è è Large Large and and flexible flexible setting setting ranges ranges è è One One system system for for profile profile and and flatness flatness è è Dynamic Dynamic shifting shifting under under load load è è Robust Robust 4-high 4-high design design
Shifting Range = +/- 150 mm CRA = 1.00 mm WR bending F B = 0... 1750 kN/chock
1,200 1.200 setting range roll gap profile C40 [mm]
1,000 1.000 a) Work roll with conventional crown and backup cylindrical 0,800 0.800
0,600 0.600
0,400 0.400
0,200 0.200
0,000 0.000 1 800 2 1250 3 1850 strip width [mm] b) Work roll and backup roll with CVC contour CVC PLUS provides sufficient control range and additional Contact load distribution equivalent flexibility to conventional rolls
PLUS CVC Technology Practical Results and Performance Data
• High variety of alloys, strip
width, strip thickness and strip profile are usual requirements • The full range of the installed CVC PLUS setting range is used • Only one identical CVC PLUS work roll crown for all mill stands
PLUS CVC Technology Practical Results and Performance Data
Strip length [m] Strip length [m]
Alloy AA 5182 Thickness = 2.8 mm Width = 2210 mm
• A significant share of the installed WR-bending
capacity has to be used to compensate this influence of variation in rolling force and thermal crown on strip profile and flatness along strip Source: ALU Norf
length • The large setting capabilities of CVC PLUS for presetting allow that the whole WR-bending capacity is available for inbar-control Strip length [m]
PLUS CVC Technology Advantages in Rolling Performance
CVC PLUS
with pos./neg. bending
Width change from narrow to minimized gap time, target strip profile is a) long gap time needed to reach target wide achieved already for the first coil after width profile after change change ........decreased productivity ....... decreased flexibility b) minimized gap time results in rolling the first coils after change beyond target profile .........decreased quality
Rolling target profile with wide setting range allows rolling of nearly all limited setting range results in: good flatness products (alloys, width, thickness) with target - target profile cannot be reached for a lot of profile and good flatness products (alloys, width, thickness) with good flatness ........ decreased quality - desired thickness for some products cannot be rolled with acceptable profile and flatness ........ decreased flexibility ........ decreased quality PLUS Stable rolling during wide setting range of CVC for preset and Neg. bending cannot be used for threading in threading in and tailing out usage of pos. bending for inbar control and tailing out. It is necessary to switch to ensures good flatness and stable rolling pos. bending/balancing. This results conditions even for head and tail end. especially for the tail ends in heavy profile changes forcing bad flatness conditions and mass flow disturbances with the risk of damages of strip and equipment ....... decreased productivity ....... decreased quality
Principle Changing of work roll crown by work Variation of load distribution of
roll sifting. backup roll. The roll gap is directly effected The roll gap is effected indirectly , thus the efficiency is considerably (3 - 5 times) smaller.
Extremely cumbersome mechanical design: • At least seven servo-valves are mounted inside one backup roll Hydraulic shifting cylinder (p>500 bar) • Seven high-pressure cylinders are installed inside one backup roll Actuator • Only two hydraulic cylinders per roll (p>500 bar) • High reliability • Seven pads with hydrodynamic • Simple design bearings inside one backup roll • Limited reliability • Complex design
Backup roll material According to conventional aluminium Special high duty material for the hot mill sleeve is necessary due to extremely high pulsating loads ( fatigue stress limit )
Mill modulus High mill modulus ensured by Reduced mill modulus by weak conventional 4-high design backup roll design (appr. up to 40% for top and bottom DSR)
Tilting behaviour Proven swivelling stiffness of Reduced swivelling stiffness of DSR
Grinding process No special requirements Complex and time-consuming
procedure: • Separate support and adjustment for sleeve and for stationary beam necessary, which leads to enlarged preparation times • Steady rest areas for sleeve are relatively small which causes temperature problems • Special drive system for rotation of sleeve necessary • Special protections required to avoid water getting between sleeve and stationary beam • A constant sleeve thickness is essential for thickness control (eccentricities)
Conclusion: • DSR-System provides insufficient setting capabilities. The mechanical effort and the requirements for the related control systems are extremely high. • At the same time the reliability and robustness required in a Hot Rolling Mill is not given.
