-----Original Message-----

From: Sacc Luigi [mailto:l.sacca@stam.it]

Sent: Martes, 10 de Octubre de 2006 08:15 a.m.
To: Antonio Muraira Gonzlez; Sacc Giovanna
Cc: Ignacio Manuel Prieto Salinas
Subject: RE: Tata rail spec's and incoming material

Dear Antonio,
Here enclosed you find my comments.
I have to say that all these points have been already discussed between STAM and TATA,
when they were investigating on a new RF line.
I am surprised that you ask us what is possible and what is hard to achieve in terms of
tolerances, from the roll former: after all, you have been using a RF machine since years,
and you have three machines under control.
We know that the result depends much on the incoming material; we have the records
from Roanoke, from Volvo, from Scania, when using different coils, or, better, different
coils coming from a wide mother-coil.
It is absolutely clear that a cambered coil will make the life hard, to get a straight beam.
So, please read the enclosure that shows our experience on the matter.
 Final World
STAM
No Description Truck
Tolerances
Tolerences COMMENTS

Maximum & minimum web

1 +2mm /-0 mm
depth +1.5mm/-0 mm

tighter tolerances are possible, by using

+ 3mm/ -2 mm side guides placed inside the machine (
Maximum & minimum flange our ref=C355)
2 + 3 / -2 mm
in mm for F1,F2,F3 versions

Deflection of web inside &

3 + / - 0.5 mm +/- 0,5 mm
outside (Flatness)

with the passes 14 and 15 you can

Squareness after forming
4 +1 / - 0 deg + 1 / - 0,5 deg adjust the center of the tolerances, for
(Angularity) instance '+ 0,75 /-0,75 deg

Allowable vertical deflection in Within 3 mm over 1 mm per 1 meter, this is a difficult tolerance and the result
5 max 5 mm on 12 depends very much on the material
mm (Camber) entire length. meters geometry
this is an easy tolerance and it is clear
Allowable horizontal deflection Within 5 mm over 1,5 mm/meter, max that the rail is very flexible in the
6
in mm (Bow) entire length. 8mm on 12 meters direction of the bow. So this is never a
problem
Actually, this has never been a
1,5 deg on 6
Allowable twist in degrees Within 2 deg. over problem. Nobody measure this twist. If
7 metres; 3 deg on
there is twist, then the rail has bigger
(Twist) entire length. 12 meters
problems
+/-0.2mm in
Group &
8 Hole position accuracy in mm NOT STAM !
+/-0.5mm from
reference
Max & min bending radii in
mm (possibility of indicating
Inside bending Metalsa in Mexico and Roanoke has
only one radius for different
RAD=14 mm For 12,7 mm. Other customer have 12mm,
12 thickness should be considered. Scania 11 mm. 14 mm is possible,
all LM is possible
It will minimize change over but: is it the right choice?
(+1.5mm -1mm)
time and will improve
productivity)

As far as I know, the problems are two (all the other tolerances are easy to achieve, with a
careful management of the machine):

-The camber (= the flanges are curved): this one depends clearly on the camber of the
strip. Our machine does something to correct the camber of the strip, but not all.
-the difference between the flanges: however, with a normally good strip, we are within
the tolerances requested by Tata. I add that, for a customer who punches before
rollforming, we have made a modification on the machine, adding some 3-4 sets of side
guides between the first passes of the rollformer. These guides are numerically controlled.
This customer achieves, as far as I know, a +/- 0,7 mm between the flanges. But why to
have also the guides if the flange measurements are not so important?
About Radius: why 14 mm? For me it is OK, we can design a new machine with such a
radius, by it is opposite to the tendencies (smaller radius means more consistent profile).
However, you have 12,7, which is not far from 14 mm.

Cp Cpk. Sorry, we stay with 1,33. Otherwise we will put a requirement on the
tolerances on the incoming strips, that will be impossible for the steel makers.

For sure, we will not promise them tolerances tighter than those we promise to you.

Best regards,

Luigi

About meeting next week: for me it is impossible, my passport is without something that
is required in the USA (footprint, digital photo, or something else). I have applied for a
new passport, but it will take time.
Speaking with Nico Soenen and Mogens Nielsen, they also have problems (remember
that there is an important exibition for us, next weeks).
I am sure that we can managed by phone and email, unless you find another solution...

-----Original Message-----
From: Antonio Muraira Gonzlez [mailto:antonio.muraira@metalsa.com.mx]
Sent: luned 9 ottobre 2006 23.35
To: Sacc Luigi; Sacc Giovanna
Cc: Ignacio Manuel Prieto Salinas
Subject: Tata rail spec's and incoming material
Importance: High

Dear Luigi/Giovanna,

After our conference call, we found out that our customer in India would like lo have an
answer and a commitment on the formed u beam (rail) and on the incoming material
specifications and tolerances by the end of this week.

In order to try to establish the process and product specifications, please review what
TATA people has requested us. Also they are requesting process capability Cpk of 1.67
minimum to 2.00 at regular production.

In the other hand, we would like to hear your latest comments about our request for a
meeting in Roanoke, next week.

Best regards
Antonio Muraira/Ignacio Prieto