Company:

Company
Our Advantages
Manufacturing Facilities
Promoters
Quality Control

Company

IRLE KAY JAY ROLLS PVT LTD has been set up in the year 2007 as a joint
Venture between WALZEN IRLE GmbH, Germany and KAY JAY CHILL ROLLS
PVT LTD, India. It is a new green field project using latest state of art
technology for the manufacture of Mill Rolls used in the various industries.

It is located in the green, unpolluted environs of Barwala & Panchkula,

adjoining the beautiful & lush green city of Chandigarh, which is the most
modern Indian city. Panchkula & Chandigarh are situated 250 Kilometers
north of Indias capital, New Delhi.

Our manufacturing facilities & equipments boast of latest German

Technology from WALZEN IRLE GmbH, having more than 190 years of
immense experience in Roll Making. Grades & quality of rolls manufactured
at IRLE KAY JAY ROLLS will be to the specifications of WALZEN IRLE, under
their supervision. The staff and technical personnel of IRLE KAY JAY ROLLS
have been trained at WALZEN IRLE to assure Rolls manufactured meet the
highest and stringent international quality standards. As such we call them
TOOLS OF PERFECTION.
Get the best essay help essaysale.net/essay-help.
The complete range of rolls for various industries &applications will be
marketed by IRLE KAY JAY ROLLS in India, using about 40 years of experience
of KAY JAY CHILL ROLLS in manufacturing & selling rolls in India and in other
countries.

Most of the equipments in our foundry & machine shops have come from
WALZEN IRLE GmbH, Germany, besides some new equipments purchased
from Europe, USA & with in India.

After R&D and technical support from Walzen Irle & Kay Jay Chill Rolls, IRLE
KAY JAY ROLLS also developed and starting manufacturing Roll Grinding &
Fluting Machines.

Irle Kay Jay Rolls is an ISO 9001 Certified Company.

Our Advantages

German Technology for High Quality Rolls

Trained Staff from Germany for quality assurance

Induction Melting Furnaces for best molten metal

Complete Quality Control Lab. to attain right composition of molten

metal

Spin Casting Machines of Latest Design for best casting results

CNC Lathe Machines for quality, speed & accuracy

Boring Machines for proper boring of the rolls

Grinding Machines for best finish on the rolls & shafts/journals

Balancing Machine for vibration free operation & to increase life of

machines

Quality Control Equipments to check & confirm the quality of our rolls

An ISO 9001 Certified Company

Manufacturing Facilities

Foundry

Complete new manufacturing facilities were made for Irle Kay Jay Rolls Pvt
Ltd, under technical supervision our German Parent Company. We produce
mill rolls for various industries with highest quality standards. Most of the
equipments in our foundry & machine shops have come from WALZEN IRLE
GmbH, Germany, besides some new equipments purchased from Europe,
USA & with in India.

Foundry Capacities
Melting Facilities: 2 electric melting furnace (induction
furnaces), to produce a roll of up to 7.5 Tons.

Testing Facilities: Modern and computerized laboratory

equipments for in-process quality controls.

Casting Facilities: Horizontal Centrifugal Casting Machines

to produce a roll of maximum 1200 mm diameter

Heat Treatment Facilities: Our foundry is capable of heat treatment of

the rolls (if required), up to 450C.

Machining

Complete new manufacturing facilities were made for Irle Kay Jay Rolls Pvt
Ltd, under technical supervision our German Parent Company. We produce
mill rolls for various industries with highest quality standards. Most of the
equipments in our foundry & machine shops have come from WALZEN IRLE
GmbH, Germany, besides some new equipments purchased from Europe,
USA & with in India.

As per the specifications & drawings of the rolls, we have complete range of
machines & equipments are installed to carry out various operations like,
turning, boring, milling, shaft fitting, finishing, grinding, fluting, dynamic
balancing, inspection & control.

Our machine shops are also capable of handling rolls of 1200 mm diameter
and 7.5 Tons in weight.

For the production of Roll Grinding & Fluting Machines, we also have
complete equipment and machinery.

Machining Capacities

Machining: CNC Controlled Turning Machines, Boring Machines, Milling

Machines, Grinding Machines, Fluting Machines, Dynamic Balancing
Machines, Honing Machine, Slotting Machine, etc.

Promoters
Walzen Irle GmbH from Germany
www.walzenirle.com

WALZEN IRLE is a world-wide leading company in the

production of rolls for various areas of industry. WALZEN IRLE stands for over
more than 190 years of experience, technological competence and
continuous research and development in the production of rolls.

The traditional and consequently close cooperation with machine builders

and operators of constructions has lead to permanent and successful
improvements of the Walzen Irle technologies and has made them an
innovative technology leader.

Kay Jay Chill Rolls Pvt Ltd from India

www.kjrolls.com

Kay Jay Chill Rolls has established itself

as a trustworthy name in manufacturing chilled cast iron rolls or mill rolls by
the centrifugal casting process using the double pour technique since the
year 1979.

Kay Jay Chill Rolls is a family owned company located in Panchkula. Kay Jay
Chill Rolls has been exporting & supplying rolls used in flour milling, oil seed
crushing & flaking, feed milling, pipe & tubes mills to the full satisfaction of
its customer. Kay Jay Chill Rolls is a leading company for roll manufacturing
in India.

Quality Control

Since we are a subsidiary of a German Roll Manufacturing Company therefore

quality is always our highest priority. We have full technical support from our
German Partners, whenever it is required and for any kind of support. We
have got standards and other special parameters from Germany to make
good & consistent quality rolls & machines, which are strictly followed by us
while the manufacturing process is going on. The same is also reviewed by
our German Parent Company from time to time.

We are An ISO 9001 Certified Company, Please Click Here to view the
certificate

We have all the necessary equipments & instruments which are required to
control good quality rolls & machines.

Company

Company
Our Advantages
Manufacturing Facilities
Promoters
Quality Control

Products-Machines

Combined Roll Grinding and Fluting Machine

Roll Grinding Machines
Roll Fluting Machine (Grooving Machine)
Sand Blasting Machine

Grinding cum Fluting Machines

This grinding cum fluting machine serves to grind & flute blunt chilled
cast iron rolls (mill rolls), but it also fulfills the requirement of other
types of industries where chilled rolls are employed for similar
purposes. For example: flour mills, feed mills, oil seed crushing &
grinding, etc.

Capacity:
 Suitable to machine rolls with max. diameter of 400 mm and
length of 1600 mm.

Spiral cutting up to 20%. Left and right spiral can be cut.

Number of flutes from 100 to 1200.

Grinding wheel diameter 500 mm max.

Features:

Extra heavy duty cast iron bed forms a rigid base where the
machine table travels on Prismatic and Flat guides.

Grinding/Fluting head is mounted on machine basement.

Easy positioning and changing of head from grinding to fluting

side.

Complete with grinding wheel and fluting tools holder.

The fluting control is carried out by driving head and indexing

gears.

The cutting tools are fixed on tool holders, two cutting tools can
be used at a time.

The roll turning movement is automatically driven by the

carriage movement and pitching mechanism.

Forced lubrication system ensures perfect lubrication of all

moving parts and guides.

Rolls support universal type.

Equipped withal necessary motors and electric panels.

 Technical

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Rolling mill Rolls and Roll Shop

Posted by Satyendra on Dec 10, 2015 in Technical | 0 comments

Rolling mill Rolls and Roll Shop

Rolls are the main and very costly consumables in a rolling mill. They are
used to roll steel in the rolling mill and their performance depend on many
factors which include the materials used and the loads to which they are
subjected to during service. The roll design is influenced by the limitations
applied by the rolling load, the roll strength and the torque available for
rolling. In case of flat rolling it is also influenced by the allowance made for
roll bending and by cambering of the rolls. The roll design is to take-care the
load and torque required for any pass. In addition it must ensure that the
physical dimensions and material of the roll are capable of withstanding the
heaviest loads arising during the rolling sequence. Another important factor
where roll life is concerned is the wear properties of the roll material.

Roll materials

In the rolling of steels, the material of the rolls is to be capable of

withstanding loads which plastically deforms the rolling stock without itself
being plastically deformed. In the rolling of hot steel this is not a difficult
problem and iron or steel rolls are suitable if they are operated at a
temperature considerably lower than that of the rolling stock. Whether iron
or steel rolls are used in any particular case depends on the specific duty
they have to perform and whether toughness, resistance to thermal cracking
or shock loading or hard wearing properties is most important.

Rolls can be classified according to the roll materials (Fig 1) and the method
of manufacture, the first main subdivision being (i) iron rolls, and (ii) steel
rolls. This division depends on the carbon content of the material. In the case
of rolls the demarcation line is usually taken at about 2.4 % C. Normally rolls
are referred as being steel base below this figure, and iron base above this
figure. There is a marked structural distinction between these two types as
there is no free graphitic carbon in steel base rolls. Steel rolls may be either
cast or forged so giving a further subdivision. One other division which cuts
across the above classification is that of double poured duplex rolls which
may be cast with a hard metal outer surface and a tougher and stronger
metal forming the centre of the roll.

Fig 1 Classification of rolls based on roll materials

Iron rolls

Iron rolls are of the following types.

Grey iron rolls These are cast by sand casing and consist of grey cast
iron (contains flakes of free graphite). The structure of the roll is
uniform throughout and is very resistant to fire cracking. It is to some
extent self-lubricating due to the free graphite which is an advantage
where thrust collars arc used to resist end thrust during rolling. A
typical analysis of the roll material is carbon (C) 2.5 % to 3 %, silicon
(Si) 0.5 % to 1 %, manganese(Mn) 0.4 % to 0.8 %, phosphorus (P)
0.5 % max, and sulphur (S) 0 0.1 % max. The P is allowed up to 0.5 %
to increase the fluidity of the metal during pouring but it is
advantageous to reduce this if higher casting temperatures are
possible as P is deleterious to the properties of cast iron. S is kept to a
minimum and Si is chosen to regulate the free graphite content, since
the presence of Si promotes graphitization. Mn is used to neutralize the
 S and to deoxidize the metal. Too high a Mn content resists
graphitization.

Alloy iron rolls To improve the quality of the grey cast iron various
alloying elements may be added to give the roll an increased hardness.
These alloy iron rolls have only small quantities of nickel (Ni),
chromium (Cr) and molybdenum (Mo) and they give slightly better
wear and strength than the straight grey iron. The alloy iron roll with
higher quantities of alloy additions is much harder and wears better
though naturally it is more costly and must yield higher rolled tonnage.
The presence of Ni promotes the formation of graphite but as it is in a
very finely distributed form it leads to greater toughness and
resistance to fire cracking. Cr increases the tendency to form combined
carbon and restricts graphite formation so giving a much harder but
more brittle iron. Mo and tungsten (W) promote the formation of
combined carbon and in addition they add to high temperature
strength. With a Cr alloy iron there is a tendency for collar breakage in
section rolls due to the brittleness and in addition a good supply of
water is necessary for cooling the rolls to avoid fire cracking. A typical
analysis of the roll is C- 3 %, Si- 1%, Ni 1 % (or Mo -0.5 %) and Cr 1
%. A common brand of alloy iron roll is Adamite iron. The hardness of
rolls is a measure of the resistance to wear and it is usually expressed
in degrees of Shore scleroscope hardness. The relatively soft grey iron
rolls have hardness of 30-40 deg Shore, but these can be increased to
the range 38-50 deg in the alloy iron rolls. This latter is a grey iron but
the graphite is finely divided and the matrix is harder. Softer rolls are
favoured for the roughing and intermediate stages of rolling and the
harder alloy grain ones for finishing.

Clear chill or definite chill rolls A clear chill roll has a surface layer of
white iron produced by inducing rapid cooling at the surface (by means
of a chill in the mould) which restricts the formation of free graphite.
The core is of grey iron due to the slower rate of cooling and the
intermediate zone is a mixture of white and grey iron. The necks and
wobblers or spade ends are not to be chilled and hence retain greater
toughness. The chilled layer is hard and wear resistant but it is brittle.
It is generally about 25 mm thick on plain rolls but may be increased
where shallow grooves are required. The analysis is similar to grey iron
rolls though the C content is higher. Lower C gives a lower hardness
but it strengthens the roll and reduces the incidence of surface
cracking and spalling hence it is used in cases of high stress such as in
 plate rolling. The surface hardness may be between 55 and 65 deg
Shore but the rolls have good resistance to temperature change and
fire cracking. A part chill roll is produced by chilling chosen parts of the
barrel (e.g. finishing passes) and leaving the rest as grey iron. Alloying
elements may be added to chill rolls to give hardness values of 65 to
90 deg Shore and may contain about 4.5 % of Ni with Cr balance the
tendency to form free graphite. The Ni bearing chill rolls are claimed to
have a work hardening tendency and are more suitable for cold rolling
due to their susceptibility to fire cracking.

Composite or duplex roll A method of combining a very hard surface

with a tough core is to cast the roll by double pouring. The first pour
gives a shell of highly alloyed white iron which cools rapidly on the
surface in a chill mould after which the second pour (often of grey iron)
displaces the molten centre of alloy iron and replaces it with a tough
core. The shell hardness is 75 95 deg Shore.

Indefinite chill With this type of roll there is a very thin clearly defined
white graphite-free chill and no intermediate mix zone. The surface
layers contain very small particles of graphite and the structure
changes smoothly into the grey core. The hardness decreases slowly at
first from the surface at a rate of about 1 deg Shore per 10 mm of
depth and then more quickly towards the soft centre. Hence there is a
good usable depth. The surface is more resistant to fire cracking and
spalling than the definite chill roll and the rolls grip the rolling stock
better. An alloy indefinite chill roll with a surface hardness of 55 to 75
deg Shore may contain Ni, Cr, and Mo. These rolls may be heat treated
to toughen them against shock loadings. An example of this type is the
Adamite indefinite chill. These rolls may be heat treated and are
resistant to spalling and fire cracking.

Spheroidal graphite iron rolls Spheroidal graphite (SG) iron rolls are
finding use in some mills. It is having graphite in the nodular form
when cast by the use of a special casting procedure involving the
addition of magnesium (Mg). The spheroidal graphite iron has much
greater strength and toughness, the former being about twice that of a
high duty flake graphite iron and the latter is increased about twelve
times. Most of the rolls have a pearlitic structure but the acicular
structure is also available giving better wear resistance. A good finish
may be obtained on the rolls though care in machining is necessary as
noxious fumes are given off. The wear properties of SG iron rolls are
 that they wear evenly and at a similar rate to flake graphite iron. They
are suitable for use where a normal iron roll is not strong enough and
where steel rolls give poor life due to excessive wear but, as they are
more expensive than both iron and steel rolls, care in the choice of
application is necessary. Hardness can be obtained up to 80 deg Shore
or more.

Steel rolls

Steel rolls may be cast or forged. They are much stronger and tougher than
iron rolls and are used therefore where an iron roll is considered not strong
enough. They permit heavier draughts to be used especially where deep
grooves are required. Breakages due to shock loading are much less likely to
occur and the properties can be varied considerably by suitable heat
treatment. However, C steel rolls wear more quickly than iron rolls due to
their low hardness.

Cast steel rolls These may vary considerably according to analysis.

The straight C roll has from 0.40 % to 0.90 % C and the hardness is
from 28 to 36 deg Shore. Heavy mills (blooming, slabbing and heavy
roughing) use the lower grades (up to 0.60 % C) while billet roughing
stands use the higher grades. The addition of about 0.5 % Mo to this
type of roll together with small amounts of Ni and Cr (or higher Mn)
gives increased strength and reduces the severity of any fire cracks
which may occur. The hardness is 30 42 deg Shore. More highly
alloyed rolls usually lie within the ranges of analysis having C 0.80 %
to 1.0 %, Mn 0.60 % to 0.90 %, Ni 1.0 % to 2.5 %, Cr 0.50 % to
1.10 % and Mo 0.20 % to 0.40 %. A C- Cr roll (C -1 %, Cr 1.5 % to
1.75%) is also made. These rolls are usually heat treated, the hardness
range is 35 -55 deg Shore and they are commonly used as back-up
rolls in 4-high rolling mills. An alloy steel containing tungsten (W) and
with a hardness of 40 50 deg Shore is very resistant to fire cracking
and is sometimes used for roughing rolls in hot strip mills. Cast alloy
steel base rolls are made also with the analysis ranging C 0.9 % to
2.5 %, Si 0.5 % to 1.0 %, Mn 0.4 % to 0.6 %, Ni 0.25 % to 1.0 %,
and Cr 0.5 % to 1.5 %. The C content is in a higher range than in the
cast steel roll. The entire C is in combined form. The hardness range is
30 55 deg Shore, according to C content, and the rolls wear well and
are strong. The life is in line with the cost. Good water cooling is
required.
 Forged steel rolls These rolls are forged from a cast steel ingot and
the necessary mechanical working results in an improved tougher
structure. In the C steel form (0.35 % to 0.75 % C) they are used for
blooming, slabbing and heavy roughing mills in the lower end of the C
range and for smaller intermediate mills in the higher end of the range.
This is somewhat arbitrary and depends on the particular mill
conditions. They are normalized before use and the hardness range is
24 30 deg Shore. In the alloy steel form they may be heat treated to
give a wide range of hardness. In the range 50 55 deg Shore range,
they are used for large back-up rolls, around 80 deg Shore range for
small back-up rolls in cold rolling, and 90 100 deg Shore range (fully
hardened) for work rolls in cold rolling. A typical analysis is 1 % C, 1.5
% to 1.75 % Cr and 0.5 % Ni. Forged steel rolls in the hot rolling
hardness range are highly resistant to shock loading.

ESSENTIAL DUTIES AND RESPONSIBILITIES

o Support Account Management in fielding routine and ad hoc

client requests

o Conduct strategic fleet analyses and provide accurate, timely

interpretations of vehicle cost, use patterns and trends that focus
on running and optimal fleet

o Work independently with stakeholders to define ad hoc analyses

and develop complex modeling tools and repeatable business
process

o Extract and manage large volumes of data, synthesize and

interpret the results and display the findings as appropriate, in
creative and easy to understand charts and tables

o Structure data visualization tools for appropriate data source,

filtering, and statistical methodology application

o Develop a working understanding of the Wheels tools and

databases and how to access data, fleet metrics, fleet reports

o Maintain a consummate team attitude that fosters creative

development within the organization
 o Assist project coordinators with the development and execution
of Results+ deliverables and other duties and special
assignments

Desired Skills and Experience

SKILLS/COMPETENCIES

o Strong analytical skill

o Proficiency in Microsoft Office

o Development in data visualization tools (Tableau/Qlik)

o Great organizational and planning skills

o Excellent verbal, written and interpersonal communication skills

o Ability to function in multi-project environment with tight

deadlines

EDUCATION and/or EXPERIENCE

Bachelor's Degree in finance, statistics, economics or math; or a

minimum of 5+ years experience analyzing data and developing
solutions utilizing business analysis tools

Masters Degree preferred

LANGUAGE SKILLS

Ability to synthesize vast amounts of data into clear, understandable

summary form and articulate and display results

Ability to write clear, concise reports, business correspondence

MATHEMATICAL SKILLS
 Ability to work with mathematical concepts such as probability and
statistical inference

Ability to apply concepts such as fractions, percentages, ratios, and

proportions to practical situations

REASONING ABILITY

Ability to apply principles of logical or scientific thinking to a wide

range of intellectual and practical problems

Notes

Degarmo, Black & Kohser 2003, p. 384.

Degarmo, Black & Kohser 2003, p. 408.
http://www.mostredileonardo.com/site.asp?
idSito=1&idLingua=10&idPagina=246
Landes, David. S. (1969). The Unbound Prometheus:
Technological Change and Industrial Development in Western
Europe from 1750 to the Present. Cambridge, New York:
Press Syndicate of the University of Cambridge. p. 91. ISBN
0-521-09418-6.
Swank, James M.,History of the Manufacturers of Iron in All
Ages, Published by Burt Franklin 1892, p.91
Roberts 1978, p. 5.
R. A. Mott (ed. P. Singer), Henry Cort: the great finer (Metals
Society, London 1983), 31-36; English patents, nos. 1351
and 1420.
Roberts 1978, p. 6.
Degarmo, Black & Kohser 2003, p. 385.
Degarmo, Black & Kohser 2003, p. 387.
Degarmo, Black & Kohser 2003, p. 388.
http://metalsforasteel.com
"Hot Rolled Steel". Retrieved 31 March 2014.
 Capece Minutolo, F.; Durante, M.; Lambiase, F.; Langella, A.
(2005). "Dimensional Analysis in Steel Rod Rolling for
Different Types of Grooves". Journal of Materials Engineering
and Performance 14 (3): 373377.
doi:10.1361/01599490523913.
Capece Minutolo, F.; Durante, M.; Lambiase, F.; Langella, A.
(2006). "Dimensional analysis of a new type of groove for
steel rebar rolling". Journal of Materials Processing
Technology 175 (1-3): 6976.
doi:10.1016/j.jmatprotec.2005.04.042.
Lambiase, F. (2014). "Prediction of geometrical profile in slit
rolling pass". The International Journal of Advanced
Manufacturing Technology 71 (5-8): 12851293.
doi:10.1007/s00170-013-5584-7.
Lambiase, F.; Langella, A. (2009). "Automated Procedure for
Roll Pass Design". Journal of Materials Engineering and
Performance 18 (3): 263272. doi:10.1007/s11665-008-9289-
2.
Lambiase, F. (2013). "Optimization of shape rolling
sequences by integrated artificial intelligent techniques".
The International Journal of Advanced Manufacturing
Technology 68 (1-4): 443452. doi:10.1007/s00170-013-
4742-2.
http://spaco.org/hrvscr.htm
"Cold Rolled Steel". Retrieved 31 March 2014.
Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994),
Manufacturing Processes Reference Guide, Industrial Press
Inc., pp. 300304, ISBN 0-8311-3049-0.
http://www.enotes.com/how-products-
encyclopedia/aluminum-foil
Degarmo, Black & Kohser 2003, p. 386
Behrens, B.-A.: Final Report Summary - DEVAPRO
(Development of a variable warm forging process chain). 2nd
September 2015.
 Behrens, B.-A.: Forge Rolling. In: CIRP Encyclopedia of
Production Engineering.
ASM International: ASM Handbook Metalworking: bulk
forming. ASM International, 2005
Roberts 1978, p. 64.
Kindl, F. H. (1913), The Rolling Mill Industry, Penton
Publishing, pp. 1319.
G Pin, V Francesconi, FA Cuzzola and T Parisini. Adaptive
task-space metal strip-flatness control in cold multi-roll mill
stands. Journal of Process Control, 2012.
http://dx.doi.org/10.1016/j.jprocont.2012.08.008
Definition of standard mill terms, archived from the original
on 03-04-2010, retrieved 03-04-2010. Check date values in: |
access-date=, |archive-date= (help)[dead link]
Glossary of Metalworking Terms, retrieved 2010-12-12.

Roberts 1983, pp. 158162

Bibliography

Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003),

Materials and Processes in Manufacturing (9th ed.), Wiley,
ISBN 0-471-65653-4.
Roberts, William L. (1978), Cold Rolling of Steel, Marcel
Dekker, ISBN 978-0-8247-6780-8.
Roberts, William L. (1983), Hot Rolling of Steel, Marcel
Dekker, ISBN 978-0-8247-1345-4.
Doege, E.; Behrens, B.-A.: Handbuch Umformtechnik:
Grundlagen, Technologien, Maschinen (in German), 2nd
Edition, Springer Verlag, 2010, ISBN 978-3-642-04248-5
Further reading

Ginzburg, Vladimir B.; Ballas, Robert (2000), Flat Rolling

Fundamentals, CRC Press, ISBN 978-0-8247-8894-0.
Lee, Youngseog (2004), Rod and bar rolling, CRC Press, ISBN
978-0-8247-5649-9.
Swank, James M. (1965), History of the Manufacture of Iron
in All Ages (2nd ed.), Ayer Publishing, ISBN 978-0-8337-3463-
1.
Reed-Hill, Robert, et al. "Physical Metallurgy Principles", 3rd
Edition, PWS publishing, Boston, 1991. ISBN 978-0-534-
92173-6.
Callister Jr., William D., "Materials Science and Engineering -
an Introduction", 6th Edition, John Wiley & Sons, New York,
NY, 2003. ISBN 0-471-13576-3

External links

o Wikisource has the text of the 1921 Collier's

Encyclopedia article Rolling mill.

How Liners Achieve the Desired Quality of the Product Being

Rolled
History of Rolling Mills
Key to metals: Steel Rolling
Typical gauge distribution: Hot Rolled Steel
Stockiest, Slitters & Distributors of Cold Rolled Steel
Steel Rolling Mill Machines
Hot Rolled Steel