...Cold Rolling Jeffry S. Asher DT1410 Unit 4 Assignment 2 ITT Technical Institute January 18, 2016 Cold rolling is a metal forming process in which the shape and the structure of steel are altered through drawing, extruding, hammering, pressing, rolling, spinning, and stretching at temperatures below the steel's recrystallization point, usually room temperature. These processes result in changes to the metal's composition which permanently increases its hardness and tensile strength, and improve the surface finish, but decrease ductility and impact resistance. After hot rolling, many steel products undergo a further processing in the cold state. This stage of processing may not necessarily alter the shape of the steel, but it does reduce its thickness and significantly improve its performance characteristics. Hot rolled coil is commonly known as cold rolled, also known as cold reduced. Cold rolling is a process by which the sheet metal or strip stock is introduced between rollers and then compressed and squeezed. The amount of strain introduced determines the hardness and other material properties of the finished product. The advantages of cold rolling are good dimensional accuracy and surface finish. Cold rolled sheet can be produced in various conditions such as skin-rolled, quarter hard, half hard, full hard depending on how much cold work has been performed. This cold working hardness is often called temper, although this has nothing to do with heat treatment temper...
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...1. Introduction Steel is one of the most important industrial products of our life. It is used from power cables to safety pin. In tools, military weapons, making our homes and so and so on. Steel industry is considered backbone of industrial growth. Its sustained growth is vital given the cascading impact it has on the economic development in many sectors such as oil and gas, electrical and electronics, transport, shipbuilding, building and construction, fabrication, machinery and equipment as well as the national trade balance 2. Overview Malaysian steel industry contributes ~ 4% to the economy, employing ~150,000 people •There’s a ~ 22.4 MTA demand in ASEAN - 18.3 MTA for flat products. •A fully developed steel industry could contribute up to ~6.5% to the Malaysian economy by 2020. •Malaysia steel demand is the 4th largest in ASEAN (Thailand, Viet Nam, Indonesia) and growing at 6% for past 20 years. MITI presentation, SECOND NATIONAL MARINE INDUSTRIES FORUM 2012 (2NMIF) Production: Losses: The Economic Transformation Programme (ETP) initiated by the Malaysian Government has begun to show some positive results. As the ETP is rolled out in stages, the significant impact on steel demand will not be shown until after the full implementation of all these infrastructure and construction projects. However, the Economic Stimulus measures put in place by the Malaysian Government during the global financial crisis continued to stabilise the economy, helping businesses...
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...week’s case, Nucor Steel, finds itself at a critical inflexion point: Should it invest in a new steel mill to commercialize thin-slab casting? This paper examines why Nucor is considering making such an investment and what risks are involved if they choose to adopt the technology. Based on this analysis, the paper will conclude with a recommended path for Nucor Steel. YOU CAN NEVER BE TOO RICH OR TOO THIN The flat sheet segment accounts for 52% of the U.S. market for steel. The large integrated steel mills such as U.S. Steel, LTV Steel, and Bethlehem Steel dominate this important segment. Minimills such as Nucor are shut out of the flat sheet market because with conventional steel-making technology, the minimum efficient scale for flat sheet production is too high, with optimal capacities for each plant reaching 3 million tons per year and investment costs close to $2 billion. In contrast, minimills typically only produce 800,000 to 1 million tons per year, with investment levels closer to $300 million. The cost advantages from thin-slab casting are substantial. If viable, thin-slab casting minimills could become a category killer in the flat sheet segment. For hot rolled flat sheets, the operating costs per ton for a thin-slab minimill is 14% less than a modernized integrated steel mill, and 25% less than an unmodernized mill. For cold rolled flat sheets, the cost advantages are even more dramatic – with thin-slab minimills costing 19% less than a modernized steel mill, and 30% less...
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...selection depends totally on application of Fastener, which is further decided on Physical Properties and Chemical composition. 2.2.2. Fabrication of Fasteners [3] This process can be done with the help of different process like Hot/Cold rolling, drawing,etc which again depends on type of Bolt to be...
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...Introduction to the industry Metals have accompanied mankind since ancient ages, and steel, if we begin to follow it from the moment of its historically famed damascene form - for some millennia. From the era of craftsman-like small-scale production to today's form of industrial mass production, steel has covered an intricate path lined with significant innovations in production processes, development of range and quality of products, and perpetually growing productivity of labour, improving economies and ecological load. In addition, a radical change in relationship to the customers is occuring at the end of this century, namely by a pronounced shift of readiness towards the needs and requirements of these customers. Steel's indisputable significance is confirmed by the fact that it has become the second most mass-produced commodity after cement production, attaining the world-wide production volume of approx. 750 mil tons yearly. The art of iron production from ore arose in connection with the practices of copper and lead technologies in Anatolya, in northern Syria and possibly also in part of Iran. Iron ores were added as fluxes for treatment of sulphide copper ores. Iron drops, which the local manufacturers identified already 3000 years BC, comparing these with meteoritic iron, already hinted at the existence of the possibility of producing iron, but this only occurred practically 15 centuries later. Since that time, it is necessary to reckon that only small amounts of this...
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...Introduction/objectives • Rolling mills • Classification of rolling processes • Hot rolling • Cold rolling • Forces and geometry relationships in rolling • Simplified analysis of rolling load: Rolling variables • Problems and defects in rolled products • Rolling-mill control • Theories of cold rolling • Theories of hot rolling • Torque and power Suranaree University of Technology Tapany Udomphol Jan-Mar 2007 Objectives • This chapter provides information on different types of metal rolling processes which can also be divided in to hot and cold rolling process. • Mathematical approaches are introduced for the understanding of load calculation in rolling processes. • Finally identification of defects occurring during and its solutions are included. Suranaree University of Technology Tapany Udomphol Jan-Mar 2007 Introduction- Definition of rolling process • Definition of Rolling : The process of plastically deforming metal by passing it between rolls. • Rolling is the most widely used forming process, which provides high production and close control of final product. • The metal is subjected to high compressive stresses as a result of the friction between the rolls and the metal surface. www.world-aluminium.org Rolling process Note: rolling processes can be mainly divided into 1) hot rolling and 2) cold rolling. Suranaree University of Technology Tapany Udomphol Jan-Mar 2007 Introduction- Hot and cold rolling processes www.vatech.at Hot rolling • The initial breakdown of ingots into...
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...Cold rolling is a process by which the sheet metal or strip stock is introduced between rollers and then compressed and squeezed. The amount of strain introduced determines the hardness and other material properties of the finished product. The advantages of cold rolling are good dimensional accuracy and surface finish. Cold rolled sheet can be produced in various conditions such as skin-rolled, quarter hard, half hard, full hard depending on how much cold work has been performed. This cold working (hardness) is often called temper, although this has nothing to do withheat treatment temper. In skin rolling, the metal is reduced by 0.5 to 1% and results in a surface that is smooth and the yield point phenomenon--excessive stretching and wrinkling in subsequent operations, is eliminated. This makes the metal more ductile for further forming and stretching operations. Quarter Hard, Half Hard, Full Hard stock have higher amounts of reduction, upto 50%. This increases the yield point; grain orientation and material properties assume different properties along the grain orientation. However, while the yield point increases, ductility decreases. Quarter Hard material can be bent (perpendicular to the direction of rolling) on itself without fracturing. Half hard material can be bent 90º; full hard can be bent 45º. Thus, these materials can be used for in applications involving great amounts of bending and deformation, without fracturing. Annealing, in metallurgy and materials...
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...QUES 1 1. Products : HOT ROLLED & COLD ROLLED PIPES Shape: Circular, Oval, Rectangular Length: Std. Length 6mt or in cut sizes as per customer req. Diameter: 18mm – 120mm Thickness: up to 8mm 2. Customer: * Automobile Industries to make parts & components from pipe * Domestic market like pipe lines etc. 3. Raw Material: * HOT ROLLED & COLD ROLLED STEEL COILS Width: 500, 1200, 1500, 1800 mm Length: in form of coils Weight: 3MT to 30MT 4. Estimated No. of workstations: 08 Slitting + Accumulator 1 + Accumulator 2 + Tube mill 1 + Tube mill 2+ Cleaning + Cutting 1 + Cutting 2 QUES 2 1. R.M Availability/Variations: * Planning & Ordering on Monthly Basis from various Domestic & Overseas Suppliers * Receiving of Daily/ Weekly lots * Variation availability of required thickness & tonnage with suppliers * Variation also depends on prices (more fluctuations in prices of steel) 2. Customer Demand Variations * Order Estimation from customers is monthly (with minimum qty. contracts) * Further, Some customers give daily/weekly schedule (so may have variations in quantity) QUES 3 Impact on JIT QUES 4 1. Yes, we need incoming inspection. * Coils need to be checked for condition like rust, dents etc. * Also, inspection to check thickness, width, tonnage, specifications as per ordered and received material * Coils can only be checked visually and on basis of stickers & details on invoice, covers, packing...
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...Pakistan Steel Mill -A Blow To Economy Introduction Sixty three years ago the world's map underwent a great change and the Indian subcontinent was divided into two independent states: India and Pakistan. It did not take much time to change the maps nor did it affect the neighboring countries in any great way, but this division was the result of an intense and dedicated struggle by millions of people of the subcontinent. Background At the time of partition, the areas comprising Pakistan received only five per cent of the subcontinent's industry. . The foundation stone of Pakistan Steel was laid by the then Prime Minister Zulfiqar Ali Bhutto on 30th September 1973. Pakistan Steel is the pioneer in the engineering industries of the country. Experts agree that setting up of a Steel Mill was primarily not for earning profits but to give an impetus to the engineering industry for the country's economic progress.The government established the Pakistan steel mills corporation thinking that that economic growth would not be possible without a self sufficient iron and steel making plant.They believed that depending on imported steel would cost the country too much. How wrong could they have been? They would never have believed that it would come to such a point that the Steel mills would ask for steel imports to be banned so that it could sell its steel at a higher price.It may be interesting to note that Pakistan Steel Mills remained a profitable organization from 2001 to...
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...forgings, extrusions, wires, cables, pipes, etc., and find their application in a number of sectors such as agriculture, infrastructure facilities like power plants, automobiles, railways, telecommunications, building and construction and in engineering and chemical plants. There are significant reserves of non-ferrous metal ores in India. India is rich in bauxite (aluminium ore) and has grades of zinc, lead and copper reserves. Copper, lead and zinc are also imported as scrap or concentrates to be processed by secondary/custom smelters. Nickel and tin are also imported by India. Ferrous metals primarily consist of iron and different varieties of steel. Indian steel industry has shown strong performance in the recent past in terms of production, capacity utilisation, exports and consumption. India is now a major competitor among steel producers in the world. The sSteel industry contributes 1.3 per cent to India’s GDP and accounts for 10 per cent in Excise Duty collections. The industry provides employment to 0.4 million people directly and 0.6 million people indirectly. While this sector covers a large domain consisting of a variety of metals, this report focuses on four key metals...
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...Nucor Corporation: Competing against Low-Cost Steel Imports Week 8 Assignment Bus 599 Nucor Corporation is today one of North America largest steel maker company. Although the company has a strong position in the steel market today, things have not always been as positive. According to Crafting & Executing Strategy, Nucor was first known as Nuclear Corporation of America, a company involved in the nuclear instrument and electronic business in 1950’s and early 1960’s. Facing bankruptcy, the company changed direction and decided to invest in the stable steel-joist business. The new name, Nucor Corporation, came along with the change in 1972 to break away from the nuclear image and embrace the new venture. This transformational change was due to the vision of new CEO and president, F. Kenneth Iverson. His strategic initiatives revealed to be a blessing as Nucor Corporation has been successfully growing since its creation. Discuss the trends in the steel industry and how it may impact Nucor’s strategy. The electric arc furnace technology was introduced in 1960. The “mini-mills” was limited when compared to integrated mills in the industry. In addition, the operating costs of companies are lower compared to integrated mills because they use electric arc furnaces that can produce various steel products to minimize production costs. (Thompson, Strickland, & Gamble, 2010). Nucor Corporation started using thin-slab casting during the 1980’s and it was their...
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...HOT ROLLING MILL (HRM): Salem steel plant is a special steel unit of the Indian Steel giant. Steel Authority of India Limited (SAIL) pioneered the supply of wider cold rolled stainless steel coils and sheets in India. Phase-1 of the plant was commissioned in 1981 with French technical know-how. The capacity was augmented from the initial 32,000 tons of cold rolled stainless steel sheets and coils to 70000 tons per annum in 1991under Phase-2 expansion. A most modern stainless steel blanking line was installed in 1993 to produce coin blanks and utility blanks. The technical know-how foe the engineering process was done by the centre of engineering and technology (CET), the consultants of SAIL. The hot rolling facility commissioned in November 1995 has an installed capacity of more than 200000 tons of hot rolled flat products. The main four high steckel hot strips mill, four high reversing roughing mill and down coiler have been supplied by M/S SMS SCHLOEMANN SIEMAG, Germany. ITALIAMPIANTI, Italy have supplied the walking beam reheating furnace and M/S TOSHIBA, Japan have supplied the roll grinding machines. The main electronics are supplied by M/S Siemens, Germany. The hot strip mill, the mother unit of hot rolling facility is provided with hydraulic Gange setting and Automatic Gange Control (AGC). The continuously variable crown (CVC) which controls the profile flatness by the work roll shifting and bending ensures top notch quality hot rolled products meeting customer’s exact...
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...INTRODUCTION KNG Ribbed Steel is an easily weldable, high strength and high bond reinforcing steel which conforms to Indian Standards IS 1786-2008 and International Standards ASTM-A497,BS-4483, 4449, DIN 488. It can be produced in Fe-500 and Fe-550 grade. The availability in smaller diameter sizes makes it very economical and helps contribute to conservation of steel. FEATURES 1. Can be used with any grade of concrete, M20 and above 2. Made from low Carbon mild steel (less than 0.20% Carbon) 3. Diameter sizes of 5mm, 6mm, 7mm, 9mm are available in Fe 500 and Fe 550 grade MANUFACTURING PROCESS 1. Superior and latest German technology called ’Cold Rolling and Ribbing’ is involved in the manufacturing of KNG Ribbed steel 2. The processes ’Cold Flattening’ and ’Cold Ribbing’ make KNG Ribbed Steel stronger than Hot Rolled bars 3. International quality manufacturing process that involves latest technology makes KNG Ribbed Steel the best choice in terms of quality and efficiency ADVANTAGES 1. Ultimate Strength: KNG Ribbed Steel has a high proof strength of 550 N/mm2 compared to a proof strength of 415/500 N/mm2 of the 415/500 grade steel 2. Excellent Replacement: Conventional high strength deformed bars of Fe 415/500 grade, of diameters 8mm and 10mm can be replaced by KNG Ribbed Steel of diameters 7mm and 9mm. Similarly, KNG Ribbed Steel of diameter 5mm can replace mild steel bars of 6mm, which is often used as secondary reinforcement ...
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...STEEL INDUSTRY ANALYSIS 1. Industry trends: Indian and Global perspectives, recent happenings. Steel is the back bone of human civilization, it is very crucial in development of a modern economy. The per capita consumption of steel shows the living standard of people in any country. Global Perspective: The industry directly employs about more than two million people worldwide, with a further two million contractors and four million people in the supporting industries. Considering steel’s position as the key product supplier to industries such as automotive, construction, transport, power and machine goods, and using a multiplier of 25:1, the steel industry is at the source of employment for more than 50 million people. World crude steel production has increased from 851 mega tonnes (Mt) in 2001 to 1,527 Mt in 2011. (It was 28.3 Mt in 1900).World average steel use per capita has steadily increased from 150 kg in 2001 to 215 kg in 2011. India, Brazil, South Korea and Turkey have all entered the top 10 steel producers list in the last 40 years. World Steel in Figures 2012 The World Steel Association (world steel) has published the 2012 edition of World Steel in Figures. World Steel in Figures provides essential facts and statistics about the global steel industry. The book contains comprehensive information on crude steel production, apparent steel use, pig iron production, steel trade, iron ore production and trade, and scrap trade. World Steel in Figures lists major...
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...Tension Test [pic] (Fractured Copper Specimen) By: Christl Burns Mechanics of Materials Sec. 4 Lab Preformed on: 2/9/12 Introduction The tensile test was preformed on the following commonly used materials; 836 Cold Rolled Steel, T351-2024 Aluminum, 110 Copper, Grey Cast Iron, and HDPE Plastic. The first objective was to examine the stress-strain curves in order to calculate and identify the significant mechanical properties of these materials. The curves are also used to give a better understanding of what these mechanical properties mean. The second objective was to compare the mechanical properties and physical appearance of these materials. In order to get the stress-strain curves, each specimen was placed in the tensile testing apparatus. The load frame slowly stretches the specimen until it breaks. The extensometer, was placed directly on the specimen and was hooked up to a computer program that collected all of the data, which was used to make the stress-strain curves. Procedure First a punch was used to mark off a two inch section on each specimen. This section was marked off so that it could be used as a reference in finding the elongation of the specimen.Then, using a caliper, the diameter of each was measured and recorded. Now the mechanist calipers were set up in increments of 0.05 inches starting at 2.05 inches. Next the specimen was loaded into the tensile testing apparatus, the extensometer was put onto the specimen, and the data-acquisition...
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