Rolling Stand Lubrication and Cooling for Low-Consumption Skin Pass
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Solution Overview
Problem
Existing rolling devices for rolling stock in rolling mills face inefficiencies in lubricant and coolant consumption, and operational costs, particularly in the first operating mode where significant thickness reduction requires high lubrication and cooling, leading to material brittleness and increased costs.
Innovation Solution
A rolling device equipped with a lubricant mixture application device using a carrier gas and lubricant, a coolant application device for cooling water, and a skin-passing agent application device, which reduces lubricant and coolant usage, and incorporates a cleaning fluid application for roll stand maintenance, with features like atomization devices and spray nozzles for targeted application and a coolant circuit for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricating emulsion with high lubricant content (5% to 30%) is applied to the rolling stock before passing through the first roll stand, then sufficient lubrication is achieved for significant thickness reduction, but lubricant consumption and costs increase
Solution Approach 1:
The invention changes the concentration parameter of lubricant in the emulsion from high (5-30%) to low (0.1-5%), and changes the physical state parameter by using a foam instead of a liquid emulsion. This allows sufficient lubrication to be achieved with much lower lubricant consumption while maintaining the lubrication effectiveness required for significant thickness reduction in the first roll stand
Solution Approach 2:
The invention introduces a foam application system that uses gas (air) to create and deliver the lubricating foam to the rolling stock. The foam generation device mixes lubricant with air to create a foam structure that provides lubrication through the gas-liquid matrix, reducing the amount of liquid lubricant needed while maintaining lubrication effectiveness
2Temperature
If a cooling emulsion is applied to the work rolls and/or rolling stock after passing through the first roll stand, then cooling is achieved, but coolant consumption and the need for emulsion production and recycling increase
Solution Approach 1:
The invention changes the coolant formulation from a water-rolling oil emulsion to a water-based cooling liquid with minimal or no rolling oil content. This parameter change in composition allows effective cooling to be achieved while dramatically reducing coolant consumption and eliminating the need for complex emulsion production and recycling systems
Solution Approach 2:
The invention extracts and removes the rolling oil component from the cooling emulsion, retaining only the essential water-based cooling function. This separation allows the cooling system to operate with minimal lubricant content, reducing consumption and simplifying the coolant management system
3Manufacturing precision
If the rolling stock is significantly reduced in thickness in the first rolling stand, then the desired thickness is achieved, but the rolling stock becomes relatively brittle and fragile requiring heat treatment
Solution Approach 1:
The invention applies preliminary action by using a foam application system that delivers lubrication before and during the rolling process, preventing excessive brittleness from developing during significant thickness reduction. The foam provides continuous lubrication that reduces friction and heat generation, allowing greater thickness reduction without making the material too brittle, thereby reducing or eliminating the need for subsequent heat treatment
Solution Approach 2:
The invention replaces the traditional mechanical rolling process that causes severe work hardening and brittleness with a lubrication-enhanced process using foam application. The foam lubrication system substitutes for the purely mechanical contact by introducing a lubricating medium that reduces friction and heat, allowing significant thickness reduction while maintaining material toughness
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 configuration reduces lubricant and coolant consumption, enhances operational efficiency, and maintains material toughness by minimizing the need for emulsion production and recycling, while allowing for effective skin-passing and cooling across various operating modes.
Implementation Method 1
a lubricating mixture application device with a lubricating mixture of a carrier gas and a lubricant for applying the lubricating mixture to a side of at least one work roll of the first roll stand that faces away from the second roll stand and/or to at least one rolling stock surface of the rolled stock on a side of the first roll stand that faces away from the second roll stand
Implementation Method 2
a coolant application device for applying coolant to a side of at least one work roll of the first roll stand that faces the second roll stand and/or to at least one rolling stock surface of the rolled stock on a side of the first roll stand that faces the second roll stand
Implementation Method 3
A mixture of lubricant and a carrier gas is generated in an atomization device and applied to at least one work roll and/or the rolling stock by means of an arrangement of spray nozzles
Implementation Method 4
applied to at least one work roll and/or the rolling stock by means of an arrangement of spray nozzles
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a rolling apparatus (1) for rolling a rolled material (3), and to a method for operating the rolling apparatus (1). The rolling apparatus (1) has two rolling stands (5), which each have two working rolls (11) distanced from one another by a nip (15), through which the rolled material (3) can be guided. In a first operating mode, a lubricant mixture, formed of a carrier gas and a lubricant, and coolant are applied to at least one working roll (11) of a first rolling stand (5) and/or to at least one rolled material surface (25, 27) of the rolled material (3). In a second operating mode, a skin pass agent is applied to at least one working roll (11) of the first rolling stand (5), at least one working roll (11) of the second rolling stand (7) and/or at least one rolled material surface (25, 27) of the rolled material (3).