Cold Rolling Fundamentals


Schedule

9–13 September 2018 • The Westin Huntsville • Huntsville, AL USA

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Sunday, 9 September 2018

4–6 p.m. 

Registration 

6 p.m.

Welcome Reception

Monday, 10 September 2018

7 a.m.

Registration and Continental Breakfast 

8 a.m. 

Introductions and Opening Remarks

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. 

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.

9:55 a.m.

Break

10:15 a.m.

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

11:05 a.m.

Line Arrangements
Mike Peretic, SMS USA LLC

Noon

Lunch 

1 p.m.

Entry Mill Equipment
Frank Beddings, Primetals Technologies USA LLC​

1:55 p.m.

Mill Exit Equipment

2:50 p.m.

Break

3:10 p.m.

Cold Mill Upgrades: Modernizing the Status Quo 

4 p.m.

Hot Band Characteristics That Influence Cold Rolling
John Manko, Outokumpu Stainless USA LLC
The purpose is to identify meltshop, hot strip mill and annealing technical parameters and defects that influence cold rolling performance.

4:40 p.m.

Roundtable Discussion

5 p.m.

Adjourn

Tuesday, 11 September 2018

7 a.m.

Breakfast

8 a.m.

Cold Mill Chatter
Stu Critchley, Salvis Group
A few familiar and elementary concepts used in simple vibration theory are reviewed at a basic level. The mechanisms and features of the most common forms of mill vibration are then introduced and illustrated in some detail. In this way, rolling mill chatter and vibration are introduced and explained with continuing reference to the basic mechanics of the main rolling mill components and the fundamental processes happening in the mill roll bite. The last portion of the session is a comprehensive review of causes and control strategies for the chatter or vibration. Explanations are built on the basic interactions between the main mill components and the strip that are analyzed in more mathematical detail in the cold rolling theory and modeling sessions presented by others later in the week

9:50 a.m. 

Break

10:05 a.m.

Roll Specifications and the Influence on Rolling Behavior
Ron Perhosky, Union Electric Steel Corp.​

11:10 a.m. 

Cold Mill Roll Shop Practices
Bill Jennings, Rockport Roll Shop LLC
An overview of practices to safely grind and surface rolls to today’s high quality standards in today’s competitive market. This includes scheduled maintenance of grinder and lathes as well as roll bearings and scheduling of production with the mill changes

Noon

Lunch 

1 p.m.

Depart for Plant Tour of Nucor Steel–Decatur LLC

5 p.m.

Return From Plant Tour

5–6 p.m.

Reception

Wednesday, 12 September 2018

7 a.m.

Breakfast

8 a.m.

Cold Mill Quality and Defects
Liz Hunter, Nucor Steel-Berkeley
An overview of the key elements associated with cold-rolled steel and quality, as well as an overview of common incoming and outgoing defects.

9 a.m.

Cold Mill Safety

9:50 a.m.

Break

10:10 a.m.

Cold Rolling Theory
Mark Zipf, Cold Rolling Technologies Inc.​
This presentation is an 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 are discussed, along the longitudinal plane, including methods of modeling and characterizing the rolling process conditions and dynamics. 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.

11:10 a.m.

Cold Rolling Theory

Noon

Lunch

1 p.m.

AFC Shape/Flatness
Mark Zipf, Cold Rolling Technologies Inc.
This presentation gives an introduction into the overall shape/flatness control problem, including specific definitions of profile, shape and flatness. An overview of the distortion phenomena and its sources/formation is given, including an analysis of the force-loaded transverse roll stack deflection characteristics, thermal reactions and available corrective shape actuators. Included is an examination of how to measure shape/flatness and the strategies used in contemporary systems. Discussion will also focus on the primary components, architecture, and theory of operation of automatic shape/flatness measurement and control systems. At the close will be an examination of shape/flatness control performance characterization and specification

2 p.m.

Automatic Gauge Control
Mark Zipf, Cold Rolling Technologies Inc.
This presentation is an 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) are discussed, as well as their performance characteristics and when/where to use them, including their adaptations for variations in the rolling conditions. A study of critical couplings/interactions between AGC activities, strip tensions, roll bite friction/rolling speed and shape control activities is followed by an expansion to tandem mill configurations and constrained actuation/sensing arrangements. An examination of AGC performance characterization and specification will wrap up the session

3 p.m.

Break

3:20 p.m.

Intermediate Concepts and Special Topics
Mark Zipf, Cold Rolling Technologies Inc.​
This paper will provide 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.

 4:20 p.m.

Roundtable Discussion

5 p.m.

Adjourn

Thursday, 13 September 2018

7 a.m.

Breakfast 

8 a.m.

Cold Rolling Lubricant Fundamentals and Rolling Solutions System
William Hartley, Quaker Chemical Corp.
This presentation will focus on cold rolling lubricant fundamentals. It will include information on key components of rolling oils and how lubrication is important in the cold rolling process.

8:50 a.m.

Rolling Solution Systems

9:40 a.m. 

Break

10 a.m.

Operations and Maintenance of Solution Systems

10:30 a.m.

Hydraulic Systems Troubleshooting

11 a.m.

Inspection for Cold Rolling
Mark Blankenau, HyCAL Corp.
Requirements, methods of work, equipment used, standards and lessons learned will be presented.

Noon

Lunch 

1 p.m.

Rolling AHSS
Leland Robinson, Primetals Technologies USA LLC

2 p.m.

Surface Texture Design
Mark Blankenau, HyCAL Corp.

2:45 p.m.

Break

3 p.m.

Motors and Drives
Ronald Tessendorf, TMEIC
Overview of motors and drives as applied to cold rolling.

3:40 p.m.

Air Blow-Off Systems
Anthony Sobczak, Silvent Intech
Air blow-off systems are the most effective way to completely clean the strip from the center all the way off the edges.

4:10 p.m. 

Operation Bottlenecks

4:40 p.m.

Roundtable Discussion

5 p.m.

Conference Adjourn