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Metal Manufacturing Processes and Energy Systems
Published in Swapan Kumar Dutta, Jitendra Saxena, Binoy Krishna Choudhury, Energy Efficiency and Conservation in Metal Industries, 2023
Swapan Kumar Dutta, Binoy Krishna Choudhury
In rolling mills, both hot rolling and cold rolling are used, as per requirement. In the case of hot rolling, steel is heated and passed through heavy rollers to reduce the thickness or provide the desired shape. Hot rolled steels are used primarily for grain orientation and also reduce thickness and smooth surfaces faster than cold rolling. Cold rolling mills are known for better surface finishes and packed grain orientation, which make the product more durable, but consumes more electrical energy and thermal energy is used for pickling, followed by treatment in a tandem mill. The final process involves finishing of the product, whereby annealing and surface treatment are done particularly for the products from hot rolling mills. This principle applies to all metals—both ferrous and non-ferrous.
Metal Forming II—Bulk Deformation
Published in Zainul Huda, Manufacturing, 2018
Rolled steel products include plates, sheets, bars, structural shapes (I-beams, channels, etc.), and rails as well as intermediate shapes for wire drawing or forging (Ginzburg, 1989). Flat rolling is used to reduce the thickness of a rectangular cross section (such as a slab). In “shape rolling,” a square cross section (bloom or billet) is formed into a shape such as an I-beam by using grooved rolls. The equipment used in rolling is called a rolling mill. Depending on the number of rolls used, rolling mills may be divided into the following types: (1) two-high rolling mill, (2) three-high mill, (3) four-high mill, (4) cluster mill, and (5) tandem rolling mill. Four-high mills use smaller-diameter rolls as compared to three-high mills, and the latter use smaller-diameter rolls as compared to two-high mills (Ginzburg and Ballas, 2000; Huda, 2017).
Metal Rolling
Published in Jerry P. Byers, Metalworking Fluids, Third Edition, 2018
Cold rolling steel achieves greater strength properties in lighter finished gauges, so the reductions at a cold rolling mill become more demanding. Generally, the only way to achieve the desired end result is to go to more unstable emulsions so that there is more lubricant available at the roll bite. More oil in the roll bite is important; but what is in that oil film controls the way it wets the surface of the metal and rolls, as well as how the lubricant resists breaking down at the point of contact. Finally, the lubricant film residue that remains on the strip as it leaves the cold mill should be easy to remove, either in a cleaning step or through evaporation, known as burn-off in the heat-treating process. The type of emulsion and the selection of components are critical in achieving the best result.
Comparison of biodegradation of lubricant wastes by Scenedesmus vacuolatus vs a microalgal consortium
Published in Bioremediation Journal, 2019
Stella Beverly Eregie, Sumaiya F. Jamal-Ally
In aluminum and steel production, coolant lubricant contains various additives which make up the final rolling emulsions used for lubrication of the hot rolling mills, reduce the friction, prevent metal-to-metal contact between the work rolls and the work piece, and to control the temperature of the work rolls. Inevitably the day to day functioning of industries results in the production of waste lubricant emulsions known as spent oil (Asgari et al. 2017). Lubricant wastes are mixtures of a base material, usually derived from oil and additives. They consist of about 90% of oil base stocks plus 10% additives (Asgari et al. 2017; Soni and Agarwal 2014).