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.

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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.

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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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