presentation of cold rolling
TRANSCRIPT
HERO CYCLES(C.R.DIVISION)HERO CYCLES(C.R.DIVISION)
PRESENTED BY:PRESENTED BY:
P.N.MISHRA P.N.MISHRA
PLANT OVERVIEWPLANT OVERVIEW
COMPANYCOMPANY PROFILEPROFILE
DATE OF COMISSIONINGDATE OF COMISSIONING JULY JULY 19911991
PLOT AREAPLOT AREA 12 ACRE12 ACRE BUILT UP AREABUILT UP AREA 9 ACRE9 ACRE
HERO GROUP COMPANIESHERO GROUP COMPANIES HERO CYCLES LTD.HERO CYCLES LTD. HERO HONDA LTD.HERO HONDA LTD. MUNJAL SHOWAMUNJAL SHOWA MUNJAL CASTINGSMUNJAL CASTINGS MUNJAL AUTOMUNJAL AUTO ROCKMAN CYCLEROCKMAN CYCLE MAJESTIC AUTOMAJESTIC AUTO HERO CYCLES - C.RDHERO CYCLES - C.RD HERO MOTORSHERO MOTORS SUNBEAM CASTINGSUNBEAM CASTING
BICYCLEBICYCLE MOTOR BIKEMOTOR BIKE SHOCK ABSORVERSSHOCK ABSORVERS NON FERROUS CASTINGSNON FERROUS CASTINGS AUTO PARTSAUTO PARTS AUTO & BICYCLES CHAINAUTO & BICYCLES CHAIN MOPEDMOPED CR STEEL STRIPSCR STEEL STRIPS HERO PUCHHERO PUCH NON FERROUS CASTINGSNON FERROUS CASTINGS
HERO GROUP COMPANIESHERO GROUP COMPANIES HERO MINDMINEHERO MINDMINE HERO TECHTOUCHHERO TECHTOUCH HERO SERVITHERO SERVIT
TRAINING & EDUCATIONTRAINING & EDUCATION ERP/SAPERP/SAP ITIT
PRODUCTPRODUCT
COLD ROLLED COLD ROLLED STEEL STRIPSSTEEL STRIPS THICKNESSTHICKNESS 0.15 - 5.0 MM0.15 - 5.0 MM WIDTHWIDTH 20 - 760 MM20 - 760 MM GRADEGRADE D/DD/EDD/IF/MC-D/DD/EDD/IF/MC-
11/12/HC11/12/HC FINISHFINISH BRIGHT/DULLBRIGHT/DULL SHAPESHAPE COIL/SHEETCOIL/SHEET WEIGHTWEIGHT 150-12000 KGS150-12000 KGS
LIST OF SEGMENTLIST OF SEGMENT
BICYCLE INDUSTRIESBICYCLE INDUSTRIES AUTOMOTIVE INDUSTRIESAUTOMOTIVE INDUSTRIES ELECTRICAL INDUSTRIESELECTRICAL INDUSTRIES CONTAINER INDUSTRIESCONTAINER INDUSTRIES WHITE GOODS INDUSTRIESWHITE GOODS INDUSTRIES TRACTOR INDUSTRIESTRACTOR INDUSTRIES PICTURE TUBESPICTURE TUBES COSMETIC ITEMSCOSMETIC ITEMS
UTILITIESUTILITIES
CONNECTED LOADCONNECTED LOAD 19228.23 KW19228.23 KW CONTRACT DEMANDCONTRACT DEMAND 12500KVA12500KVA
H.R.SLITTERH.R.SLITTER TO CUT THE WIDE COIL INTO NARROW TO CUT THE WIDE COIL INTO NARROW
COILAS PER THE REQUIREMENT OF COLD COILAS PER THE REQUIREMENT OF COLD ROLLING MILLROLLING MILL
TO CONTROL THE O.D. OF THE COIL AS TO CONTROL THE O.D. OF THE COIL AS PER THE REQUIREMENT OF MILLPER THE REQUIREMENT OF MILL
IN CASE OF SINGLE SLIT TO REMOVE THE IN CASE OF SINGLE SLIT TO REMOVE THE CRACKED / DAMAGE EDGE CRACKED / DAMAGE EDGE
H.R.SLITTERH.R.SLITTER
PINCH ROLLERPINCH ROLLERFLATTNERFLATTNER ROLLERROLLER DEFLECTORSDEFLECTORS
UNCOILERUNCOILER
RECOILERRECOILER SHEAR UNITSHEAR UNIT SCRAP WINDERSCRAP WINDER
ARBORARBOR
DIRECTION OF OPERATIONDIRECTION OF OPERATION
GUIDE ROLLSGUIDE ROLLS
DEFECTS IN H.R. COILSDEFECTS IN H.R. COILS
SLIVERSSLIVERS SEAM LINESSEAM LINES ROLLED IN SCALEROLLED IN SCALE PITTINGPITTING LAMINATIONLAMINATION CENTRE LOOSENESSCENTRE LOOSENESS
PICKLING MACHINEPICKLING MACHINE
PICKLING IS THE PROCESS OF MILL SCALE PICKLING IS THE PROCESS OF MILL SCALE REMOVAL WITH THE HELP OF ACIDREMOVAL WITH THE HELP OF ACID
H2SO4 , HCL , HF , HNO3H2SO4 , HCL , HF , HNO3 HCL IS USED FOR THE PICKLING OF HCL IS USED FOR THE PICKLING OF
CARBON STEELCARBON STEEL HCL PICKLING PROVIDES SMUT FREE HCL PICKLING PROVIDES SMUT FREE
SURFACE SUITABLE FOR COLD ROLLING , SURFACE SUITABLE FOR COLD ROLLING , ELECTROPLATING , ETCELECTROPLATING , ETC
PICKLINGPICKLING
UNCOILERUNCOILER RECOILERRECOILER
FLATTNER FLATTNER ROLLERROLLER
SHEAR UNITSHEAR UNIT
ACID TANKSACID TANKS
BURR MESHERBURR MESHER
PINCH ROLLERPINCH ROLLER STRIP DRYERSTRIP DRYER
RINSE TANKSRINSE TANKS
BREAKER BREAKER UNITUNIT
ROLLING ROLLING
COLD ROLLING IS THE PROCESS OF COLD ROLLING IS THE PROCESS OF THICKNESS REDUCTION WITH THE HELP OF THICKNESS REDUCTION WITH THE HELP OF ROLLS AT ROOM TEMPROLLS AT ROOM TEMP
HEAT IS GENERATED IN THE PROCESS OF HEAT IS GENERATED IN THE PROCESS OF COLD ROLLING HENCE FOR THE COOLING OF COLD ROLLING HENCE FOR THE COOLING OF ROLLS AND STRIP COOLANT IS USED ROLLS AND STRIP COOLANT IS USED
Cont....
ROLLING ROLLING
THE PURPOSE OF COOLANT IS ALSO TO THE PURPOSE OF COOLANT IS ALSO TO IMPART ANTI RUSTING PROPERTIES TO THE IMPART ANTI RUSTING PROPERTIES TO THE SHEET AND THE ROLLEDSHEET AND THE ROLLED
ROLLING LEADS TO INCREASE OF THE STRIP ROLLING LEADS TO INCREASE OF THE STRIP HARDNESS HARDNESS
SURFACE FINISH IMPROVES AND GAUGE SURFACE FINISH IMPROVES AND GAUGE VARIATION BECOME UNIFORMVARIATION BECOME UNIFORM
4HI MILL4HI MILL
BACKUP ROLLSBACKUP ROLLS
WORK ROLLSWORK ROLLS
STRIPSTRIP
PAY OFF REELPAY OFF REELDEL. TENSION REELDEL. TENSION REEL
ENTRY TENSION REELENTRY TENSION REEL
NGNG
6HI MILL6HI MILL
BACKUP ROLLSBACKUP ROLLS
W.R.W.R.
E.T.RE.T.RD.T.R.D.T.R.
P.O.RP.O.R
I.M.R.I.M.R.
NGNG
SKIN PASS2HI MILL
SKINPASS:SKINPASS: IT HELPS IN IMPARTING IT HELPS IN IMPARTING FLLATNESS TO THE COIL FLLATNESS TO THE COIL
DECREASE HARDNESS OF COIL.DECREASE HARDNESS OF COIL. REMOVES WRINKLES OF COILREMOVES WRINKLES OF COIL REMOVES STRESSES FROM WITHIN THE REMOVES STRESSES FROM WITHIN THE
COIL.COIL.
2HI MILL2HI MILL
WORK ROLLSWORK ROLLS
SHEAR UNITSHEAR UNITCOIL STRIPCOIL STRIP
RECOILERRECOILER
UNCOILERUNCOILER
ANNEALINGANNEALING
Cont.….
Cold rolling of strip is a work hardening process Cold rolling of strip is a work hardening process and renders the strip hard and brittle. There are and renders the strip hard and brittle. There are very few uses of the cold rolled strip in this very few uses of the cold rolled strip in this condition. condition.
Annealing is a process of heating, soaking Annealing is a process of heating, soaking and controlled cooling of coil in a non-and controlled cooling of coil in a non-oxidizing atmosphereoxidizing atmosphere..
Metallurgically, the annealing process relieves Metallurgically, the annealing process relieves the stresses developed by Cold Rolling and the stresses developed by Cold Rolling and renders the strip soft and restores its ductility renders the strip soft and restores its ductility and formability. and formability.
We have two types of Annealing based on the We have two types of Annealing based on the atmospheres used atmospheres used
– HNX (95% N2+5%H2)HNX (95% N2+5%H2)
– HPH (100% HydrogenHPH (100% Hydrogen))
100% Hydrogen are the latest built furnaces and the 100% Hydrogen are the latest built furnaces and the strip that comes out of the furnace is extremely bright in strip that comes out of the furnace is extremely bright in appearanceappearance
TYPES OF ANNEALINGTYPES OF ANNEALING
ANNEALING BASE AND FURNACE
ANNEALING BASE AND FURNACE
ANNEALING BASE AND FURNACE
C.R. SLITTERC.R. SLITTER
C.R.S. unit (1,2,3) is employed for cutting C.R.S. unit (1,2,3) is employed for cutting rolled sheet to desired width & length as req. rolled sheet to desired width & length as req. by the customer. by the customer.
It has a number of cutters with spacers in It has a number of cutters with spacers in between them so that the desired width of between them so that the desired width of sheet can be obtained.sheet can be obtained.
The rolled sheet is mounted on one side of The rolled sheet is mounted on one side of the unit i.e. the uncoiler & is collected on the the unit i.e. the uncoiler & is collected on the coiler side with the req. widths.coiler side with the req. widths.
CUT TO LENGTH (CTL)CUT TO LENGTH (CTL) Cut to length unit (1,2,3) is req. for cutting the Cut to length unit (1,2,3) is req. for cutting the
sheet to desired lengths. sheet to desired lengths. A cutter that works under pressure does cutting. A cutter that works under pressure does cutting.
This is a programmable m/c, which cuts the sheet This is a programmable m/c, which cuts the sheet when it reaches the desired length with pressure. when it reaches the desired length with pressure.
Pressure application capacity is 0-7 Kg/cm^2. Pressure application capacity is 0-7 Kg/cm^2. Pressure applied is hydraulically controlled.Pressure applied is hydraulically controlled.
The maximum length cut is 2500mm. The capacity The maximum length cut is 2500mm. The capacity of the machine is 62 Tones / Shiftof the machine is 62 Tones / Shift
QUALITY SYSTEM QUALITY SYSTEM CERTIFICATIONCERTIFICATION
ISO-9001 2000ISO-9001 2000 ISO-14001ISO-14001
PRODUCT PRODUCT SPECIFICATIONSSPECIFICATIONS
IS 513IS 513 IS 7226IS 7226 JIS 1641JIS 1641 JIS 3141JIS 3141 DIN 1623DIN 1623 BS 1449 BS 1449 AS PER CUSTOMERS’ SPECIFICATIONSAS PER CUSTOMERS’ SPECIFICATIONS
PROPERTIES OF VARIOUS GRADESPROPERTIES OF VARIOUS GRADES
Stand. Grade Equiv.Grade Hard (RB) ECV UTS YS Elong.
JIS-3141 SPCC D 65 max. As 28 min. ----- 32 min.SPCD DD ------ per 28 min. ----- 34 min.SPCE EDD ------ chart 28 min. ----- 36 min.
Mechanical properties
Stand. Grade Equiv.Grade C% Mn% Si% S% P% Al%
JIS-3141 SPCC D 0.12 max 0.50 max. ----- 0.045 max. 0.04 max. -----SPCD DD 0.10 max 0.45 max. ----- 0.035 max. 0.035 max. -----SPCE EDD 0.08 max 0.40 max. ----- 0.03 max. 0.03 max. -----
Chemical composition
PROPERTIES OF VARIOUS GRADESPROPERTIES OF VARIOUS GRADES
Stand. Grade Equiv.Grade Hard (RB) ECV UTS YS Elong.
IS-513 D 65 max. As 27-41 28 max.28 min.DD 57 max. per 27-37 25 max.32 min.EDD 50 max. chart 27-35 22 max.36 min.
Mechanical properties
Stand. Grade Equiv.Grade C% Mn% Si% S% P% Al%
IS-513 D 0.12 max 0.50 max. ----- 0.04 max. 0.04 max. -----DD 0.10 max 0.45 max. ----- 0.035 max. 0.035 max. -----EDD 0.08 max 0.40 max. ----- 0.03 max. 0.03 max. -----
Chemical composition
PROPERTIES OF VARIOUS GRADESPROPERTIES OF VARIOUS GRADES
Stand. Grade Equiv.Grade Hard (RB) ECV UTS YS Elong.
BS-1449 CS4 D 65 max. As 28 min. 14 min. 34 min.CS3 DD 62 max. per 28 min. 14 min. 36 min.CS2 EDD 55 max. chart 28 min. 14 min. 38 min.
Mechanical properties
Stand. Grade Equiv.Grade C% Mn% Si% S% P% Al%
BS-1449 CS4 D 0.12 max 0.60 max. ----- 0.05 max. 0.05 max. -----CS3 DD 0.10 max 0.50 max. ----- 0.04 max. 0.04 max. -----CS2 EDD 0.08 max 0.45 max. ----- 0.035 max. 0.03 max. -----
Chemical composition
PROPERTIES OF VARIOUS GRADESPROPERTIES OF VARIOUS GRADES
Stand. Grade Equiv.Grade Hard (RB) ECV UTS YS Elong.
DIN-1623 ST12 D 65 max. As 27-41 28 max.28 min.ST13 DD 57 max. per 27-37 25 max.32 min.ST14 EDD 50 max. chart 27-35 21 max.38 min.
Mechanical properties
Stand. Grade Equiv.Grade C% Mn% Si% S% P% Al%
DIN-1623 ST12 D 0.10 max ----- ----- ----- ----- -----ST13 DD 0.10 max ----- ----- ----- ----- -----ST14 EDD 0.08 max ----- ----- ----- ----- -----
Chemical composition
PROPERTIES OF VARIOUS GRADESPROPERTIES OF VARIOUS GRADES
Stand. Grade Equiv.Grade Hard (RB) ECV UTS YS Elong.
IS-7226 C40 MC-11 83 max. ----- ----- ----- -----C55 MC-12 85 max. ----- ----- ----- -----C70 88 max. ----- ----- ----- -----C80 HC-14 92 max. ----- ----- ----- -----
Mechanical properties
Stand. Grade Equiv.Grade C% Mn% Si% S% P% Al%
IS-7226 C40 MC-11 0.35-0.45 0.60-0.90 0.15-0.35 0.04 max. 0.04 max. -----C55 MC-12 0.50-0.60 0.50-0.80 0.15-0.35 0.04 max. 0.04 max. -----C70 0.65-0.75 0.50-0.80 0.10-0.35 0.04 max. 0.04 max. -----C80 HC-14 0.75-0.85 0.50-0.80 0.10-0.35 0.04 max. 0.04 max. -----
Chemical composition
PROPERTIES OF VARIOUS GRADESPROPERTIES OF VARIOUS GRADES
Stand. Grade Equiv.Grade Hard (RB) ECV UTS YS Elong.
50 max. ----- 25-30 15 - 20 44 min.
Mechanical properties
IF
Stand. Grade Equiv.Grade C% Mn% Si% S% P% Al%
0.01 max. 0.20 max. ----- 0.02 max. 0.02 max. -----
Chemical composition
IF
THICKNESS TOL. AS PER JIS-3141THICKNESS TOL. AS PER JIS-3141
Width Under 160 160 - 250 250 - 400 400 - 630Thickness (mm)Under 0.25 +/- 0.02 +/- 0.025 +/- 0.03 +/- 0.030.25 - 0.40 +/- 0.025 +/- 0.03 +/- 0.035 +/- 0.0350.40 - 0.60 +/- 0.035 +/- 0.04 +/- 0.04 +/- 0.040.60 - 0.80 +/- 0.04 +/- 0.045 +/- 0.045 +/- 0.0450.80 - 1.00 +/- 0.04 +/- 0.05 +/- 0.05 +/- 0.051.00 - 1.25 +/- 0.05 +/- 0.05 +/- 0.05 +/- 0.061.25 - 1.60 +/- 0.05 +/- 0.06 +/- 0.06 +/- 0.061.60 - 2.00 +/- 0.06 +/- 0.07 +/- 0.08 +/- 0.082.00 - 2.50 +/- 0.07 +/- 0.08 +/- 0.08 +/- 0.092.50 - 3.15 +/- 0.08 +/- 0.09 +/- 0.09 +/- 0.103.15 & over +/- 0.09 +/- 0.10 +/- 0.10 +/- 0.11
PERMISSIBLE DEVIATION IN PERMISSIBLE DEVIATION IN PRODUCT ANALYSISPRODUCT ANALYSIS
(IS 513)(IS 513)
C %C % 0.020.02 Mn %Mn % 0.030.03 Si %Si % 0.020.02 S%S% 0.0050.005 P%P% 0.0050.005
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