Variable-frequency Drive Wire Drawing Machine Application

Variable-frequency Drive Wire Drawing Machine Application

1. Device Overview

The high-speed wire drawing machine is mainly used for drawing copper wire. Its main electrical transmission part consists of a drafting motor, a take-up motor, and a wire arrangement motor. 

Other auxiliary parts of the equipment include a swing bar (tension frame), positioning wheel, line dividing wheel, reciprocating wire arrangement rod, etc. 

The drafting motor drives the drawing wheel to operate. The four-stage drawing wheel is linked through the belt to realize metal stretching, and the take-up motor realizes winding. 

The equipment overview and functional requirements are as follows:

1.1 Basic parameters of equipment:

Product name: High speed thin wire drawing machine

Drafting motor (KW): 11/4P

Take-up motor (KW): 4/4P

Incoming wire diameter (mm): Φ0.6-1.20

Outlet wire diameter (mm): Φ0.08-0.32

Maximum mechanical speed (m/s): 2500(max)

Tension frame resistance value: 5KΩ

1.2 Technical specifications and requirements:

◎ Synchronization requirements when the equipment starts to increase speed;

◎ Keep the tension constant when the equipment is running;

◎ Synchronization is required when parking, without wire breakage or tension relaxation;

◎ Disconnection protection required for equipment safety production;

◎ Inching threading function

◎ External button starts operation;

◎ Running speed display;

◎ The diameter ratio of the winding empty disk to the full disk is about 1:3;

◎ Full plate weight is about 50kg;

◎The maximum operating frequency is about 70HZ.

2. System composition

◎ According to the equipment conditions, select the following models and components as electrical transmission equipment

INV1: Drafting VFD (Variable-frequency Drive) Sunwoele HSF600

INV2: Winding VFD (Variable-frequency Drive) Sunwoele HFV3000

Braking resistor: 1000W/80Ω

◎ The drafting motor adopts Sunwoele HSF600 VFD (Variable-frequency Drive), and the winding motor adopts HFV3000 winding-specific VFD (Variable-frequency Drive) (with external braking resistor)

The operation command and output frequency signal of the host INV1 is used as the operation command and frequency command of the slave INV2 to achieve synchronous operation.

◎ When parking, brake in the opposite direction for a heavy disc to prevent wire breakage caused by inertia.

◎ Use the JOG function to realize the jogging function during threading operations

◎ The pendulum output voltage signal is used as the feedback signal for internal variable PID correction control, and VFD (Variable-frequency Drive) unique winding curve is used for speed prediction graphic operation to achieve constant linear speed winding to meet process requirements.

◎ The pendulum output voltage signal is used as the feedback signal for internal variable PID correction control, and VFD (Variable-frequency Drive) unique winding curve is used for speed prediction graphic operation to achieve constant linear speed winding to meet process requirements.

3. Conclusion

During the entire working process of the high-speed thin wire drawing machine, the process requirements are mainly to maintain constant tension during winding. 

Especially during high-speed operation and rewinding, there are higher requirements for the acceleration and deceleration synchronization control of VFD (Variable-frequency Drive) and the control of the inertia of the rewinding wheel during deceleration and parking. 

After debugging and running, series VFD (Variable-frequency Drive) meets the user's process requirements during acceleration and deceleration operation, high-speed operation, and parking braking.

In order to meet the requirements for safe production, the disconnection protection function of the series VFD (Variable-frequency Drive), in addition to the normal set correction amount holding area, the winding VFD (Variable-frequency Drive) uses the frequency value given by INV1 As a reference value, the PID adjustment effect caused by the action of the tension frame is limited.

What is Enameled Wire?

What is Enameled Wire?

Enameled wire, also known as wound wire or coil insulated wire, is an insulating material widely used in the manufacture of electrical products. It must meet the requirements of various uses and manufacturing processes. These requirements include the shape and size of the enameled wire, and its ability to work at high temperatures for short and long periods of time. On some special occasions, the enameled wire needs to be able to withstand strong vibration and centrifugal force at high speed or withstand corona and breakdown under high voltage. In addition, enameled wires need to be able to withstand chemical corrosion under special atmospheric conditions.

In addition to the above physical performance requirements, the enameled wire also needs to be able to withstand mechanical stress such as stretching, bending, and abrasion during the manufacturing process. At the same time, in the process of dipping and drying, the enameled wire also needs to be able to withstand phenomena such as expansion and erosion.

According to the basic composition of enameled wire, conductive core wire, and electrical insulation layer, enameled wire can be classified. In general, enameled wires can be classified according to the insulating material used and the method of manufacture. For example, enameled wire, wound wire, enameled wire, and inorganic insulated wire are common classifications.

The manufacturing process of enameled wire is relatively complicated. First, the corresponding lacquer liquid is applied to the conductor, then the solvent is evaporated, and the lacquer film is cured and cooled. According to the different insulating enamel used, the enameled wire can be divided into various types, such as polyester enameled wire, polyester imide enameled wire, polyamide-imide enameled wire, polyimide enameled wire, etc. Sometimes, it is also classified according to the particularity of its use, such as self-adhesive enameled wire, refrigerant-resistant enameled wire, etc.

The earliest enameled wire is oily enameled wire, which is made of tung oil and so on. However, due to the poor abrasion resistance of the paint film, this type of enameled wire cannot be directly used to manufacture motor coils and windings. Therefore, it needs to be wrapped with cotton yarn when used. Later, the advent of polyvinyl formal enameled wire greatly improved its mechanical properties, so that it can be directly used in motor windings, known as high-strength enameled wire.

With the development of weak current technology, self-adhesive enameled wire appeared. This type of enameled wire does not require dipping and baking to obtain coils with better integrity. However, due to its poor mechanical strength, it can only be used in micro motors and small motors. In addition, in order to avoid the trouble of removing the paint film when soldering, a direct soldering enameled wire has been developed. In the high-temperature tin enameled bath, the paint film can fall off by itself, making the copper wire easy to fall off and solder.

Composite enameled wire is a new type of enameled wire developed in recent years. Its inner and outer paint films are composed of different polymer materials, such as polyetherimide/polyamide-imide enameled wire.

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The Manufacturing Process of Cemented Carbide Wire Drawing Die

The Manufacturing Process of Cemented Carbide Wire Drawing Die

1. Mold Blank Processing

The core of the cemented carbide wire drawing die will shrink during the sintering process, and the amount of shrinkage varies greatly due to the difference in composition, pressing, and sintering process; due to the different shrinkage rates of each part of the mold blank, it often forms a "saddle" or "trumpet" shape. 

Although the fluctuation of the shape and size of the mold blank meets the mold standard, it far exceeds the interference requirement of the mold group, which leads to serious uneven prestress of the mold core during mold loading, and greatly reduces the service life of the mold. 

Therefore, the mold blank must be ground externally, and a special fixture must be used on the grinding machine to grind it with a diamond grinding wheel.

2. Interference Amount of Installation Settings

In order to obtain a certain prestress of the mold core during installation, the diameter of the inner hole of the mold sleeve should be smaller than the outer diameter of the mold core. 

The difference between the two is called the interference amount. 

The amount of interference should be determined according to the size and deviation of the mold core, the draft stress, and the method of the sleeve. 

There are two types of mold sets: hot pressing method and cold pressing method. The cold pressing method has a small interference and a small precompression stress. 

It is mostly used to make wire drawing dies with smaller specifications and draw soft metals.

3. Mold  Sleeve Processing

The molded sleeve is formed by turning on a lathe, and the control points during processing are as follows:

(1) The roughness of the inner diameter of the mold sleeve must reach 0.80-I.6m, which is conducive to close cooperation with the mold sleeve;

(2) The inner diameter of the mold sleeve should correspond to the outer diameter of the mold blank to ensure that the interference of each mold is accurate;

(3) The bottom surface of the inner hole of the mold sleeve must be parallel to the outer end surface of the mold, and ensure that it is perpendicular to the center line of the mold hole after installation;

(4) The ellipticity of the inner hole of the mold sleeve should be as small as possible, not more than 0.02mm. When hot-loading, the outer surface of the mold sleeve should be polished and smooth to ensure uniform cooling after installation.

4. Mounting Process

The cold press mounting process involves pressing the blank into a mold sleeve with a press at room temperature. 

The cold pressing method requires accurate interference between the mold core and the sleeve, and high dimensional accuracy. The advantage is that no heating equipment is required, which saves energy and reduces costs.

Automatic Wire Drawing Machine Use Precautions

Precautions for the Use of Automatic Wire Drawing Machine

The automatic wire drawing machine is suitable for surface drawing and sweeping treatment of copper, iron, stainless steel, etc., and is widely used in various industries such as machinery, automobiles, and hardware parts. 

In order to help you use the automatic wire drawing machine correctly, YF Metal Tech summarizes some precautions for using the automatic wire drawing machine, let’s have a look together.

1. Before operating the automatic wire drawing machine, you need to check the power supply and keep it intact. The specific process of safe start-up of the automatic wire drawing machine is to connect the external power supply first, then turn on the main power switch of the equipment, and finally start the power switch of the equipment.

2. Make sure to check the exhaust port of the body motor before work, and make sure it is unobstructed.

3. Carry out a safety inspection on the automatic wire drawing machine before work, and let the wire drawing machine run idly. In addition, it is also necessary to check whether the fasteners of each part are loose to ensure safe production.

4. During the working process of the automatic wire drawing machine, you should always check whether the impeller and the motor connecting rod are loose, which is conducive to finding problems in time, and can work after adjustment, so as to ensure the safety of personnel in production.

5. When replacing the impeller of the automatic wire drawing machine, the power should be turned off first, and after the power is replaced, check whether the equipment is normal.

6. If it is found that the automatic wire drawing machine is working abnormally, it should stop working immediately and check the equipment. If the problem cannot be solved, find a maintenance worker in time for repair.

7. It is forbidden to extend any part of your body into the polishing area when the automatic wire drawing machine is working automatically to prevent injuries.

8. When the polishing machine is working, if there is an emergency, the main power switch should be turned off immediately.

9. At the working site of the automatic wire drawing machine, it is necessary to keep the ground clean and tidy, and not to place objects randomly.

10. The motor should be maintained regularly, and the bed dust should be cleaned every Saturday, and the motor should be maintained, so as to ensure the normal operation of the wire drawing machine equipment.

11. It is not allowed to randomly connect and pull wires at random. When cleaning or cleaning the equipment, water should be prevented from splashing on the power supply.

12. Non-staff personnel should not enter the work area without authorization to avoid danger.

The above content is organized by YF Metal Tech.

YF Metal Tech focuses on the R&D and manufacturing of wire drawing machines and polishing machines. Currently, it provides automatic wire drawing machines, planar wire drawing machines, plate wire drawing machines, water mill wire drawing machines, round tube wire drawing machines, stainless steel wire drawing machines, and other equipment. Welcome to consult.

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Straight-in Wire Drawing Machine Applicable Standards

The straight-in wire drawing machine is a non-sliding way to draw medium and low carbon steel wire, stainless steel wire, molded steel wire, and non-ferrous metal wire coarse and medium diameter and developed equipment, suitable for standard parts industry, supermarket shelf production industry, steel wire to material processing enterprises.

The straight-in wire drawing machine mainly comprises frame, reducer box, reel, drop wire frame, carriage, pneumatic system, communication frequency control electric control system, and motor.

The reel is placed upside down in the lower part of the reduction box, and the drawn wire can be collected directly to the drop wire frame, and then the end of the large tray collects the wire again.

The drive system of the straight-in wire drawing machine uses a powerful narrow V-belt combination hardened gear reducer or oscillating ring reducer; the wire collecting plate is serious; the reel is forced air cooled; the pneumatic pressure wheel; the lower wire plate is independently driven and the diameter of the lower wire coil is adjustable; the communication frequency conversion speed control makes the machine easy to operate, safe and reliable, and saves more than 30% of energy.

Straight into the wire drawing machine in the motor through the pulley and three-stage gear drive, driving the reel placed on the reducer box rotation output shaft, traction wire end pulling.

After pulling the wire through the lead roller, into the drop wire frame, the drop wire frame and reel synchronous rotation.

The straight-in wire drawing machine is highly automated and can draw and collect wires together.

The wire collecting plate can be as large as 2 tons, easy and reliable to unload, simple operation, high production efficiency, safe, and reliable; it can be positively rotated and decontrolled when the whole machine is running, so as to avoid the formation of accidents by mistake; the appearance is neat and beautiful.

Article Source: Straight-in Wire Drawing Machine Applicable Standards

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What is a Metal Drawing Machine?

What is a Metal Drawing Machine?

YF Metal Tech Introduces the System Components of a Wire Metal Drawing Machine

◎ The following models and components are selected as electrical transmission equipment for the wire metal drawing machine situation

INV1: Draw frequency converter S011Z3

INV2: Winding frequency converter S004G3

Braking resistor: 1000W/70Ω

S011Z3 inverter for the drawing motor and S004G3 inverter for the winding motor (with external braking resistor)

Synchronous operation by using the operation command and output frequency signal of the main machine INV1 as the operation command and frequency command of the slave machine INV2

◎ When stopping, reverse direction braking is used to prevent wire breakage caused by inertia for heavy full reels

◎ JOG function to realize the pointing function during the threading operation

◎ Internal variable PID complementary control using the pendulum output voltage signal as a feedback signal Speed prediction graphic operation with the unique winding curve of the Sanchip inverter series to achieve constant wire speed winding and meet process requirements.

◎ Internal variable PID correction control with the pendulum output voltage signal as the feedback signal, and speed prediction graph operation with the unique winding curve of inverter series, to achieve constant line speed winding and meet the process requirements.

YF Metal Tech’s main products are drying boxes, pay-off equipment, wire drawing machines, linear wire drawing machines, cleaning machines, winding machines, annealing furnaces, rewinding machines, flip-top water tank drawing machines, baling machines, and double twisting machines.

Year-round for stainless steel and carbon steel extension enterprises to undertake technical transformation and complete sets of equipment manufacturing.

The Article Resource: What is a Metal Drawing Machine?

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What is Cast Iron?

What is Cast Iron?

The material consists of iron with more than 2% of carbon.

Cast iron is a very wide range of consumer as well as commercial applications.

Types of Cast Iron

1. Gray Cast Iron

Most common consists of small fractures of a graphite micro-structure which is responsible for creating the appearance of a gray color.

The gray cast iron offers various compressive strengths as steel. This as a result makes it a popular choice for metal applications that can involve compressive strength.

2. White Cast Iron

It has an off-white color, which in turn results in iron compounds that are known as cementite.

White cast iron is known to be hard, so having excellent resistance against abrasions.

3. Ductile Cast Iron

Also known as nodular cast iron it is a type of soft, ductile iron alloy accompanied by a high carbon content.

Its graphite is in the form of very tiny nodules that are accompanied with the graphite in the form of concentric layers which forms the nodules.

The properties are similar to the malleable iron, whereas the parts can be cast with larger sections.

4. Malleable Cast Iron

Created by using the heat treatment processes on the white cast iron.

As a result, the carbon in iron carbide is found to transform into either graphite or ferrite plus carbon.

The slow process forms spheroidal particles instead of flakes.

The properties of malleable cast iron are likely to be those of mild steel.

5. Alloy Cast Iron

The properties of the cast iron are changed by adding various alloying elements.

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And free send inquiries to us.

Email: stella@hanrm.com   stellarollingmill@gmail.com

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Technical Progress Of High Speed Wire Rod Rolling Mill

Technical Progress Of High Speed Wire Rod Rolling Mill

Technical progress of high-speed wire rod rolling mill as followings: 

1) Continuous, torsionless and high-speed rolling. Roughing rolling and intermediate rolling are arranged alternately, and pre-finishing rolling is installed in front of the finishing mill. The maximum final rolling speed is designed to reach 120 m/s. 

According to the latest production practice, the maximum rolling speed will be guaranteed according to different specifications of wire rods. For example, in 2010, Siemens Austria Steel United Corporation (Morgan Company was annexed by the company) designed and manufactured high-speed for Xuanhua Iron and Steel Company. The guaranteed final rolling speed of the wire rod rolling mill is small wire rod Φ5.5-7.5 mm | 112 m/s, Φ5mm | 105 m/s for medium and 85 m/s for small diameter 6 mm quenched threaded steel. 

Improving the finishing rolling speed of the wire rod mill is a systematic project. It involves not only the main rolling mill machinery and electrical equipment but also the number of finishing mills, the rack spacing, and the cooling system. It does not affect the mechanical properties of products because of the high finishing rolling speed and the high finishing rolling temperature. 

It also requires supporting equipment such as a spinning machine and flying shear to withstand the high-speed impact of wire rods. 

2) Adding reducing and sizing equipment to improve product accuracy and solve the temperature control problem in the wire rod finishing rolling process.

3) Increasing the cross-section of the feed billet can not only meet the need for an upstream continuous caster to improve the productivity and quality of the billet but also increase the coil weight and increase the productivity and yield of the wire rod rolling mill.

4) The qualified billet is heated and soaked directly into the heating furnace through the hot charging roller. The hot charging temperature can reach over 600 C, which improves the productivity of the heating furnace, reduces the energy consumption during billet heating and the loss of oxide scale during billet cooling and heating, and improves the metal yield.

5) Low-temperature rolling. The starting rolling temperature is controlled at 950 C. The stiffness of the mill stand and the capacity of the main motor can meet this requirement in order to achieve overall energy savings and reduce metal burning.

6) Controlled cooling and temperature rolling.

7) Single-pass system. All products (small 5.0-25mm) only need to change rollers on four reducing and sizing mills, and no rollers need to be changed for other mills, thus significantly improving the productivity and productivity.

8) The latest generation of spinning machines and winding stations. In the form of asymptotic bending, the ideal trajectory of wire moving in the spinning tube is given, so that the wear of the spinning tube can be reduced and the running stability can be achieved.

The 90m High-Speed Wire Rod Rolling Line Project In Ethiopia Start Production

The 90m High-Speed Wire Rod Rolling Line Project In Ethiopia Start Production

December,13th,2016, the 90m high-speed wire rod rolling line project in Ethiopia contracted and constructed by Hani Tech has been put into production at 10 am local time. This means the whole rolling project and all the steel rolling mills it contains customized for SHENZHEN STELL with an annual capacity of 300,000 tons have been officially accomplished and transferred.

This whole project of a wire rod rolling production line with an annual capacity of 300,000 tons only takes WEIKEDUO less than a year to construct, which seems really miraculous for it could cost 3 years of construction for a complex project like this. As an experienced professional manufacturer of metallurgical types of machinery like monoblock mills, hot rolling mills, flying shears, and other associated equipment, WEIKEDUO has dedicated itself to developing and providing advanced and durable machinery equipment for all our clients around the world.

This brand new rolling line in Ethiopia will provide more job opportunities for local people and government while it would also boost the local economy vigorously. The present Director of Investment from the Ethiopian government, Fitsum, has once again declared the fact that the Ethiopian government will encourage and support all Chinese companies with competitive advantages and good faith to invest and develop in Ethiopia as always. And they will provide a solid foundation for all these companies to grow.

The deputy director of the Eastern Industry Zone, Jiao Yongshun, has also congratulated the success of the project and indicated that this rolling project could be another achievement to our current One Belt and One Road Initiative.

The Additional Processing Steps In The Manufacture Of Cold Rolled Sheets

The Additional Processing Steps In The Manufacture Of Cold Rolled Sheets

The cold-reduced coil, as it exists, is very hard and possesses very limited applicability. It is very stiff and exhibits high amounts of spring back when bent. Therefore, this steel must be annealed (heated to high temperatures) to soften it and make it useful.

During the process of heating, the steel will be soft and can subsequently be used for a multitude of applications. Continuous annealing involves passing the steel through a high-temperature furnace in the form of a continuous ribbon. That is to say, the coil is fed from a payoff reel into the furnace. It reaches a high temperature when its passage through the furnace. The steel sheet cooled, and recoiled at the exit end of the furnace.

Whether the steel is batch annealed or continuously annealed, the specific properties of the steel sheet, after annealing, depend on the steel chemistry, the temperatures used during hot rolling, the amount of cold reduction, and the annealing cycle (time and temperature).

Whichever method of annealing is used, the steel is maintained under a protective (non-oxidizing) atmosphere using hydrogen and nitrogen to prevent oxidizing the steel while it is at high temperature. Furthermore, to prevent oxidation, the protective atmosphere is designed to clean the steel by breaking down the oils that are present after cold rolling and entraining the oil vapors in the hydrogen/nitrogen gases that are passed through the furnace.

The Adjustment Of Steel Rolling Mill

The Adjustment Of Steel Rolling Mill

Before the steel rolling mill is used, the roll pass, controlling plate shape, and backup roll should be adjusted according to the requirement; and the fixed position of the rolls in the rolling mill should be maintained. The workload of the rolling bearing is heavy and varies greatly, so the friction coefficient of the bearing is required to be small. After determining the product rolled by the rolling mill, the line speed of the rolling mill can be basically determined. The hardness of the raw materials is measurable. The rolling stock of the rolling mill is determined by changing the plastic deformation size.

Usually, the newly installed steel rolling mill has a running-in process. During the running-in process, the rolls are operated in a second operation, and the operation speed is 50%, 65%, 75%, and 85%. Different steel rolling mill models use rolls with different materials and specifications for different rolling products.

After the steel rolling mill is installed, the gears of the reducer and the gearbox need to have meshed, the rolling speed is too fast, and the torque is enhanced. After the normal operation of the rolling mill for 30 days, stop the rolling mill and check the meshing of the large and small gears, and waits for everything to be normal, the rolling speed can be increased.

Under normal circumstances, it is not necessary to adjust the rolling speed. The rolls in the steel rolling mill are constantly worn during the running process. In order to keep the rolling mill stable in the controlled rolling requirements, the roll must be repaired in time, and the rolls need to be replaced in serious cases.

The steel rolling mill needs labor, even the automated equipment needs to be monitored manually in the console. The conveyor roller and shearing machine located in the automatic rolling mill must be strictly controlled during operation to avoid the failure of stacking steel or jamming. If the wear of roll and guide exceeds the specified range, it needs to be replaced.

The rolling of the billet causes the roll to be squeezed instantaneously, and the bearing is subjected to correspondingly high pressure, thereby affecting the product size of the rolled steel. We may also need to make in-depth improvements, but the ultimate goal is to get better steel rolling mill equipment.

The Advantages And Disadvantages Of Electric Arc Furnace

The Advantages And Disadvantages Of Electric Arc Furnace

There are several essential elements that caused the evolution of the electric arc furnace:

1) The increasing quantity of scrap steel;

2) The rapid development of the entire steel industry. The supply and the price of electricity become stable, which makes it possible to generalize the arc furnace;

3) The arc furnace tends to be larger and more powerful;

4) Less investment, quick to construct, and fast cost recovery;

5) The temperature and the component of the molten steel can be controlled with accuracy. The arc furnace can also smelt various kinds of different steels.

Compared with others, the electric arc furnace also has several obvious advantages:

1) The arc furnace can heat the furnace and the steel up to 4000-6000℃ directly and smelt special steels that contain refractory elements like W and Mo.

2) The arc furnace could remove the toxic gases and the inclusions while deoxidizing and desulfurating.

3) High flexibility. The arc furnace is capable of engaging production continuously or intermittently.

Currently, owing to the development of related technologies, the electric arc furnace could be well-integrated with traditional steel-making processes. But there are also several deficiencies that need to be improved:

(1) The arc can only generate point-like heating sources, which will cause uneven heat distribution in the furnace.

(2) The arc will react with the furnace gases and vapor and release large quantities of H2 and N2.

With further improvement of the electric arc furnace, new smelting techniques will embrace a brighter prospect.

The Advantages Of Induction Furnace

The Advantages Of Induction Furnace

According to Wikipedia, the induction furnace is an electrical furnace in which the heat is applied by induction heating of metal. Induction furnace capacities range from less than one kilogram to one hundred tons capacity and are used to melt iron and steel copper, aluminum, and precious metals.

Heating fast, high temperature, easy operation and control, and the less pollution

It is an electric furnace for heating a material using an induced current generated by an induction coil. The material will be placed in a crucible made of refractory material if the metal material is heated. If the non-metallic material is heated, the material is placed in a graphite crucible. Furthermore, the induced current frequency will be corresponding to the increase and result in increased heat when the AC frequency is increased. Induction furnace heating fast, high temperature, easy operation and control, and less pollution of material in the heating process to ensure a high-quality product.

Clean, Energy-efficient

The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of metal smelting. Most modern foundries use this type of furnace, and now also more iron foundries are replacing cupolas with induction furnaces to melt cast iron, as the former emit lots of dust and other pollutants.

Uniform heating, small table temperature difference, high accuracy of temperature control

The reason why the uniform heating and the small core table temperature difference is simply because of heat generated in the workpiece itself. And the application of the temperature control system can achieve precise control of the temperature to improve product quality and pass rate.

In addition, the medium frequency induction furnace heating device has the advantages of small volume, light weight, high efficiency, excellent quality of hot processing, and environment-friendly. It rapidly replaces the coal-fired stove, gas stove, fuel stove, and ordinary resistance furnace, which is a new generation of metal heating equipment.

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Stainless Steels

Stainless Steels

Stainless steels are selected in accordance with their corrosion resistance. They have been used for almost more than 100 years cause of their durability, appearance, and cleanability. These things can be found in your home, prestigious buildings, transport, food, and beverage handling, chemical plant, and medical equipment.

Chromium is one of the essential elements of stainless steel, which makes it has stainless characteristics, but most commonly the used grade is type 304, containing 8% nickel. Furthermore, it is one of a family of grades known as “austenitic”. They are featured with good ductility as well as ease of forming and welding. Because it is maintained at very low temperatures, so they can be selected for cryogenic applications. While some grades retain their properties to high temperatures as well. 

Nickel is an important alloying element in all the commercial grades of the duplex stainless steel family. These have higher strength than the common austenitic grades but cannot be used over such a wide temperature range. Nevertheless, they are finding increasing use in structural applications where strength is important.

Some grades within the other families of stainless steels - ferritic, martensitic, and precipitation hardening - do contain a small percentage of nickel which enhances their properties.

Stainless steel is the largest single first use of nickel, accounting for 60.9% of nickel production in 2009. In the same period, 58.3% of the stainless steel was melted with chromium-nickel austenitic grades.

We can supply the rolling mill machine that can produce stainless steel. If needed, please mail at stella@hanrm.com.

The Device Of the Electric Arc Furnace

The Device Of the Electric Arc Furnace

Electric Arc Furnace

An electric arc furnace consists of a shell, spout, cover(optional), furnace wall, bottom electrode device, and tilting system.

The furnace shell is water cooling style, the furnace side has a spout, the furnace inside wall has refractory, water cooling electrode style, temperature testing, and the spout was made by refractory.

Electrode Lifting Device

Electrode lifting device includes a conductive arm, lifting pole column, guiding column, electrode clamp, and lifting reduction box device.

Electrode clamps of conductive arms use non-magnetic conductive stainless steel, high mechanic, high wear resistance, deep hole, water cooling inside and cooling directly, and enhance the cooling effect, prolong the operational life span.

Large Current

Large current includes DC power supply compensator, copper bar, furnace body electrode connector, eliminator supply cable connector, big section cable, conductive arm, electrode clamp, and graphite electrode.

Water Cooling

The water cooling system is composed of the current switch, water distributor, return line, water cooling pressure less than 2XlO5Pa, and water cooling temperature below 32℃, this device has flow warning, it alarms when the flow is below the related value.

Please contact stella@hanrm.com for a quotation.

And free send inquiries to us.

Email: stella@hanrm.com   stellarollingmill@gmail.com

Whatsapp/Wechat:+8615877652925

The Application Of Flying Shear

The Application Of Flying Shear

The Flying Shear is a common industrial application in rolling mill production lines for cutting a product into smaller lengths, without stopping the line, this means that the main production process is not interrupted, and so machine productivity is maximized.

The cutting tool is typically mounted on a carriage that moves either parallel to the product flow or at an angle across the product flow. The flying shear drive accelerates the carriage to synchronize with the line speed, while synchronized the cut is done and the carriage then decelerates and returns to its original position ready to cut again. There are also many other similar applications where a carriage must be synchronized at line speed and most of these can also be accommodated using the flying shear application software.

Typical applications include various types of cut-to-length machines, depositors, punches, product inspection, or any other process where synchronization at line speed is required.

A machine extrudes plastic pipes that must be supplied to the customer in pre-cut lengths. The extrusion process requires the extruder to run at a continuous speed to maintain the quality of the product. The pipe is uniform along its length and provided the length is within a set tolerance then the pipe is fit for sale. The flying shear is used to cut the product cyclically.

The actual design of the machine that we observed in the mill was very large in size and it cut the hot billets of diameter 1\2 inch to 1 inch and length will be in several meters and it cost thousands of dollars we cannot make this machine as FYP. So according to the situation, we had to design a machine of a small size to cut something other than a hot billet. We chose the design of the printer as a model as the design idea was similar to the printer and select copper wire as a job. The sketch will be shown below.

The Cold Rolling Mill

The Cold Rolling Mill

In the article How Many Types of Rolling mill, we know that rolling is divided into two types that are hot rolling and cold rolling according to the different temperatures when metal is rolled. If the temperature is above its recrystallization temperature, then this kind of process is known as hot rolling. If the temperature is below its recrystallization temperature when mentally rolled, the process is called cold rolling.

While this article mainly talks about cold rolling. Cold rolling is fulfilled by making steel strips through plenty of tandem rolling mill stands. And each one of the stands has vertically stacked rolls that are powered by a huge motor to impart high compressive stresses into the strip. While hot rolling, pickled coils fed into the cold rolling mill from an entry-end reel and progressively reduced in thickness in each stand, to achieve the final desired thickness, as the strip exits the last stand. After the last stand, the strip recoiled. At this step, the strip is highly cold and not very useful for most applications. It needs to be annealed to soften the steel and make it more formable. 

Another method of cold reduction needs to use of a reversing mill. In this process, the strip is passed back and forth between mandrels on each side of a single or two-stand mill. The strip is reduced in thickness on each pass until the final required thickness is attained. The typical percent cold reduction ranges from 60 to 80 percent; such reducing a hot rolled strip of 0.100-inch thick to a 0.030-inch thickness results in 70 percent cold reduction.

The Concept And Process Of Rolling Mill

The Concept And Process Of Rolling Mill

Steel is widely used in our daily lives and holds a critical position in the national economy and most of the steel products we need are produced by rolling mills. The rolling process plays an important role as the final link of the steel-making process in modern steel enterprises.

Steel rolling, as its name, is a process of shaping the steel billet with rollers. And the rolling mill is what you need to get the job done. The complete rolling production process contains a series of different rolling techniques and it can be complicated. However, despite all those various requirements, the basic production process always contains the following procedures: reheating the steel billet and further treatments, rolling process, and the final finishing rolling process.

When the billets arrive, they need to be treated with chemicals like acids to remove the oxidation film and the obvious defects on the surface must be removed too. Then the billets will be reheated to a certain temperature to be ready for the coming rolling process. The rolling process is the core of this whole production, the billets will be rolled into different shapes and the rolling technique is crucial for the quality of the final product. It must meet the requirements from three different aspects: the product’s geometry dimension accuracy, internal organization, and performance, and clean and smooth surface. 

After all these processes, the product still has a complicated finishing rolling process. As a guarantee of the product, the finishing process can be different for the various requirements and standards. After the cooling, straightening, heat treatment, and other certain process procedures, the final product will meet all those customized requirements.

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The Development Of Electric Arc Furnace

The Development Of Electric Arc Furnace

The electric arc furnace is the most widely used steel furnace around the world, it can be used to smelt high-quality steel and other special steels. 

Though the arc furnace came out in the 1900s, the major development waited its time till the end of WWII. During the latest decades, the development has escalated and brought revolutionary changes to the steel industry. 

While the total output capacity remains growing slowly, the percentage of crude steel made from scraps has risen fiercely to 40% in 2001. One of the major solutions, an arc furnace can be built and operated at a lower cost than the traditional blast furnace. 

Since the concept of the UHP arc furnace (ultrahigh power arc furnace) emerged in the mid-60s, people have tried to build bigger furnaces with higher power and capacity. 

The application of advanced technologies like dynamic compensation systems and water-cooling systems boosts the development vigorously.

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The Development Of Rolling Process And Technology

The Development Of Rolling Process And Technology

The rolling technique improvement happening worldwide is mainly focusing on the following aspects: the optimization of the rolling process, the variety, and diversity of the rolling products, higher quality, and smarter management. The future of the rolling mill industry is as follows: 

Rolling-casting Integration

Traditional rolling machines with rollers can provide high-speed production rates with efficiency while still remaining controllable with high-tech equipment like computers. This kind of machine will keep dominating the market with its obvious advantages. However, the development of the rolling technique and the rolling mill is just in sight. In the 20th century, continuous casting has gradually eliminated the roughing process. With the thin steel plate it provides, the continuous casting process could just be integrated with the hot-rolling process. This rolling-casting integration improvement will optimize the whole rolling production process and make a further step in cost control. 

A Cleaner Rolling Process

In the whole hot-rolling process, the oxidation of steel leads to the waste of raw material and energy, more pollution, and further processing difficulties. Hence, the application of low-oxygen combustion techniques and low-cost hydrogen will become elementary to the no-oxidation heating process. With a brand-new acid-free cleaning(AFC) descaling technique, the product is smooth and completely oxide-free. This kind of improvement can give you a cleaner rolling process you’ve never experienced before. 

The Application of Cutting-edge Technology

What has driven the improvement of the rolling mill in the 20th century is the application of information technology. Automatic shape control of the steel plate, Free rolling, and High-precision, multi-parameter online tests, have all become available. And these techniques back fed the whole rolling mill industry. In the sight of the future, artificial intelligence will boost this industry to a brighter future.

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The Development Of The Steel Industry In China

The Development Of The Steel Industry In China

The development of the steel industry in China closely relies on other industries and shares mutual encouragement with them. Other industries like manufacturing, construction, and transportation have had higher demands for the quantity, variety, and quality of steel materials while they are looking for a leap forward. To meet their requirements, steel enterprises got to have a positive attitude and must seek an opportunity to develop their products like non-quenched and tempered steel, silicon steel, structural steel with fine mechanical properties, and other various sheets of steel applied to different industries to provide low-cost, environment-friendly materials with high-standard performances and lead their way in the rapid development.

In order to develop cutting-edge products, new treatment processes, equipment and techniques are essential. Domestic scientists and engineers have made some major breakthroughs in the new-generation automotive steel, flexible retreat technology for cold rolling, and advanced coating techniques and products. These achievements have boosted the development of revolutionary products and China’s national economy. As a crucial premise and foundation, experiment research can lead to a new process and technique innovation. Hence, strengthening the construction of research institutes and setting up its own hardware, software technology, and product development platform is critical while establishing a combination system of production and research technology innovation. The application of new techniques, new steel technology, and new steel products are just down the road.

With the global competition in the steel business growing fiercely, the market has got higher and stricter requirements for the quality and quantity of its product. The traditional rolling force calculation formula will fade and be replaced by a more ideal design method with higher accuracy -- mathematical models. It is incredibly difficult to analyze the rolling process with all kinds of factors influencing the whole procedure. The application of mathematical models like neural networks can deal with this problem. They can predict accuracy and improve the level of production control by quantitatively and qualitatively optimizing the production process to provide low-cost optimization strategies for the steel industry.

As an upcoming technology, the soft computation was applied to optimize the design of the rolling system. To solve the uncertainty and ambiguity in practical problems, the combination of human knowledge and solution methodology comes in handy, including evolutionary computation, fuzzy logic, neural computation, and probability computation.

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The Explain Of Roughing Mill Process

The Explain Of Roughing Mill Process

Steel strips are produced by steel slabs in hot rolling mills. One part of the production process consists of reheating the steel slabs in a slab reheating furnace to a pre-defined temperature, usually between 1200℃ and 1300℃. After that, the steel strips are formed by the rolling slabs. The first mill of the steel slab goes through is the roughing mill. After the roughing mill, the slab's temperature between 1050℃ and 117℃, and the slabs should be called transfer bars. Then, the transfer bar goes through another few more procedures. Among all these processes, the most important two processes are finishing mills and cooling. Here is the detail of roughing Mill process below this paragraph.

The roughing mill consists of six independent rolling mill stands and four incorporated small vertical rolling mills called edgers at the end of it. Slabs are heated first reheating in the furnace until they glow bright orange-yellow, then they are rolled through one stand at a time to produce the so-called transfer bars in order to be suitable for finish rolling. High-pressure water-jet nozzles clean the oxidized iron, or scale, from the surface along the way.

At the end of the transfer bar where exits are the last roughing mill stand, the thickness of the leading edge of the bar is estimated. Similarly, a pyrometer measures the temperature of the bar from head to tail and there is a special camera photograph at both ends. In accordance with the gauge, width, and grade of the product to be rolled, the average temperature of the bar as it goes through the last roughing mill is usually between 1900° to 2100° Fahrenheit. All of these data are collected with the anticipation of finishing rolling. The Computer begins to calculate the speeds and gaps immediately for threading the six finishing mills, which will roll the steel in tandem with one another.

For another, the last four roughing mills each incorporate edgers for width control and roll the bar from five to six inches thick incrementally down to around an inch and a quarter, as a function of the customer’s demanded width, gauge, and steel grade. As we mentioned previously in this article, the third and fifth roughing mills each have high-pressure descaling headers operating at 1,500 psi. The individual roughing mills are spaced increasingly further apart to accommodate the lengthening of the transfer bars when they are rolled thinner and thinner.

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The Features Of Billet Continuous Casting Machine

The Features Of the Billet Continuous Casting Machine

The Features Of the Billet Continuous Casting Machine

The billet continuous casting machine belongs to one of the steel rolling mill machines.

Usually, the billet continuous casting machine is designed and manufactured according to the user’s demand. And it is used for continuously casting the square billet, the cross-section of which is 80×80, 100×100 or 120×120, 150×150 mm with a length of 6m/12m operated by an automatic control system. It contains single stand, double strands, and multiple strands CCM as well as a straightening machine, automatic cutting machine, billet cooling bank, billet spreader, molten steel spreader, and other auxiliary devices and facilities such as soft water treatment and water cooling system. CCM is a Continuous casting machine.

The Features of the Billet continuous casting machine are as follows:

The casting speed with high efficiency.

It has many different types of Multi-functional.

CCM equipment is always used in the steel rolling mill production line, a Continuous casting machine with high reliability and high ease of operation.

Billet continuous casting machine with a fast return on investment and low cost.

Continuous casting machine for steel with high technology.

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The Features Of Furnaces And Matters Need Attention

The Features Of Furnaces And Matters Need Attention

It is necessary that explain what is a furnace. According to Wikipedia: “A furnace is a device used for high-temperature heating. The name derives from the Greek word Fornax, which means oven.”

Also, there was a popular statement that a furnace is a device that is used to heat the material in order to exchange its shape as like in shaping and forging or the properties of the material can be changed. These furnaces are mostly used for melting the metals that are used for casting. The furnace can be termed as a type of oven. In addition, it is an enclosed structure inside, which makes the material heated at very high temperatures. It can be designed to perform water or air heating as well as circulated throughout a building in a heating system.

Furthermore, the way of a furnace design like this has its advantages and features, which as a way to consume fuel and heat as less as possible in a given time that would require low labor costs at first. Second is the apparent efficient features: The amount of heat that is to be given is prior determined to the material. 

Therefore, there exists a sufficiency in the liberation within the furnace heat of the required material. Proper heat and temperature would be successfully transferred from the gases to the surface of the heating stock take place.

What calls for special attention is that temperature should be uniform within the stock. Making the heat loss from the furnace needs to be minimized to the least.

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The Finishing Mill Group For High-Speed Wire-Rod Production

The Finishing Mill Group For High-Speed Wire-Rod Production

A rolling mill is a very useful machine manufactured by humans, one of its functions is to reduce the thickness of material quite accurately or compress the material to create wire rods, re-bar, cold coils, or other products.

At the same time, rolling mill machines are not standard machine tools, nor are they built for stock. They are built-to-order to specifically accomplish an end product or process.

During the industrial revolution in America, the United States led the world in hot and cold rolling, plate mills, slabbing mills, and blooming mills. So many years passed, and we still can see the contribution of this revolution time has made.

Nowadays, the steel rolling mill machine has made a very great improvement like the 135m finishing mill group researched by Hani Steel. 

The finishing mill group is the extra-heavy top 45° high-speed wire rod finishing mills designed for the high-speed wire rod production line. 

The finishing mill group is located in the high-speed wire rod workshop. Rolling by 10-unit rack continuous micro-tension rolling mill, rolling the ɸ17--ɸ21mm of rolled piece transported from upstream into ɸ5.5--ɸ16mm finished wire rod. The mill's guaranteed exit speed is 90m/s. ( when the specification of the finishing product is ɸ5.5mm).

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The Historical Background Of Rolling Mill Development

The Historical Background Of Rolling Mill Development

The earliest known rolling mill of metals was around the fourteenth century, its very small rolls were used to flatten cold metals such as gold, and silver, or used in jewelry or works of art. As well as we knew that Leonardo da Vinci describes in his notes machines for the cold rolling of sheets and bars in 1480, but it is unlikely that these mills were ever constructed. Until the last half of the sixteenth century, the cold rolling particularly began to take on more importance as lead, began to be used for roofing and other applications such as organ pipes.

The seventeenth century saw the hot rolling of bars of ferrous materials into thin sheets throughout Europe and especially in Germany, with applications later in that century in England and Wales. These mills were single-stand mills. It was not until the eighteenth century that metal was rolled in successive stands arranged as a tandem mill, the first record of which was for the hot rolling of wire rods in England in 1766, and in 1798 a patent was issued for a tandem mill for rolling iron plates and sheets.

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The History Development Of Rolling Mill

The History Development Of Rolling Mill

Hot and cold rolling mill between two or more rolls has been in existence since long before the industrial revolution. As a matter of fact, Leonardo da Vinci was credited for the metalworking mill prior to his death in 1519.

When most people think of a rolling mill, they visualize sizable machinery in ferrous (iron, carbon steel, and stainless steels) and non-ferrous (copper, brass, lead, etc.) integrated or electric arc furnace (EAF) steel mill of today, to small manually cranked rolling devices used at jewelers to reduce the thickness of the precious metal or impart a pattern on the surface of the metal to be fabricated into a chain or ring.

Rolling mills have many functions. They can be used to reduce the thickness of material quite accurately (+/-.0001”) or compress the material to create a uniform density throughout the strip or import a surface finish on one or both sides of the material, just to name the most common methods.                    

Rolling mills are not standard machine tools, nor are they built for stock. They are designed and built to order to specifically accomplish an end product or process.

At one point during the industrial revolution in America, the United States led the world in hot and cold rolling, plate mills, slabbing mills, and blooming mills. Companies such as Mesta, United, Blaw-Knox, Lewis, Continental, and Bliss were attributed to building some of the largest rolling mills in the world before World War II.

Many of these old mills are still running today as a result of upgraded electrical and hydraulic systems, including hydraulic screwdowns, hydraulic roll bends, and tension control.

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The History Of Rolling Mills

The History Of Rolling Mills

Hot rolling mills and cold rolling mills of metalworking between two or more rolls have been in existence since long before the industrial revolution.

When most people think of a rolling mill, they visualize sizable machinery in ferrous (iron, carbon steel, and stainless steels) and non-ferrous (copper, brass, lead, etc.) integrated or electric arc furnace (EAF) steel mill of today, to small manually cranked rolling devices used at jewelers to reduce the thickness of the precious metal or import a pattern on the surface of the metal to be fabricated into a chain or ring.

Rolling mills have many functions. They can be used to reduce the thickness of material quite accurately (+/-.0001") or compress the material to create a uniform density throughout the strip or impart a surface finish on one or both sides of the material, just to name the most common methods.

Rolling mills are not standard machine toll, nor are they built for stock. They are designed and built to order to specifically accomplish an end product or process.

At one point during the industrial revolution in America, the United States led the world in hot and cold rolling, plate mills, slabbing mills, and blooming mills. Companies such as Mesta, United, Blaw-Knox, Lewis, Continental, and Bliss were attributed to building some of the largest rolling mills in the world before World War II. In fact, Mesta and United pioneered the rolling process to reduce very thick as cast slabs into the plate, the plate into hot rolled coils and cold rolled coils.

Many of these old mills are still running today as a result of upgraded electrical and hydraulic systems, including hydraulic screwdowns, hydraulic roll bends, and tension control.

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The Main Tendency And Features Of Rolling Mill

The Main Tendency And Features Of Rolling Mill

Since the 1960s, with the development of iron-making and steel-making technology and the progress of the mechanical and electrical industry; with the wide application of computer automatic control technology and advanced science and technology, the production of steel rolling technology has made leaps in the growth and development. In a word, the main tendency and features of its development as the following:

1. The production process of strip and wire rods is continuous in the recent 20 years and would be more perfect if the continuous tube rolling mill and section continuous rolling mill came into being. And there are new types of rolling mills that were invented such as endless rolling, which is a completely continuous rolling production line. Including electric release ‘fat, annealing, cooling, k and coiling' process of finishing the rolling mill line also appeared in recent years cause of the widely applied wire rod mill in cold rolling belt californium and continuous welded pipe, which has greatly increased the production efficiency.

2. The constant improvement of rolling speed and the continuous production process created the condition of increased operating speed. All kinds of rolling mill speeds increased, Over the past 20 years. The Current wire rod rolling speed has reached 100 meters per second, cold rolled strip speed at 41.7m/s, and steel tube tension reducing speed up to 20 meters per second. And with the development of continuous automation, a variety of operating speeds will be increasing continuously. 

3. Production process automation is improving at all levels not only the important factor of production capability increased by technology and science but also the important prerequisite for improving product quality, labor-saving, and reducing consumption. The electronic computer developed after the 1960s has been applied more widely, especially the strip rolling has made the most full use of it. The currently used multi-level computer control system not only realizes the process control and digital direct control but also makes the computer technology applied by enterprise management. Many factories are expanding the electronic computer automatic control technology to the steel material finishing, heat treatment, nondestructive, and so on.

All in all, the increasingly large scale of iron-making and steel-making production capacity is bound to expand the rolling production scale. 

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