Cold Rolling Fundamentals


Schedule

5–9 March 2017 • Hyatt Regency Indianapolis • Indianapolis, IN, USA

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Sunday, 5 March 2017

4–6 p.m. 

Registration 

6 p.m.

Welcome Reception

Monday, 6 March 2017

7 a.m.

Registration and Continental Breakfast 

8 a.m.

Introductions and Opening Remarks
Mark Blankenau, HyCAL Corp.

8:10 a.m.

Overview
John Speer, Colorado School of Mines
General overview of products, metallurgy, and processing from steelmaking to finishing, including product properties, end users and applications.

9 a.m.

Break

9:10 a.m.

Cold Rolling Fundamentals
John Speer, Colorado School of Mines
Deformation and metallurgical properties, iron-carbon phase diagram, grain size, stress-strain relationship, work hardening, effects of annealing, effect of percent reduction on R and N values, and effect of composition on properties.

10 a.m.

Break

10:10 a.m.

Rolling Mill Designs
Michael Peretic, SMS USA LLC
This presentation will open with a brief history of rolling technology, and will include a discussion of how material and process needs drove the development of roll stack designs and gap shape actuators. Examples of 2-high, 4-high, 6-high, MKW and cluster mill stack designs will be discussed with regard to their product applications. Finally, various line configurations — including reversing mills, batch tandem mills and continuous tandem mills — will be presented, showing the relative impact on production

11 a.m.

Break

11:10 a.m.

Line Arrangements
Michael Peretic, SMS USA LLC

Noon

Lunch 

1 p.m.

Entry Mill Equipment
Frank Beddings, Primetals Technologies USA LLC

2 p.m.

Break

2:10 p.m.

Mill Exit Equipment
Eric Thokar, Primetals Technologies USA LLC

3 p.m.

Break

3:10 p.m.

Hot Band Requirements for Cold Rolling 

4 p.m.

Break 

4:10 p.m.

Roundtable Discussion

Tuesday, 7 March 2017

7 a.m.

Continental Breakfast 

8 a.m.

Roll Specifications and the Influence on Roll Performance

9 a.m.

Break

9:10 a.m.

Roll Shop Practices
William Jennings, Rockport Roll Shop
Basic understanding of the management of a critical tool for all steel processing units. Mill rolls are costly and can determine the quality of the product.

10 a.m.

Break

10:10 a.m.

Cold Rolling Lubricant Fundamentals
Matthew Knapik and William Hartley, Quaker Chemical Corp.
Basic training in rolling oil chemistry used in the steel cold rolling process. Process control of coolants to optimize mill performance and strip surface quality.

11 a.m.

Break

11:10 a.m.

Rolling Solution Systems

Noon

Lunch 

1 p.m.

Depart for Plant Tour of Nucor Steel–Indiana

5 p.m.

Return From Plant Tour and Adjourn

5:30 p.m.

Reception

Wednesday, 8 March 2017

7 a.m.

Continental Breakfast 

8 a.m.

Hydraulic Systems, Corey Sutherlin, Andritz Metals Inc.

9 a.m.

Break

9:10 a.m.

Inspection for Cold Rolling 
Mark Blankenau, HyCAL Corp.
The specific inspection techniques for cold rolling mills will be discussed. Defect types, root causes and corrective actions will be the focus.

10 a.m.

Break

10:10 a.m.

Cold Rolling Theory
Mark Zipf, Cold Rolling Technologies Inc.
Examination of what’s going on in the roll bite and how the cold reduction/rolling process works. Analytic details of the force-loaded interaction and deformation behavior of the work rolls and material along the longitudinal plane, including methods of modeling and characterizing the rolling process conditions and dynamics.  

11 a.m.

Break

11:10 a.m.

Cold Rolling Theory (cont’d)
Mark Zipf, Cold Rolling Technologies Inc.
Discussion will focus on the practical use of and how to apply this theoretical understanding, including: process design and off-line simulation, what-if scenarios, performance and production prediction, multi-stage reduction/annealing planning, pass scheduling and setup modeling, mill/equipment sizing and selection, operational assistance, and guidance in problem resolution.

Noon

Lunch 

1 p.m.

Automatic Gauge Control
Mark Zipf, Cold Rolling Technologies Inc.
Investigation of the thickness control problem, including available sensors, actuators, control dynamics, perturbation sensitivities and algorithms. Details of the basic automatic gauge control (AGC) modes (in an ideal, fully instrumented, single-stand configuration), their performance characteristics and when/where to use them, including their adaptations for variations in the rolling conditions. Study of critical couplings/interactions between AGC activities, strip tensions, roll bite friction/rolling speed and shape control activities, followed by an expansion to tandem mill configurations and constrained actuation/sensing arrangements. A closing examination of AGC performance characterization and specification.

2 p.m.

Break

2:10 p.m. 

Shape/Flatness Measurement and Control
Mark Zipf, Cold Rolling Technologies Inc.
Introduction into the overall shape/flatness control problem, including specific definitions of profile, shape and flatness. Overview of the distortion phenomena and its sources/formation, including an analysis of the force-loaded transverse roll stack deflection characteristics, thermal reactions and available corrective shape actuators.  Examination of how to measure shape/flatness and the strategies used in contemporary systems. Discussion of the primary components, architecture, and theory of operation of automatic shape/flatness measurement and control systems. A closing examination of shape/flatness control performance characterization and specification.

3 p.m.

Break

3:10 p.m.

Intermediate Concepts and Specials Topics
Mark Zipf, Cold Rolling Technologies Inc.
Exposure to the next level of concepts and approaches, including non-circular arc rolling theories, advanced controls and multi-variable concepts/methods, a closer look at the subtle details of the overall shape/flatness control problem, envelope and control range depictions of mill capabilities, a study of 20-high cluster/Sendzimir Mills (AGC and shape), strategies for different materials and thickness ranges, multi-stage and multi-pass rolling operations, coordination of mill setup/roll crowns, pass scheduling, and shape target progression.

4 p.m.

Break

4:10 p.m.

Roundtable Discussion

Thursday, 9 March 2017

7 a.m.

Continental Breakfast 

8 a.m.

Cold Mill Safety, Phil Littell and Chris Hudson, Nucor Steel–Indiana

9 a.m.

Break

9:10 a.m.

Cold Rolling Operation Bottlenecks — Pickling Line Minus Tandem Mills
Harald Van Bracht, AM/NS Calvert LLC

10 a.m.

Break 

10:10 a.m.

Rolling AHSS
Leland Robinson, Primetals Technologies USA LLC, and Matt Baur, AK Steel Research

11 a.m.

Break

11:10 a.m.

Surface Texture Design
Mark Blankenau, HyCAL Corp.

Noon

Lunch 

1 p.m.

Motors and Drives
Ronald Tessendorf, TMEIC Corp., Curtis Parrott and Barra O’Fathaigh, Nucor Steel-Arkansas
Topics covered include motor types in use, various drive topologies and a review of a cold mill that has experienced many of these configurations since coming on-line in 1998.

2 p.m.

Break

2:10 p.m.

Chatter
Stuart Critchley

3 p.m.

Break

3:10 p.m.

Chatter (cont’d)
Stuart Critchley

4 p.m.

Break

4:10 p.m.

Roundtable Discussion

5 p.m.

Conference Adjourn