US20140260476A1 - Manufacturing methods and apparatus for targeted lubrication in hot metal rolling - Google Patents

Manufacturing methods and apparatus for targeted lubrication in hot metal rolling Download PDF

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Publication number
US20140260476A1
US20140260476A1 US14/209,484 US201414209484A US2014260476A1 US 20140260476 A1 US20140260476 A1 US 20140260476A1 US 201414209484 A US201414209484 A US 201414209484A US 2014260476 A1 US2014260476 A1 US 2014260476A1
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nozzles
lubricant
lubrication
bite
cooling fluid
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Krzysztof Ryszard Januszkiewicz
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Novelis Inc Canada
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B45/00—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B45/02—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills for lubricating, cooling, or cleaning
    • B21B45/0239—Lubricating
    • B21B45/0245—Lubricating devices
    • B21B45/0248—Lubricating devices using liquid lubricants, e.g. for sections, for tubes
    • B21B45/0251—Lubricating devices using liquid lubricants, e.g. for sections, for tubes for strips, sheets, or plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
    • B21B27/06—Lubricating, cooling or heating rolls
    • B21B27/10—Lubricating, cooling or heating rolls externally
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B45/00—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B45/02—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills for lubricating, cooling, or cleaning
    • B21B45/0203—Cooling
    • B21B45/0209—Cooling devices, e.g. using gaseous coolants
    • B21B45/0215—Cooling devices, e.g. using gaseous coolants using liquid coolants, e.g. for sections, for tubes
    • B21B45/0218—Cooling devices, e.g. using gaseous coolants using liquid coolants, e.g. for sections, for tubes for strips, sheets, or plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B45/00—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B45/02—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills for lubricating, cooling, or cleaning
    • B21B45/0203—Cooling
    • B21B45/0209—Cooling devices, e.g. using gaseous coolants
    • B21B45/0215—Cooling devices, e.g. using gaseous coolants using liquid coolants, e.g. for sections, for tubes
    • B21B45/0233—Spray nozzles, Nozzle headers; Spray systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B21B2003/001—Aluminium or its alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
    • B21B27/06—Lubricating, cooling or heating rolls
    • B21B27/10—Lubricating, cooling or heating rolls externally
    • B21B2027/103—Lubricating, cooling or heating rolls externally cooling externally
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B45/00—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B45/02—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills for lubricating, cooling, or cleaning
    • B21B45/0239—Lubricating
    • B21B45/0242—Lubricants

Definitions

  • the present invention relates to manufacturing methods and apparatus for hot rolling sheet metal.
  • the invention provides manufacturing methods and apparatus having enhanced lubrication for improving the surface quality of rolled sheet metal, such as hot rolled aluminum.
  • the invention provides manufacturing methods and a rolling mill apparatus having enhanced targeted lubrication to improve the surface quality of rolled sheet metal and efficiency in production.
  • the invention is particularly useful in hot rolling of aluminum in a rolling mill having multiple stands of rollers.
  • the invention provides delivery of a lubricant, often a poorly-emulsified lubricant, to one or more lubrication nozzles for discharge to the rollers, preferably directed toward the roll nip or bite (e.g. bite nozzles).
  • the poorly-emulsified lubricant is delivered only to specific mill stands, rolls or headers.
  • the poorly-emulsified lubricant may be delivered to different mill roll stacks, rolls, or headers in different amounts or compositions. This targeted lubrication allows for improved control of lubrication (e.g. increased or decreased friction) at specific mill stands as needed.
  • the delivery rate of an additional lubricant or lubricant component should be such that it does not exceed the daily addition rate of make-up lubricant.
  • Targeted lubrication with a poorly-emulsified lubricant can rapidly improve the surface quality of rolled aluminum and improve consistency in lubrication during the rolling processing.
  • This feature may also be used to overcome various other mill control problems by either decreasing or increasing friction between the work roll and aluminum strip surfaces as required to control differential friction between aluminum and the top versus bottom work rolls or tension problems created by skidding at some mill stands.
  • FIGS. 2A-2B show schematics of aluminum hot rolling tandem mills in accordance with certain aspects of the invention.
  • FIG. 3 shows a conventional header (shown in view I, II) and a header modified (shown in view III) in accordance with aspects of the invention.
  • FIG. 4 shows a tandem mill with additional bite spray header in accordance with aspects of the invention.
  • FIG. 5 graphically exemplifies the effects of lubricants having differing emulsifier concentrations on oil film thickness during hot rolling.
  • FIG. 6 graphically exemplifies the effect of lubricants having differing oil-water concentration emulsions on oil film thickness during hot rolling.
  • FIG. 7 graphically compares the hot rolling loads with lubricants used in the form of emulsion with the rolling loads for the same lubricants in the neat form without water.
  • Embodiments of the invention relate to a rolling mill for hot rolling metal, particularly hot rolling of aluminum with a rolling mill having multiple stands of roll stacks and methods for rolling metal, as described herein.
  • the rolling of metals, such as aluminum, in hot-strip mills is a type of metal forming process that is well known.
  • metal stock is conveyed through a pair of rolls known as a roll stack and rolled into a coil or cut into sheets.
  • the type of rolling process is classified according to the temperature of the metal rolled. If the metal temperature exceeds its recrystallization temperature during rolling, the process is termed hot rolling; if the temperature remains below the recrystallization temperature, then the process is referred to as cold rolling.
  • the metal is rolled through multiple roll stands or stacks of rolls, the sheet of metal reducing in thickness as it passes through each stack and forming a smooth, finished surface.
  • the different stacks may have different configuration or operating condition or applied pressure depending on the process.
  • FIG. 1 depicts a conventional rolling mill having three roll stacks, Stack A , Stack B and Stack C, through which a sheet of metal 1 is reduced in thickness in a hot rolling metal forming process.
  • the mill includes a cooling system that discharges a cooling fluid, such as water but more often lubricating oil emulsion in water, onto the rolls to transfer heat and prevent overheating of the rolls during the metal forming process.
  • a cooling fluid such as water but more often lubricating oil emulsion in water
  • the cooling system includes a coolant pump 10 that pumps the same cooling fluid through various discharge nozzles of the cooling system.
  • the cooling system includes roll coolant headers 23 , each containing 2 or 3 rows of nozzles 24 directed toward an inlet side of a roll stack that discharges cooling fluid onto the roll surfaces on an upstream side of the pair of rollers.
  • Some rolling mills may also have coolant nozzles, aiming at the rolls at the metal exit side of each roll stack.
  • a lubricant-in-water emulsion having a relatively low concentration of lubricant is used as a cooling fluid, which is then discharged throughout all nozzles of the cooling system.
  • the emulsified lubricant provides a thin layer of lubricant on the surface of the rolls during rolling. Because the water and lubricant are typically immiscible, to prevent separation and ensure a consistent amount of lubricant delivered with the cooling water, emulsifiers are used to form an emulsification to ensure a more uniform distribution of lubricant within the cooling water.
  • a cooling fluid having a relatively low level of emulsified lubricant is generally used. Even when using such techniques, variations in friction may still occur, leading to a poor surface quality of the rolled metal and/or excessive rolling loads with excessive friction or skidding of the work rolls on the metal with inadequate friction.
  • an additional amount of lubricant e.g. oil, synthetic oil, or the like
  • juicing is injected into the common mill supply coolant line sometimes without emulsifiers for discharge through all the coolant headers and nozzles, a process commonly known as “juicing”).
  • Such a direct lubrication effect lasts between 10-15 minutes, which is the time equivalent of rolling 2 coils of sheet metal.
  • Juice Lubricant pumping rate larger increases in the amount of lubricant flowing to the mill can be produced, for example, adding 9.1% more lubricant over 10 minutes.
  • the present invention allows for targeted lubrication of select roll stacks and/or bite spray nozzles of a hot rolling apparatus, which allows for more consistent lubrication and control over the lubrication in different roller stacks.
  • the improved lubrication allowed by embodiments of the invention, provides improved surface quality and increases throughput and efficiency in production.
  • targeted lubrication includes delivery of a poorly-emulsified lubricant (possibly but not necessarily with little or no emulsifier-agents) to lubrication nozzles directed toward the roll nip of the roller stack (bite sprays), the lubrication nozzles for a particular stack being fed by a header.
  • the delivery of the additional lubricant is targeted only to the bite sprays and only to the specific headers, the total amount of lubricant delivered is lower than that under present “non-targeted” juicing practices.
  • the direct effect of the same 330 gallons of Juicing Lubricant can be extended to 188 minutes (assuming the injection rate producing 6.25% of additional oil as related to the oil originally-present in the coolant) or can be extended to 125 minutes with the injection rate producing 9.1% of additional oil.
  • FIG. 2A illustrates a rolling mill that provides targeted and controlled delivery of lubricant to Stack A.
  • the piping system has been modified such that the work roll cooling discharge nozzles that previously discharged the same cooling fluid through all banks of nozzles (coolant and bite sprays) are configured to discharge a loose-emulsion of lubricant formed in a static mixer through the bite spray nozzles and cooling fluid through the coolant nozzles.
  • the rolling mill configuration in FIG. 2A similar to that in FIG. 1 , has been modified to provide targeted delivery of lubricant to select roller stacks.
  • the rolling mill includes a separate lubrication pump 20 and cooling fluid pump 10 .
  • the cooling fluid pump 10 is fluidly coupled with the coolant spray set of nozzles 24 of the header 23 for each stack through a piping system.
  • the piping system includes an in-line mixer 22 at select stacks to allow formation of the loose-emulsion for discharge at the select stack when desired.
  • the mill is configured with a set of bite lubrication nozzles 25 at the inlet of Stack A that discharge coolant directly toward the bite of the rolls of Stack A and the rolled metal 1 .
  • the lubrication pump 20 is fluidly coupled to the bite lubrication nozzles 25 through a lubrication section of the piping system that includes the in-line static mixer 21 .
  • the lubricant is introduced into the lubrication section through a separate line and mixes in the in-line mixer 22 with the cooling fluid.
  • the introduction of lubricant into the coolant flow is selectively controlled through valve 21 .
  • the lubricant mixes with the cooling water to form a loose emulsion, which is an emulsion that contains relatively large lubricant droplets that can coalesce and separate from cooling water.
  • the loose emulsion is then discharged through the lubrication nozzles to the rolls of the select roll stack, in this embodiment, discharged to the roll bite through the bite lubrication nozzles 25 .
  • the lubrication at the roll bite can be readily controlled throughout the rolling process without otherwise altering the flow or composition of the cooling water discharged through the remaining nozzles.
  • the system design assumes 330 GPM bite spray coolant flow and up to 3 GPM injection of the poorly-emulsfiable oil (“juice lubricant”) at an operating pressure of 150 psi.
  • a static mixer with a 4′′ diameter and a 40′′ length allows sufficient incorporation of the injected oil and cooling water to form a loose-emulsification for discharge through the lubrication nozzles.
  • the calculated linear velocity of coolant flow through the mixer would be 8.3 ft/s with a pressure drop 5.5 psi.
  • a 1 ft/s minimum flow rate is recommended to maintain turbulent flow in the static mixer, although for most blending applications a 2-3 ft/s flow rate should be sufficient. In some embodiments, a 7-8 ft/s flow rate might be particularly suited to create liquid-liquid dispersions. It is appreciated that mixers of various sizes and shapes may be used in accordance with the principles of the present invention. Generally, a pump 20 capable of delivering 3 gallon per minute lubricant flow at 170 psi pressure would be suitable to inject the neat lubricant in front of the static mixer, although various other pumps may be used depending on the particular system and associated operational characteristics.
  • part of the mill coolant stand supply stream Prior to the lubricant injection port, part of the mill coolant stand supply stream is split from the typical 6′′ or 8′′ stand coolant supply line into a separate bite spray supply line of the smaller diameter, such as a diameter of 4,′′ which is equipped with the static mixer pipe 22 .
  • the juicing lubricant is supplied from the neat lubricant tank and injected into the bite spray supply line right upstream of the static mixer. Typically, this utilizes a specially-selected pump having the appropriate pressure and a precisely-controlled flow rate.
  • the lubricant is mixed with the coolant in the static mixer 22 and then carried by the bite spray coolant stream to the header 23 and discharged through the bite spray nozzles 25 .
  • the milling system is adapted to allow targeted delivery of the lubricant between two or more roller stacks of a rolling mill.
  • the system may include multiple lubricant pumps, each fluidly coupled with the lubrication nozzles at one or more stacks or at different roller stacks. This feature allows delivery of differing amounts and/or type of lubricants to one or more select stacks.
  • the system may include one or more additional valves between the lubricant pump and the lubrication nozzles associated with each stack, such that adjustment of the one or more additional valves allows for differing amounts/concentrations of lubricant to be delivered to one or more stacks, to different stacks or to be varied during the rolling process as needed. Adjustment of the one or more valves may be performed either by user input command or by an automatic control algorithm based on various operating characteristics.
  • FIG. 2B illustrates another embodiment in which the piping system includes a static mixer 22 at multiple stacks to allow selective lubrication, as needed, at a particular roll stack.
  • the piping system has been modified such that the work roll cooling discharge nozzles that previously discharged the same cooling fluid through all banks of nozzles (coolant and bite sprays) are configured to discharge a loose-emulsion of lubricant formed in the static mixer 22 through the bite spray nozzles at each stack, while cooling fluid continued to discharge through the coolant nozzles.
  • valves 21 the juice lubricant is selectively introduces so that the loose-emulsion is formed for discharge only at the selected stacks.
  • lubrication at each stack can be readily adjusted, either manually or automatically, in response to observed or determined excessive friction or slipping at a particular stack.
  • the lubricant can be delivered where it will have the largest impact on the rolled metal surface quality and rolling performance of the rolling mill. For example, reroll surface quality on most mills can be markedly improved by aiming the bite/lubrication coolant sprays into the roll nip. In addition, during rolling only some stands may operate under lubrication starvation condition, leading to poor surface finish. Based on the empirical data shown in the graphs in FIGS. 5 and 6 , the optimal lubricant thickness on the rollers may vary according to the rolling speed. Stands with higher rolling speeds may have an insufficient amount of lubricant released on the rolls or in the roll nip.
  • roll nip temperature might be so high that lubricant is volatilized and degraded.
  • the present invention allows additional lubricant to be delivered to rolls having higher rolling speeds, without “juicing” the cooling fluid for the other stands or the entire cooling supply line.
  • the invention provides a modified header in which the header chamber and control logic may be modified to allow separate feeds to the cooling spray cavity and to the bite spray cavity, valves and nozzles.
  • the modified header may include a separation within the header cavity to define a first portion separate from a second portion such that input of cooling water into the first portion of the header cavity that feeds the cooling discharge nozzles does not mix with lubrication fluid in the second portion that feeds the bite lubrication nozzles. As shown in the example of FIG.
  • a conventional header 23 ′ such as that shown in view I, includes one or more inlets i through which cooling water is supplied for discharge through the nozzles 24 , 25 .
  • the conventional header 23 ′ includes a common header cavity such that cooling fluid within the cavity is common to all discharge nozzles.
  • a modified mill header 23 such as that shown in view III, allows for separate feeds to cooling discharges nozzles 24 and bite lubrication nozzles 25 by use of a separation between the lower part of the header cavity (for bite spray) and the top cavity (for coolant spray).
  • the modified header includes port or ports feeding the header cavity connected through inlet valves i 1 to each of the two banks of cooling nozzles, separate from a port or ports feeding the header cavity connected through valves i 2 to the bite spray/lubrication nozzle bank.
  • the separation between the ports and header cavities allows feeding of the cooling nozzles and the bite lubrication nozzles with two different fluids.
  • This modified mill header can readily replace a conventional mill header, thereby allowing retrofitting of convention mills to provide targeted lubrication in accordance with the principles of the present invention.
  • the system may include additional modifications to provide targeted roll bite lubrication in conventional mills that do not already have bite sprays.
  • the “targeted lubrication” concept can be explored in only limited way by injecting additional lubricant into lines feeding entry headers of the individual stands. In this case the lubrication effect would likely be diminished and its duration reduced in proportion to the coolant flow rate through these headers, as shown below in Table 2.
  • the size of the static mixer may be increased.
  • a static mixer device having a 6′′ diameter and a length of 60′′ may be used to accommodate 1100 GPM coolant flow with 11 psi pressure drop, and a size of the oil injector pump can be increased to handle 6-9 GPM of additional poorly-emulsified oil.
  • the advantages of targeted lubricant delivery can be further realized by directing or focusing lubricant delivery on the rolling nip of the rollers and metal sheet. Since conventional rolling apparatus often include lubricating nozzles that discharge generally towards the rollers and not towards the roll bite, such apparatus can be modified in accordance with aspects of the invention to further target delivery of lubricant to the nipping part or bite. For such mills that lack bite sprays and with level control of cooling, suitable headers can be engineered and installed that provide a discharge stream mixed with lubricant and directed to the roll bite.
  • FIG. 4 depicts retrofitting of bite sprays into the tandem mill without the bite sprays, showing modifications to guide plates and additional shielding that direct the discharge mixed with lubricant to the roll bite.
  • the lubricant may be delivered in various ways, such as being fed directly through the header, being delivered as a loose-emulsion from a bulk lubricant tank through an in-line mixer, or delivery by any other means suitable for mixing with a bite spray coolant stream at one or more select stacks.
  • the system may include two separate sections for the top and bottom rolls such that the targeted lubrication may differ between the top surface of the strip metal and the bottom surface of the strip metal during rolling.
  • This aspect may be used to provide improved control over surface quality as well as control of friction between the top and bottom side of the slab.
  • FIGS. 5-7 demonstrate the advantages of using a neat lubricant or a loose emulsion with little or no emulsifier agents in a rolling mill in accordance with aspect of the invention.
  • FIG. 5 illustrates the effect of non-ionic emulsifier concentration at 50° C. on oil film formation (data source: Cambiella, A., Benito, J. M., Pazos, C, Coca, J., Ratoi, M, Spikes, H. A., Tribol. Lett. 22, 53-65, 2006).
  • FIG. 6 illustrates the effect of the oil-water concentration in emulsions on oil film formation (data source: Yang, H., Schmid, S. R., Reich, R. A., Kasun, T.
  • FIG. 7 illustrates rolling loads measured on the laboratory rolling mill with neat lubricants and their associated oil-in-water emulsions, the distance from the diagonal to each data point increases along with increasing differences in anti-friction properties between the neat oils and their corresponding emulsions.
  • targeted lubrication can be easily modified to feed hot water or hot water with emulsifiers selectively into select bite sprays. This should result in the increase of friction, allowing mill threading without refusals as well as control of differential friction such as between top and bottom rolls and between stands.
  • principles of the present invention may be used to modify conventional rolling mills and provide the advantages and benefits described herein.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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US14/209,484 2013-03-15 2014-03-13 Manufacturing methods and apparatus for targeted lubrication in hot metal rolling Abandoned US20140260476A1 (en)

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EP (1) EP2969278B1 (es)
JP (1) JP2016512174A (es)
KR (1) KR20160012994A (es)
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US20140138054A1 (en) * 2011-07-21 2014-05-22 Mitsubishi-Hitachi Metals Machinery, Inc. Cooling apparatus, and manufacturing apparatus and manufacturing method of hot-rolled steel sheet
US20160151814A1 (en) * 2013-07-03 2016-06-02 Thyssenkrupp Steel Europe Ag Production lines and methods for hot rolling steel strip
CN112658034A (zh) * 2019-10-15 2021-04-16 Posco公司 轧制设备的混合溶液供应装置
CN117798191A (zh) * 2024-02-28 2024-04-02 常州市力俊机械有限公司 一种可调控黑色金属压延定位工装及使用方法

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WO2018064218A1 (en) 2016-09-27 2018-04-05 Novelis Inc. Systems and methods for non-contact tensioning of a metal strip

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EP2969278A1 (en) 2016-01-20
JP2016512174A (ja) 2016-04-25
KR20160012994A (ko) 2016-02-03
EP2969278B1 (en) 2017-08-02

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