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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The New 140m Laying Head And Increasing Gearbox Of Hot Rolling Mills To Iran Customer

The New 140m Laying Head And Increasing Gearbox Of Hot Rolling Mills To Iran Customer

Our company, Xi’an Hani Tech Co., Ltd, an enterprise with decades of experience in the business, has become one of the most advanced hot rolling mill equipment manufacturers and exporters in China.

We provide steel rolling mill project solutions for our customers in Dubai, Nepal, Abu Dhabi, Senegal, Indonesia, Sri Lanka and Pakistan, Arab, India, Egypt, Turkey, Bangladesh, Iran, and Iraq.

We provide complete technical details of our hot rolling mill products to our customers. 

Our rolling mills have received compliments from our clients worldwide due to their corrosion & rust-proof surface and sturdy structure.

The recent new products of laying head and increasing gearbox for Iran customers are as follows:

1. 140m laying head Core Parts.

2. 140m Laying Head Parts.

3. The New Increasing Gearbox for Hot Wire Rod Mill Production Line.

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The New Method Of Combining Emulsion And Neat Oil Lubrication In Cold Rolling Lubrication

The New Method Of Combining Emulsion And Neat Oil Lubrication In Cold Rolling Lubrication

One of the key processes in cold rolling is known as the cooling and lubrication process(cold rolling lubrication), it is not only determined the surface quality and strip shape but also reduced the rolling power consumption, and extends the life of the roll even during high-speed operation. 

As we discussed, a new method combining emulsion lubrication and neat oil lubrication was applied to solve the problems related to individual passes. Plenty of tests on stainless steel strips came to the conclusion that this new lubrication method can improve the surface quality of the strip, and control the rolling friction in the deformation zone, and it has the great potential of making lubrication systems simpler, easier to operate, all those while reducing the negative environmental impact from the processing. 

In direct supply lubrication, oil and water are mixed and then sprayed on the strip surface in the inlet zone directly, and there is a separate cooling system, therefore is most of them used for high-quality, tinned thin strips. 

Recirculated supply lubrication, as we knew, is mainly used for relatively thick strips and an emulsion sprayed on the roll and the strip acts as both a coolant and a lubricant.

However, in combined supply lubrication, the high-concentration emulsion is sprayed on the strip, and the low-concentration is sprayed on the rolling process. As generally known, high-concentration emulsions are better at cooling. Both of them are circularly used for relatively thick strips.

Although the above two methods have their merits, with the growing consumer demand for different types of high-quality products and the need for increased production, improvements in cooling and lubrication method are necessary and inevitable. So, the new method of lubrication that combines neat oil and emulsion lubrication takes advantage of its merits.

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The Rolling Mill Laser Cladding Technology

The Rolling Mill Laser Cladding Technology

The rolling mill laser cladding technology is a brand new surface strengthening technique that heats the powdered alloy or ceramic and the surface of the substrate to fuse them and cover the substrate with a less-dilution metallurgically bonded coating after the removal of the laser. This new type of treatment can improve the surface properties of the material like wear resistance, corrosion resistance, heat resistance, and oxidation resistance, along with its electrical characteristics. The ordinary 60# steel can reach a hardness high as 2200HV after being laser clad with tungsten carbide and perform 20 times better in wear resistance. The wear resistance of the Q235 steel laser clad with CoCrSiB alloy is also better than the flame-spraying ones.

As an advanced economically beneficial technology, laser cladding can cover low-cost metal substrates with high-performance alloy coatings without changing their original properties and reduce the cost of rare metals. Every industrially advanced country in the world is paying great attention to related research.   

The superiority of rolling mill laser cladding technology can be reflected in the following aspects:

 1. High cooling velocity (106K/s). Fine-grained micro-structures and rare phases like unstable phases and amorphous phases that could not be formed under common conditions can be easily gained with this fast solidification process.

2. Low dilution rate (less than 5%). The metallurgical bond between the coating and the substrate, and the Interface diffusion bond can be controlled with the technical parameters of the laser to obtain an excellent low-dilution coating with adjustable compositions.

3. Less thermal input and distortions. The distortions can be controlled within the range of tolerance, especially when it’s been laser clad with high power density.

4. Unrestricted coating powders, especially when cladding the fusible metal substrates with refractory alloys.

5. Large coating ranges. The thickness of the coating can vary from 0.2 to 2.0mm with one single powder feed.

6. Regional cladding with superior cost efficiency.

7. Flexible beam-aiming cladding to the inaccessible areas.

8. Easily automated and totally fit for the repair of common abrasions. 

The rolling mill laser cladding technology can also be used in the wear resistance and corrosion resistance fields for its large range of applicability which covers almost every aspect in the machinery manufacturing industries, such as coal, petroleum, electricity, railway, automobile, and aviation. Take the petroleum industry as an example, a large number of equipment like valves, centrifugal pumps, oil pumps, plunger pumps, screw pumps, and compressors breaks down every year. These units are expensive and various in type, which makes them hard to repair. But it won’t be a problem anymore with the help of laser cladding technology.

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The Solution For Slower Start-Up Speed Of Rolling Mill Machine

The Solution For Slower Start-Up Speed Of Rolling Mill Machine

The speed at which the rolling mill machine is started during operation has an important effect on the efficient operation of the rolling mill. If the rolling mill machine is slow to start when it is ready for operation, it indicates that the rolling mill has obvious defects in performance, which will seriously affect the working efficiency of the rolling mill. The force between the blank or the rolled stock and the roll also does not reach a good condition.

The rolling stock cannot be fully rolled in the rolling mill. In this case, the power consumption of the rolling mill is several times higher than usual. If this happens frequently, the speed of the rolling mill is not effective when it is turned on. Increasing the efficiency of the billet or the rolled piece will lower and lower. For the rolling mill machine, if the rolling mill is not capable of rapid overload start, the billet rolling speed will be too slow, and Hani Tech will analyze it. The reason why the rolling mill machine startup speed is slow. 

Before starting the rolling mill machine, first check the motor power, rolling speed, product specifications, hole type process, etc., to ensure that the blank load capacity does not exceed the bearing capacity of the rolling equipment, otherwise the equipment start speed will be slower. There is also a need to check the bearing of the rolling mill to see if the lubrication of the bearing is sufficient. If the lubrication is not enough, the start of the rolling mill machine will be slower or even malfunction.

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The Structure Of Flying Shear

The Structure Of Flying Shear

With rolling continuous, high-speed, highly developed degree of automation, flying shear has become a continuous rolling lone indispensable equipment, mainly for hot-rolled and cold-rolled unit length, cutting head, cut tail, cut the sample as well as incident handling, including cold-rolled strip steel drum flying shear, generally arranged before the winding machine, cutting the strip, for sub-volume …. 

As key equipment Rolling Integral continuous production line, support roller bear products at the online clipboard with curly taken to task. Acid rolling mill output of up to 500,000 yuan / h, whether the normal operation of the shears, directly determine whether the normal capacity of the entire line of play. 

A steel rolling mill in 420 acid production early l 998 in the first half, frequently appeared on the shears can not cut the strip normal phenomenon, causing huge economic losses.

With a flying shear structure, the drum-type mill bearing, generally composed of three parts flying shear body gear and equipment lubrication piping, whose chassis and rotating hub into one, as a whole, not only set up to replace the pair often transfer hub, simple structure rigidity, high cutting precision. 

Flying shear machine body is shown in Figure l, including the transmission mechanism, and cutting mechanism. Flying shear drive mechanism, mainly by the electric motor, gearbox, and synchronous transmission gear mounted on the upper and lower rollers on the drive side of the composition.

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The Structure Of Rolling Mill

The Structure Of Rolling Mill 

A rolling mill has a common construction independent of the specific type of rolling being performed:

· Work rolls

· Backup rolls - are intended to provide rigid support required by the working rolls to prevent bending under the rolling load

· Rolling balance system - to ensure that the upper work and backup rolls are maintained in proper position relative to lower rolls

· Roll changing devices - use of an overhead crane and a unit designed to attach to the neck of the roll to be removed from or inserted into the mill.

· Mill protection devices - to ensure that forces applied to the backup roll chocks are not of such a magnitude to fracture the roll necks or damage the mill housing

· Roll cooling and lubrication systems

· Pinions - gears to divide power between the two spindles, rotating them at the same speed but in different directions

· Gearing - to establish desired rolling speed     

· Drive motors - rolling narrow foil product to thousands of horsepower

· Electrical controls - constant and variable voltages applied to the motors

· Coilers and uncoilers - to unroll and roll up coils of metal

Slabs are the feed material for hot strip mills or plate mills and blooms are rolled to billets in a billet mill or large sections in a structural mill. The output from a strip mill is coiled and, subsequently, used as the feed for a cold rolling mill or used directly by fabricators. Billets, for re-rolling, are subsequently rolled in either a merchant, bar, or rod mill. Merchant or bar mills produce a variety of shaped products such as angles, channels, beams, rounds (long or coiled), and hexagons.

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The Usage And Features Of Ladle Refining Furnace

The Usage And Features Of Ladle Refining Furnace

LF refining furnace was successfully developed in 1971 by Japanese technical staff. And the furnace hasn’t had vacuum equipment, so the heating arc processing occurs on the steel surface of the slag in which LF refining furnaces the so-called submerged arc refining.

When adding the synthetic slag, stirring the molten steel with argon is necessary, and the refining occurs under a non-vacuum-reducing atmosphere. Afterward, the LF Furnace was improved, it can refining in the vacuum and heated under the non-vacuum circumstance when the vacuum extraction equipment is installed.

The main use of an LF refining furnace is for primary melting furnace (electric arc furnace, Converter, intermediate frequency furnace) refining of molten steel. It’s crucial metallurgical equipment for producing high-quality carbon steel, alloy structural steel, bearing steel, tool steel, stainless steel, etc, and meets the needs of Continuous Casting and Continuous Ligation.

This kind of LF refining Furnace has functions electric are heating, argon stirring, wire feeding, measuring temperature and sampling, alloying, etc. And in the terms of purchasing the LF refining furnace, the users can make choice by the steel grade and smelting technology.

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The Usage And Types Of Straightener

The Usage And Types Of Straightener

The Usage of the Straightener

During the heating, rolling, finishing, and transportation process of the rolling piece, the external force, temperature changes, internal force changes, or some other factors, very easily lead to curve, deform, and some other variations, for solving these problems, we need to use a straightener to eliminate the stress from both inside or outside, then we can get straight final steel, the straightener is essential equipment in a rolling mill workshop, and is widely used for other workshops like cars and ships.

The Types of the Straightener

According to the requirement of the final product specification requirement, the straightener style would be the difference, divided by working theory, and application purpose can be divided as the following:

Press straightener

Parallel straightener

Cross rolls straightener

Stretch straightener

Bending straightener

Reverse straightener

Except for the above straightener, there are still a lot of special straighteners, basically, with the development of technology, the straightener will be promoted very quickly, for different requirements of the application.

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The Usage Of Water In Rolling Mill Machines

The Usage Of Water In Rolling Mill Machines

With the development of the steel industry, more attention is paid to the protection of mechanical machines, such as roughing machines, reversible rolling mills, pre-finishing rolling mills, finishing rolling mills, and wire-rod mills. Therefore, most of the water used in the iron and steel industry is used for cooling, protecting equipment, and improving the working conditions of the employees. The Health and safety of the employee require dust control, which is commonly accomplished by sprinkling water on floors and machines.

Water use in all types of hot rolling mills is mainly for scale removal and temperature control. When steel is heated to the high temperature desired for hot rolling, its surface is oxidized and a hard scale is formed. If not removed before rolling, this scale would be rolled into the steel and would cause surface defects.  A common method of scale removal is to spray water under a pressure of as much as 2,000 psi (pounds per square inch) against the steel immediately before it enters the rolls.

Cooling water is sprayed on the rolls during hot rolling to prevent distortion and reduce erosion of the roll surfaces. Because considerable heat is produced by the rolling processes, water also serves to keep the steel at its proper rolling processes. Upon emergence from rolling mills, steel may be sprayed with water to hasten cooling. This spray prevents excessive scale formation. Roll bearings also require cooling. Spent cooling water flows to the scale pit along with that used for scale removal and may be reused after clarification and cooling.

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The Use And Maintenance Of Roller

The Use And Maintenance Of Roller

The roller is the biggest wearing part, expensive so for reducing the cost, we should carefully maintain it.

1. Full quality test before entering the workshop

The roller is a high technology, high value-added product, should apply quality tests according to the quality standard, test the roller surface, and end’s hardness, the hardness deviation should be below ±（2-3）HS, apply ultrasonic to test the inside flaws, surface wave for testing surface quality, visual inspection for outside flaws.

2. Regular refacing

We should change the roller regularly for better protection even if the surface is flawless, roller working hours should be 50-100H, and the supportive roller should reface after 2000-3000h, for removing the working layer, the remover layer should be thicker than the working layer.

3. Use the roller in the right way.

Use the roller according to the guidance, should adjust the temperature to 70-80℃ when switching rollers, the cold roller should be at 30-50℃, should cold down in the water, and the roller neck should be lubricated, keep clean, avoid rusting and grinding damage iron sheet, prevent misoperation and accident.

4. Avoid roller break accident

Breaking down of  roller is a destructive accident, there are normally two reasons, one is because of the quality of the roller, normally we can find flows in the breaking point, the other reason is from the outside and causes the roller's power and torque is overweight, we should avoid this circumstance.

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The Characteristics Of Horizontal Rolling Mill And Tandem Rolling Mill

The Characteristics Of Horizontal Rolling Mill And Tandem Rolling Mill

The horizontal rolling mill is mainly used for the production of various sections of steel, narrow hot strips, and small billets. The following are the main features of the horizontal rolling mill :

(1) A row of rolling mills is driven by a motor. The rolling speed of each rolling mill is the same, and the rolling speed cannot be increased as the length of the rolling stock increases, so the output is low and the labor productivity is low;

(2) The structure of the rolling mill is generally three-roller or two-roller alternate;

(3) The rolling mill operation mode is mostly shuttle rolling or loop rolling. With flexible deformation and strong adaptability, each rolling mill can roll several times. The product range is wide and the operation is relatively easy;

(4) The rolling mill equipment is simple, with less investment and quick construction.

The tandem rolling mills are arranged in a row according to the rolling direction of the rolling stock. The rolling stock is only rolled once on each rolling mill. Each rolling mill is driven separately. Each rolling mill has different rolling speeds, that is, the rolling speed of the rolling rolls can be related to the rolling stock. The reduction in the section or the increase in the length of the rolled piece increases. Therefore, compared with the horizontal rolling mill, the rolling mill has the advantages of short gap time, high production efficiency, and less auxiliary equipment.

However, when this kind of rolling mill works, the rolling stock sequentially enters each rolling mill without forming a continuous rolling relationship, and the rolling stock is lengthened as the number of rolling passes increases, and the distance between the racks increases as the length of the rolling stock increases, so Longitudinal mills occupy a longer plant. This type of rolling mill is only suitable for large and medium-sized steel production. In order to overcome this shortcoming, the tandem mill was further developed into an off-road and a chess mill.

In cross-country rolling mills and staggered rolling mills, the head and tail of the rolling stock are alternated in different passes, which means the upper head becomes the tail of the track, and the tail of this track becomes the next head again. The rolling stock has lateral movement during the rolling process. The arrangement of the cross-country rolling mills and staggered rolling mills is more concentrated, which overcomes the shortcomings of the long mill. These mills also have a fast rolling speed and are suitable for the production of large, medium, and small complex sections of steel such as I-beam, channel steel, and H-beam.

The Work Theory Of Film Bearing

The Work Theory Of Film Bearing

Film bearing is a radial running bearing that uses lubricant as a media, the basic working theory is, during the rolling process, the bearing journal moves because of the rolling power, and the bearing center and the bearing journal have skewing, making two zones in the gap of film bearing and journal, one is called amplification area, the gap is getting bigger and bigger according to the rotating direction, one is called constriction area, the gap is getting smaller according to the rotating direction. When the rotating journal brings the lubricant from the amplification area to the constriction area, the gap becomes smaller and smaller, forming a lubricant wedge, creating pressure on the lubricant oil pressure, the pressure from every point in the film altogether is bearing capacity of film bearing, when the rolling power is bigger than the bearing capacity, the journal center and the bearing center eccentric distance enlarges, in the constriction area, the gap between bearings changing fast in the direction of journal rotating, the thickness of film get to the thinnest, the pressure of film getting bigger, carry capacity getting bigger, until balance the rolling power of the journal will not deviation, the bearing and journal completely separated by the film, become all liquid lubricant in theory.

From the film bearing theory, we can sense that the most important specification is film thickness, if the thickness is too thin, and the impurity in the lubricant is too big, which is just like metal touching directly, can lead to burning inside, meanwhile, if the thickness of the film is too thin, if steel pushing accident happens, it is very easy to course direct contact which leads to burning, the smallest thickness of the film is related to bearing structure material, related parts’ accuracy, and film bearing system assemble accuracy, lubricant, and rolling power.

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Types Of Furnaces---Induction Furnace (Two)

Types Of Furnaces---Induction Furnace (Two)

Induction Furnace:

Induction heating of metal will provide the heat required for the electrical furnace. An induction furnace will provide a clean, energy-efficient, and well-controlled process of melting when it is compared with other processes. Most of modern foundries use this type of furnace instead of cupolas to melt cast iron as the former emits lots of duct along with other pollutants. 

The capacity ranges from less than one kilogram to a hundred tonnes capacity is used in melting iron, steel, copper, aluminum, and other precious metals. As the process does not use combustion, the material temperature is not higher than the required to melt it. This process prevents the loss of valuable alloying elements. The induction furnace lacks the refining capacity where the charge materials clean the oxidation products and the known composition. The alloying elements may have a chance to lose alloying elements due to oxidation.

The frequency of operation is high and is dependent on the material that is to be melted, and the furnace capacity required. If the volume of the melts is small then it requires a higher frequency. A pre-heated furnace of the melting iron can melt the cold charge by tapping of the readiness within an hour. The power supply range is from 10 KW to 42 KW which melts in size ranges of 20 kg to 65 tonnes of the respective metals. The operating induction furnace can be used by the operators to identify the correct operation and its corresponding power level.

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Types Of Furnaces --- Open Hearth Furnace（Three）

Types Of Furnaces --- Open Hearth Furnace（Three）

Open Hearth Furnace:

The open heart process is also called a Siemens-martin process i.e. steel making technique for most of the applications in the 20th century. This process seeks a means to increase the temperature in a metallurgical furnace that uses the waste heat given out from the furnace that directs the fumes from the furnace through a brick checker work. A brick is heated to a high temperature, and then it is introduced into the furnace. The device is first used to produce steel that is charged with pig iron and wrought iron along with their scrap. The US and Britain are best suited to the open hearth process.

Natural gas or atomized heavy oils are used as fuel. The air and fuel are heated before combustion. The furnace gets charged with blast furnace iron in liquid form, steel crap that is combined with ore, limestone, dolomite, and fluxes. The roofs and body of the furnace are made of highly refractory materials such as magnetic bricks. 600 tons is the capacity of the open hearth furnaces that are installed in groups for massive auxiliary equipment, that is needed to charge up the furnaces and to handle the liquid steel that can be employed efficiently. It is most commonly used in industrial applications such as electric arc furnaces and oxygen process-based furnaces.

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