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Hot mill operations are constantly called upon to reduce energy consumption, improve product quality, increase yield, and raise productivity. Online roll grinders--grinding machines built into rolling mills to maintain roll profile during rolling--offer one means of meeting these demands. Based on extensive research into grinding wheels suitable for online grinding, Hitachi has developed an online roll grinder--the Roll Shaping Machine--that can be installed in the limited space available within either new or existing rolling mills.
Currently in use at four hot strip mills in Japan, the Roll Shaping Machine has demonstrated its full capabilities for efficient, stable grinding and for highly accurate roll profile measurement. Confirmed user benefits include improvements in strip edge shape and surface quality, online correction of wear profile, and a reduction in the frequency of work-roll changes.
Furthermore, we also demonstrate that, because the service life of the grinding wheel is longer than the periodical change of the backup roll, usually two weeks, the replacement of the grinding wheel can be carried out at the same time as the replacement of the backup roll resulting in no adverse effect on productivity.
These results may suggest that success of an online Roll Shaping Machine will accelerate the implementation of a mini-hot-strip mill.