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E-raamat: Steel Rolling: Principle, Process & Application

  • Formaat: 526 pages
  • Ilmumisaeg: 23-Jun-2021
  • Kirjastus: CRC Press
  • Keel: eng
  • ISBN-13: 9781000401745
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Steel Rolling: Principle, Process & ApplicationSuurem pilt
  • Formaat: 526 pages
  • Ilmumisaeg: 23-Jun-2021
  • Kirjastus: CRC Press
  • Keel: eng
  • ISBN-13: 9781000401745
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This book covers all aspects and elements of rolling technology in one volume with even the most technical jargon being communicated in an easy to understand language. The book is exhaustive as topics ranging from rolls, rolls cooling, roll turning, roll reclamation, investigation of roll breakage, roll management and roll bearing all have been dealt in detail as these constitute the most important element of production cost. A separate chapter has been dedicated to operational management of a rolling mill, which includes safety and inventory. Packaging of the finished products and modern operating mill practices and technologies are also discussed in detail. This book will be a useful tool for shop floor personnel and for all senior management operating in the rolling mill industry; it is also a must read for all polytechnic / engineering students of metallurgical / mechanical / process engineering.
This book may also be useful as reference book for students/professionals of rolling technology.


Note: T&F does not sell or distribute the Hardback in India, Pakistan, Nepal, Bhutan, Bangladesh and Sri Lanka.

Pt1 Roll Pass Design 1(58)
1 Introduction
1(1)
2 Roll Pass Design
1(3)
2.1 Object of Roll Pass Design
1(1)
2.2 Basic Purpose of Roll Pass Design
2(1)
2.3 Characteristics of Efficient Roll Pass Design
2(1)
2.4 Specified Conditions Under Which Roll Pass Design is Based Upon
3(1)
2.5 Constraints to Efficient Roll Pass Design
3(1)
3 Characteristics of Hot Rolling
4(18)
3.1 Draft/Draught
4(1)
3.2 Elongation
5(1)
3.3 Spread
5(2)
3.4 Types of Spread
7(2)
3.5 Computation of Spread
9(6)
3.6 Contact Area, Contact Angle, Angle of Bite and Roll Bite Condition
15(2)
3.7 Methods to Improve Roll Biting Conditions
17(1)
3.8 Forward Slip, Neutral Plane and Neutral Angle
18(1)
3.9 Forward Slip in Groove Rolls
19(1)
3.10 Tension
19(1)
3.11 End Thrust
20(1)
3.12 Mill Spring
21(1)
4 Pass
22(5)
4.1 Type of Passes
22(1)
4.2 Classification of Passes
23(1)
4.3 Elements of Passes
24(2)
4.4 Neutral Line of the Pass
26(1)
5 Diameter of Rolls
27(7)
5.1 Average Diameter
27(2)
5.2 Redressing Co-efficient
29(1)
5.3 Roll Collars
29(1)
5.4 Determination of Rolling Diameter
30(1)
5.5 Pitch Line, Line of Rolling
31(1)
5.6 Top and Bottom Pressure (Over or Under Draught)
32(2)
6 Distribution of Draught In A Pass
34(2)
6.1 Principle of the Distribution of Draught
34(1)
6.2 Maximum Reduction
35(1)
7 Roll Pass Design for Non-Uniform Deformation
36(4)
7.1 Analysis of Non-Uniform Deformation
36(3)
7.2 Computation of Draught In Non-Uniform Deformation
39(1)
8 Characteristics of Rolling in Flanged Shapes
40(8)
8.1 Direct and Indirect Draught
40(1)
8.2 Effect of Taper
41(2)
8.3 Effect of Friction
43(1)
8.4 Speed of Rolling in Flange Profile
43(1)
8.5 Asymmetry of Deformation in a Flange Pass
44(1)
8.6 Stages of Rolling in a Flange Pass
45(1)
8.7 Distribution of Draught Among the Elements of Flanged Profile
46(1)
8.8 Features of Deformation in a Closed Web-Cutting Pass
46(2)
9 Consideration for Design of Finishing Passes
48(2)
9.1 Co-efficient of Expansion
48(1)
9.2 Rolling with Negative Allowance
49(1)
10 Specific Feature of Roll Pass Design of A Continuous Mill
50(1)
11 Computation of Power Requirement
51(8)
11.1 Rolling Load
51(1)
11.2 Power Requirement and Rolling Torque
52(4)
11.3 Factors Deciding The Size and Type of Main Drive Motor
56(1)
11.4 Factors Affecting Rolling Load
56(3)
Pt2 Mechanical Working and Rolling Process 59(32)
1 Introduction
59(1)
2 Hot and Cold Working
59(1)
3 Theory of Microscopic Plasticity
60(1)
4 Methods of Metal Working
60(2)
5 Allotropy of Iron
62(1)
6 Iron-Carbon Diagram
62(3)
7 Transformation in steel
65(1)
7.1 Transformation in Eutectoid Steel
65(1)
7.2 Transformation in Hypo Eutectoid Steel
65(1)
7.3 Transformation in Hyper Eutectoid Steel
66(1)
7.4 Critical Temperature
66(1)
8 The Effects of Various Elements on Plastic Properties of Steel
66(1)
9 The Effect of Rolling on Grain Structure
67(1)
10 Definition and Classification of Thermo-Mechanical Processing
68(1)
11 Quenched and Self-Tempered Rebars (QST)
69(2)
12 Stages of Quenching and Self-Tempering Cycle
71(2)
12.1 First Stage
71(1)
12.2 Second Stage
72(1)
12.3 Third Stage
72(1)
13 Main Equipments of TMT Process
73(1)
14 Different Metal Forming Operations
74(2)
15 Rolling
76(2)
15.1 History of Rolling
76(1)
15.2 What is Rolling
76(1)
15.3 Methods of Rolling
77(1)
16 Classification of Products
78(2)
16.1 General Purpose Rolled Sections
79(1)
16.2 Special Purpose Rolled Section
79(1)
16.3 Main Categorization of Rolled Products
79(1)
17 Classification of Rolling Mills
80(8)
17.1 Classification as per Number of Rolls
81(1)
17.2 Classification as per Nos. of Drives in the Mill
82(1)
17.3 Classification as per Products Rolled
83(2)
17.4 Classification As Per Layout
85(2)
17.5 Continuous/Non-continious Rolling Mill
87(1)
17.6 Classification wrt Direction of Rolling
88(1)
18 Special Types Mill
88(1)
18.1 Double Duo Mill
88(1)
18.2 Sandzimar Planetary Mill
88(1)
19 Determination Of Mill Size
89(2)
19.1 Where Rolls are Individually Driven
89(1)
19.2 Where Rolls are Driven by Single Motor Through Pinion Stand
90(1)
19.3 Flat Rolling
90(1)
Pt3 Rolls, Roll Cooling and Roll Management 91(44)
1 Introduction
91(1)
1.1 There are Three Parts in a Roll, Namely
91(1)
2 Classification of Rolls
92(1)
2.1 Classification wrt Purpose
92(1)
2.2 Classification wrt Specific Duty
93(1)
3 Rolls Qualities
93(3)
3.1 Effect of Alloying Elements in Iron and Steel Rolls
93(1)
3.2 Effect of Casting Practice
94(1)
3.4 Quality Classification of Rolls
95(1)
4 Cast Iron Rolls
96(6)
4.1 Grain Rolls
96(1)
4.2 Clear or Definite Chill Rolls (CCCI)
96(1)
4.3 Indefinite Chill Cast Iron Roll (ICCI)
97(2)
4.4 Spheroidal Graphite Rolls (SGCI)
99(3)
4.5 Double Poured or Composite Iron Rolls
102(1)
5 Steel Rolls
102(2)
5.1 Forged Steel Rolls
103(1)
5.2 Cast Steel
103(1)
6 Cementite Carbide Roll (Rings)
104(1)
7 Sleeve Roll
104(1)
8 Selection of Rolls for different category of Rolling Mills
105(2)
8.1 Blooming and Slabbing Mills
105(1)
8.2 Structural Mill
106(1)
9 Proper Care of Rolls
107(3)
9.1 Care During Design
108(1)
9.2 Proper use During Rolling
109(1)
9.3 Care of Roll by Mill Crew
109(1)
9.4 Care to Avoid Over Loading
109(1)
9.5 Other Precautions
110(1)
10 Proper Cooling of Rolls
110(8)
10.1 Methodology of Wear-Out
110(2)
10.2 Factors Affecting Wear-Out of Rolls
112(1)
10.3 What is Proper Roll Cooling
112(1)
10.4 Conventional Roll Cooling
113(1)
10.5 Effective Roll Cooling System
113(1)
10.6 Roll Cooling Parameter
114(1)
10.7 Basic Requirements of Effective Roll Cooling System
115(3)
11 Roll Management
118(5)
11.1 Objective of Roll Management
119(1)
11.2 Roll Inventory
119(1)
11.3 Proper Layout of the Shop
119(1)
11.4 Investigation of Roll Failures
120(3)
12 Reclamation of Rolls
123(6)
12.1 Automatic Submerged Arc Welding
123(2)
12.2 Factors Affecting the Building up of Roll
125(1)
12.3 Pre-heating of Rolls
125(1)
12.4 Post heating or Stress Relieving of Rolls
125(1)
12.5 Process of Arcing
125(1)
12.6 Welding Machine
125(1)
12.7 Welding Head
126(1)
12.8 Fluxes
126(1)
12.9 Preparation of the Job for Weld Deposition
127(1)
12.10 Welding of Rolls
127(1)
12.11 Defects of Welding
128(1)
13 Roll Bearings
129(6)
13.1 Open Journal Bearing
130(1)
13.2 Roller Bearing
131(2)
13.3 Enclosed Oil Film Bearing
133(2)
Pt4 Rolling of Blooms and Slabs 135(30)
1 Introduction
135(1)
2 Ingot
136(2)
2.1 Classification of Ingot
136(1)
2.2 Selection of Dimensions and Design of Ingot
137(1)
3 Mill Proper
138(10)
3.1 Layout
138(1)
3.2 Roll Stand
139(1)
3.3 Stand Housing
139(1)
3.4 Rolls for Primary Mill
140(1)
3.5 Selection of Rolls for Primary Mill
141(1)
3.6 Bearing for Primary Mill
142(1)
3.7 Top Roll Adjustment System
142(2)
3.8 Spindles for Primary Mill
144(1)
3.9 Roll Speed
144(1)
3.10 Main Drives of Motor
145(1)
3.11 Roll Tables, Manupalaters of Mill
146(1)
3.12 Shears for Primary Mill
146(2)
3.13 Scale Disposal for Mill
148(1)
4 Comparative Study of Blooming Mills
148(1)
5 Roll Pass Design for Blooming Mill
149(2)
5.1 Pattern of Reduction
149(1)
5.2 Arrangement of Grooves in Blooming Mills Rolls
150(1)
6 Types Of Passes used hi Blooming Mills
151(1)
7 Size and Shape of Pass
152(1)
7.1 Height of Pass (H)
152(1)
7.2 Width of Pass
152(1)
7.3 Taper
152(1)
7.4 Corner Radii
152(1)
7.5 Pass Convexity
153(1)
7.6 Roll Collars
153(1)
8 Bottom Pressure
153(1)
9 Turning of the Workpiece
153(1)
10 Roll Pass Design Data Sheet of Blooming Mills
153(3)
10.1 Rolling Schemes for Rolling Different Size of Blooms/Beam Blanks
155(1)
11 Pass Design of Blooming Mill
156(2)
11.1 Barrel or Bullhead Pass
156(1)
11.2 First Pass
157(1)
11.3 Second or Finishing Pass
157(1)
11.4 Beam Blank
158(1)
12 Defects in Bloom Rolling
158(7)
12.1 Defects due to Rolling
158(2)
12.2 Defects due to Steel
160(1)
12.3 Defects due to Bad Heating Practice
161(4)
Pt5 Rolling of Billets 165(52)
1 Introduction
165(1)
2 Types of Mill and General Layout
165(8)
2.1 Open Train Billet Mill
167(1)
2.2 Cross Country Billet Mill
168(1)
2.3 Continuous Billet Mill
168(5)
3 Specific Features of Continuous Mill
173(2)
3.1 Advantages of Individually Driven Stand Over Group Combined Driven Stand
174(1)
4 Pass Design Details of Billet Mill
175(4)
4.1 Open Box Pass
175(1)
4.2 Diamond-Diamond System
175(2)
4.3 Diamond-Square Sequence
177(1)
4.3.1 Advantages of Diamond-square System
178(1)
4.3.2 Disadvantages of Diamond-Square Sequence
178(1)
4.4 Oval-Square System
178(3)
4.4.1 Advantages of Oval-square System
179(1)
4.4.2 Disadvantages of Oval-square System
179(1)
5 Selection of a Pass Sequence
179(1)
6 Comparative Study of Billet Mills
180(1)
7 Layout of Continuous Billet Mill
180(1)
8 Roll Pass Design of Billet 90 mm x 90 mm
181(34)
8.1 Details Regarding Input Bloom and Finished Product
182(1)
8.2 Details Regarding Mill
182(1)
8.3 Tolerance of Billet
183(1)
8.4 Computation of Reduction
183(2)
8.5 Roll Pass Design of Finishing Group
185(14)
8.6 Roll Pass Design of Roughing and Intermediate Group
199(15)
8.7 Rolling Scheme of Billet 90 x 90 mm From Bloom 325 x 325 mm with Intermediate Size of 150 x 150 mm
214(1)
9 Defects in Billet Rolling
215(2)
9.1 Defects Due to Bad Rolling
215(2)
Pt6 Rolling of Rounds and TMTS Bars 217(42)
1 Introduction
217(1)
2 Selection of Rolling Sequence
218(3)
2.1 First Method
219(1)
2.2 Second Method
220(1)
2.3 Third Method
220(1)
2.4 Fourth Method
220(1)
2.5 Fifth and Sixth Method
220(1)
2.6 Seventh, Eighth, Ninth and Tenth System
220(1)
3 Rolling Tolerances of Rounds as per BIS Specification
221(1)
3.1 On Size of Round
221(1)
3.2 Ovality or Out of Square
221(1)
3.3 Weight
221(1)
4 Design of Passes
221(7)
4.1 Design of Finishing Pass
221(3)
4.1.1 Height of Finishing Pass
222(1)
4.1.2 Width of Pass
222(1)
4.1.3 Roll Gap
223(1)
4.1.4 Radius of Finished Pass
223(1)
4.2 Design of Pre-finishing Oval Pass
224(1)
4.2.1 Height of Oval
224(1)
4.2.2 Width/Height Ratio of Oval Pass
225(1)
4.2.3 Radius of oval
225(1)
4.2.4 Outer radius r of Oval Pass
225(1)
4.2.5 Area of Oval Pass
225(1)
4.3 Design of Strand Pass
226(1)
4.3.1 Strand Plug oval/edge Oval
226(1)
4.3.2 Strand Square
227(1)
4.3.3 Strand Round
227(1)
4.4 Design of Following Passes in Rolling Sequence
227(1)
5 Rolling Scheme of Round-32 mm
228(1)
6 Roll Pass Design R-32 mm
228(4)
6.1 Stand-12 (Finishing Pass)
228(1)
6.2 Pass-11 (Pre-finishing Pass)
229(1)
6.3 Pass-10 (Strand Pass)
229(1)
6.4 Pass-8 (Rd-32-36 Pass)
229(1)
6.5 Pass-6 (Rd-32-36 Pass)
230(1)
6.6 Pass-4 (Rd-32-36 Pass)
230(1)
6.7 Roll Design of Finishing Pass
230(1)
6.8 Roll Design of Pre-finishing Pass
231(1)
6.9 Roll Design of Strand Pass
231(1)
7 Layout of Merchant Mill
232(1)
8 Rolling of TMT Bars
232(4)
8.1 Process of TMT
232(1)
8.2 Comparison of Different TMT Grades
233(1)
8.3 The Effect of Carbon Equivalent on Weldability
234(1)
8.4 Rib Design
234(1)
8.5 Control Data for Thermo Mechanically Treated Wire Rods/Baps
235(1)
8.6 Roll Pass Design of TMT-32
235(1)
9 Oiling Defects and its Solution
236(4)
9.1 Ovality
236(1)
9.2 Diagonal Difference
237(1)
9.3 Fin
237(1)
9.4 Under-Filled
238(1)
9.5 Fish-tail
238(1)
9.6 Lap
238(1)
9.7 Worn out Mark
238(1)
9.8 Pipe Formation in TMT
239(1)
9.9 Pass Mark
239(1)
10 Mill Setting of Rounds/TMTS
240(4)
10.1 Twisting
240(2)
10.2 Bending of Bars (Side Ways)
242(1)
10.3 Bend up and Down
242(1)
10.4 Slipping in Stands
243(1)
10.5 Rolling Scheme
243(1)
10.6 Pass Positioning and their Dimensions
244(1)
11 Major Points during Rolling
244(3)
11.1 Setting of Roughing group
244(1)
11.2 Setting of the Intermediate Group
244(1)
11.3 Setting of The Finishing Group
245(2)
12 Slit Rolling of Bars
247(9)
12.1 Why Slitting is Required
247(1)
12.2 Sections Produced by Slit Rolling
248(1)
12.3 The Process of Slitting
248(3)
12.4 Control of Loop Heights between Stands 4 and 5 and 5 and 6
251(1)
12.5 Method of Slitting
251(2)
12.6 Slitting and Slit Guide
253(2)
12.7 Problems Faced During Slit Rolling and its Solutions
255(1)
13 Mill Setting problem during Slitting
256(3)
13.1 Rib Height below Tolerance on Both the Top and Bottom of The Bar
256(1)
13.2 Rib Height Below Tolerance on Either the Top or Bottom of the Bar
256(1)
13.3 Oval With Unequal Fill Due to Misalignment of the Entry Guide
256(1)
13.4 Small Kinks Every 1 to 1.2 m
256(1)
13.5 Lap
256(1)
13.6 Variations in Filling Between Strands
257(2)
Pt7 Rolling of Flats and Squares 259(24)
1 Introduction
259(1)
2 Selection of Rolling Sequence for Rolling Flats
259(5)
3 Roll Pass Design for Flat 50 x 12 - 16 mm
264(4)
3.1 Selection of Mill, in which section is to be rolled
264(1)
3.2 Customer's Requirement wrt Specification, Tolerance etc.
265(1)
3.3 Rolling Scheme for Flat 50 x 12 & 50 x 16
266(1)
3.4 Pass Design of Flat 50x 12 & 50x 16 mm
266(1)
3.5 Design of Pre-finishing Pass (Pass-11-Vertical Stand-Edging Pass)
267(1)
3.6 Pass-7 (Vertical Stand-Intermediate Group)
267(1)
4 Mill Setting and Section Control
268(1)
5 Inspection and checking of dimensions of flat sections
269(1)
6 Defects and its Rectifications
270(2)
6.1 Round Edges (convex)
270(1)
6.2 Concave Edges
270(1)
6.3 Dished
270(1)
6.4 Dished and Convexed
271(1)
6.5 Wedge
271(1)
6.6 Opposite Diagonals Rounded
271(1)
6.70 Rhomboid
271(1)
6.8 Sticker Mark - Due to Sticking of Metal on the Edger
271(1)
6.9 Wear out Mark on Top and Bottom Edges-Due to Worn out Flat Pass or Edger
271(1)
6.10 Lap- due to Fin from edger
272(1)
6.11 Diagonal Difference
272(1)
7 Rolling of Spring Steel Flats
272(1)
8 Guides used in Flat Rolling
273(2)
8.1 Entry Guide
273(1)
8.2 Delivery Guide
273(2)
9 Rolling of Squares
275(1)
10 Selection of Rolling Sequence for Rolling Square
275(3)
11 Roll Pass Design of Square-50 mm
278(3)
12 Rolling Scheme for Square
281(1)
13 Defects and its Rectifications
282(1)
13.1 Overfill
282(1)
13.2 Under Fill
282(1)
13.3 Lap
282(1)
13.4 Offsquare
282(1)
Pt8 Rolling of Angles 283(38)
1 Introduction
283(1)
2 Types of System used for Angle rolling
283(2)
3 Selection of Rolling System
285(1)
4 Salient Features of Rolling Angle
286(2)
4.1 Selection of Mill Size
286(1)
4.2 Design of Finishing Pass
287(1)
4.3 Computation of the Size of Billet
287(1)
4.4 Co-efficient of Deformation
288(1)
5 Modern Method of Rolling Angles
288(3)
5.1 Roll Pass Design of Equal Angle
289(1)
5.2 Selection of Mill
289(2)
5.3 Customer's Requirement wrt Specification, Tolerance etc.
291(1)
6 Pass Design of Angle 55 x 55 x 6 mm
291(15)
6.1 Design of Finishing Pass
291(1)
6.2 Computation of Thickness of other Passes of Angle Rolling
292(1)
6.3 Pre-finishing Pass (Stand -10)
293(2)
6.4 STRAND PASS (Stand-09)
295(2)
6.5 Intermediate Group
297(5)
6.6 Roughing Group
302(4)
7 Rolling Computation Sheet for Angle 55 x 55 x 6 mm
306(1)
8 Roll Pass Design of Unequal Angles
306(5)
8.1 Design of Finishing Pass
307(3)
8.2 Determination of Sizes of other Passes
310(1)
8.3 Computation of Prefinishing Pass
310(1)
9 Mill Setting of Angle Rolling
311(5)
9.1 Setting of Roughing and Intermediate Stands
311(4)
9.2 Setting of Finishing Stands and Profiles for Angle Rolling
315(1)
10 Defects and its Rectification
316(5)
Pt9 Rolling of Channels 321(38)
1 Introduction
321(1)
2 Methods of Pass Design
322(4)
2.1 Conventional Method of Rolling Channel
322(3)
2.2 Modern Method of rolling Channel
325(1)
3 Salient Feature of Channel Pass Design
326(9)
3.1 Draughting
326(1)
3.2 Work Feature
327(1)
3.3 Fillets
327(1)
3.4 False or Counter Flange
328(1)
3.5 Profile Radii
329(1)
3.6 Spread in Channel Rolling
330(3)
3.7 Pitch Line Location
333(1)
3.8 Condition of Entry of Strip Into Pass
333(1)
3.9 Guides Used in Channel Rolling
334(1)
4 Roll Pass Design for Channel 100 x 50 mm
335(4)
4.1 Selection of Mill
335(1)
4.2 Customer's Requirement wrt Specification, Tolerance etc.
336(1)
4.3 Selection of Billet
337(1)
4.4 Determination of Co-efficient of Reduction for the Different Elements of Channel Design
338(1)
5 Computation of Elements of Pass Design
339(12)
5.1 Design of Finishing Pass
340(4)
5.2 Pre-finishing Pass (Pass-10)
344(1)
5.3 Strand Pass (Pass-9)
345(1)
5.4 Pass-8
346(1)
5.5 Pass-6
347(1)
5.6 Pass-5
348(1)
5.7 Pass-3
349(1)
5.8 Pass-2
350(1)
5.9 Stand-1
350(1)
6 Mill Setting of Channel
351(2)
7 Defects of Channels and its Rectification
353(6)
Pt10 Rolling of Beam 359(38)
1 Introduction
359(1)
2 Methods of Beam Design
359(3)
2.1 The First Method
359(1)
2.2 Second Method
360(1)
2.3 Third Method
361(1)
2.4 Fourth Method
361(1)
3 Mill Layout
362(1)
3.1 Conventional Rail & Structural Mill
362(1)
3.2 Universal Rail and Structural Mill
363(1)
3.3 Continuous Combined Bar and Structural Mill
363(1)
4 Special Features of Beam Design
363(2)
5 Important considerations for Roll Pass Design of Beam
365(6)
5.1 Selection of Bloom Size and Numbers of Passes
365(1)
5.2 Advantage of using Beam Shaped Bloom/Billet
365(1)
5.3 Elements of Beam Section
366(1)
5.4 Draughting Strategy for Beam Design
367(1)
5.5 Spread
367(1)
5.6 Flange Design
368(1)
5.7 Buckling of Web
369(1)
5.8 Fillets
369(1)
5.9 Thrust
370(1)
6 Roll Pass Design of Beam 125 x 70 mm
371(7)
6.1 Selection of Mill
371(2)
6.2 Customer's Requirement wrt Specification, Tolerance etc.
373(1)
6.3 ISMB-Details of Specification as Per BIS
373(1)
6.4 Design of Finishing Pass
373(2)
6.5 Selection of Billet
375(1)
6.6 Determination of Co-efficient of Reduction for the Different Elements of Beam Design
376(2)
7 Computation Sheet for Beam 125 x 70 MM
378(2)
7.1 Computation Sheet for Flange
378(1)
7.2 Computation for The Web
379(1)
7.3 Computation for Pass height, Pass Area
379(1)
8 Pass Design of Beam 125 x 70
380(8)
8.1 Pass Design of Finishing Stand (12th)
380(1)
8.2 Design of Pre-finishing Stand (10th)
380(1)
8.3 Design of Strand Pass (9th)
381(1)
8.4 Intermediate Group (Stand-8)
382(1)
8.5 Intermediate Group (Stand-6)
383(1)
8.6 Design of Pass-5
384(1)
8.7 Design of Pass-3
385(1)
8.8 Design of Pass-2 ("V" Pass)
386(1)
8.9 Design of Pass-1
387(1)
9 Rolling Scheme for Beam 125 x 70
388(1)
10 Mill Setting of Beam
388(1)
11 Control of Weight of Beam Section
389(2)
12 Special Precaution is to be taken during Beam Rolling
391(1)
13 Defects of Beam and its rectification
391(6)
Pt11 Rolling of Rail 397(42)
1 Introduction
397(2)
2 Development Trends
399(1)
3 Rail Shaping Practice
400(6)
3.1 Conventional System
400(2)
3.2 Basics of Rail Design
402(4)
4 Salient Features of Rail Pass Design
406(8)
4.1 Draughting
406(1)
4.2 Design Efficiency
407(1)
4.3 Roughing Pass Design
407(1)
4.4 Combination Rolls
408(1)
4.5 Proper Pass Distribution
408(1)
4.6 Size of Bloom
409(1)
4.7 Rolling Temperature
409(1)
4.8 General Consideration
409(1)
4.9 Mill Setting
410(1)
4.10 Diagonal Rolling
411(2)
4.11 Bearing Collars
413(1)
4.12 Roll Spring
413(1)
4.13 Roll Diameter
414(1)
5 Conventional Rail and Structural Mill
414(3)
5.1 Rail Specification
415(1)
5.2 Layout of Rail and Structural Mill
415(1)
5.3 Details of Equipments: Mill and Furnace
415(1)
5.4 Details of Major Equipments in Finishing Area
416(1)
5.5 Welding
417(1)
6 Rail Testing
417(1)
7 Roll Pass Design for RAIL
418(10)
7.1 Rolling Scheme of Roughing line
419(2)
7.2 Rolling Scheme of Finishing Line
421(1)
7.3 Pass Design of Individual Pass in Finishing Line
422(4)
7.4 Computation Sheet for Rail Design
426(1)
7.5 Graph for computation of Co-efficient of Reduction
426(2)
8 Universal Roll Pass Design
428(4)
8.1 Advantages of Shaping in Universal Pass
430(1)
8.2 Mill Configuration with Universal Rolling Practice
430(1)
8.3 Layout of Finishing Line
431(1)
9 Defects and Its Rectifications
432(7)
9.1 Steel Defects
432(1)
9.2 Mill Defects
433(3)
9.3 Finishing Defects
436(3)
Pt12 Operation, Safety and Quality Management 439(20)
1 Operation Management
439(11)
1.1 Principal Elements of the Operation Management
439(2)
1.2 Technological Instruction on Preparation of Rolls and Rolling in Light Structural Mill
441(2)
1.3 Precautions to be Taken During Roll Changing
443(1)
1.4 Points/areas to be Checked after Roll Changing
444(2)
1.5 Starting the Mill After Major Roll Changing
446(1)
1.6 Examination of the Finished Products
447(1)
1.7 Technical and Economical characteristics of Rolled Metal Production
448(2)
2 Safety Management of Rolling Mill
450(1)
2.1 Accident Prevention Regulations in the Rolled Metal Production
450(1)
3 Quality Management in Rolling Mills
451(8)
3.1 Quality concept of Products
451(1)
3.2 Reliability, Availability and Maintainability of Products
452(1)
3.3 Rolled Product Quality Control
453(2)
3.4 Quality Control in the Production of Rolling Products
455(2)
3.5 Requirement of TMT Rolling
457(2)
Pt13 Packaging of Steel Products 459(10)
1 Introduction
459(1)
2 Objective
459(1)
3 Concepts of Packaging
460(5)
3.1 Role of Packaging
460(1)
3.2 Theoretical Aspects of Packaging
461(2)
3.3 Approach to Packaging Design
463(1)
3.4 Importance of Steel Product Packaging
464(1)
3.5 Advantages of Packaging of Steel Products
465(1)
4 Packaging of Long Products
465(4)
4.1 Piling
465(1)
4.2 Bundling
466(1)
4.3 Binding
467(2)
Pt14 Energy Efficient Practices and Technologies 469(26)
1 Introduction
469(1)
2 Role of Reheating Furnace
470(2)
2.1 Type of Furnace
470(1)
2.2 Purpose of Heating Metal for Rolling
471(1)
2.3 Problem Associated with Heating
471(1)
3 Operational Energy Efficient Improvement Practices in Furnace and Mill
472(7)
3.1 Optimal Operation of Combustion System
472(1)
3.2 Optimization of Thermal Regimes
473(1)
3.3 Furnace Pressure Regimes
473(1)
3.4 Hot Charging of Material
473(1)
3.5 Furnace Productivity
474(1)
3.6 Hearth Coverage
474(1)
3.7 Use of Coil Box
475(1)
3.8 Unfired Preheat Zone
475(1)
3.9 Recovery of Waste Energy
475(1)
3.10 Stack Efficiency
476(1)
3.11 Thermal Cover of Roll Table in the Mill
476(1)
3.12 Computer/combustion Control Model
476(1)
3.13 Discharge Temperature
477(1)
3.14 Using Higher Mill Speed
477(1)
3.15 Using Bigger Diameter Roll
477(1)
3.16 Running Mill Concept
478(1)
3.17 Establishing Communication System Between Furnace and Mill Proper
478(1)
3.18 Idle Running of the Mill
478(1)
3.19 Automatic Stoppage of Mill Drives/Roll Tables
478(1)
3.20 Use of VVVF Drives with Air Blowers and Auxiliaries
478(1)
4 Use of Energy Efficient Operating Technologies
479(1)
5 Improvement in The Rolling of Rebar Technology
480(9)
5.1 Reheating
480(1)
5.2 Low Temperature Rolling
480(1)
5.3 Increased Capacity
481(5)
5.4 Dimensional Tolerances
486(1)
5.5 Endless Welding and Rolling (EWR)
486(2)
5.6 Improved Mill Utilization
488(1)
5.7 Size-free Rolling
488(1)
5.8 Thermo-Mechanical Treatment (TMT) Process
489(1)
6 Recent Developments in Production of Structurals
489(6)
6.1 Size-Free Rolling of H-shapes
490(1)
6.2 Quenching and Self Tempering (QST) Process for Structural Steel
491(2)
6.3 Endless Welding and Rolling (EWR) for Structural Steel
493(1)
6.4 High Precision Rolling (HPR)
493(1)
6.5 In-line Head Hardening of Rails
493(1)
6.6 Vanadium Steels
494(1)
Index 495
N.K. Gupta, Managing Consultant, Roll Pass Design Solutions
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