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Production The steel grade of the billets which we use : Important note: The
billet temperature must be below 723c to remain its magnetic characteristics to
transport it to the furnace by the magnetic winch according to the iron carbon
diagram: The alloy remains ferrite (BCC) crystal structure below 723c to
conserve its magnetic characteristics and above this temperature it will be
Austenite (FCC) which doesn't have magnetic characteristics.
3. Reheating furnace: Reheating furnace in plant is divided to 3 parts with 14
burners : Preheatig Heating Soating There are 14 burner in the furnace
The billet is outing from furance at around 1230 C to 1250c . There are 22
rolling steps to make 8mm wire rod and there are two extra rolling stands to
make it 6mm . Roughing : from 1 to 8 Intermediate: from 9 to 14 Finishing: from
15 to 22
4. Note: Hot rolling temperature must be above 850c, below it it will be cold
rolling and the stresses will maximize over the stands PGV (mono block ) High
speed rolling (32m/sec) Rolling technology Fundamental principles of metal
rolling process Rolling process:- The process of shaping metal and alloys into
the semi-finished or finished condition by passage between rolls is known as
rolling. The rolls rotate in opposite directions, one counter clockwise and the
other clockwise. Rolling involves plastic deformation of metal in which the
thickness of the strip is reduced and the length and width are increased.
DEFINITIONS Draft or Draught:- Draft is simply a reduction in thickness and can
be either direct draft or indirect draft. -Direct Draft is a reduction made
horizontally between the rolls - -Indirect Draft is a reduction made at an angle to
the roll barrel The difference between the initial and final thicknesses of the
strip is called absolute draught H = H1- H2 Elongation:- Is the increase in bar
length after being drafted. Is around 70 % The difference between the final and
initial lengths
5. Is called the absolute elongation L = L2 L1 * The coefficient of elongation,
i.e. the ratio of the length of the metal after rolling to its initial length Spread:- Is
the lateral or sideways movement of stock. Is around 30 % The difference
between the final and initial widths Is called the absolute spread B = B2 B1
Spread :- If we assume the same volume of material enters and leaves the stand
rolls, then the reduction in thickness must be allied to an increase in width and
length. The increase in width is termed spread and it is generally around one
third of the draft, but the exact amount is determined by the following factors; 1Temperature The hotter the material the less spread. 2- Chemical composition
The higher the carbon the more spread. 3- Roll diameter The larger the roll the
greater the spread. 4- Speed The higher the speed the less spread. 5- Pass shape
some passes restrict spread while others have zero control, and so flat rolls (no
pass groove) will have greater spread The Angle of Bite and the Arc of Contact:
The Angle of Bite is the angle formed from the point of contact of bar entry to a
perpendicular line through the roll.Consider 30 as absolute maximum, and 22
as a general angle for smooth bite. The Arc of Contact is the arc formed by the
angle of bite. The larger the roll diameter the smaller the angle of bite Speed
control system:- Modern continuous mills have a speed control system for control
and continuous adjustment of individual stand speeds.
6. 1- tension control system:- In the roughing and intermediate stands 2-loop
control system :- In the finishing stands, between each two stands ( the volume
of steel going through each stand must be the same to avoid tension or
compression.) inference important :- A1 V1 = A2 V2 = An Vn = Constant
Constant = Area (mm2) x speed (m/sec) Speed control system 1- tension control
system :- push- pull conditions :- For continuous rolling:- volume flow must be
balanced Speed and /or areas must be correctly designed and adjusted to
achieve this i.e. Area 1 * speed 1 = area 2 * speed 2 = area 3 * speed 3
Compression between two stands :- volume flow out of first stand is greater than
can be accepted by second stand loop forms and continues to grow Tension
between two stands:- Volume flow delivered by first stand is less than is
7. required by the second stand bar is pulled between stands and will neck down
and pull apart if tension is severe enough 2-loop control system :- Important
note: Having said this, one very important point, if adjustments are made to
loopers or any other equipment then the product must be checked after each
adjustment. So make your adjustments slowly, one by one, and check after each
adjustment. Fail to do this and one day you will roll scrap. Rolls Materials Types
There are three types of materials used to made mill rollers 1- iron rollers 2-steel
rollers 3-carbides rollers 1- Indefinite chill rolls - or grain-iron, these are a low
cost roll, versatile and would be found in slabbing mills, plate mills,roughing
stands, intermediate stands and finishing stands of section mills 2- Double
poured rolls - (sometimes called composite, although this leads to
misunderstanding with the carbide composites) are cast in two stages with an
alloyed iron barrel surface for hardness and an unalloyed core for toughness,
these rolls are to be found in strip mills and plate mills. 3- Definite chill rolls - an
older type of roll with limited surface depth, still in use in the shallower grooves
of the finishing stands of rod and bar mills 4- Nodular iron rolls or spheroidal
graphite have great resistance to fire cracking and distortion with good pass
life, the general applications are throughout the mills of rod, bar and small
sections
8. Steel Rolls Steel rolls have high strength and resistance to deflection, the
types of steel rolls available are: 1- Cast steel rolls - used where strength and
toughness are the main requirements. The surface of cast steel rolls is prone to
break-up and local distortion. Cast steel rolls may be found as back-up rolls in
four high mills, blooming and slabbing mills, large section mills and billet mills 2Forged steel rolls - provide greater strength, hardness and wear resistance than
cast steel but are more expensive. Forged steel may be found in blooming and
slabbing mills, cold strip mills. 3- Steel base rolls - regarded as cast steel rolls
although the carbon content places them between a steel roll and an iron roll.
They are manufactured in the same way as a conventional cast steel roll but are
usually alloyed. In certain applications their characteristics are similar to
Indefinite chill iron rolls. Steel base rolls are to be found in large structural and
section mills. Carbide Rolls Carbide rolls are in fact a compound of tungsten
2
13. Holder and turning insert The methods of manufacture in CNC 1-write G-code
program for simple works 2- use cycles inside CNC control for more complex
work piece 3-CAD-CAM software for complex geometry work piece Applications:
The applications of CNC include both for machine tool as well as non- machine
tool areas. In the machine tool category, CNC is widely used for lathe, drill press,
milling machine, grinding unit, laser, sheet-metal press working machine, tube
bending machine etc. Highly automated machine tools such as turning center
and machining center which change the cutting tools automatically under CNC
control have been developed. In the non-machine tool category, CNC
applications include welding machines (arc and resistance), coordinate
14. measuring machine, electronic assembly, tape laying and filament winding
machines for composites. Etc. Open Loop Control Systems : The open-loop
control means that there is no feedback and uses stepping motors for driving the
leadscrew . A stepping motor is a device whose output shaft rotates through a
fixed angle in response to an input pulse. Open loop control system Closed-loop
Control Systems: Closed -loop NC systems are appropriate when there is a force
resisting the movement of the tool/work piece .Milling and turning are typical
examples. In these systems. The DC servomotors and feedback devices are used
to ensure that the desired position is achieved. The feedback sensor used is an
optical encoder. The encoder consists of a light source, a photo detector, and a
disk containing a series of slots. The encoder is connected to the lead screw.
Closed-loop control system
15. PART PROGRAMMING FOR CNC: we will describe how the part programmers
execute manually the part programs. A part programmer must have an extensive
knowledge of the machining processes and the capabilities of the machine tools
First, the machining parameters are determined. Second, the optimal sequence
of operations is evaluated .Third, the tool path is calculated .Fourth, and a
program is written. Sequence Number, N: Consisting of typically three digits, its
purpose is to identify the specific machining operation through the block number
particularly when testing a part program. Preparatory Function, G: It prepares the
MCU circuits to perform a specific operation. The G- codes (some) are shown in
the Table 1 implies incremental mode of operation *G codes used in CNC
systems. Table: 1 Preparatory commands (G-code) G00 Point-to-point positioning
G01 Linear interpolation G02 Clockwise circular interpolation G03 Counterclockwise circular interpolation G04 Dwell G05 Hold G33 Thread cutting, constant
lead G40 Cancel tool nose radius compensation G41 Tool nose radius
compensation - left G42 Tool nose radius compensation - right G43 Cutter length
compensation G44 Cancel cutter length compensation G70 Dimensions in inches
G71 Metric dimensions G90 Absolute dimensions
16. G91 Incremental dimensions G92 Datum offset Dimension Words 1 . Distance
dimension words, X,Y,Z 2 . Circular dimension words, I,J,K for distances to the arc
center 3 . Angular dimensions, A,B.C Spindle speed, S Programmed in rev/min, it
is expressed as RPM or by a three-digit code number that is related to the RPM.
Miscellaneous Function, M Consisting of two digits, this word relates to the
movement of the machine in terms of spindle on/off, coolant on/off etc shown in
4
bar used for hot/cold pressing Internal cracks Steel analysis with S higher than
0.02% and C between 0.17 and 0.25% Non uniform primary cooling
Deformed mold tube Irregular cooling at the mold exit High steel tapping
temperature Defects on the hot rolled products when the crack is not deeper
than 5 mm Diagonal cracks Not uniform primary cooling or at the mold e xit
area Guide rolls not aligned Cracks in the sub skin area up to 5 mm Can
create defects on hot rolled products
25. Rhombodity higher than 5% can create problems on hot rolling Cracks due
to uneven cooling Not uniform primary cooling Not unifor m secondary
cooling Not correct alignment between mold and guide rolls Too high steel
tapping temperature Subsurface cracks can cause defects on hot rolled bar
Internal cracks may have no negative effect on hot rolled bar And here are some
of these defects that we could record during our training For the coils Heavy
oscillation marks More bending Scratches
26. For the coils: In the factory the inspection of the coils mainly concerns to the
mechanical properties and the dimensions measurements. The mechanical
properties includes the yield and tensile strength, bending and elongation Test
method Test specimens are accurately measured before testing .specimen are
then fitted into the jaws of the tensile testing machine and subjected to a
continually increasing tensile force until the specimen fracture. The tensile
strength (Rm) is calculated by dividing the maximum load by the cross sectional
area of the test specimen measured before At the bent billet surface near the
surface cut
27. testing. The dimensions must be equivalent to the required dimensions with
a maximum tolerance of +0.3 and -0.3 These coils are used Concrete
Reinforcement with dimensions start from 5.5 mm to 12mm of low carbon steel
in order to achieve the Egyptian standard specifications (ES262/2009) grade
B240B-P Suggestions for quality department The quality department is
restricted only on billet and the coils which is considered to have few functions
We have to expand the quality control functions to include the whole factory
especially the rolling mills and other equipment so that we can minimize the
malfunctions as much as possible and predict it before its occurrence. For the
billet and coils there are only few tests that are used as mentioned above such
as chemical analysis , mechanical properties and dimensions measurements
We have to introduce various testing methods such as Non Destructive Testing
and Destructive Testing which will help in the prediction of defects before
malfunction7