Copar - Rolling Process

Bottlenecks in Rolling Mills is the project that presents the individual production capacity for all the products of a rolling mill considering all the equipment involved with the production area, in matrix form and in graphical form. The different types of steels, weights and bundle lengths are considered when determining the product list.

The bottleneck matrix allows to identify the production capacity limit for each product, the bottleneck production equipment, and the capacities for all other rolling mill equipment. Thus we have an excellent tool to determine the investment strategy for the rolling mill and to facilitate production scheduling from effectively real capacity data.

Considering the variations of product mix, operational utilization, and working time, it is posible determine accurately the annual production capacity, or the monthly capacity of the rolling mill. The managers of the company can use or simulate production conditions that take into account the actual capacity of the mill. Companies that use bottlenecks effectively dominate their production and investment scenarios.

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Roll pass design for roughing, intermediate, and finishing mills. The pass design is developed for rebars, rounds, sbq rounds, wires, squares, flats, angles, tees, and channels.

The study of the contact is presented for all passes of the rolling mill. This allows to determine a long groove life. Increasing the groove life we have a production with more quality and less downtime due to lower set ups.

For all passes are calculated the rolling power, the bite conditions, the groove factor, the effective diameter factor, the deformation, the area reduction, the process parameters and many other information.

Drawings of grooves, templates, groove profile, roll barrel and rolling schedule are presented, allowing easy viewing of the nominal gap for each pass.

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Projects and studies to promote quality in rolling mills. The studies are designed to increase the quality of products and processes. Problems of existing defects are solved from the study of the deformation in the rolling passes: area reduction, groove drawing, contact study, irregular wear groove, and others.

Defects like cracks, stripes, laps, scales, rolls marks, incrustation of scale, overlaps and others are eliminated from the process ensuring a product of excellent quality.

The parameter rolled billets against lost billets and the rolling mill productivity improves with the elimination of process defects.

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The specification of new equipment for rolling mills is performed from the calculation of the passes power, rolls diameter, and rolling speed.

Considering the rolling stands, are specified the motors for nominal power, basic and maximum speed, the gearboxes for gear ratio and admissible torque, the rolls for mechanical safety and material specification, drive shafts for size and torque, and couplings for admissible torque.

Flying shears, cooling beds, and cold shears are specified too.

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Safety studies for the main equipment of a rolling mill are developed from the calculation of the rolling efforts of the passes.

The equipment checked for safety is: motors, gearboxes, drive shafts, couplings, rolls and bearings.

The calculations allow predicting situations of insecurity and we can strengthening the drive of the stand to avoid the risk of overloading or even breaking the equipment. The process conditions can be modified to avoid overload problems in a rolling mill.

Flying shears, cooling beds and cold shears have their operational safety checked too.

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The rolling process can be simulate using the HRS software. The roll pass design of the rolling mill can be done using the HRS too.

This system calculates the powers, the steel deformation and the main parameters of the process like bite conditions, forward slip, control factors for the automation, tension between passes, gap settings, contact study, speeds, metallurgical structure in the roughing mill, and measures for the dimensioning of guides.

HRS software can be used in simulation studies for rolling mills. It can also be sold to the customer if desired.

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Projects for the development of new products in the rolling mill program. These projects study the feasibility of the product from the point of view of deformation and from the point of view of the existing equipment capacity.

The complete roll pass design for the rolling process of the new product is developed and we can do the follow up of the preparation for rolls, guides and control factors. We can also participate in the start-up. The best process quality concepts are used to ensure the desired result in the product.

Studies of Master Plan and Strategic Planning for the development of rolling mills creating an important tool for the management of investments in the rolling mill or improvements in the existing situation.

Technical support about rolling process to the areas of engineering in the steel companies.

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Support to the implementation of projects for the management of the rolled billets against lost billets operational parameter in rolling mills, determining an important increase in the productivity of these mills.

These projects have demonstrated an intense increase of the performance in the rolling mills, reaching levels never before achieved.

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Complete program for the training of roll pass designers in rolling mills. The development of the professional is done according to the following steps:

1. Complete knowledge of the rolling process

2. Roll Pass Design for round bars, rebar and wire rod

3. Roll Pass Design for sections 

4. Process calculation for checking rolling equipment

 

The roll pass designer training will be done according to his program of interest. See below the training alternatives considering the 4 points indicated above.

a) Roll Pass Designer of Bars and Wires: training in points 1 and 2

b) Roll Pass Designer of Sections: training in points 1 and 3

c) Roll Pass Designer of Bars, Wires and Sections: training in points 1, 2 and 3

d) Senior Roll Pass Designer: training in points 1, 2, 3 and 4

This type of training that we do is unique in the world.

 

Training time:

1 year for roll pass designer of bars or roll pass designer of sections

1,5 to 2 years for roll pass designer of bars, wires and sections, or for senior roll pass designer.

During the training program the professional does not stop working in his company.

 

The training program is theoretical and practical. The practice is done in his company or in a rolling mill available.

The meetings can be face-to-face or virtual using online contact tools.

Our professional experience is transmitted integrally to the professional in training.

After the training period, it is guaranteed that professionals dedicated to the program will be fully trained in roll pass design.

We certify the trained professional as roll pass designer.

He will be ready to work within the company with all his knowledge.

Contact us using our contact form.

 

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Training programs for rolling mill people creating a learning sequence unique in the world. These training programs allow to operational people a complete evolution in their knowledge of the rolling process. Our training programs provide direct support to the training and human resources areas of steel companies.

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HRC Hot Rolling Control: DIGITAL OPERATOR

Operational Process in the Hand

New project. Unique in the world.

The rolling process in the hand of the operational people and their supervision.

There will be no further problems with rolling mill adjustments. There will be no more quality problems generated in the process. The operational people will know exactly what they are doing.

We have arrived in the future before. Ask for information through our contact form.