shape the metal to desired shape. - Here in VSP the application is for Hot Rolling of Steel only. - Rolling is very important process among the various methods as 90% of the metal products used are Rolled products only.
Theory of Rolling - Hot Rolling of metal involves heating of the metal above the recrystallization temperature and is performed between the temperatures of 1200 C to 900 C. - Heating is done in the Furnaces. - Hot Rolling is done in the 2-High Roll stands.
Theory of Rolling Angle of Bite Top Roll Bottom Roll Input H0 Output H1 Theory of Rolling Angle of bite is 25-30 Degrees in case of Continuos Mills and a max of 20 Degrees in case of Cross-country Mills. The picture also indicates that the more the Roll Dia the more is the spread. There is also a condition of Forward & Backward slip which effects the speed of the material to some extent. Theory of Rolling The important point considered for Rolling process is - The Volume is always constant i.e the input volume is equal to the output volume. B0 X H0 X L0 = B1 X H1 X L1 or (B0/B1)x(H0/H1)x(L0/L1) = 1 wherein B0/B1 is Spread H0/H1 is Draft L0/L1 is elongation Rolling Process in VSP STEEL MELTING SHOP Bloom 320X250
Bloom 250X250 LMMM MMSM BRM WRM PRODUCTS- BARS & ROUNDS Light STRUCTURALS PRODUCTS- ROUNDS and Medium STRUCTURALS Types of Mills Cross Country mills - Low Production - More Manual involvement - 2-high or 3-high Rolling - High Section Change time Continuous Mills - High Production - More Rolls & Guides. - 2-high Rolling - Less Manual intervention - easy section changes Theory of Rolling-Roll Pass design It is a Rolling Technology which deals with production of desired shape within permissible deviations with the required surface finish free from any surface defects.It also has to ensure optimum utilization of mill equipment,high rolling rate and safe working conditions of operators. Theory of Rolling- Roll pass Design The following factors are considered for development of Roll pass design:- Power Availability. No. of Stands. Roll barrel length , roll material etc Input material. Theory of Rolling- Roll pass Design Factors influencing the spread are: - Reduction in height or the Draft. - Roll Diameter. - Rolling Temperature. - Friction between rolls and the rolled material - Steel Composition. Theory of Rolling- Roll pass Design The degree of spread of a steel depends on the steel composition:- - Carbon:Increase in Carbon increases spread - Chromium: same as above. - Nickel : inversely proportional to spread. - Manganese: Directly proportional to spread. Theory of Rolling- Roll passDesign The Various Shapes of passes for round rolling: BOX Diamond Square Oval Round Theory of Rolling- Roll passDesign The different Rolling Sequences used in Roll pass design as per requirement are:- - Box Oval Round. - Box Diamond Square. - Square Oval Round. - Box Box - Box - Butterfly pass is used in Angle Rolling. - Edger pass is used in Flat Rolling. - Closed passes are used in Chanel & Beam Rolling Theory of Rolling-Rolling Practice The most important points to noted for efficient Rolling practice are:- -Proper Mill Settings -Roll Pass & Guide alignment. - Roll wear compensation. - Timely Pass Changes. - Material Temperature. - Speed adjustments. Existing Mills Proposed Mills Wirerod mill 2 0.6 MtPY Structural mill 0.7 MtPY Spl. Bar mill 0.75 MtPY Seam less tube mill 0.3 MtPY WRM-1 1.05 MtPY MMSM 1.05 MtPY LMMM 0.9 MtPY TOTAL ROLLS REQUIRED BY VSP
TONNAGE : 1200-1500 T/Year
No of rolls/year : 400-500 VSP : ROLLS REQUIREMENT TYPES OF ROLLS USED IN VSP
CAST IRON CAST STEEL FORGED
Strand No Roll Size (mm) (Dia x B.L) Roll Material BILLET MILL WORK ROLLS 1& 2 850 x 1200 AFS 40-45 SHC UTS 85-100 Kgf/mm 2 3 730 x 1000 AFS 40-45 SHC UTS 85-100 Kgf/mm 2 4 730 x 1000 SGCI 50-55 SHC 5 650 x 1000 SGCI 50-55 SHC 6 650 x 1000 SGCI 55-60 SHC 7 630 x 1000 SGCI 55-60 SHC TYPE OF ROLLS USED Strand No Roll Size (mm) (Dia x B.L) Roll Material WIRE ROD MILL- WORK ROLLS H1& H2 610 x 1000 SGCI 48-53 SHC H3 TO H5 610 x 1000 SGCI 52-57 SHC H6 490 x 960 SGCI 52-57 SHC H7 490 x 960 SGCI 52-57 SHC H8 TO H10 480 x 840 SGCI 68-72 SHC H11 TOH13 375 x 740 SG(AC) 70-75 SHC TYPE OF ROLLS USED Strand No Roll Size (mm) (Dia x B.L) Roll Material MMSM- WORK ROLLS -1 1 TO 10 (Rounds & squares) 680 x 1000 ACS 40-45 SHC & UTS 740-960 N/mm 2 1 TO 14 (Structurals) 660 x 825 ACS 40-45 SHC & UTS 740-960 N/mm 2 11 TO 14 (Rounds & squares) 680 x 1000 SGCI 50-55 SHC 15 TO 20 (Rounds, squares, flats & beams) 555 x 630 SGCI 58-63 SHC 15 TO 20 (Angles & channels) 555 to 670 SGCI 58-63 SHC 375 x 740 SG(AC) 70-75 SHC TYPE OF ROLLS USED Strand No Roll Size (mm) (Dia x B.L) Roll Material MMSM- WORK ROLLS-2 11 & 13 U-H 1070 x 180 SGCI 58-63 SHC
15,16,18 &20 U-H 900 X 180 SGCI 58-63 SHC
11 & 13 U-V 710 x 170 HICRCI 63-68 SHC 15,16,18 & 20 U-V 600 x 170 HICRCI 63-68 SHC TYPE OF ROLLS USED Strand No Roll Size (mm) (Dia x B.L) Roll Material BAR MILL- WORK ROLLS -1 H1 610 x 1244 AFS 40-45 SHC UTS 85-100 Kgf/mm 2
H2 TO H4 610 X 1244 ACS 40-45 SHC & UTS 85-100 N/mm 2 H5 TO H8
460 x 1084 SGCI 50-55 SHC
H6 TO H8 (angles&channels)
430 TO 495 x 850 SGCI 50-55 SHC H9 TO H 18 380 TO 495 x 850 SGCI 50-55 SHC TYPE OF ROLLS USED Strand No Roll Size (mm) (Dia x B.L) Roll Material BAR MILL- WORK ROLLS -2 V11 & V16 360 x 600 SGCI 58-63 SHC V 19 V21 360 X 600 SG(AC) 70-755 SHC
H 22(all rebars) 360 x 600 SGCI 68-73 SHC H 20 H22 (round TO 36 mm) 360 x 600 SG(AC)68-73 SHC H 20 H22 (angles) 340 TO 450 x 600 SGCI 56-60 SHC H20 TO H 22 340 TO 450 x 600 SGCI 56-60 SHC TYPE OF ROLLS USED Y.V.S.Naidu DCM(O) ; RS&RS
Heat-Treatment of Steel: A Comprehensive Treatise on the Hardening, Tempering, Annealing and Casehardening of Various Kinds of Steel: Including High-speed, High-Carbon, Alloy and Low Carbon Steels, Together with Chapters on Heat-Treating Furnaces and on Hardness Testing
Turning and Boring
A specialized treatise for machinists, students in the industrial and engineering schools, and apprentices, on turning and boring methods, etc.