Niekurzak Mariusz, Kubińska-Jabcoń Ewa
Faculty of Management, AGH University of Science and Technology, 30-067 Krakow, Poland.
Materials (Basel). 2022 Mar 21;15(6):2334. doi: 10.3390/ma15062334.
An important element in the correct operation of the rolling mill is appropriate planning of the condition of the rolls because this factor constitutes a limiting element in the production process. In this work, with the aim of indicating the method of proper use of production tools-metallurgical rollers during their operation in a Polish rolling mill, the wear and tear of particular kinds of rollers built in the whole rolling set was determined. For this purpose, data were collected at the strip mill from grinding processes, production reports and roll files, while our statistical analysis, laboratory calculations and measurements were used. These data were used to perform computer calculations on the service life of metallurgical rollers installed in the rolling line. Wear mechanisms were identified in industrial practice. The characteristic features of roller wear were investigated using non-destructive tests, including eddy currents. The laboratory tests reproduced the wear mechanisms in very hot rolling rolls. The statistical method for determining the service life of working rolls indicated that their reconstruction is determined both by natural physical phenomena and inappropriate use in about 30% of cases, mainly in the F5 and F6 cages of the finishing unit. Calculations indicated the possibility of replacing the working rolls made of high chromium cast iron Hi-Cr with those made of HSS in the F5 and F6 cages, which will contribute to an increase in the durability of the rolls, a reduction in production costs and a decrease in the number of roll rebuildings. The service life of HSS rolls is 14,000-20,000 Mg of rolled material per 1 mm of wear on its surface in the radial direction, compared to 2000 Mg for rolls made of high chromium cast iron Hi-Cr. The constructed model may be a source of information for further analyses and decision-making processes supporting the management of metallurgical enterprises. On the basis of the constructed model, it was shown that the analyzed projects, depending on their type and technical specification, will bring measurable economic benefits in the form of reduced annual energy consumption and environmental benefits in the form of reduced carbon dioxide emissions into the atmosphere. The constructed model of the roll consumption, verified in the real conditions of the rolling mills, will contribute to the fulfillment of energy and emission obligations with the EU.
轧机正确运行的一个重要因素是对轧辊状况进行适当规划，因为这一因素是生产过程中的一个限制因素。在这项工作中，为了指明在波兰一家轧机中运行期间正确使用生产工具——冶金轧辊的方法，测定了整个轧制机组中特定类型轧辊的磨损情况。为此，从带钢轧机的磨削工艺、生产报告和轧辊档案中收集数据，同时运用了我们的统计分析、实验室计算和测量方法。这些数据用于对安装在轧制线上的冶金轧辊的使用寿命进行计算机计算。在工业实践中确定了磨损机制。使用包括涡流检测在内的无损检测方法研究了轧辊磨损的特征。实验室测试再现了热轧辊中的磨损机制。确定工作辊使用寿命的统计方法表明，在大约30%的情况下，其修复是由自然物理现象和不当使用决定的，主要发生在精轧机组的F5和F6机架中。计算表明，在F5和F6机架中，可用高速钢（HSS）制成的工作辊替代高铬铸铁（Hi-Cr）制成的工作辊，这将有助于提高轧辊的耐用性、降低生产成本并减少轧辊修复次数。高速钢轧辊在其表面径向每磨损1毫米的情况下，其使用寿命为轧制材料14000 - 20000吨，而高铬铸铁轧辊为2000吨。所构建的模型可能是进一步分析和决策过程的信息来源，有助于冶金企业的管理。基于所构建的模型表明，所分析的项目根据其类型和技术规格，将以降低年度能源消耗的形式带来可衡量的经济效益，并以减少向大气中排放二氧化碳的形式带来环境效益。在轧机实际工况下验证的轧辊消耗模型，将有助于履行欧盟规定的能源和排放义务。
