Reversing Mill Lubrication Decoupling Cooling
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Solution Overview
Problem
In reversing rolling mills, the lubricant amount in the roll gap is primarily determined by cooling requirements rather than lubrication needs, leading to suboptimal lubrication effects and increased oil consumption, with limited control over friction conditions.
Innovation Solution
The lubricant is applied to the rolling stock in a previous coiling step, allowing it to be evenly distributed and squeezed out by subsequent layers, decoupling lubrication from cooling and enabling precise adjustment based on rolling process parameters, with separate coolant supply for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If emulsion is applied to the inlet side or work rolls for roll gap lubrication, then lubrication is provided, but the amount of oil in the roll gap is predetermined by cooling requirements rather than lubrication needs, leading to increased oil consumption
Solution Approach 1:
The lubricant is applied to the rolling stock in a previous work step during coiling, before the rolling process begins. This preliminary application allows the lubricant to be evenly distributed and squeezed out by subsequent layers, ensuring adequate lubrication in the roll gap without being constrained by cooling requirements.
Solution Approach 2:
The lubrication function is separated from the cooling function. Lubrication is achieved through preliminary application during coiling, while cooling is provided separately through coolant application during rolling. This segmentation allows each function to be optimized independently.
2Loss of energy
If emulsion is used for both cooling and lubrication, then both functions are provided, but the oil concentration is well below 100%, reducing the lubricating effect and requiring significantly higher rolling oil consumption
Solution Approach 1:
The lubrication and cooling functions are completely separated. Lubrication is achieved through pure lubricant application during coiling, while cooling is provided separately through coolant application during rolling. This eliminates the compromise of using diluted emulsion and allows optimal lubrication with minimal oil consumption.
Solution Approach 2:
The coiling process acts as an intermediary that enables uniform lubricant distribution. By applying lubricant during coiling and allowing it to be squeezed out by subsequent layers, the system achieves even lubrication without requiring high concentrations of oil in the cooling medium.
3Manufacturing precision
If the entire amount of emulsion per stand is applied to the work rolls on the inlet side, then lubrication is provided, but the amount of oil made available in the roll gap is insufficient due to cooling requirements
Solution Approach 1:
The lubricant is applied in advance during coiling, allowing sufficient time for even distribution throughout the rolling stock. This preliminary action ensures that the roll gap receives adequate lubrication without requiring large amounts of lubricant to be applied at the inlet side.
Solution Approach 2:
The rolling stock itself serves as the medium for lubricant distribution. By applying lubricant during coiling, the rolling stock absorbs and carries the lubricant through subsequent layers, automatically distributing it evenly without requiring additional application mechanisms at the inlet side.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces rolling oil consumption, enhances surface quality by minimizing chatter marks, and allows for better lubrication adjustment, while reducing energy usage and investment costs by decoupling lubrication and cooling media.
Implementation Method 1
the lubricant is squeezed and evened out by the layers lying one on top of the other
Implementation Method 2
the cooling medium, e.g. water, can be supplied at a lower temperature compared to emulsion lubrication, so that heat dissipation is better
Data Source
Figure 1
Figure 2~3
AI summary
Operating method for a reversing rolling mill, comprising at least one reversing rolling stand (2) for rolling a rolled material (5), wherein the rolled material (5) passes the at least one reversing rolling stand (2) in a sequence of passes with an alternating passing-through direction (7) and after each pass is wound up by means of a reversing reel (3, 4) acting as a winding-up reel (31, 41), wherein exclusively rolling oil, without water as a carrier medium, is applied to the rolled material (5) by means of a rolling-oil application device (6), which is arranged between the at least one reversing rolling stand (2) and the winding-up reel (31, 41).