Sunteți pe pagina 1din 65
Basics of Rolling Mill Guide Design By Morgan Construction Company - A Siemens Company Worcester,

Basics of Rolling Mill Guide Design

By

Morgan Construction Company - A Siemens Company Worcester, MA 01605 USA

Contents

Contents
Contents Page 2 20-Mar-09 R. Stanard Introduction Long rolling mill guide design parameters Restbars and other

Page 2

20-Mar-09

R. Stanard

Introduction

Long rolling mill guide design parameters

Restbars and other ancillaries

Optical alignment equipment

Rod finishing mill guides

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

SVAI Long Rolling (LR) Services:

Spares, Guides, Upgrades & Services

SVAI Long Rolling (LR) Services: Spares, Guides, Upgrades & Services

Global Organization:

Morgan Worcester

Siemens VAI Italy (Pomini)

Morgan India

Morgan Shanghai

Siemens VAI UK (Ashlow – Morgan Europe)

Siemens VAI Brazil (Morgan do Brazil)

and the other Siemens VAI Service locations throughout the world

With this expanded network we can be even closer to customers to support all activities and requirements

Page 3

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

SVAI Long Rolling Services

SVAI Long Rolling Services

A growing global organization focused on the needs of all rolling mills

MAINTENANCE

REBUILDS

RECONDITIONING

of all rolling mills MAINTENANCE REBUILDS RECONDITIONING SPARES Mission: TRAINING Maximize Mill Utilization Page 4

SPARES

all rolling mills MAINTENANCE REBUILDS RECONDITIONING SPARES Mission: TRAINING Maximize Mill Utilization Page 4 UPGRADES

Mission:

TRAINING

MAINTENANCE REBUILDS RECONDITIONING SPARES Mission: TRAINING Maximize Mill Utilization Page 4 UPGRADES SERVICES 20-Mar-09

Maximize Mill Utilization

Page 4

UPGRADES
UPGRADES
UPGRADES
UPGRADES

UPGRADES

UPGRADES

SERVICES

20-Mar-09

R. Stanard

GUIDES GUIDES
GUIDES GUIDES
GUIDES GUIDES

GUIDES GUIDES

GuideDesignBasics.ppt

4 UPGRADES SERVICES 20-Mar-09 R. Stanard GUIDES GUIDES GuideDesignBasics.ppt AUDITS MT LR Services Strictly Confidential

AUDITS

MT LR Services

Strictly Confidential

Guide Equipment

Guide Equipment

It all started in 1879 with the first of many patents from Company founder Charles Hill Morgan

Together with Siemens VAI guides (Ashlow) we offer the most expansive guiding solutions of any guide supplier in the industry

Page 5

20-Mar-09

R. Stanard

any guide supplier in the industry Page 5 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Siemens VAI guides

Siemens VAI guides
Siemens VAI guides Page 6 20-Mar-09 R. Stanard Main benefits: Highest competitiveness Quick and simple adjustment

Page 6

20-Mar-09

R. Stanard

Main benefits:

Highest competitiveness

Quick and simple adjustment

Minimum maintenance requirements

Long operational service life

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Siemens VAI guides

Siemens VAI guides

Our vast guide portfolio covers the following applications and more

Applications: including but not limited to rounds, rebars, flats, squares, hexagons and angles

Also providing:

Restbars Interstand loopers and guiding Air/oil lubrication systems Optical setting equipment Water cooling headers High-speed flaw detector guides

Leading technology in multi-slit rolling with over 40 references worldwide

Page 7

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Guide Design and Rolling

Guide Design and Rolling

The Basics of Guide Design Agenda Basic Rolling Requirements

It all starts in the Roll Shop

Basics of Guide Design

Equipment design and operating parameters

General Guide Topics

Types of guides, considerations etc.

Page 8

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Conventional Rolling Stands

Mill Roll Groove Pass Alignment

A program for mill roll pass groove preparation and roll tracking is required Together is standard practices the rolls and stands are consistently prepared for the rolling mill The productivity of the rolling mill is directly related to the roll shop

of the rolling mill is directly related to the roll shop Page 9 20-Mar-09 R. Stanard
of the rolling mill is directly related to the roll shop Page 9 20-Mar-09 R. Stanard

Page 9

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Conventional Rolling Stands

Restbar and Saddle Alignment

The restbar elevation and position must be properly set and maintained

Premature guide failures and increased wear can be a result of poor restbar design or condition

Poor positioning results in

hooked front ends, cobbles,

and guide failures

results in hooked front ends, cobbles, and guide failures Page 10 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT

Page 10

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Restbar and Saddle Alignment Mechanical tools for checking alignment

Saddle Alignment Mechanical tools for checking alignment Page 11 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR

Page 11

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Restbars and Guide Mountings

Restbar designs must be durable and provide years of accurate location of guides

Mounting and clamping surfaces must be maintained

Adjusting restbars must be rebuilt and maintained for correct operation

Secondary adapter plates and fine pass adjustment bases can be used for smaller guides or guides requiring more location accuracy

Page 12

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Restbars & Guide Mounting Equipment

Restbars & Guide Mounting Equipment

Traversing and fixed restbars Guide mounting adapter plates Fine-pass adjusting bases

Guide mounting adapter plates Fine-pass adjusting bases Page 13 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR
Guide mounting adapter plates Fine-pass adjusting bases Page 13 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR
Guide mounting adapter plates Fine-pass adjusting bases Page 13 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR

Page 13

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Conventional Rolling Stands Stand alignment to interconnecting equipment

Proper alignment through all areas of the mill must be maintained

Premature guide failures and increased wear can be a result of poor alignment

Forcing equipment out of position is not sound rolling practice

Page 14

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Conventional Rolling Stands

Roll Groove Cooling

Pass design, guide design, and cooling header design all must be considered together for proper roll cooling

Advances in materials and methods for mill roll manufacture demand increased awareness and optimization of roll cooling designs

Proper roll cooling reduces pass wear, increases product quality and mill utilization and decreases operating costs

Typical Static Delivery Guide With-Header

Twist Delivery Guide With-Header

Page 15

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Conventional Rolling Stands Roller guide cooling and lubrication

Review of the piping and systems for applying the roller cooling and bearing lubrication is required before and during the guide service time in the mill

Failure to monitor the roller cooling and bearing lubrication directly causes roller and bearing failures and cobbles

Page 16

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Cantilevered Rolling Stands Mill roll groove alignment

Mill roll grooves must be properly cut and inspected

Mounting sleeves and tooling must be inspected and proper procedures followed

Some variables can be reduced with adjustments to the guiding equipment

Page 17

20-Mar-09

R. Stanard

to the guiding equipment Page 17 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly Confidential

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Cantilevered Rolling Stands Roll housing preparation and condition

A schedule for maintenance must be created

Inspection and proper procedures must be followed to maximize the equipment life

Damaged or worn housings can result in increased guide delays and operating costs

Page 18

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Cantilevered Rolling Stands Bracket and saddle alignment

Mounting brackets rigidly align and hold the guides to the roll housing

The mounting surfaces and clamping equipment must be free of damage and scale

A schedule for maintenance must be created and spare parts available

Page 19

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Cantilevered Rolling Stands Roll cooling and pass life

The design requirements for roll cooling increases with mill roll hardness and rolling speed

Roll cooling headers need to be inspected regularly at mill roll and guide changes

Worn, damaged, or poorly designed headers directly affect pass life and product quality

Page 20

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basic Rolling Requirements

Basic Rolling Requirements

Cantilevered Rolling Stands Flutter and the finishing mill

A great deal of testing of the effects of the flutter related to feed area, steel grade, and temperatures has allowed Morgan to make advances in roll pass design to reduce some of the flutter and produce the highest quality finished product tolerances at the world’s fastest finishing speeds Please contact Morgan Rolling Services for assistance in this area

tolerances at th e world’s fastest finishing speeds Please contact Morgan Rolling Servic es for assistance

Page 21

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Design input requirements for guides (required for all mill locations and installations)

Mill roll maximum and minimum diameter

Mounting restbar dovetail dimensions and locations from the center of the mill stand

The distance from the stand centerline to the interconnecting equipment

The distance between the rolling stands

The location and design of the mill roll cooling headers

The pass groove details of the incoming feed section

The pass groove details of the outgoing rolled section

Page 22

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Design input requirements for guides (cont’d) The mill roll partings for each pass groove and section rolled The key tolerance and size if the restbar has a key and keyway design The inside dimension of the stand housing window The distribution of passes along the mill roll barrel The dimension from the end of the roll barrel to the mill roll chocks The dimension of the strand centers (for multi-strand mills only)

Page 23

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Design input requirements for guides (cont’d) Additional requirements for cantilevered stands only

The dimension of the roll housing to the centerline of strand

The location of the pinion bore to the guide mounting location and the dimension of the eccentric throw

The design of the seal plate

The dimensions for the mounting holes and keyways for guide mounting brackets

Page 24

20-Mar-09

R. Stanard

for guide mounting brackets Page 24 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly Confidential

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Design input requirements for guides (cont’d)

The main point is that ALL input requirements must be considered when designing and installing guides to get the optimum performance and reliability

Page 25

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

What guides should be supplied?

Once all the parameters are gathered a final decision is required to determine what type of guide is required

A review of the progression of passes is required to understand the guiding requirements and options

Page 26

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Stable pass progressions

Stable progressions typically do not require secondary support from direct contact guiding

Some examples of stable progressions…

contact guiding Some examples of stable progressions… Page 27 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR

Page 27

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Stable pass progression examples…

Basics of Guide Design Stable pass progression examples… Page 28 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR
Basics of Guide Design Stable pass progression examples… Page 28 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR

Page 28

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

A few Un-stable pass progression examples…

of Guide Design A few Un-stable pass progression examples… Page 29 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT

Page 29

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Review of pass progressions leads to the final decision of the type of guide to be used for the specific application

There are many reasons to choose a guide design but all factors and requirements must be reviewed for the correct choice for each rolling location

A simple but critical type of guide in the mill is the static receiving guides that deal with a wide variety of stable pass progressions

Page 30

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Static Receiving Guides Illustration for receiving guide discussion

Page 31

20-Mar-09

for receiving guide discussion Page 31 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Static Receiving Guides The guide bore must be less than the full width on face of that stands work roll pass The guide bore is typically 85-90% of said pass width of face The length of the rifling is typically 2-3 times the guide bore for stability Worn static receiving guides lead to delivery guide cobbles and twist guide failures from hooked and knuckled head ends

Page 32

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Static Delivery Guides The main function of delivery guides is to ensure the smooth passage of the bar from the rolling stand to the next piece of mill equipment There are two basic guide types: stripper and catcher

Stripper guides are used to minimize hooks Catcher guides are used to reduce change time

Stripper guides are used to minimize hooks Catcher guides are used to reduce change time

The chance of cobbles must be considered with the guide and mounting bracket design to protect the rolling mill stand

Page 33

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Static Delivery Guides

Illustration for delivery guide discussion

Page 34

20-Mar-09

R. Stanard

for delivery guide discussion Page 34 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly Confidential

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Roller Entry Guide Designs

Two basic guide design types, leaf and block

Both types have design points that must be reviewed for each application and operator preference

Two and four roller guides have specific application points and must be reviewed for each application and operator preference

Page 35

The back rollers of the 4 roller guide are set slightly larger than the front rollers to promote a rollerized funnel effect

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Entry Guides

The main function of the roller entry guide is to prevent the rolled section from rotating in the work roll pass groove

Exiting product tolerance is a direct result of durability and accuracy of the guide setting and guide roller and static insert design

The static entry insert must minimize the impact on the guide roller and bearings but must not rub on the bar through the length of the billet

The guide roller design must be carefully reviewed to maximize roller and bearing life and product quality

Page 36

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Roller Entry Guide Roller Design

Profile and V-grooves are the two main types

For hard-metal mill rolls the profile rollers are preferred and outperform V-groove rollers

Both roller types need to be designed to utilize the full operating range of the roller entry guide assembly to provide the maximum payback for the rollers

Page 37

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Roller Entry Guide Roller Design Comparison of V-groove versus profile rollers V-groove rollers typically contact at around 65% of W.O.F. Profile rollers should have minimum contact of 75%

Page 38 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services
Page 38
20-Mar-09
R. Stanard
GuideDesignBasics.ppt
MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Entry Guides

Roller design W.O.F. Contact Assembly capacity Insert clearance Roller parameters

Page 39

20-Mar-09

R. Stanard

clearance Roller parameters Page 39 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly Confidential

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Entry Guides

Insert design with twisting entering section into guide

Insert design with twisting entering section into guide Page 40 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR

Page 40

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Entry Guides (cont’d) The insert clearances are 15-30% larger than the guided section based on location and speed of the guided section The guide roller needs to support at least 75% of the oval pass width and can approach 100% for the smallest leader ovals for high-speed wire rods Bearing lubrication and guide roller cooling are key to guide life

Page 41

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Roller Entry Guide Nosepiece The nosepiece is used to fill the space from the guide roller to the mill roll bite With correct settings and alignment the nosepiece should never be in contact with the rolled section The nosepiece width is typically equal, or nearly equal, to the dimension of the height of the preceding roller entry guide static inserts

Page 42

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Other Roller Entry Guides The open top 4 roller guide with symmetrically adjusting base provides the flexibility to guide the process passes for flats, channels and angles with only adjustments for width and centering spacer shape A top adjusting three roller guide is often used for angle and channel passes but the guide is limited to longer distances from the roll bite

Page 43

The main requirement for this guide are for the production of sharp apex angle sections

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Roller Twist Delivery Guide Designs Four basic guide design types: link, top adjust, outboard, and cassette. Link-style provides design and rolling flexibility Top adjust provides ease of maintenance but limited flexibility Outboard provides ease of maintenance and rolling flexibility but is limited in installation options Cassette design offers strength but increased maintenance and limited installation options All types have design points that must be reviewed for each application and operator preference

Page 44

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Twist Delivery Guides

The main function of the roller twist delivery guide is to apply a force to rotate the rolled bar to the required rotational position for the next rolling stand

The delivery guide insert bore must have clearance for the horizontal and twisted section to ensure no rubbing occurs

The guide roller shape must consider the guide operating capacity, maximum roller diameter, and point of contact for the application of the twisting force

Bearing lubrication and guide roller cooling are key to guide life

Page 45

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Twist Delivery Guides

Calculation of twist at the RE guide rollers

X = Distance from stand to stand

Z = Distance back from stand to RE guide rollers

Y = Distance from stand to Twist guide rollers

T = The required twist angle

(see page 33 in guide design document for illustration)

Page 46

20-Mar-09

R. Stanard

X – Z Y

=

90 o

T

Solve the ratio for ‘T’ where ‘T’ is the twist angle in degrees

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Twist Delivery Guides Layout of guide rollers Show rolled section at calculated twist angle T Rotate rollers to near maximum guide twist Construct tangent on rolled section at 75% W.O.F. Construct gauge diameter between two guide rollers

Page 47

20-Mar-09

R. Stanard

between two guide rollers Page 47 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly Confidential

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Basics of Guide Design

Basics of Guide Design

Roller Twist Delivery Guides

Delivery inserts

Basic design is the same for a delivery guide, either stripper or catcher type The insert must consider the back-twist of the rolled section

for a delivery guide, either stripper or catcher type The insert must consider the back-twist of

Page 48

20-Mar-09

R. Stanard

back-twist of the rolled section Page 48 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services Strictly Confidential

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Guide Roller Bearing Design The proper tools must be used to install any bearings with imparting damage before the bearing is even used Tapered roller bearings for slower speeds and higher load Deep groove ball bearings for higher speeds and longer bearing life Ball bearing spacers must be undamaged to prevent bearing preload when installed

Page 49

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

General Guide Topics

General Guide Topics

Optical Alignment of Guides and Mountings

Bench Optics for use in the roll shop

Portable Optics for use in aligning restbars and guide mounting brackets

System allows for guide life and product tolerances not achievable with mechanical guide setting techniques

Page 50

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Bench Optics Alignment Equipment

Bench Optics Alignment Equipment

Universal bench optics to setup a large range of roller guides in the roll shop

to setup a large range of roller guides in the roll shop Page 51 20-Mar-09 R.

Page 51

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Bench Optics Alignment Equipment

Bench Optics Alignment Equipment

Provides consistent setting of guides in the roll shop by all operators

No variability from operator feel and guesswork using gauge bars or cobbled sections for setup

Superior resolution for precise guide setting and increased guide life and product quality

Calibration matched to Portable Optics system

Page 52

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Optical Calibration

Optical Calibration

Care is taken to calibration match the bench and portable optics to ensure superior precision

Using the same mounting plates and alignment tooling the bench and portable optics are set to the exact same mechanical and optical centerline

are set to the exact same mechanical and optical centerline Page 53 20-Mar-09 R. Stanard GuideDesignBasics.ppt

Page 53

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Portable Optics Alignment Equipment

Portable Optics Alignment Equipment

Unsurpassed finished product tolerances

Alignment Equipment Unsurpassed finished product tolerances Portable optics setting in the NTM Clamped on the X-clamp

Portable optics setting in the NTM

product tolerances Portable optics setting in the NTM Clamped on the X-clamp mounting system Page 54

Clamped on the X-clamp mounting system

Page 54

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Portable Optics Alignment Equipment

Portable Optics Alignment Equipment

Precise positioning of the roller entry guide bracket to the centerline of the roll groove

Used as a tool for checking roll cross indicating…

Worn flingers in cantilevered mill stands Incorrect pass grinding or re-cutting in the mill rolls Worn tapered sleeves on cantilevered mill stands Worn thrust bearings Incorrect mill roll mounting or positioning

rolls Worn tapered sleeves on cantilevered mill stands Worn thrust bearings Incorrect mill roll mounting or
rolls Worn tapered sleeves on cantilevered mill stands Worn thrust bearings Incorrect mill roll mounting or
rolls Worn tapered sleeves on cantilevered mill stands Worn thrust bearings Incorrect mill roll mounting or
rolls Worn tapered sleeves on cantilevered mill stands Worn thrust bearings Incorrect mill roll mounting or

Page 55

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Portable Optics Alignment Equipment

Portable Optics Alignment Equipment

Conditions of roll cross

Portable Optics Alignment Equipment Conditions of roll cross If crossed rolls are found then proper corrective

If crossed rolls are found then proper corrective action procedures must be in place for the operators to make a determination when the billets should be rolled

Page 56

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Results: Maximum Guide Life

Results: Maximum Guide Life

RE-20 guide rolling 5,5mm at 18,100ft/minute (92m/s) 5,831 tons rolled

rolling 5,5mm at 18,100ft/minute (92m/s) 5,831 tons rolled Page 57 20-Mar-09 R. Stanard No changes to

Page 57

20-Mar-09

R. Stanard

(92m/s) 5,831 tons rolled Page 57 20-Mar-09 R. Stanard No changes to rollers or bearings Campaign

No changes to rollers or bearings Campaign completed with no guide changes

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Specialized Guide Topics

Specialized Guide Topics

Multi-strand Slit Rolling of Rebars

The dividing of the billet into 2,3, or 4 bars for the production of multiple finished products in a single strand rolling mill

Page 58

This is done by using a forming pass design to define to areas of the individual finished strands and “slitting” the bar using slitting delivery guides or powered slitting machine

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Multi-strand slit rolling of rebars

Multi-strand slit rolling of rebars
Multi-strand slit rolling of rebars Powered slitting machine Page 59 20-Mar-09 R. Stanard 3-Strand Slitting guide

Powered slitting machine

Page 59

20-Mar-09

R. Stanard

rebars Powered slitting machine Page 59 20-Mar-09 R. Stanard 3-Strand Slitting guide on the Bench Optics

3-Strand Slitting guide on the Bench Optics

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Multi-strand Slit Rolling of Rebars

Multi-strand Slit Rolling of Rebars
Increased production for smaller finished diameters 10mmRebar 140.0 120.0 1 x10mm 2 x10mm 100.0 3
Increased production for smaller
finished diameters
10mmRebar
140.0
120.0
1 x10mm
2 x10mm
100.0
3 x10mm
4 x10mm
80.0
60.0
40.0
20.0
0.0
Rolling Rate (m t/h)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Finishing Speed (m/s)

Page 60

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Multi-strand Slit Rolling of Rebars

Multi-strand Slit Rolling of Rebars

Slit rolling pass sequence example

Page 61 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT LR Services
Page 61
20-Mar-09
R. Stanard
GuideDesignBasics.ppt
MT LR Services

Strictly Confidential

Multi-strand Slit Rolling of Rebars

Multi-strand Slit Rolling of Rebars

Slit rolling pass sequence example

Slit Rolling of Rebars Slit rolling pass sequence example Page 62 20-Mar-09 R. Stanard GuideDesignBasics.ppt MT

Page 62

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Multi-strand Slit Rolling of Rebars

Multi-strand Slit Rolling of Rebars

Higher production of small rebar can be achieved without large capital equipment expenditures

The rolling mill can be operated to its full design capacity for the entire product mix

The product mix can be expanded to small sizes that were not cost effective to produce via conventional rolling methods

Can be easily applied to most bar mill configurations

Page 63

20-Mar-09

R. Stanard

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Siemens VAI Guides

Siemens VAI Guides
Siemens VAI Guides Page 64 20-Mar-09 R. Stanard Guides for all mill types Recent Guiding Projects:
Siemens VAI Guides Page 64 20-Mar-09 R. Stanard Guides for all mill types Recent Guiding Projects:

Page 64

20-Mar-09

R. Stanard

Guides for all mill types

Recent Guiding Projects:

POMINI

MORGAN High speed rod mills worldwide

Rod and bar mills worldwide

ASHLOW

High speed rod mills worldwide

SMS

Rod mill in Saudi Arabia

DEMAG

Bar mill in Saudi Arabia

SIMAC

Rod and bar mill in Egypt

NKK

Bar mill in Egypt

DANIELI

Flexi mill in Saudi Arabia

SKET

Rod mill in Ukraine

VAI

Bar mill in Kuwait

GuideDesignBasics.ppt

MT LR Services

Strictly Confidential

Thank You for your time and attention

Thank You for your time and attention