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milling mc

milling mc

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Published by: api-19775783 on Nov 28, 2009
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05/03/2015

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CHAPTER-1
1.1INTRODUCTION
What is Profile Hot Rolling?

As we know, Mechanical Working of a metal is simply plastic deformation performed to change dimensions, properties, and/or surface condition by means of mechanical pressure. Mechanical working may be either hot working or cold working. Plastic deformation above recrystallization temperature, but below the melting or burning point is called hot work. Some hot working processes are

Extrusion is a process in which a heated billet or slug of metal is forced by high
pressure through an orifice that is shaped to provide the desired form to the
finished part.
Drawing is pulling the metal through a die or a set of dies to achieve a reduction
in diameter.
Rolling is the most rapid method of forming metal into desired shapes by plastic

deformation in between rolls. In the hot rolling process, metal in a plastic state is passed between two rolls revolving at the same speed but in opposite direction. As metal passes through the rolls, it is reduced in thickness and increased in length. It is used either for changing dimension of metal sheets or for forming of bars having cross sectional area of simple shapes, i.e. square, rectangular

Think of the large number of small components used to manufacture a variety of appliances, instruments, equipment and machinery. From springs to blades, cutting tools to chisels and sections to rings. Though so large in numbers quantity when translated into tones. High precision parts which are used in small quantities may turn out to be too low weight wise to justify production on

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conventional Rolling Mills. The machining of rounds into different shapes to continues conventionally. The result? Increased labor, heavy tooling charges and prolonged schedules leading to a build up of unnecessarily large inventories at the users\u2019 end.

The Profile Rolling Mill, on the other hand, is a new concept in India and has some unique features. Various pre-shaped sections with stringent dimensional tolerances can be produced on it thereby avoiding the scrap generated due to turning or milling. We can also call this process as Unconventional Rolling process.

\ue000
Advantages Over Conventional Rolling
Such an arrangement of continuous heating & rolling has following advantages
over conventional rolling:
\u2022
Reduced scaling on account of electrical heating.
\u2022
Better dimensional tolerances due to reduced scaling.
\u2022
Consistency in dimensions due to continuous rolling.
\u2022
Reduced material wastage on account of better tolerances.
\u2022
Reduced cost of machining operations and saving in time.
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CHAPTER-2
2.1PROFILE HOT ROLLING MILL

The Profile hot rolling mill has a state of the art manufacturing facility for producing 6000 MT per annum of hot rolled & cold drawn solid steel sections with close dimensional tolerances. This mill is manufactured by FALCI in Italy. These types of only four mills are in the whole world. From these four mills two are it self in Italy, one is in U.S.A and last one is in India.

The uniqueness of this latest technology lies in the fact that the profiles are rolled from wire rods that are continuously heated on-line with electrical resistance heaters, unlike from billets that are heated in fuel fired furnaces in conventional rolling mills. Hot rolled profiles are solid shapes or sections that are manufactured from either billets or wire rods. Unlike extrusion, where molten metal is pushed through a die to obtain the required shape, the hot rolling process involves shaping of the heated billets or wire rods by passing through a set of rolls that are rotating in opposite direction. These roll sets are arranged in tandem in a number of rolling stands. The rolls have groves cut in it as per the specific roll pass design and each roll has a different set of groves. These profiles or sections have the same shape or cross section throughout the length i.e. they are two dimensional shapes.

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