Everything to know about Rolling of Square wire
Everything
to know about Rolling of Square wire
Square wire is usually manufactured through rolling in a high speed rolling mill where
the temperature of steel must be above 1000 degree Celsius and the maximum
rolling speed must exceed 120 meters per sec. The production of square wire can
be up to the lengths of 10 kilometers. During the rolling process of square
wire, a continuous rolling mill usually takes 25 to 30 passes.
Square
wire is a material that is used in a wide range of applications. These
applications include the automotive industry, electrodes, tire cord, connecting
elements, wire products, springs, steel structures, and much more. This is why
a square wire mill is designed and constructed with versatility in mind. As a square
wire mill is energy intensive, it becomes important that the ideal solutions
are included in the design without a compromise on flexibility. The production
of all materials, alloys, and size ranges need to be carried out efficiently,
providing high productivity.
A
square wire mill usually requires
·
Heating facilities to
heat the raw material (also known as billet) to appropriate rolling
temperatures.
·
Rolling facilities
equipped with guards, guides, rolls, and chocks.
·
Appropriate equipments
for heat treatment, laying, and coiling.
·
Appropriate equipments
for conveying and handling.
All
these machines and equipments in a square wire mill must work properly in close
coordination, in compliance with a control in gap time loss, cobbles, rolling
temperatures, speed loss, con-conforming product, and the deviations in quality
that leads to diversion or rejection.
Major
requirements from a square wire mill
There
are a few significant boundaries for rolling square wire in a square wire mill.
An advanced square wire mill is mostly intended to work with OEE theory. OEE
(overall equipment effectiveness) value of a square wire mill is the worth
acquired by increased factory use, plant proficiency, and the yield time of the
plant. The square wire mill usage is the accessible working time divided by the
production time of the mill and is denoted in percentage. The square wire mill
productivity is the running time divided by the accessed working time of the
mill and denoted in percentage. The square wire mill yield time is the time for
creating the top-rated item connected with the running time. The yield of
product is denoted as the weight of the coil divided by the weight of the raw
materials and is denoted in rate.
Square
wire mills ordinarily have lower OEE than different sorts of mills due to the
greater downtime required for stand changing, roll changing, and the
adjustments in guide and groove during the movement of items. The square wire mill's
OEE can be enhanced by reducing this downtime. The limit of hypothetical
production of a mill is the limit that can be acquired with no losses, for
example with 100 percent of yield, 100 percent use, and 100 percent of
effectiveness. Though, the real limit is subject to the OEE level of the
factory. In case that the OEE level of the mill is 60 percent then, at that
point, the production limit of the mill stands at 60 percent of the
hypothetical limit. The OEE level in a condition of craftsmanship square wire
mill with a distinct advanced plant is typically at the degree of 80 percent.
In
an advanced square wire mill, the fundamental spotlight is on usefulness and
quality. High use, proficiency, and yield give high usefulness. Though, high
usefulness itself isn't the main thing for the accomplishment of a square wire
mill. It needs to deliver items that are worth to the clients and they get the
quality square wire deserving of the amount which they are making for the square
wire.
Flexibility
of the square wire mill
In
a square wire mill, the raw material steel is warmed above its temperature of
recrystallization and gone through a few scores of the rolls in the moving
factory. The common roll pass design used in square wire mills is squared. But
the same mill can also produce square-oval, diamond-square, box passes, false
round-oval, diamond-diamond, & round-oval designs as per requirements. In
the square wire bar processes regularly size free rolling is being done, which
means square wire of any size can be moved without the restrictions of the pass
sizes of the rolls held in the plant. This is additionally being known as the
adaptability of the series.
Moreover,
the improvement of the pass timetable of an upstream moving mill empowers the
recurrence of the roll changing to be significantly brought down. The more
extensive the scope of the item size equipped for being moved with similar
rolls, the more prominent is the impact of decreased recurrence of roll
evolving. The size-free rolling isn't restricted to the completing mill. It can
also be applied to the pre-completing plant.
Conclusion
The
quality and productivity of a square wire production highly depends on the
advancements of the square wire mill. The square wire mills equipped under Matta Drawing Works
are highly advanced and produce high quality square wire and other end
products.
Publish Date : 19-01-2022