Rolling Shop Research Articles

Peculiarities of the timing approach to standardizing the productivity of technologically related rolling shops

Peculiarities of the timing approach to standardizing the productivity of technologically related rolling shops

Components of the development of methods for calibrating rollers for rolling channels based on changed non-uniformsty of deformation

Introduction. In metallurgy, the final stage of production is metal processing in rolling shops. The main component of the development of technologies for rolling graded profiles is the calibration of rolls. 90% of the steel that is smelted is processed by rolling. Rolling mill calibration methods are constantly being improved. Calibration methods are used in which there is a significant uneven deformation of the profile elements, which leads to rapid wear of the rolls and an increase in costs. Formulation of the problem. It is necessary to develop a method of calibrating rolls in the production of channels based on the reduction of deformation unevenness. Goal. The purpose of the article is to analyze the methods of calibrating rolls for the production of channels with an indication of their advantages and disadvantages and to justify the application of the components of the developed method of calibrating rolls based on the reduction of unevenness of deformation. The results. The analysis of various methods of calibrating channel rolls showed that the smallest unevenness of deformation is present in the method of rolling by the bending method. The greatest uniformity of deformation along the width of the profile is achieved, the wear of the rolls is reduced in connection with ensuring a minimum difference in the diameters of the rolls in the gauge, and energy costs are reduced. To reduce the uneven deformation of the metal, it is suggested to use a rectangular blank or strip. Scientific novelty. For the first time, the methods of calibrating rolls for channel rolling were analyzed in detail. To reduce uneven deformation of shelves and flanges in the center of deformation in the gauge, it is proposed to use the bending calibration method. It is proposed to use strips as a blank for the first time. Practical meaning. The application of channel rolling technology based on the developed method of calibrating rolls with reduced unevenness of deformation in the first passes allows to reduce the cost of products and give an economic effect

Installation of portals in the sections of the column demolition during the re-equipment of Tagmet JSC workshops

Introduction. The article presents the materials on the activities, carried out in the pipe rolling shops of the Tagmet JSC during the modernization period, starting from 2007. The Research Institute of Building Constructions named after V.A. Koucherenko, conducted prolonged surveys of plant workshop structures in order to issue conclusions on their industrial safety and recommendations for the repair and strengthening of damaged elements in building structures for their further safe operation, including workshops, where the technological process has been changed due to the installation of new equipment.Aim. To demonstrate one of the ways to reconstruct industrial buildings using the example of workshops, located in the territory of the Tagmet JSC, based on a survey of combined structures, calculations and analyzes of their bearing capacity margins.Materials. The article provides the drawings of original metal structures and photographs of steel structures, already built to reinforce them and change the existing parameters of the building frame to suitable ones for new operating conditions.Results. Recommendations for structural strengthening, applicable for similar activities, are given. Due to the scientific and technical support for the design and construction of three modernized Tagmet workshops, the plant continuously increased its productivity in subsequent years.Conclusions. No defects and damage, which exceed the values, established by the current regulatory documents, and affect the operational suitability of buildings, were revealed during the inspection and operational safety examination of Tagmet plant structures. The results of the calculations, performed to the portal structures at the column demolition sections of the plant workshop building frames, proved the assurance of their strength and stability. The design solutions were successfully implemented during the reconstruction of workshops at the Tagmet JSC.

Roosting and nesting ecology of house sparrow (\(\textit{Passer domesticus}\)) in Guwahati city, Assam

Aves are unique in having a coat of feathers and in balancing on the hind limbs alone. They are known as the feathered bipeds. Roosting, nest building in birds has been considered a remarkable behaviour in aves. The nesting ecology of birds is likely the most important component of its life history and it is affected by several ecological and environmental factors. Guwahati city, a rapidly growing city in northeast India inhabits a lot of species of birds. It is located between the Brahmaputra River’s southern bank and the Shillong plateau’s foothills. Total of the 57 nests, 28% were discovered in the rolling shop shutters, followed by 27% in the tin sheet roofs of homes, followed by 19% in building crevices, 9% in building holes, 7% in advertisement hoarding and 5% in AC outdoor units and 5% in unused building pipes. It is also observed that 49% of the nests are located at a height between 2–4 metres from the ground level, 70% of the nests are located between 1–5 metres from the nearest food source, and 58% of the nests are located between 1–5 metres from the nearest water source. Out of the 57 nests observed, 50 were found to be solitary, 5 were found to be Pair, and 2 were found to be cluster type. The study found that choosing a nest is influenced directly by the location of the nearest food source and nearest water source in Guwahati city. The study presents the merit and needs for studying the nesting ecology of birds in India, also suggests best practices to conserve bird’s nest specific to the Indian context which might provide important information for the nesting ecology of House Sparrows (Passer domesticus).

ОБ ИСПОЛЬЗОВАНИИ ОТРАБОТАННЫХ ОПРАВОК ПРОКАТНОГО СТАНА ДЛЯ ИЗГОТОВЛЕНИЯ МАТРИЧНЫХ КОЛЕЦ ПРЕССОВЫХ ЛИНИЙ ТПЦ-2 В УСЛОВИЯХ АО «ВТЗ»

The possibility of using secondary raw materials from waste mandrels of the continuous TPA mill 159-426 mm of the pipe rolling shop TPP-3 in the manufacture of matrix rings (matrices) for the press lines of the pipe-pressing shop TPP-2 of VTZ «JSC» has been confirmed. The approach used allows us to reduce costs, and the development of the metal structure with subsequent heat treatment increases hardness and further increases the durability of pressing tools for pipe production.

PROPANE-BUTANE SUPPLY FOR COKE OVEN AND BLAST FURNACE GAS ENRICHMENT IN REHEATING FURNACES

This article proposes organizational and technical measures to reduce energy consumption of re-heating furnacessection of hot rolling mill 1700 in hot rolling shop No.1 of “ArcelorMittal Temirtau” JSC, such as fuel combustionquality management, performed and presented calculation of energy consumption per unit of production. The industrial experiment was performed there. As it is known, one of the features of re-heating furnaces is the fact that the minimum specific fuel consumption takes place when burning it with the maximum possible pyrometric effect. To solve the research tasks, a fundamentally new 3D model of combustion products motion with the possibility of parameters correction to calculate and optimize the energy-efficient operation of the furnace was applied. Experimental data were obtained on high-precision stationary and portable equipment, metering devices passed state inspection, which excludes the unreliability of the data obtained.

Force calculation and new design of the grip unit pliers metallurgical crane

In the rolling shops of metallurgical enterprises connected with the processing of steel ingots in the preparation (slabbing, blooming) well taps with pincer grabbers are used. Such cranes work in the sections of heating wells, where they are used, first of all, for planting ingots in the well and issuing them for rolling after heating. In addition, cranes can be used to perform auxiliary operations for well maintenance and equipment repair. During the design processing of tong grippers of such cranes, there is a need to determine the ingot clamping forces, which in this gripping device are related to the weight of the ingot itself and the weight of the tongs of the crane. In addition, the design features of the clamping zone itself are of great importance, that is, the design of the parts that transfer the clamping forces to the ingot. These parts are called cores. It is clear that the clamping force and the design of the cores must guarantee reliable retention and safe movement of the ingot. During the operation of the crane, the cores are subjected to a wide range of loads: shock, compressive, crushing loads from impact. At the same time, being in contact with the heated ingot, they themselves heat up to the same temperature. And because they are periodically cooled in tanks with water, they work even in conditions of cyclic heat changes. The design and physical condition of the cores are of great importance for the reliability of the tick gripper. Untimely replacement of cores can lead to negative consequences during ingot retention, cause it to break off with the destruction of the circle, damage to floor equipment and danger to service personnel. Several options for new, more effective designs are proposed in the work based on the force calculation of the pincer gripper and the analysis of the advantages and disadvantages of modern core designs. The authors created a mathematical model of the interaction between the core and the ingot to check the depth of penetration of the core into the body of the ingot and compared it with the indicators of known cores. It was found that at the ingot release temperatures, the depth of penetration into the body of the ingot for cores of the new design is 4 times less than for conventional conical cores. The use of these designs will ensure the reliability of the gripping device while simultaneously improving the quality of the workpiece by reducing the number of cracks and dips associated with damage to the faces of the ingot from deep indentation of the cores

Improvement of the cold rolling mill diagnostic system based on the data base of its electromechanical processes

Purpose. To improve the diagnostic system of the cold rolling mill based on the database of its electromechanical processes, by developing a fuzzy decision-making system as to the condition of the rolling mill electrical drives, which will increase the efficiency of the existing diagnostic system. Methodology. Mathematical and computer modeling. Findings.A fuzzy decision-making system about the state of two interconnected electric drives of the unwinding mechanism and the rolling mill has been developed to investigate and prevent the pre-emergency state associated with the break of the rolling metal strip. The specified decision-making system is built on the basis of a database of electromechanical processes of electric drives of the skin-threat single-celled state of cold rolling of the cold rolling shop No. 1 of PJSC "Zaporizhstal". At the input of this system, the voltage of the armature circuit of the unwinding mechanism motor, the armature circuit current of the unwinding mechanism motor, the tension of the rolled metal strip in the area between the unwinder and the rolling cage are set. At the output, the general state of the system is obtained, which depends on the values of the input data. Information on the value of the tensile strength of the rolled metal strip can be obtained on the basis of the pressure data and voltage sensors, which are installed on industrial equipment. Information about the value of the tension force of the rolled metal strip can be obtained both by installing additional measuring devices and indirectly, using mathematical models of the roll current radius and the linear speed of the rolled metal strip. Originality. The system for diagnosing the condition of cold rolling has been improved by introducing a fuzzy decision-making system into its composition based on a database of electromechanical processes of the electric drives of the unwinding mechanism and the cage, which will allow to prevent an emergency condition caused by a break in the rolled metal strip. Practical value. Prevention of breaking of the rolled metal strip on the basis of an improved system for diagnosing the state of cold rolling, which uses information from the database of its electromechanical processes in order to improve the efficiency of the product quality management process. Using complete organized information and experience of operating a cold rolling mill, you can form technical and technological solutions for the modernization of existing and development of new technological equipment and systems for automatic control of electric drives of rolling mills.

Development of situation models for duration of production cycles of manufacturing finished rolled products. Message 1

The problems of system analysis and development of a complex set of models necessary for constructing an algorithm for situational (multivariant) estimation of the duration of production of different batches of rolled products in the conditions of a modern automated medium-sized shop (object of study), including rigidly connected production sections with continuous and cyclic technological processes (feeding blanks, heating in method furnaces, rolling, cutting the rolled stock into strips, cooling, trimming the ends of the bundles of rolled stock, cutting to cut lengths, forming and tying bundles of finished rolled products, loading bundles into railway cars). The study of the functioning of the rolling shop was carried out in the following order: the study of technological processes; technical characteristics of the main and auxiliary equipment; analysis of technical and economic indicators; performance of chronometric and monitoring observations of the metal flow, the operation of units and equipment; decomposition of the production process into operations, elements and trace elements; analysis of the influence of the human factor in the organization of production and operational management of processes; analysis of expert assessments of real and possible production situations related to the fulfillment of orders for finished products. The duration of production cycles is proposed to be classified as follows: piece (corresponding to a workpiece, a pack of workpieces, a package of finished rolled products); batch (corresponding to the shipment of products); subsystem and system (related to sections, departments, workshop as a whole); technically possible, normative, planned, predictive and actual. Based on the preliminary development of situational batch models of the duration of production cycles of the departments of the shop, a situational system model of the duration of the production cycle for manufacturing a batch of finished rolled products is determined by selecting the models of the unit with the maximum cycle duration. To bring the duration of the production cycles of subsystems and the system as a whole into a comparable form, the quantitative characteristics of rolled products batches are determined. Mathematical models of the duration of the production cycle of the warehouse of blanks are built; technological line. The clock models of work of the warehouse of blanks, the production line, the warehouse of finished products have been formed.

Structural features of buildings from metal structures

The article is devoted to the issue of preserving the architectural heritage of the outstanding Russian engineer V.G. Shukhov. Three objects are considered: the Moscow Radio Tower on Shabolovka, the “Shukhov Prolet” of the Sheet Rolling Shop and the Water Tower, located in the city of Vyksa, Nizhny Novgorod Region. The main design parameters of these structures and the results of their technical examination, the emergency response measures taken to ensure the safety of the Radio Tower in Moscow, and recommendations for the restoration of all three structures with the transfer of the Sheet Rolling Shop and the Water Tower to the central part of Vyksa are presented. It is planned to reconstruct the historical appearance of the buildings, as well as to improve the surrounding area. It is supposed to restore the geometric shape of the section by laser deposition of powder metal, and only if it is impossible to restore the element, its replacement is provided. To preserve the historical appearance, the joints of steel structures will be bolted, imitating rivets. In the course of excavation, archaeological research is planned, since within the boundaries of the construction site (the city of Vyksa) there may be areas of preserved cultural strata of the cultural heritage site “Estate-industrial complex, XVIII-XIX centuries”.

РЕСТАВРАЦИЯ АРХИТЕКТУРНОГО НАСЛЕДИЯ В.Г. ШУХОВА

The article is devoted to the issue of preserving the architectural heritage of the outstanding Russian engineer V.G. Shukhov. Three objects are considered: the Moscow Radio Tower on Shabolovka, the "Shukhov Span" of the Sheet-rolling Shop and the Water Tower located in Vyksa, Nizhny Novgorod region. The main technical parameters of these structures and the results of their technical inspection are presented, emergency measures taken to ensure the safety of the Radio Tower in Moscow and recommendations for the restoration of all three structures with the transfer of the Sheet Rolling Shop and the Water Tower to the central part of the city Vyksa. It is planned to recreate the historical appearance of the buildings, as well as the improvement of the adjacent territory. It is supposed to restore the geometric shape of the cross-section by laser spraying of powdered metal, and only if it is impossible to restore the element, its replacement is provided. In order to preserve the historical appearance, the joints of steel structures will be on bolts imitating rivets. Archaeological investigations are planned during the excavation, as areas of preserved cultural strata of the cultural heritage object "Manor-industrial complex, XVIII-XIX centuries" may lie within the boundaries of the construction territory (Vyksa).

Best available techniques for noise reduction in the iron and steel industry

Iron and steel industry takes a leading position in Russia. Occupational morbidity associated with noise among ferrous metallurgy workers is about a third of the total occupational morbidity. Noise levels at the workplaces of metallurgists and in residential areas exceed the limit values up to 26 dBA. To reduce the impact of noise, the best available technologies are used, the effectiveness of which varies from 3 to 25 dBA. The article describes noise protection measures for blast furnaces, BOF and electric arc furnaces, rolling shops, as well as auxiliary equipment. It is shown that the most effective measures include use of low-noise equipment, use of materials with a high sound insulation and sound absorption index, installation of silencers and soundproof hoods. The usage of measures related to changing the design of equipment and its individual elements can also be considered as promising areas for additional noise reduction.

Features of product quality management of the sheet rolling shop in the production stream

The basic principles and a practical technique developed on their basis for solving the issue of managing technological processes in the production flow (at the pace of the process) are presented. The basic principles of the methodology can be formulated as follows: on the entire technological chain of production, any change in the technological factor (processing mode) at the previous unit (section), which has an impact and can cause a deviation of quality indicators from the task, thanks to the developed methodology, it becomes possible to compensate for them by introducing appropriate corrective actions on the downstream unit. This correction will cause a deviation of the same indicators of the same value, but of the opposite sign, on the monitored batch (or section) of the semi-finished product, which will provide the required level (range) of product quality. A mathematical description of the formulated principles can be built in the form of a multi-response multidimensional mathematical model for the formation of quality indicators within the given batches of semi-product, which is a set of models. A technique for solving a task of this kind is presented on the example of the production of thin-sheet rolled products within the framework of the PJSC NLMK`s dynamo shop.

Guest Editorial: Situational awareness of integrated energy systems

Guest Editorial: Situational awareness of integrated energy systems

Reengineering of the roller hardening machine of the sheet-rolling shop of JSC Ural Steel

In connection with the planned increase in the production of heat-treated rolled products of large thickness and bridge steel at JSC "Ural Steel", it became necessary to increase the productivity of thermal equipment. For this purpose, the roller hardening machine of the sheet rolling shop was re-engineered. Currently, the lifting and lowering of the lifting frame of the hardening machine is carried out by a spindle drive consisting of an electric motor, a bevel gearbox, spindle gears and cardan shafts. In the process of operation, the equipment of the electromechanical drive for lifting and lowering the pressure frame often fails due to the presence of a large number of rubbing elements, and significant labor costs are required to restore the working condition of the unit. To increase the reliability of the hardening machine, it is proposed to carry out its reengineering by replacing the electromechanical drive of lifting and lowering the pressure frame with a hydraulic drive. Replacing the electric drive with a hydraulic drive is advisable because the existing design already has hydraulic equipment, and at the same time a number of advantages are achieved: stepless regulation of the speed of the output link and ensuring small stable speeds; small size and weight; reversing the movement of the output link of the hydraulic transmission; high performance; Protection against overloads, due to the presence of safety valves, etc. The economic efficiency of design solutions is to reduce the cost of one ton of flat products due to a reduction in repair downtime (by 54 hours) and an increase in production (by 0.9%).

Integrated scheduling of hot rolling production planning and power demand response considering order constraints and TOU price

When participating in demand response, the industrial adjustable load has the advantages of large capacity, high benefit, and easy management compared with commercial and residential loads. However, the stage of the production process is strongly coupled with the power consumption process, especially in the steel industry. Here, a multi-objective optimization model for the optimal scheduling of hot rolling load considering the actual production operation conditions was proposed, the model was abstracted into a vehicle routing problem (VRP) ,which is a typical combinatorial optimization problem .To minimize the cost of electricity and the risk of delivery order default, this paper considered the jump penalty value between adjacent slabs simultaneously, constructed an integrated scheduling model of hot rolling shop scheduling and power demand response, and designed a multi-objective production scheduling algorithm based on NSGA-II to solve the problem. The results showed that the proposed method can realize the reasonable distribution of production load under the constraints of electricity price and production.

Production of hot-rolled coils in the casting and rolling complex of MMK Metalurji. Mastering experience, results achieved, prospects for further development

The article describes the practical experience of the foreign asset of the PJSC “Magnitogorsk Iron and Steel Works” - MMK Metalurji, consisting of a “hot” stage (casting and rolling complex (CRC) and a “cold” stage (cold rolling shop, hot-dip galvanizing unit, polymer coating line, metal service center) located at the production site in Iskanderun (Turkey). A brief technical description is given and the main parameters of the units used for the production of continuously cast slabs in the casting and rolling complex are given — an electric arc furnace (EAF), a ladle furnace (LF), a steel degassing unit (SDU) and a continuous casting machine (CCM), as well as advantages and disadvantages of the used concept of mini-mills. Two periods of CRC operation are described: during the starting and mastering of new units and technology (2011–2012), and from July 2021, when the complex was re-commissioned after a long period of conservation. The last part of the article indicates the actual parameters achieved for the period June-September in terms of chemical composition, assortment, standard sizes and productivity. Additionally, information is presented on the content of harmful elements and gas saturation of steel, as well as an assessment of the evolution of macrostructure defects on templates.

Reduction of equipment unplanned downtime during repairs and modernization based on strength analysis

In order to identify bottlenecks in the equipment operation and accumulate data for the development of organizational and technical measures to reduce unplanned equipment downtime, JSC “Vyksa Metallurgical Plant” keeps records of downtime of the main technological equipment. All equipment downtime is recorded by production personnel in the automated analysis system of the workshop. Reliability specialists in the workshops have classified all units into criticality categories, which are presented in the form of a matrix that includes two groups of indicators: 1) severity of the consequences – personnel safety, safety of equipment and environment, production losses, troubleshooting costs; 2) probability of occurrence – high, medium, low, or very low. When determining the criticality assessment of an equipment unit, the most critical case of equipment failure and the worst one are considered. Classification of equipment by criticality categories is used to rank equipment in terms of reliability. The article considers the criteria for operability of machine parts, as well as the main software complexes for strength analysis that exist today. Two have been selected that will be used as strength analysis tools. The analysis of equipment unplanned downtime due to the destruction of parts was carried out on the example of the wheel rolling shop of JSC “Vyksa Metallurgical Plant”, unloaded from the shop automatic analysis system. The authors proposed the directions of application of the selected strength analysis tools and made the strength analysis of equipment parts in order to increase their structural reliability. An assessment of the potential economic effect of introduction of strength analysis tools showed the feasibility of using this innovative approach leading to downtime reduction.

A Production Scheduling Method for Resolving Multiple Equipment Operation Conflicts in Lithium Battery Mills

Due to the wide variety of production orders and complex processes in the lithium battery cell rolling shop, it is easy to cause conflict deadlock problems when multiple devices are operating at the same time, thus blocking the tasks and affecting productivity. In this paper, we build a task scheduling framework for the rolling shop by combining the production process of lithium battery cells, and establish a production scheduling model for the rolling shop by considering the scheduling rules of order splitting and order prioritization. An improved genetic algorithm is proposed to solve the model with the completion time and delay time as the optimization objectives. First, heuristic rules are combined with GLR initialization methods to generate initial populations to improve population quality. Secondly, a simulated annealing algorithm with an elite retention strategy is introduced to screen the new population, and a neighborhood exchange strategy based on order priority ranking is proposed to overcome the problem that the iterative process is prone to illegal solutions. Finally, the encoding method and mutation repair mechanism are improved, and adaptive crossover and mutation operations are used to improve the search capability of the algorithm. The experimental results show that the improved genetic algorithm is feasible and effective in solving the optimization problem of rolling operation shop scheduling, and the algorithm has certain application value in improving the efficiency of smart shop operation.

Technical and economic advantages of using elongating mandrel made of forged blank when rolling on a continuous mill with a controlled‑movable mandrel

In the article, the current problem of reducing the cost of pipe‑rolling products, which is especially acute in the world market of metal products high competition conditions is considered. A significant share in the cost of pipe products stands at the cost of rolling tools. Reducing the cost of buying a deforming tool allows you to make considerable savings in the seamless pipes’ production. The article presents: analysis of the economic efficiency of manufacturing long cylindrical mandrels from a semi‑finished product – forged billet at OJSC «BSW – management company of «BMC» holding»; development of the technological process for the production of long mandrels depending on the required size; the results on the manufacture of long cylindrical mandrels from forged billet at OJSC «BSW – management company of «BMC» holding», as well as their industrial tests in the conditions of the pipe rolling shop. A positive result of using long mandrels of the PQF mill made of forged blanks was obtained.