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63-467: The first continuous-caster for slabs in the world was commissioned in Dillingen in 1962. A further machine, permitting casting of slabs of up to 400 mm in thickness – the thickest produced anywhere in the world at that time – was added, along with other new facilities, in 1998. In 2010, Dillinger Hütte successfully produced the first 450 mm thick slab – another world record. The principal equipment in

126-421: A continuous casting operation, the products are usually fed directly into the rolling mills at the proper temperature. In smaller operations, the material starts at room temperature and must be heated. This is done in a gas- or oil-fired soaking pit for larger workpieces; for smaller workpieces, induction heating is used. As the material is worked, the temperature must be monitored to make sure it remains above

189-463: A reduction mill or mill , has a common construction independent of the specific type of rolling being performed: Slabs are the feed material for hot strip mills or plate mills and blooms are rolled to billets in a billet mill or large sections in a structural mill. The output from a strip mill is coiled and, subsequently, used as the feed for a cold rolling mill or used directly by fabricators. Billets, for re-rolling, are subsequently rolled in either

252-451: A finite element model (FE) for predicting the final shape of a rolled bar in round-flat pass. One of the major concerns when designing rolling mills is to reduce the number of passes. A possible solution to such requirements is the slit pass , also called split pass , which divides an incoming bar in two or more subparts, thus virtually increasing the cross section reduction ratio per pass as reported by Lambiase. Another solution for reducing

315-529: A hammer. Although Cort was not the first to use grooved rolls, he was the first to combine the use of many of the best features of various ironmaking and shaping processes known at the time. Thus modern writers have called him "father of modern rolling". The first rail rolling mill was established by John Birkenshaw at Bedlington Ironworks in Northumberland , England, in 1820, where he produced fish-bellied wrought iron rails in lengths of 15 to 18 feet. With

378-417: A lot of residual stresses, which usually occurs in shapes that have a non-uniform cross-section, such as I-beams . While the finished product is of good quality, the surface is covered in mill scale , which is an oxide that forms at high temperatures. It is usually removed via pickling or the smooth clean surface (SCS) process, which reveals a smooth surface. Dimensional tolerances are usually 2 to 5% of

441-416: A merchant, bar or rod mill. Merchant or bar mills produce a variety of shaped products such as angles, channels, beams, rounds (long or coiled) and hexagons. Mills are designed in different types of configurations, with the most basic being a two-high non-reversing , which means there are two rolls that only turn in one direction. The two-high reversing mill has rolls that can rotate in both directions, but

504-443: A parametric Finite element model and to optimize and automatically design rolling mills. Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases the strength via strain hardening up to 20%. It also improves the surface finish and holds tighter tolerances . Commonly cold-rolled products include sheets, strips, bars, and rods; these products are usually smaller than

567-433: A rolling mill can produce 10 to 20 or more bars at the same time. A patent was granted to Thomas Blockley of England in 1759 for the polishing and rolling of metals. Another patent was granted in 1766 to Richard Ford of England for the first tandem mill. A tandem mill is one in which the metal is rolled in successive stands; Ford's tandem mill was for hot rolling of wire rods. Rolling mills for lead seem to have existed by

630-411: A single pass is limited by the friction between the rolls; if the change in thickness is too great the rolls just slip over the material and do not draw it in. The final product is either sheet or plate, with the former being less than 6 mm (0.24 in) thick and the latter greater than; however, heavy plates tend to be formed using a press , which is termed forging , rather than rolling. Often

693-454: A small diameter rolls. To reduce the need for small rolls pack rolling is used, which rolls multiple sheets together to increase the effective starting thickness. As the foil sheets come through the rollers, they are trimmed and slitted with circular or razor-like knives . Trimming refers to the edges of the foil, while slitting involves cutting it into several sheets. Aluminum foil is the most commonly produced product via pack rolling. This

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756-490: A works school founded. The plant was 65% destroyed during the Second World War; nearly 200,000 shells fell on the plant site. The consequences were months of clearance work, and a completely fresh start. After the war, Dillinger Hütte continued to invest in steel, investing in worldwide innovations, such as the first slab caster in 1962, the new heavy-plate rolling mill in 1971, the world's most powerful rolling stand in 1985,

819-407: Is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical property. The concept is similar to the rolling of dough . Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then

882-570: Is a type of thermomechanical processing which integrates controlled deformation and heat treating . The heat which brings the workpiece above the recrystallization temperature is also used to perform the heat treatments so that any subsequent heat treating is unnecessary. Types of heat treatments include the production of a fine grain structure; controlling the nature, size, and distribution of various transformation products (such as ferrite , austenite , pearlite , bainite , and martensite in steel); inducing precipitation hardening ; and, controlling

945-536: Is continuously deformed to produce a certain finished product with smaller cross section dimension and geometry. Starting from a given billet, different sequences can be adopted to produce a certain final product. However, since each rolling mill is significantly expensive (up to 2 million euros), a typical requirement is to reduce the number of rolling passes. Different approaches have been achieved, including empirical knowledge, employment of numerical models, and Artificial Intelligence techniques. Lambiase et al. validated

1008-427: Is done in one pass. In a traditional rolling mill rolling is done in several passes, but in tandem mill there are several stands (>=2 stands) and reductions take place successively. The number of stands ranges from 2 to 18. Tandem mills can be either of hot or cold rolling mill types. Cold rolling mills may be further divided into continuous or batch processing. A continuous mill has a looping tower which allows

1071-411: Is evident from the two different surface finishes; the shiny side is on the roll side and the dull side is against the other sheet of foil. Ring rolling is a specialized type of hot rolling that increases the diameter of a ring. The starting material is a thick-walled ring. This workpiece is placed between two rolls, an inner idler roll and a driven roll , which presses the ring from the outside. As

1134-419: Is fed in between two rollers , called working rolls , that rotate in opposite directions. The gap between the two rolls is less than the thickness of the starting material, which causes it to deform . The decrease in material thickness causes the material to elongate. The friction at the interface between the material and the rolls causes the material to be pushed through. The amount of deformation possible in

1197-420: Is mainly used to preform long-scaled billets through targeted mass distribution for parts such as crankshafts, connection rods, steering knuckles and vehicle axles. Narrowest manufacturing tolerances can only partially be achieved by forge rolling. This is the main reason why forge rolling is rarely used for finishing, but mainly for preforming. Characteristics of forge rolling: A rolling mill , also known as

1260-576: Is now Belgium to England in 1590. These passed flat bars between rolls to form a plate of iron, which was then passed between grooved rolls (slitters) to produce rods of iron. The first experiments at rolling iron for tinplate took place about 1670. In 1697, Major John Hanbury erected a mill at Pontypool to roll "Pontypool plates" – blackplate . Later this began to be rerolled and tinned to make tinplate . The earlier production of plate iron in Europe had been in forges, not rolling mills. The slitting mill

1323-403: Is obtained. Roll forming is ideal for producing parts with long lengths or in large quantities. There are three main processes: 4 rollers, 3 rollers and 2 rollers, each of which has as different advantages according to the desired specifications of the output plate. Flat rolling is the most basic form of rolling with the starting and ending material having a rectangular cross-section. The material

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1386-613: Is used for these products. Dillinger Hütte is also a 50% owner of Europipe GmbH, Europe's largest manufacturer of large-caliber line pipe, with facilities in Germany, France and the USA. Dillingen is the only location in the Saar region at which iron is smelted. The jointly owned ROGESA blast furnace operator also supplies Saarstahl, the other co-owner, with hot metal. Further examples of the use of steel from Dillinger Hütte: In 1685, Louis XIV of France -

1449-765: The Moses Mabhida Stadium in Durban, and the luxury liner , Queen Mary 2 . The striking arc of the Olympic Stadium in Athens was also welded from plate supplied by Dillinger Hütte. The main application for Dillinger Hütte's heavy plate output, however, is the making of large-caliber line pipe for major pipeline projects. The so-called thermomechanical rolling process, an extremely sophisticated rolling method which permits attainment of maximized mechanical properties combined with optimum working (bending and welding) characteristics,

1512-561: The rolling mill now takes the form of two four-high stands, of which one is currently the largest in the world, with an effective rolling width of 5.5 m and a rolling pressure of 110 MN. The Dillinger Hütte group also includes a further rolling mill operated by GTS Industries in Dunkirk (France). The group's parent company is DHS Holding, which owns 95.28% of the shares in the operating company, AG der Dillinger Hütte. Another 4.72% are held in free float . The company's products are marketed under

1575-580: The semi-finished casting products into finished products. There are many types of rolling processes, including ring rolling , roll bending , roll forming , profile rolling , and controlled rolling . The earliest rolling mills in crude form but the same basic principles were found in Middle East and South Asia as early as 600 BCE. The invention of the rolling mill in Europe may be attributed to Leonardo da Vinci in his drawings. Earliest rolling mills were slitting mills , which were introduced from what

1638-429: The toughness . In order to achieve this the entire process must be closely monitored and controlled. Common variables in controlled rolling include the starting material composition and structure, deformation levels, temperatures at various stages, and cool-down conditions. The benefits of controlled rolling include better mechanical properties and energy savings. Forge rolling is a longitudinal rolling process to reduce

1701-789: The Back-up Rolls from about Stand 3 of the Hot Strip Mill through to the Finished Product. The Back-up Roll eccentricity can be up to 100 μm in magnitude per stack. The eccentricity can be measured off-line by plotting the force variation against time with the Mill on creep, no strip present, and the Mill Stand below face. A modified Fourier analysis was employed by the 5 Stand Cold Mill at Bluescope Steel, Port Kembla from 1986 until that Cold Mill ceased production in 2009. Within each coil,

1764-522: The Backup Rolls of each Stand. If a Mill Stand is fitted with Hydraulic Pistons in series with, or instead of the electrically driven Mechanical Screws, then it is possible to eliminate the effect of that Stands Back-up Roll eccentricity. While rolling, the eccentricity of each Back-up Roll is determined by sampling the roll force and assigning it to the corresponding portion of each Back-up Roll's rotational position. These recordings are then used to operate

1827-602: The Dillinger Hütte GTS trade name . The shares in DHS Holding are owned 33.4% by the international ArcelorMittal steel group, with 33.75% held by Saarstahl AG and 15.00% by Struktur-Holding-Stahl. Reciprocal part-ownership exists with Saarstahl AG, in which Dillinger Hütte holds 25.10%. Dillinger Hütte also owns 50% of the ROGESA Roheisengesellschaft iron smelting company, whose blast furnaces , located on

1890-572: The Dillinger Hütte plant site, produce inter alia the "hot metal" (liquid pig iron ) required for steel production. ROGESA itself also has a stake in the ZKS Zentralkokerei Saar coking-plant operator, the facilities of which also form part of the Dillinger Hütte site. Dillinger Hütte produces heavy steel plate, cast slag pots and semi-finished products, such as pressings, and (pressure) vessel heads and shell sections. Total production when

1953-520: The French subsidiary, GTS Industries, is included is well over two million tonnes of heavy plate annually, in a thickness range extending from 6 to 440 mm, making the company Europe's largest heavy plate producer. This robust material is used for fabrication of drilling rigs, ships, petrochemicals plants, bridges and heavy machinery; reference projects include the Öresund Bridge and the Millau Viaduct ,

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2016-473: The Hydraulic Piston so as to neutralize the eccentricities. In a flat metal workpiece, the flatness is a descriptive attribute characterizing the extent of the geometric deviation from a reference plane. The deviation from complete flatness is the direct result of the workpiece relaxation after hot or cold rolling, due to the internal stress pattern caused by the non-uniform transversal compressive action of

2079-521: The advancement of technology in rolling mills, the size of rolling mills grew rapidly along with the size of the products being rolled. One example of this was at The Great Exhibition in London in 1851, where a plate 20 feet long, 3 1 ⁄ 2 feet wide, and 7/16 of an inch thick, and weighing 1,125 pounds, was exhibited by the Consett Iron Company . Further evolution of the rolling mill came with

2142-408: The back side of the smaller rolls. A four-high mill has four rolls, two small and two large. A cluster mill has more than four rolls, usually in three tiers. These types of mills are commonly used to hot roll wide plates, most cold rolling applications, and to roll foils. Historically mills were classified by the product produced: A tandem mill is a special type of modern rolling mill where rolling

2205-415: The beginning of the 19th century the workforce had grown to over 2,500. The so-called "Dillingen platemaker's gauge", covering twenty-four different plate thicknesses, had by then long become the definitive standard throughout Europe. Dillinger Hütte was also progressive in the social sphere: an assistance and a pension fund were set up, and a works hospital, a residential estate for the plant's workers and

2268-405: The center as compared to the average thickness at the edges of the workpiece. Wedge is a measure of the thickness at one edge as opposed to the other edge. Both may be expressed as absolute measurements or as relative measurements. For instance, one could have 2 mil of crown (the center of the workpiece is 2 mil thicker than the edges), or one could have 2% crown (the center of the workpiece

2331-490: The construction of the first plate rolling-mill in continental Europe. These developments brought the factory to the forefront as Prussia's largest black and tin plate producer. With approval from emperor Napoléon Bonaparte, Dillinger Hütte in 1809 became Germany's first joint stock company, and one of the first in Europe. The company adopted the name Anonyme Gesellschaft der Dillinger Hüttenwerke in 1828. State-of-the-art rolling facilities and blast furnaces were installed, and by

2394-402: The cost of being more expensive. Roll bending produces a cylindrical shaped product from plate or steel metals. Roll forming, roll bending or plate rolling is a continuous bending operation in which a long strip of metal (typically coiled steel) is passed through consecutive sets of rolls, or stands, each performing only an incremental part of the bend, until the desired cross-section profile

2457-403: The cross-section is relatively uniform and the transverse dimension is relatively small. Cold rolling shapes requires a series of shaping operations, usually along the lines of sizing, breakdown, roughing, semi-roughing, semi-finishing, and finishing. If processed by a blacksmith, the smoother, more consistent, and lower levels of carbon encapsulated in the steel makes it easier to process, but at

2520-436: The cross-sectional area of heated bars or billets by leading them between two contrary rotating roll segments. The process is mainly used to provide optimized material distribution for subsequent die forging processes. Owing to this a better material utilization, lower process forces and better surface quality of parts can be achieved in die forging processes. Basically any forgeable metal can also be forge-rolled. Forge rolling

2583-403: The differential fiber elongation across the width of the workpiece. This property must be subject to an accurate feedback-based control in order to guarantee the machinability of the metal sheets in the final transformation processes. Some technological details about the feedback control of flatness are given in. Profile is made up of the measurements of crown and wedge. Crown is the thickness in

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2646-467: The disadvantage is that the rolls must be stopped, reversed, and then brought back up to rolling speed between each pass. To resolve this, the three-high mill was invented, which uses three rolls that rotate in one direction; the metal is fed through two of the rolls and then returned through the other pair. The disadvantage to this system is the workpiece must be lifted and lowered using an elevator. All of these mills are usually used for primary rolling and

2709-427: The exit thickness deviation times 10 for every meter of strip was stored in a file. This file was analyzed separately for each frequency/wavelength from 5 m to 60 m in steps of 0.1 m. To improve the accuracy, care was taken to use a full multiple of each wavelength (100*). The calculate amplitudes were plotted against the wavelength, so that the spikes could be compared to the expected wavelengths created by

2772-465: The famous "Sun King" - granted approval to the Marquis Charles Henri de Lénoncourt for the construction of an ironworks, complete with a smelting furnace, before the gates of the fortress of Saarlouis. Locational factors for the founding of this works were excellent - the nearby Prims river supplied the necessary water-power, the surrounding woods the fuel for the furnaces, and the ore deposits in

2835-441: The immediate vicinity the feed materials for production. The first products were iron forgings, nails and cast artifacts such as pots, pans and so-called "Takenplatten", decorative iron plates that carried the heat of the kitchen over into the adjacent living space by conduction and radiation. Production was gradually optimized over succeeding years, with plate beginning to predominate in the mill's product mix as from 1802, following

2898-524: The introduction of three-high mills in 1853 used for rolling heavy sections. Hot rolling is a metalworking process that occurs above the recrystallization temperature of the material. After the grains deform during processing, they recrystallize, which maintains an equiaxed microstructure and prevents the metal from work hardening . The starting material is usually large pieces of metal, like semi-finished casting products , such as ingots , slabs , blooms , and billets . If these products came from

2961-431: The late 17th century. Copper and brass were also rolled by the late 18th century. Until well into the eighteenth century, rolling mills derived their power from water wheels . The first recorded use of a steam engine directly driving a mill is attributed to John Wilkinson 's Bradley Works where, in 1786, a Boulton and Watt engine was coupled to a slitting and rolling mill. The use of steam engines considerably enhanced

3024-512: The mill to continue rolling slowly the strip in the tower, while a strip welder joins the tail of the current coil to the head of the next coil. At the exit end of the mill there is normally a flying shear (to cut the strip at or near the weld) followed by two coilers; one being unloaded while the other winds on the current coil. Looping towers are also used in other places; such as continuous annealing lines and continuous electrolytic tinning and continuous galvanising lines . In hot rolling, if

3087-409: The number of passes in rolling mills is the employment of automated systems for Roll Pass Design as that proposed by Lambiase and Langella. subsequently, Lambiase further developed an Automated System based on Artificial Intelligence and particularly an integrated system including an inferential engine based on Genetic Algorithms a knowledge database based on an Artificial Neural Network trained by

3150-524: The overall dimension. Hot-rolled mild steel seems to have a wider tolerance for the level of included carbon than does cold-rolled steel, and is, therefore, more difficult for a blacksmith to use. Hot rolling is used mainly to produce sheet metal or simple cross-sections, such as rail tracks . Rolling mills are often divided into roughing, intermediate and finishing rolling cages. During shape rolling, an initial billet (round or square) with edge of diameter typically ranging between 100 and 140 mm

3213-627: The process is known as hot rolling . If the temperature of the metal is below its recrystallization temperature, the process is known as cold rolling . In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes. Roll stands holding pairs of rolls are grouped together into rolling mills that can quickly process metal, typically steel , into products such as structural steel ( I-beams , angle stock, channel stock), bar stock , and rails . Most steel mills have rolling mill divisions that convert

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3276-510: The production capabilities of the mills, until this form of power was displaced by electric motors soon after 1900. Modern rolling practice can be attributed to the pioneering efforts of Henry Cort of Funtley Iron Mills, near Fareham in Hampshire , England. In 1783, a patent number was issued to Henry Cort for his use of grooved rolls for rolling iron bars. With this new design, mills were able to produce 15 times more output per day than with

3339-706: The recrystallization temperature. To maintain a safety factor a finishing temperature is defined above the recrystallization temperature; this is usually 50 to 100 °C (122 to 212 °F) above the recrystallization temperature. If the temperature does drop below this temperature the material must be re-heated prior to additional hot rolling. Hot-rolled metals generally have little directionality in their mechanical properties or deformation-induced residual stresses . However, in certain instances non-metallic inclusions will impart some directionality and workpieces less than 20 mm (0.79 in) thick often have some directional properties. Non-uniform cooling will induce

3402-428: The roll diameters range from 60 to 140 cm (24 to 55 in). To minimize the roll diameter a four-high or cluster mill is used. A small roll diameter is advantageous because less roll is in contact with the material, which results in a lower force and power requirement. The problem with a small roll is a reduction of stiffness, which is overcome using backup rolls . These backup rolls are larger and contact

3465-488: The rolling occurs the wall thickness decreases as the diameter increases. The rolls may be shaped to form various cross-sectional shapes. The resulting grain structure is circumferential, which gives better mechanical properties. Diameters can be as large as 8 m (26 ft) and face heights as tall as 2 m (79 in). Common applications include railway tyres, bearings , gears , rockets , turbines , airplanes , pipes , and pressure vessels . Controlled rolling

3528-413: The rolls and the uneven geometrical properties of the entry material. The transverse distribution of differential strain/elongation-induced stress with respect to the material's average applied stress is commonly referenced to as shape. Due to the strict relationship between shape and flatness, these terms can be used in an interchangeable manner. In the case of metal strips and sheets, the flatness reflects

3591-399: The rolls are heated to assist in the workability of the metal. Lubrication is often used to keep the workpiece from sticking to the rolls. To fine-tune the process, the speed of the rolls and the temperature of the rollers are adjusted. For thin sheet metal with a thickness less than 200 μm (0.0079 in), the rolling is done in a cluster mill because the small thickness requires

3654-427: The same products that are hot rolled. Because of the smaller size of the workpieces and their greater strength, as compared to hot rolled stock, four-high or cluster mills are used. Cold rolling cannot reduce the thickness of a workpiece as much as hot rolling in a single pass. Cold-rolled sheets and strips come in various conditions: full-hard , half-hard , quarter-hard , and skin-rolled . Full-hard rolling reduces

3717-476: The slab caster for the world's thickest slabs in 1998, and the world's largest plate-edge miller, in 2005. Dillinger Hütte workers have traditionally been dubbed "Hüttenbären", or "steel mill bears" in the local region. This led to the company's day-center for employees' children being christened "Kleine Hüttenbären", or the "steel mill cubs", at its opening in 2007. Karlheinz Blessing was CEO from 2011 to 2015. Rolling mill In metalworking , rolling

3780-412: The surface and thereby reduces the possibility of formation of Lüders bands. To avoid the formation of Lüders bands it is necessary to create substantial density of unpinned dislocations in ferrite matrix. It is also used to break up the spangles in galvanized steel. Skin-rolled stock is usually used in subsequent cold-working processes where good ductility is required. Other shapes can be cold-rolled if

3843-432: The temperature of the workpiece is not uniform the flow of the material will occur more in the warmer parts and less in the cooler. If the temperature difference is great enough cracking and tearing can occur. The cooler sections are, among other things, a result of the supports in the re-heat furnace. When cold rolling, virtually all of the strip thickness variation is the result of the eccentricity and out-of-roundness of

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3906-490: The thickness by 50%, while the others involve less of a reduction. Cold rolled steel is then annealed to induce ductility in the cold rolled steel which is simply known as a Cold Rolled and Close Annealed . Skin-rolling, also known as a skin-pass , involves the least amount of reduction: 0.5–1%. It is used to produce a smooth surface, a uniform thickness, and reduce the yield point phenomenon (by preventing Lüders bands from forming in later processing). It locks dislocations at

3969-486: Was adapted to producing hoops (for barrels) and iron with a half-round or other sections by means that were the subject of two patents of c. 1679. Some of the earliest literature on rolling mills can be traced back to the Swedish engineer Christopher Polhem in his Patriotista Testamente of 1761, where he mentions rolling mills for both plate and bar iron. He also explains how rolling mills can save on time and labor because

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