1.

0 INTRODUCTION TO COLD ROLLING

1.1 COLD ROLLING:Process by which hot rolled strip or stock is introduced between rollers and then squeezed or compressed to the desired thickness Amount of strain introduced determines the properties of the finished product.

1.2 PURPOSE OF COLD ROLLING:yGood Formability ySuperior Surface Finish yReasonable Strength yClose Dimensional Tolerance

. 1.3 COMMONLY USED GRADES OF COLD ROLLED STEEL:D/DD - Drawing/Deep Drawing EDD - Extra Deep Drawing IF (Interstitial Free) Simple forming/bendingApplications. Deep Drawn components Critical Draw and Stretch Components in terms of geometry of the component, type and depth of draw and press parameters. For components involving draw and requiring resistance against dent and impact.

IFHS (Interstitial Free High Strength)

1.5 PROCESS FLOW OF CRM:. PICKLING

(To remove oxides and scales) COLD ROLLING in Tandem Mill to desired thickness
BATCHANNEALING for stress relieving

INSPECTION, FINISHING DESPATCH

SKINPASSING to remove Ludder lines, develop mech prop.,impart desired surface finish, improve flatness

4.1 PRODUCTION FACILITIES AT CRM: The major production facilities as part of the CRM Complex includes : yPickling Line And Tandem Cold Rolling Mill of over 1.2 mtpa capacity along with Acid Regeneration Plant. Shallow Bath Pickling Line using hydrochloric acid is carried out and after pickling, the coils are rolled. Mitsubishi Heavy Industries, Japan (MHI, Japan) supplied the Pickling Line and the Tandem Mill was provided by Hitachi, Japan. yHydrogen Batch Annealing Facility And Coil Cooling And Storage Units has a 0.8 mtpa production capacity. It consists of 42-bases. This was supplied by LOI, Germany. ySkin Pass Mill (SPM) for rolling annealed products has a capacity of 0.83 mtpa and it was supplied by IHI, Japan. yTwo Continuous Galvanizing Lines has about 0.4 mtpacombined capacity (CGL#1 of 0.1-mtpa capacity and CGL#2 of 0.3-mtpa capacity). Suppliers of CGL#1 are Flat Product Eng. India (FPE, India) and that of CGL#2 is CMI, Belgium. yFinishing Facilities including two Recoiling Lines for a variety of finishing operations (such as tension levelling, oiling, inspection, trimming etc.) and Coil Packing Line. The recoiling line has a capacity of 0.75 mtpa and was supplied by DBA, USA. The coilpackaging line with a capacity of 1 mtpa was supplied by Indomag, ITW Singnode. . yOther Auxiliary facilities include power supply, utilities, water supply, communication and mobile equipments and work transportation.

4.2 DIFFERENT LINE OPERATIONS AT CRM:

PICKLING AND COLD ROLLING:This operation eliminates oxides formed on the surface during hot rolling to facilitate subsequent cold rolling but also for annealing and galvanizing of cold rolled strips because of surface considerations. Pickling consists of treatment of the surface of the strips with hydrochloric acid. To improve the efficiency of pickling, mechanical descaling with the help of a tension leveler to crack and partially eliminate the oxides precedes it. The pickling process then removes the remaining oxides and leaves a clean surface. Tata Cold Rolling Complex has a shallow bath hydrochloric acid pickling technology. After the hot rolled coil surface is free from scales, it is cold rolled at room temperature, a process also referred to as Cold Rolling. The Cold Rolling Mill consists of five stands, each in a 6 Hi Configuration (i.e. two work rolls, two intermediate rolls and two back-up rolls in each stand). Also, the Pickling and Cold Rolling operations are fully coupled and the operation is continuous. Therefore, the input hot rolled coils gets pickled and cold rolled, in one continuous automatic operation. The emulsion oil is used at cold rolling mill during rolling as a coolant and lubricant.

ANNEALING:
CRM has 100% Hydrogen Batch Annealing as the annealing route. During batch annealing, the coils are stacked one over another up to a total height of around 6.3 meters and the entire stack is given a heating and cooling from outside through a protective inner cover. The annealing temperature is 100% hydrogen and the maximum annealing temperature is around 700 degree centigrade. The entire annealing cycle may take around 30 to 50 hours depending upon the steel grade and product quality needed. The coils are then unloaded from the annealing bases at the end of the cycle and transferred to Coil Cooling and Storage Units (CCSU) by means of coil transfer cars. The CCSU bases provide a temporary cooling and storage facility for coils under protective dehumidified atmosphere until they are ready to be processed in the Skin Pass Mill.
SKIN PASSING: Annealing coils are given a small cold reduction (typically around 1 %) in the Skin Pass Mill. In this operation, the yield point of material is suppressed and also the right surface roughness is imparted on the strip surface as per the customer specifications. During the Skin Passing Temper Agent Oil is applied on strip surface for cleaning purpose. In addition, a metallurgical defect known as stretcher strains is eliminated and also the flatness of the strip is improved.

GALVANIZING FACILITY:As mentioned earlier, two galvanizing lines constitute the galvanizing facility. The first line CGL#1, caters to low end construction sector with a capacity of 0.1 mtpa and the second, CGL#2, caters to the high end auto and white goods with a capacity of 0.3 mtpa. The different lines are necessary because it may not be easily possible to process the entire product-mix of the CRM Complex in a single line. Since the quality requirement in terms of coating characteristics, strip flatness and tolerances are quite different for the construction, general engineering grades and auto/home appliances sector. Both the Galvanizing Line have strip cleaning facility with Electrolytic Cleaning Section in which strip surface is cleaned with alkaline solution.

FINISHING FACILITY:The finishing facility includes Recoiling Lines which performs several functions such as thorough inspection of coils, oiling, edge trimming, ID changing with capacity of 0.75 mtpa etc. Coils Packaging Line is designed to package the coils the coils to be dispatched and to protect the coils from damage and rust during transportation to the end user.

1.6.1 PURPOSE & PROCESS OF PICKLING:yTo remove scales and oxide layers present on the surface of hot rolled steel yMake the steel surface suitable for cold rolling Scales and oxide layers are harder than steel and hence hinder the process of cold rolling of low carbon steel. Hot rolled strip is passed through tanks containing hydrochloric acid wherein the acid dissolves the oxide layer. The strip is then rinsed with water to remove any excess acid. dried and the strip is ready for cold rolling.

1.7 COLD ROLLING PROCESS:Hot rolled Pickled Coils are reduced to the desired thickness Achieved either in Reversing Cold Rolling Mills: Thickness achieved by repeated passes through the same rolling stand back and forth. Or Tandem Cold Rolling Mills: Thickness achieved through series of

rolling stands in Tandem Mill. .

Features:yAutomated Shape and Gauge Control. yThickness tol. achievable - +/- 0.5% of thickness along centre line with edge drop of 30 microns. yMill Cleaning System..

1.8 ANNEALING:1.5.1 PURPOSE OF ANNEALING:Steel Coils becomes hard and brittle after Cold Rolling and has elongated grain structure which are suitable for end use. Annealing ensures: ySoftening of the cold rolled steel- Relieving the internal stress developed during cold rolling. yDevelop desired mechanical properties suitable for intended applications. yBright surface finish. . 1.9 SKIN PASS 1.9.1 PURPOSE ING:- OF SKIN PASSING:yTo achieve the optimum mechanical properties (Hardness, YS, etc.). yTo prevent occurrence of stretcher strains in annealed steel. yTo impart desired surface finish - matte on the strip surface. yTo improve strip shape.

SPECIAL FEATURES: yHydraulic Roll Force Control System yWork Roll Bending System (Positive and negative bending) yTension Meter and Roll Force Load Cells yCenter Position Control yElongation Control

yOnline Weighing, Strapping and Marking.

4.3.4 BATCH ANNEALING FURNACES (BAF):

SPECIAL FEATURES: ySophisticated safety features yAutomation features including level 0,level 1 & level- 2 ySpecial Instrumentation System

. 4.3.6 CONTINUOUS GALVANISING LINE # 1 (CGL # 1):

SPECIAL FEATURES: . yGalvanizing line of 100,000tonnes per year capacity with optimum facilities at least cost. yFacility set up in record time of 18 months from placement of order yTrial run conducted 2 months ahead of schedule

. 4.3.8 RECOILING & INSPECTION LINE # 1 (RCL # 1):

yOver and Under unwinding yHead and Tail End Cropping. yEdge Trimming yInspection & Defects Logging ySurface Oiling yParting to Divide into Smaller Coils yOver and Under Winding yChange of Inner Dia.of Coils

4.3.9 RECOILING & INSPECTION LINE # 2 (RCL # 2):FACILITIES AVAILABLE: yOver and Under unwinding. yEdge Trimming. yTension Levelling. yThorough Inspection & Defects Logging. yThickness Measurement. ySurface Oiling. yParting to Divide into Smaller Coils. yOver and Under Winding.

yChange of Inner Diameter.

4.3.10 RECOILING & INSPECTION LINE # 3(RCL # 3):

Facilities Available: yOver and Under unwinding. yCoil Preparation at Entry. yHead and Tail End Cropping. yStrip Surface Cleaning By Wash & Brush Unit. yEdge Trimming. yTension Levelling. yThorough Inspection Of Coil & Defects Logging. yWidth Measurement. yThickness Measurement. ySurface Oiling. yParting to Divide into Smaller Coils. yOver and Under Winding. yChange of Inner Diameter.

4.3.12 COIL PACKAGING LINE:Special Features: yFirst dedicated Packaging Line Installed for a CRM in India yThe stretch film wrapping facility (with COIL MASTER) is also being incorporated for the first time.

Ctitical map skilling of the contractor employees of CRM

INTRODUCTION
In todays competitive business scenario and era of flatter organization, structures enabling high quality performance/contribution from each individual have become essential. The leaders role in motivating, guiding and facilitating employees in raising their performance and realizing their potential has assumed greater significance. Further, managers are called upon to develop the softer skill, attitudes and behaviors so as to ensure that each individual integrates well with the team and the overall organization culture. Also, employees today expect their manager to play an active and effective role in their career planning and professional development. Thus for knowing the needs of the training and development of the employees, Toyota Motor, Japan has introduced the concept of Critical Skill Mapping by Four . By the use of this model managers are able to evaluate and analyze theprogress of skill index of a group of employees of same profile.