TRAINING REPORT

ON
COLD ROLLING MILL

Prepared By
Mr. Vikas Sharma
INTRODUCTION
Rolling is a metal forming process in which metal
stock is passed through one or more pairs of rolls to
reduce the thickness and make thickness uniform.

Rolling Types:
1) Hot Rolling Mill
2) Cold Rolling Mill
1) HOT ROLLING MILL :- The temperature of the
metal is above the recrystallization temperature of
the material.
After the grains deform during processing , they
recrystallize which maintain an equiaxed
microstructure and prevent the metal from work
hardening.
2) COLD ROLLING MILL :- The temperature of the
metal is below the recrystallization temperature of
the material.
CR increases strength, improves surface finish
and holds tighter tolerance.
CRM Process Flow Diagram
CPL
CCM
ECL
BAF
SPM
RCL
APL
Continuous Pickling Line (CPL)
CONTINUOUS PICKLING LINE (CPL)
The oxides scales are formed on the surface of the
strip during hot rolling process.
Types of Scales:
1) Fe
2
O
3
2) Fe
3
O
4
3) FeO
Pickling is the process to remove all these oxide scales
by using conc. HCl. The pickling process line is
continuous that why it is called continuous pickling
line.

CPL MAIN PROCESS FLOW DIAGRAM
PAY OF REEL
(UNCOILING)
PINCH ROLL
CUM 5 ROLL
FLATTNER
ENTRY UPCUT
SHEAR
LASER BEAM
WELDER WITH
NOTCHER
TENSION
LEVELLER CUM
SCALE BREAKER
HOT AIR DRYER
NO. 1
PRE WASH
TANK
PICKLING
TANK 1
PICKLING TANK
2
PICKLING TANK
3
PICKLING TANK
4
PICKLING TANK
5
PICKLING TANK
6
5 STAGE RINSE
TANKS
HOT AIR DRYER
NO. 2
EDGE TRIMMER
ELECTROSTATIC
OILER
EXIST SHEAR
RECOILER
CPL MAIN PARTS
1) ACB ROLL:- ACB ( Anti Coil Break Roll) is installed upward of pay of
reel and its main function is break or loose the primary scales of
HR Coil also provide uniform feeding of coil from Pay of reel to
Pinch roll cum 5 roll flattner. This also prevent the CBL (Coil break
line defect.

2) Welder:- Welder is used to join head and tail of 2 HR coils and it is
necessary because it is continuous line.

It has mainly 3 parts a) Laser Entry Lopper b) Laser Exit lopper c)
Center / Carriage

Tail of first coil is stored in exist lopper and head of another coil is
stored in entry lopper after shear cutting and centering of both
coils carriage come forward head of second coil is charged and
butted up tail of first coil and high voltage and current applied
across the seam melting the two ends. The two strips are then
forced together hydraulic joining.

3) TLL:- TLL ( Tension leveller)provide the elongation in strip which is
increases the pickling efficiency by breaking the surface oxide
scales and also provide a degree of strip flatness.



4) Looper Car :- looper cars store or accumulate steel strips allowing
different sections to keep running usually the pickle and rinse
while one section is stopped





5) Pickle tanks :- In pickle tanks chemical reaction with conc. HCl
takes place which removes the oxide scales.
There are Six pickling tanks because line is designed for
optimization purpose during pickling process conc. Of each tank
decreases after some time then we transfer the decreased Conc.
HCl to other tank which required less Percentage of Conc. Acid.
This process is also called cascading.
Process Parameter of Pickling Tanks





Pickling Tank No. Acid % Iron (Fe gm/lt) Max Temperature
1 1~4 160 60~90
O
C
2 1.5~6 140 60~90
O
C
3 5~12 130 60~90
O
C
4 7~14 90 60~90
O
C
5 9~16 70 60~90
O
C
6 12~19 40 60~90
O
C
6) Rinse Tanks:- Rinse tanks clean the residual acid from the surface of
the strip.
The process parameter
pH Value ( DM water) = minimum 4.5 pH

7) Hot Air Dryer :- It removes the excess water to prevent rust or strain

8) Squeeze Rolls:- It Prevent the Carryover from acid/ Water from one
tank to other tank

9) Thickness Gauge : Measured the thickness of the strip

10) Width Measuring Device : Measured the Width of the Strip







11) Edge Trimmer:- It cuts the edge for width control purpose as per
customer requirement






Horizontal Distance b/w cutter is called gap and vertical distance is
called lap. Only 30 to 40% is shearing (Gap) and 40 to 60% broken
due to tension (Lap)

s.no Description Meaning Tolerance
1 HT HR Coil Trimmed +4mm
2 DT Double Trimmed +0.5 mm
3 UT Un Trimmed +12 mm
4 CT CR Coil Trimmed Customer Specific
5 NT No Trimming +20 mm
12) Electrostatic Oiler :- Electrostatic oiler adds a thin layer of oil for
rust protection.
Electrostatic oiler has two plates one in upper side and other is in
bottom side each plates has oil pipe in both side. In both plates
+ve ions current is passing from one side and ve ions current is
passing other side when is ions met a uniform spray of oil takes
place on strip (top & bottom) which is passing in between of two
plates.

Rust Preventive oil is used for oiling purpose (61308 quaker)







CPL Defects
1) Over Pickled : This defects generated at C.P.L Because line speed is
slowly run that time yellowish Band created on sheet surface By
Conc. HCl


2) Under Pickled : This defects generated at C.P.L line, because H.C.L
acid concentration in temperature decreased at line so that time
surface on the sheet is improperly cleaned by acid ,so sheet is
Black surface carry over .


Cold Compact Mill (CCM)
COLD COMPACT MILL (CCM)
Cold Compact mill in which thickness reduction is takes
place also get the desired profile shape.
CCM has 6 twin stand reverse pull mill. It has 2 work
rolls, 2 intermediate Rolls (IMR) and 2 backup rolls

It give maximum 40% thickness reduction in one stand
and total 80% thickness reduction.



Backup
Roll
IMR
W
R
Backup
Roll
IMR
Backup
Roll
IMR
W
R
W
R
W
R
IMR
Backup
Roll
TR1
TR2
Stressometer 1 Stressometer 2
Entry X RAY
Thickness & Laser
speed measuring
Gauge
X RAY
Thicknes
s & Laser
speed
measurin
g Gauge
Exit X RAY
Thickness
& Laser
speed
measuring
Gauge
Entry
Tension
Exit
Tension
Tension
Measur
ing Roll
Passline
roll
CCM Layout
Work Roll
Diameter = 400 ~450 mm
Barrel Length =1770 mm

IMR
Diameter = 500~560 mm
Barrel Length =1950 mm

Backup Roll
Diameter = 1150~1250 mm
Barrel Length =1770 mm

CCM Construction
CCM MAIN PROCESS FLOW DIAGRAM
PAY OF REEL
(UNCOILING)
STRESSOMETER 1
ENTRY X RAY
THICKNESS & LASER
SPEED MEASURING
STRIP PRESS WITH
SIDE GUIDE
6 HI-1
CROSS CUT SHEAR
6 HI-2
PASS LINE ROLL
INTERSTAND X RAY
THICKNESS & LASER
SPEED MEASURING
TENSION
MEASURING ROLL
EXIT X RAY
THICKNESS & LASER
SPEED MEASURING
STRESSOMETER 2 RECOILER
CCM MAIN PARTS
1) Work Roll:- work is the main part of CCM and is used for thickness
reduction purpose . The strip is passed between the work rolls and
reduction of thickness is takes place under the rolling load .
2) Intermediate Roll :- These rolls are axially shifted . The shifting
symmetrical to the middle of the stand, is carried out with
reference to the strip width during rolling process and it permits
the surface of backup rolls only for the necessary part , thus
keeping a uniform force distribution along width due to this a
better control of strip profile and also get better effectiveness of
work roll bending systems from the shifting of the intermediate
rolls.
3) Backup Rolls :- these are intended to provide rigid support
required by working rolls to prevent bending under the rolling
load.

4) CVC:- CVC is continuous variable crown is used for better shape
control as per requirement.
CVC has S shaped rolls which may be axially shifted in the interval
of time between rolling of a strip and the following one, to join
suitably roll gap profile with that of the strip.
Profile Requirement
CRCA (concave Type Profile )

CRFH ( Convex Type Profile )




5) Stressometer:- Stressometer is also called shapemeter is used to
measure shape of the strip.
Stressometer measuring roll is divided into 33 measuring zones
across the roll and the display unit has same number of indicating
instruments.
Each zone measures the stress in the corresponding part of strip,
independent of adjacent zones . The whole roll assembly and the
individual measuring zones are very much stiffer than the curved
part of the strip.
The stress distribution in the strip is exclusively the result of the
shape.




CCM Process parameter
Emulsion :- Emulsion is the coolant is used for keeping cooling rolls and also used for
better lubrication.
It Contains 3 to 4 % base oil
96 to 97% contains water
Base oil is used Quaker 1.0