Roll Pass Design and Mill Operation

During this time we will cover the basics of metal deformation, the rolling of steel, and Roll Pass Design concepts. The course will provide the participants with the theoretical knowledge, practical skills, and confidence to deal with day-to-day roll pass, quality, and production issues.

Engineers and mill operators typically learn their craft in the mill from the more experienced workers. Rarely does the opportunity arise for the ability to step back and analyze the rolling process without the pressure of the production environment. This course offers that chance. We will study the roll pass design, equipment and methods used in the production of hot rolled steel.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

• Apply the latest Techniques, tools and Procedures on Roll Pass Design and mill Operation
• Review and updated knowledge on hot rolling concepts and the metallurgy of rolling for Ferrous
• Determine the different elements of roll pass design according to power, torque and separating force calculations
• Recognize the aspects of rounds and rod pass design & become acquainted with round rolling sequences
• Apply several guiding and troubleshooting techniques in roll pass design and mill operation
• Enhance knowledge on beams and channels through their products, tolerances and sequences
• Recognize the various types of angles as well as several angle products and their tolerances

Course Outline

Day 1

HOT ROLLING CONCEPTS

• The metallurgy of rolling
• Plastic deformation
• Average reduction and elongation
• Bite angle calculations and limitations
• Mass flow

ROLL PASS DESIGN

• Billet to product
• Rolling plan
• Breakdown sequences
• Spread
• Power, torque, and separating force calculations
• Creating and using power curves

Day 2

MILL LAYOUTS AND EQUIPMENT CONSIDERATIONS

• Historical mill arrangements
• Reheating
• Rolling mill arrangements
• Finishing Considerations
• Mills layouts
• Continuous mills
• Cross-country mills

FLAT PASS DESIGN

• Types of flat products and their tolerance
• Flat rolling sequences
• Example flat pass design

Day 3

ROUNDS AND RODS PASS DESIGNS

• Types of round products and their tolerances
• Round rolling sequences
• Example round pass design
• Finishing block rolling

ANGLES

• Angle products and their tolerances
• Angle rolling sequences
• Example angle pass design

Day 4

BEAMS AND CHANNELS

• Beam products and their tolerances
• Beam rolling sequences
• Example Beam pass design
• Channel products and their tolerances
• Channel rolling sequences
• Example channel pass design

GUIDING

• Basic guiding
• Static guides
• Roller guides
• Shape guiding

Day 5

TROUBLESHOOTING

• Defect cause and effects
• Products tolerances
• Production

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation