Section and rail rolling

Solutions for the efficient production of sections and rails

Metals Technologies
www.siemens-vai.com
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Fast and flexible in the
production process
Your challenge:
Creating a fast and flexible process is
challenging, and fulfilling customers
orders quickly is key to staying competi-
tive. Thats why its so important to stay
on top of new technologies for each and
every step of the production line from
beginning to end. When it comes to the
finishing section, you need a seamless
workflow with fast, changeable stands
and fully automatic stacking and binding
systems.
Our solution:
Siemens VAI answers these challenges
with seamless solutions that address
all final processing demands. From fast
cutting stands to compact stacking and
convenient binding systems, the entire
production process is smooth with great-
er efficiency. Short cycle times and a
flexible machine layout help to process
different kinds of steel products with
minimal changeover downtime.
Universal stands with
the renowned Red Ring design
One of our final processing solutions
features builds on our new generation
of universal stands, which are based
on our renowned Red Ring design. Our
new universal stands also include the
original features.
Automatic stackers and binding system
Our stackers are designed for specific
tasks: Our magnetic type is ideally suited
for handling medium to large sections,
while our combined magnetic-mechani-
cal stacker manages small to medium
sections. Finally, our completely auto-
matic and hydraulically operated binding
machine can handle binding bundles
in any section.
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Advantages of
Siemens VAI universal stands:
Fast roll changes
When rolling structural shapes in the mill, our universal stands
can be exchanged with horizontal stands. In addition to the
horizontal rolls, they are fitted with a set of idle vertical rolls to
work the flange shapes. Our special design means that rolls can
be changed in just a quarter of the time it used to take.
Easy installation
Installing universal stands into existing rolling trains requires no
significant foundation work, modifications or lengthy downtimes.
So for a minimum investment, a wide variety of mills can be
quickly and flexibly upgraded.
Low weight
Weighing only half the mass of conventional stands, our universal
stands allow the rolls and rolling equipment to be quickly and
easily replaced. Theres no need for high-capacity overhead cranes
or costly and bulky extraction carriages.
Remote-control change
A remote-controlled roll change robot helps to significantly reduce
the roll assemblies changeover time.
Advantages of
Siemens VAI stackers and binding system:
Fully automatic stacking
Fully automatic operation minimizes personnel costs while
increasing on-the-job safety.
Friction-free product handling
Safe binding mechanisms ensure friction-free product handling
without surface damage, improving product quality.
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As with our 2-high Red Ring stand, our Red Ring uni-
versal stand has no requirement for a standby stock
of chocks. Instead, roll changes are performed using
a robot system, which mechanizes the assembly/disas-
sembly of roll chocks. The process of disengaging a
universal stand from the rolling line, such as for stand
clamping or spindle holding, is exactly the same as
for a normal Red Ring 2-high stand.
Advances with Red Ring 5XX series:
Increased rigidity, for minimal deflections
Possibility of using rolls with a larger diameter,
hence reducing the bite angle
Improved design of chock pivoting system,
for longer bearing lifetime
Best selection of material for tie rods
Optimized manufacturing of chocks
A sophisticated roll system
The rolls in our system adjust symmetrically around the
pass line through a hydraulic motor-driven screw system.
For maximum load carrying capability, our system uses
4-row cylindrical bearings with separate thrust bearings.
To allow accessibility, hydraulic plungers outside of the
tie rods locate roll balance.
In our original version, the conversion 2-high/universal
was performed by adding an assembly consisting of
chocks and roll gap setting devices of vertical rolls. In our
modified version, vertical idle rolls have been added along
with chocks and roll gap control devices. Also, for quick
assembly and disassembly, the vertical frame is separated
from the rods and is locked to the massive rest bar by
hydraulic nuts. Both horizontal and vertical rolls are
hydraulically adjusted and can be controlled remotely.
Increased life span and cleaner operation
The main bearings and labyrinth seals in all types of Red
Ring stands operate with oil/air lubrication instead of
automatic grease. That reduces the amount of continuous
lubricant thats needed, and it also lowers bearing operat-
ing temperatures. Using oil/air lubrication also increases
the life span of the main bearings and labyrinth seals and
makes for an overall cleaner operation, especially in the
roll change area. Finally, it reduces flume water
contamination.
Continuous universal mill at Corus, Scunthorpe, UK Medium-beam rolling
Universal stands quickly reconfigured
for maximum flexibility
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Counterbalanced spindle support
The spindle support, which contains the spindles in a
wrapped bearing design, is completely counterbalanced.
This feature ensures that hubs remain parallel. It also
eliminates hub wobble, and greatly reduces wear. Also,
generous tapers on hub entry and roll ends mean that,
in most cases, stands can be changed without moving
the spindles.
The spindle support and stand are connected by a cross
cylinder and pin. The shift cylinder is connected to the
spindle support, not the stand. When changing stands,
the cross cylinder disconnects the two, and the shift cylin-
der retracts the spindle support, which in turn uncouples
the service fluids as well as the spindles.
Remote-control change
One of the outstanding features of this design is that
theres no need for physical connections between roll
spade endings and the spindle hubs. The design allows
the stand to be changed via remote control and it signifi-
cantly reduces the roll assemblies changeover time. We
also furnish a roll change robot to aid with the change
operation. The unit is normally located in the roll shop
and is equipped with a hydraulic power unit.
Features:
Easy conversion to conventional
horizontal stands
4-row cylindrical bearings with
separate thrust bearings allow
maximum load carrying capability
Fast stand and roll change
Vertical frame separates from the
tie rods for quick assembly
Hydraulically adjusted vertical and
horizontal rolls
Universal stand spindle holder Universal stand on baseplate with spindle holder
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Cooling and precambering systems
In order for the straightening process to be effective, sec-
tions arriving from the cooling area must present a suit-
able temperature below approximately 100 C and correct
geometry. For this reason, according to product and lay-
out, the cooling bed may be equipped with spray cooling
technology. Rails and other special sections may require a
prestraightening operation thats applied at the cooling
beds entrance. In fact, nonuniform mass distribution in
the cross section of the rail tends to bend it inwards on its
head side. If not corrected, this would make postcooling
straightening very difficult. Rails therefore are precam-
bered before being deposited onto the cooling bed and
are hydraulically clamped and lifted on the web side. The
clamps are mounted on motor-driven cars, each with indi-
vidually programmable travel distances that allow for the
application of different precamber patterns. Precamber
geometries are calculated according to cooling models
and rail parameters, which include grade, shape, specific
mass, length, and temperature.
Features:
Rails precambered before cooling bed
Rails hydraulically clamped and lifted
Individually programmable travel distances
Straightening systems
Straightening of sections before cutting to final length
is necessary to remove the deformations caused by the
asymmetrical cooling effects. The sections have to be
subjected to a mechanical deformation to reach the
yield tensile strength.
Straighteners are composed of a rigid frame containing
two staggered rows of double-supported or cantilever-
mounted horizontal rollers. The number of rollers varies
with the bar size and productivity requirements. The roll-
ers of one row are driven by an electrical motor, while the
others are idle. The top rollers position is vertically adjust-
able according to the bar size, with hydraulic counterbal-
ance to eliminate backlashes. Top and bottom rollers are
axially adjustable. On either row, the centerline distance
of rollers may be fixed or adjustable to accommodate
medium and heavy sections, which present a wide range
of plastic section moduli.
The rollers are mounted in a removable cassette. For a
quick changing operation, the cassette is automatically
removed and replaced with another cassette thats ready
with standby rollers.
For an effective straightening process, the sections are
kept in order and firmly guided with special combing
devices or pinch rolls that ensure bar separation. Magnetic
rollers at the straighteners exit prevent bars from slipping
during travel to the dividing shear.
Straightening rollers are independently
adjustable at both sides.
9-roller straightener with removable cassette
Effective cooling and straightening
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A suction system removes the scale peeling off the
bars during straightening.
Other types of straightening systems are designed
for rail and special sections processing.
Features:
Rigid frame contains two sets of
double-supported horizontal rollers
Top rollers position is vertically
adjusted according to bar size
Hydraulic counterbalance eliminates
vertical movement backlashes
Axial adjustments for rollers
Rollers mounted in removable cassette
for quick changing operation
Special combing devices or pinch rolls ensure
bar separation for effective straightening
process
Magnetic rollers at straighteners exit
prevent bars slipping
Suction system removes scale during straightening
Straightening rollers are independently
adjustable at both sides.
Rail precambering system
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The layers of sections arriving from the straightening
and cold-cutting area are properly braked and buffered
onto the first transfer table of the stacking area.
Aligning rolls and stoppers gives bars an orderly
disposition. Should there be out-of-tolerance bars or
emergency conditions, a special system directs bars
to separate cradles.
Individual layers with the desired number of bars are
formed and separated by using disappearing stoppers
and variable-speed devices.
According to the section shape and size requirements, the
appropriate sequence of straight and 180-degree rotated
layers will be sent to the stacking device. The synchronized
operation of suitable devices with mechanic or hydraulic
drives provides the necessary movements of lift, travel
and rotation. Devices are equipped with electromagnets
to provide a firm grip on the bars, and special equipment
to release them when demagnetized.
The stack is formed on a lowering cradle, where layers
are deposited with the correct sequence of straight and
rotated sections until the desired stack is completed. The
stack dimensions are calculated as a function of weight,
section type and size, and stability requirements.
Combined magnetic-mechanical stacker
Stacking systems for all section sizes
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An adjustable-width roller table transfers the stacks to the
binding area. The roller table is equipped with horizontal
and vertical rollers in order to maintain a good stack
alignment during travel.
Tying or strapping machines provide the binding to meet
customers processed weight requirements.
After applying the preset number of bindings, the stacks
are weighed, labeled, and dispatched to the storage area.
All operations are fully automatic and computer-controlled.
The stacking area is designed to give bars enough resi-
dence time in order to provide flexibility and accumulation
capability with respect to the rolling mill.
Stacking systems have a divisible design that provides the
flexibility needed to process different stacks of different
lengths. This feature significantly increases the productivity
rate for stacks with shorter lengths.
For the most part, a fully magnetic stacker is used for
medium to large sections. For processing small to medium
sections, a combined mechanical-magnetic type is pre-
ferred, which avoids the residual magnetization effect on
light bars, preventing misalignment and an incorrect stack
formation.
Working sequences of stacking and binding are fully
automated and integrated with the other areas of the
rolling mill.
Features:
Special system directs out-of-tolerance bars
to separate cradles
Disappearing stoppers and variable-speed devices
form and separate individual layers
Synchronized operation of suitable devices
ensures correct sequence of straight and
180-degree rotated layers
Electromagnets equip devices for firm grip on bar
Adjustable-width roller table transfers stacks
to binding area
Horizontal and vertical rollers maintain good stack
alignment in transit
Operations all fully automatic and computer-controlled
Divisible design provides flexibility needed to process
different stacks of different lengths for greater
productivity
Combined mechanical-magnetic type processes small
to medium sections
Working sequences of stacking and binding fully
automated and interfaced with the other areas of
the rolling mill
Magnetic stacker
Straight and rotated layers for stack stability
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For hot-cutting rails to finished lengths and medium-
large sections, sawing may be preferred over shearing
equipment for several reasons. Sawing can eliminate
the deformation of bar ends and obtain better cut
quality and precision. Depending on the application,
process parameters, and operational requirements,
hot-sawing processes with either metallic or abrasive
disc technologies can be used. According to the
application, the requirements of postprocessing
operations such as burr removal and edge trimming
are eliminated or significantly relieved.
During cutting, the bar is firmly clamped at both sides
of the wheel. Depending on the dimension and shape of
the bars to be cut, the wheel approaching and receding
movements can be either pendulum or linear type.
The saw is also used for nose and tail cropping, with an
automatic crop discharge system. Bar samples can also
be cut with a special conveyor to remove them.
Cut swarf is collected in a bin at the saw, while a separate
dust removal and filtering system is provided.
An automatic system compensates for the wheel wear
and helps to minimize the process cycle time.
Features:
Metallic or abrasive disc technologies available
Pendulum or linear disc movement
Automatic removal of nose and tail crops
Collection of sawing swarf
Dust removal and filtering system
Fully automated sawing procedures
Metallic disc saw Abrasive disc saw for rails
Sawing units
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Excellence derived from experience
Selected success stories with Siemens VAI section & rail rolling
Expanding business opportunities
Customer: ArcelorMittal Temirtau, Temirtau,
Kazakhstan
Plant type: Bar and section mill
Our solution: A continuous mill with 16 horizontal,
vertical and convertible Red Ring stands
Technical data: 400,000 tpy
The result: Flexibility for a large range
of sections
Worlds first 120-m in-line continuous
finishing mill
Customer: Corus Scunthorpe (TATA),
Scunthorpe, United Kingdom
Plant type: Section and rail mill
Our solution: Seven universal/horizontal Red Ring stands,
plus eleven standby units
Technical data: 570,000 tpy (sections),
200,000 tpy (rails)
The result: New engineering solutions for easy stand
conversion and replacement; continuously
rolled rails up to 120 m length
Large production
Customer: SAIL Steel Authority of India Limited,
Durgapur, India
Plant type: Bar and section mill
Our solution: A continuous universal rolling mill
with 16 Red Ring stands
Technical data: 1,000,000 tpy of sections
up to 300 mm
The result: Maximum flexibility for one of the
largest capacity rates
Stainless quality
Customer: Viraj Profiles, Mumbai, India
Plant type: Bar and section mill for stainless steel
Our solution: A Red Ring sliding rougher followed
by a continuous rolling mill with 18
Red Ring stands
Technical data: 180,000 tpy of sections
up to 300 mm
The result: Top-class installation for stainless
market
Competence Center:
Siemens Industry Inc.
15 Belmont Street
Worcester, MA 01605-2665, USA
Phone: +1 508 755-6111
Fax: +1 508 832-0139
E-mail: longrolling.metals@siemens.com
Siemens VAI
Metals Technologies S.r.l.
Via L. Pomini, n. 92
21050 Marnate (VA), Italy
Phone: +39 0331 741211
Fax: +39 0331 741386
Headquarters:
Siemens VAI
Metals Technologies GmbH
P.O. Box 4, Turmstr. 44
4031 Linz, Austria
Phone: +43 732 6592-0
Fax: +43 732 6980-0
E-mail: contact.metals@siemens.com
www.siemens-vai.com
Order No. E10001-M4-A117-V1-7600
Dispo No.: 21661 K-No.: 28104 | Printed in Germany
GB 110083 WS 06111.5 | 06.2011, Siemens AG
All rights reserved. Subject to change without prior notice.
The information provided in this brochure contains merely general
descriptions or characteristics of performance which in actual case of use
do not always apply as described or which may change as a result of further
development of the products. An obligation to provide the respective
characteristics shall only exist if expressly agreed in the terms of contract.