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ColdRollingMasterclassShanghai,July2011RobHudsonCONFIDENTIALWhoamI?RobHudson,MetalsScientist–EuropeHonoursdegreeinAppliedChemistryandCharteredChemistWorkforI&DmetalworkinginMonchengladbachGermanyLiveinManchesterintheUKWorkedintechnicalMetalworkingrolessince1988
CONFIDENTIALAgendaColdRollingoverview
-Overviewofmarket
-Introductiontorollingandcoldmill
-Milltypes;problemsandbenefits
-Metallurgylimitations
-Forwardslip–definitionTraditionalapproachestocoldrollinglubrication
-FormulationconceptsSCRFproject
-Classicalevolutionofthetechnology
-ResearchworkCONFIDENTIALColdRolledSteel
CONFIDENTIALGlobalColdMillMarketMarketSectorNumberofMillsMarketValue
M$TotalMarketAnalysed746380CarbonSteel(>1mwide)351325StainlessSteel(>1mwide)16526Others23029TotalMarketValue~USD380millionSalesCONFIDENTIALColdRollingMarketSegments
CoolantandMillTypesCoolantTypeSpecifictoprocess:
CarbonSteel
Emulsionsforcostandhighproduction
StainlessSteelNeatOilforhighsurfacefinishproducts
ElectricalandSpecialSteels
Emulsionsorneatoil
CONFIDENTIALGlobalColdMarket
RegionalandCountrySplitMarketRevenuebyMajorCountriesCONFIDENTIALGlobalColdMarket
TechnicalDrive
Increaseinreductions
-higherdemandforlightergauge;AutoandHDG
-efficiencyofprocessdemands;picklelineandCAPL
-savingthenumberofpassesonreversingmill
-theneedforultrathinorultrahardmaterials
ImprovementsinStripCleanliness
-exitingstripiseithercleanedonrouteasstandaloneprocess(ECL)orincorporatedintocontinuousprocess(CAPL)
-Cheaperoptionis“millcleansheetroute”;wherematerialisonlyannealedbutrequiresgoodqualityrollinglubricantstoannealcleanCONFIDENTIALRollingTheoryLeonardoDeVinciproposedprinciples(1452-1519)ManglesandpastasheetrollersadoptthesamemechanicsCONFIDENTIALRollingTheory-1Rollingisaprogressivereductionatvaryingspeed,ofsheetsteelthickness,toextendlengthbyapplyingverticalforce(load)LoadLoadCONFIDENTIALRollingTheory-2Rollingisaprogressivereductionatvaryingspeed,ofsheetsteelthickness,toextendlengthbyapplyingverticalforce
load
andlongitudinalforce
(tension).tensiontensionLoadLoadCONFIDENTIALColdRollingTheoryEntrysideExitsideNeutralpoint–noslipmeansthestripandrollsarerunningatthesamespeedStripfasterthanrollsRollsfasterthanstripCONFIDENTIALToConsider…..MillType–ReversingorTandemWorkroll
-diameter
-thermalcrown/camber
-flattening
-forcevpressureAreasofrestrictedflowWorkhardeningandannealstressrelief(Slip)CONFIDENTIALChoiceofMill
ProcessandcommercialSinglestand
OperateinreversingsequencesMixedschedules,lowervolumeswithlongertimetorunindividualcoilsthroughthemillGenerallyslowerspeedstypically600–800m/minMuchmoreflexibleapplicationsOftenfirstopportunityforlubricantandmaterialtrials
Tandemmill
Offeraonce-throughcontinuousprocessStandardschedules,highvolumesExtremespeedsoftenwithaccumulatorsinfrontandbehindthemillsoasmillonly‘slowsdown’forweldLowestcostmodelforproduction,hencehighestriskfortrialworkCONFIDENTIALCarbonSteelColdRolling.4or6HighMillsStainlessSteelColdRolling.ColdRolling-MillConfigurationsReversingMillUpto350,000t.p.a.2StandReversingMillUpto800,000t.p.a.TandemMillUpto1,000,000t.p.a.ContinuousTandemMillUpto2,000,000t.p.a.12/20HighReversingMillUpto120,000t.p.a.4/6/ZHighReversingMillUpto150,000t.p.a.ProductionVolume:MillTypeCONFIDENTIAL4highConfigurationExitsideEntrySideReversingsinglestandmills,typical800m/min
Multistagemillssetupintandemwithfirststandfeedingthenext(typ4-6stands)Upto2000m/min
Variableentrygauges(3mmmax)downtovariableexitgauges;autosheet@0.7mm
Typicalreductionperstand/pass@25–40%
Typicalstriptempsonexitupto130°CCONFIDENTIAL4highTandemMillExitsideEntrySideCONFIDENTIAL6highConfigurationBackuprollsIntermediaterollsWorkrollsRollNo2carriestaperCONFIDENTIALSendzimirArrangement–20HighOutokomputrialworkCONFIDENTIALWorkRolls:ForcevPressureAThegreaterthereductionthelargerthecontactarea=largerarearequiresgreaterforcetomaintainunitpressureBThesmallertherollsthesmallerthecontactarea=unitpressuregreatestforsmallerworkrollsMaxreductions=smallworkrollsCONFIDENTIALColdRolling-MillStandTypes2High WRDia650–1050mm4High&6High WRDia400–600mmZHigh(or18High) WRDia100-180mmClusterorSendzimirMill WRDia50-150mm12High,20HighMKWMills WRDia200-350mmWorkRoll:SizeCONFIDENTIALWorkRolls-flatteningNoloadRolling–rollsflattenRollsdeflectedRollingCONFIDENTIALWorkRollsApairofrollsapplyingforcetometalarethemselvesbeingforcedapart–hence+vecamberrequiredtoallowforflatteningCONFIDENTIALWorkRolls-SummaryForexample:Smalldiameterworkroll
=smallerarcofcontact
=highunitpressure
=higherlevelsofdeformationperpass
=butmorepronetobeingdeformeditself
=requirescomplexsupportrollsystemtostopbending/flexing
=thermalcrownisdifficulttocontrol
=rollwearcanbehighCONFIDENTIALWorkRolls:ThermalCrownandCamberNotenoughcoolingandcrowngrowstooverreduceinthecentreToolittlecrownandtheedgesbecomeover-rolledCambermanagedin2ways–grindingorthermalcrownPleaseNote–coolantcontrolISshapecontrolCONFIDENTIALVitalFactorsforRollingPressuretodeformmetaldependson:
1–Hardnessandworkhardening2-Sizeoftheareasofrestrictedflow,whichrelatestotheareaofcontactbetweenstripandroll3–Thedistanceapartfortherestrictedflowzonestopandbottom–i.e..Howmuchfreemetalislefttoflow4–Theamountoflubricationintherollbite–thisremovestheinfluenceofrollroughnessPressurePressurefrictionRegionsofrestrictedflowCONFIDENTIALVitalFactorsforRollingLimitstorollingappearwhen:Asthematerialisrolledthinnerandthinnertheregionsofrestrictedflowaretooclosetogether
-thereislittlefreematerial,unrestrictedbyfriction,todeformAsaconsequencemoreloadisplacedontherolls
-whichinturnflattenstherollsincreasingsurfacecontactareaandmakingtheregionsofrestrictedflowlargerstill
-rollsflattensounitpressureisactuallyreducing
MaterialalsoworkhardensCONFIDENTIALVitalFactorsforRolling
AreasofrestrictedflowStand1Stand2Stand3Bystand3,highresistancetoflow,higherappliedforce,moreflattening–viscouscirclethatwillnotimprovedeformationCONFIDENTIALWorkHardening
Workhardening(strainhardening)isthestrengtheningofamaterialbyplasticdeformation
Strengtheningoccursduetodislocationmovementswithinthecrystallinestructureofthematerial
Themoreseverelyyoudeformthemoreyouharden;thisintroducestheneedforanneal;forstressrelief
Annealfollowedbyselectivere-hardening–throughtemperrolling/skinpass/DCRCONFIDENTIALDefinition:ForwardSlipRollspeed=stripspeedStripmovingfasterthanrolls–neutralpointpushedbackwardsintotheentrysideofthemill=forwardslipCONFIDENTIALSimplifiedColdRollingProcessRouteCONFIDENTIALTargetCarbonSheet
RecirculatingemulsionsCONFIDENTIALColdRolling–MillTypesZHighMill5StandCoupledTandemMillReversingMill3StandTandemMillinDRAPLine20HighMill4HighMillWhatdoesacoldMilllooklike?CONFIDENTIALColdMillLubrication
TheObjectivesFrictionmodification,coolingandfilmdepthtoseparatemetalandworkrolls,aswellasinter-rolllubrication
Levelofrequiredlubricityrequiredaremuchhigherthaninotherdeformationoperations
Thelevelofrequiredlubricityinrollingisdeterminedby:
-Materialrolled,stainless,highcarbon,lowcarbon,HSS,otherwhiteoryellowmetals
-Milltype;Tandem,Reversible,Sendzimir
-Workrollsize,workrollfinishandroughness
-Targetreductionsperstand(orperpass)CONFIDENTIALColdMillLubrication
TheObjectivesFilmstrength,toresistagainstcompressionintherollbite
Thermalstability,higherdemandsonthelubricantwillresultinhigherbiteandrolledstriptemperature;thermaldegradationofthefluidwillrenderitdifficulttoremoveincleaningoranneal
Chemicalstability,thefluidmustresistchemicaldegradation,forexamplehydrolysisandironsoapformation,againdirtystrip
wouldprevail
Plateout,isrequiredonworkrollsandstripsurfacetoprovideasufficientseparatingforceintherollbiteCONFIDENTIALColdMillLubrication
TheObjectivesPolarityoftheoil,thelowerthepolaritythelowertheoilplateoutwhichwillgivecleanersurfacebutlubricationwillbepoorhencelotsofironfines–balance
ParticleSize,iftoosmalltoolittleoilwilladheretostrip
WettingandDetergency,higherthedetergencythelessoilresidualonthesurfaceofthesteel;thisisgoodinthelaststandbutmaymeantoolittleoilinthereductionstands–underlubricationBALANCEISTHEKEY;CleanlinessandLubricationCONFIDENTIALColdMillLubricationOtherpropertiesofcoldmillcoolantinclude:
-needstoberelativelyconsistentandunchanginginuse
-rejectincomingrogueoils/demulsifying
-managemetallicfinestofilters
-offerdetergencyinuse
-offersomelevelofcorrosionresistancetomillhousingandcoil
-needstoannealclean–batchandcontinuous
-operatoracceptable
-offerextendedsumplife
-reducerollwear/lossofroughnesstorolls
-controlthermalstabilityofrollsthroughcoolingCONFIDENTIALTemperMillLubricationRollingThephysicalpropertiesareenhancedbythetemperpassthroughelongation;0.5%–7%max,andinclude:
DimensionaltruenessandrepeatabilitySuppressionofyieldpointelongationImprovedproductsurfacefinish,shapeandflatnessIncreaseproductyieldstrengthanddevelopstiffness
Rollfinishesrangefromgroundandpolishedrollstoimpartabrightfinish,toshot-blastedorelectric-dischargedtexturedrollsthatproduceadull,velvetyfinishonthesteelsurface.CONFIDENTIALStribeckCONFIDENTIALQuickFluidComparisonEmulsionRangeofTechnologyNeatOilsWetTemperContinuousPhaseWater>95%NeatoilWater>95%FilmformingcomponentMixedhighqualityestersCheapesterNone/tracepolymer–highlevelsofcorrosioninhibitorsPhosphorusSpecialistblends–wetting,FMandwearSimpleFMandwettingNoneSulphurSpecialistpacksforEPandannealNotcoreadditiveNoneSurfactantSpecialistandproprietaryNoneYesCONFIDENTIALGlossary
EstersSaponificationValueDefinesthecontent(butnottype)ofesterinthefluidEsteristhefilmformingcomponentPossesseshigherfilmformingcapabilitythanmineraloilSapvaluedefinesperformanceHighSapvaluedefinesshorterchainesters…..i.e.,CoconutC10/C12CONFIDENTIALEstersStructureAlcohol+Acid=Ester+WaterButylstearate=MonoesterTriglyceridePentaerythritolesterPolyester()()PolymeresterRapeseed;PalmCoconutCONFIDENTIALEsterAdsorptionOC=C=C=OOOOOCCCOC=C=C=OOOOOCCCOC=C=C=OOOOOCCCFeFe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+CONFIDENTIALTypicalFattyacidDistribution
Saponifiablematter
CONFIDENTIALGlossary
IodineValue
Iodinevaluemeasurethedegreeofun-saturationonthefattychainItisexpressedas“mgIodineper100goffluid“ThehigherthenumberthedirtierthefattycomponentThelowerthenumberthecleanerthefluidthroughannealandthemoreconsistentitperformsthroughitslifetimeTheun-saturationmeasuredonthetestisintheformofdoublebondsalongthechain–sitesofhighelectrondensitythatwillbepronetoreaction
CoconutoilhasnearzeroIodinevalueandiscleaninannealRapeseedOilhas90–110IodinevalueandisnotcleanbutlubricatesbetterCONFIDENTIALGlossary
AcidvalueAcidvalueisameasureofthefreeaciditywithintheemulsionItisanimportantcriteriaforformulationasacidsprovide:
-boundaryperformance
-somecorrosionprotectionandfilm
-anironscavengingrole
-solubilisingroleforotheradditives
Acidvaluewillincludefattyacids(Oleine),butalsopartialphosphateswherethereisfreeacidityCONFIDENTIALGlossary
EPandAntiwearPerformancechemistrypackagesSulphurdesignedtoenhancefilmformingperformanceandpreventfilmbreakdown,addedbenefitofaidingannealbyreductionofcarbonPhosphorusaddedasfrictionmodifierandantiwearadditive,providingimprovedsurfacefinishestotherolledproduct,acidicnaturecanalsoactasscavengerforironCONFIDENTIALSulphurChemistrySulphurAdditivescanrangeasfollows:
PolysulphidesorSulphurisedunsaturatedprecursors(e.g.ester)Colour(yellowtoblack)Viscosity(40–~2000cst)SulphurContent(8–44%)Smell(mild–hardtocope/toostrong/pungent)CopperStaining(Note0-4)Solubilityinesters(mostlygood–butnotalways)Flashpoint(100->220°C)Price(mediumtoveryexpensive)SulfurAdditivesCONFIDENTIALSulphurisedesters
ModeofactionFe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+SO=CRC=OOOCCCC=OSOSS-SRS2-4S2-4S2-4S2-4S2-4S2-4S2-4[]][(S0-3)SH(S0-3)CONFIDENTIAL
S-S-S-S-SCCS-S-S-S-SCCS-S-S-S-SCCFe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Fe+Polysulfide
AdsorptionCONFIDENTIALPhosphoricacid(ester)
acidic/neutral
Hardtoformulate–synergyandmultitaskingadditivesExpensivechemistryHighperformanceevenatmoderateconc.OptimumoftendifficulttofindinrollingPaletodarkcolourandlittletonosmellPotentialbreakdownproductduringusageProductLabellingWastedisposalcostsCONFIDENTIALPhosphoricacid(ester)R1–O–P–O–R2O=–OH-NH-RR1–O–P–O–R2O=–OR3
Phosphoricester,acidic/neutralPhosphoricester,neutralCONFIDENTIALSurfactantSystemsCationicDispersions
pHcontrolledcationiccharacterHigherlubricityforequivalentsapvalueShearinsensitivesystemwithhighparticlesizeOildropletsplateoutonceagitationceasesandtheemulsionfullysplitsVerytightpHbandforfullcationiccharactermakesthempronetoinfluencefromcontaminationorchangesinwaterqualityCONFIDENTIALSurfactantSystems
Non-ionic
2typesofsystem;withandwithoutpolymerPolymerfreetendtobelessstablesystemsusedwithinsmallermoreturbulentsystemsPolymeractsasstabilisersystemcoatingoildroplettoretainparticlesize–butpreventsfurtherrogueoilemulsif
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