
and plant utilization
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
SMS Demag flatness measurement roll
Inline inspection line
„Rotary-Inspect“
SORM roughness
measurement
with control system
Advantages:
▬ Continuous monitoring and documentation of quality parameters
▬ Close tolerances by means of integration in closed loops
In cooperation with:
16SMS metallurgy Conference 2007
►►
Most recent technologies in cold rolling
SMS Demag flatness measuring roll in new design
Edge Drop
Control
T-roll® process
technology
Lubrication
and cleaning
concepts
Online measure-
ment systems
Advantages:
▬ Easy sensor installation even at site
▬ Applicable at high temperatures e.g. production of Si-steel grades
▬ Individual arrangement of sensors
▬ Closed surface
▬ Application-based coating
References in 18 months:
7 plants with a total of 10
shapemeter rolls
17. Modernization concept of the
four-stand tandem cold rolling mill,
BILSTEIN GmbH & Co. KG
Dipl.-Ing. Detlef Böttner
Deputy General Manager
Sales Cold Rolling Mills Electrical and Automation Systems
Dipl.-Ing. Falk Töpfer
General Manager
Technical Sales Cold Rolling Mills
Dipl.-Ing. Arnulf Wurm
Senior Project Manager
Technical Sales Cold Rolling Mills
SMS Demag AG
Hilchenbach, Germany
18.
19. Modernization concept of the four stand tandem cold mill,
BILSTEIN GmbH & Co. KG
Detlef Böttner, Falk Töpfer, Arnulf Wurm
Ever increasing requirements on the cold
strip qualities and the continuously grow-
ing material and variant diversity more
and more force rolling mill owners to
keep their plants on the most recent
technological level or to get them there.
Due to the concurrently very high de-
mand volume and thus the plant utiliza-
tion in recent years, they had to face
particular challenges.
SMS Demag took up these customer
problems and elaborated and constantly
developed special concepts in recent
years to cope with them. This is one of
the reasons why the company BILSTEIN
with their registered office in Hagen,
Germany, tasked SMS Demag with the
extensive modernization of their four-
stand tandem cold mill.
BILSTEIN is processing a diversified ma-
terial and product mix starting from the
standard grades over case-hardening
and special grades up to micro-alloyed
high-strength steels. The tandem mill is
the central key plant for the complete
production at BILSTEIN and in some
cases also for their subsidiary com-
panies. Therefore a consistent and reli-
able modernization concept was even
more significant for taking the decision to
award the contract.
The rolling mill was supplied in 1969 by
SMS Demag and was during the years
upgraded and modernized several times.
This mill produces every year 400,000 t
of cold strip of width from 320 to 670 mm
and thicknesses from 7.5 to 0.3 mm. The
input stock is produced by slitting hot
strip normally into two to three stripes.
Therefore the input stock has different
wedge profiles what is a particular chal-
lenge for the sequences in cold rolling.
The modernization is related to a large
number of objectives of which the follow-
ing are the most important ones:
▬ Improvement of the plant availability
▬ Increase of the production volume by
60,000 t/year
▬ Improvement of the product quality
▬ Increase of the degree of automation
A particular requirement which made the
matter more complicated is that due to
the above mentioned plant utilization the
proper revamp times could only be taken
during regular shutdowns. The total time
available for this is three shutdown peri-
ods of altogether five weeks. After each
modification period, production has to be
run up to the set point volume according
to agreed run-up curves as fast as possi-
ble. In the process, the comprehensive
product mix of wedge-shaped hot strip
20. has to be considered and the currently
applicable safety standards have to be
observed.
For various reasons, SMS Demag won
the contract for this modernization.
SMS Demag has wide experience in
large and complex modernizations and
was also in this case able to present a
coherent overall concept. The "All from a
single source" supply, i. e. the symbiosis
of mechanics, hydraulics, electrics and
automation as well as development and
technology from one single supplier cre-
ates the optimal conditions for modern-
ization which were critical in terms of
technology and time. Essential mechani-
cal components as e. g. the hydraulic
adjustment cylinders and valve stands
are produced in the SMS Demag work-
shop and carefully tested before deliv-
ery. Moreover, the extensive actions ac-
companying the order are performed for
safeguarding the short modification
phases. Among these are careful site in-
vestigation, early setup of a "listening
mode", a state-of-the-art integration test,
the early operator training on the simu-
lated plant up to a sophisticated change-
over concept between the old and the
new control system.
For achieving the modernization objec-
tives, many components are replaced by
new and more recent ones or additional-
ly integrated into the rolling mill.
For increasing and stabilizing the strip
back tension in the first stand, an addi-
tional strip pinch roll unit will be installed
in the entry guide. It is hydraulically
approached, the additional strip tension
is applied by means of electrically actu-
ated rolls. That way it operates similar to
a bridle roll unit but compared to that it
bears the advantage that it can still be
used for large entry thicknesses.
All mill stands will be equipped with hy-
draulic adjustment cylinders. That way it
is not only possible to increase the rol-
ling force by 30 % in each mill stand but
for the first time it is possible to measure
the precise positions of the cylinders.
This is the prerequisite for converting the
strip thickness control from the currently
used roll gap control to a quick volume
flow control.
Moreover, the rolling speeds of all mill
stands are increased and optimized with
regard to one another. For this purpose,
among other things new gearwheel sets
will be installed. For minimizing the re-
maining quantity of residual oil on the
strip, the patented SMS Demag Dry Strip
System (DSS) will be installed down-
stream of the last mill stand.
The coiling tension will in a similar way
as on the entry side be separated by a
new approachable bridle roll unit from
the exit tension of the last stand. When
the bottom roll of this unit is not ap-
proached, it behaves like a "normal" de-
flector roll, i. e. also this bridle roll unit
can, as the strip pinch roll unit on the
entry side, be started up step by step
without any risk. Various other mechani-
21. cal extensions supplement the modern-
ization. Among these are in particular:
▬ Various improvements for guiding
and threading the strip
▬ Improvements for calibrating the roll
assemblies
▬ Installation of work roll bending sys-
tems at all stands
▬ New hydraulic valve stands for all
mill stand functions
▬ Installation of devices for measuring
strip position, strip tension and strip
speed at different positions.
The existing electrical and automation
systems will to a large degree be re-
placed by new systems. Interfaces are
created with the remaining components
and systems. All main drives will be re-
placed. For the mill stands, advanced
synchronous motors in medium voltage
technology will be used. Compared to
the asynchronous motors, they provide a
higher operating efficiency at a simulta-
neously smaller moment of inertia which
leads to improved control dynamics.
State-of-the-art multi-drive converters
with a direct current intermediate circuit
supply the medium-voltage motors of the
mill stands as well as the low-voltage
motors of the strip drives for the reels,
pinch roll units and bridle rolls. This reac-
tive power-free drive constellation both
minimizes possible energy losses and
negative effects on the feeding network.
The plant will for the first time be operat-
ed from a newly erected main control
pulpit. Except new operator stations and
an HMI system which can also be ac-
cessed from all local stations, strip edge
detection and camera systems will be in-
stalled at different locations. The latter
are provided for visual monitoring of the
partly automated threading process by
the operator. This is particularly required
when threading the wedge-shape slit
strip.
The automation system will be complete-
ly replaced. In the process, all Level 1
functions from the sequence processes
up to the technological controls are all
implemented on a uniform hardware and
software platform.
In particular for safeguarding the in-
creased requirements on the automation
system, faster coil sequence times and
an improvement of the strip quality at the
head-end, for the first time a Level 2 sys-
tem will be used on this mill. Above the
required interfaces and various report
functions, this system makes available a
model-based setup value calculation be-
fore start of rolling. For this purpose,
SMS Demag uses the complete imaging
of the rolling processes through self-
adapting physical models.
For safeguarding the required run-up
curves after the respective short modifi-
cation phases, SMS Demag uses a con-
cept of several parallel actions. First the
current status is detected by means of
detailed examinations and used as the
basis of the following modifications.
Among these are e. g. detection and
localization of the mechanical and elec-
trical components, functional and pro-
22. cess-technological aspects as well as
the plant operation.
By documentation of this site investiga-
tion, the engineering could start. On site
almost simultaneously the preparation of
the interfaces is started for the systems
required in the individual modification
phases which are continued to be oper-
ated. Moreover, a "listening mode" is es-
tablished. For this purpose, so-called
process IO servers are installed step by
step which enable forwarding each sig-
nal from or to the process to the existing
control (maintaining the existing status)
but also making available these signals
in a global memory for the later new con-
trol systems. That way the new system
has knowledge of the current process
events at a very early stage. This result-
ing process data basis will be integrated
in the engineering and the pre-commis-
sioning of the new system. That way for
example the mathematical models can
already at that time automatically adapt
to the material to be rolled and the exist-
ing plant.
In a next step, the complete new auto-
mation system will be set up in the
SMS Demag workshop. In parallel, the
rolling mill will be simulated in every de-
tail in real time. Here not only the rolling
process itself is simulated but also all
movements and all interfaces with the
automation system. By means of this
"integration test", already beforehand a
pre-commissioning, complete functional
and production tests are performed. This
comprehensive simulation is also used
for an intensive operator training. Only
that way it is possible to achieve the
short run-up phases.
Now the previously installed listening
mode is expanded in a modification
phase and the following optimization
phase to the effect that new functions or
controls can be added in, tested and op-
timized either completely or also partly.
For this purpose the old and the new
open- and closed-loop systems are oper-
ated in parallel. That way the original
condition can quickly be re-established
by digital adding-in. It is only after all
new functions were sufficiently verified
and optimized that the "old" components
will be dismantled and the final new en-
hanced condition is established.
This modernization concept provides
both the plant operator company
BILSTEIN and the contractor
SMS Demag with the sufficient safety for
a smooth sequence of the modification
as well as the certainty that the modifica-
tion objectives are really achieved within
the defined time frame.
23. 1SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
BILSTEIN GmbH & Co. KG, Hagen-Hohenlimburg
employees: 600
dispatch volume: 400,000 t/year
▬ cold-rolled steel strip
▬ cold-rolled steel sheet
▬ construction steel
▬ case hardening steel
▬ electrical steel
▬ spring steel
▬ special purpose steel
▬ enameling steel strip
The customer and their products
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
2SMS metallurgy Conference 2007
Four-stand tandem cold rolling mill
of BILSTEIN GmbH & Co. KG, Germany
Main mill data
▬ four-stand batch tandem cold mill
▬ Supplier: DEMAG, 1969
▬ Rolling speed: max. 745 m/min
▬ Rolling force: max 6,000 kN per stand
Modernization concept of the four-stand tandem cold mill
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
24. 3SMS metallurgy Conference 2007
Four-stand tandem cold rolling mill
of BILSTEIN GmbH & Co. KG, Germany
Material data
▬ Strip width: 320 to 670 mm
▬ Strip thickness: 7.5 to 0.3 mm
▬ Annual production : 420,000 t
Others
▬ Several modernizations over the years
▬ Four operators, all “on site”
▬ Low automation grade of mill sequences
Modernization concept of the four-stand tandem cold mill
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
4SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Targets of the modernization
General targets
▬ Increase of mill availability
▬ Increase of production rate by 60,000 t/y
▬ Improvement of product quality
▬ Higher degree of automation
Special requirements
▬ Rolling and threading of wedge-type strips
▬ Extensive product-mix
▬ Change to operating with only three operators
▬ Only the regular mill downtimes can be used (in total five weeks)
▬ High priority in safe and steep run-up after each modernization
step
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
25. 5SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Reasons for placing the order with SMS Demag
▬ Experiences with
comprehensive modernizations
▬ Convincing overall
modernization concept
▬ Supply from one single
source
▬ Manufacture at SMS Demag
workshop
▬ Advanced integration test
▬ Operator training in advance
▬ Switch-over
concept
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
6SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of mechanical equipment
Entry-side pinch roll unit
▬ improve the strip tension behavior
▬ increase the strip tension
Advantages
▬ independent of the strip thickness
▬ deflector roll mode possible
26. 7SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of mechanical equipment
Hydraulic screw down cylinders for all stands
▬ rolling force increase from 6,000 kN to 8,000 kN
▬ high resolution position measurement
Advantages
▬ higher reduction
▬ change from roll gap to position control mode
8SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of mechanical equipment
New gear sets respect. shifting gear sets between the stands
▬ increase the rolling speeds; from 745 to 1,000 m/min at last stand
27. 9SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of mechanical equipment
Dry Strip System after last stand
▬ increase the removal of the emulsion on the strip surface
Advantages
▬ reduced noise level
▬ best dryness of the strip surface
10SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of mechanical equipment
Exit-side swiveling bridle S-roll set
▬ improve the strip tension behavior
▬ increase the strip tension
Advantages
▬ deflector roll mode possible
28. 11SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
New synchronous motors for mill stands and tension reel
▬ increase the rolling speed of each stand
Advantages
▬ high efficiency
▬ low inertia, i. e. high dynamic behavior
Modernization of electrical equipment
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
12SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of electrical equipment
New multi-drive converter systems
▬ IEGT converters for MV mill drives
▬ IGBT converters for LV drives
Advantages
▬ low energy losses, low power feed-in
▬ high dynamic performance
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
29. 13SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of electrical equipment
New pulpit, operator panels and HMI system
▬ full HMI access at all operator panels
▬ industrial TV system and strip-edge monitoring systems
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
14SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Modernization of electrical equipment
New Pulpit, Operator Panels and HMI-System
full HMI access at all operator panels
industrial TV system and strip edge monitoring systems
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
New Level 1 automation system
▬ additional measurement devices for strip speed and tension
▬ position sensors of screw down cylinders, vibration monitoring
Advantages
▬ switch-over from roll gap control to position control
▬ introducing fast volume control mode
▬ one uniform system platform
G3 G2 G1 G0
HGC
Decoupling Net
Speed and
Torque Control
Speed
Control
Speed and
Torque Control
Speed
Control
Speed
Control
Speed
Control
Thickness
Control
HGCHGCHGC
Tension
Control
Thickness
Control
Thickness
Control
Thickness
Control
Tension
Control
Tension
Control
Tension
Control
30. 15SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
High-accuracy Level-2 setup system
▬ physical-based models
▬ short-term and long-term self-adapting models
Advantages
▬ reduction of off-gages/off-flatness length
▬ fast learning behavior
▬ flexible adaptation to new materials
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
Modernization of electrical equipment
Mill limits and
configuration
Rolling force
model
Flatness
model
Temperature
model
Tribological
Model
Material
model
16SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
High accuracy of SMS Demag Level-2 process models
(Example: Single-stand reversing mill for silicon steel)
thickness deviation at head end
[%]
frequency[%]
1,514
strips
force deviation at head end
[relative, kN]
frequency[%]
1,525
strips
0
5
10
15
20
25
30
20001,6001,2008004000-400-800-1,200-1,600
77 % within 0 % to + 3 %
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
0
5
10
15
20
25
30
35
40
45
1086420-2-4-6-8
31. 17SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Overall modernization concept:
Engineering, test and interfaces preparation in parallel
Site
investigation
Preparation of interfaces/
listening mode
Installation Switch-
over
Engineering Plug &
Work test
Stepwise
time
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
18SMS metallurgy Conference 2007
Site
investigation
Preparation of interfaces/
listening mode
Installation
Switch-
over
Engineering
Plug &
Work test
Stepwise
Modernization concept of the four-stand tandem cold mill
Site investigations
▬ hardware and layout
piping, routing, locations, etc.
▬ functional technology
signals, interfaces, etc.
▬ process sequences and mill operation
standard operation procedure
▬ process technology
pass schedules, emulsions, etc.
Site investigation
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
32.
33. 21SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Hot run tests and “shadow mode”
▬ stepwise function and production test
with mechanic and media systems
▬ test of sequences, test of dynamic behavior
▬ always possible to switch back to old controls
(“shadow mode”)
Old New
~
~
M
~
PPS /L3
Process
models /L2
Process
control /L1
RIOs
PIOS
Process
Models /L2
Process
control /L1
PIOS (Process IO Server) =
“electronic terminals”
Installation Switch-
over
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
Site
investigation
Preparation of interfaces/
listening mode
Installation
Switch-
over
Engineering
Plug &
Work test
Stepwise
22SMS metallurgy Conference 2007
Modernization concept of the four-stand tandem cold mill
Typical run-up curve for a modernization
with production increase
0
10
20
30
40
50
60
70
80
90
100
110
120
130
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
Weeks
Productionperweek[%]
Downtime
Introduction
Modernization
objectives
Modernization
items
Modernization
concept
34.
35. Cold rolling of stainless steel
using continuous high-perfor-
mance tandem mills
Dipl.-Ing. Rainer Effertz
Deputy General Manager
Filtration Systems/Roll Coolant Systems
Dipl.-Ing. Rüdiger Holz
Executive Vice President
Cold Rolling Mills Division
Dipl.-Ing. Ralf Matzka
General Manager
Technical Sales Cold Rolling Mills and
Stainless Steel Lines
Dipl.-Ing. Thorsten Bode
Manager
Metal Forming Technology
SMS Demag AG
Düsseldorf/Hilchenbach, Germany
36.
37. Cold rolling of stainless steel using continuous high-performance
tandem mills
Ralf Matzka, Thorsten Bode, Rainer Effertz, Rüdiger Holz
The market for cold-rolled stainless steel
strip is characterized by continuous
growth. The ever higher growth rates of
cold rolled products require ever higher
capacities of the process lines and
rolling mills. Further the market requires
reasonable prices for these products,
with the optimization potential mainly be-
ing the cost of production.
As long ago as 1969, the Nisshin Steel
company in Japan attempted to satisfy
this market requirement by installing a
then highly productive multi-stand tan-
dem mill for the production of cold-rolled
stainless steel. Another high-perfor-
mance mill, supplied by SMS Demag,
went in operation in 1999 at AK Steel in
the United States, rolling both stainless
steel and carbon steel grades. The new
plant concept developed by SMS Demag
for stainless-steel tandem mills consists
of several rolling mills in a tandem ar-
rangement, with extremely slender and
therefore horizontally supported work
rolls.
Setting up a continuous rolling mill for
the production of stainless steel strip is a
cost-effective option where a cold-rolling
stage with a capacity of more than
400,000 t/year is to be implemented.
This plant concept requires the lowest
cost of conversion due to the as com-
pared to conventional stainless steel
rolling on reversing rolling mills higher
yield, less manpower and the lower
specific investment cost. The new plant
concept using rolling oil makes it pos-
sible to produce surface finishes that
bear comparison with cold rolled strip
produced in 20-roll mills. As compared
with the well-known fully integrated lines
for the production of stainless steel strip
(integrated rolling, annealing and pickling
lines), the concept of a continuous tan-
dem mill has a much higher flexibility.
The differences between the continuous
tandem mills set up so far for the produc-
tion of cold-rolled stainless steel strip are
as follows: The first mill in Japan was set
up as a semi-continuous line and has no
continuous exit. The mill stands are of
20-roll type and accordingly have long
roll-changing times of the backing ele-
ments and intermediate rolls. Another
critical item in this mill stand design is
the relatively poor accessibility in case of
strip breaks. The continuous tandem mill
at AK Steel was designed for the mass
production of carbon steels and austenit-
ic as well as ferritic stainless steels. The
rolling mills are of four-high (mill stands 1
to 3) and six-high type (mill stands 4
and 5. The roll diameters were chosen to
suit stability requirements and the
torques needed to drive the work rolls,
38. they warrant a simple mill stand design
with associated high service life and
availability. Thanks to the application of
a special cooling lubricant and the use of
the required roll roughness it has also
been possible to satisfy customers' sur-
face finish demands. The new
SMS Demag concept for a continuous
rolling mill for stainless steel strip is
based on the quality requirements of a
specialized cold strip production using
20-roll mills. To achieve the necessary
overall reduction, a very slender work roll
was chosen which via laterally arranged
intermediate rolls is supported on both
sides by two rows of backup bearings.
The mill stand design encompasses a
six-roll mill with backup, intermediate
and work rolls. The intermediate rolls are
axially shifted and equipped with a roll
bending facility. The tandem rolling mill
is equipped for fully continuous oper-
ation, i. e., on the entry side a welder
and strip accumulator to bridge the non-
productive entry time are arranged,
whereas on the exit side coils are
changed on the fly. The above requires
the exit tension in the last mill stand to
be maintained with the help of a pinch-
roll mill stand and the continuous supply
of paper through the use of carousel-
type paper winders and automatic
threading devices.
In the production of cold-rolled stainless
steel strip in continuous tandem mills,
the following special technical items
need to be considered:
▬ The large variety of the products to
be rolled in terms of their dimenions
and mechanical properties requires
an adapted mill stand design.
▬ The benefit of the high yield can be
achieved only in continuous opera-
tion.
▬ The excellent surface finishes can be
achieved only through the use of
suitable cooling and lubrication sys-
tems as well as an effective surface
inspection.
▬ The benefit of the lower specific in-
vestment cost becomes fully effective
especially in a modular mill design.
The mill stand design follows the require-
ments of the rolling process. The neces-
sary small work-roll diameter results
from the strength of the material and the
finish gauge to be achieved. Since the
degree of slenderness in the necessary
work-roll dimensions becomes too large,
these rolls need to be supported horizon-
tally. Lateral backup rolls, which are ad-
ditionally guided by two rows of backing
bearings, absorb the horizontal forces
39. and transmit them to the adjustable sup-
port bridges. The benefits of this mill
stand design mainly include the applica-
tion of the CVC plus®
technology for set-
ting the roll-gap geometry, the use of the
HS (horizontal stabilization) system for
optimization of the horizontal forces and
above all a quick work and intermediate
roll change.
Another important criterion for the design
of a tandem rolling mill for cold-rolled
stainless steel strip is the temperature
control in the rolling process. The cooling
lubricant used to attain the required sur-
face finishes has a limited heat absorp-
tion capacity and the deformation energy
is predominantly transformed into heat,
i. e., the temperature of the material
rises. The compact design of the rolling
mill further allows the limited installation
of cooling sections. An exact prediction
of the material temperature forms the
basis for the production of excellent sur-
face finishes with very good gloss and
reflection properties.
The already mentioned cooling and
lubricant system of the rolling mill essen-
tially has to satisfy two requirements: on
the one hand it must support a high
thickness reduction at relatively low rol-
ling speeds while on the other hand it
has to produce the gloss properties of
the cold-rolled strip surface. The benefits
of SMS Demag's cooling lubrication
technology consist of the technological
know-how of the cooling lubricant's
pressure absorption capacity, lubrication
effect, cooling efficiency, the filter tech-
nology which for this rolling duty is based
on the SUPAFINE®
technology and the
technological design of the coolant sys-
tem with the additional possibility of
setting different viscosity levels of the
lubricant in the various mill stands.
In SMS Demag's CVC®
18-HS rolling
mills, the potential flatness position er-
rors of the cold rolled strip are compen-
sated by tried-and-tested quick-response
actuators. Intermediate-roll bending and
edge-oriented shifting of the intermediate
rolls allow a very good correction of strip
edge waves and center buckles. How-
ever, the high degree of slenderness of
the work roll as well as the absence of
bending on the latter limit the potential
for correction in the case of so-called
quarter buckles.
To be able to use this additional adjust-
ment potential, SMS Demag has devel-
oped a special CVC plus®
grinding for
the 18-HS rolling mills.
In addition to the expanded control range
of the roll-gap geometry, this CVC plus®
grinding features an improved distribu-
tion of rolling forces over the length of
the roll barrel and thus across the entire
strip width, thereby increasing the ser-
vice life of the rolls in the mill stands.
The HS system installed in
SMS Demag's rolling mills allows the
horizontal shifting of the work roll in the
direction of rolling as a function of the
predicted horizontal forces caused by
the drive torque. This allows high thick-
40. ness reductions during each rolling pass,
a longer service life of the lateral backing
elements and, through the integration of
the CVC plus®
system in flatness control,
an excellent strip quality.
The HS system with its adjustable hori-
zontal offset of the work rolls reduces the
necessary supporting force which needs
to be absorbed by the lateral backing
elements. A more stable rolling process
and lower maintenance cost are the es-
sential benefits of this technology.
As a competent partner, SMS Demag
has a large number of reference installa-
tions at its disposal. This basis warrants
the efficient processing of projects as
well as a quick start of production. The
modular design of SMS Demag's rolling
mills, which has been successfully em-
ployed many times before, guarantees a
high availability and low operating cost.
SMS Demag offers rolling mill owners re-
liable solutions and high-quality engi-
neering at a cost-benefit ratio in line with
the market.
41. 1
SMS metallurgy Conference 2007
Applications
Continuous tandem cold mills for stainless steel
1969 1999 2007
Nisshin Steel
AK Steel
SMS Demag
continuous
tandem mills
combined
stainless steel/carbon steel
stainless steel
2
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
▬ High productivity ⇒ capacity of more than 400,000 t/year
▬ Lowest conversion costs:
• highest yield
• less personnel
• low specific investment costs
▬ Excellent quality
▬ High flexibility compared to fully integrated lines
Advantages for stainless steel
42. 3
SMS metallurgy Conference 2007
Nisshin Steel
Continuous four-stand 20-high tandem mill
Continuous tandem cold mills for stainless steel
Main data
material: stainless steel
max. rolling speed: 600 mpm
capacity: 220,000 t/year
Existing plants
4
SMS metallurgy Conference 2007
AK Steel
Continuous five-stand four-high/six-high tandem cold mill
Continuous tandem cold mills for stainless steel
Main data
material: carbon steel
stainless steel (austenitic, ferritic)
max. rolling speed: 1,900 mpm
capacity: 3,600,000 t/year
Existing plants
43. 5
SMS metallurgy Conference 2007
Four-stand CVC® 18-HS tandem cold mill
Continuous tandem cold mills for stainless steel
Main data
material: stainless steel
max. rolling speed: 400 mpm
capacity: 720,000 t/year
Advanced SMS Demag tandem mill
6
SMS metallurgy Conference 2007
Increase in
output/yield
Continuous rolling,
two-high tension stand
Top surface quality for
subsequent processing
SUPAFINE® filtration
Quick and reliable
strip surface control
Inline inspection
Low maintenance and
operational costs
Modular and robust mill design
Wide range of products CVC® 18-HS technology
Continuous tandem cold mills for stainless steel
Tandem mill technology for stainless steel production
44. 7
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
four-high
Admissibleandrequiredlineload[kN/mm]
Required line load for
strip thickness of 0.2 0.4 0.8 1.6 mm
Example:
Tensile strength 1000 N/mm², reduction 40 %, strip width 1300 mm
CVC plus® 18-HS
Work roll diameter [mm]
no horizontal
stabilization required
horizontal
stabilization required
Line concept for cold rolling of high-strength steels
8
SMS metallurgy Conference 2007
▬ CVC plus® technology
• improved roll gap setting and thus
improved strip flatness
• equal load distribution between the
rolls and thus reduced roll wear
▬ HS system (Horizontal Stabilization)
• reduced load of horizontal backing
rolls
• less wear of backing rolls
▬ Easy roll change
• by installation of intermediate, work
and backing rolls in change cassettes
Benefits compared to the conventional 18-roll mill
Continuous tandem cold mills for stainless steel
CVC plus® 18-HS
45. 9
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Simulation of strip temperature
10
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Requirements from the rolling process
High reduction under
low rolling speed
Optimized roll coolant system
in terms of cooling,
lubrication and filtration
High-performance
rolling oil with excellent
lubrication and cooling properties
High surface quality
demands 2B
46. 11
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Advantages of SMS Demag coolant technology
Design of the rolling oil system allows
optimum adaptation to the rolling process
in terms of heat removal and lubrication.
Highest cleaning efficiency due to a
SUPAFINE® filtration system and
magnetic separator.
Environmentally friendly concept as
no filter aid is required.
Viscosity can be adapted to each mill
stand by means of inline coolers.
12
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Available flatness actuators of 18-roll mills
flatness actuators
▬ IMR bending
▬ strip-edge-oriented
IMR shifting
flatness defects result
▬ small influence with
IMR bending and
conventional shifting
▬ insufficient influence
of multi-zone cooling
center buckles
edge waves
quarter buckles no significant improvement
significant improvement
CVC® 18-HS
47. 13
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Principle of CVC® 18-HS
Axially shiftable IMR with
special CVC® shape of
higher order
▬ Flatness control of higher
order – defects possible
(strip edge and quarter
buckles)
▬ Due to special CVC® shape
smooth load distribution
between WR and IMR
achievable
14
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Mill data:
WR dia.: 140 mm
IMR dia.: 355 mm
BUR dia.: 1,350 mm
Conventional
18-roll mill
Strip width: 1,200 mm
Spec. rolling force: 10 kN/mm
IMR
shifting
IMRbending
Comparison: Roll-gap adjusting field on conventional
18-roll and CVC® 18-HS mills
CVC®18-HS
mill
48. 15
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
CVC® 18-HS mill with reduced work roll diameters
Features Advantages
Reduced work roll diameters High thickness reduction possible
Horizontal Stabilization (HS) of Longer lifetime of side support
work rolls (SMS Demag patent) clusters due to adjustable force
Flatness control by proven IMR Excellent strip quality
bending and axial shifting system
(CVC plus® )
Horizontal Stabilization system (HS):
Work rolls can be laterally shifted depending on
strip data and rolling conditions.
▬ More than 15 references worldwide
▬ Ideal solution for stainless-steel tandem mills
16
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Principle of Horizontal Stabilization system (HS)
With HS system:
supporting force can be adjusted
▬ Stabilized rolling process
▬ Longer lifetime of side support inserts
▬ Less maintenance
FTo
FD
FR
without HSHS systemsystem
required
supporting
force
FT1
rolling direction
FR rolling force
FD tangential drive force
FTo strip tension force entry
FT1 strip tension force exit
horizontal
roling force
component
e (shift)
with HS sHS systemystem
FTo
FD
FR
FT1
required
supporting
force = 0
49. 17
SMS metallurgy Conference 2007
Continuous tandem cold mills for stainless steel
Benefits of SMS Demag technology
▬ SMS Demag is a competent partner in process technology
▬ Great number of reference plants with proven
technology fast start-up and reliable operation
▬ Low operational cost and high availability due
to modular design
▬ Excellent quality, high reliability, always on time
▬ Reasonable cost-benefit ratio
50.
51. The new galvanizing line
for SeAH Steel –
Results and experiences
Dipl.-Ing. Werner Haupt
General Manager
Preacquisition and Integrated Projects
Dipl.-Ing. Joachim Kuhlmann
General Manager Process Engineering
Strip Processing Lines Division
SMS Demag AG
Hilden, Germany
Y. J. Lee
Director
SeAH Steel Corp.
Kunsan-City, Jeonbuk, Korea
52.
53. The new galvanizing line for SeAH Steel – Results and experiences
Y.J. Lee, Werner Haupt, Joachim Kuhlmann
The new and also first hot-dip galvaniz-
ing line of SeAH Steel Corporation is the
heart of the new cold rolling mill complex
built in Gunsan in the western part of
South Korea. The following topics report
on the construction of the facility by
SMS Demag as well as on our first oper-
ating results:
▬ General overview
▬ Market development
▬ Layout/technical data of the CGL
▬ Erection phase
▬ First coil
▬ Operation
▬ Results and experiences
SeAH Steel Corporation specializes in
the production of steel pipes, stainless
steel pipes for gas and water plumbing
installations in buildings as well as gal-
vanized strip and pre-coated material.
The annual production capacity is more
than 1,200,000 t.
Besides supplying the domestic market,
high export rates to the USA and Japan
are achieved.
The subsidiaries of SeAH Steel include:
▬ Busan Pipe America Inc. (USA)
▬ State Pipe & Supply Corp. (USA)
▬ Vinapipe Corp. (Vietnam)
▬ Saigon Steel Pipe Corp. (Vietnam)
▬ SeAH Japan Co., Ltd. (Japan)
The history of the company is as follows:
1960 Establishment of the company
as “Busan Steel Industry” in
Gammandong, Busan City.
1979 to 1982 – Acquisition of several
specialist companies for the pro-
duction of steel pipes.
1996 The company’s name was
changed into “SeAH Steel
Corporation”.
2005 Completion of the new cold
rolling mill complex in Gunsan.
As part of the new cold rolling mill
in Gunsan, the agreement with
SMS Demag for the supply of a hot-
dip galvanizing line was signed on
November 28, 2003.
54. With a market share of 660,000 t, SeAH
Steel covers 22 % of the demand for
steel pipes in the South Korean market
and is South Korea’s biggest enterprise
in this product sector.
With 350,000 t of cold rolled steel, gal-
vanized and pre-coated strip, SeAH
holds just a small market share among
the big players and has to compete with
producers which, owing to the size of
their companies, are able to produce
high-grade products at favorable cost.
The new galvanizing line has been de-
signed for the production of hot-dip gal-
vanized steel strip of the steel grades
CQ, DQ, DDQ and FH (full hard). These
products are used for white goods, in
the electrical and building as well as the
construction industries.
Designed for an annual capacity of
300,000 t, the line galvanizes strip 0.23
to 1.8 mm thick and 600 to 1,300 mm
wide. In the coating section, the strip
runs at speeds of up to 200 m/min, while
the entry and exit sections attain speeds
of maximum 280 m/min.
The line configuration is following the
demand for hot-dip galvanized strip of
highest surface quality. Pre-cleaning
takes place in the entry section and full
cleaning right upstream of the furnace.
To facilitate installation, the vertical strip
loopers feature a new modular design.
They are completely balanced and
equipped with a redundant drive system
with amply dimensioned ropes to ensure
reliable operation and a long service life.
The radiant-tube-heated Drever furnace
with a capacity of 73 t/h and the highly
precise Duma air-knife system complete
the process section.
Downstream of the four-high skin-pass
mill and the tension leveler unit, a ver-
tical coater takes care of passivating the
strip.
The new galvanizing line of SeAH Steel
was built by a consortium comprising
SMS Demag AG, Germany, Drever
International S.A., Belgium, and Duma
GmbH, Germany.
Picture 6 shows the steel structures of
the two cleaning sections during erec-
tion.
Picture 7 on the left shows the area of
the post-treatment section during instal-
lation. The picture on the right reflects
the line from the entry looper system, via
the center cleaning section up to the
vertical furnace.
Erection started in November 2004 and
was completed in June 2005. In total,
more than 4,000 t of machines and steel
structures were installed. As early as
21 months after contract signing, the
first galvanized coil was produced.
55. Thanks to the excellent performance of
all suppliers under the leadership of
SMS Demag and the superb coopera-
tion between the consortium and SeAH
Steel, the first saleable strip was pro-
duced four weeks before the scheduled
contractual date.
Picture 8 shows the festive celebration
of production start, which is a very im-
portant ceremony in the Korean self
understanding and culture.
As a result of this early and successful
hot commissioning, the full production
capacity was already achieved after
23 months and the Final Acceptance
Certificate (FAC) was issued as soon as
after 21 months.
Picture 9 on the top shows the vertical
post-treatment section in operation with
roll coater, drying oven and air coolers.
The right bottom picture reflects the op-
eration of the line in the area between
the pre-cleaning section and the vertical
furnace. The picture provides a clear
view of the entry-end vertical looper ar-
ranged between the two cleaning sec-
tions. The picture on the left is a top
view of the Duma air-knife system.
The remarkably steep run-up curve of
the line is documented by the following
production evaluations covering the ini-
tial months after line startup.
▬ Run rate
▬ Production volume
▬ Yield
▬ Run-up curve
▬ Coating tolerances or accuracy
Already in the first month, the line at-
tained a relatively high availability of
74.5 %, and from the end of the third
month on, the values stabilized around
the target of 98 %.
Picture 12 reflects the volumes pro-
duced for direct sales and for processing
in the own color-coating section.
It is obvious also in this case that the
line achieved its planned production
after a short time.
Picture 13 represents the ratio between
input material and finished products. A
high value means, for example, low
scrap losses. As early as in the second
month, the target value of 98 % was ex-
ceeded. Values of over 100 % may re-
sult owing to a weight increase due to
coating.
56. The run-up curve is the best way to de-
scribe the performance of the line as a
combination of availability and yield.
Just one month after commissioning, the
value stabilized around the target of
96 %, and after eight months ideal val-
ues of nearly 100 % were achieved.
The coating accuracy is one of the most
important factors for the product quality
and, when zinc prices are high, decisive-
ly impacts the operating costs.
Thanks to the Duma air-knife system,
coating uniformity is more than satis-
factory. Currently, each 1 % in closer
coating tolerances reduces operating
costs by up to EUR 1 million per year.
57. 1SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Contents
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
▬ General overview
▬ Market developments
▬ Layout/Technical data
▬ Erection phase
▬ First coil
▬ Operation
▬ Results and experiences
2SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Company profile
SeAH Steel Corporation is specialized in the production of
▬ steel pipes,
▬ stainless steel pipes for plumbing and structures,
▬ galvanized steel and pre-coated metal
Annual production capacity: 1,200,000 t of steel products
Export of products to the USA and Japan
Subsidiaries:
▬ Busan Pipe America Inc. (USA)
▬ State Pipe & Supply Corp. (USA)
▬ Vinapipe Corp. (Vietnam)
▬ Saigon Steel Pipe Corp. (Vietnam)
▬ SeAH Japan Co., Ltd. (Japan)
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
58. 3SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Company history
1960 Establishment of the company as “Busan Steel Industry
in Gammandong, Busan City
1979 - 82 Several acquisitions of specialized companies
1996 Change of company name into SeAH Steel Corp
2005 Completion of new CRM in Gunsan area
28.11.2003 Purchase agreement with SMS Demag
for the new CGL
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
4SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Market shares
52.71,591Others
1003,019Total
Husteel
SeAH Steel
Hysco 16.4495
21.9660
9.0273
Portion
in %
Market
share
7.8932Union Steel
10.61,258Others
10011,910Total
Dongbu Steel
Posco
Hysco 12.11,437
54.16446
15.41,837
Portion
in %
Market
share
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
Market share Cold rolled steel
(in '000 t)
Hysco
Posco
Dongbu
Steel
Union
Steel
Others
Market share steel pipe
(in '000 t)
Hysco
Seah
Steel
Husteel
Others
59. 5SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Technical Data:
Products: GI / CQ, DQ, DDQ, FH (full hard)
Application: White goods + construction
Production capacity: 300,000 t/year
Strip thickness: 0.23 to 1.6 mm
Strip width: 600 to 1,300 mm
Line speed: 200 m min (process section)
General
overview
Market
development
Layout
Erection phase
Operation
Results and
Experiences
Continuous galvanizing line – SeAH Steel, Korea
6SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Erection phase
All main equipment by SMS group
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
Continuous galvanizing line
was built by a consortium
between
▬ SMS Demag AG, Germany
▬ Drever International S. A.,
Belgium
▬ Duma GmbH Germany
for air knife system
60. 7SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Erection phase
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
▬ 21 months from purchase
agreement to first coil
▬ erection period November 2004
until June 2005
▬ total weight: 4,114 t
8SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
The first coil was produced in saleable quality
four weeks before scheduled date
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
61. 9SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Operation
Cleaning section,
entry looper and furnace
Air knife
Post treatment
▬ FAC after 21 months
▬ Full production after 23 months
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
10SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Results and experiences
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
▬ Run rate
▬ Production of main products
▬ Benefit (output/input)
▬ Startup curve
▬ Coating accuracy
62. 11SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Run rate (prod. time/planned prod. time)
70
75
80
85
90
95
100
Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar. 06 Apr 06 May 06
Month
Rate(%)
Run rate target 98 %
First month
273hrs
437.7hrs
306.7hrs
405hrs
576.9hrs
491.4hrs
602.6hrs
600.4hrs
588.6hrs
hrs: Production hours
Results and experiences
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
12SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Production
-
5.000
10.000
15.000
20.000
25.000
Sep
05
Oct
05
Nov
05
Dez
05
Jan
06
Feb
06
Mar
06
Apr
06
May
06
Month
tons/month
GI FOR SALE MATERIAL FOR CCL TOTAL
Results and experiences
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
63. 13SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Benefit (output/input)
70
80
90
100
110
Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06
Month
Rate(%)
Benefit target 98%
First month
Results and experiences
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
14SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
Startup curve
0
10
20
30
40
50
60
70
80
90
100
Sep 05 Oct 05 Nov 05 Dez 05 Jan 06 Feb 06 Mar 06 Apr 06 May 06
Month
Rate(%)
Target startup curve 96 %
First month
Results and experiences
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
64. 15SMS metallurgy Conference 2007
The new galvanizing line for SeAH Steel
SeAH is very satisfied with the achieved coating
tolerances of the Duma air knife. Due to increased zinc
costs each 1 % improvement of tolerances reduces our
operation costs by approx. 1 million EUR per year.
Coating tolerances
General
overview
Market
development
Layout
Erection phase
First coil
Operation
Results and
experiences
65. Economical solutions for
high-quality processing lines
Dipl.-Ing. Stefan Melster
General Manager
Technical Sales
Strip Processing Lines Division
Dr. Hans-Georg Hartung
Executive Vice President
Strip Processing Lines Division
SMS Demag AG
Hilden, Germany
66.
67. Economical solutions for high-quality processing lines
Stefan Melster, Dr. Hans-Georg Hartung
While in the past many investment deci-
sions were clearly made on the grounds
of technical preferences, the majority of
decisions nowadays is based on eco-
nomic considerations or facts. The refer-
ence figure today is the total cost, fig-
ure 1. Costs such as the percentage of
depreciation, overheads and the prices
of raw materials cannot be influenced by
plant builders. Investment cost or, in
other words, the price of the line is a
matter of technical requirements and so-
lutions or, respectively, a matter of nego-
tiation and by far not the most important
factor. In the long run, it is the cost for
maintenance, yield loss, staff and con-
sumables that makes the difference be-
tween standard lines and economically
and profitably operating processing lines.
For about ten years, our development of
new equipment and the optimization of
existing components have been follow-
ing just one guideline – to improve the
customer benefit and profit. This can on
the one hand be achieved by technical
improvements which have an economic
impact, but also by cost-cutting with a
subsequent price reduction which is
based on a different design, but does not
affect equipment performance.
SMS Demag today offers the full range
of high-quality strip processing lines with
obviously significant economic advan-
tages, figure 2, as demonstrated by the
large number of recent references. Be-
sides 13 continuous pickling lines and
coupled pickling lines/tandem cold mills,
six color coating lines, twelve continuous
annealing lines and 14 galvanizing lines,
SMS Demag has during the last six
years received orders for more than
70 further strip processing lines. Among
these are high-tech lines like silicon strip
processing lines, processing lines for
aluminum strip or acid regeneration
plants.
Figure 3 is a summary of our latest ma-
jor worldwide references. Our guideline
for achieving best total cost of ownership
can be best explained by two recent ex-
amples: the pickling line of the new
coupled pickling line/tandem cold mill of
Baosteel’s cold rolling mill No. 5 and the
continuous galvanizing line No. 3 of
US Steel Kosice in Slovakia.
Figure 4 is a sectional view of Bao-
steel’s new PLTCM, designed for an an-
nual production capacity of 1.74 million t
of steel, mostly high-quality grades for
68. the automotive industry. To explain the
cost-saving potential of our technologies,
three examples are provided of which
more details will be shown:
▬ the turbulence pickling technology
▬ the horizontal loop accumulator
▬ the ASC side trimming shear
Since the early 50s, SMS Demag has in-
fluenced the design of all types of high-
performance pickling lines all over the
world. Meanwhile all components for
pickling lines including mechanical and
chemical equipment, even acid regener-
ation plants and laser welding machines,
can be supplied from one single source.
This is a benefit to our customers as it
involves a consistent process technology
and minimizes potential interface prob-
lems.
The turbulence pickling method, fig-
ure 5, developed by SMS Demag, is not
only the most effective, but also the most
economical pickling technology in terms
of operating cost. The design of
SMS Demag’s turbulence pickling line is
characterized by shallow and horizontal
pickling channels, the patented immer-
sion covers and acid injection by spray
headers on the entry and exit sides of
each pickling tank. The straight, horizon-
tal channel which is integrated into the
main pickling tank, allows operation of
the line at high strip tension for improved
strip guiding. Its small height of about
150 mm not only ensures a high acid
flow velocity and hence large turbu-
lences, but also a much faster adjust-
ment of the acid temperature, due to less
acid circulation volumes. This improves
process flexibility. The immersion cover
seals off the pickling channel towards
the top and thus prevents any free acid
surface and acid evaporation in the pick-
ling tank, which leads to significant ener-
gy and operating cost savings. By injec-
ting the acid at high pressure from the
entry and exit sides into the pickling
channel and onto the strip, the turbulent
acid flow and the acid exchange on the
strip surface are increased through the
high input of kinetic spraying energy.
During the pickling process the entire
pickling channel is filled with acid,
whereas the entry- and exit-side acid in-
jection serves for hydrodynamic sealing
of the pickling channel, figure 6. This
ensures wetting of the full strip surface
even at high strip speeds, as well as an
improved acid separation between the
pickling tanks. The high intensity of the
turbulence pickling line allows a very
compact design of this process section.
Steam and power consumption as well
as acid losses are significantly lower
than in conventional pickling systems,
due to the immersion covers. A much
faster heat transfer from acid to strip and
more intensive acid exchange at the strip
surface can be achieved through the
high kinetic spraying energy. This leads
to a better acid utilization and an accel-
erated pickling process. Due to the good
controllability of the process, no pickling
inhibitors are necessary. The rinse sec-
tion has a second spray rinse circuit in
order to avoid staining during line stops.
69. Therefore, no rinsing inhibitors are
needed here either. For a pickling line
with a production capacity of about
1.8 million t/year, annual savings may
total 600,000 EUR just because of the
above-mentioned features.
The turbulence pickling process can be
further optimized through the application
of SMS Demag’s process model, fig-
ure 7, which sets all essential pickling
parameters to the relevant strip quality
automatically and ten to 20 coils in ad-
vance. The main objective is to prevent
underpickling or overpickling and to set
the lowest possible acid temperature.
The lowest possible bath temperature
means minimum energy and acid con-
sumption, but also an increased lifetime
of all equipment exposed to acid. A 5 °C
drop in the bath temperature may result
in a 50 % longer lifetime of plastic pipes.
Part of this process model is the simula-
tion of the pickling process for incoming
coils. Based on all major pickling and
strip parameters, the pickling result can
be controlled by the correct setting of the
acid pressure in consideration of the
strip speed and the required bath tem-
perature. The model controls the transi-
tion from one strip to the next, so that the
pickling process is adapted to the next
strip without any visible change in the
pickling results. In addition to the above-
mentioned cost savings, the application
of the SMS Demag process model may
result in further savings of up to
300,000 EUR per year due to reduced
power and fluids consumption.
SMS Demag’s horizontal looper system,
figure 8, is characterized by two main
features: the retained looper car and the
Maltese-cross looper gate design. The
retained looper car means that the
looper car is pulled on each side by
ropes, whereas other systems use a
rope for pulling on one side and the strip
only for pulling on the other side. The ad-
vantages of our system are lower ten-
sion fluctuations and a more stable
looper car operation. Constant strip ten-
sion and thus untroubled operation of the
coupled tandem mill is not the only bene-
fit of the closed loop system. For mainte-
nance purposes the looper car can be
moved without strip in the line.
Due to the Maltese-cross looper gate
system, the looper gate arms can be
opened and closed smoothly by the
looper car without any shock even at
high looper car speeds. The special me-
chanism leads to a soft acceleration and
deceleration of the looper arm without
inertia-caused overloading of the me-
chanical parts. Frequent consequential
damage can thus be avoided. Each da-
maged gate costs a total of approx.
90,000 EUR. These expenses for
spares, maintenance work, production
loss and fixed costs can be saved.
70. The combined ASC side trimmer and
chopper unit is one of the most impres-
sive cost savers in our lines, figure 9.
On each side of the line two trimming
shears with associated scrap choppers
are mounted on a turntable platform in a
180-degree arrangement. This arrange-
ment allows the safe maintenance of the
standby trimmer/scrap chopper unit also
during production, with the other unit in
operation. All settings of the knife gap
and knife overlap are performed
automatically by eccentrics. In
comparison, linear shifting devices with
bushes tend to wear and are always a
matter of maintenance. In contrast, ec-
centrics are backlash- and almost main-
tenance-free. Due to the automatic knife-
gap and knife-overlap setting, an ex-
tended lifetime of the blades and im-
proved cutting qualities can be achieved.
The knife blades are face-ground and
mounted against mechanical stops,
therefore no calibration is required after
a blade change.
The side-trimmings chute between the
trimmer and chopper is undivided with-
out any gaps. Gaps in the side-trimmings
chute are usually the cause of scrap
cobbles and each cobble can take
approximately one to two hours to be
removed.
During a width change, the complete
side trimmer and chopper unit will be re-
adjusted within seconds without produc-
ing any extra scrap. Our design avoids
the above-mentioned typical operational
problems, i. e. unscheduled downtimes
for troubleshooting like scrap jam remov-
al. Even in the unlikely case of trouble or
in case of normal maintenance, the
whole system together with its problem
is simply turned out of the line and re-
placed by fully operative equipment with-
in 60 seconds. The problem can then be
fixed in the safe 180-degree position
while the line is running. With one
trouble per week, this ASC side trimming
system can save up to 1 million EUR per
year in high-performance pickling lines.
The combined ASC side trimmer unit is
not only used in our pickling line, but al-
so in most of our other strip processing
lines.
Another good example for economical
processing-line solutions is the new gal-
vanizing line No. 3 of US Steel Kosice,
figure 10. This is a typical line for the
production of exposed automotive mate-
rial with GI and GA coatings. Highly so-
phisticated structural steel grades are al-
so part of the product mix.
71. The total-cost-of-ownership guideline is
explained by the following examples:
▬ Coil transport system
▬ Cleaning section
▬ Air knife
▬ Post-treatment/coating section
Our coil cars, figure 11, are of extremely
compact and flat design and do not need
any deep, expensive and eventually also
dangerous foundation pits. Still they are
as sturdy as necessary for metallurgical
works. As opposed to other scissors-
type coil cars, the cylinder force acts in
the load direction and not in transverse
direction. The scissors just have a guid-
ing function, but do not transmit any
load. Besides safety and maintenance
aspects, the cost reduction for the foun-
dations of three coil cars is about
70,000 EUR.
Our strip cleaning sections, figure 12,
are characterized by three main fea-
tures. First, sealed modules with lower
required fume exhaust volumes at the
connection points of the modules reduce
energy losses significantly. Second, the
changing of rolls is fairly easy and can
be done during operation with no addi-
tional downtimes or maintenance work
required. Finally, special tongue-shaped
spray nozzles guarantee a clog-free op-
eration. No clogging means no surface
stripes, no subsequent downgrading and
no prematurely damaged brush rolls.
Based on European cost basis, up to
600,000 EUR can be saved per year.
SMS Demag can provide two prime-
quality air knife systems: Fontaine and
Duma, figure 13. Both air-knife systems
are technically excellent. Both can be
equipped with width-adjustment actua-
tors without any negative influence on
the surface quality produced. Depending
on the product mix, such a blow-off width
adjustment can save up to 30 % of com-
pressed air or, respectively, nitrogen. In
the production of automotive strip such
nitrogen savings can add up to
1 million EUR a year in case the nitrogen
has to be purchased. The high precision
of our air knife systems results in closer
coating tolerances than in other systems.
A mere 1 % more precise coating can
save zinc worth up to 1 million EUR per
year in a typical hot-dip galvanizing line
producing approx. 400,000 t/year and
approx. 190 million m² strip surface.
In modern lines that conform to the latest
health and safety standards, the heart of
the post-treatment section is the roll
coater, figure 14. Using two separate
circuits, our coaters can be used for
chromating as well as anti-fingerprint
coating. Due to the use of coated pans
and the automated cleaning and rinsing
system, a change in coating agent is not
very time-consuming. Alternatively, a
two-coater or shuttle coater system can
be provided. The rolls can be changed
without any major maintenance effort.
But the most impressive property is no
doubt the outstanding accuracy of the
coating. With this system, a coating ac-
curacy of plus/minus a quarter of a mi-
cron can be achieved. In comparison
72. with other coating systems with ac-
curacies of plus/minus 1 micron, this
means, in addition to other benefits, sav-
ings of up to 500,000 EUR per year for
the post-treatment system of hot-dip gal-
vanizing lines. In color-coating lines,
three times this amount can easily be
saved due to the particularly high cost of
chemicals and paints.
All the above-mentioned examples are
the result of a continuous improvement
process, figure 15. All developments
must follow the total-cost-of-ownership
guideline. This means that improve-
ments must pay off to our customers in
terms of reduced operating cost, less
energy consumption, less maintenance,
less downgrading, higher yield or a mar-
ketable better product quality. All these
economical solutions for high-quality pro-
cessing lines are incorporated in our lat-
est reference list and have been suc-
cessfully commissioned. As a conse-
quence, a steep ramp-up curve is part of
our customer benefit.
73. 1SMS metallurgy Conference 2007
Economical solutions for high-quality processing lines
Introduction
Introduction
Strip
processing
lines
Pickling line
technology
Summary
No cost influence
by SMS Demag
Cost influence
by SMS Demag
Investment
cost
Overheads Depreciations
Total cost
of ownership
Staff costYield loss
Consumables
& media
Maintenance
Raw material
Hot-dip
galvanizing line
technology
2SMS metallurgy Conference 2007
Strip processing lines – Major references since 2000
Economical solutions for high-quality processing lines
Carbon steel
… in total more than
50 new processing lines
since 2000
… incl. seven lines for
silicon strip
… incl. seven lines for
aluminum strip …
… plus approx.
60 service lines …
… plus 13 new ARPs
13 CPL/PLTCMs
14 CGLs
12 CALs
6 CCLs
1 ETL
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
74. 3SMS metallurgy Conference 2007
Economical solutions for high-quality processing lines
Strip processing lines – Major references since 2003
Customers and type of lines
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Tokyo Steel CPL + ARP
Shougang Jing-Tang CAL
Nucor CGL
ILVA Taranto and Cornigliano 2 CGLs
Baosteel 4 Si-lines
Tiantie PLTCM
Salzgitter CPL
SeverCorr CGL + PLTCM
Baosteel CAL + PLTCM
Shougang CAL + PLTCM
US Steel Kosice CGL
Jinan CPL
WISCO 3 CGLs + CAL + PLTCM
Anshan CAL
Seah CGL
Rasselstein ETL
Baosteel CAL + PLTCM
US Steel Kosice CGL
Hot-dip
galvanizing line
technology
4SMS metallurgy Conference 2007
Introduction
Pickling line
technology
Summary
Products:
Strip thickness
Strip width:
Pickling speed:
Production capacity:
CQ, DQ, DDQ, EDDQ, SEDDQ, DP, Trip
1.8 to 6.0 mm
700 to 1,650 mm
270 m/min
1,740,000 t/year
Technical data
Economical solutions for high-quality processing lines
Pickling line/tandem cold mill
Baosteel, Baoshan/China
Hot-dip
galvanizing line
technology
75. 5SMS metallurgy Conference 2007
Economical solutions for high-quality processing lines
Turbulence pickling technology
Turbulence pickling channel
Immersion cover
Outer cover
Pickling tank
▬ Flat and horizontal pickling channel
▬ Immersion covers – less acid evaporation
▬ Hydrodynamic sealing
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
6SMS metallurgy Conference 2007
▬ Better controllability due to less acid volumes in circulation
▬ Less steam, acid and energy consumption due to immersion covers
▬ No pickling and rinsing inhibitors
▬ Lower possible acid temperature – less energy, longer lifetime
Economical solutions for high-quality processing lines
Turbulence pickling technology
Turbulence pickling tank with circulation system
Total potential on cost savings: up to 600,000 EUR/year
Draining chamber with spray bars and
squeegee roll unit (hydrodynamic sealing)
Acid supply
piping
Cascade piping
Pump
Heat exchanger
Steam
Condensate
Waste acid
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
76. 7SMS metallurgy Conference 2007
Economical solutions for high-quality processing lines
Turbulence pickling technology
▬ Minimized overpickling:
less material loss
less energy
higher yield
▬ Automatic setting and control of process actuators
▬ Minimized bath temperature
less energy
longer lifetime
less maintenance
Total potential on cost savings:
up to 300,000 EUR/year
SMS Demag process model for turbulence pickling
Turbulence
Temperature
Desired bath temp.Strip speed
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
8SMS metallurgy Conference 2007
Economical solutions for high-quality processing lines
High-speed looper concept – Technical advantages
Steering Curve
Tension Rope
Retaining Rope
Each damaged gate costs EUR 90,000
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Maltese-cross looper gates
▬ impact-free opening and closing
▬ less damages
▬ longer lifetime
▬ less maintenance
Hot-dip
galvanizing line
technology
Closed loop system
(two-side rope pulling)
▬ less tension fluctuation
▬ better maintainability
77. 9SMS metallurgy Conference 2007
Economical solutions for high-quality processing lines
ASC trimming shear
Features:
▬ No line stop during
knife change
▬ Easy and safe
maintenance access
▬ No extra scrap during
width change
▬ No calibration of knives
after change
Potential cost savings up to 1 million EUR/year
due to less downtime
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
10SMS metallurgy Conference 2007
Products:
Strip thickness
Strip width:
Process speed:
Production capacity:
CQ, DQ, DDQ, EDDQ, SEDDQ, HSS-CQ,
HSS-DQ, HSS-DDQ, BH, DP
0.3 – 2.0 mm
800 – 1,850 mm
180 m/min
410,000 t/a
Technical data:
Economical solutions for high-quality processing lines
Continuous galvanizing line
US Steel Kosice, Slovak Republic
78. 11
Coil transport systems
Economical solutions for high-quality processing lines
SMS Demag technology
▬ Coil cars with extremely flat
design and rigid design for
metallurgical works
▬ Guiding scissors are load-
free
▬ No expensive and
dangerous foundation pits
▬ Good maintainability
Reduction of foundation cost
up to 70,000 EUR
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
12SMS metallurgy Conference 2007
Potential cost savings: up to 600,000 EUR/year
Economical solutions for high-quality processing lines
SMS Demag technology
▬ Sealed modules – less energy
▬ Easy roll changes – less
maintenance
▬ No clogging – no brush roll
damages, no stripes, no
downgrading
Strip cleaning section
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
79. 13SMS metallurgy Conference 2007
SMS Demag technology
▬ Width adjustable
▬ Outstanding coating accuracy
▬ Minimized over-coating
Possible reduction of production costs per year:
up to EUR 1,000,000 nitrogen savings for customers
without oxygen plants
1 % better coating accuracy = approx. 1,000,000 EUR
cost savings for zinc
Air knife
Economical solutions for high-quality processing lines
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
14SMS metallurgy Conference 2007
SMS Demag technology
▬ Outstanding coating accuracy
▬ Simple roll change
▬ Automated cleaning of rolls, pans
and media systems
▬ Minimized over-coatings due to
higher coating accuracy
Post-treatment
Economical solutions for high-quality processing lines
A coater accuracy of ± 0.25 μm instead of
± 1.0 μm can save up to 500,000 EUR/year
for post-treatment
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
80. 15SMS metallurgy Conference 2007
Summary
▬ Cost savings resulting from …
• less operating materials and energy consumption
• less maintenance and longer service life
• less downgrading of product quality
• less downtimes and higher yield
▬ Better product quality
▬ Higher flexibility and faster start-up curves
The essentials of economical solutions are …
Economical solutions for high-quality processing lines
Introduction
Strip
processing
lines
Pickling line
technology
Summary
Hot-dip
galvanizing line
technology
81. The SMS Demag laser welding
machine
Dipl.-Ing. Lutz Kümmel
Senior Project Manager
Strip Processing Lines Division
Dr. Hans-Georg Hartung
Executive Vice President
Strip Processing Lines Division
Dipl.-Ing. M.B.M. Markus Jaenecke
Senior Project Manager Project Planning
Strip Processing Lines Division
SMS Demag AG
Hilden, Germany
82.
83. The SMS Demag laser welding machine
Dr. Hans-Georg Hartung, Markus Jaenecke, Lutz Kümmel
Some three years ago, SMS Demag and
Oxytechnik, a German welder manufac-
turer, agreed to jointly develop a laser
welder for strip processing lines. Tech-
nology and design are the results of
many years of experience in designing
high-performance strip processing lines
and equipment as well as welding ma-
chines including laser welders for special
applications.
Nowadays, laser welding machines are
the first choice for continuous pickling
lines. These welders are meanwhile
cheaper than flash butt welders and
easier to commission, especially if new
materials or material combinations are to
be welded. In addition, these welding
machines are able to weld thinner strip
and strip with higher amounts of alloying
elements. Based on the experiences
gained from many projects, we devel-
oped a new laser welder design. Thanks
to the closed-frame concept, the ma-
chine is more compact than C-frame-
type machines and can usually be trans-
ported on trucks.
The laser resonator is fixed on a sepa-
rate foundation. No resonator vibrations
will influence the welding accuracy. For
maintenance purposes, access to the
machine as well as to the resonator is
excellent.
Another remarkable feature is the posi-
tioning system that aligns the head end
of the new strip with the tail end of the
previous strip. That means that it is the
center line of the leaving strip that de-
fines the correct alignment, and not the
center line of the machine. After joining,
the two strips will have one common
center line and definitely no so-called
dog-leg shape. One of the biggest ad-
vantages is that the strip edges will not
be damaged. The clamping of the strip
will not be interrupted until welding is
finished.
The integrated shear is not a notcher-
type shear with more or less no gap be-
tween top and bottom knives. Such a de-
sign leads to huge perpendicular forces
acting on the knives and subsequently to
high wear and less accuracy. The laser
welder consists of a robust, mill-type-de-
sign dividing shear with automatically ad-
justable knife gaps separately for the
outgoing and ingoing strip ends. The
knife crossbeam is supported at several
positions across the width and doesn’t
allow any relevant breathing. The blade
lifetime is at least three times as long as
for other laser welders and, due to the
cassette design, the blades can be
changed easily by an electro-hydraulical-
ly changing device. The top knife can be
used twice, the bottom knives four times
before regrinding. The precise cut has
84. the potential to allow using lasers with
less power in the future because the de-
focusing of the beam can be reduced.
This leads to less laser power and con-
sequently to a longer laser lifetime. For
the same reason we expect that more
and more Neodymium-YAG lasers will
be used in the near future instead of
high-power CO2 laser sources. One ma-
jor advantage is the possibility to feed
the beam via fiber-optic cable to the weld
spot – subsequently no mirrors can be
contaminated.
The shear remains in the machine during
welding. Therefore, we could avoid the
either heavy or flimsy C-frame design.
Scrap can be discharged directly into a
pit or be removed by a conveyor belt.
In case of different strip thicknesses, the
joint can be made centrically, top side or
bottom side orientated. Real zero-gap
welding is possible due to the shifting
function of the strip clamping device.
As an option for special applications a
wire feeder can be provided. Mixed gas
or helium is used as inert gas.
Along with the design work plenty of
laboratory tests were conducted. The
test results were very promising, even
for hard-to-weld steel grades like C60
with a carbon content of 0.67 %. The
cross-sections of the welds were excel-
lent and so were the microstructures of
the heat influence zone and of the weld
itself. The main components of the mi-
crostructure of this high-carbon steel are
ferrite and perlite. Post-annealing and
particularly preheating and post-anneal-
ing led to a highly uniform hardness dis-
tribution in the vicinity of the weld as
compared to the results without anneal-
ing. In order to ensure the best possible
heat treatment of the weld, new inductive
pre- and post-heaters were developed
together with our sister company
SMS Elotherm. The main features are
fast heating during preheating and post-
annealing with retarded cooling.
Early in 2006, we received an order from
Salzgitter Flachstahl GmbH, Germany,
for a heavy-duty laser welding machine.
This laser welder for 800 up to 1,900-
mm-wide strip will be installed in a 2.5-
million-t/year continuous pickling line that
will also be supplied by SMS Demag.
The strip thickness ranges between 1.5
and 6 mm and the yield stress may ex-
ceed 1,100 N/mm². Some of the steel
grades are extremely difficult to weld
such as C60. The laser welder for Salz-
gitter is currently being tested in our
workshop. In April 2007 Tokyo Steel,
Japan, placed a further order for a laser
welder with us.
85. 1SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Development of SMS Demag laser welding machine
▬ In 2004, a cooperation between SMS Demag and
was established in order to develop a
laser welding machine for strip processing lines
Introduction
Main features
Laboratory test
Laser welding
machine for
Salzgitter
2SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Laser beam source
CO2 laser resonator
Introduction
Main features
▬ The laser resonator is fixed
beside the machine on a
separate foundation
▬ No vibrations, no influence
on the welding accuracy
▬ Easy access for maintenance
Laboratory test
Laser welding
machine for
Salzgitter
86. 3SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Strip alignment
Introduction
▬ Incoming strip head is aligned with the tail end of the
previous strip
▬ Center line of the leaving strip defines the right alignment
▬ No pushers – no strip edge can be damaged
Laboratory test
Laser welding
machine for
Salzgitter
Main features
4SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Shear design
▬ Robust, mill-type design dividing shear with automatically
adjustable knife gaps separately for outgoing and ingoing
strip
Introduction
Laboratory test
Laser welding
machine for
Salzgitter
Main features
87. 5SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Shear design details
Introduction
▬ Knife lifetime triples
▬ Quick knife changes
▬ Precise cuts =
precise weld
Multiple support of knife crossbeam
Knife changing device
Laboratory test
Laser welding
machine for
Salzgitter
Main features
6SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Welding process
Introduction
▬ The joint can be made
centrically, top side or
bottom side oriented
▬ For special steel grades a
wire feeder can be installed
▬ For shielding, mixed gas or
helium is used
Laboratory test
Laser welding
machine for
Salzgitter
Main features
88. 7SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Results of laboratory test
Introduction
Main features
▬ Cross-sections of the welds as well as the microstructure of
the heat influence zone and of the weld itself were excellent.
▬ Hard-to-weld steel grades
like C60 with a carbon
content of 0.67 %
were welded successfully
Laboratory test
Laser welding
machine for
Salzgitter
8SMS metallurgy Conference 2007
The SMS Demag laser welding machine
Influence on weld seam hardness by heat treatment
Preheating and post-
annealing of coils
Introduction
Main features
▬ Fast preheating and soft post-
annealing with retarded cooling
200
300
400
500
600
700
800
900
1000
-5,0 -4,0 -3,0 -2,0 -1,0 0,0 1,0 2,0
Position [mm]
HV1
Probe 10.2
Probe 8.2
Probe 5.1
Pr. 5.1, Grundwerkstoff
C60, Anlieferung
Laboratory test
Laser welding
machine for
Salzgitter
89. 9SMS metallurgy Conference 2007
The SMS Demag laser welding machine
The new laser welding machine will be installed
in the new 2.5-million-t/year continuous pickling line
of Salzgitter Flachstahl GmbH
Introduction
Main features
▬ The order was placed in March 2006
▬ Carbon content up to 0.67 %
▬ Strip width between 800 and 1,900 mm
▬ Strip thickness between 1.5 and 6 mm
▬ Yield stress up to 1,100 N/mm²
▬ Pre-commissioning underway in our Hilchenbach
workshop
Laboratory test
Laser welding
machine for
Salzgitter
90.
91. Innovative and flexible:
the Automatic Coil Transporter
(A.C.T.®) developed by SIEMAG
Dipl.-Ing. Bernd Klein
CEO
Dipl.-Ing. Volker Schneider
Project Manager Sales
Dr. rer. nat. Horst Thorn
Head of Sales Department
SIEMAG GmbH
Netphen, Germany