University of the East

College of Engineering

PLATE NO. 2
ROLLING MILL

NME 3106/ ME-1

PABLO, JOHN EDERSON B.

20160130665
Sept. 6,2020

ENGR. DIOSDADO C. DOCTOR

PROFESSOR
 TABLE OF CONTENTS

I. DEFINITION OF TERMS

II. INTRODUCTION

III. MANUFACTURING PROCESS

-FLOW CHART
-DISCUSSION AT THE PROCESS
-RAW MATERIALS
-DEFECTS
-EQUIPMENT OF MACHINERIES

IV. REFERENCES
I. DEFINITION OF TERMS

• Bars - Long steel products that are rolled from billets. Merchant bar and
reinforcing bar (rebar) are two common categories of bars, where merchants
include rounds, flats, angles, squares, and channels that are used by fabricators
to manufacture a wide variety of products such as furniture, stair railings, and
farm equipment. Rebar is used to strengthen concrete in highways, bridges, and
buildings.
• Billet - A semi-finished steel form that is used for “long” products: bars, channels
or other structural shapes. A billet is different from a slab because of its outer
dimensions; billets are normally two to seven inches square, while slabs are 30
inches to 80 inches wide and two inches to ten inches thick. Both shapes are
generally continually cast, but they may differ greatly in their chemistry.
• C Purlins - are horizontal beams that are used for structural support in buildings.
Most commonly, purlins are major components of roof
structures. Roof purlins are supported either by rafters or building walls and
the roof deck is laid over the purlins.
• Bloom - A semi-finished steel form, with a rectangular cross-section that is more
than 8”. This large cast steel shape is broken down in the mill to produce the
familiar I-beams, H-beams, and sheet piling. Blooms are also part of the high-
quality bar manufacturing process: Reduction of a bloom to a much smaller
cross-section can improve the quality of the metal.
• Casting - The process of pouring molten metal into a mold so that the cooled,
solid metal retains the shape of the mold.
• Continuous Casting - A method of pouring steel directly from the furnace into a
billet, bloom, or slab directly from its molten form.
• Converter - Processes steel into a more finished state, such as pipe, tubing, and
cold-rolled strip, before selling it to end users. Such steel generally is not sold on
contract, making the converter segment of the mills’ revenues more price
sensitive than their supply contracts to the auto manufacturers.
• Edge Rolling - Rolling a strip of steel to smooth the edges. By removing the burr
off the coil, it is safer for customers to manipulate.
• Fabricate - To work a material into a finished state by machining, forming, or
joining.
• Finish - The surface appearance of steel after final treatment.
• Hot metal - The name for the molten iron produced in a blast furnace. It proceeds
to the basic oxygen furnace in molten form or is cast as pig iron.
• Flux - An iron cleaning agent. Limestone and lime react with impurities within the
metallic pool to form a slag that floats to the top of the relatively heavier (and now
purer) liquid iron.
• Hot mill - The rolling mill that reduces a hot slab into a coil of specified thickness;
the processing is done at a relatively high temperature (when the steel is still
“red”).
• Scrap (Ferrous) - Ferrous (iron-containing) material that generally is remelted
and recast into new steel.
 II. INTRODUCTION
Semi-finished steel is intermediate steel, which occurs by casting liquid steel or by
rolling and forging of the initial solidification of liquid steel in a foundry. The chemical
properties of semi-finished steel are adjusted in accordance with the physical properties
and grade requirements depending on the industrial process it is to be used in. Semi-
finished steel requires further processing to produce finished goods. Thus, semi-finished
steel is available in various grades, sizes, and forms to cater to the diverse
requirements of different industrial processes.

With Semi finished manufacturing, a refractory-lined vessel is used as the furnace.

The furnace is also equipped with a roof that insulates the scrap iron as it is heated. The
defining characteristic of secondary steelmaking, however, is its use of an electric arc.
Primary steelmaking uses a blower to force oxygen through molten iron, whereas
secondary steelmaking is characterized by the use of an electric arc. The electric arc is
able to heat up the scrap iron until it achieves a molten state. Furthermore, it is
important to note that primary steelmaking does not dissolve the oxygen. It simply blows
oxygen through the molten iron. Although it is most commonly performed with scrap
iron, secondary steelmaking can produce large yields of steel. According to Wikipedia,
secondary steelmaking can produce about 100 tons of steel every 40 to 50 minutes.
Primary steelmaking, of course, can also produce large yields.

In metal manufacturing rolling mill is important it is a metal forming process in

which metal stock is passed through one or more pairs of rolls to reduce the thickness
and to make the thickness uniform. Rolling is classified according to the temperature of
the metal rolled. If the temperature of the metal’s above its recrystallization temperature,
then the process is known as hot rolling. If the temperature of the metal is below its
recrystallization temperature, the process is known as cold rolling. Roll stands holding
pairs of rolls are grouped together into rolling mills that can quickly process metal,
typically steel, into products such as structural steel I-beams, angle stock, channel
stock, bar stock, and rails.
 Structural steel or C Section purlins is the product to discuss in this study. The exact
size of C purlins is (50.8 x 152.4 x 21.5 x 1.8) millimeters. This size produce by C One
Steel Corporation. The role of C Purlins is to act as secondary support for roofing
sheets and composite panels to used in a wide range of industrial and commercial
applications. The purlins are accurately roll formed from high strength zinc coated steel
and provide an efficient, light weight, economical solution for roofing & cladding. Rolling
or casting of C Section purlins can be classified in different sizes but it depends to the
requirements of the order . Purlins are used in building which are two or more bays long
and are made continuous using “Purlin sleeves”. Sleeves should be of the same section
as the purlins, but used in reverse for joining.
III. MANUFACTURING PROCESS

FLOW CHART

Billet Gage Mill Anneal

Bed Cool
Cutting
Elongate

Reheat
C Purlins
Sizing
DISCUSSION OF THE PROCESS
In this rolling mill process, Billet is the raw use, with a cross sectional area of
80cm x 80cm (height and width) with a length of 6meters. a piece of material is passed
between two rotating cylinders to reduce the cross-sectional area. In this process, the
equipment should be able to expose the burning material to a sequence of passes. The
size of billet will undergo cutting process, the 6 meters will cut into 3 pieces to have a 2
meters length. The billet is rolled to charge at the entrance of the reheating furnace. The
steel material is pushed forward on entrance of the furnace by means of a pusher
machine. At the end of the soaking zone of the furnace, the billet is discharged from the
furnace by ejector for rolling in the rolling mill. Bunker is the type of gas use to melt the
steel billet, it has a high viscosity requirement in heating. The temperature of the heated
steel material can vary in the range of 1100 degrees Centigrade to 1500 degrees
Centigrade. The operation of reheating furnaces is therefore of great importance to the
ferrous metallurgy process from economic, production, and environmental viewpoints.
Economically, the consumption of fuel needed for reheating can represent up to 15% of
the operational cost of a rolling process. With respect to productivity, a furnace capacity
commonly dictates the production rate for the rollers, which means that reheating is
usually the bottleneck in achieving the maximum production volume.

The rolled billet simultaneously burnished inside and outside by a reeling

machine. Then will undergo into sizing mill, the size of C purlins is C (50.8 x 152.4 x
21.5 x 1.8) millimeters. The volume of raw materials after cutting is 12,800,000mm 3 and
the volume of finish product is 3,113,100mm3, then it will come up to 4.11 pieces of C
purlins. Roughing mill has two categories, Box beam rolling will be charged to reach the
minimum thickness requirement of the material, And the Edger rolls used to roll the
edged of the billet and center it. In Intermediate it will undergo, C Purlin roll forming it is
used to produce C Purlins with respective sizes with punch on web and flange side.
Then will be continuous to reduce until it reaches the percentage of reduction. Then
lastly, the finishing mill has two categories Anneal mill, at a temperature of 1100 to 1500
degrees Centigrade is cooled further under controlled conditions by a water curtain on
the run-out table. The purpose of cooling is to reduce the temperature for coiling and
transportation, but also to allow faster cooling of the finished product, resulting in higher
strength. Cooling beds, are crucial to the process, carefully moving, and cooling the hot
steel after the rolling process. As this is an integral part of a Steel Mill's process, any
mechanical problems or failures to the cooling bed will have huge consequences for the
mill. The cooling bed need to be manufactured to the highest quality standards and
thoroughly tested before installation.
Sample computation:
𝐶 50.8 𝑥 152.4 𝑥 21.5 𝑥 1.8𝑚𝑚
𝐴1 = 3.14(1.8𝑚𝑚)2 = 10.17𝑚𝑚2
𝐴2 = 2(1.8𝑚𝑚)(21.5𝑚𝑚 − 1.8𝑚𝑚) = 70.92𝑚𝑚2
𝐴3 = 2(50.8 − 1.8𝑚𝑚 𝑥 2)(1.8𝑚𝑚) = 169.92𝑚𝑚2
𝐴4 = (152.4 − 1.8𝑚𝑚 𝑥 2)(1.8𝑚𝑚) = 267.84𝑚𝑚2
𝐴𝑡 = 10.17 + 70.92 + 169.92 + 267.84 = 518.85𝑚𝑚2

C purlins total volume if 6 meters

𝑉𝑡 = (518.85𝑚𝑚2 )(6000𝑚𝑚) = 𝟑, 𝟏𝟏𝟑, 𝟏𝟎𝟎𝒎𝒎𝟐
Billet total Area if 2 meters length
𝐴𝑡𝑏 = (80𝑥80) = 𝟔𝟒𝟎𝟎𝒎𝒎𝟐
Billet total volume if 2 meters length
𝑉𝑡𝑏 = (80𝑥80𝑥2000) = 𝟏𝟐, 𝟖𝟎𝟎, 𝟎𝟎𝟎𝒎𝒎𝟑

Volume Ratio
12,800,000𝑚𝑚3
= 𝟒. 𝟏𝟏 𝒑𝒖𝒓𝒍𝒊𝒏𝒔 ; If 6 meters (4.11)(3) = 𝟏𝟐. 𝟑𝟑 𝒑𝒖𝒓𝒍𝒊𝒏𝒔
3,113,100𝑚𝑚3

% Reduction

𝐴𝑏𝑖𝑙𝑙𝑒𝑡 − 𝐴𝑐𝑝𝑢𝑟𝑙𝑖𝑛𝑠 6400 − 518.85

%𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = ( ) 𝑥100 ; ( ) 𝑥100 = 𝟗𝟏. 𝟖𝟗%
𝐴𝑏𝑖𝑙𝑙𝑒𝑡 6400

Therefore, 91.89% total reduction of 2meter billet in one C purlins.

 RAW MATERIALS
Billets are also known as the second-stage product of steel production. They can
be produced in two ways namely continuous casting or rolled directly from the casting
process by billet mills. Steel billets are very ductile and are produced in square cross-
sections. They are not always practical until they have been formed into various shapes
and sizes to be sold at hardware stores or used for other applications. Hence, it is
classified as a semi-finished casting product and can be processed into final products
such as bars, rods, tubes, pipes, wire, and wire products. The size and dimension of
billet is (80 x 80 x 2000) millimeters. And has a total volume of 12,800,000mm3. With
this volume, it can produce 4.11 pieces respect to the size of C purlins.

Billets
 DEFFECTS

Internal Structural defects

Mill spring

is a defect in which the rolled sheet is thicker than the required thickness
because, the rolls get deflected by high rolling forces. Elastic deformation of the mill
takes place. Using of stiffer rolls, namely roll material of high stiffness or elastic
constant, could avoid mill spring.

Wavy edge

If rolls are elastically deflected, the rolled

sheets become thin along the edge, whereas at
center, the thickness is higher. Similarly, deflected
rolls result in longer edges than the center. Edges of
the sheet elongate more than the center.

Center Crack

If rolls have excess curve, then the center of

the sheet metal will have more elongation than the
edges. This leads to a defect called center buckle.
Non-homogeneous material deformation across the
thickness leads to high secondary tensile stress along edge.

Roll elastic deformation

Roll elastic deformation may result in uneven sheet thickness across. Roll
material should have high elastic modulus for reducing the roll deformation. For
producing very thin gage sheets like foils, small diameter rolls are used. They are
supported with larger rolls.
Alligatoring

Due to non-homogeneous flow of material

across the thickness of the sheet. This is because
the surface is subjected to tensile deformation
and center to compressive deformation. This is
because greater spread of material occurs at
center.

Surface defects

a) crazing e) patch

b) folding f) pitted surface

c) inclusion g) rolled-in scale

d) original h) scratch
 EQUIPMENT OF MACHINERIES

Hydraulic Cutting Shear

Steel shear is an efficient tool for
demolishing steel structures where large steel
plates or steel girders must be cut.

Reheating Furnace
are responsible for heating steel billets to
desired temperatures. In this process, billets go
into a furnace, are heated, and then exit at ideal
temperatures for the rolling process

Rolling Mill
The rolling mill consists of a roughing mill
train, intermediate mill trains, and finishing mill
train with D.C. drives, for continuous operation.
This is used primarily for converting billets
into high-quality Steel bars by applying heat,
pressure and subjected to quenching.
• Box beam roll
This Roll Forming Machine is
designed to produce fluted box beam profile
for C purlins and to reduce the thickness.
This roll formed beam was made from
500Mpa, hi-tensile steel.

• Edge Roll
This roll stiffens the edge of the
purlins or any place where a stress crack
needs to be avoided. All edge rolls are
made from heat treated tool steel for a
lifetime of quality service.

• C Purlin Roll
It has a manual decoiler, and has
entrance and guide roller of 7 rollers, 3 up
and 4 down. The speed of forming is
30meters per minute without any cutting
and punching. In PLC, it controls the
quantity, punching length, cutting length.
And to punch product support frame or
logo.
 Cool Bed
used for the uniform air cooling of the rolled
materials and transport it in a phased manner from
the entry side of the cooling bed to its discharge side.
It transfers the bars one by one to the roller table, on
which they are transported to the finishing section.

IV. REFERENCES

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A., Saswata Baksi (2020, June 08). Rolling Process: Working, Application, Defects,
Type of Rolling Mills [PDF]. Retrieved September 09, 2020, from
https://learnmechanical.com/rolling-process/
F. A. Jordan (n.d.). PROCESS OF ROLLING MILLS. Retrieved September 13, 2020,
from https://www.linkedin.com/pulse/understanding-rolling-process-long-product-mill-
farooq-amir

Lenard, J. G. (2014). Finishing Mill. Retrieved September 13, 2020, from

https://www.sciencedirect.com/topics/engineering/finishing-mill

S., W. (n.d.). Steel Pipe and Manufacturing Processes. Retrieved September 13,
2020, from
http://www.wermac.org/pipes/pipemaking.html?fbclid=IwAR3dRS5ff2w8FcaeHNU6e
1N8quy43rKnesaEr3WypDqYmvb1MHkCW939GQY

Techminy. (2016, November 30). Rolling defects of after machined metals.

Retrieved September 13, 2020, from https://techminy.com/rolling-
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HkCW939GQY

Santos, H., Almeida, P., & Cardoso, R. (2017, June 07). Fuel Costs Minimization on
a Steel Billet Reheating Furnace Using Genetic Algorithms. Retrieved September
13, 2020, from https://www.hindawi.com/journals/mse/2017/2731902/