Click here for a list of Advertisers

September
Vol. 5, No. 9
Long Products Rolling

About the Cover

Failure Analysis of Automotive Suspension Coil Springs
Y. Prawoto, M. Ikeda and S.K. Manville, NHK International Corp., Wixom, Mich. (yunan.prawoto@gmail.com, maiko.ikeda@nhk-intl.com, sonia.manville@nhk-intl.com); and A. Nishikawa, NHK Spring Co. Ltd., Yokohama, Japan

This paper discusses automotive suspension coil springs, their fundamental stress distribution, material characteristics, manufacturing and common failures. An in-depth discussion on the parameters influencing the quality of coil springs is also presented.

Custom-Made Roll Shop Management Systems for Optimized Roll Organization
Karl-Heinz Adamek and Dirk Schmidt, Waldrich GmbH & Co. KG, Burbach, Germany (karl-heinz.adamek@waldrich-siegen.de, dirk.schmidt@waldrich-siegen.de); Chi-Ming Chiang, HCC/KPM Electronics GmbH, Siegen, Germany (c.chiang@herkules-group.com); and Mike Smith, Waldrich GmbH Inc., Ford City, Pa. (michael.smith@waldrich.de)

A professional Roll Shop Management System manages an entire roll inventory and organizes the trouble-free flow of all rolls in a rolling mill. This paper discusses the components of such a system, its advantages and its many features.

Remote Machinery Monitoring at Nucor Steel–Arkansas
Jay Henderson, maintenance manager, Nucor Steel–Arkansas, Sheet Mill Group, Amorel, Ark. (jhenderson@nucorar.com), and Don E. Rainey, director, Azima Inc., Woburn, Mass. (drainey@azimainc.com)

Nucor Steel’s hot strip mill in Hickman, Ark., wirelessly monitors more than 200 points on dozens of critical machines. This paper focuses on how the mill benefits from the new technology, as well as the steps involved in deploying the system on such a large scale.

A Study of the Relationships Between Inclusion Morphology and Reduction Ratio for Bar Products
Yanjun Huang (pictured), principal engineer — materials, Key Safety Systems Inc., Sterling Heights, Mich. (huangy@keysafetyinc.com), and J. Yang, corporate metallurgist, The Cold Heading Co., Warren, Mich. (jyang@coldheading.com)

The morphology of inclusions on samples with various hot reduction ratios has been studied. A set of parameters is used to define the morphology of the inclusion, and the relationships between the inclusion morphology and reduction ratios are discussed.

Adaptive Dimension Models for Optimization of Long Products Rolling
Anders Daneryd (left), principal scientist, and Rickard Lindkvist (center), research engineer, ABB Corporate Research, Västerås, Sweden (anders.daneryd@se.abb.com, rickard.lindkvist@se.abb.com); and Mats G. Olsson, ABB Process Automation/Metals, Västerås, Sweden (mats.g.olsson@se.abb.com)

This paper presents the ABB ADMTM tool for optimization and simulation of long products rolling. Cornerstones of the tool are state-of-the-art optimization and model learning techniques, along with unique, simplified mechanical and physical models.

Calcium: Toy, Tool or Trouble?
Wouter Tiekink, Begoña Santillana and Rob Boom, Corus Research, Development & Technology, IJmuiden, The Netherlands (wouter.tiekink@corusgroup.com, begona.santillana@corusgroup.com, rob.boom@corusgroup.com); Rob Kooter and Fokko Mensonides, Corus Strip Products, IJmuiden, The Netherlands (rob.kooter@corusgroup.com, fokko.mensonides@corusgroup.com); and Brahma Deo, Dept. of Materials and Metallurgical Engineering, Indian Institute of Technology, Kanpur, India (bdeo@iitk.ac.in)

A calcium addition to steel will transform alumina inclusions into calcium aluminates and will simultaneously react with sulfur to form calcium sulfide (CaS).1–4
Liquid calcium aluminates prevent clogging during casting without using argon injection as an anti-clogging measure. Solid CaS is known for causing clogging in resulfurized calcium-treated, aluminium-killed steels, for instance in billet casting of forging steels.5–8 A calcium treatment that failed leads to calcium aluminates with a low CaO content, e.g., CaO · 6Al2O3, which cause rapid clogging at the caster; fierce reoxidation after a calcium treatment creates similar high-alumina calcium aluminates and may cause clogging.