2.

Production The steel grade of the billets which we use : Important note: The
billet temperature must be below 723c to remain its magnetic characteristics to
transport it to the furnace by the magnetic winch according to the iron carbon
diagram: The alloy remains ferrite (BCC) crystal structure below 723c to
conserve its magnetic characteristics and above this temperature it will be
Austenite (FCC) which doesn't have magnetic characteristics.
3. Reheating furnace: Reheating furnace in plant is divided to 3 parts with 14
burners : Preheatig Heating Soating There are 14 burner in the furnace
The billet is outing from furance at around 1230 C to 1250c . There are 22
rolling steps to make 8mm wire rod and there are two extra rolling stands to
make it 6mm . Roughing : from 1 to 8 Intermediate: from 9 to 14 Finishing: from
15 to 22
4. Note: Hot rolling temperature must be above 850c, below it it will be cold
rolling and the stresses will maximize over the stands PGV (mono block ) High
speed rolling (32m/sec) Rolling technology Fundamental principles of metal
rolling process Rolling process:- The process of shaping metal and alloys into
the semi-finished or finished condition by passage between rolls is known as
rolling. The rolls rotate in opposite directions, one counter clockwise and the
other clockwise. Rolling involves plastic deformation of metal in which the
thickness of the strip is reduced and the length and width are increased.
DEFINITIONS Draft or Draught:- Draft is simply a reduction in thickness and can
be either direct draft or indirect draft. -Direct Draft is a reduction made
horizontally between the rolls - -Indirect Draft is a reduction made at an angle to
the roll barrel The difference between the initial and final thicknesses of the
strip is called absolute draught H = H1- H2 Elongation:- Is the increase in bar
length after being drafted. Is around 70 % The difference between the final and
initial lengths
5. Is called the absolute elongation L = L2 L1 * The coefficient of elongation,
i.e. the ratio of the length of the metal after rolling to its initial length Spread:- Is
the lateral or sideways movement of stock. Is around 30 % The difference
between the final and initial widths Is called the absolute spread B = B2 B1
Spread :- If we assume the same volume of material enters and leaves the stand
rolls, then the reduction in thickness must be allied to an increase in width and
length. The increase in width is termed spread and it is generally around one
third of the draft, but the exact amount is determined by the following factors; 1Temperature The hotter the material the less spread. 2- Chemical composition
The higher the carbon the more spread. 3- Roll diameter The larger the roll the
greater the spread. 4- Speed The higher the speed the less spread. 5- Pass shape
some passes restrict spread while others have zero control, and so flat rolls (no
pass groove) will have greater spread The Angle of Bite and the Arc of Contact:
The Angle of Bite is the angle formed from the point of contact of bar entry to a
perpendicular line through the roll.Consider 30 as absolute maximum, and 22
as a general angle for smooth bite. The Arc of Contact is the arc formed by the
angle of bite. The larger the roll diameter the smaller the angle of bite Speed

control system:- Modern continuous mills have a speed control system for control
and continuous adjustment of individual stand speeds.
6. 1- tension control system:- In the roughing and intermediate stands 2-loop
control system :- In the finishing stands, between each two stands ( the volume
of steel going through each stand must be the same to avoid tension or
compression.) inference important :- A1 V1 = A2 V2 = An Vn = Constant
Constant = Area (mm2) x speed (m/sec) Speed control system 1- tension control
system :- push- pull conditions :- For continuous rolling:- volume flow must be
balanced Speed and /or areas must be correctly designed and adjusted to
achieve this i.e. Area 1 * speed 1 = area 2 * speed 2 = area 3 * speed 3
Compression between two stands :- volume flow out of first stand is greater than
can be accepted by second stand loop forms and continues to grow Tension
between two stands:- Volume flow delivered by first stand is less than is
7. required by the second stand bar is pulled between stands and will neck down
and pull apart if tension is severe enough 2-loop control system :- Important
note: Having said this, one very important point, if adjustments are made to
loopers or any other equipment then the product must be checked after each
adjustment. So make your adjustments slowly, one by one, and check after each
adjustment. Fail to do this and one day you will roll scrap. Rolls Materials Types
There are three types of materials used to made mill rollers 1- iron rollers 2-steel
rollers 3-carbides rollers 1- Indefinite chill rolls - or grain-iron, these are a low
cost roll, versatile and would be found in slabbing mills, plate mills,roughing
stands, intermediate stands and finishing stands of section mills 2- Double
poured rolls - (sometimes called composite, although this leads to
misunderstanding with the carbide composites) are cast in two stages with an
alloyed iron barrel surface for hardness and an unalloyed core for toughness,
these rolls are to be found in strip mills and plate mills. 3- Definite chill rolls - an
older type of roll with limited surface depth, still in use in the shallower grooves
of the finishing stands of rod and bar mills 4- Nodular iron rolls or spheroidal
graphite have great resistance to fire cracking and distortion with good pass
life, the general applications are throughout the mills of rod, bar and small
sections
8. Steel Rolls Steel rolls have high strength and resistance to deflection, the
types of steel rolls available are: 1- Cast steel rolls - used where strength and
toughness are the main requirements. The surface of cast steel rolls is prone to
break-up and local distortion. Cast steel rolls may be found as back-up rolls in
four high mills, blooming and slabbing mills, large section mills and billet mills 2Forged steel rolls - provide greater strength, hardness and wear resistance than
cast steel but are more expensive. Forged steel may be found in blooming and
slabbing mills, cold strip mills. 3- Steel base rolls - regarded as cast steel rolls
although the carbon content places them between a steel roll and an iron roll.
They are manufactured in the same way as a conventional cast steel roll but are
usually alloyed. In certain applications their characteristics are similar to
Indefinite chill iron rolls. Steel base rolls are to be found in large structural and
section mills. Carbide Rolls Carbide rolls are in fact a compound of tungsten
2

carbide with a binder or cement normally of cobalt. This technology involves

heating (sintering) and compressing fine powdered particles until all porosity is
eliminated and the particles are fused together under extreme pressure. The
final product is a permanently compressed shape of superior mechanical
composition, very hard with a very high resistance to wear, (a carbide roll pass
will outlive a cast iron roll pass to the order often to one).
9. GUIDES Guides are considered the very heart of a rolling process. They are
probably the most significant factor in adjusting and control in the rolling
process. Every stand is consisting of entry guide, mill roll and exit guide. GUIDES
TYPES There are two main types of guide 1- Entry guides:- The entry guide
responsible to receive the bar that is coming from previous and ensure enters to
mill roll without any deviation 2- Exit guides:- The exit guide delivery the bar to
the next stand without any deviation too and so on 1-Entry guide types 1- Static
or friction entry guide:- These types used to receive the bar section such as box
or diamond or square or round shape 2-Roller entry guide:- These types used to
receive the bar section such as oval or former shape And there are three types of
roller entry guides 1- Single pair roller guide (SR) 2-double pair roller guide (DR)
This type consist of this type consist of two rollers four rollers 2-Exit guide types
1- Static or friction exit guide:- The static guide shape depends on the metal
stock and roll pass for stand. There are three types:
10. 1- Box exit static guide: such as used in roughing mill Products There will be
two products in this plant after constructing the rebar line soon: 1- Wire Rod:
Wire rod are small profiles including ordinary low carbon steel wire rods, welding
rod, blasting line with the rod, threaded rod straightening and quality wire rod.
Common wire rod is mainly used for construction, wire drawing, packaging,
welding and manufacturing bolts, nuts and rivets. 2- Rebar: The rebar is
commonly used in reinforced concrete and reinforced structures. It is usually
formed from high carbon steel, and is given ridges for better mechanical
properties into the concrete. It is widely used in various constructions, especially
for large, heavy, light thin and high-level construction. It's an important material.
* The production of the factory is 300,000 ton/year
11. Workshop 1-the main function of workshop is to manufacture all required
mechanical components of spare parts of mill machine. 2- for periodic turning of
corroded rings to re-use it again in rolling operation. 3-to return rollers of roller
guides. 4-fabrication works that required inside the plant. Definition: Computer
Numerical Control (CNC) is one in which the functions and motions of a machine
tool are controlled by means of a prepared program containing coded
alphanumeric data. CNC can control the motions of the work piece or tool, the
input parameters such as feed, depth of cut, speed, and the functions such as
turning spindle on/off, turning coolant on/off. remachined rings Grinding CNC for
tungsten carbide with electroplated diamond grinding wheel

12. general turning machinig Directions Mandrel to fix work piece

13. Holder and turning insert The methods of manufacture in CNC 1-write G-code
program for simple works 2- use cycles inside CNC control for more complex
work piece 3-CAD-CAM software for complex geometry work piece Applications:
The applications of CNC include both for machine tool as well as non- machine
tool areas. In the machine tool category, CNC is widely used for lathe, drill press,
milling machine, grinding unit, laser, sheet-metal press working machine, tube
bending machine etc. Highly automated machine tools such as turning center
and machining center which change the cutting tools automatically under CNC
control have been developed. In the non-machine tool category, CNC
applications include welding machines (arc and resistance), coordinate
14. measuring machine, electronic assembly, tape laying and filament winding
machines for composites. Etc. Open Loop Control Systems : The open-loop
control means that there is no feedback and uses stepping motors for driving the
leadscrew . A stepping motor is a device whose output shaft rotates through a
fixed angle in response to an input pulse. Open loop control system Closed-loop
Control Systems: Closed -loop NC systems are appropriate when there is a force
resisting the movement of the tool/work piece .Milling and turning are typical
examples. In these systems. The DC servomotors and feedback devices are used
to ensure that the desired position is achieved. The feedback sensor used is an
optical encoder. The encoder consists of a light source, a photo detector, and a
disk containing a series of slots. The encoder is connected to the lead screw.
Closed-loop control system
15. PART PROGRAMMING FOR CNC: we will describe how the part programmers
execute manually the part programs. A part programmer must have an extensive
knowledge of the machining processes and the capabilities of the machine tools
First, the machining parameters are determined. Second, the optimal sequence
of operations is evaluated .Third, the tool path is calculated .Fourth, and a
program is written. Sequence Number, N: Consisting of typically three digits, its
purpose is to identify the specific machining operation through the block number
particularly when testing a part program. Preparatory Function, G: It prepares the
MCU circuits to perform a specific operation. The G- codes (some) are shown in
the Table 1 implies incremental mode of operation *G codes used in CNC
systems. Table: 1 Preparatory commands (G-code) G00 Point-to-point positioning
G01 Linear interpolation G02 Clockwise circular interpolation G03 Counterclockwise circular interpolation G04 Dwell G05 Hold G33 Thread cutting, constant
lead G40 Cancel tool nose radius compensation G41 Tool nose radius
compensation - left G42 Tool nose radius compensation - right G43 Cutter length
compensation G44 Cancel cutter length compensation G70 Dimensions in inches
G71 Metric dimensions G90 Absolute dimensions
16. G91 Incremental dimensions G92 Datum offset Dimension Words 1 . Distance
dimension words, X,Y,Z 2 . Circular dimension words, I,J,K for distances to the arc
center 3 . Angular dimensions, A,B.C Spindle speed, S Programmed in rev/min, it
is expressed as RPM or by a three-digit code number that is related to the RPM.
Miscellaneous Function, M Consisting of two digits, this word relates to the
movement of the machine in terms of spindle on/off, coolant on/off etc shown in
4

Table 2 Table: 2 Miscellaneous commands (M-code) M00 Program stop M01

Optional stop M02 End of program M03 Spindle start clockwise M04 Spindle start
counter-clockwise M05 Spindle stop M06 Tool change M07 Mist coolant on M08
Flood coolant on M09 Coolant off M10 Clamp Mll Unclamp M13 Spindle clockwise,
coolant on M14 Spindle counter-clockwise, coolant on M30 End of tape rewinds.
17. Quality Control Steel billet quality is one of the important factors affecting
the quality of rebar or coils that are produced in the Egyptian steel factory
because a small surface defect of a billet will be elongated during the rolling and
becomes an extensive product defect, requiring a considerable cost for
conditioning and fixing. In the factory the function of the quality control
department mainly concerns in the billet as the initial source of the product and
the coils which are the final product of the factory. For the Billet The inspection of
the billet has many stages of inspection to insure that the billet has the minimum
defects with which it can work and it's also inspected by the chemical analysis
test Here are some of the expected defects that we may encounter in the
billet and their causes
18. Defect Possible causes Possible effects on rolled product Surface Minor
Pinholes Insufficient steel deoxidation High content of gas in the steel
(O,N,H) Excessive amount of casting oil Long and very superficial cracks on
wire rod Defects on cold headed produc t Very small pin holes Use of too
much lubrication oil in the mold Very minor influence on hot rolled product
Surface slag >5mm Too much slag in the steel Trapping of products from
deoxidation Trapping of products from refractory erosion Mn/Si ratio lower
than 2.5 High alumina content in the covering powder In correct distribution
of Clearly visible cracks and fracture Overlapping containing slag Steel
sections with outer edges not completely formed
19. covering powder Sudden and consistent steel level in the mold Excess
of Al wire feeding in the mold Surface slag <5mm Not much slag in the steel
Excess of Aluminium wire feeding in the mold Mn/Si ratio very low
Secondary oxidation Trapping of covering powder Cracks of var ious
dimensions according to slag particle dimensions Imperfect surface Transverse
cracks at the corner Deformed mold tube Excess of mold tapering
Deposits on external mold surface tube Low hot elongation of steel (low Mn/Si
ratio) High steel temperature High cooling of the bar concentrated in a
small area Irregular oscillation Incorrect mold Large cracks on the surface
Rough surface especially on wire rod Possibility breaking-off of the bar
during hot rolling
20. lubrication Longitudinal cracks Worn mold tube Too large corner radius
in the mold tube Excess of mold cooling or uneven mold cooling pattern Too
high steel tapping temperature Misalignment of foot rollers or guide and
sprays Long and deep surface cracks Folding an d cold welding Worn or
deformed mold tube Mold lubrication not suitable Excess of slag in the steel
Low steel tapping temperature Low casting speed Cracks and laps
Danger of breaking-off of the bar during hot rolling Healed breakouts Worn o r
5

deformed mold tube Defective mold lubrication Uneven mold cooling

Excess of slag in the steel High steel tapping temperature Consistent
surface defects
21. Steel stream from tundish not well centred to the mold Aluminium surface
deposits Wrong position of the aluminium wire feeding in the mold that will
result in a concentration of the product at the mold face Defects of the surface
Transversal cracks at the bent billet surface Steel analysis as high content of
the impurities such as Pb,Cu,Zn,Sb,S,P Problems during rolling that can be
overcome by increasing the length of the head and tail cropping Heavy
oscillation marks Low carbon content in the steel Excess of mold tube
tapering Mold oscillation stroke too large Wrong ratio be tween oscillation
frequency and casting speed Irregular oscillation Mold lubrication not
correct Very seldom the oscilation marks will cause surface defects on rolled
products Sometimes it can result in very small cracks on the wire rod surface
Longitudinal facial cracks Worn mold tube Primary cooling not uniform
Longitudinal consistent cracks
22. Incorrect(not centred) steel stream position in the mold Incorrect
alignment of mold tube with foot rollers Difficulties during hot rolling
Transversal corner cracks Bending and/or straightening of the bar at too low
temperature Insufficient mold lubrication Sudden liquid steel level variation
in the mold Deep transversal cracks Difficulties during hot rolling
Transversal facial cracks Excess of cooling in the mold Sticking of the bar
solidified skin to the mold face Excess of cooling in the secondary spraying
system Difficulties during hot rolling with possibilities of bar breaking off
Longitudinal depressions Worn mold tube Incorrect alignment Not
uniform primary cooling Covering powder not suitable or badly distributed
Under skin cracks at 5 mm depth may cause serious cracks on hot rolled bar
Transversal depression Lack contact between solidified skin Under skin
crack can cause serious
23. and mold walls Not uniform lubrication Excess of mold cooling
Sudden liquid steel level variation in the mold defects in the rolled bar Surface
scratching and roll marks Jammed guide rolls Rolls not correctly aligned
Other obstructions in the guide rolls Normally no effect on rolled product False
wall Interruption of the steel flow from the tundish Danger of hot rolled
product breaking-off during rolling Plating Low steel tapping temperature
Surface defects False face Lack of mold lubrication Mold powder not
suitable Spreading of surface particle Spreading of steel stream fro, the
tundish Surface defects Surface trapped slag Product coming from
deoxidation or refractory material tundish covering powder or mold covering
powder not suitable or badly distributed such Surface defects
24. products entrapped in the skin formation area are drawn to the mold side
walls Internal defects Blow holes Not appropriate steel deoxidation The
blowholes can expand during rolling causing cracks on rolled products Star
cracks Too high or irregular secondary cooling Problems in the hot rolled
6

bar used for hot/cold pressing Internal cracks Steel analysis with S higher than
0.02% and C between 0.17 and 0.25% Non uniform primary cooling
Deformed mold tube Irregular cooling at the mold exit High steel tapping
temperature Defects on the hot rolled products when the crack is not deeper
than 5 mm Diagonal cracks Not uniform primary cooling or at the mold e xit
area Guide rolls not aligned Cracks in the sub skin area up to 5 mm Can
create defects on hot rolled products
25. Rhombodity higher than 5% can create problems on hot rolling Cracks due
to uneven cooling Not uniform primary cooling Not unifor m secondary
cooling Not correct alignment between mold and guide rolls Too high steel
tapping temperature Subsurface cracks can cause defects on hot rolled bar
Internal cracks may have no negative effect on hot rolled bar And here are some
of these defects that we could record during our training For the coils Heavy
oscillation marks More bending Scratches
26. For the coils: In the factory the inspection of the coils mainly concerns to the
mechanical properties and the dimensions measurements. The mechanical
properties includes the yield and tensile strength, bending and elongation Test
method Test specimens are accurately measured before testing .specimen are
then fitted into the jaws of the tensile testing machine and subjected to a
continually increasing tensile force until the specimen fracture. The tensile
strength (Rm) is calculated by dividing the maximum load by the cross sectional
area of the test specimen measured before At the bent billet surface near the
surface cut
27. testing. The dimensions must be equivalent to the required dimensions with
a maximum tolerance of +0.3 and -0.3 These coils are used Concrete
Reinforcement with dimensions start from 5.5 mm to 12mm of low carbon steel
in order to achieve the Egyptian standard specifications (ES262/2009) grade
B240B-P Suggestions for quality department The quality department is
restricted only on billet and the coils which is considered to have few functions
We have to expand the quality control functions to include the whole factory
especially the rolling mills and other equipment so that we can minimize the
malfunctions as much as possible and predict it before its occurrence. For the
billet and coils there are only few tests that are used as mentioned above such
as chemical analysis , mechanical properties and dimensions measurements
We have to introduce various testing methods such as Non Destructive Testing
and Destructive Testing which will help in the prediction of defects before
malfunction7