Process automation and control

Short of a new mill, nothing gives flat rolled producers a bigger leg up on the competition than state-of-the-art
automation of key mill functions. Automation will get you there faster...less expensively...and more efficiently
than any other available option. These systems offer so much promise that Fives DMS has put together an
own team of specialists to meet the growing need. Together the team covers all the required disciplines-
electronics, software development, electromechanics, electrohydraulics, computer modeling, CAD/CAM and
man/machine interfacing. They offer the depth of experience to understand your requirements and assemble
an automation package that puts you years ahead of where you are today.

What do you need? Greater productivity? Improved Quality? Fewer man-hours? Lower costs? Some
combination of these factors?
Our team's recommendations reflect a whole new wave of technology. Self teaching software, finite element
analysis and adaptive setup models are more than just buzzwords. They're the key to better mill proficiency.
Touch screens and man/ machine interfaces take the place of meters, strip charts and other conventional
means of tracking strip conditions throughout the mill. Our advanced automation packages range from full mill
integration to any combination of individual systems that make up the whole.

These include:
Automatic gauge control
Hydraulic gap control
Roll bending control
Interstand tension control
Roll eccentricity control
Drive controls
Shape controls
Statistical process control
Data logging
From this list, our automation team will give you a set of recommendations that you can grow, trim, or fine tune
to suit your operating and budget goals.

Rolling mill
From Wikipedia, the free encyclopedia

Rolling mill for plates and wires (goldsmith tool).

Rolling mill for cold rolling metal sheet like this piece of brass sheet.

A rolling mill is a machine or factory used to shape and process metal by passing it between
a pair of working rolls. The metal is passed between two tough cylinders numerous times,
with the distance between the cylinders being decreased with each pass so the metal
becomes thinner and thinner. Depending on the temperature of the metalworking application
rolling mills are typically hot or cold rollingmills.
 Contents
[hide]

• 1 History

o 1.1 Iron and steel

o 1.2 Other metals

• 2 Modern Rolling

• 3 Hot Rolling Mill

• 4 Cold Rolling Mill

• 5 Components of a Rolling Mill

• 6 Classification of Rolling Mills

• 7 Finished Products of Rolling Mills

o 7.1 First Group

o 7.2 Second Group

o 7.3 Third Group

• 8 Foot Notes

• 9 See also

• 10 References

• 11 External links

[edit]History

[edit]Iron and steel

The earliest rolling mills were slitting mills, which were introduced from what is
now Belgium to England in 1590. These passed flat bars between rolls to form a plate of iron,
which was then passed between grooved rolls (slitters) to produce rods of iron. The first
experiments at rolling iron for tinplate took place about 1670. These were followed by the
erection by 1697 by Major John Hanbury of a mill at Pontypool to roll 'Pontypool plates' -
blackplate. Later this began to be rerolled and tinned to make tinplate. The earlier production
of plate iron in Europe had been in forges, not rolling mills.

The slitting mill was adapted to producing hoops (for barrels) and iron with a half-round or
other sections by means that were the subject of two patents of c. 1679.

Some of the earliest literature on rolling mills can be traced back to Christopher Polhem in
1761 in Patriotista Testamente, where he mentions rolling mills for both plate and bar iron.
[1]
He also explains how rolling mills can save on time and labor because a rolling mill can
produce 10 to 20 and still more bars at the same time which is wanted to tilt only one bar with
a hammer.
A patent was granted to Thomas Blockley of England in 1759 for the polishing and rolling of
metals. Another patent was granted in 1766 to Richard Ford of England for the first Tandem
Mill.[2] A tandem mill is where the metal is rolled in successive stands; Ford’s tandem mill was
for hot rolling of wire rods.

[edit]Other metals
This section requires expansion.

Rolling mills for lead seem to have exited by the late 17th century. Copper and brass were
also rolled by the late 18th century.

[edit]Modern Rolling
The modern rolling practice can be contributed to the efforts of Henry Cort of Fontley Iron
Mills, near Fareham, England. In 1783 a patent was issued to Henry Cort for his use of
grooved rolls for rolling iron bars.[3] With this new design mills were able to produce 15 times
the output per day than with a hammer.[4] Although Cort was not the first to use grooved rolls;
he was the first to combine the use of all the best features of various ironmaking and shaping
processes known at the time. Thus the term “father of modern rolling” was giving to him by
modern writers.

The first rail rolling mill was established by John Birkenshaw in 1820 where he produced fish
bellied wrought iron rails in lengths of 15 to 18 feet.[5] With the advancement of technology in
rolling mills the size of rolling mills grew rapidly along with the size products being rolled.
Example of this was at The Great Exhibition in 1851 a plate 20 feet long, 3 ½ feet wide, and
7/16 of inch thick, weighed 1,125 pounds was exhibited by the Consett Iron Company.
[6]
Further evolution of the rolling mill came with the introduction of Three-high mills in 1853
used for rolling heavy sections.[citation needed]

[edit]Hot Rolling Mill

Hot rolling is a hot working metalworking process where large pieces of metal, such as slabs
or billets, are heated above their recrystallization temperature and then deformed between
rollers to form thinner cross sections. Hot rolling produces thinner cross sections than cold
rolling processes with the same number of stages. Hot rolling, due to recrystallization, will
reduce the average grain size of a metal while maintaining an equiaxed microstructure where
as cold rolling will produce a hardened microstructure.

[edit]Cold Rolling Mill

Cold rolling is a metalworking process in which metal is deformed by passing it through rollers
at a temperature below its recrystallization temperature. Cold rolling increases the yield
strength and hardness of a metal by introducing defects into the metal's crystal structure.
These defects prevent further slip and can reduce the grain size of the metal, resulting in Hall-
Petch hardening.

Cold rolling is most often used to decrease the thickness of plate and sheet metal.

[edit]Components of a Rolling Mill

 The work rolls and their bearings - made of material harder than it is intended to
roll
 The backup rolls and its bearings -are intended to provide rigid support required by
the working rolls to prevent their flexure or bending under the rolling load
 The Mill Foundation - reinforced concrete for every ton of mill weight
 Rolling balance system - to ensure that the upper work and back up rolls are
maintain in proper position relative to lower rolls
 Work 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
 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
 Motor Couplings - used to connect the shafts of motors to reduction gears in pinion
stands
 Drive motors - rolling narrow foil product to thousands of horsepower
 Motor Generator Sets - constant and variable voltages applied to the motors
 Coilers - provides high forward tensions
 Mill Instrumentations - sensors to monitor all important parameter processes
 Operating Controls - enable the mill operator to handle rolling process

[7]

[edit]Classification of Rolling Mills

Mills classified in accordance with the name of the product which they roll, follow: Blooming,
cogging and slabbing mills, being the preparatory mills to rolling finished rails, shapes or
plates, respectively. If reversing, they are from 34 to 48 inches in diameter, and if three-high,
from 28 to 42 inches in diameter.

 Billet mills, three-high, rolls from 24 to 32 inches in diameter, used for the further
reduction of blooms down to 1J^ x IJ^-inch billets, being the preparatory mills for the bar
and rod
  Beam mills, three-high, rolls from 28 to 36 inches in diameter, for the production of
heavy beams and channels 12 inches and over.
 Rail mills with rolls from 26 to 40 inches in diameter.
 Shape mills with rolls from 20 to 26 inches in diameter, for smaller sizes of beams
and channels and other structural shapes.
 Merchant bar mills with rolls from 16 to 20 inches in diameter.
 Small merchant bar mills with finishing rolls from 8 to 16 inches in diameter, generally
arranged with a larger size roughing stand.
 Rod and wire mills with finishing rolls from 8 to 12 inches in diameter, always
arranged with larger size roughing stands.
 Hoop and cotton tie mills, similar to small merchant bar mills11.
 Armour plate mills with rolls from 44 to 50 inches in diameter and 140 to 180-inch
body.

Plate mills with rolls from 28 to 44 inches in diameter13.

 Sheet mills with rolls from 20 to 32 inches in diameter.

 Universal mills for the production of square-edged or so-called universal plates and
various wide flanged shapes by a system of vertical and horizontal rolls
 Tube mills for the production of tubes.
 Special mills, such as slitting, piercing, tire wheel mills, etc.
 Cold mills.[8]

[edit]Finished Products of Rolling Mills

[edit]First Group
Bars, rods, wire rods, bands and hoops, constituting the first group, are produced from
blooms, slabs and billets by reducing this material to the simplest forms, such as squares,
rounds and flats. These' forms resemble the cross-section of the material from which they are
rolled, and their final "section determines their nomenclature. The materials of this group have
great length compared with their width and thickness. The steel from which they are rolled is
prepared to conform to certain specifications, and the section must be within certain limits as
to size and weight, and must be suitable for further fabrication into bolts, nuts, spikes, chains,
rivets, wire, wire nails, hoops, cotton ties, springs, etc.[9]

[edit]Second Group
Shapes, constituting the second group, are reduced from blooms, slabs or billets to forms
having more or less irregular section. In the process of rolling, the original material is not only
reduced in section, but it is also developed into a definite shape. The various shapes are
given commercial names, such as rails, splice bars, I-beams, channels, zees, tees, angles,
etc. The heavier and larger sizes of these shapes are frequently rolled direct in one heat from
the ingot to the finished material. After leaving the rolling mill, shapes are cut to length and
are cooled on cooling beds. The shapes are subsequently straightened by means of
straightening rolls or presses, the latter work being performed in suitable shops adjoining the
rolling mill, and in this condition they are known commercially as structural shapes. These
shapes are further developed and worked into various products at shops specially adapted to
carry out the character of the work for which they are intended. For example, the fabrication of
products built for building construction is carried on in architectural iron works; bridges at
bridge works; ships at ship yards, and railroad construction at car shops.[10]

[edit]Third Group
Plates and skelp, of the third group, is the material obtained by rolling slabs and blooms in
mills known as plate and skelp mills. A sheet is the product obtained by rolling sheet bars in
sheet mills. While bars and shapes have great length compared with their other dimensions,
this does not apply to plates and sheets where the width is also well developed; this form of
product is known as sheets when rolled to a thickness less than No. 12 gage. The United
States government limits this thickness to No. 10, United States standard gage. With
reference to quality and use, plates may be divided into tank, bridge, ship and boiler plates.
The steel entering into the material from which plates are rolled is prepared to conform to
standard specifications governing the above classes. Boiler plates are further divided (with
reference to the grade of steel to be used for certain parts of the boiler) into flange, fire box
and extra soft steel. Plates, after being rolled, have frequently an uneven surface, which is
flattened by passing them through straightening rolls. Long plates are straightened by being
held in place against guides and are hammered flat with wooden hammers. Plates, after
being straightened and cooled, are transferred to the shearing department, usually adjoining
the plate mill, where they are cut to size. Plates having irregular edges must be sheared.
Universal mill plates have their edges rolled and need only be sheared on the ends. Universal
mill plates are rolled from 18 to 60 inches in width. .[11]

[edit]Foot Notes

1. ^ Swank, James M., History of the Manufacturers of Iron in All Ages, Published by Burt

Franklin 1892, p.91

2. ^ Roberts, William L., Cold Rolling of Steel, Copyright 1978 by Marcel Dekker, Inc., p.5

3. ^ R. A. Mott (ed. P. Singer), Henry Cort: the great finer (Metals Society, London 1983), 31-

36; English patents, nos. 1351 and 1420.

4. ^ Roberts, William L., Cold Rolling of Steel, Copyright 1978 by Marcel Dekker, Inc., p.6

5. ^ Roberts, William L., Cold Rolling of Steel, Copyright 1978 by Marcel Dekker, Inc., p.6
 6. ^ Roberts, William L., Cold Rolling of Steel, Copyright 1978 by Marcel Dekker, Inc., p.6

7. ^ Roberts, William L., Cold Rolling of Steel, Marcel Dekker, Inc., 1978, p.64

8. ^ Kindl, F. H., The Rolling Mill Industry, Penton Publishing Company 1913, p.16

9. ^ Kindl, F. H., The Rolling Mill Industry, Penton Publishing Company 1913, p.21

10. ^ Kindl, F. H., The Rolling Mill Industry, Penton Publishing Company 1913, p.16

11. ^ Kindl, F. H., The Rolling Mill Industry, Penton Publishing Company 1913, p.16

[edit]See also

 Bernard Lauth
 John B. Tytus
 Rolling (metalworking)
 Structural steel
 Steel mill

[edit]References

 Robert C. Allen, 'International Competition in Iron and Steel, 1850-1913', Journal of Economic

History Vol. 39, No. 4 (Dec., 1979), pp. 911-937.[1]

 Roberts, William L., Cold Rolling of Steel, (Marcel Dekker, Inc.1978)[2]

 Roberts, William L., Hot Rolling of Steel, (Marcel Dekker, Inc. 1983)[3]

 Roberts, William L., Flat Rolling Fundamentals, (Marcel Dekker, Inc. 2000)[4]

 Roberts, William L., Rod and Rolling Bar Theory and Applications, (Marcel Dekker, Inc. 2000)[5]

 Swank, James M., History of the Manufacturers of Iron in All Ages, (Burt Franklin 1892)[6]

 Kindl, F. H., The Rolling Mill Industry, (Penton Publishing Company 1913)[7]

[edit]External links

 Photos of a steam-powered rolling mill.

 Pictures of many rolling mills and big steel plants
 History of Rolling Mills

Categories: Rolling mills

 COLD ROLLING MILL

There are two types of Cold Rolling Mills operates, which are 6 Hi Cold Rolling Mill and 4 Hi Cold
Rolling Mill.

Pickled Hot Rolled Coils of higher guages are reduced to required thinner guages by passing through
the Mills. In 6 Hi Mill the reduction achieved is upto 0.13mm ultra thin guage whereas 4 Hi can reduce
the thickness upto 0.25mm. The computer controlled rolling process ensure closure thickness
tolerances and perfectly flat strips.

The installed production capacity of 6 Hi Mill is 2,30,856 MT/annum and 4 Hi Mill is 43,502 MT per
annum.

Cold Rolling Mills

A R Engineering is a manufacturer and supplier of Cold Rolling Mill Equipment for rolling ferrous
and non-ferrous products as per design &
specification of the customer.
We have worked for renowned industrial and
engineering organizations. Some of them are as
below.
» M/s Mecon (I) Ltd., Ranchi This Public Sector
Consultancy and Contracting organization has
placed orders on us, as follows:- a) Various drives
including combination reduction gear boxes and
pinion stand for a cold rolling mills which they have
set up for M/S Roadmaster Industries Ltd., at
Rishikesh, M/s Hero Cycle, Ludhiana & Nagarjuna Request A Quote
Steel, Hydrabad.

a) Rolling mill items for major revamping of Cold

Rolling Mill functioning at Bharat Aluminium
Company, Korba. This order includes hydraulic rolls
force cylinder, oil mist system with inter connecting
piping, air wiper at entry and delivery of mill rolls
and modification of screw down platform etc.
Measuring devices and roll wiping equipment and
chocks of various types etc. were also on order.

b) Cold rolling mill for non-ferrous strips required

for Ambernath Ordnance Factory & Kolkata Mint.
This includes the main mill stand (200 and
Request A Quote
370x350) weighing over 16 tonnes, complete with
B.U. and W. R. roll chocks etc., one pay off reel,
and, two tension reels, we may point out that the tension reels with wedge type segments
expanded by rotating hydraulic cylinder and hollow sleeves are of latest sophisticated design
requiring precise and complicated machining. Deflector rolls, vacuum strips wiper etc. were also
supplied by us and the drives for the tension reels and the pay off reels. This is just an
indicative list of the items of sophisticated rolling mills supplied after strict inspection by
MECON.

c) TMT LINE : Flying shear, pinch roll, tail breaker etc for a TMT line, under the technical license
of H&K Rolling Mill Engineers, Mumbai for the thermex system.
» Chocks for cold strips mill of Bokaro Steel Plant - 3.5 MT each - 12 Numbers.

» Mukand Ltd. for Rourkela Steel Plant - Rolling Mill Back Up Roll Chocks & Tension Reels-
We completed an order for large Rolling Mills Chocks and Tension Reel segment/sleeve
assembly to Mecon design for Rourkela Steel Plant and for various Gears etc.

» Jindal Iron & Steel Co. Ltd., Vasind B. U. and W. R Chocks for Cold Rolling Mills.

Other Steel Plant Equipment

1 a) Complete equipment for a 4 strand , 130x130, Billet Caster, for Malvika Steel Ltd.
b) Gear Boxes of various types, including ones with a pawl/ratchet arrangement for EOT
Cranes in Bokaro Steel Plant.

2. Sugar Plant Machinery Head Stocks, Bearing Blocks & Girth Gear Wheels.

3. Cement Plants Girth Gears of Outside Diameter, 5000mm and Module 40, and, matching
Pinions, Mills Cheeks, etc.

4. Turn-Key Work- Completed 1x300 tpd Lime Calcining Plant for Malvika Steels Ltd.

5. Power Sector- Drive Gear Box-1300 CRS and large gears, and pinions for coal mills drives to
several State Electricity Boards and to Bharat Heavy Electricals Ltd. Jobbing work of machining,
to fine accuracies, 500 MW Turbine Bearing Pedestals, and Other Steam Turbine parts, like main
Housings, Inner and Outer casings, Valve Chests, Elbows etc.

6 Mining Sector- 18& 10 MT Haulage Winches for export to the then USSR (Russia). Iron Ore &
Non Ferrous Ore Cone Crushers- 1750 & 2200 sizes.

Other Equipment
Complete equipment for a 4 strand, 130x130, billet caster, gear boxes of various types,
including ones with a pawl, ratchet arrangement for EOT Cranes.

• Sugar Plant Machinery: Sugar plant machinery head stocks, bearing blocks & large
gear wheels.

• Cement Plants: Cement plants large girth gears of outside diameter, 5000mm and
module 40, and, matching pinions, mills cheeks, etc.

• Turn-Key Work: Turn-Key Work- Completed 1x300 tpd Lime calcining plant for Malvika
Steels Ltd..

• Power Sector: Drive Gear Box-1300 CRS and large gears, and pinions for coal mills
drives to several State Electricity Boards and to Bharat Heavy Electricals Ltd. Jobbing
work of machining, to fine accuracies, 500 MW turbine bearing pedestals, and other
steam turbine parts, like main housings, inner and outer casings, valve chests, elbows
etc.

• Mining Sector: 18 & 10 MT Haulage Winches for export to the then USSR (Russia). Iron
ore & non ferrous ore cone crushers- 1750 & 2200 sizes. 5 Cu. M. Excavator Gear
Boxes- the entire set- for Heavy Engineering Corporation, Ranchi.
 Cold Rolling Mill

Product Description

Cold Rolling Mill

Cold rolled sheet is used widely for galvanization, color coating, automobile, household electric
appliance, aviation, instrument and food package etc, due to its good mechanical performance, such as
nice surface quality, high degree of finish and high dimensional precision. With the economic
development, the demand for high-quality cold-rolled sheet is increasing rapidly. We can provide
reversible cold rolling mill and continuous cold rolling mill.

Reversible Cold Rolling Mill

Reversible cold rolling mill is that one stand of mill is laid out in the line, and strip will pass the mill
reciprocally till termination product. This line is characteristic with low cost, small occupation and flexible
production. We can provide four-high reversible cold rolling mill, six-high reversible cold rolling mill,
twelve-high reversible cold rolling mill and twenty-high reversible cold rolling mill.

Tandem Cold Rolling Mills

The continuous rolling mill is that several mills are laid out in the line, and strip will pass the mills
continuously till termination product. The quantity of rolling passes equal to the quantity of mill stands.
Compared with single mill, continuous rolling mill has high-efficiency, good quality and high automatic
degree, so that it suit for production with high yield. We can provide two-stand cold rolling mill, three-
stand cold rolling mill, four-stand cold rolling mill and five-stand cold rolling mill, which equipped with
hydraulic screw-down AGC and automatic thickness gauge, and applied with the technology of endless
rolling and automatic welding.

Cold Rolling Mills

We specialize in manufacturing high quality
4Hi/6Hi Cold Rolling Mills in different
dimensional specifications. Using latest
technology and digital drives operated by
PLCs (Programmable Logic Controller) a
high degree of automation can be achieved.
We use standard products for
manufacturing cold rolling mills and other
equipment.

These mills provide excellent results

specially when it comes to roll very thin
gauges. We offer cost-effective solution for
designing, development and commissioning
of the mills on turnkey basis. Our Cold
Rolling Mills are available with coolant,
filtrations and other accessories.
 Cold Rolling Mills
We specialize in manufacturing high quality 4Hi/6Hi Cold Rolling Mills in different dimensional
specifications. Using latest technology and digital drives operated by PLCs (Programmable Logic
Controller) a high degree of automation can be achieved. We use standard products for
manufacturing cold rolling mills and other equipment.

These mills provide excellent results specially when it comes to roll very thin gauges. We offer
cost-effective solution for designing, development and commissioning of the mills on turnkey
basis. Our Cold Rolling Mills are available with coolant, filtrations and other accessories.

A systematic procedure for the design of a cold rolling

mill

U. S. Dixit , P. S. Robi and D. K. Sarma

Department of Mechanical Engineering, Indian Institute of Technology, Guwahati 781 039, India

Available online 20 November 2001.

Abstract
This paper presents a systematic design procedure for the design of a laboratory cold rolling mill. In
order to arrive at proper decisions at various stages of the design, the concepts of fuzzy sets and priority
decision tables were employed. The design process starts from deciding specifications and gradually
reaches the detailed design phase. Specifications were fixed by trading-off various conflicting goals
using the fuzzy set-based methodology. The various factors to be considered for deciding the roll
diameter are presented. The roll diameter and motor power are chosen using the fuzzy set-based
technique. Three possible arrangements for transmitting the power to rolls were conceived. The best
among these three design alternatives was chosen by preparing a priority decision table. After the
conceptual and embodiment stages of the design, the detailed design was carried out in a conventional
way. The present paper gives more emphasis to a systematic design procedure for the conceptual and
embodiment stages in the design process.