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Rolling: Cold strip rolling and processing lines I (25 June / 14:00 - Room 12)

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25 June / 14:00 - Room 12:

Cold rolling strategies for improving the magnetic properties of non-grain-oriented electrical steel

A. Krämer
(RWTH Aachen University, Germany)

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Title: Cold rolling strategies for improving the magnetic properties of non-grain-oriented electrical steel


Author:
A. Krämer

Company:
RWTH Aachen University, Germany

Co-Authors:
X. Wei, G. Hirt

Abstract:
Non-grain oriented (NGO) electrical steel is generally used for the production of stators and rotors of electric engines due to its excellent soft magnetic properties. Especially for efficient engines at high speeds, electrical steel with high permeability and low core losses is required. These properties are affected not only by final thickness of the NGO electrical steel sheets, but also the microstructure, in terms of grain size and texture. In order to improve the magnetic properties, the whole process chain of producing electrical steel sheets should be considered, including hot rolling, cold rolling, annealing and shear cutting. Among the process chain, cold rolling determines the final thickness and affects the final microstructure by providing driving force for recrystallization. By using proper cold rolling strategies, the magnetic properties of NGO steel can be improved. Traditionally the cold rolling is done in a symmetrical rolling mill at room temperature. In this study, two innovative cold rolling strategies, namely asymmetrical rolling and rolling at temperatures between 50 °C and 400 °C, are investigated using common electrical steel with 2.4 wt.-% silicon content. The grain size and texture resulting from these strategies are quantitatively analyzed through the process chain. Finally, the rolling strategies are compared with traditional cold rolling, and their influence on microstructure and magnetic properties (permeability and core loss) is discussed. The result shows, by using appropriate cold rolling strategies, grain size after annealing is mostly unaffected and the favorable texture components are intensified, in turn improving magnetic properties of the investigated NGO electrical steel.

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25 June / 14:20 - Room 12:

Development of a strip temperature profile measurement system to improve strip flatness after cold rolling

J. Kremeyer
(VDEh-Betriebsforschungsinstitut GmbH, Germany)

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Title: Development of a strip temperature profile measurement system to improve strip flatness after cold rolling


Author:
J. Kremeyer

Company:
VDEh-Betriebsforschungsinstitut GmbH, Germany

Co-Authors:
G. Mücke, T. Reichardt, C. Pinno, J. Polzer, S. Böhlke, C. Warias, J. Hinzpeter, A. Ahlrichs

Abstract:
Strip flatness is a crucial quality characteristic and important in each processing stage for a safe and stable process operation. Current cold rolling mills are therefore equipped with flatness measurement systems like BFI-type shapemeter rolls which ensure good flatness during rolling. However, strip flatness is very often unsatisfactory when reaching subsequent process steps or when strip is sold directly. Increasing market demands for even better strip flatness can often not be fulfilled.

Major reasons for this are temperature gradients within strips during rolling. Current flatness control systems only consider strip flatness directly during rolling. However, when cooling down after rolling, strips shrink irregularly according to their temperature profile. This physical effect generates subsequent flatness defects which have not been present during rolling. In the case of steel, a strip temperature gradient of 10 °C results in flatness defects of more than 12 I Units.

BFI has improved their well-established shapemeter roll to provide high resolution live and continuous measuring of strip temperature distribution over strip width and length during rolling. This type of measurement does not only provide valuable information about the mill’s cooling system and thermal influence on the strip but also allows predicting flatness changes of each strip during cooling process. The new information can be used to adapt target flatness during rolling in order to obtain desired flatness when the strip has cooled down or even to improve selective work roll cooling.

A prototype of the new temperature measurement roll has been tested thoroughly in semi industrial environment in an experimental rolling plant. The first industrial application has been proved successfully during cold rolling in a steel plant. The new technology paves the way for a new level of strip quality by addressing a physical influencing factor which is neglected in current flatness measurement systems.

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25 June / 14:40 - Room 12:

Improvement of productivity based on DNN Set-up in cold rolling

G. Song
(POSCO Co., Ltd., Republic of Korea)

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Title: Improvement of productivity based on DNN Set-up in cold rolling


Author:
G. Song

Company:
POSCO Co., Ltd., Republic of Korea

Co-Authors:

Abstract:
Recently, automobile companies have benn increasing consistantly the usage of high strength steel and giga steel to cope with environment restrictions and collision safty. The high strength steel and giga steel lead to a decrease in productivity during cold rolling due to material deviations of hot rolled strip. Increased production of giga steel reduces the productivity of mild steel. Therefore, to improve productivity in cold rolling is very importanrt. To respond this problem, a set-up model based deep learning(DNN)was developed to increase the prediction accuracy of rolling force of high strength steel and to obtain optimal load distribution of motor in consideration with operation conditions of hot rolling, chemical composition of hot rolled strip and operation conditions of cold rolling. As a result of field application, prediction accuracy of rolling force of high strength steel is improved 3.3%, productivty is increased 1.6%, spare rate of motor load during cold rolling is decreased 6% and manual operation rate of a set-up to modify reduction is decrease nearly 0 percent.

Rolling: Maintenance: plant availability and condition monitoring I (25 June / 14:00 - Room 13)

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25 June / 14:00 - Room 13:

High quality predictive maintenance advance analytics

K. Stohl
(Primetals Technologies Austria GmbH, Austria)

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Title: High quality predictive maintenance advance analytics


Author:
K. Stohl

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
J. Davis, B. Li, K. Stohl

Abstract:
The Condition and Health status monitoring of equipment in metal production plants is of steadily growing importance, as statistics and white papers are demonstrating clearly. Primetals Technologies is a preferred partner in the industry since many years with a big number of clients and installed systems and has increased its portfolio by a reinforced partnership with ITR LLC in the US.

Beside the classical approach of limits and gradient limit checks nowadays also machine learning methods are applied to further improve efficiency and accuracy in prognosis and ruling out of failures and failure causes of rotating devices and machinery. Machine learning methods allows Primetals to react even faster and more precise than nowadays done with standard tools and methods. Such newly developed tools are an essential support even for most experienced analysts.

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25 June / 14:20 - Room 13:

Novel method for measuring anomalies and detecting defects in drive trains

A. Nkwitchoua Djangang
(VDEh-Betriebsforschungsinstitut GmbH, Germany)

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Title: Novel method for measuring anomalies and detecting defects in drive trains


Author:
A. Nkwitchoua Djangang

Company:
VDEh-Betriebsforschungsinstitut GmbH, Germany

Co-Authors:

Abstract:
A novel method for monitoring drivetrains with respect to upcoming defect situations is presented. It uses defined electrical signals, which are artificially injected into the bearing. The subsequent system answer following this signal injection depends on the precise electromagnetic characteristics of the lubricants (oil or grease). Based on this answer, imminent defects of the bearing can be detected very early in advance. The talk reviews existing technologies for drivetrain surveillance and defect detection, to contrast them against the new concept. It identifies the warning lead time as a crucial, quantitative key performance indicator. Together with the more qualitative aspect of ease of deployment – meaning here, how easy the new technology can be integrated or retrofitted into existing drivetrains –, a basis is set for the scientific evaluation of such equipment. The talk also explores upcoming possibilities to include the new sensor as Industry 4.0 component. Such a system could continuously predict the probability of failure for the drivetrain, feeding this into the larger Big Data context of the plant operation. It enables novel predictive maintenance approaches and allows lifetime prognostics.

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25 June / 14:40 - Room 13:

Novelty detection and predictive maintenance in steel production plants

S. Klanke
(SMS group GmbH, Germany)

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Title: Novelty detection and predictive maintenance in steel production plants


Author:
S. Klanke

Company:
SMS group GmbH, Germany

Co-Authors:

Abstract:
Monitoring the condition of critical equipment is a key factor in reducing unplanned downtime. Still, for many types of faults, optimally adjusting alarm thresholds remains an open problem: A too sensitive system quickly loses its credibility due to false alarms. At the other extreme, faults are detected too late, if at all. Moreover, in steel production, single machines are often unlike any other regarding their make and operating conditions, so there is very little a-priori information about how a fault might show in the measurements.
In the context of Industry 4.0 we demonstrate how to tackle this problem with machine learning: We use novelty detection algorithms in order to model the joint distribution of process variables (e.g., rolling speed), measurements (e.g. temperature), and statistics derived from measurements (e.g. amplitudes in a vibration spectrum). Such models are trained separately for each machine, based on data taken in healthy condition. Later on, these models can score newly taken data, in effect yielding a measure of how far the machine has deviated from health. As a by-product, a similar calculation on marginal distributions prevents raising alarms only because the machine briefly operates with previously unseen process parameters (e.g. higher speeds than those in the training data), and conditional distributions can yield a cleaned-up version of any derived trend graph.
By combining machine learning with our know-how about the equipment, the process and classical condition monitoring, we can effectively monitor a large number and a wide variety of machines, while still presenting the results in a familiar form. We apply a novelty detection algorithm to automatically warn us when certain calculated characteristics at the beginning of a bearing fault become unusually high given the process conditions. The corresponding warning is shown including the usual marked vibration spectrum, immediately giving reassurance to the maintenance personnel.

Rolling: Hot strip rolling (25 June / 15:30 - Room 26)

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25 June / 15:30 - Room 26:

X-Shape-Hot - new flatness measuring system for hot rolling process

F. Gorgels
(SMS group GmbH, Germany)

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Title: X-Shape-Hot - new flatness measuring system for hot rolling process


Author:
F. Gorgels

Company:
SMS group GmbH, Germany

Co-Authors:
M. Buhr, O. Jepsen, A. Kastner, P. Siemann, J. Kremeyer, G. Mücke

Abstract:
Flatness defects are critical in relation to the stability of the rolling process and the quality of the rolled product. Whereas flatness measurements in cold rolling are well established, the measurement of flatness during hot rolling is limited to parts of the strip that are not under tension. The reasons behind this lay not only in the rough conditions but also in the challenges of signal evaluation. With the continuous hot rolling of steel in particular, the steady strip tension makes flatness control without measurements almost impossible. As a result of growing markets for direct-sold, hot-rolled strip and related thinner finished thicknesses, flatness control is becoming a fundamental element of the hot rolling process.

In terms of measuring systems for hot rolled strip under tension, this gap has now been closed with the new product developed by SMS group that brings the proven X-Shape technology, which is based on the world market leading BFI flatness measurement concept, to the hot rolling process. In cooperation with BFI and ArcelorMittal, the prototype has been successfully installed and operated at ArcelorMittal’s hot rolling mill in Eisenhüttenstadt. Installed downstream between the cooling section and side guides, the measurement system offered a detailed insight into the effects of flatness in the finishing mill when rolling with tension, as well as the effects of laminar cooling.

The system offers a reliable and robust method of measuring flatness. The results of the measurement can be used for both profile and flatness control and for cooling line adjustment. In the CSC model the signals can be used to adapt the edge masking system settings and make inline corrections. The flatness information now available is opening up new ways of optimizing the hot rolling process.

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25 June / 15:50 - Room 26:

Determination and implementation of requirements in hot rolling mill in order to produce high quality API steel strip

S. Mani
(Mobarakeh Steel Company, Iran)

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Title: Determination and implementation of requirements in hot rolling mill in order to produce high quality API steel strip


Author:
S. Mani

Company:
Mobarakeh Steel Company, Iran

Co-Authors:

Abstract:
Some steel grades need different design and production procedure in hot rolling mill due to their special final properties. One of the special steel grades which we are going to produce much more qualified, is a kind of API steel that has specific mechanical properties. This type of steel is mainly used for pipe production for oil & gas industries.

The major special property of this type of API steel is percentage of ductility. The needed value of ductility is offered by the customer, regarding the piping production condition standards. The final ductility result of the strip is measured via specific test which is named DWTT. In this test, sample is impacted by a drop weight at a specified temperature and finally the situation of the broken area is investigated as a criteria to define the percentage of ductility. The main specific point of ductility result is that it cannot be measured and evaluated during hot rolling and should be measured later (few days after rolling) in laboratory, however finishing temperature and coiling temperature are two other main quality parameters that affect mechanical properties and those can be measured (& modified) during rolling.

So, In order to ensure about final quality conditions of this special product in advance (during rolling; before DWTT test being done), we have to define a special procedure for rolling this type of steel in hot rolling mill.

In this paper, we are going to describe the implemented determinations in different parts of hot rolling mill as a special procedure in theory & practice to obtain qualified API steel strip in stable rolling condition.

Key words: API steel, hot rolling, piping steel ductility

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25 June / 16:10 - Room 26:

Transfer bar cooling system significantly improves production capacity at Tata Steel Port Talbot's hot strip mill

L. Pichler
(Primetals Technologies Austria GmbH, Austria)

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Title: Transfer bar cooling system significantly improves production capacity at Tata Steel Port Talbot's hot strip mill


Author:
L. Pichler

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
A. Seilinger, A. Rimnac, F. Lettner, K. Weinzierl, J. Milbredt

Abstract:
Recently, a Transfer Bar Cooling system supplied by Primetals Technologies was commissioned in the hot strip mill of Tata Steel´s Port Talbot. The purpose of the new cooling system, installed after the roughing mill, is the precise control of the strip temperature before it enters the finishing mill, without having to slow down the roughing mill or to increase the finishing mill entry temperature. This can significantly improve the productivity at the hot strip mill and still ensures a finishing rolling below recrystallization temperature, especially for thick thermo-mechanically rolled products.
The Transfer Bar Cooling system is based on Primetals Technologies´ Power Cooling technology in combination with a full-fledged state-of-the art automation system. It employs a total of 9 pairs of spray headers and has a total length of approximately 10 meters. In order to cope with a large variety of steel grades and process requirements, especially the minimum surface temperature of the bar during cooling, the flow rates of the Power Cooling headers are adjustable over a wide range. Therefore a lower cooling intensity is also achievable as required for each individual product. The benefits of Primetals Technologies’ Transfer Bar Cooling technology and first operational results from the hot strip mill of Tata Port Talbot are presented in the paper.

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25 June / 16:30 - Room 26:

A study on width control head & tail ends of slab a hot rough rolling using learning method

J. Jung
(Hyundai Steel Co., Ltd., Republic of Korea)

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Title: A study on width control head & tail ends of slab a hot rough rolling using learning method


Author:
J. Jung

Company:
Hyundai Steel Co., Ltd., Republic of Korea

Co-Authors:
Y. Lee, H. Han, H. Kim

Abstract:
Control of slab width is achieved by sizing press process and vertical rolling process, and various researches were carried out. Recently, various researches performed to reduce the width defect of head and tail ends of slab. For improving width quality, many factories are using SSC, and it is open loop control using programmable logic control system. Nevertheless, because factories produce various sizes and various types of steel, there is limitation to improve the width quality using open loop control. These days, customers demanded high quality and guarantee narrow range of coil width. In this study, core technology is developed of the new short stroke control using dynamic width control instead of open loop control.
In order to decide which SSC is applied, using roll gap and roll force of vertical roll is judgement standard. If roll force is applied before SSC setup roll gap is worked, the SSC is not applied. On the other case, SSC is applied.
To judge the width head and tail ends of slab after roughing mill, we use the width gauge at the roughing mill exit. From the measured width information, the head and tail portion is designated, and the width tendency is judged within the range. The width can be classified into four types; width normal, over, under, and simultaneous situation. If the SSC is normally applied and the head end is judged to be width over, the compensation value is determined by calculation. This compensation value is used to the next identical material and conditions such as same coil thickness and width, and width draft.
In this study, we have secured the technology to automatically control the width of the head and tail by using width learning technology.
In the conventional control, the judgment and the manipulation are directly performed by the New SSC.

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25 June / 16:50 - Room 26:

Integrated temperature model

A. Sprock
(SMS group GmbH, Germany)

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Title: Integrated temperature model


Author:
A. Sprock

Company:
SMS group GmbH, Germany

Co-Authors:
C. Hassel, K. Grybel, H. Hof, W. Fuchs

Abstract:
Integrated Temperature Model (ITM)

The production of hot strip at conventional Hot Strip Mills is divided in individual process steps, starting from reheating, rolling at roughing mill and finishing mill, strip cooling at run out table and coiling. All the process steps run in principle one after the other and independently.
In this way, each individual processing step is optimized in isolation while adhering to the individual set values. This conventional procedure does not attain the best overall result as the optimization of one process step may have adverse consequences for another process step, i.e. the interaction between them is neglected. The Integrated Temperature Model (ITM) of SMS group completely remedies these disadvantages. By using the temperature setpoints from the traditional strategy an integrated, higher-level temperature profile from the furnace to the coiler is determined. This profile is updated cyclically; the individual process steps interact via this profile. Possible deviations from the temperature profile due to disturbances are corrected by controller actions of the Integrated Temperature Model (ITM) under consideration of the plant limits and the microstructure. The coupled microstructure model calculates the components and the mechanical properties of the hot strip as a result of its thermal and mechanical load in the overall process. This concept extends the possibilities to improve the desired mechanical properties with the Microstructure Properties Optimizer. The advantages of additional plant components, such as a transfer bar cooling system, thermal heat panels and compact cooling, may be analyzed and optimized quantitatively by this integrated temperature model in order to realize a gain in production and product quality.

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25 June / 17:10 - Room 26:

Advanced technologies of process control to hot strip rolling mill

N. Shimoda
(Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan)

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Title: Advanced technologies of process control to hot strip rolling mill


Author:
N. Shimoda

Company:
Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan

Co-Authors:
H. Imanari, A. Suzuki, M. Sano, K. Ohara

Abstract:
In the hot strip rolling mill, process control technology of rolling is being advanced as higher accuracy for dimension and material quality of product is required. In recent years, stable rolling and highly performed control becomes increasingly important in order to produce steel sheets with higher strength and weight saving against the background of increased production of steel sheets for automobiles, structural steel, pipeline steel, and so on.
Meanwhile, since the 1990s, a number of hot rolling plants have been built mainly in East Asian countries such as China, South Korea, Taiwan and others. We have responded to the requirements for higher qualities of product by applying control technology making full use of the features of diverse equipment configuration.
In this paper, we introduce the recent application trend of process control technology contributing to hot strip rolling in so-called “conventional mill” line. First we introduce technology of strip width control. It is important to study various factors of width changes such as width spread by thickness reduction, dog-bone recovery by edger rolling, and tension effect in finishing tandem mills rolling. Synergy with accurate prediction model of width changes and dynamic control along a bar contributes to high performance of product width which is close and uniform to aimed width.
Second we introduce technology of strip temperature control. A finite difference method (FDM) is applied to calculate the change of strip temperature by each time step and temperature distribution of a bar. The node was originally split in thickness to calculate surface and inside temperature of a bar separately. Nowadays it is also split in width direction to enable to estimate and evaluate the temperature drop around strip side edge.
We also show example of calculation and control result applied to the online system of hot strip rolling mill.

Rolling: Plate Rolling (25 June / 15:30 - Room 28)

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25 June / 15:30 - Room 28:

Large-scale expansion of equipment and product range: Modernization of NLMK DanSteel's heavy plate mill

M. Breuer
(SMS group GmbH, Germany)

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Title: Large-scale expansion of equipment and product range: Modernization of NLMK DanSteel's heavy plate mill


Author:
M. Breuer

Company:
SMS group GmbH, Germany

Co-Authors:

Abstract:
In Frederiksvaerk, Denmark, NLMK DanSteel A/S is operating a 4.25-m heavy-plate mill supplied by SMS group in 2012, together with a hot-plate leveler. In order to extend the product range further especially in terms of grades and sizes, NLMK DanSteel decided to revamp and expand the heavy-plate rolling mill. End of December 2017, NLMK DanSteel placed a corresponding order with SMS group. The large-scale expansion and modernization comprises a new laminar plate cooling system with water treatment equipment, new heavy plate cooling bed and a revamp of the existing cold-plate leveler.
The new plate cooling system will allow NLMK DanSteel to produce high-strength plate for various applications, like e.g. line pipe, shipbuilding and offshore wind parks. Also possible is thermomechanical rolling and manufacture of heavy plate, supported by the X-Pact® cooling model. The new water treatment system will filter and cool the cooling water and feed it back into the process in a closed circuit.
A new cooling bed for thick plate is to be installed downstream of the laminar cooling system and existing hot-plate leveler. The plate will be delivered automatically to the cooling bed, which will be able to handle plate weights of up to 40 tons and more. The X-Pact® electrical and automation system calculates the cooling time for plate removal as a function of the plate temperature and dimensions. The existing cold-plate leveler will also undergo a comprehensive revamp.
In order to reduce shutdown times to a minimum, suitable installation strategies and optimized erection schedules were developed on the basis of a 3D laser survey. The paper will provide insights in the partly highly complex modifications and implementation strategy. It is intended to prepare the paper jointly with NLMK DanSteel.

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25 June / 15:50 - Room 28:

Application of the upgraded cooling system in CSC plate mill

W. Lo
(China Steel Corporation, Taiwan)

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Title: Application of the upgraded cooling system in CSC plate mill


Author:
W. Lo

Company:
China Steel Corporation, Taiwan

Co-Authors:

Abstract:
To meet the demand for ultra-high strength steel from customers, China Steel Corporation (CSC), the only one hot rolled steel plate producer in TAIWAN, had revamped the controlled cooling facility with the aim to increase the essential cooling rate and temperature accuracy for the required steel grades. New cooling headers (MULPIC®) were installed upstream to the existing laminar cooling headers. Thanks to the effective integration between associated automation systems, the upgraded cooling system can utilize both type of header at the same time and successfully extends CSC’s plate producing technology into direct quenching (DQ) standard. New products based on martensitic microstructures, which were unable to produce due to insufficient cooling capability, are now being developed in the form of abrasion-resistant steel as well as quenched and tempered structural steels. To make most of new cooling system, efforts also being taken on quality improvements of existing TMCP products. It was demonstrated that by employing the ‘hybrid’ accelerated cooling process and proper adjustment of flow actuators, notable benefit from more uniform properties and less plate distortion could be achieved by this upgraded cooling system.

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25 June / 16:10 - Room 28:

MultiFlex®-Quench: Setting new standards for plate cooling in heavy plate heat treatment lines

D. Schmidt
(SMS group GmbH, Germany)

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Title: MultiFlex®-Quench: Setting new standards for plate cooling in heavy plate heat treatment lines


Author:
D. Schmidt

Company:
SMS group GmbH, Germany

Co-Authors:

Abstract:
SMS group has been successful in establishing a new technology for plate cooling in heat treatment lines in the markets. It is called MultiFlex®-Quench. Flexible cooling strategies allow standard and special materials to be produced as well as newly developed grades with high quality demands. In 2016, the new MultiFlex®-Quench at SIJ Acroni in Jesenice, Slovenia processed the first heavy plate. To this customer, SMS group supplied a complete, new heat treatment line designed for an annual production of 80,000 tons of heavy plate. At the beginning of 2020, the new treatment line of Ilsenburger Grobblech GmbH, a subsidiary of Salzgitter Group, will start operation. The production capacity there will be more than 200,000 tons per year.
Two “cutting-edge” heavy-plate heat treatment lines are using - respectively are going to use MultiFlex®-Quench technology. From an economical point of view, the production of heavy plate will be particularly efficient, if it can also serve the growing market of new special steels and quarto plates. The high-strength and ultra-high-strength plates are used in the growth sectors of wind energy, power technology, tubes and pipes, mechanical engineering and crane building as well as the construction industry. At the same time, these applications, demanding excellent ductility and good weldability combined with perfect flatness, push the advancement of the material steel. To produce state-of-the-art heavy plates all process parameters, from austenitization to targeted cooling at optimized cooling speeds and further to adapted tempering temperatures and times, must be in perfect harmony in order to tap the full potential of the material steel.
In the paper, various aspects of the new plate cooling technology will be discussed, including.
• Development of the new cooling technology
• Flexible cooling with numerous options
• Models and process development
• Operating results of the first installation

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25 June / 16:30 - Room 28:

Optimization of work roll change intervals through data-driven roll wear models

B. Wiegand
(AG der Dillinger Hüttenwerke, Germany)

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Title: Optimization of work roll change intervals through data-driven roll wear models


Author:
B. Wiegand

Company:
AG der Dillinger Hüttenwerke, Germany

Co-Authors:

Abstract:
Prediction of roll wear in heavy plate rolling is essential to control the target thickness of the rolled plates, ensure even plate surfaces and economically schedule roll changes. Physical roll wear models demand deep domain-specific knowledge and input from special sensors and physical simulations.

This paper shows that data-driven roll wear models using techniques from the field of machine learning are able to outperform a simple physical roll wear model. Three alternatives to include roll wear models into the process of roll change scheduling are proposed. The flexibility of these methods enables their application in any process with accumulating wear and with wear measurements only available at the end.

Rolling: Cold strip rolling and processing lines II (25 June / 15:50 - Room 12)

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25 June / 15:50 - Room 12:

steelytics® Hot Rolling - calculation of steel properties over strip length

T. Baron
(thyssenkrupp Steel Europe AG, Germany)

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Title: steelytics® Hot Rolling - calculation of steel properties over strip length


Author:
T. Baron

Company:
thyssenkrupp Steel Europe AG, Germany

Co-Authors:
A. Latz, S. Schreiber

Abstract:
steelytics® Hot Rolling enables the simulation of the hot rolling process and the calculation of steel properties over strip length using real process data. In contrast to many other simulation systems this new modular approach is able to bring together process data and new enhancements in physically based and empirical microstructure simulations. The system is designed to be easily extendable to new data sources, processes and products. A modern web application makes the simulations usable for a wide range of user groups e.g. technical customer service, quality management and steel developers. The combination of physical approaches and data driven modelling makes well-founded estimates and optimization of alloy concepts and process parameters for improved material properties of hot rolled strips possible. Compared to state of the art process controls with neural network this approach gives insight to the microstructure in every single process step like, reheating, rolling, cooling and coiling. Here we will demonstrate the validity of the system for a wide range of steels from deep drawing steels over carbon steels to complex phase steels.

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25 June / 16:10 - Room 12:

Recent developments in on-line setup and control of Tata Steel's cold mills

C. Hol
(Tata Steel Europe Ltd., The Netherlands)

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Title: Recent developments in on-line setup and control of Tata Steel's cold mills


Author:
C. Hol

Company:
Tata Steel Europe Ltd., The Netherlands

Co-Authors:

Abstract:
Tata Steel is one of the largest steel producers in the world. Tata Steel has several cold mills in Europe. Outstanding process control of these mills is vital, as it determines to a large extent the off-gauge performance, shape performance and mill throughput, and it enables the rolling of new steel grades. The required rolling forces, torques, speeds, reductions and powers are calculated at these cold mills using an online setup model. This model is an in-house development of Tata Steel. It consists of a common core and mill-specific code in the shell. The setup application contains sub-models for the material properties, roll flattening, friction and shape and profile. The desired setup is calculated using an online optimization routine.
New cold rolled products expand the well-known banana diagram towards ultra-high strength steels, with higher formability in combination with higher strength. These grades are typically more difficult to produce, stretching the capabilities of the mills. Furthermore the product mix gets more and more varied and the cold mill setup must be flexible enough to cope with these variations. New sensors are being developed and added to the cold mill, which give extra information. Finally, the mills are becoming interconnected with the upstream and downstream process through more elaborate data communication. The recent developments to cope with these trends are briefly addressed in this paper.

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25 June / 16:30 - Room 12:

Concept for contactless roll cleaning during skin-pass milling and first operating results

M. Blumenau
(thyssenkrupp Steel Europe AG, Germany)

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Title: Concept for contactless roll cleaning during skin-pass milling and first operating results


Author:
M. Blumenau

Company:
thyssenkrupp Steel Europe AG, Germany

Co-Authors:
D. Roggenkämper, G. Faak, R. Nüssen, U. Zocher, O. Moll

Abstract:
Today’s automotive engineering strives to higher surface quality for exposed parts. This development raises increasing demands on avoiding surface defects during the production of strip steel, which is typically used by OEMs for outer panel applications. Aim of this presentation is to illustrate how thyssenkrupp Steel Europe AG (tkSE) meets this requirement by the example of using a contactless cleaning device at the in-line skin-pass mill (SPM) of its continuous annealing line (CAL):

This SPM operates without using any liquid medium for cleaning neither working nor back-up rolls in order to avoid rust dots on the uncoated steel surface. Due to that, dirt appears and may result in dents into the strip surface, which represent major quality defects. To reduce surface defects caused by dirt while keeping the SPM operating in the wanted dry mode a contactless cleaning device has been developed by tkSE. This device combines a precision blowing on the SPM’s roll surface with a high-performance extraction. In recent years, this procedure of contactless cleaning was successfully implemented and industrially tested at the tkSE's CAL in Dortmund. Today, an automatized contactless cleaning device is continuously operating in this line with a positive effect on dirt-related surface defects. The use of this contactless cleaning device is not only advantageous in terms of improving the steel’s surface quality, but also regarding economic and environmental concerns (use of enviromental air as cleaning medium).

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25 June / 16:50 - Room 12:

Advanced cold rolling for silicon and stainless steel (DMS EcoMill)

A. Duchene
(Fives DMS S.A., France)

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Title: Advanced cold rolling for silicon and stainless steel (DMS EcoMill)


Author:
A. Duchene

Company:
Fives DMS S.A., France

Co-Authors:

Abstract:
In the field of stainless steel flat product cold rolling and silicon steel flat product cold rolling, the 20-Hi mill has clearly proved its technological superiority compared to other rolling mill types such as 6-High rolling mill. However, nowadays, steel producers are under considerable competitive pressure. They are asked for perfect management of Capital expenditure (CAPEX) and operating expenditure (OPEX) but addressing meanwhile the new humans and environmental challenges such as safety, human factor, environmental pollution and energy consumption.

Fives DMS has integrated in its rolling mill design number of new features addressing these new challenges:
• New design of strip and work roll spraying
• New design of strip wipers SCP® 3.0
• Improvement of fume exhaust
• New concept of flatness actuators
• New concept of mandrel greasing

This pioneering 20-Hi mill concept, named as DMS EcoMill, warrant steel producers to operate with the state of the art rolling technology.

Rolling: Maintenance: plant availability and condition monitoring II (25 June / 15:50 - Room 13)

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25 June / 15:50 - Room 13:

Changing the reality of proactive maintenance

D. Phillips
(Regal Beloit Corporation, United States)

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Title: Changing the reality of proactive maintenance


Author:
D. Phillips

Company:
Regal Beloit Corporation, United States

Co-Authors:

Abstract:
Performing maintenance on equipment only when the condition warrants it has been proven to be the most cost-effective strategy for industrial organizations. However, efficiently determining the condition can be challenging and often relies on experienced analysts to interpret the data and make recommendations on corrective actions. This usually results in a significant lag between the time when a fault is identified and when action is taken. Automated prescriptive analyses shaped by domain expertise can provide clear direction on the timing of specific actions that need to be completed, easily understood throughout all levels of the organization, and ensuring proactive alignment with business objectives.

Further streamlining of proactive maintenance can be achieved by converging the physical asset with its digital representation. Augmented reality provides the means to accomplish this, eliminating the need to sort through disparate databases, alleviating the struggle to interpret complex machinery data, and providing a more efficient alternative to lengthy O&M manuals.

A case study on the deployment and use of these technologies on a metal forming machine will be included.

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25 June / 16:10 - Room 13:

Evaluation of a vision technique to detect small motions in steel process machinery

J. Niemi
(Swerim AB, Sweden)

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Title: Evaluation of a vision technique to detect small motions in steel process machinery


Author:
J. Niemi

Company:
Swerim AB, Sweden

Co-Authors:

Abstract:
We present the development and evaluation of a vision technique for small motion detection in a sequence of images. The developed vision system can identify and measure very small motions that cannot be perceived by the human eye or by conventional image processing techniques. The base in the vision system is an image processing algorithm developed and provided by MIT, USA. The algorithm amplifies very small sub-pixel motions in a video to pixel regions, allowing image processing algorithms to detect and analyse the motions in the images. With the method, one can potentially measure µm level motions or vibrations in a construction. The technique provides information about all motions in x-y directions contained in the images. The motion microscope technology has been found to be very well suited for the tested application. The technique measured the deflection in the frame of a roller straightener during straightening. The optical measured deflection was compared with a conventional laser triangulation sensor and was found to be comparable. The outcome from the vision system is a plot showing the motions from the selected area and a video with the amplified motions. The tested measurement technique could be relevant for the steel industry as there are many similar tasks. In rolling mills interesting areas for investigations are stability in continuous lines, elongations in the frame and other asymmetrical behaviour in the process machinery. The tested vision technique can contribute to better process control and also provide a basis for maintenance by detecting malfunctions.

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25 June / 16:30 - Room 13:

Chatter management at cold rolling mills today

S. Richard
(SMS group GmbH, Germany)

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Title: Chatter management at cold rolling mills today


Author:
S. Richard

Company:
SMS group GmbH, Germany

Co-Authors:
M. Krüger, K. Rues

Abstract:
In cold rolling mills vibrations of mechanical parts and/or strip can interfere several quality parameters like thickness, shape, surface quality and others. Since vibrations occur at higher speeds in most of the cases rolling speed of single- or multi-stand mills for steel and aluminium has to be limited quite often.

Among other mechanisms at cold rolling mills the so-called 3rd Octave and 5th Octave Chatter are the most important vibration issues. They are introduced by explaining related mechanisms and showing results of operational measurements.
Subsequently well-known measures against Chatter issues and their consequences are listed and explained, along with practical examples:
• Online Chatter monitoring with Auto-Slow-Down (ASD-) functionality,
• Mill design optimization,
• Optimized maintenance / service practice.

After giving a general survey about vibration issues in cold rolling mills and related conventional counter measures a new, promising approach is introduced. An active vibration damping system has recently been developed at SMS group. The system uses piezo electric elements as actuators which are located in an actuator box placed underneath the bottom backup roll chocks of a mill stand.
The active damping system comprises also a special control technology which uses the signals of conventional accelerometers. Using these signals and adaptive filter technologies the control system calculates actuator signals capable to induce additional damping into the mill stand. Apart from the 3rd Octave Chatter vibrations the additional damping can be allocated to other vibrations in parallel in order to reduce the corresponding amplitudes as well.
A first pilot installation using the new active damping technology was started in 2017 at an operating 4-stand Aluminum Tandem Cold Mill built by SMS group. After some optimization steps the system provided an increase of the rolling speed which creates significant potential of increase to the mill’s production.

Rolling: Rod and bar rolling (25 June / 17:00 - Room 28)

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25 June / 17:00 - Room 28:

Intelligent robotic coil trimming for wire rod mills

R. Kirkwood-Azmat
(Primetals Technologies USA LLC, United States)

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Title: Intelligent robotic coil trimming for wire rod mills


Author:
R. Kirkwood-Azmat

Company:
Primetals Technologies USA LLC, United States

Co-Authors:
S. Teegavarapu

Abstract:
One requirement in wire rod production to achieve uniform material properties throughout a finished coil is trimming head and tail ends to eliminate those rings with property variations. Installing in-line trim shears prior to coiling at the laying head has been the only automatic option, but this requires space in the rolling line and the shears are difficult to operate and maintain.

Therefore most mills rely on manual operator trimming at a coil inspection station ahead of the coil compactor, which is a labor-intensive and potentially dangerous task. Manual trimming also results in variations in yield, since the number of rings to be removed is usually subject to operator judgement. In wire rod lines such tasks will be eliminated as operators will have a more sophisticated skill set and focus on more value added functions.

A new Autonomus Robotic system system has been developed for trimming within the coil handling area. A The robotic system is guided with a “Intelligent” vision-assisted system and the robot equipped with a ring separator and trimmer can identify, trim and remove unwanted rings. As a self-contained, accurate and repeatable system, it provides provides superior performance and control of the process, and thus improves efficiency and coil quality.
The new system’s capabilities are presented with results from a pilot facility and an operating wire rod mill.

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25 June / 17:20 - Room 28:

Interstand tension measuring technique for bar mill and its application

S. Yanagi
(Kobe Steel, Ltd., Japan)

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Title: Interstand tension measuring technique for bar mill and its application


Author:
S. Yanagi

Company:
Kobe Steel, Ltd., Japan

Co-Authors:
M. Kobayashi, H. Nakamura, T. Taira, Y. Morimoto

Abstract:
Online interstand tension measuring technic was developed for bar mill. To calculate the interstand tension, the current change that is generated when the head of the bar is rolled into the downstream stand is detected and is converted into interstand tension. The rolling model for wire rolling is used in this procedure. A clustering method is used to obtain the reliable tension estimation out of the noisy current data. The calculated interstand tension is displayed in real time on the monitor screen that is installed in the bar mill operating room. This tension monitor helps the bar mill operators recognize the interstand tension easily and adjust the roll speed to obtain the suitable tension level, including no tension state, that is required for the stable rolling.

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25 June / 17:40 - Room 28:

Peak performance for billet and large bar rolling mills

T. Maßmann
(SMS group GmbH, Germany)

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Title: Peak performance for billet and large bar rolling mills


Author:
T. Maßmann

Company:
SMS group GmbH, Germany

Co-Authors:

Abstract:
Billet Mills are one of the oldest products of the entire rolling mill industry reaching back to times when continuous casting was a dream of far future. Casted ingots had been converted to square billets required for wire rod or bar production in order to ensure a high reduction ratio and lowest possible internal defects. The same has been done later with casted blooms. Today semi-finished products such as blooms, billets or even large round and square dimensions are produced on billet mills and large bar mills. These applications require the most reliable and strong equipment available on the market. Therefore, SMS group has developed a new generation of ultra-rigid closed-type housing Compact Stand (CS stands). For closest tolerance requirements, also HCS stands with hydraulic screw down are available. In combination with SMS group’s PROGAUGE laser gauge system, these stands automatic size control (ASC®) for high-quality large round bars.
Today the CS and HCS stands have been implemented in various rolling mills. In some cases they have been used in to replace old reversing blooming mills with continuous mills in order to increase feed sizes and productivity. Other applications are finishing mills for billets and bars.
By unifying the solidity of 20th century equipment with the latest technology and automation available SMS group´s billet and large bar mills can be a benchmark for the coming decades.

Forging and Forging Steels (26 June / 09:00 - Room 26)

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26 June / 09:00 - Room 26:

Forming induced anisotropy of product properties in cold extrusion

F. Kolpak
(Technical University of Dortmund, Germany)

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Title: Forming induced anisotropy of product properties in cold extrusion


Author:
F. Kolpak

Company:
Technical University of Dortmund, Germany

Co-Authors:
C. Dahnke, A. Tekkaya

Abstract:
The forming induced direction-dependence of the local yield strength, caused by the Bauschinger effect, is rarely considered in the field of cold forging, neither during the product design stage, nor in the numerical simulation of the processes. The process of forward rod extrusion allows for a direct analytical calculation of the resulting strains along the central axis of the extruded rods. By a variation of the extrusion ratio, the material can be subjected to a known pre-strain, which exceeds any other strain achieved by means of conventional material testing methods. This allows for a detailed investigation of the influence of the Bauschinger effect on the resulting local strength of cold forged parts. The direction-dependence was proven experimentally by example of the typical case-hardening steel 16MnCr5 by means of tensile and upsetting tests on specimens pre-strained by forward extrusion. It is shown, that the difference between the tensile and compressive strengths, indicated by the Bauschinger coefficient, increases with the pre-strain, which is in accordance with the behavior that is observed in smaller strain ranges. The difference amounts up to 30%, which is significant, considering the fact that it is never accounted for in conventional forming simulations. To improve the numerical prediction of local product properties various isotropic-kinematic hardening models were evaluated, which are capable to model the Bauschinger effect. The results indicate that for single-step forming processes, even the use of simple isotropic-kinematic hardening models that are available in most commercial FE-programs lead to a remarkable improvement of the prediction of the local product strength. In addition to this, an experimental method is proposed to fit the model parameters of the enhanced hardening models.

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26 June / 09:20 - Room 26:

A new high performance hot top insulation to improve quality of forging ingots

F. Hippenstiel
(BGH Edelstahl Siegen GmbH, Germany)

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Title: A new high performance hot top insulation to improve quality of forging ingots


Author:
F. Hippenstiel

Company:
BGH Edelstahl Siegen GmbH, Germany

Co-Authors:

Abstract:
High quality forged products are characterized by a high requirement for homogeneity and uniformity of mechanical and technological properties. To ensure this, not only the melting technology but also the solidification of the ingots plays a decisive role. In ingot casting, a controlled solidification from the bottom of the ingot to the well-insulated top of the ingot is essential objective. It should be the hot top volume, which is performed after the forging as internal crop-loss in circulation, as small as possible. As part of the presentation, a newly developed system for insulating the hot top of forging ingots will be presented. Basis of the development is a new insulating material, which was specially adapted to the requirements of hot tops of ingots. This results in the advantages of increasing the insulating effect to improve the solidification behavior of the forging ingots and a simplified handling in the casting shop including health and safety of the employees in the steel plant. Comparative conventional hot tops solutions of forging ingots are to be considered in order to show the improvement on the basis of the mechanical-technological properties and the segregation behavior.

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26 June / 09:40 - Room 26:

Effect of the sulphur content on the fatigue strength of the forged steel 38MnVS6

M. Scurria
(Technical University of Darmstadt, Germany)

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Title: Effect of the sulphur content on the fatigue strength of the forged steel 38MnVS6


Author:
M. Scurria

Company:
Technical University of Darmstadt, Germany

Co-Authors:

Abstract:
Microalloyed forging steels are used as structural materials for automotive components to meet needs such as lightweight design and high performance at lower costs. The machinability of these steels is improved by alloying additions of sulphur, which produce manganese sulphides (MnS). These non-metallic, ductile inclusions with high melting temperature (1610 °C) retard the grain growth and contribute to avoid cracking during hot working. Nevertheless, their presence reduces the fatigue strength of the steel, which has to be taken into account during the design phase of cyclically loaded components. In this paper, the fatigue behaviour of forged steel 38MnVS6 with respect to the content of MnS, and subjected to different forging levels and mean stresses is analysed. Two types of rolled steel 38MnVS6 with different sulphur contents (0.0728% and 0.0372%) are examined. Small scale specimens are extracted from both the lateral position and the centre of the wrought material, where different contents of MnS have been observed by microsections and metallographic analysis. Furthermore, cylinders orthogonal to the rolling direction are extracted from the wrought materials and forged in the axial direction at three different stages by an upset (logarithmic) strain of -0.7, -1.35 and -1.50. Additional specimens have been manufactured from these forged billets. Load-controlled fatigue tests with a stress ratio of R=-1 and R=0 at a frequency up to 150 Hz have been performed using a piezo actuator. The fracture regions have been evaluated with respect to shape and content of MnS. Finally, through this analysis, a correlation between the local logarithmic strain, determined by FEA forging simulation, and the fatigue strength of the material is evaluated.

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26 June / 10:00 - Room 26:

Application of fast models for equivalent strain, temperature and microstructure in open-die forging

M. Wolfgarten
(RWTH Aachen University, Germany)

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Close26 June, Room 26 ( 10:00 )
Title: Application of fast models for equivalent strain, temperature and microstructure in open-die forging


Author:
M. Wolfgarten

Company:
RWTH Aachen University, Germany

Co-Authors:
G. Hirt, F. Rudolph

Abstract:
Open-die forging is an incremental forming process, which is mainly used for the production of large parts with high requirements regarding the mechanical properties and reliability of the forged parts. Besides achieving an intended final shape, one main aim of open-die forging is the adjustment of the mechanical properties towards a fine-grained microstructure. Nowadays, new open-die forging processes are mainly designed using a geometry-based pass-schedule calculation, which only gives a statement on the geometrical evolution. Furthermore, during forging, no in-process control of the workpieces properties can be realized.
An alternative approach is the development and application of fast models for equivalent strain, temperature and microstructure, which are capable of calculating these decisive process values within few seconds. This paper presents introduces the application of fast models for property-based pass-schedule design and process monitoring in open-die forging.
For pass-schedule calculation, the models were successfully coupled to pass-schedule algorithms. By coupling these models and realizing a graphical user interface, it is possible to calculate pass-schedules within seconds and based upon that, analyze and optimize forging processes regarding the most decisive parameters.
Regarding the online monitoring of open-die forging process, by coupling the models to appropriate measurement technology, the models can be applied to visualize equivalent strain, temperature and microstructure during forging. This allows an in-process control of the workpieces properties for the operator allowing to react if e.g. deviation in the chosen forging schedule occurs. Here, the realization of a demonstrator system at the industrially scaled forging press at IBF is presented. Furthermore, a concept for an in-process optimization of forging process is introduced.
Altogether the hereby presented approach indicate that fast models offer a large potential both for process design as well as process monitoring in open-die forging allowing for a process optimization in open-die forging.

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26 June / 10:20 - Room 26:

Effect of forging processes on mircrostructure and properties of TC25 titanium alloy

M. Xinhua
(Baosteel Co., Ltd., China)

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Close26 June, Room 26 ( 10:20 )
Title: Effect of forging processes on mircrostructure and properties of TC25 titanium alloy


Author:
M. Xinhua

Company:
Baosteel Co., Ltd., China

Co-Authors:
J. Cheng

Abstract:
Abstract :This paper introduced the mircrostructure and the properties of TC25 titanium bar after different amounts of deformation(X,X+15%)in the α+β two-phase ragion. From the experimental results ,the mircrostructure and the properties of these two kinds of process bars all met the technical requirements.If the deformation was increased 15% on the basis of X,the mircrostructure was brokened more uniform and smaller,and the primary α equiaxed was better.The room temperature properties and 550℃ high temperature properties met the corresponding requirements too.The plasticity at the room temperature was also improved significantly.
Keywords:TC25 titanium; forging; mircrostructure; properties

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26 June / 10:40 - Room 26:

Optimisation of blank weights and reduction of cost per cut at large diameter forging lines

P. Pirolt
(Linsinger Maschinenbau GmbH, Austria)

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Close26 June, Room 26 ( 10:40 )
Title: Optimisation of blank weights and reduction of cost per cut at large diameter forging lines


Author:
P. Pirolt

Company:
Linsinger Maschinenbau GmbH, Austria

Co-Authors:

Abstract:
-

Rolling of tubes, sections and rails (26 June / 09:00 - Room 27)

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26 June / 09:00 - Room 27:

3D inspection of profiled material

C. Mittag
(IMS Messsysteme GmbH, Germany)

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Close26 June, Room 27 ( 09:00 )
Title: 3D inspection of profiled material


Author:
C. Mittag

Company:
IMS Messsysteme GmbH, Germany

Co-Authors:

Abstract:
Abstract ESTAD 2019
3D inspection of profiled material
Dipl. Eng. Christian Mittag
IMS Messsyteme GmbH
Product Manager
Heiligenhaus, Germany

In section mills, surface defects are caused by different production steps and have a wide range of serverity, critical for the quality of the final product. A 100% surface inspection will warant the quality of the later parts of e.g. building structures. 3D inspection based on laser sectioning, well known from flat products now enters the more complex shapes.

The rolling process is one of the critical parts of production. 3D Surface inspection systems nowadays provide full control of the rolling process based on new developed and fast 3D sensors. Worth environmental conditions need to be considered during the design of systems. Extremly varying shapes and dimensions are the biggest challenge for this kind of inspection systems.

The presentation will show the requests and parameters of optical systems which need to be taken into account.

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26 June / 09:20 - Room 27:

ShapeControl - assistance in pipe production

M. Thome
(SMS group GmbH, Germany)

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Close26 June, Room 27 ( 09:20 )
Title: ShapeControl - assistance in pipe production


Author:
M. Thome

Company:
SMS group GmbH, Germany

Co-Authors:
S. Zeller

Abstract:
In the production of longitudinally submerged-arc welded (LSAW) large-diameter steel pipes – covering diameters in the range of 18 to 56 inch – a complex sequence of manufacturing processes has to be planned and optimized to match strict market requirements. Thus, two approaches are essential. On the one hand process optimizations have to be done with regard to the process interrelations along the whole process chain. On the other hand process deviations based on material variations have to be managed with reference to each individual steel plate.
In this context, a new concept for process chain control is presented comprising an up-to-date calculation model for offline and real-time optimization of the LSAW pipe production process chain – including measuring and feedback-control systems. Core processes are controlled in consideration of real-time information coming from upstream and downstream processes. Due to intelligent algorithms, interrelations between subsequent forming processes (e.g. plate edge crimping, pipe forming, pipe closing, tack welding, pipe expanding) are processed by a superior process chain model.
As a practical example, the efficiency of the real-time feedback control algorithm is shown with focus on the pipe forming press. Influencing factors (e.g. variations in yield stress and wall thickness, bend positioning accuracy) are discussed on the basis of extensive simulations. Corresponding model algorithms are presented and compared with FEA and practical results.
The presented concept aims at a reduced start-up time for producing new pipe dimensions and at tighter tolerances for finished pipe dimensions. Furthermore, it allows for traceable real-time optimization of current production in existing LSAW pipe mills.

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26 June / 09:40 - Room 27:

Research on shape deformation of H-Beam in universal rolling with finite element method

S. Wang
(Dragon Steel Corporation, Taiwan)

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Title: Research on shape deformation of H-Beam in universal rolling with finite element method


Author:
S. Wang

Company:
Dragon Steel Corporation, Taiwan

Co-Authors:

Abstract:
H-beam rolling is more complicated than plate due to complicated contour, therefore, it’s more difficult to control the precise dimension than plate rolling. Among several different parts of H-beam, flange width is the most difficult part to be controlled accurately. Poorly control of flange width will cause the dimension failure, which leads to mass rejection and yield loss in the production, hence, we take it as the first priority issue to study. The defect in the dimension of flange width can be roughly classified into three classes, one is dimension deviation along whole length of the product, another is affected by the speed mismatching between each rolls during tandem mill rolling, and the other is deviation occurred at the end of the bar. In this study, we aimed at reducing flange width deviation near the bar ends. We surveyed the production data and found that several factors such as rolling speed, temperature distribution at the ends of the bar, and setup of rolling parameters that affect the deviation, this study validates these factors by Finite Element Method (FEM) and improve the dimensional accuracy of the product.

Keywords: H-beam, Finite Element Method, Flange width, Universal rolling, Rolling parameter

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26 June / 10:00 - Room 27:

Pert Bs stand application in a upgrade of section mill - case history -

M. Tomba
(Pert S.r.l., Italy)

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Close26 June, Room 27 ( 10:00 )
Title: Pert Bs stand application in a upgrade of section mill - case history -


Author:
M. Tomba

Company:
Pert S.r.l., Italy

Co-Authors:

Abstract:
Today’s long steel products market with ever smaller profit margins and stronger competition requires the use of rolling mills with minimized operational cost and the capability of assuring a final product of very high quality. Starting from these considerations, a PERT customer in Turkey decide to use the PERT BS (bi-Support Stands) in order to upgrade the existing section mill.The new stands was installed starting from the roughing area up to the finishing area. In the finishing area a particular tailor made solution was developed for the production of flat bars in order to perform the edging passes without the use of traditional convertible stands in order to reuse as much was possible the existing equipment and avoid new civil works and long stops in production for the upgrade of the line.The described case history, will show at the audience all the project developments starting from the preliminary customer request (increase in production quality, reuse existing electrical motors, short installation time, fast installation for the new stands, reduced investment cost...etc) up to the production restart.

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26 June / 10:20 - Room 27:

Economical cutting-edge technologies for rolling of beams, sections and rails

E. Krieg
(SMS group GmbH, Germany)

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Close26 June, Room 27 ( 10:20 )
Title: Economical cutting-edge technologies for rolling of beams, sections and rails


Author:
E. Krieg

Company:
SMS group GmbH, Germany

Co-Authors:

Abstract:
A number of new technologies and innovative equipment have been developed and implemented on the market for the production of beams, sections and rails. Universal rolling of rails, inline rail head hardening, thermomechanical rolling and quenching from rolling heat of beams and sections for better material properties of finished products and lower conversion costs, mill stands and straightening machines with hydraulically under-load adjustment and automated quick program changing for higher product quality and better time utilisation for rolling of all kind of sections and rails are well known and successfully in operation in many plants worldwide. HCS®-stands for continuous finishing and sizing of light and medium sections as well as for large bars and billets represent a new generation of ultra-rigid stand design with new features for achieving closest tolerances of the finished product. Inline profile gauges are meanwhile State-of-the Art in section rolling mills; simultaneous inline surface defect detection after finish rolling in hot condition is a fast-emerging technology.

The main focus of this paper lies on the introduction of innovative concepts for the cost effective production of sections and rails in order to meet the market demands. The benefits for the user’s competitiveness of the remarkable innovations developed in the past are illustrated.

The concepts described in this paper enable an excellent product quality to be achieved, whilst at the same time allowing the products to be produced at lower conversion costs and higher availability.

Rolling: Improved efficiency and product quality I (26 June / 09:00 - Room 28)

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26 June / 09:00 - Room 28:

Cold rolling mill technology for improved yield and enhanced operation stability

J. Sieghart
(SMS group GmbH, Germany)

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Close26 June, Room 28 ( 09:00 )
Title: Cold rolling mill technology for improved yield and enhanced operation stability


Author:
J. Sieghart

Company:
SMS group GmbH, Germany

Co-Authors:
D. Böttner, W. Spies

Abstract:
Cold Rolling Mill Technology for improved yield and enhanced operation stability

Ongoing development of advanced control technology for flat steel cold rolling mills improves the production yield and rolling stability. Several new control functions will be explained and recent results of commissioning presented.

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26 June / 09:20 - Room 28:

Influence of water quality on formation of scab in hot rolled strip

S. Roy
(Tata Steel Ltd., India)

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Title: Influence of water quality on formation of scab in hot rolled strip


Author:
S. Roy

Company:
Tata Steel Ltd., India

Co-Authors:

Abstract:
Surface quality is very critical for hot rolled material intended for cold rolling and cold forming operations. Scab formation is very detrimental for surface in hot rolled strips, it creates a depth on surface associated with foreign entrapment. During rolling specifically in later strands, foreign material falls from mill house due to vibration and gets embedded on surfaces in final stand which led to scab. Fallen material is always amorphous in nature albeit some sporadic cases.
In this study, we have characterized the nature and composition of amorphous material. Chemical and structural properties of deposit material in mill has been studied and verified with plant trial. Hard water deposits have been observed as potential source of such amorphous material. An optimum condition for operation also have been suggested to avoid formation of scab defect.

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26 June / 09:40 - Room 28:

State-of-the-art solutions for cutting, grinding and deburring of large-scale steel and special alloy products

G. Richter
(BRAUN Maschinenfabrik GmbH, Austria)

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Close26 June, Room 28 ( 09:40 )
Title: State-of-the-art solutions for cutting, grinding and deburring of large-scale steel and special alloy products


Author:
G. Richter

Company:
BRAUN Maschinenfabrik GmbH, Austria

Co-Authors:

Abstract:
At various stages during their manufacturing processes – from casting to finishing before delivery – semi-finished steel and special alloy products must be cut and surface-treated as well. The requirements for the individual conditioning steps, however, can be quite different. For example, the workpiece can be hot, warm or cold. At any rate, the product must always be perfectly prepared for the next manufacturing step – reliably, in the shortest-possible time and at the lowest-possible cost. For cutting, grinding and deburring, BRAUN has developed innovative technologies and highly flexible, tailor-made solutions which meet these requirements in the most optimal way. In particular, BRAUN’s cutting, grinding and deburring technologies can also be used for large-scale products.

Rolling: Sensors and control, online measurement technologies I (26 June / 09:00 - Room 13)

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26 June / 09:00 - Room 13:

Inline measurement using Camera Cluster Technology

J. Blonski
(IMS Messsysteme GmbH, Germany)

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Close26 June, Room 13 ( 09:00 )
Title: Inline measurement using Camera Cluster Technology


Author:
J. Blonski

Company:
IMS Messsysteme GmbH, Germany

Co-Authors:

Abstract:
For optical measuring systems IMS Messsysteme GmbH uses unique, patented Camera Cluster Systems (CCS). They consist of a number of high-speed, intelligent and yet inexpensive cameras that are arranged closely next to each other in groups – the clusters. The distance between two cameras is 20mm, each cluster consists of 16 cameras, 100 cameras are used for two-meter inspection. By lining up multiple cluster modules next to each other, it is possible to measure foil, strip and plate of any width as well as long products.

The innovative technology makes the clusters highly interesting for a number of measurement tasks in the steel, aluminium and nonferrous metal industries for cold and hot applications. IMS uses CCS for high accurate width measurement in rolling mills and processing lines. With a software add-on, the system can be extended by an edge crack and/or hole detector. Information on defects is extremely important not only for quality assurance, but also to avoid broken strip. Due to the high resolution and steep angle of sight, the technology can also be used economically for the first time for inline measurement of slit strip width in slitting lines. Especially for tinplate and aluminium packaging material camera cluster systems are applicable for detection of pinholes in the size of several micrometer. Wherever the flatness, levelness, contour is necessary to be measured, the camera cluster technology in combination with laser line projection (laser triangulation principle) is used. In cut-to-length lines this technology is applicable for sheet and plate dimension measurement such length, width, out of squareness, diagonals and camber. IMS also uses the innovative technology for surface inspection as well. For long products camera cluster are used for straightness measurement.

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26 June / 09:20 - Room 13:

Dynamic flatness control by interstand looper shape meter for hot strip mill in TATA Steel Kalinganagar

N. Migakida
(Primetals Technologies Austria GmbH, Austria)

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Title: Dynamic flatness control by interstand looper shape meter for hot strip mill in TATA Steel Kalinganagar


Author:
N. Migakida

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:

Abstract:
Hot strip mill line for TATA steel Kalinganagar (TSK ) is the latest and most-leading edge hot strip mill in India. Primetals Technologies have developed a number of advanced technologies in hot strip rolling field and provided them for TSK hot strip mill so that solutions to the customer demands could be offered. Pair cross mill provides the highest strip crown/flatness control combined with Mill stabilizing device to improves capability of high reduction.
Looper shape meter was provided in between last three finishing stands and successfully detected flatness distribution of strip under loading tension. Primetals’ Looper shape meter is the only interstand shape meter that is working in commercial production of hot strip mill line due to its robust design. For TSK plant, dynamic strip flatness control was firstly provided by using feedback data from Looper shape meter, though it was impossible to control strip shape dynamically by using a conventional optical shape meter after loading strip tension between a finishing mill and a down coiler. The dynamic flatness control was properly operated and daily improving strip flatness.
This paper introduces the unique technologies of Primetals Technologies applied in the hot strip mill for TSK plant, especially focusing on Lopper shape meter.

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26 June / 09:40 - Room 13:

Sensors and measurements towards industry 4.0 in CRM Group

L. Gilon
(CRM Group, Belgium)

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Title: Sensors and measurements towards industry 4.0 in CRM Group


Author:
L. Gilon

Company:
CRM Group, Belgium

Co-Authors:
G. Moreas

Abstract:
The industry 4.0. domain is very large, so Industrial process control and measurements department of CRM Group has started with a focus on technology bricks which are the basis of I4.0.
First focus concerns digital integration and standardisation of data exchange protocols
In that aim, several protocols are currently under development by specialists, the currently most used is OPC UA for connection between computers and PLC: both are using basic common language and start conversations.
Second focus concerns miniaturisation of our systems implying integration of micro-PC like Raspberry or Arduino to acquire and process the data and to control sensor status and communication. Big control unit, bigger than human height, can so be replaced by a control unit of hand size.
Sensor fusion is also implemented more and more. Indeed, for example, the combination of infrared and visible images will give more information than each one alone.
Equipping industrial lines with several miniaturised sensors requires developing wireless communications adapted to the large space and metallic environment of industrial plants. This can be combined with energy harvesting to power these small sensors thanks to vibrations, temperature of engines, rolls movements, …
Finally, taking into account the more and more increased amount of data to be processed as well as their frequency, it is essential to use Data learning or Machine learning to process the whole collected data and to determine the best running mode.
All these points will be illustrated by an industrial example.

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26 June / 10:00 - Room 13:

New online inspections system for internal defects in thin steel strip

J. Scharzmann
(IMS Messsysteme GmbH, Germany)

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Title: New online inspections system for internal defects in thin steel strip


Author:
J. Scharzmann

Company:
IMS Messsysteme GmbH, Germany

Co-Authors:
S. Fritsch, H. Krauthäuser

Abstract:
Steel contains different types of non-metallic inclusions (NMI). The size of this inclusions ranges from microscopic to visible by eye. Certain NMI lead to problems in the further processing, for example during deep drawing. Thus, a non-destructive and contactless online measuring system, which could detect these NMI is needed to guarantee the required product quality.

The magnetic flux leakage measurement (MFL) is a technology, that is used online or in the laboratory e.g. as magnetic powder testing. IMS developed a new internal defect detection system that also uses the MFL principle. Sensitive GMR sensors allow an increase of lift off compared to conventional hall sensors. The GMR sensors, a magnetization device and a digitalization device are combined in one compact module which acts as a MFL line scan camera. A variable number of these modules can be combined to ensure a continuous testing over the whole strip width. The MFL cameras are connected via standard Gig-E interface to an image processing computer.

The signal processing software separates the defect signals from the material background noise and creates a defect map of the strip. Furthermore, the defect images of the MFL cameras are rated by a defect classification system. The knowledge of the different defect types helps the operator to grade the quality of the material.

This paper presents the concept of the new measuring system and shows first results.

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26 June / 10:20 - Room 13:

Sectional strip tension meter - Shapemeter roll

J. Benč
(UVB TECHNIK s.r.o., Czech Republic)

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Title: Sectional strip tension meter - Shapemeter roll


Author:
J. Benč

Company:
UVB TECHNIK s.r.o., Czech Republic

Co-Authors:

Abstract:
Sectional strip tension meter - Shapemeter roll

Sectional strip tension meter is designed for evaluating of metal strip flatness in cold rolling mills. The principle of the flatness evaluation is based on measuring of pressure forces of a metal strip in the individual zones of the measuring roll. A visual unit displays measured tensions across the strip in real time on monitor in the form of a column and flat graphical mapping.

Depending on the graph shape on the monitor, the operator can make the adjustment of the rolling mill. Or the equipment can be integrated into the regulating loop AFC (Automatic Flatness Control).


Rolling: Improved efficiency and product quality II (26 June / 10:20 - Room 28)

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26 June / 10:20 - Room 28:

SMS group solutions of thin slab casting and rolling concepts for flexible and profitable hot strip production

K. Hoen
(SMS group GmbH, Germany)

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Title: SMS group solutions of thin slab casting and rolling concepts for flexible and profitable hot strip production


Author:
K. Hoen

Company:
SMS group GmbH, Germany

Co-Authors:
B. Kintscher, C. Klein, S. Krämer, C. Cecere

Abstract:
The situation of the steel industry is challenging. Worldwide overcapacities, increasing tariffs and political instability all have their impact on profitability. At the same time alternative materials like carbon composites or aluminum are pushing into classic steel application areas.

More than ever, SMS group is focused on providing the steel industry with flexible and profitable technologies and systems over the whole process chain in order to secure and enhance the competitiveness of steel in close cooperation with the steel producers.

Regarding thin slab casting and rolling technology, during the last decade a new generation of plant concepts with the ability of endless rolling was established. These concepts based on continuous casting machines with increased throughput by operating at casting speeds of 6 m/min and more with a slab thickness of up to 130 mm. As pioneer of thin slab casting and rolling by introducing the CSP® technology, SMS group offers the full variety of concepts.

This paper presents today’s two distinguished generations of thin slab casting and rolling concepts. It explains the plant concepts offered by SMS group and the possibilities of adapting them to the special requirements of steel producers. To round out the picture concerning flexibility and profitability, new technologies implemented to further improve operation and plant efficiency will be presented as well as Industry 4.0 products.

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26 June / 10:40 - Room 28:

The relation between microstructure of pure titanium and edge crack in cold rolling

K. Kimijima
(Kobe Steel, Ltd., Japan)

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Close26 June, Room 28 ( 10:40 )
Title: The relation between microstructure of pure titanium and edge crack in cold rolling


Author:
K. Kimijima

Company:
Kobe Steel, Ltd., Japan

Co-Authors:

Abstract:
Commercial pure titanium sheets are usually manufactured by hot rolling process, annealing-pickling process, and cold rolling process. To reduce sheet gauge largely in cold rolling, the second annealing-pickling is performed after the first cold rolling and then, the second cold rolling is performed.
From the viewpoint of cost and productivity, it is to be desired to omit second annealing-pickling. However, high rolling reduction increases the risk of edge cracking and sheet rupture of rolled material.
We investigated the tendency of edge cracking in cold rolling of pure titanium and find appropriate annealing conditions before cold rolling to prevent edge cracking. This report describes the relation between microstructure of pure titanium and edge crack in cold rolling.

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26 June / 11:00 - Room 28:

Experiences with press hardening furnaces and tailored tempering systems

P. Seemann
(Ebner Industrieofenbau GmbH, Austria)

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Title: Experiences with press hardening furnaces and tailored tempering systems


Author:
P. Seemann

Company:
Ebner Industrieofenbau GmbH, Austria

Co-Authors:
P. Seemann

Abstract:
Experiences with Press Hardening Furnaces and Tailored Tempering Systems

The press hardening process allows the automotive industry to produce structural components that combine very high strength and minimal springback, thus offering major advantages in terms of lightweight construction and crash safety.
Steel blanks for the production of body-in-white parts are heat treated in furnaces of the HotPHASE product line developed by EBNER. The design features essential for optimum heat treatment will be shown in the presentation. It also concentrates on newest developments of centering systems, automatic process control and optimized atmosphere compositions.

Tailored tempering is used to produce functional optimized hot formed parts for the automotive industry with regions of increased ductility and higher energy absorption in the event of a crash. There are different methods to accomplish tailored properties, each of them with advantages and disadvantages. A brief comparison of existing production processes for tailored tempering will be given.

Rolling: Processing of new steel grades (26 June / 11:00 - Room 27)

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26 June / 11:00 - Room 27:

Pioneering across continents and cultures for the next welding technology breakthrough

S. Mauuary
(Primetals Technologies France S.A.S., France)

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Title: Pioneering across continents and cultures for the next welding technology breakthrough


Author:
S. Mauuary

Company:
Primetals Technologies France S.A.S., France

Co-Authors:
T. Yagi, S. Kaga, S. Mauuary, S. Maillard

Abstract:
By combining different cultures, Primetals Technologies is a particularly favorable environment for the emergence of new technologies. This principle has been applied to strip welding, where the respective significant experience and technological setups have been assessed and mutualized : European and Japanese expertise’s, from laser optical to metallurgical and mechanical skills, from laboratory & robot based test facility to scale 1:1 pilot machine.
Driven by the ever growing demand for new grades Primetals Technologies breaks through strip welding by expanding the welder LW21M “Asolid” technology used on low gauges for high-end market such as automotive CAL/CGL. Addressing the usual drawbacks in maintenance, operation and safety of current welding system based on mechanical cutting and CO2 laser welding, the newly developed LW21H “Solid state” technology now benefits from a smarter approach by processing thicker strips up to 7 mm with solid-state laser cutting and welding. This new welder generation will set new state-of-the- art and is brought to reality through a scale 1:1 pilot developed, manufactured and tested in Primetals Technologies workshop. The latest results will be shared by a multicultural team.

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26 June / 11:20 - Room 27:

HYPER UC-MILL The advanced 6Hi UC-Mill for High Grade Non-Gain Oriented Electrical Sheet Production

T. Nakayama
(Primetals Technologies Japan Ltd., Japan)

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Close26 June, Room 27 ( 11:20 )
Title: HYPER UC-MILL The advanced 6Hi UC-Mill for High Grade Non-Gain Oriented Electrical Sheet Production


Author:
T. Nakayama

Company:
Primetals Technologies Japan Ltd., Japan

Co-Authors:
H. Ke, Y. XingLiang, Y. Mingcheng, S. Yasunari, T. Tomino

Abstract:
The worldwide trend to electro-mobility requires higher amounts of electrical steels to reduce emissions as well as high strength steels to reduce the weight of the vehicles. The electrical drive system for these vehicles require high grade non-grain oriented electrical steel sheets (HNGO) for high performance and advanced high strength steel (AHSS) for a light weight body which contributes to the extension of the driving distance.
The “HYPER UC-MILL” is the advanced 6Hi UC-Mill (Universal Crown Control Mill) equipped with significantly smaller work rolls. This allows to roll the harder and thinner materials with the 6-high technology with a higher productivity compared to the conventional cold rolling process using a 20-high cluster type mill. The small work rolls of the HYPER UC-MILL are driven by newly developed gear type spindles called “MH Spindle” to transmit the higher rolling torque compared to conventional universal joint type and/or gear type spindles. At the same time the new spindles allow to minimize the work roll horizontal deflection for the high product flatness quality with the optimized combination of intermediate and back-up roll diameter.
The first conversion of an existing reversing cold mill to a HYPER UC-Mill has been successfully completed in Maanshan Steel in China during a short downtime period August 2018. After completion and fast start-up, Maanshan Steel expanded the product mix from middle grade NGO to high grade NGO (HGNO) and could improve both the product quality and productivity.
This paper introduces the effects of the conversion of the existing mill to a HYPER UC-MILL for the expansion to HNGO comparing the production data before and after the upgrade.

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26 June / 11:40 - Room 27:

X-Pro® laser welder for high strength steel grades

J. Szonn
(SMS group GmbH, Germany)

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Title: X-Pro® laser welder for high strength steel grades


Author:
J. Szonn

Company:
SMS group GmbH, Germany

Co-Authors:
C. Dornscheidt, J. Artel, C. Sasse

Abstract:
In the entry section of strip processing lines, strips of different and partially difficult-to-weld steel grades have to be connected to form an endless strip in a short time. The X-Pro® laser welder by SMS group is perfect for the production of hard-to-weld strip materials mainly due to the patented inductive heat treatment. Further advantages are the automatic welding parameter calculation, the quality assurance system, and the low cycle time. Thanks to the modular design of the welding machine and the consequent separation between weld seam preparation and the welding process itself, the welding source can be easily replaced. This gives the opportunity to use a conventional carbon dioxide laser source or a state of the art solid state laser source. The most recent machines have been equipped with solid state laser sources, which features certain process and cost advantages.
The machine can be integrated in existing lines but it is also perfectly suitable for revamps. For example, to replace old flash butt welding machines or conventional laser welding machines which are not able to weld modern grades in a reliable manner, since the high alloying contents have an influence on the weld ability of the materials. The compact design with simple foundations and the flexible layout arrangement ensure, that it can also be integrated in existing lines with small or complicated space conditions.
The paper will describe machine, requirements and process with emphasis on the production of high strength steel grades. It will include information about solid state lasers, weld-seam heat treatment, revamps, maintenance and digitization. Furthermore, it will show some results of reference implementations.

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26 June / 12:00 - Room 27:

Wet Flash Cooling®: a flexible and high performance quenching technology for Gen3 AHSS

S. Mehrain
(Fives Stein S.A.S., France)

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Title: Wet Flash Cooling®: a flexible and high performance quenching technology for Gen3 AHSS


Author:
S. Mehrain

Company:
Fives Stein S.A.S., France

Co-Authors:

Abstract:
Water Quench technology has been implemented in some continuous annealing lines since more than 30 years for the production of HSS grades. The automotive steel market tendency for higher strength steel grades is accelerating today, and a large variety of Gen3 AHSS grades are developed in which, besides yield strength, other properties are also considered, particularly to improve formability. The production of AHSS grades in a continuous processing line requires a proper cooling control to follow the required thermal cycles for each grade and to secure a stable production of first choice products with improved flatness and mechanical properties. The Wet Flash Cooling® technology has been developed to reach these goals, offering a full flexible control of the strip cooling cycle, including control of final strip temperatures, accurate modulation of cooling rates and strip crosswise temperature homogeneity control.
This technology is successfully operating in a large capacity industrial annealing line since 10 years, and is under implementation in another new automotive strip processing line. This paper summarizes the new challenges of quenching technologies to respond to the Gen3 AHSS production needs, and describes the main features of the Wet Flash Cooling® technology.

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26 June / 12:20 - Room 27:

State-of-the-art PL-TCM (pickling lines and tandem cold strip mills)

T. Kikkawa
(JP Steel Plantech Co., Japan)

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Close26 June, Room 27 ( 12:20 )
Title: State-of-the-art PL-TCM (pickling lines and tandem cold strip mills)


Author:
T. Kikkawa

Company:
JP Steel Plantech Co., Japan

Co-Authors:

Abstract:
CMI Industry Metals and JP Steel Plantech Co. have decided to extend their respective business models and to combine both companies’ marketing efforts focusing, in a first step, on complete, high quality Pickling Lines and Tandem Cold Mills for the steel industry and particularly the Advanced/Ultra High Strength Steel (A/UHSS) market segment.
Introducing features include the newest technologies for improving operational reliability, compactness and ensuring efficiency as well as achieving quality standards for automotive market and advanced high strength steel products. One major focus is the result of the highly efficient Spray Pickling Technology as well as an effluent-free technology as Fluidized Bed Acid Regeneration Plant.
Another major feature for TCM is SPEOS Mill Technology that gives the best solution for crown control and edge drop control simultaneously with better strip flatness, even when used for 4-high rolling mills.
In this paper the latest reference in terms of technological highlights and implementation results for a very broad range of size and grades (IF to AHSS and electric steel) will be presented.

Rolling: New Developments (26 June / 11:20 - Room 26)

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26 June / 11:20 - Room 26:

DUE - The successful start-up of the first Danieli universal endless plant

M. Van Reimersdahl
(Danieli Germany GmbH, Germany)

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Close26 June, Room 26 ( 11:20 )
Title: DUE - The successful start-up of the first Danieli universal endless plant


Author:
M. Van Reimersdahl

Company:
Danieli Germany GmbH, Germany

Co-Authors:
M. Knigge, M. Bulfone, C. Bilgen

Abstract:
Danieli Universal Endless (DUE®) the new flag ship within the QSP family combines the advantages and the abilities of “universal” rolling modes, endless and coil to coil within one single plant configuration by making this plant a major technology innovation compared to the previous generation.
This new approach can be seen as the natural evolution of the original, successful Danieli concepts of the thin slab route, namely the application of the vertical curved design thin slab caster and the separation of the rolling stands into high reduction units and finishing units, which is now successfully proven in SGJT, China.

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26 June / 11:40 - Room 26:

Intelligent roll-gap lubrication improves strip surface cleanliness in Thyssenkrupp Steel's tandem cold rolling mill

M. Bergmann
(Primetals Technologies Austria GmbH, Austria)

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Close26 June, Room 26 ( 11:40 )
Title: Intelligent roll-gap lubrication improves strip surface cleanliness in Thyssenkrupp Steel's tandem cold rolling mill


Author:
M. Bergmann

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
K. Krimpelstätter, B. Nilsson, S. Karakavaf, R. Leffers

Abstract:
In cold rolling, tribological effects prevailing at the interface of the work roll and strip surface greatly influence the rolling process and the quality of the final cold rolled product. In particular, the amount of iron fines generated in the roll gap significantly influences strip surface cleanliness.
Research work done on this topic has shown that improving the lubrication efficiency especially in the early mill stands helps to avoid excessive wear generation and thus allows to improve the surface quality of the final product. This paper explains the wear mechanism and the influence of strip, process and lubricant parameters on the generation of strip wear in cold rolling.
Innovative lubrication systems such as Minimum Quantity Lubrication MQL® allow mill operators to take advantage of unused optimization potential. Minimum Quantity Lubrication MQL® was installed in thyssenkrupp Steel Europe’s batch tandem cold mill in Bruckhausen, Germany. MQL® applies small amounts of rolling oil atomized with air directly onto the surface of the work roll and allows to control the oil film thickness independent of the mill speed in a flexible way ensuring a product-specific lubrication.
The system is currently operated based on a lubrication table depending on the steel grade and process parameters. Operational results are presented that demonstrate a reduction of the required rolling forces and power consumptions by improved roll-gap friction. Measurements of the strip surface cleanliness after cold rolling have shown a significant improvement compared to the previously installed conventional emulsion lubrication system.
Currently, intelligent model-based lubrication control concepts are being investigated that allow to influence crucial process parameters such as the coefficient of friction or the forward slip.

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26 June / 12:00 - Room 26:

New developments for heat treatment of AHSS strips

M. Pressler
(Ebner Industrieofenbau GmbH, Austria)

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Close26 June, Room 26 ( 12:00 )
Title: New developments for heat treatment of AHSS strips


Author:
M. Pressler

Company:
Ebner Industrieofenbau GmbH, Austria

Co-Authors:
M. Pressler, P. Seemann

Abstract:
New Developments for heat treatment of AHSS strips

Author: Peter Seemann, EVP product Development
Co-author: Michael Pressler



Technical advance generates permanent pressure to improve the mechanical and technological properties of materials. Improved passenger safety together with reduced car emissions lead to new steel grades such as AHSS to address the light-weighting car initiative. These materials put new demands on the thermal processing equipment to obtain the desired mechanical properties. Higher annealing temperatures, faster cooling rates, better strip shape and more uniform tempering are required. But most of all a precise control of the heating and cooling curve is demanded.

In the last few years Ebner developed many features addressed to achieve these goals not only for small scale hardening and tempering lines but also for automotive manufactures and their tier 1 suppliers. To obtain precise control of the quenching temperature Ebner developed the Hicon/H2 Quench. This new Quenching technology creates new possibilities to adjust the mechanical properties of AHSS strips. Now it is not only possible to precisely control the cooling gradient but also adjust the "end of quenching temperature" in a very small window.

EBNER Industrieofenbau GmbH
Ebner Platz 1
4060 Leonding
see@ebner.cc

Rolling: Sensors and control, online measurement technologies II (26 June / 11:20 - Room 13)

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26 June / 11:20 - Room 13:

Customized solutions for dimension control and surface analysis of hot rolled products ready for Industry 4.0

P. Schalk
(TBK Automatisierung GmbH, Austria)

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Close26 June, Room 13 ( 11:20 )
Title: Customized solutions for dimension control and surface analysis of hot rolled products ready for Industry 4.0


Author:
P. Schalk

Company:
TBK Automatisierung GmbH, Austria

Co-Authors:

Abstract:
In a competitive market, low operation costs and prime quality products are even more important. Therefore devices and tools are to measure the finished or intermediate products in the mill line and to get the feedback about the size and quality of the product immediately. This laser gauge devices are available to measure the complete shape respectively image of the product as well as to detect surface defects.
The harsh conditions in rolling mills pose a huge challenge to measuring technology. Measurement systems made by TBK (SMS group) have matured through years of experience and stand out due to high thermal and mechanical stability. Thanks to the laser light section technology and the measurement frequency, this device allows a high consistency of the measured data and also for the quality of the derived parameters. Further, closed-loop controls have been developed in cooperation with SMS group for automatic roll setting to the required adjustment values based on the measurement results. TBK adapts its measurement technology to the customer’s requirements and prepares tailor-made solutions, if so desired.
The presentation will focus on tailor-made solutions for dimension control and surface analysis of rolled products for all tube and pipe, wire rod and bar as well as section mills included in the portfolio of SMS group. The core competence to be highlighted is the continuous monitoring of ongoing production processes with focus on the use of tried and tested laser technology. Contactless precision measurements visualize production processes and permit statistical process controls to be made in a number of variants.

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26 June / 11:40 - Room 13:

Installation of flaw detector

T. Murayama
(Godo Steel Ltd., Japan)

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Close26 June, Room 13 ( 11:40 )
Title: Installation of flaw detector


Author:
T. Murayama

Company:
Godo Steel Ltd., Japan

Co-Authors:

Abstract:
Godo Steel, Ltd. Funabashi Works produces reinforced bar about 300,000 tons per year.

The flaw of our reinforced bar includes scabs. Scabs can cause serious complaints in some cases.

In April 2016, Funabashi Works installed a hot line sensor camera type flaw detector as a measure to prevent scabs. After the installation, accuracy check was carried out, and it was adjusted to the operation level.
The number of complaints due to scabs was reduced from 5 to 1 per year after installing the flaw detector.
This paper describes the outline and results of flaw detector.

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26 June / 12:00 - Room 13:

Online tensile-structure properties evaluation by means of stress-strain analysis of skin pass process data

A. Ferraiuolo
(Marcegaglia Ravenna S.p.A., italy)

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Close26 June, Room 13 ( 12:00 )
Title: Online tensile-structure properties evaluation by means of stress-strain analysis of skin pass process data


Author:
A. Ferraiuolo

Company:
Marcegaglia Ravenna S.p.A., italy

Co-Authors:

Abstract:
This paper presents the results of the development of an innovative methodology using a mathematical model to skin pass mill process data in order to measure online the tensile-structure properties of flat steel products. The proposed approach could represent a new solution to define the annealing process conditions (CAL, HDG, BA) to achieve the target microstructure, improved mechanical properties as well as enhanced forming-ability properties of high strength steels. The online measurement of flow stress allowed to evaluate important microstructural features such as the ferrite grain size in the final product and the austenite fraction formed at the soaking temperature. Laboratory tensile tests and metallographic investigations confirmed a good agreement with the online structure-properties characteristics calculated with the mathematical model. The proposed method is promising to produce products with exceptional uniform tensile properties and at the same way guarantee the best annealing process efficiency and low global energy consumption.

Key words:
Online tensile properties, epitaxial ferrite, online austenite fraction measure, online grain size measure, skin pass.


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26 June / 12:20 - Room 13:

Optical measurement of flatness changes during laminar cooling in SSAB's hot strip mill

P. Kierkegaard
(Shapeline AB, Sverige)

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Close26 June, Room 13 ( 12:20 )
Title: Optical measurement of flatness changes during laminar cooling in SSAB's hot strip mill


Author:
P. Kierkegaard

Company:
Shapeline AB, Sverige

Co-Authors:

Abstract:
Laminar cooling is a critical process that, unless perfectly regulated, can have a detrimental effect on the finished product in terms of flatness and shape while still attain the desired microstructure and metallurgical properties.

Historically, a wide variety of flatness measurement technologies has been developed and introduced on the market, with varying level of success. In particular hot strip mill applications has proven to be extraordinarily challenging, and often results in inaccurate and unreliable readings. High strip speed combined with an incredibly harsh and hostile environment featuring the compounding effect of heat shimmer, steam and water, scale and vibrations complicates the measurement process tremendously.

In recent years, together with SSAB in Borlänge and Vinnova (Sweden’s innovation agency), Shapeline developed a flatness gauge system to be installed and located immediately after the finishing stand in the hot strip mill where it’s subjected to the most challenging of conditions. Over the past year this system has proven to be reliable with a high degree of availability and performance while also being easy to service, maintain and calibrate without stopping the mill.

After this successful project, the stakeholders agreed to move to the next phase which included adding a second flatness gauge, based on the same resilient design as the existing, to be located immediately after the laminar cooling.

The objective with this project was to record and compare the flatness-profiles, before and after the laminar cooling process, and use this information to regulate the cooling process to minimize the negative impact on strip flatness.

This paper explains the measurement principle and how the systems operate. It will also provide some insight into the specific project after having been in operation for almost one year.

Rolls for Rolling (Wear and lubrication, grinding, new materials, roll surface, roll inspection) I (26 June / 11:40 - Room 28)

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26 June / 11:40 - Room 28:

The digital roll shop for improved quality, performance and process monitoring

R. McWhirter
(Tenova S.p.A., Italy)

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Close26 June, Room 28 ( 11:40 )
Title: The digital roll shop for improved quality, performance and process monitoring


Author:
R. McWhirter

Company:
Tenova S.p.A., Italy

Co-Authors:

Abstract:
The challenges of a modern roll shop are becoming more demanding as the requirements for quality, productivity and automation are continually increased. Not only must the automated equipment be extremely accurate and reliable but it must also incorporate high levels of process control, process monitoring and product inspection.
An integrated suite of software based functions has been developed by Pomini Tenova SpA, to achieve these required high levels of performance, monitoring and reporting in roll shop equipment. Such functions as Digital Texturing, on-line machine parameter monitoring, vibration monitoring, In-Process surface inspection and roll inspection combined in one device, continuous profile measurement and correction plus additional packages are available to operate as an integrated system. These functions provide an enhanced level of machine intelligence that delivers improved process monitoring and control.

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26 June / 12:00 - Room 28:

Work roll roughness topography and strip cleanliness during cold rolling automotive sheet

C. Gaspard
(Union Electric Akers, Belgium)

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Close26 June, Room 28 ( 12:00 )
Title: Work roll roughness topography and strip cleanliness during cold rolling automotive sheet


Author:
C. Gaspard

Company:
Union Electric Akers, Belgium

Co-Authors:

Abstract:
A point of great importance of cold rolling process for automotive sheet is the cleanliness of the strip. This is particularly critical in case of batch annealing with inefficient cleaning lines. In these specific cases, pollution of the strip surface could be prohibitive when rolling in the early stands of tandem mill with conventional forged rolls as ground. The strip cleanliness strongly deteriorates during rolling mainly with high roughness rolls and iron fines coming from the strip surface are progressively sticking on the sheet.
It is well known that chrome plating the conventional forged rolls in the early stands delays the onset of strip cleanliness degradation during rolling.
This paper summarizes the results of 3D surface roughness topography study on forged work rolls, with and without chrome plating, combined with sheet cleanliness measurement during rolling. It shows that a well determined topography has to be obtained on the work rolls used in early stands in order to roll in the mixed lubrication regime, as described by the Stribeck curve, minimizing the friction coefficient and therefore optimizing the cleanliness of the rolled sheet.
The main roll roughness parameters to take into account for that purpose are the roughness level Sa, and even more, the Kurtosis parameters Sk, Spk, Svk, Ssk and Sku.
The ideal surface morphology promotes deep valleys to the detriment of peaks, leading to a roll surface capable of retaining/trapping oil in the valleys, while peaks are minimized, thus reducing the abrasive effect in the roll bite and the amount of iron fines produced.
To achieve this objective, new grinding wheel technologies are currently developed, in partnership with wheel manufacturers, to create such ideal morphology of roughness well adapted to forged HSS rolls.

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26 June / 12:20 - Room 28:

Optimization of Work Roll Cooling in Rolling

P. Kotrbacek
(Brno University of Technology, Czech Republic)

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Title: Optimization of Work Roll Cooling in Rolling


Author:
P. Kotrbacek

Company:
Brno University of Technology, Czech Republic

Co-Authors:
M. Pohanka, K. Schörkhuber, M. Zachar

Abstract:
The optimal cooling of rolls should be designed with respect to two aspects. The first is the wearing of a roll where high temperature decreases the durability of the surface layer. The second aspect is thermal deformation of a roll. There are many factors which can influence the efficiency of the nozzle cooling system: type of nozzle, geometrical configuration (nozzle pitch, distance from the roll, orientation, number of manifolds), coolant pressure and temperature. Cooling intensity is mostly specified through the heat transfer coefficient or heat flux distribution. Coolant flow on the rotating roll surface makes the problem complex. Surface temperature of the cylinder plays an important role in the heat transfer mechanism, especially for higher temperatures where boiling must be considered. No analytical or numerical solution of heat transfer and fluid flow for this case is known. The task can be successfully solved experimentally. An experimental bench and methodology of realistic boundary conditions determination was developed in the Heat Transfer and Fluid Flow Laboratory.

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26 June / 12:40 - Room 28:

On the performance and surface quality of graphitic HSS roll grades at voestalpine hot strip mill

A. Paar
(Eisenwerk Sulzau-Werfen, R. & E. Weinberger AG, Austria)

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Title: On the performance and surface quality of graphitic HSS roll grades at voestalpine hot strip mill


Author:
A. Paar

Company:
Eisenwerk Sulzau-Werfen, R. & E. Weinberger AG, Austria

Co-Authors:
L. Elizondo, M. Brandner, H. Hölzl, M. Aigner, T. Trickl, K. Böldl

Abstract:
Graphitic HSS roll grades such as ESW’s brand VANIMO can be considered as the latest developments for the last finishing stands in hot strip mills. These roll grades are developed on the basis of the alloying concept of (Carbide Enhanced) Indefinite Chill work roll materials. During the development of VANIMO, the amounts and types of carbide forming elements were increased and adjusted into the direction of cast HSS roll grades. The microstructure of graphitic HSS roll grades therefore consists of tempered martensite, cementite and several different carbide types as well as a well-defined amount of free graphite.
The main purpose of graphitic HSS roll grades is the combination of the high surface quality of Indefinite Chill alloys as well as the high wear resistance of HSS roll grades. The development and introduction of this very advanced roll grade at voestalpine Hot Strip Mill in Linz/Austria was done in a close cooperation between the customer and the roll supplier. Several systematic steps were taken to increase the wear performance from Carbide-Enhanced Indefinite Chill grades to the more advanced VANIC grade to reach the highest alloyed roll grade VANIMO. In every development step, the surface quality of the roll grades was carefully monitored.
This paper describes the improvement of the wear performance for roll grades in the last finishing stands in voestalpine’s HSM by introducing higher alloyed roll grades, up to VANIMO. Different appearances of the strip surfaces with relation to the work roll material are presented and the root causes for these phenomena are explained. Finally some possible strategies to improve the surface quality of graphitic HSS roll grades are presented.

Rolling: Annealing, galvanizing and finishing (26 June / 13:40 - Room 27)

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26 June / 13:40 - Room 27:

Preoxidation technology dedicated to AHSS

M. Dubois
(CMI Industry, Belgium)

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Title: Preoxidation technology dedicated to AHSS


Author:
M. Dubois

Company:
CMI Industry, Belgium

Co-Authors:

Abstract:
Full oxidation of the surface of Advanced high strength steel is a technology that is today used in conjunction of high dew point to promote the wettability and coating adhesion of zinc coating.
Results of laboratory experient will be presented first. This includes trials on Si TRIP steels as well as DP980 but also classical DX51 grade. It is observed that the surface after pre-oxidation contains mostly Fe203 and Fe3O4 but without FeO for AHSS, whereas on a classical low carbon steel FeO is clearly identified. The coatability is characterized not only by bare spots identification but also with bending adhesion tests. It turns out that the pre-oxidation step significantly improves zinc wetting and coating adhesion but should not be conducted at too high temperature. The reduction process that follows is an important step to ensure a full iron oxide reduction before dipping.
Similar cycles done on classical low carbon steel show that they oxidize much faster than AHSS, with O2 levels as low as 0.5%. FeO is now the oxide formed. This means that the managemnt of the transition between AHSS and classical steel requires some skils
Then the technological concept of the oxidation chamber is presented as well as the basics of its instrumentation.

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26 June / 14:00 - Room 27:

Danieli cold processing technology: Innovative approaches for new lines and upgrades

R. Holz
(Danieli & C. Officine Meccaniche S.p.A., Italy)

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Title: Danieli cold processing technology: Innovative approaches for new lines and upgrades


Author:
R. Holz

Company:
Danieli & C. Officine Meccaniche S.p.A., Italy

Co-Authors:
L. Vignolo, T. Settimo

Abstract:
Optimized CAPEX, OPEX, new products, yield and product quality in new process equipment as well as by upgrading of existing facilities are the key factors for success and profitable operation.
For this, innovation in processes and design is crucial. Danieli can support their clients by offering innovative and well-thought-out process equipment and upgrade solutions.
In 2018, Danieli has put into operation a complete cold processing complex in Turkey, which includes a new continuous pickling tandem mill featuring latest generation of market oriented technologies.
In this line, dedicated to run a broad range of size and grades (IF to AHSS as DP1000), the highly efficient Turboflow® pickling process was selected. This technology already proved its efficiency and ability in former applications handling ultra-thin gauges at speeds even exceeding 400 m/min in the pickling tanks.
The 5-stand 6-high OSRT tandem mill features important developments, like actuators to improve significantly strip flatness and a special air knife arrangement on the tandem mill exit side to generate perfect strip surface cleanliness.
In galvanizing lines, the zinc pot is the most effective area to reduce costs in operation and consumables and increase the product quality.
Danieli has spent significant efforts in developing most advanced technology for the wiping process. A fully integrated system solution has been designed to perform a wiping process with high quality, economy, accuracy and productivity.
Center part is the newly developed X-Jet / Compact X-Jet air knife, added by new generation electromagnetic stabilizer as well as robotic systems to reduce human intervention and health risks in this area.
This technological package is ideal also for upgrade of existing lines, typically generating a return of investment less than 1 year.
On top, Danieli has developed advanced automation systems including L2 and L1 controls to achieve outstanding product performances.

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26 June / 14:20 - Room 27:

Hot dip galvanizing at 240mpm, dream or reality

M. Dubois
(CMI Industry, Belgium)

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Title: Hot dip galvanizing at 240mpm, dream or reality


Author:
M. Dubois

Company:
CMI Industry, Belgium

Co-Authors:

Abstract:
Since an increase of line productivity is a major source of profitability, the feasibility of Zn coating at speed as high as 240mpm is addressed whereas the standard industrial practice is in the range of 180 to 200 mpmn . The challenges related to the coating process to reach such a high speed are addressed. It turns out first that the physical minimal coating thickness that can be reached is 6µ whereas the expected industrial value is estimated 2 µm thicker due to the limitation in the wiping gas flow. Secondly, the model describing the full splashing phenomena that exists at high speed predicts a physical limit around 200-210 mpm for Gi and around 220-230 for Zn5%Al. Those high values requires however optimized nozzles shapes. Thirdly, the analysis of the risk of pot roll stoppage due to the development of Zinc film leads to the conclusion that a careful design of the equipment is required and for specific strip size the addition of a drive. Finally, the issue of skimming production and melting rate is addressed. Both are expected to require technical solution due to the significant increase of both

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26 June / 14:40 - Room 27:

Closed looped control of the AHSS annealing process via X-ray phase fraction measurement

U. Sommers
(SMS group GmbH, Germany)

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Title: Closed looped control of the AHSS annealing process via X-ray phase fraction measurement


Author:
U. Sommers

Company:
SMS group GmbH, Germany

Co-Authors:
F. Brühl, T. Daube , C. Klinkenberg, C. Sasse, S. Melzer, D. Fintelman, F. van den Berg, C. Ionescu, J. Crutzen, O. Pensis, A. Lhoest, T. Terlau, H. Krauthäuser, E. Montagna

Abstract:
The production of modern advanced high strength steel grades (AHSS) places high demands on the thermal process in annealing and hot-dip galvanizing lines. In particular, the automotive industry requires homogeneous properties of the steel strips from coil to coil and over the entire length of the coils. In order to achieve this, information on the microstructure is necessary to control the process and compensate possible deviations because of upstream processes. A closed loop control with a measurement system in the line exit section is not possible because at that position the material already has its final mechanical properties.
Processed AHSS grades consist of a combination of two or more phases to reach the required material properties. During the heat treatment, the fraction of austenite in front of the rapid cooling determines the amount of secondary, hard phases formed during subsequent cooling stages. For AHSS the secondary phase fraction is the main influence for the strength of the final product.
SMS group, Drever International and IMS Messsysteme jointly developed a system for the real time quantification of the austenite content during the annealing process. The new online measuring system uses X-ray diffraction to derive the crystalline phase fraction, thus the austenite content, in front of the rapid cooling section of the furnace. The continuous measurement of the austenite content in the furnace allows to compensate process and material changes directly, which otherwise would lead to product quality deviations.
A first system was installed – inside a protective housing – on a hot-dip galvanizing line at Tata Steel in the SEGAL plant in summer 2017. The measurement results were compared to the final product strength.
The paper will present the possibility of the closed loop furnace control and show first test results.

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26 June / 15:00 - Room 27:

Twisting towers in finishing lines

M. Dubois
(CMI Industry, Belgium)

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Title: Twisting towers in finishing lines


Author:
M. Dubois

Company:
CMI Industry, Belgium

Co-Authors:

Abstract:
If Twisting towers have been used many times to couple the pickling line to cold rolled mills, there use in finished product is not the practice. The situation is indeed very different due to the fact that the product is thin (between 0.2 to 2mm) and may be soft in case of DDQ and EDDQ. Therefore the potential problems in case of incorrect design are buckles and impact in the final flatness due to elongation of edges. Some Finite elements approach has been done to understand the root causes of potential buckling. Finally, a practical model has developed a including the various aspects from stress distribution on, the rolls, sensitivity to buckles and impact on the flatness. The key design parameters including roll diameter, tower dimensions and twisting angles are clearly identified. This model has been used to optimize the definition of the twisting tower on 2 industrial lines.

Rolls for Rolling (Wear and lubrication, grinding, new materials, roll surface, roll inspection) II (26 June / 14:00 - Room 28)

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26 June / 14:00 - Room 28:

Prevention of premature contact fatigue damages to roughing mill rolls

S. Flament
(CRM Group, Belgium)

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Title: Prevention of premature contact fatigue damages to roughing mill rolls


Author:
S. Flament

Company:
CRM Group, Belgium

Co-Authors:
M. Sinnaeve, O. Lemaire, G. Walmag

Abstract:
More and more hot rolling mills worldwide face premature failures of their roughing mill rolls. These failures, often due to contact fatigue damages in the bonding zone occur before reaching the scrap diameter of the roll. Several causes including longer rolling campaigns, harder rolled steel grades, reduced passes to increase mill throughput or inadequate backup or work roll maintenance.
These premature fatigue failures are often followed by requests to roll makers to increase the shell thickness. In some cases this could be avoided by an optimisation of the roll use. Marichal Ketin and CRM developed a numerical tool to optimize both work and back-up rolls geometries. This tool enables to evaluate the influence of various parameters such as rolls geometries (crowning and chamfering procedure, shell thickness and material design) or rolling parameters (campaign length, rolling forces) on stresses generated in the rolls and how to optimize the situation to decrease roll fatigue risks.
This paper will review the history of rolls in roughing mills as well as how an optimization of the roll use can decrease its contact fatigue damages occurrence.

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26 June / 14:20 - Room 28:

Influence of Carbide Morphology of HSS Roll on Wear Resistance and Thermal Crack Resistance

S. Ito
(Nippon Steel Corporation, Japan)

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Title: Influence of Carbide Morphology of HSS Roll on Wear Resistance and Thermal Crack Resistance


Author:
S. Ito

Company:
Nippon Steel Corporation, Japan

Co-Authors:
S. Uchida, T. Inoue

Abstract:
The influence of the different carbide morphologies on the wear resistance and thermal crack resistance of HSS roll (high-speed steel roll) materials were investigated through experiments, by experimentally producing three types of HSS roll materials, changing the amount of each carbide and grain size, under the condition in which the total amounts of MC type carbide and eutectic carbide are equally maintained. As a result, it was confirmed that i) the greater the amount of MC type carbide, the more the wear resistance is enhanced; ii) the less eutectic carbide, the more the thermal crack resistance is enhanced; and iii) the finer granular size in carbide becomes, the thermal crack resistance is enhanced.

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26 June / 14:40 - Room 28:

Development and implementation of VICTURATM rolls in the late finishing stands of hot strip mills

Z. Zhang
(Union Electric Åkers, Sweden)

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Title: Development and implementation of VICTURATM rolls in the late finishing stands of hot strip mills


Author:
Z. Zhang

Company:
Union Electric Åkers, Sweden

Co-Authors:

Abstract:
By applying high-end rolls with utmost performance and superior surface quality, hot strip mills can be further optimized. Operations in the mill have been also waiting for improved roll solutions that can minimize required roll changes which impact production efficiency. Limitations are usually due to the low performance and surface degradation of the rolls in the late finishing stands (F5 – F7). VICTURA is the most recent developed grade for rolls utilized in the late finishing stand at Union Electric Åkers (UEÅ). These rolls have been tested and applied in mills all over the world. A significant improvement over the enhanced ICDP rolls has been observed. Hot strip mills are realizing improved operating efficiency and Total Cost of Ownership (TCO) through the transition of their entire roll inventories to these break through products.

Industry 4.0 - in forming technology (26 June / 14:00 - Room 13)

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26 June / 14:00 - Room 13:

The metals enterprise service bus

S. Martens
(PSI Metals GmbH, Germany)

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Title: The metals enterprise service bus


Author:
S. Martens

Company:
PSI Metals GmbH, Germany

Co-Authors:
L. Van Nerom

Abstract:
International automation standards such as ANSI/ISA-95 organize metals production in a layered hierarchical way: from process control (L1), process automation (L2), manufacturing execution(L3) up to business management (L4). This automation pyramid has been broadly accepted and implemented by most metals producers worldwide. These implementations are driven by software applications that focus on one or part of these automation layers and interface with another layer through standard or customized data interfaces. As long as business processes remain in one layer these applications work perfectly and efficiently.

This approach is heavily questioned in the past years by the rising demand for cross layer business processes and functionalities, especially since technologies like Big Data Analytics, Machine Learning, IoT, Sensors Everywhere etc., have become mature enough to be used in an industrial environment. Often these cross layer business processes meet artificial layer borders as obstacles. These obstacles are creating problems like lack of needed data due to layering abstraction, inflexibility to adapt changes between layers fast enough, performance issues caused by unneeded transformations crossing several layers and so on.

In the I4.0 world, software hierarchies or automation layers become vague or can even be abandoned. Therefore the next evolutionary step towards the internet of things is needed. Booking a flight and reserving your seat is a perfect example of this cross layered functionality world. During this booking process many services are being used, but we expect them to be part of a seamless business process where all involved layers remain invisible. The same cross layer expectations are required for the next generation of production management solutions for the metals industry.

This paper describes the challenges of metals production management solutions related to B2B metals e-commerce on the business level and the automation revolution that comes with I4.0 on the shop floor level. We will explain how to adapt and break up the automation layers into smaller services communicating and collaborating together based on one common enterprise service bus. Finally we will introduce the Metals Enterprise Service Bus, as an industry standard for that purpose.

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26 June / 14:20 - Room 13:

TPO pioneering: Digitalization of high efficiency high quality production

T. Pfatschbacher
(Primetals Technologies Austria GmbH, Austria)

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Title: TPO pioneering: Digitalization of high efficiency high quality production


Author:
T. Pfatschbacher

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
J. Plaul, L. Pichler, B. Schürz, W. Oberaigner, N. Hübner, M. Kügel

Abstract:
A key cornerstone for being successful in Steel and Metals Business is to achieve a high efficient overall production process enabling the economical successful production of high quality products with high yield at competitive low costs.

This – only on the first look easy combination – can be pushed to higher levels by Digitalization and sufficient Know How.
Primetals has developed a pioneering digitalization solution for this – TPO, Through Process Optimization. TPO combines the modern, highly functional Primetals Technologies’ Digitalization IT System “TPQC – Through Process Quality Control” with the digitalized Know How and experience of Domain Experts and AI algorithms. TPO enables metals producers to control and optimize the production and product quality across the entire process chain.

By collecting the right data with TPQC out of all automation systems, measurement systems, smart sensors and even from operators the data is transformed in valuable information, KPIs, decisions, advices and actions enabling a higher level of production and product quality.

This papers explains the cornerstones and main elements of TPO, the background of the development, a view and outlook on the further potential and gives some examples of successful customer implementation.

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26 June / 14:40 - Room 13:

Anomaly and causality analysis in process data streams using machine learning with specialised eigenspace topologies

M. Neuer
(VDEh-Betriebsforschungsinstitut GmbH, Germany)

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Close26 June, Room 13 ( 14:40 )
Title: Anomaly and causality analysis in process data streams using machine learning with specialised eigenspace topologies


Author:
M. Neuer

Company:
VDEh-Betriebsforschungsinstitut GmbH, Germany

Co-Authors:
N. Link, A. Quick, T. George

Abstract:
The broad progress of digitalisation provides an increasing amount of online available data, often large data streams, from all relevant production processes. In many cases, this data is stored and used for posterior data analytics to explore the reasons for malfunctions or product degradation. The talk presents new search and monitoring techniques, mainly originating from the technological Big Data developments and applied mathematical research, to find suspicious patterns in signal streams. Moreover, it shows how these pattern locations can be effectively used to step from pure correlation analysis to context related causality analysis. Moreover, sometimes operators even do not know about the characteristic shape or pattern they must associate with a process anomaly. Then, algorithms are required to allow automatic retrieval of the most common and the most exotic patterns in the data. The talk will present such algorithms and demonstrate their usage. It will show latest machine learning approaches to cluster, detect and identify anomalies in processes and their causal interrelationship with other process situations. Such approaches have already succesfully been deployed in products of large system providers for maintenance and process forensics. In recent research activities, similar concepts are now tested for online application. Here, the same algorithms must be adapted and reduced to run highly efficient within the processing time, to allow a prediction right in time.

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26 June / 15:00 - Room 13:

Machine learning based predictive quality

J. Coppe
(PSI Metals GmbH, Germany)

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Title: Machine learning based predictive quality


Author:
J. Coppe

Company:
PSI Metals GmbH, Germany

Co-Authors:
E. Dral, E. Samuylova

Abstract:
In the metals industry up to 4% of the production needs to be scrapped even with the highest standards related to quality control. Most defects are related to the early stages of the production process (casting and milling) but mostly only discovered at the finishing stages of the product.
Most defects and scrap could be avoided if discovered early in the process by:
- Re-assigning the material to a less demanding order
- Selecting different production route
- Adapting some parameters of remaining production steps
- Adding a rework step to correct the defect
But the quantity of data to be analyzed makes it impossible for human operators and quality experts to predict these defects.
Machine learning based predictive quality can predict up to 75% of the defects, most of which can then be avoided. This will reduce the scrap production of the plant drastically.

The big challenge is how to combine mathematics and production, in other words how to use a machine learning model to fit to the operational world. This includes correct choice of problem statement, prediction target and definition of the business use case.
One way to integrate a machine learning-based quality prediction in the existing process is by applying a certain set of actions for all coils considered “suspicious”. For that, we need to define a threshold for the probability of defect above which we will act on the coils to avoid the defect. This threshold can be calculated based on the cost of corrective action and the cost of defect. It should also take into account some business and technical limitations based on the chosen actions.

This paper describes how such models can be achieved and maintained and how they can be embedded in the operational quality management of a metals production plant.

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26 June / 15:20 - Room 13:

Innovations & first application of the intelligent new energy pallet-car coil conveying system

F. Wei
(Beijing Shougang Yunxiang Industrial Technology Co. Ltd., China)

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Close26 June, Room 13 ( 15:20 )
Title: Innovations & first application of the intelligent new energy pallet-car coil conveying system


Author:
F. Wei

Company:
Beijing Shougang Yunxiang Industrial Technology Co. Ltd., China

Co-Authors:

Abstract:
This paper summarized the developments of the steel coil conveying technology of metallurgical enterprises in this century, introduced the super-capacitor and its applications in the public transportation area, described the first intelligent new energy coil pallet-car and its innovations in detail, compared two technical proposals of a real project that using the new pallet-car system and the traditional pallet system. It also described the first practical application in a hot strip mill, and pointed out the advantages and the possible applications of this technology in other fields and industries. The technology meets the requirements of Industry 4.0, and provides a reliable solution for intelligent heavy load logistics.

Rolling: Digitalization and Smart Factory-solutions for processing industry (27 June / 09:00 - Room 26)

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27 June / 09:00 - Room 26:

The ever increasing role of automation in the development of the "Intelligent Plant" of the future

E. Plazzogna
(Danieli Automation S.p.A., Italy)

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Close27 June, Room 26 ( 09:00 )
Title: The ever increasing role of automation in the development of the "Intelligent Plant" of the future


Author:
E. Plazzogna

Company:
Danieli Automation S.p.A., Italy

Co-Authors:

Abstract:
Danieli Group is deeply involved in the technological improvements stimulated by Industry 4.0 concepts, widely applied to metal industry and process automation. The development of the so called "Intelligent Plant" is the natural evolution of the consolidated company know-how and of the undisputed leadership in the fields of mini-mill and turnkey plants. Complete and structured data collection is the basis for real-time analysis and process optimization in terms of quality, efficiency and easy maintenance. The centralized repository of information is possible thanks to the strong interconnection between process control system architecture and intelligent sensors, together with dedicated software tools leading to an intuitive approach to data analytics.

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27 June / 09:20 - Room 26:

Technology improvements with cyberphysical cooling system at HSM #1 of Thyssenkrupp Steel

K. Weinzierl
(Primetals Technologies Germany GmbH, Germany)

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Close27 June, Room 26 ( 09:20 )
Title: Technology improvements with cyberphysical cooling system at HSM #1 of Thyssenkrupp Steel


Author:
K. Weinzierl

Company:
Primetals Technologies Germany GmbH, Germany

Co-Authors:
E. Hermann, L. Pichler, A. Seilinger, A. Reljic

Abstract:
In 2010 development of a cyberphysical cooling system has been started and finished now with the completion of the pilot project at thyssenkrupp hot strip mill I in Bruckhausen.
While a classical automation system divides the plant into its process areas roughing mill, finishing mill and cooling section with separate controllers for each of them, Primetals Technologies has reorganized the automation of finishing mill and cooling section with only one comprehensive controller and underlying model. With a classical automation system, the separate controllers for finishing mill and cooling section often interfere with each other when trying to reach competing control targets resulting in a semi-optimum overall performance. Primetals’s Comprehensive Strip Temperature Control enables optimum performance results of both the finishing mill and the coiling temperature, as presented results from the pilot plant show.
The hot strip mill in Bruckhausen is equipped with Primetals state of the art strip cooling technology. For the transfer bar cooling, an equipment which was firstly operated as prototype installation in 2002 at voestalpine is installed. One main feature is a special header design with 3 separate individually flow controllable chambers. In the run out table cooling Primetals Power Cooling is installed featuring 16 pairs of top and bottom headers. The advantages of Power Cooling technology are due to very high achievable cooling rates and homogeneous water flow over the width which are both required to improve production costs and strip quality.
Furthermore, the model drives also the transfer bar cooling device and entire water management system. Homogeneous temperatures along length and width of transfer bar when entering the finishing mill are requested and improving material quality.

Thus, the newly developed cooling technology combined with the cooling model forms a cyberphysical system with proven superior performance at thyssenkrupp steel WBW 1.

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27 June / 09:40 - Room 26:

Metals production in the streaming age: How to create a streamline of non-predictable metal products

E. Meta
(PSI Metals GmbH, Germany)

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Close27 June, Room 26 ( 09:40 )
Title: Metals production in the streaming age: How to create a streamline of non-predictable metal products


Author:
E. Meta

Company:
PSI Metals GmbH, Germany

Co-Authors:
L. Van Nerom, A. Betzold, R. Jäger

Abstract:
The digital revolution changed the way we acquire products and as a result changed customers’ expectations and behavior. Until recent years customers went to stores to find the product they needed and selected from the different available choices. Today customers, instead of selecting from a limited set of options, search for the product they want and place orders through a seamless acquisition process, creating a streamline of products delivered to their door. These changes caused several players in the industry to be under threat by newcomers, while others adapted their business models increasing the value of the products offered to their customers, providing a better customer experience and reduced friction during the acquisition process.

The same changes are currently happening in the industrial goods market. Customers’ requirements are propagated upstream through the supply chain up to industrial manufacturers, creating new demands for the market. In response to new market demands, some online retailers are already offering standardized industrial metals products, increasing the pressure for metals producers to process customer requirements faster.

To compete in this new business environment, metals manufacturers should improve their business model from an efficiency oriented production to a service oriented production, offering real-time accurate answers to their customers. Such business model requires a combination of real time final product design linked to semi-finished inventories, advanced production planning and scheduling to make accurate delivery promises and end-to-end visibility through the whole production process up to the delivery.

The purpose of this paper is to describe how Industry 4.0 technologies allow metals producers to develop the core abilities required for a service oriented production and create a streamline of non-predictable metals products where customers are able to place orders through a real-time seamless acquisition process, a solution only metals manufacturers can provide.

Rolling: Process and production control, transportation and logistics I (27 June / 09:00 - Room 27)

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27 June / 09:00 - Room 27:

Bar mill dynamic pacing control

M. Rinaldi
(Danieli & C. Officine Meccaniche S.p.A., Italy)

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Close27 June, Room 27 ( 09:00 )
Title: Bar mill dynamic pacing control


Author:
M. Rinaldi

Company:
Danieli & C. Officine Meccaniche S.p.A., Italy

Co-Authors:
L. Sandrigo, H. Tabikh, M. Rinaldi

Abstract:
Dynamic pacing at ABS Marte bar mill is control system improving plant productivity and bar temperature stability at hot saw inlet considering the on-line condition both of rolling and finishing mill, which are directly linked.
Rolling mill configuration has 3 reversible stands producing a wide bars section range, but this solution puts productivity under pressure, therefore there is need of optimisation tools.
The system is able to detect on-line both maximum pacing achievable by rolling stands and bars jam before hot saw and before NDT, to foresee finishing mill productivity and slow-downs due to order separation/sampling on the cooling bed. Moreover software is able to detect the condition of ‘hot blooms’ at furnace outlet and increase maximum discharging pacing if blooms inside RHF are hotter than aim and there is no risk from internal quality point of view.
Software allows collaboration among different single plants, so when it foresees a slow down due to future order separation, it rebalance it increasing accordingly reheating furnace maximum pacing for the blooms immediately before order separation. This event is very frequent in case of special bars qualities due to small orders dimensions and this innovative optimisation needs the management of huge amount of data.
Dynamic pacing control allowed a 3-18% net productivity increase depending on sections size together with 1-10% increase in bars having surface within ± 20°C before hot saw for small sections.

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27 June / 09:20 - Room 27:

Innovative control concept for thin gauge rolling at ESP

D. Kotzian
(Primetals Technologies Germany GmbH, Germany)

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Title: Innovative control concept for thin gauge rolling at ESP


Author:
D. Kotzian

Company:
Primetals Technologies Germany GmbH, Germany

Co-Authors:
A. Grüss, B. Linzer

Abstract:
To enable an outstanding strip thickness quality and a high stability during thin strip rolling up to 0,6 mm exit thickness in Endless Strip Production (ESP), Primetals Technologies has developed an innovative control concept for the Finishing Mill which is called “Ultra-Thin Rolling Control” (UTR). This is an adapted control concept of Tandem Cold Mills, which has been used successfully many times during cold rolling.
The UTR is successfully in operation at Rizhao ESP line 4 during thin strip rolling with outstanding stability and exit thickness performance. Depending on the material dimension or the rolling condition the UTR mode will be selected during rolling accordingly and with smooth transition functionality. The UTR consists of an entry tension control via roll gap and roll speed and it contains a Roll Eccentricity Compensation for work and backup rolls. Thereby the load cell of the interstand looper measures the strip tension between the stand while the looper is in position control and holds its position constant.

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27 June / 09:40 - Room 27:

Integrated overall quality management

J. Gnauk
(PSI Metals GmbH, Germany)

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Title: Integrated overall quality management


Author:
J. Gnauk

Company:
PSI Metals GmbH, Germany

Co-Authors:
J. Hackmann, X. Liu, K. Huang, V. Berenzon

Abstract:
Traditional quality management systems (QMS) regard local processes and often still act on level 2 automation systems. A novel type of integrated QMS was developed as part of, and fully integrated in, an existing and continuously developing level 3 production management system. In contrast to former software products, the high integration not only allows the standard functionality of conventional QM installations but also a transparent elaboration of quality targets and indicators as well as traceability and control of intermediate and final quality decisions.
Inside the overall integrated structure a knowledge base is defined. Rules derive quality targets and quality indicators from customer orders. These quality targets and indicators are related to a characteristic set of produced materials as well as to details of production processes. The common repository stores quality data provided by arbitrary providers like MES, LIMS, SIS, L1 and L2 systems, etc. Quality Deviation Management allows to automatically resolve recognized quality problems by initiating e.g. rework or down grading.
Also tools like statistical process control and root cause analysis are available not only on isolated facilities but also spanning various production steps to better optimize quality tracking and prevention of defect occurrences. Deep learning algorithms, already used in a PSI pilot project will guide and enhance this process in future versions of this software.

Rolling: Plant upgrades and new equipment developments I (27 June / 09:00 - Room 28)

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27 June / 09:00 - Room 28:

Technical solutions for safe handling of high-strength coils

C. Mengel
(SMS group GmbH, Germany)

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Title: Technical solutions for safe handling of high-strength coils


Author:
C. Mengel

Company:
SMS group GmbH, Germany

Co-Authors:
C. Mengel, T. Holzhauer

Abstract:
Hot rolling of high-strength grades is gaining importance. Among the carbon steels, these are particularly the multi-phase steels for the automotive industry, higher- strength structural steels, tube steels and wear- resistant steels. In the segment of stainless steels, these are duplex steels and special-purpose steels, part of which is produced with relatively low coil weights of up to 16 tons. The thicknesses of strip made of the above materials are increasing to as much as 25.4 mm.

In addition to the technical challenge presented by the production of these materials on hot rolling mills, there is also the aspect of the safe handling of these coils. Basically, there is a distinction to be made between the temporary securing of steel coils during delivery from the coiler and permanent own securing of the coil due to specific plastic deformation of the final wraps already on the hot strip coiler.

A combination of two methods provides a wide production range for the plastic deformation of the outer wraps:

The tail end cooling is in particular effective when coiling high strength materials with average and higher thickness at a certain temperature level. The deformation is applied with a thermal-mechanical bending.

The tail end forming device offers the highest benefit for ultra-high strength material at average or thinner thickness. The deformation is applied with mechanical bending.

The objective is to ensure coil handling without risk at least till the next securing by a strapping machine.

The paper presents the technical problem definition, shows already implemented technical solutions, and gives an outlook to further possible future oriented solutions, featuring the following measures:
• Stabilization of the coil on the coil car
• Coil clamping from above
• Clamping in the coil eye
• Reduction of residual stresses
• Thermal method for stabilization of the outer wrap
• Direct pallet system

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27 June / 09:20 - Room 28:

Arvedi ESP: Pioneering mature technology for endless casting and rolling

A. Jungbauer
(Primetals Technologies Austria GmbH, Austria)

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Title: Arvedi ESP: Pioneering mature technology for endless casting and rolling


Author:
A. Jungbauer

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
S. Grosseiber, T. Lengauer

Abstract:
Arvedi ESP is the first hot rolling process ever to produce cold rolled substitutes in industrial scale and big varieties of final products are now produced directly from ESP hot band without implementing a cold rolling process. Energy consumption and related CO2 emissions are drastically reduced on the one hand by the compact layout of ESP lines as well as by omitting subsequent cold rolling steps. Details of successful endless strip production as well as new features under development for currently running projects will be discussed in this paper.

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27 June / 09:40 - Room 28:

Development and application of POSCO's innovative endless rolling technology(CEM®) for various steel products

K. Cha
(POSCO Co., Ltd., Republic of Korea)

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Title: Development and application of POSCO's innovative endless rolling technology(CEM®) for various steel products


Author:
K. Cha

Company:
POSCO Co., Ltd., Republic of Korea

Co-Authors:
J. Kong, J. Chung, Y. Ko, M. Cho

Abstract:
POSCO has developed CEM® (Compact Endless casting and rolling Mill) process, which is the competitive and innovative strip making process. CEM® has two key technologies which include high speed thin slab casting and endless rolling technologies. By optimizing the fluid flow and minimizing the bulging through various technology development, CEM® process has achieved high speed casting with maximum 8m/min and it allows to make highly valuable hot-rolled products through a directly connected process between casting and rolling line. Especially, CEM® is most efficient process to produce high-strength thin gauge products because it has the advantage of obtaining excellent shape and homogeneous material properties by constant speed and isothermal rolling process.
In recent years, POSCO has made great efforts to develop production technology for a variety of products such as HSLA(High Strength Low Alloy), AHSS(Advanced High Strength Steel) and silicon steel in addition to ultra-thin products using the CEM® process. And some results will be introduced in this paper.

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27 June / 10:00 - Room 28:

Revamping of skin pass section for automotive products

F. Dumortier
(CMI Industry, Belgium)

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Title: Revamping of skin pass section for automotive products


Author:
F. Dumortier

Company:
CMI Industry, Belgium

Co-Authors:

Abstract:
Due to the increasingly stringent requirements of the automotive industry, galvanizing lines dedicated to automotive products have to be modernized in order to follow market needs. Beginning of 2017, SEGAL a Tata Steel CGL line in BELGIUM placed an order with CMI to increase the line capacity on the one hand, and on the other, to be able to process a wider range of steel grades according to automotive requirements.

One part of the project was to revamp the skin pass section. The objectives were first to increase the work roll diameter from Φ560mm to Φ650mm in order to be able to transfer the required roughness with low elongation on soft material and second to increase the rolling force and tension to reach higher elongation on high strength steels. Existing mechanical elongation system has also been changed to completely new single AC motors per roll.

CMI achieved such complicated revamping in a very short time span since the shutdown started only 6 month after the contract signature. Moreover, the shutdown down schedule has been optimized in order to restart the galvanizing line in less than after three weeks, including loopers and furnace capacity increase and new water cooling system.

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27 June / 10:20 - Room 28:

20+ euro/t savings by combining K-weld and K-spool technologies optimizing bar mill yield for the lowest OPEX

D. Vinetti
(Danieli & C. Officine Meccaniche S.p.A., Italy)

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Title: 20+ euro/t savings by combining K-weld and K-spool technologies optimizing bar mill yield for the lowest OPEX


Author:
D. Vinetti

Company:
Danieli & C. Officine Meccaniche S.p.A., Italy

Co-Authors:
A. Mestroni, D. Vinetti

Abstract:
Some of the most significant Danieli innovations in the field of long products are the
EWR® Endless Welding Rolling process and the “Spooler Line” for bar-in-coil production.
>> The EWR® system, through automatic flash welding of billets at reheating furnace exit side, enables endless rolling of bars, wire rod and bar in coils, thus granting uninterrupted production at the rolling mill.
>> The Spooler process, featuring twist-free winding of hot-rolled rebars into highly compact/ultra-heavy coils is the revolutionary process for bar-in-coil production.
Thanks to their unique cobble-free un-coiling capability, spooled coils can be directly fed to the downstream cold-processing lines without any traditional off-line operation (de-coiling, stretching & re-winding).
This paper presents the two systems and their combined application, which has made it possible for endless rolling of spooled bar in coils, enabling to cumulate the benefits of the two processes in terms of productivity, efficiency and reduction of production costs thereof.

Rolling: Virtualization and HMI* in rolling and finishing operations (27 June / 10:40 - Room 26)

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27 June / 10:40 - Room 26:

Dynamic, Adaptive and Mobile System for Context-Based and Intelligent Support of Employees in the Steel Industry

K. Hermsen
(celano GmbH, Germany)

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Title: Dynamic, Adaptive and Mobile System for Context-Based and Intelligent Support of Employees in the Steel Industry


Author:
K. Hermsen

Company:
celano GmbH, Germany

Co-Authors:
M. Jansen, N. Zengeler, M. Grimm, Z. Qasem, D. Keßler, A. Arntz, S. Eimler, U. Handmann

Abstract:
In order to fulfill the customer's requests for more product variety and quality, the processes in heavy industry companies are becoming shorter and more complex. These changes will also affect the demands on employees. At last, they make decisions within the diverse hierarchical levels that influence the production planning and the production process and thus ensure economic success. These decisions are increasingly based on a reliable, transparent and real-time provision of production and process data. This data should be provided in a simple and intuitive manner. To ensure this, it is important to recognize and consider the respective context. It must be decided who needs which data, at which moment and which place. The role of the user, the production situation and location must be recognized and evaluated.
The research project “DamokleS4.0-Dynamic, adaptive and mobile system for context-based and intelligent support of employees in the steel industry” (1.7.2016-30.6.2019) explores how new technologies, like mobile and smart devices or augmented reality as envisioned in Industry 4.0, can be used to provide context-based and intelligent support to employees in the steel industry. The project, in which celano and the Hochschule Ruhr West - University of Applied Sciences collaborate, is funded by the European Union.
Exemplified by four scenarios derived from real situations in the steel industry the context-based data provision is described as well as the use of mobile devices and wearables with internal and external sensors and image processing methods. For interaction with the user the use of technologies like smart glasses are evaluated concerning usability and safety.

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27 June / 11:00 - Room 26:

The digital twin - one solution for different tasks

M. Haverkamp
(SMS group GmbH, Germany)

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Title: The digital twin - one solution for different tasks


Author:
M. Haverkamp

Company:
SMS group GmbH, Germany

Co-Authors:

Abstract:
Abstract

A digital twin can have different characteristic features. Real-time capable models can simulate movements of a plant in a logical way. If these models are coupled via the projected fieldbuses with the real control hardware a control loop is generated (hardware in the loop = HIL). Thereby the real control software can be checked before the real plant is erected at customer site.
This approach can be expanded so that real-time process models for e.g. rolling forces, temperature and shape of the rolled product are also calculated in parallel. This approach provides a perfect platform for replicating errors during trainings since the risk for damage or shutdown is excluded. Furthermore the digital twin can be used by experts to identify parameters in the process controls long before they are applied in reality. Additionally, the twin can also be used for the optimization of the production process before it is transferred to the real plant. Thus potential problems can be detected and solved in advance or errors can be reproduced without interrupting the real production. This paper describes exemplarily a digital twin of a ring rolling machine including the achieved real-time simulation results regarding material deformation as well as the identification of optimized parameters for the process control.
In case 3D inspections of collisions or trainings are the main interest for using a digital twin, 3D models can be coupled with the simulation and the plant status can be observed by VR glasses. The immersion is increased by the stereoscopic view and the additional use of sound so that the user is one with the virtual world. Hence complex maintenance sequences can be playfully learned in a game with the help of controllers for tracking the hand movement. Another example will be presented in which way 3D collisions could be detected.

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27 June / 11:20 - Room 26:

Basic technologies to achieve smart rolling mills

H. Imanari
(Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan)

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Title: Basic technologies to achieve smart rolling mills


Author:
H. Imanari

Company:
Toshiba Mitsubishi-Electric Industrial Systems Corporation, Japan

Co-Authors:
N. Shimoda, H. Inami, N. Kubo

Abstract:
It is important for the manufacturers to operate and to maintain the production lines efficiently and cost effectively to keep the competitiveness in the market. Against the targets there are some difficulties such as the customer requests on small volume production in many lots, quick delivery with lower prices. Also there are issues that highly skilled employees and their successors have been reduced in their companies.
One of the measures to solve these problems is a highly automated production line with flexible control systems, i.e. much more advanced automation systems than before. The system should give or suggest the optimal solutions which include the preventive and predictive maintenance for facilities and for products, easy communication means to assist operators and engineers.
The recent technologies related to big data analytics, IoT and AI have become a basis of the advanced automation systems in industries. Also it is principle to acquire, accumulate and utilize the data from the production lines efficiently to apply those technologies effectively to the objective plants. Here we focus on the rolling mills as our objectives, thus the data acquisition speed should be very high, and therefore the amount of accumulated data becomes very large.
We call the advanced automation systems for the rolling mills as the smart rolling mills. In this paper we will discuss the basic technologies to build them such as data acquisition tools, HMI based on IoT, and data analytics. The HMI will become a center of cyber-physical systems to get all information and to manipulate everything by operators. Then we will show some examples of the predictive maintenance for main motors and induction heaters, and the methods to predict steel strip tail chews and other failures in hot strip mills. The examples will be shown with actual data.

Rolling: Process and production control, transportation and logistics II (27 June / 10:40 - Room 27)

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27 June / 10:40 - Room 27:

Modular coil shuttle system - the next generation for coil logistic system operating at ATIs hot strip mill

L. Pichler
(Primetals Technologies Austria GmbH, Austria)

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Title: Modular coil shuttle system - the next generation for coil logistic system operating at ATIs hot strip mill


Author:
L. Pichler

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
C. Salzmann, R. Hofer, T. DeLuca

Abstract:
PRIMETALS TECHNOLOGIES (PT) was awarded to build a new, fully integrated hot-rolling mill on a process-turn-key basis including a water treatment plant. The hot rolling mill was put into operation jointly with Allegheny Technologies Incorporated (ATI) in the year 2014 in Brackenridge, Pennsylvania, in the United States. The mill is capable of rolling a wide range of highly diversified carbon and stainless steels and specialty metals at widths up to 2,083mm.

A core component of the hot strip mill at ATI is its next generation coil logistic system with the Modular Coil Shuttle (MCS) system. The MCS system is a rail-based fully automated modular coil transport system arranged in a loop design. There is a loaded track (coils are transported from down coiler area to the coil yard or the next processing facility) and an unloaded track (the empty cars are transported back to the coiler). Multiple stations located around the track perform several movements, like shifting, turning or lifting/lowering of the MCS car. These modules can be flexibly arranged to realize each plant layout according to the customer`s needs.

The operating cars are controlled independently from each other by using industrial wireless LAN. The quantity of active cars flexibly adapts to the mill requirements.
The coil yard area set-up, fed by the MCS cars, is split up into two coil yard bays. It allows storing a maximum number of coils for one shift of production at short pacing by using automatic overhead cranes with automatic coil loaders. The coil loaders pick and place the coils from the MCS cars onto coil saddles in the coil storage and from the coil saddles onto rail road cars.

The benefits of Primetals Technologies’ MCS system and operational results from the hot strip mill of ATI will be presented in the paper

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27 June / 11:00 - Room 27:

Ecological and economic optimisation of auxiliary aggregates in steel production

M. Loos
(VDEh-Betriebsforschungsinstitut GmbH, Germany)

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Title: Ecological and economic optimisation of auxiliary aggregates in steel production


Author:
M. Loos

Company:
VDEh-Betriebsforschungsinstitut GmbH, Germany

Co-Authors:
M. Neuer, J. Polzer, M. Feldges

Abstract:
Auxialiary aggregates like the cooling of rolls or ventilation systems show reasonable potential for economic and ecological impacts. But those units have only been scarcely considered in optimisation attempts before and there was an urgent need to explore how auxialiary aggregates can be efficiently automatized by smart control strategies. The talk presents results of the German research project ÖkoSys, which focused on exactly this problem. It investigated how optimal automation approaches can look like, what difficulties have to be overcome and what impact could be achieved. Here, dedicated prediction models were introduced on two different complexity levels, first highly-resolving finite element models e.g. thermal details and second quick reduced models for driving control decisions. The solution concepts were finally analysed and demonstrated in a prototypical way at a steel company that produces long-products.

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27 June / 11:20 - Room 27:

The integrated production management system - the platform for innovation

H. Wolf
(PSI Metals GmbH, Germany)

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Title: The integrated production management system - the platform for innovation


Author:
H. Wolf

Company:
PSI Metals GmbH, Germany

Co-Authors:

Abstract:
Steel production is a complex, data-driven process with a large number of possible intermediate and finished products, specifications and qualities. This complexity is only manageable with the support of tightly integrated IT systems. The steel industry has been embracing digitalization for decades, by introducing shop floor automation (L1 systems), process control systems (L2 systems) and production workflow management systems (L3 systems).
Over the last years, L3 systems have moved from specialized manufacturing execution systems (MES) for a certain area, such as the primary liquid production, the hot rolling or the finishing area, to fully integrated production management systems (PMS) that cover the complete steel production process end-to-end. Typical features of an integrated PMS are:
• an integrated, consistent factory model,
• visibility of all production and quality data along the complete production process,
• integration of production tracking, quality, logistics, and planning & scheduling functionalities,
• and traceability of each semi-finished and finished piece together with its test samples and each order with all its associated production, quality and commercial information.

With the implementation of integrated PMS, steel producers have been able to leverage the availability of end-to-end process information to achieve higher process stability, to plan and schedule with higher accuracy, and to keep quality and delivery promises with higher confidence.
With the current hype around Industry 4.0 (I4.0) and Internet of Things (IoT), a lot of promising technologies are arising that could and should be evaluated by steel producers. At the same time, ever-faster changes in the economic environment, and the forces of globalization, force steel producers to innovate and change more rapidly. Both challenges must be met by the integrated PMS.
In this paper, we propose an evolutionary system architecture with the integrated PMS as the platform for innovation. Furthermore, we want to highlight some use cases how the integrated PMS is meeting current and future challenges.

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27 June / 11:40 - Room 27:

Online materialflow optimization for critical conveyance infrastructure

C. Grubert
(Celano GmbH, Germany)

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Title: Online materialflow optimization for critical conveyance infrastructure


Author:
C. Grubert

Company:
Celano GmbH, Germany

Co-Authors:

Abstract:
Modern factories rely on simulation-based planning tools to provide just-in-time delivery between various aggregates. This minimizes storage costs and maximises the overall material output due to reduced transport times. But these tools usually work offline and therefore lack the ability to react to spontaneous changes like malfunctions, which can cause the precisely planned flow to break down. Recovering from such an event can take some time and may lead to lower quality or irreparable material.
Inspired by traffic optimization systems we are using a microscopic model to periodically simulate the expected flow at identified bottlenecks a few hours ahead. Each run is based on the current state of each adjoining aggregate, including the latest material stock and known malfunctions reported by the underlaying systems or user input. It also considers transport rules such as cooldown times of material and maximum throughput at each point, depending on the given task.
The result is a forecast containing rated material jams at the bottleneck and idle times for subsequent aggregates. If the probability of occurrence is high enough, the optimization is executed to solve the issue by slowing down aggregates or requesting materials from the warehouse system. The specific actions are defined and weighted by the user to comply with the customers needs. This corresponds to the knowledge gained from traffic research, showing that an average flow leads to better results in the long term than stop-and-go movement.
Initial tests on previously recorded production data show reasonable predictions and sensible solutions of either mentioned issue. The influence of these optimizations on regular production systems is currently subject of our research. Commissioning at the customer's plant will take place in January, so that results can be shown in the presentation.

Rolling: Plant upgrades and new equipment developments II (27 June / 11:05 - Room 28)

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27 June / 11:5 - Room 28:

QSP - the most advanced thin slab technology

M. Knigge
(Danieli Germany GmbH, Germany)

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Title: QSP - the most advanced thin slab technology


Author:
M. Knigge

Company:
Danieli Germany GmbH, Germany

Co-Authors:
M. Bulfone, C. Bilgen

Abstract:
Quality Strip Production (QSP) is the latest generation of Danieli’s thin slab casting and rolling technology introducing a new level of quality and flexibility to the market. Starting with a vertical-curved caster this concept enables a higher productivity and realizes an improved slab quality and enlarged product mix capapilties.
Together with a mill design which allows true thermomechanical rolling the product portfolio can be extended towards most advanced steel grades including AHSS and API line-pipe steel.
Danieli`s latest QSP technology outperforms other thin slab casting and rolling technologies on the market in product quality, energy efficiency and plant flexibility.

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27 June / 11:25 - Room 28:

Controlled Rolling and Cooling Technology for Rebar

Y. Chen
(Sinosteel Equipment & Engineering Co., Ltd., China)

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Title: Controlled Rolling and Cooling Technology for Rebar


Author:
Y. Chen

Company:
Sinosteel Equipment & Engineering Co., Ltd., China

Co-Authors:

Abstract:
Every company wants to maintain the competitiveness in a rapidly changing market environment. In the life cycle of a production line, whether it is an existing rolling line or a new line, two aspects have always to be considered:
- higher quality
- lower cost
For this purpose, Sinosteel can provide our customers with effective technical solutions, as well as core equipments to implement the technical solutions.
1) Hot Rolling Technology
During the process of rolling, from roughing mill to finishing mill, most deformation is carried out in the normalizing rolling. For the finishing rolling, the material is rolled in the double-phase zone.
After the rolling, whether the low-temperature austenite or the deformed ferrite make results in the grain refining. Our innovative cooling method can guarantee the homogeneous and uniform grain distribution.
2) Rolling Equipment
 Wire Rod Mills
 RVM230 Module, 2 mills (independent driven)
 RVM150 Module, 2 mills (optional)
 Ratio
 Water cooling and air cooling equipments upstream and downstream the mills.
 Unique control module and software
 Bar Mill
 Two special RNM390 mills (independent driven)
 Ratio
 Water cooling equipment and cooling bed upstream and downstream the mills
 Unique control module and software

3) Actual Effect
Taking HRB400E grade rebar as an example, after long-term application, the effects are as following:
 Chemical Composition of Billet
 Wire rod (Φ6-10mm): 0.20-0.23%C、0.6%Mn. V, Nb and etc. are cancelled.
 Rebar (Φ10-25mm): 0.20-0.23%C、1.0-1.2%Mn. V, Nb and etc. are cancelled.
 Rolling temperature is 780~820℃, with the speed 90m/s for Φ8mm rebar.
Grain refine higher than 9 degree, without martensite or others.
 Be capable of developing variety steel grades.
This technology of temperature control rolling can be applied in wire rod mill, normalized bar mill, high-speed bar mill.

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27 June / 11:45 - Room 28:

FLEX-HI HOT - flexible finishing mill technology for hot rolled product mix extension

M. Hackl
(Primetals Technologies Austria GmbH, Austria)

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Title: FLEX-HI HOT - flexible finishing mill technology for hot rolled product mix extension


Author:
M. Hackl

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
A. Seilinger, S. Bragin, K. Krimpelstätter

Abstract:
Hot Strip Mills can have a wide variety of configurations depending on the material grade, strip range, width, quality requirements and productivity.
The demands related to the capabilities of a conventional hot strip mill have changed in the last years. In addition to the high level of output and productivity the demand for quality improvement and extension of product mix is still ongoing. Today there is a clear trend in developing new steel grades like 3rd generation AHSS (Advanced High Strength Steels). This trend challenges hot strip mill technology because it requires new technologies which provide more flexibility in metallurgical treatment during the rolling process. Additional there is a trend to produce a very wide thickness range on today’s hot strip mill starting from 1.2 mm (at even lower) up to thick pipe grades with 25.4 mm thickness. In parallel, the high level of productivity and quality must be maintained.
In order to meet and promote these trends Primetals Technologies is developing a new mill stand technology FLEX-HI HOT which allows to adapt the last finishing HSM-mill stand by efficiently switching from 4-high to a WR driven 6-high mode with small work roll diameter based on production needs. A smaller work roll diameter allows to achieve higher reductions and deformation rates resulting in thinner hot-strip gauges with metallurgical benefits.
FLEX-HI HOT minimizes the required revamp modernizations and represents a low investment compared to an additional new finishing mill stand. It represents no limitations on the existing product mix (in 4-high configuration) and allows to extend it by thin (and wide) hot strip gauges (produced in 6-high mode).
The developed solution concept as well as the technological and metallurgical benefits will be presented in this paper.

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27 June / 12:5 - Room 28:

EZDK's comprehensive CSP® modernization - a master plan for competitive edge in a dynamic market

H. Fahmy
(SMS group GmbH, Germany)

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Title: EZDK's comprehensive CSP® modernization - a master plan for competitive edge in a dynamic market


Author:
H. Fahmy

Company:
SMS group GmbH, Germany

Co-Authors:
K. Hoen, W. Spies, K. Pronold

Abstract:
EZDK’s comprehensive CSP® modernization – a master plan for competitive edge in a dynamic market


In a global market characterized by overcapacity and consequently tough price competition, the Egyptian steel producer EZDK looks to increase its competitiveness by more flexible production, superior product quality and by minimizing their operational costs. Only this enables to adapt economically to changing market requirements and customer needs.

Since 1999, EZDK, a subsidiary of Ezz Steel, operates a one-strand CSP® plant in Alexandria. After years of operational optimization producing an increasing portion of thin gauge strips, EZDK contracted SMS group for a comprehensive CSP® plant E&A and mechanical revamp.

EZDK’s original revamp targets of maintaining plant availability by replacing obsolete automation systems, enlarging their product mix to ultra-thin strips dimensions on the one hand and multi-phase and API steel grades on the other hand and also to significantly improving their product quality was even outperformed.

In this paper, the outline of the executed modernization will be presented. Details will be given on operational results and on reached performances after the restart in spring of 2017. Insights to EZDK’s record year 2018 will complete the picture together with a discussion of the fulfillment of the overall targets.

Authors:
Hossam Fahmy - All Ezz Dekheila Steel Company, Alexandria, Egypt; Klaus Pronold,Wolfgang Spies, Karl Hoen - SMS group GmbH, Hilchenbach, Germany

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27 June / 12:25 - Room 28:

Zoom-Mill for reversible cold rolling

T. Kikkawa
(JP Steel Plantech Co., Japan)

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Close27 June, Room 28 ( 12:25 )
Title: Zoom-Mill for reversible cold rolling


Author:
T. Kikkawa

Company:
JP Steel Plantech Co., Japan

Co-Authors:

Abstract:
New rolling method (Zoom-MillTM, Zero-oriented off-gauge minimization) that enables unrolled portions in a reversible cold rolling mill to be reduced using a leader strip and a spot welding machine and thereby aims improvement of productivity has been developed around 10 years back. Several Zoom-MillTM were put into practical use and commercial operation and have been working well as intended initially, achieving approximately 1% improvement of product yield of the products. In this article, recent development and application of Zoom-MillTM Technology will be also introduced.

Rolling: Reheating and descaling (27 June / 13:00 - Room 26)

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27 June / 13:00 - Room 26:

QHEAT: Induction heating system for long and flat products

E. Plazzogna
(Danieli Automation S.p.A., Italy)

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Title: QHEAT: Induction heating system for long and flat products


Author:
E. Plazzogna

Company:
Danieli Automation S.p.A., Italy

Co-Authors:
S. Barbanti, E. Gigante

Abstract:
Based on the experience of endless and hot charging process and the know-how in converters units, Danieli Automation has developed a new induction heating system, called Q-Heat.
The induction heating furnace is the most environmentally friendly solution for reaching the required rolling temperature without using gas or smoke emissions, and drastically reducing scale formation.
Additionally, the induction heating furnace is ready in real time: no need for long start or stop sequences, as with traditional reheating furnaces.
The power inverters used to supply the inductor coils are based to the IGBT technology.
The control structure is based on a powerful, state-of-the-art Danieli Automation Process Automation Controller (DA-PAC), that communicates with power part controller (modulator board) with Ethercat and with field bus with Level 1 plant automation.
Danieli Automation special coils design and the care in the selection of the best materials allow for an high electrical efficiency of the heating coils. Moreover, case by case the system is designed using FEM simulators.

The paper focuses on the actual induction heating state-of-the-art technology in metal production process, in the light of considerable experience coming from various QHEAT installations, both long and flat products, analyzing results from field as consumptions and performance reached by Danieli Automation installations worldwide.

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27 June / 13:20 - Room 26:

Maximizing impact force from descale headers using CFD analysis

M. Bodingbauer
(Spraying Systems Austria GmbH, Austria)

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Title: Maximizing impact force from descale headers using CFD analysis


Author:
M. Bodingbauer

Company:
Spraying Systems Austria GmbH, Austria

Co-Authors:
L. Peterson

Abstract:
Descaling is an important step in the rolling process. The oxide is removed from the surface of the product to improve surface quality and maintain the rolls. Nozzle selection and header design are important parts of an effective descaling system. The nozzles need to be sized and placed, so they provide sufficient impact force to remove the oxide with the minimal amount of water possible. Headers need to be sized to maximize the impact performance of the nozzles. Impact testing along with CFD analysis can help to determine if a header has been properly designed to provide maximum impact force. CFD analysis can determine the fluid approach velocity along with the turbulence level in the header. The spray pattern of the nozzle can then be measured for impact force and distribution under different approach velocities and turbulence levels. Comparing these to a nozzle tested under an ideal no turbulence condition can determine minimum header size requirements based on nozzle capacity and pressure. Optimizing the header can help to improve performance and minimize energy costs. This paper will show the results of several existing installations where both CFD and impact testing was used to optimize a descaling operation in hot strip mills and plate mills.

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27 June / 13:40 - Room 26:

Transverse flux induction heater at Rizhao's ESP line 4 boosts the efficiency

B. Linzer
(Primetals Technologies Austria GmbH, Austria)

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Title: Transverse flux induction heater at Rizhao's ESP line 4 boosts the efficiency


Author:
B. Linzer

Company:
Primetals Technologies Austria GmbH, Austria

Co-Authors:
T. Lengauer, S. Grosseiber, A. Jungbauer, A. Umbrasko, A. Thus

Abstract:
While all currently running ESP lines were using longitudinal flux induction heaters, Rizhao’s ESP line 4 is the first Arvedi ESP line with transverse flux induction heater. Right from the first production sequences drastic energy savings have been monitored. Flexible heater adjustments give the freedom to optimize energy consumption for all operation cases. The installation just beside Rizhao’s ESP lines 1-3 offers perfect comparison possibilities. Measurement results from the newest ESP line operating transverse flux in comparison with the existing ESP lines powered by longitudinal flux will be discussed in this paper.

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27 June / 14:00 - Room 26:

Influence of injection distance on attenuation of water droplet velocity in high pressure descaling

Y. Tamura
(JFE Steel Corporation, Japan)

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Title: Influence of injection distance on attenuation of water droplet velocity in high pressure descaling


Author:
Y. Tamura

Company:
JFE Steel Corporation, Japan

Co-Authors:

Abstract:
Hydraulic descaling is used in hot rolling mills in order to remove scale and prevent surface defects. Because the impact pressure of the descaling jet is one important factor from the viewpoint of mechanically breaking and applying thermal shock to scale layers, the water jet structure and the droplet velocity should have large effects on scale breaking properties. However, the influence of the injection distance on the jet structure and the droplet velocity has not been clearly understood. In this work, the behavior of changes in the descaling jet structure and attenuation of the water droplet velocity along the injection distance were investigated experimentally. High pressure descaling nozzles with pressures up to 25MPa were used, and the injection distance was varied in the range from 30 to 400mm. The jet structure was observed with a high speed camera, and the water droplet velocity and diameter were measured with a phase Doppler analyzer. It was confirmed that the jet structure changes continuously through a process of continuous flow, break-up, water lump, and water droplet. It was found that a continuous flow can be kept for a long distance by using a low injection pressure and large flow rate, and the water droplet diameter also becomes larger, which reduces velocity attenuation. This study showed that the velocity attenuation depends on the ratio of the injection distance to the orifice diameter under all experimental conditions.

Rolling: Modelling and simulations (27 June / 13:20 - Room 27)

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27 June / 13:20 - Room 27:

Advanced strip shaping by highly sophisticated mathematical modeling and optimization techniques - a way to contour control

A. Thekale
(Primetals Technologies Germany GmbH, Germany)

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Title: Advanced strip shaping by highly sophisticated mathematical modeling and optimization techniques - a way to contour control


Author:
A. Thekale

Company:
Primetals Technologies Germany GmbH, Germany

Co-Authors:
M. Kurz, M. Miele, A. Schmidt, J. Frenzel, C. Gusek, M. Vogt

Abstract:
Meeting customer-provided strip profile targets, e.g. C40 values, is a major task of profile and flatness control (PFC). In case of a large variety of steel grades to be rolled and small lot sizes, the application of highly sophisticated mathematical models within the PFC is required to meet given target values.

We present the latest versions of Primetals Technologies core models. They take different effects within and between mill stands into account such as roll bending and flattening, material flow in the roll gap, stand stretch, thermal and wear crown as well as inter-stand profile transmission. These models have been verified on a broad spectrum of plant types such as hot strip mills, medium-wide hot strip mills, plate mills, Steckel mills and Endless Strip Production (ESP) mills, and on a broad spectrum of strip dimensions up to 5m width in plate mills and down to 0.7mm thin strips in ESP mills. If one aims at shaping strips correctly, it is important to compare measured with calculated, model-based contours. This comparison can be used as good measure on the model quality as well.

Besides models that calculate strip contours sufficiently accurate, collecting real mill process data that allows offline recalculation is important. Having both at hand, we present an optimizer that is able to adjust internal model parameters to improve model accuracy and to analyze external model inputs to reveal input errors. This leads to reduced commissioning times, increased commissioning ramp ups, less adaptation and better extrapolation for new materials.

Moreover, these models can be used to analyze and classify contour defects. Some can be resolved by bending and shifting within PFC setup, others by mechanical modification of the plants or by changing the production schedule. Being able to handle these defects, controlling strip contour is the obvious next step.

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27 June / 13:40 - Room 27:

FE analysis of influence of roll bending on roller leveling effect of high strength thin plate

J. Negami
(Nippon Steel & Sumitomo Metal Co., Ltd., Japan)

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Title: FE analysis of influence of roll bending on roller leveling effect of high strength thin plate


Author:
J. Negami

Company:
Nippon Steel & Sumitomo Metal Co., Ltd., Japan

Co-Authors:

Abstract:
Recently, in a field of industrial machinery, application of high strength thin plate, having yield stress greater than 800MPa and thickness less than 10mm, is increasing so as to reduce weight and improve safety. High strength thin plate is often manufactured through strong cooling process. The rapid cooling, however, causes a flatness defects such as edge wave and center buckle. In order to eliminate flatness defects, roller leveler is widely applied. The roller leveling of high strength and light gauge plate is difficult because it requires strong bending. As a means of improving leveling capability, application of roll bending to roller leveling is known. In this leveling method, work rolls are deliberately bended so that the roll plunge differs along the plate width direction.
The effectiveness of roll bending has been proved by both experimental and analytical studies. On the other hand, there are not so many reports that discuss the mechanism of roll bending leveling. This paper investigate the effect of roll bending leveling of high strength thin plate having an edge wave, and discusses the mechanism of roll bending leveling. By means of an analytical evaluation, a three-dimensional finite element model based on ABAQUS/Explicit was introduced. The simulation results suggested that the major effect of roll bending on enhancement of leveling capability is a longitudinal stress occurred by the lateral distribution of roll plunge.

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27 June / 14:00 - Room 27:

Advanced control for continuous line furnaces to optimize performance and quality

J. Naveira
(CMI Industry, Spain)

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Title: Advanced control for continuous line furnaces to optimize performance and quality


Author:
J. Naveira

Company:
CMI Industry, Spain

Co-Authors:

Abstract:
CMI Industry Metals’ patented furnace control mathematical models, L-TOP® (vertical furnaces) and LH-TOP® (horizontal furnaces), are controlling all process conditions whether steady or transient, and are all integral parts of an optimized, state-of-the-art CMI furnace design. Both models have successfully been installed on more than thirty processing lines’ furnaces all over the world. The return of experience coming from these lines have allowed CMI to accumulate an invaluable know-how in furnace control and helped to provide clients with considerable performance improvements. As such, the models not only guarantee an important production increase, and considerable quality improvements, they are also, and very importantly, allowing for a consistent high product quality.
Building on this expertise, and knowing that progress never stops, CMI constantly keeps adding new features to further improve productivity and the produced strip quality. The latest additions include an optimized architecture and the split between communication and process applications. The model is now modular, and able to optimally manage each section of the line, with very short calculation cycles. This allows the management of various parameters, for instance control of the inductor type section, or speed control around the weld (horizontal lines), within few tenths of a second.

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27 June / 14:20 - Room 27:

Benchmark of resolution methods for the heat equation in Siderurgy L2 thermal modeling

G. Druart
(Vallourec S.A., France)

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Title: Benchmark of resolution methods for the heat equation in Siderurgy L2 thermal modeling


Author:
G. Druart

Company:
Vallourec S.A., France

Co-Authors:

Abstract:
In the premium steelmaking industry, the heat treatment of steel products is a key process in order to obtain the good final physical properties and in a correct range of values.

Industry 4.0 target is a complete management and control of production. Level 2 modeling is one of the keystone for process data generation: in a heating process we know the charging and discharging state by sensors, what is unknown is the physical evolution in between. The L2 model fulfil this lack.

The mastering of the processes requires the best comprehension of the temperature field’s evolution and the correlated mechanism. All thermal processes are submitted to the same partial-differential equation, the heat equation. Between the heating, the natural cooling or the quenching of a product, the only mathematical difference comes from the applied boundary conditions which are related to the considered thermal flows on the limits (radiation, convection, conduction). This equation can be analytically solved only in some particular cases which are not relevant for industrial purpose. Therefore, we have to solve the heat equation through numerical methods such as finite-difference (FD), finite-volume (FV) or finite-element (FE). The dedicated commercial software are able to solve the heat equation in a very precise way but they are not adapted to the specific needs of a real-time calculation and consistent with the measurement precision in the plants. The necessity of a model dedicated to the thermal physic, to the specific geometries and to the furnace configurations is based on these plant-oriented requirements.

The first point is the way we deal with the temporal derivative of the heat equation. This part is the most important one as it decides the flexibility of the numerical simulation. The two classical approaches, explicit and implicit methods, have their own advantages and drawbacks that we have to evaluate with the perspective of the industrials requirements. Then, we will decide the most adapted numerical method (FD, FV or FE). The choice of the numerical method has to be based on criteria such as the speed, the maintainability, the improvement capacity and the precision. The chosen models will then be tested on temperature uniformity survey trials (TUS) and compared each other.

Rolling: Plant upgrades and new equipment developments III (27 June / 13:40 - Room 28)

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27 June / 13:40 - Room 28:

MI.DA. - latest developments in endless casting and rolling of long products

A. Tellatin
(Danieli & C. Officine Meccaniche S.p.A., Italy)

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Title: MI.DA. - latest developments in endless casting and rolling of long products


Author:
A. Tellatin

Company:
Danieli & C. Officine Meccaniche S.p.A., Italy

Co-Authors:
J. Shuli, A. De Luca

Abstract:
Everything began in USA, in the early 2000’s…. when a Customer asked to Danieli to design an innovative mill to compete, in terms of operating costs and overall investment, with the big steel producers in the country.

Nowadays, The Danieli ECR Endless Casting and Rolling process is a well proven real, reliable and cost effective way to produce rebar.
Latest developments of the Danieli Micromill technology (MI.DA.) include application of the Endless Casting and Rolling technology in the production of spooled coils and wire rod as well, for both rebar and smooth rounds.

Moreover, thanks to the last extraordinary developments, MI.DA. is going to supersede the original Minimill concept mainly due to the revolutionary introduction of the Twin-strands application, matching the more and more market demands.

In fact, with Twin MI.DA. configuration, Danieli is able to design and supply to our Customer with a big scale Micromill capable to produce in endless configuration up to 1,5 Mton of finished product with a huge level of efficiency both in terms of environmental sustainability and energy saving to minimize CO2 emission and also to preserve natural resources which are essential to guarantee the future of mankind.

Danieli vision, thinking to the near future, is to constantly innovate and develop the ECR process, in order to empower it with the latest digital technologies and to extend the production range to new variety of steel grades with higher added value.

This paper deals with an overview of the latest ECR applications, expanding and consolidating the advantages of the MI.DA. technology in terms of efficiency, and last but not least to be the sole environmental friendly, safe and Smart Plant to produce steel.

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27 June / 14:00 - Room 28:

3rd generation carbon steel mechanical equipment for processing line

S. Decroix
(Fives DMS S.A., France)

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Title: 3rd generation carbon steel mechanical equipment for processing line


Author:
S. Decroix

Company:
Fives DMS S.A., France

Co-Authors:

Abstract:
In the past 50 years, steel grades for automotive experienced several revolutions to move from mild steel to the 3rd generation of Advanced High Strength Steel. Responsibility of high-end equipment suppliers, such as Fives is to support their costumers to produce these new grades.

We are now in a new breakthrough point of steel development for automotive with introduction of a grade up to 1800 MPa. Fives has developed a new range of equipment to satisfy the new requirements of steel makers to insure strip threading, anticipate bending and tension issue, succeed to fine tune mechanical properties, improve flatness

Fives’ NeoKoil® strip processing line is our state-of-the-art solution with integration of:
- OptilineTM to anticipate bending and tension control specificity
- New threading equipment and concept to insure an entry cycle
- New design for skin-pass mills and tension levelers for high elongation on AHSS
- New design for side trimmers and scrap evacuation systems

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27 June / 14:20 - Room 28:

Pert laser scanner technology for existing plants upgrade

M. Tomba
(Pert S.r.l., Italy)

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Title: Pert laser scanner technology for existing plants upgrade


Author:
M. Tomba

Company:
Pert S.r.l., Italy

Co-Authors:

Abstract:
For over two decade PERT has specialized in the metals, rolling mill, steel melt shop and environmental solutions for steel industry. PERT were one of the first to introduce laser technology to the steel industry revamping since 2007. We understand that thanks to the engineering knowledge acquire in over 800 projects worldwide and the application of 3D laser scanner technology for the upgrade of the existing a lot of benefits can be reach.
This paper summarizes the economic benefits of applying 3D laser scanning technologies to the design, construction, refurbishing and operation of existing rolling mill plant. We examine how these technologies deliver four main benefits: risk mitigation; cost reduction and schedule compression; improved safety for capital project delivery, maintenance and operations; and how these benefits are realized .
A case history of refurbished and dismantled rolling mill for bar and wire rod production from Malaysia was done by PERT with the shipping and erection in middle east on turnkey basis.

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27 June / 14:40 - Room 28:

Hot Skin Pass Mill & Tension Leveler Line for Ultra High-Strength Steel

H. Uematsu
(JP Steel Plantech Co., Japan)

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Title: Hot Skin Pass Mill & Tension Leveler Line for Ultra High-Strength Steel


Author:
H. Uematsu

Company:
JP Steel Plantech Co., Japan

Co-Authors:

Abstract:
In order to reduce CO2 generated from internal combustion engines, various efforts have been made to reduce the weight of vehicles over the last few decades. High strength steel materials are indispensable for the reduction of vehicles weight.

It is for this reason, the materials used for the frames and chassis are being made of Advanced High Strength Steel (AHSS) and/or Ultra High Strength Steel (UHSS) possessing properties of not only high yield strength, but also better mechanical characteristics.

There exist strong requirements for materials to be fed to the automobile production lines to have precise dimensional accuracy, favorable physical shape and improved surface quality.

On the other hand, in the production line of UHSS material, higher rate rapid cooling with water on the run-out table is inevitable, which becomes one of the elements of lower flatness performance than conventional strips.

To produce UHSS material to the required quality, JP Steel Plantech Co. designed, manufactured and delivered a Hot Skin Pass Mill Line with Tension Leveler adopting various techniques and innovations suitable for UHSS materials. This paper introduces details of such techniques and innovations.

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27 June / 15:00 - Room 28:

Small streams make big rivers: Innovative design & operation of 2 stands reversible mill easily expandable to PLTCM.

J. Peers
(CMI Industry, Belgium)

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Close27 June, Room 28 ( 15:00 )
Title: Small streams make big rivers: Innovative design & operation of 2 stands reversible mill easily expandable to PLTCM.


Author:
J. Peers

Company:
CMI Industry, Belgium

Co-Authors:

Abstract:
Today, there are good solutions extensively described by various OEMs & steel makers to optimize CAPEX & OPEX for small capacity Cold Rolling Mills (CRM) as well as for high capacity.

A good solution for small capacity CRM is to start with a single stand reversing mill, which can be expanded in the future into a twin stand mill. The main drawbacks in conventional practice are the off-gauge length in single stand configuration and the shutdown time of the mill, which is quite long for erection of the second stand. For higher productions CRM, it is recommended to go directly for a new PLTCM, with a high CAPEX.

But how to start with limited output and limited CAPEX without jeopardizing final ultimate expansion goal for which PLTCM is the best technico-economical choice?

Today there are no solution, and CMI has therefore developed an integrated solution which will limit the CAPEX in the first phase, without penalizing the future by an easy and economically viable expansion up to a PLTCM, without a long production stoppage.

The solution consists to first, install a twin stand mill, which can be expanded into a PLTCM by a smart layout of the line. Therefore it’s possible to have a first project phase up to 900 ktpy, and a second phase with a conversion into PLTCM for a production from 1.2 to 2mtpy, depending on the market evolution and financial capacities.

Therefore, CMI has developed an innovative concept in reversing phase with a new rolling strategy to optimize productivity and limit off-gauge compared to conventional solutions.

In addition the layout enables an easy conversion to PLTCM which allows a progressive and flexible investment adapted to the required production capacity. Long stoppage time which could be detrimental to this approach phase by phase is also avoided.