Analysis of a Progressive Failure of a Work Roll in Hot Strip Mill

Palit, Piyas; Patel, Subodh Nath; Mathur, Jitendra; Shenoy, Sandeep S

doi:10.1007/s11668-019-00688-w

Cited by 5 publications

(3 citation statements)

References 1 publication

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“…The authors of [17,53,54] have drawn similar conclusions. A previous study [53] showed that the maximum torque under shock load application is 260% of the rated motor torque, while the calculated fatigue life is critical, since it is close to the actual spindle service life.…”

Section: Spindle Designmentioning

confidence: 55%

Telemetry System to Monitor Elastic Torque on Rolling Stand Spindles

Voronin,

Loginov,

Gasiyarova

et al. 2024

JMMP

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This article outlines the relevance of building online telemetry systems for online monitoring of the technical conditions of rolling mill equipment. Electromechanical systems of the horizontal stand of the plate Mill 5000 are described, when operating in harsh conditions caused by the shock loading when workpieces enter the stand. It is noted that dynamic torque overloads, exceeding the rated motor torque by many-fold, cause the fatigue failure of spindle joints and breakage of rolls. In this regard, the development and implementation of systems for monitoring the elastic torque on spindles are extremely urgent. This issue has long been studied, but the references provide no information on the building principles and hardware composition of such systems. The use of strain gauges connected according to a balanced bridge circuit to measure the elastic torque is justified. This paper’s contribution is the proposed modular principle for building a telemetry monitoring system based on the analysis of known techniques for measuring and transmitting diagnostic data. The developed system structure is provided and the concept of data transfer and processing are explained. This article suggests the inductive power supply of a measuring unit mounted on a shaft without the use of batteries. A hardware structure was developed to be applied in a system for measuring, transmitting, and visualizing signals proportional to the elastic torque, manufactured on the basis of data measuring instruments by leading companies. The specifics of placement and connection of strain gauges are considered. The hardware providing a wireless power supply to the signal encoder and digital data transfer between the transmitter and receiver is described. The results of implementing the system on Mill 5000 are provided. The installation of a telemetry ring and a receiving head for the inductive power supply and data reception is shown. An experimental assessment of the elastic torques occurring when workpieces enter the cage was obtained by implementing a drive control algorithm which provided biting in the drive acceleration mode. The reliability of measuring the elastic torque with an error not exceeding ±5% and the reduction of dynamic loads on the spindle by 1.3–1.5 times due to the elimination of impacts from closing angular gaps in spindle joints was confirmed. This increases the service life of mechanical equipment and reduces the cost of eliminating the accident aftermath. The prospect of modifying the developed system into a cyber-physical system for monitoring the rolling mill’s mechatronic equipment conditions is shown.

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Section: Spindle Designmentioning

confidence: 55%

Telemetry System to Monitor Elastic Torque on Rolling Stand Spindles

Voronin,

Loginov,

Gasiyarova

et al. 2024

JMMP

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“…The dispersed interdendritic graphite is the result of the solidification of the residual eutectic liquid that provides an optimum combination of wear life and enhanced thermal shock resistance. In the hot strip mills, the flat slabs, proceeding from continuous casting, are rolled [2]. The rolled slabs are heated to temperatures of 1200 • C or higher, in order to go through a large reduction in the hot strip mill at a range of temperatures between 1100-1200 • C. Subsequently, in the finishing stand, the metal sheet reaches a final reduction for the winding of the metal sheet.…”

Section: Introductionmentioning

confidence: 99%

“…The finishing temperature usually oscillates between 820 • C and 920 • C. The finishing stand is made up of seven rolling stands. The work-rolls of these stands should have a high level of resistance to wear, resistance to rusting, resistance to fracture, and an excellent surface finish [2,3]. The work layer is exposed to periodic cycles of heating and cooling during contact with the metal and subsequent cooling with water.…”

Section: Introductionmentioning

confidence: 99%

Improvement in the Resistance to Wear of Work-Rolls Used in Finishing Stands of the Hot Strip Mills

Cofiño-Villar

Álvarez-Antolín

Alvarez-Perez

2021

Metals

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Work-rolls manufactured through the Indefinite Chill Double Poured (ICDP) method present an exterior work layer manufactured in a martensitic white cast iron alloyed with 4.5 %Ni, 1.7 %Cr, and 0.7 %Nb (wt.%). In its microstructure, there are abundant carbides of the type M3C and MC, which give high resistance to wear, and graphite particles which improve the service behaviour of the rolls against thermal cycling. The core of the rolls is manufactured in grey cast iron of pearlitic matrix and spheroidal graphite. These work-rolls are used in the finishing stands in Hot Strip Mills for rolling slabs proceeding from continuous casting at 1200 °C. Through the application of a Design of Experiments (DoE), an attempt has been made to identify those manufacturing factors which have a significant effect on resistance to wear of these rolls and to find an optimal combination of levels of these factors which allow for improvement in resistance to wear. To increase resistance to wear, it is recommended to situate, simultaneously, the liquidus temperature and the percentage of Si in the respective ranges of 1250–1255 °C and 1.1–1.15 (wt.%). Higher liquidus temperatures favour the presence of the pro-eutectic constituent rather than the eutectic constituent. The outer zone of the work layer, in contact with the metal sheet, which is being rolled, does not show the graphitising effect of Si (0.8–1.15 wt.%). On the contrary, it confirms the hardening effect of the Si in solid solution of the ferrite. The addition of 0.02% of Mg (wt.%) and the inoculation of 6 kg/T of FeB tend to eliminate the graphitising effect of the Si, thus favouring that the undissolved carbon in the austenite is found to form carbides in contrast to the majority formation of graphite.

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