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Bar and wire rod factory’s practice of reducing rolling mill rollers consumption


In view of the work of reducing production costs in bar and wire rod factories, measures such as adopting new material rolling mill rollers, process optimization and a series of technical transformations are used to reduce roll consumption and contribute to the cost reduction work of rod and wire rod factories.

Keyword: Use of rolling mill rollers

rolling mill rolls

In order to pursue cost minimization and benefit maximization, the rod and wire factory has been committed to its cost reduction work. The roll consumption in the high rod workshop and the roll ring consumption in the high wire workshop of the bar and wire rod factory, as the bulk of the production cost of the rod and wire rod factory, have become the focus of the cost reduction work of the rod and wire rod factory. Through a series of technical research and process optimization and improvement , which has greatly reduced the roll consumption of the rod and wire factory, reaching the domestic leading level, and made a huge contribution to the cost reduction work of the rod and wire factory.

Improve rolling mill rollers trength

At present, the diameter of the coarse and medium rolling rolls used in the high bar workshop is smaller. Especially after the new non-hole rolling process is adopted, the rolling volume increases by 50% compared with before the non-hole rolling process was adopted. At the same time, considering that the rolling load will increase after using 160mm*160mm steel billet in the future, the strength of the existing rolls is not enough to meet production needs, and it is easy to cause roll breakage, which will lead to increased production costs. Therefore, the high bar rough and medium rolling mills should be modified while meeting the requirements for roll change assembly. Expand the maximum diameter of the roll by 30-40mm on the existing basis to increase the strength of the roll, increase the total amount of steel passed during its service life, reduce roll consumption, reduce production costs, and at the same time, reduce the chance of roll breakage. After the transformation of the rolling mill, the maximum diameter of the existing rolls has been increased: the φ550mm mill roll has been increased from the current maximum φ550mm to φ580mm, the φ450mm mill roll has been increased from the current maximum φ455mm to φ480mm, and the φ380mm mill roll has been increased from the current maximum φ405mm to φ430mm. The consumption of high-bar coarse and medium-rolling rolls has also been reduced by 10%, reducing roll consumption by 120,000 yuan per year.

Improve the comprehensive utilization rate of rolling mill rollers

The bar and wire rod factory has two production lines, high bar and high wire, and uses various roll specifications, including φ600, φ550, φ490, φ455, φ380, φ330, and φ350. Therefore, how to make comprehensive utilization of rolls to significantly reduce roll consumption and reduce production costs is an important task. The bar and wire rod factory improves the comprehensive utilization rate of rolls through the following measures:

(1) Improve the traditional ordering method of φ600 and φ490 rolls in the high-line workshop, from the original flat rolls to ordering with engraved holes, to improve the wear resistance of the rolling groove, that is, to increase the rolling volume of a single groove, thereby reducing roll consumption.

(2) Improve the material of Ф550 and 455 rolls. The original medium nickel chromium molybdenum normalized cast iron roll was changed to a medium nickel chromium molybdenum centrifugal cast iron roll to improve the strength and wear resistance of the roll.

(3) The rollers used in the 1H and 2H stands of the high-line workshop must be changed from the 3H and 4H stands after one use; 5H and 7H

The rollers used in the rack must be changed from the 9V rack after one use. The rollers used in the 6H stand must be changed from the 8H stand after one use. The rolls used in the 10H and 11V stands must be prepared for turning the rolls after being used once for the 12H and 13V stands. Standardize the order of use of Ф550, Ф455, and Ф380 rolls in the high bar workshop. After the rolls of the rear stand are used, they can be used to prepare the rolls for the front stand.

By improving the comprehensive utilization rate of the rolls in the bar and wire rod factory, the roll consumption is greatly reduced, and the roll consumption can be reduced by more than 1 million yuan every year.

Using new material roller

The rolls of the high-speed bar production line finishing mill are developing in the direction of alloying. In particular, the slit K3 and pre-slit K4 passes of slit rolling usually use high-speed steel combined rolls. The high bar workshop rolls slit K3, pre-slit K4 and finished product pass K1 with specifications of Ф12~14×3mm. The rolls currently used are bainite rolls. The cutting wedges are seriously damaged, there are many process accidents, the steel passing capacity of a single groove is low, and grooves and rolls are changed frequently, which seriously affects the production efficiency and yield rate, and also increases the consumption of rolls. . Through learning and exchanges with the same industry in China, we introduced the use of high-boron high-speed steel rolls when rolling three-slits with specifications of Ф12~14×3mm, K3, pre-slit K4 and finished product pass K1. The single-slot rolling capacity of post-slit K3, pre-slit K4 and finished product pass K1 has been increased from the current 300 tons/slot, 600 tons/slot, and 100 tons/slot to 2000 tons/slot, 2400 tons/slot, respectively. 200 tons/trough, through the introduction of high-boron high-speed steel rolls made of new materials, the roll consumption is reduced by more than 800,000 yuan per year, and the economic and technical indicators and stable negative deviation control are also improved.

Rolling mill beam modification

The cooling effect of the coarse and medium rolling rolls in the high-line workshop is extremely poor, and the water volume and water pressure are seriously insufficient. Through analysis, it is due to the unreasonable design of the cross beam of the high-thickness and medium-rolling rolling mill. In order to satisfy all the rolling grooves of the rolls, two sets of cooling water pipes that supply water together are designed on the original cross beam. As a result, the unused rolling grooves are also using water, so about 50% of the cooling water is wasted. In order to make full use of water resources, improve the service life of the rolls and increase the rolling capacity of the single groove to reduce the consumption of the rolls. The existing rolling mill beams in the high-line workshop were renovated and the cooling water pipes were optimized. After the rolling mill beams were renovated, the single-groove rolling capacity of the rough and medium rolling rolls was increased by 20%. At the same time, it reduces the occurrence of thermal cracks and reduces the number of heavy vehicles. The corresponding roll consumption is reduced by 20%, and the annual roll consumption is reduced by 160,000 yuan.

Threaded roller ring assembly modification

Tungsten carbide carbide threaded roller rings are the key and main process consumable spare parts for high-speed wire rod production lines to produce threaded wire rods. Tungsten carbide carbide threaded roller rings are a kind of hard alloy with high wear resistance, toughness and thermal crack resistance. It is a good tool material, but it is expensive and accounts for a large proportion of the production cost. When the Ф210×72 threaded roller ring used in the high-line workshop of our factory adopts the existing assembly method, only two rolling grooves can be opened on one roller ring with a Ф8~Ф12mm threaded roller ring. However, our factory’s annual output of rebar wire rods It is very large. In 2009, it produced 570,000 tons of materials, including 345,000 tons of threaded wire rods, accounting for 60.63% of the annual output. After checking the strength of the currently used threaded roller ring, the assembly method of the existing threaded roller ring was improved. The Ф8mm threaded roller ring has 4 rolling grooves and Ф10~Ф12mm has 3 rolling grooves, which greatly improves the thread quality. The effective utilization rate of roller rings can greatly reduce the consumption of threaded roller rings by more than 33.3%, and reduce the consumption of threaded roller rings by more than 700,000 yuan per year.

Hole type process optimization

The current main specifications of the high-line workshop are Ф6.5mm, Ф8.0 mm, Ф10.0 mm, and Ф12.0 mm wire rods. The original hole designs are three: Ф6.5 mm, Ф8.0 mm, and Ф10.0 mm. Specification. It is inconsistent with the size of the outlet material of Ф12.0mm specification wire rod for intermediate rolling 13V and pre-finishing 17#. Every time the rolling of Ф12.0mm wire rod is changed, all the roller rings of the 14#-17# intermediate rolling mill must be replaced. The workload is large and the roll replacement time is long, about 2-3 hours. Moreover, the replaced roller ring and taper sleeve need to be cleaned, which requires high labor intensity for workers. Sometimes when rolling to other specifications, some roll rings in pre-finishing rolling are replaced before the steel content in a single groove reaches the specified use requirements (the replaced ones also have to be repaired and used), resulting in high consumption of roll rings in the pre-finishing mill. In response to this situation, the process was optimized and improved, and the common design of the pass pattern of the pre-finishing mill was completed for high-line rolling of three specifications of wire rods Ф6.5mm, Ф8.0mm and Ф10.0mm and rolling of Ф wire rods. It not only saves the time of changing rollers, improves production efficiency, but also reduces roller consumption, which is reduced by more than 100,000 yuan per year.

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Rolling mill rolls product

Classification by roll material:

Cast iron mill rolls

  • Alloy indefinite chilled cast iron rolls
  • Alloy chilled cast iron rolls
  • Alloy SG ductile cast iron roll
  • Pearlitic ductile cast iron roll
  • Bainite ductile cast iron roll
  • Centrifugal cast iron roll

Cast steel mill rolls   

  • Alloy cast steel rolls
  • Semi-steel roller
  • Graphite steel rolls
  • High-chromium steel roll
  • High-speed steel roll

Forging mill rolls

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Work rolls
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Intermediate roll

Product advantage

The world No. 1 in crude steel production steel plant, over 70% of the HSS for bar and wire are from us.

LMM high-speed steel rolls have higher steel passing per groove (times) due to their good wear resistance, which saves roll changing time, improves rolling mill operation rate, reduces roll consumption, and improve the overall efficiency of the factory.
Generally, the amount of steel passing in a single groove (times) is 3 to 5 times that of cast iron rolls.

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