Sample for Innovation of rolls of mill .ppt

rolling mill

1. Innovation Job of
Roll Shop
R.U.B.M.

2. Innovation
Job of Roll Shop (R.U.B.M.)
1). NEW ROLL PASS
DESIGN FOR NPB 450
X 190

3. Innovation
Job of Roll Shop (R.U.B.M.)
2) Modification of CR-80
& CR-100 UR Stand Roll :

4. Innovation
Job of Roll Shop
(R.U.B.M.)
3) Roll Mounting system
for CNC Lathes :

5. Innovation
Job of Roll Shop (R.U.B.M.)
4) Roll Drive and Roll
holding system for M/C #
1 and # 2

6. 1).NEW ROLL PASS DESIGN FOR
NPB 450 X 190
PROBLEM :Breakage of
BD Mill Roll for section
450x190
Non availability of spare
set.

7. Corrective Action taken :
In house developmentof New
Roll Pass design for NPB 450 X
190 to reduce the no of
passes in BD mill.
Rolling Temperature improved
by reduction in no of passes.

8. Major Advantages are:
Number of passes
reducedfrom 11 to 8
(5 in BD + 3 in KV1) .

9. Old BD Roll Design (11 Pass) :
From
RHF
K 2 Box Box K 2 K 3
K 1 K 1 Box
Box
K 1
K 1
K 1
K 2
K 3Box

10. New BD Roll Design(5 Pass):
From
RHF
K 1 K 1 K 1 K 2 K 2
K 1K 2

11. Major Advantages are:
Increasein
productivityof the
section. ( We can Roll 3
Blooms at a time one each
in BD , KV1 & Tandem Mill )

12. Major Advantages are:
Mill Lay out

13. Major Advantages are:
Operator friendly BD
Scheme because no
edging passin the
scheme.

14. Charging bloom
length is increased
because space available
before and after KVI
(Increased productivity).
Major Advantages are:

15. Cost saving :
BD mill rollis common for
NPB 500 ,UB 533,NPB
450 & UB 457 which saves
nearly Rs. 65Lacsas well
as turning time.

16. Cost saving :
Introduction of bigger
(1100MPD) dia roll in KV1
millsavednearly Rs. 50
Lacs as well as turning time
& save power(BD -8200
kWh, KV1-5800 kWh).

17. New Roll pass design
cost is Rs 35 Lacs.
Total cost saving
Rs. = 1.5 Crore
Cost saving :

18. Team Members
Mr. Girish Lakhe
Mr. V. Panda
Mr. K.M. Tripathi
Mr. Amit Sarvaiya
Mr. Ranjan Shom

19. 2). Modification of CR-80 & CR-100
UR Stand Roll :
PROBLEM :This
problem is related
with loss of
Production , revenue
and timebecause of
CR 80 & CR100 Roll
Breakage.

20. 2). Modification of CR-80 & CR-
100 UR Stand Roll :
CR-80 & CR-100UR Rolls
are of very narrow width due
to its inherent design . Thus
the rolls had inadequate
load carrying capacity
which had resulted in
breakage of 6 nos. of UR
Rollsin Mill during rolling.

21. 2). Modification of CR-80 & CR-
100 UR Stand Roll :
1 set of Roll
Costing is Rs.=
50 Lacs

22. Corrective Action taken :
Consolidation of the
bottom portion of the Roll
ring on the arbour .
Accordingly the roll design
was adequately modified .

23. Old & New Design Roll of
CR-80 & CR-100:

24. Present Status
After this modification we
have rolled 5 campaignstill
date, no roll breakagehas
occurred in CR-80 and CR-
100 UR stands..

25. Team Members
Mr. Girish Lakhe
Mr. V. Panda
Mr. Amit Sarvaiya
Mr. K. M. Tripathi
Mr. Ranjan Shom

26. 3). Roll Drive and Roll holding
system for M/C # 1 and # 2
PROBLEM : This
problem is related with
Roll turning of Tandem
Mill Rolls.

27. New Design Roll Turning
The new design rolls could not be
accommodated and machine turned on our
conventional lathes.
The need was for complete development of
Roll Drive and Roll holding system e.g.
Muffler , coupler , housings (steadies) and
extended bed for M/C # 1 & # 2

28. Loss to the Dept:
The SMS Meer Roll of TANDEM Roll can not
be turned on our conventional Lathes
without changing to new type of Muffler ,
coupler , housings (steadies) and bed for
M/C # 1 & # 2 .

29. In House Development of Relevant
drawings :
Considering the cost and time
involved , it was decided to
develop all relevant dwgs. in
house and manufacturing
these items through
outsourcing. Development of
Drgs. was no easy job since
we had no reference Drgs.

30. Present Status
Now we are machining TANDEM Mill
Roll on conventional lathe successfully.

31. Team Members
Mr. Girish Lakhe
Mr. V. Panda
Mr. K.M. Tripathi
Mr. A.K. Banerjee
Mr. Ranjan Shom

32. Cost Saving :
In house
modification
saved Rs.62 lacs
as well as time

33. 4). Roll Mounting system for CNC
Lathes :
PROBLEM : This
problem is related with
Roll turning of Tandem
Mill Rolls.

34. New Design Roll Turning
RUBM (Roll Shop) has 2 nos. CNC Roll
Turning Lathes besides other
Conventional lathes .The chucks of CNC
Lathes are designed to hold ISCOR UR /
UF Rolls directly on chucks but not
TANDEM Mill Rolls having different
design. Thus holding of UR /UF Roll of
new TANDEM Mill Rolls on chuck
became a problem for holding and
subsequent Machining.

35. Corrective Action taken :
In order to overcome this
problem , new type couplers were
designed and procured . These
couplers were mounted on
TANDEM Mill Roll wobbler , rigidly
fixed on Roll wobbler and
mounted on CNC Lathe chucks
enabling it to carryout normal
machining operation.

36. Present Status
All TANDEM Mill Rolls are being
turned successfully by this
methodology with 100 %
desired accuracy .

37. Team Members
Mr. Girish Lakhe
Mr. V. Panda
Mr. K.M. Tripathi
Mr. A.K. Banerjee
Mr. Ranjan Shom

38. Thank You