Jamuria Structural mill roll failure - probable causes & it’s solution.

As I have studied the old records for structural mill roll failures, found no particular
description, photos of failure zones and primary observations are archived. So probable roll
failure modes analysis in case to case basis could not be made and realistic failure causes
happen to take places in the operating structural mills in other plants are being mentioned here
under for roll failures occurred in the Jamuria structural mill.

PROBLEMS POSSIBLE REASONS FEASIBLE RECTIFICATION

Roll neck bearing running  Insufficient cooling /  Proper cooling to be
hot lubrication. immediately ensured.

 Too much tightening of  Temperature of the roll neck

the bearings against the bearings are to be checked
roll collars. time to time so that the
bearings do not run hot.

 Excessive rolling speed  Hot bearings scores roll

when the heat accumulated necks to propagate early
does not get dispersed. failures of the bearings.

 May develop thermal cracks

in the roll necks causing
early failure.

 Proper tightening of the

Quick wearing out of the
roll passes – less pass life in
terms of lower tonnage
rolled.
 Insufficient cooling of the
rolling grooves.
 Insufficient heat of the
materials being rolled –
lower temperature and
lower heat content of the
billet.
bearings against the roll
collar to be ensured.
 Proper cooling of the roll
passes to be immediately
ensured.
 Proper temperature and heat
content of materials to be
rolled needed to be ensured.

 Higher drafting in the pass  Proper material of striper

in question resulting from guides to be ensured.
the wear out of the
previous pass

Breakage of connecting  Insufficient heat of the  Proper temperature and heat

couplings. materials being rolled – soaking of rolled materials
lower temperature and to be ensured.
lower heat soaking causing
 increase in the torque
while rolling.
 Casting defects e.g. blow
holes, cracks etc.
Roll breakage from the  Insufficient cooling /
journal. lubrication roll neck
bearings, resulting in the
roll neck to run very hot.
 Casting defects e.g. blow
holes, cracks etc.
Roll breakage from the  Over drafting.
barrel.
 Insufficient heat of the
materials being rolled-
lower temperature & lower
heat content.
 Insufficient cooling of the
rolling grooves.
 Checking of the coupling
boxes castings before
putting into the mill
operation.
 Proper feeding of the
material to be ensured so
that thereis no sudden end
thrust.
 Proper cooling of the roll
neck bearings to be ensured.
 Checking of the roll casting
before putting into the mill
operation.
 Drafting to be as per norm.
 Proper temperature & heat
content of the to be rolled
materials to be ensured.
 Proper cooling both from
the top & bottom of the roll
barrel particularly the
rolling grooves are to
ensured.