[Technical Field]
[0001] This invention relates to a rolling mill, which can render the diameter of work rolls
small, and a tandem rolling mill equipped with the rolling mill.
[Background Art]
[0002] In a conventional so-called intermediate roll-drive six-high rolling mill (hereinafter
referred to as a six-high mill), the minimum value of the work roll diameter is determined
by the flexural rigidity value of the work rolls, which withstands the tangential
force of the intermediate roll drive, if there are no support (supporting) rolls inside
and outside the rollable strip width of the work rolls. According to Non-Patent Document
1, for example, this value is 180 mm to 380 mm in the case of a 4-feet width material
upon the intermediate roll drive.
[0003] With work roll drive, the above-mentioned tangential force does not act, but differential
tension, or a tension difference, between the inlet side and the outlet side of the
rolling mill works. Within the range of the permissible strength of the drive system,
therefore, the minimum value of the work roll diameter is determined by the flexural
rigidity value of the work rolls, which withstands the differential tension, and at
least the work roll diameter comparable to that mentioned above is feasible. With
the work roll drive, moreover, at least the work roll diameter comparable to the above
one can be achieved from this point of view, even in a four-high rolling mill (hereinafter
referred to as a four-high mill).
[0004] A conventional six-high mill may have support rolls inside the rollable strip width
of the work rolls. Further, a six-high mill, which has support bearings provided outside
the rollable strip width of the work rolls, and applies horizontal bending to the
work rolls via these support bearings, is disclosed in Patent Document 1.
[Citation List]
[Patent Literature]
[summary of Invention]
[Technical Problem]
[0007] To meet a recent demand, an attempt has been made to roll a special steel, such as
a harder stainless steel, by a six-high mill or four-high mill having no support rolls
inside the rollable strip width of the work rolls. This attempt has posed a problem
such that the aforementioned work roll diameter is too large and imposes a heavy load,
thus failing to ensure a necessary reduction in thickness by rolling, and a problem
such as poor gloss.
[0008] On the other hand, a six-high mill or four-high mill having support rolls inside
the rollable strip width of the work rolls has involved the following problems: A
space for the support roll portion is so small that sufficient strength and rigidity
are difficult to ensure. Since there are support bearings for supporting the support
rolls inside the rollable strip width of the work roll, moreover, marks of the support
bearings are transferred to or produced in the plate via the support rolls and the
work rolls, depending on their material.
[0009] A rolling mill having support bearings provided outside the rollable strip width
of the work rolls has the following problems: Since the upper and lower support bearings
are of the same phase, the bearings of a large size cannot be used, and the bearings
applied cannot be adopted for heavy load, high torque rolling of a hard material which
causes a great horizontal force.
[0010] The present invention has been proposed in the light of these circumstances. It is
an object of the present invention to provide a rolling mill, which can render work
rolls of a smaller diameter usable for the purpose of rolling a hard material, and
can thereby obtain a strip with high productivity and of high product quality, and
a tandem rolling mill equipped with the rolling mill.
[Solution to Problem]
[0011] To solve the above-mentioned problems, the present invention provides a six-high
rolling mill including upper and lower work rolls as a pair for rolling a metal strip,
upper and lower intermediate rolls as a pair for supporting the work rolls, and upper
and lower back-up rolls as a pair for supporting the upper and lower intermediate
rolls as the pair, the six-high rolling mill having no supporting rolls inside and
outside a rollable strip width of the work rolls,
characterized in that
the work rolls are driven,
a material having a high modulus of longitudinal elasticity is used for the work roll,
and
a minimum roll diameter of the work roll is intermediate between a minimum diameter
upper limit Dmax1 and a minimum diameter lower limit Dmin1, and these parameters are
expressed by the following equations:

where D4max is a minimum diameter upper limit of a conventional work roll with a strip
width of 1,300 mm: 380 mm
B is a strip width (mm)/1,300 mm, and
K is a ratio of the high longitudinal modulus material to a conventional material
(modulus of longitudinal elasticity of the high longitudinal modulus material/modulus
of longitudinal elasticity of the conventional material (21,000 kg/mm
2))

where D4min is a minimum diameter lower limit of the conventional work roll with the
strip width of 1,300 mm: 180 mm.
[0012] To solve the above-mentioned problems, the present invention also provides a four-high
rolling mill including upper and lower work rolls as a pair for rolling a metal strip,
and upper and lower back-up rolls as a pair for supporting the work rolls, the four-high
rolling mill having no supporting rolls inside and outside a rollable strip width
of the work rolls,
characterized in that
the work rolls are driven,
a material having a high modulus of longitudinal elasticity is used for the work roll,
and
a minimum roll diameter of the work roll is intermediate between a minimum diameter
upper limit Dmax1 and a minimum diameter lower limit Dmin1, and these parameters are
expressed by the following equations:

where D4max is a minimum diameter upper limit of a conventional work roll with a strip
width of 1,300 mm: 380 mm
B is a strip width (mm)/1,300 mm, and
K is a ratio of the high longitudinal modulus material to a conventional material
(modulus of longitudinal elasticity of the high longitudinal modulus material/modulus
of longitudinal elasticity of the conventional material (21,000 kg/mm
2))

where D4min is a minimum diameter lower limit of the conventional work roll with the
strip width of 1,300 mm: 180 mm.
[0013] The six- or four-high rolling mill is
characterized in that the ratio of the high longitudinal modulus material to the conventional material
(longitudinal modulus ratio), K, is 1.2 to 3.0. If the work roll is a composite material
roll, an equivalent modulus of longitudinal elasticity is preferably used as the modulus
of longitudinal elasticity.
[0014] To solve the above-mentioned problems, the present invention further provides a tandem
rolling mill including a plurality of rolling mill stands arranged therein,
characterized in that the six-high rolling mill or the four-high rolling mill is provided as at least one
of the stands.
[Advantageous Effects of Invention]
[0015] According to the features of the present invention, the high longitudinal modulus
material is used for the work roll. By so doing, the flexural rigidity of the work
roll is ensured, and the diameter of the work roll can be rendered small by an amount
corresponding to the high rigidity. Consequently, edge drops can be reduced, surface
gloss can be improved, and the minimum rollable strip thickness can be decreased.
Furthermore, the rolling mill and the tandem rolling mill can be applied to a heavy
load, high torque rolling mill for a hard material. They are preferred particularly
for cold rolling.
[Brief Description of Drawings]
[0016]
[Fig. 1] Fig. 1 is a front sectional view of a six-high mill showing Embodiment 1
of the present invention.
[Fig. 2] Fig. 2 is a sectional view taken along line II-II in Fig. 1.
[Fig. 3] Fig. 3 is an explanation drawing of a composite roll.
[Fig. 4] Fig. 4 is an explanation drawing of inlet side-outlet side differential tension.
[Fig. 5] Fig. 5 is an explanation drawing of the deflection of a work roll.
[Fig. 6] Fig. 6 is a graph showing a comparison between the work roll minimum diameter
upper limits Dmax' s in Embodiment 1 and a conventional example.
[Fig. 7] Fig. 7 is a graph showing a comparison between the work roll minimum diameter
lower limits Dmin's in them.
[Fig. 8A] Fig. 8A is an explanation drawing of a work roll offset showing an applied
example of Embodiment 1.
[Fig. 8B] Fig. 8B is an explanation drawing of load imposed on the work roll in the
applied example.
[Fig. 9A] Fig. 9A is an explanation drawing of an intermediate roll offset showing
another applied example of Embodiment 1.
[Fig. 9B] Fig. 9B is an explanation drawing of load imposed on the work roll in the
another applied example.
[Fig. 10] Fig. 10 is an explanation drawing of a work roll shift of a six-high mill
showing still another applied example of Embodiment 1.
[Fig. 11] Fig. 11 is a front sectional view of a four-high mill showing Embodiment
2 of the present invention.
[Fig. 12] Fig. 12 is a sectional view taken along line XII-XII in Fig. 11.
[Fig. 13] Fig. 13 is an explanation drawing of a work roll shift of a four-high mill
showing an applied example of Embodiment 2.
[Fig. 14] Fig. 14 is an explanation drawing of the application of the present invention
to a tandem rolling mill.
[Description of Embodiments]
[0017] A rolling mill and a tandem rolling mill equipped therewith, according to the present
invention, will be described in detail by the following embodiments using drawings.
[Embodiment 1]
[0018] Fig. 1 is a front sectional view of a six-high mill showing Embodiment 1 of the present
invention. Fig. 2 is a sectional view taken along line II-II in Fig. 1. Fig. 3 is
an explanation drawing of a composite roll. Fig. 4 is an explanation drawing of inlet
side-outlet side differential tension. Fig. 5 is an explanation drawing of the deflection
of a work roll. Fig. 6 is a graph showing a comparison between the work roll minimum
diameter upper limits Dmax' s in Embodiment 1 and a conventional example. Fig. 7 is
a graph showing a comparison between the work roll minimum diameter lower limits Dmin'
s in them. Fig. 8A is an explanation drawing of a work roll offset showing an applied
example of Embodiment 1. Fig. 8B is an explanation drawing of load imposed on the
work roll in the applied example. Fig. 9A is an explanation drawing of an intermediate
roll offset showing another applied example of Embodiment 1. Fig. 9B is an explanation
drawing of load imposed on the work roll in the another applied example. Fig. 10 is
an explanation drawing of a work roll shift of a six-high mill showing still another
applied example of Embodiment 1.
[0019] As shown in Figs. 1 and 2, a strip 1, which is a material to be rolled, is rolled
by upper and lower work rolls 2 as a pair. These paired upper and lower work rolls
2 are in contact with, and supported by, upper and lower intermediate rolls 3 as a
pair. These paired upper and lower intermediate rolls 3 are in contact with, and supported
by, upper and lower back-up rolls 4 as a pair.
[0020] The upper back-up roll 4 is supported by bearing housings 17a, 17c via bearings (not
shown), and these bearing housings 17a, 17c are supported by housings 7 (7a, 7b) via
pass line adjusting devices 5a, 5b such as worm jacks or taper wedges and stepped
rocker plates. Here, load cells may be incorporated inside the pass line adjusting
devices 5a, 5b to measure a rolling load.
[0021] The lower back-up roll 4 is supported by bearing housings 17b, 17d via bearings (not
shown), and these bearing housings 17b, 17d are supported by the housings 7a, 7b via
hydraulic cylinders 6 (6a, 6b).
[0022] A material having a high modulus of longitudinal elasticity is used for the paired
upper and lower work rolls 2. An example of the material having the high modulus of
longitudinal elasticity is a cemented carbide such as tungsten carbide (modulus of
longitudinal elasticity: 53,000 kg/mm
2), or a ceramic (modulus of longitudinal elasticity: 31,000 kg/mm
2). Special forged steel (modulus of longitudinal elasticity: 21,000 kg/mm
2) or the like has been used as a conventional material.
[0023] It is preferred that the ratio of the high longitudinal modulus material to the conventional
material (longitudinal modulus ratio), K, be set at 1.2 to 3.0.
[0024] As shown in Fig. 3, moreover, a roll composite material using a high longitudinal
modulus material as a roll surface layer material 2A and a conventional material as
a roll internal layer material 2B may be used for the paired upper and lower work
rolls 2. The modulus of longitudinal elasticity used in this case is an equivalent
modulus of longitudinal elasticity shown below.
[0025] The equivalent modulus of longitudinal elasticity, Ee, is expressed by the following
equation (1)

where d2 is the outer diameter of the roll surface layer material 2A, E2 is the modulus
of longitudinal elasticity of the roll surface layer material 2A, d1 is the outer
diameter of the roll internal layer material 2B, and E1 is the modulus of longitudinal
elasticity of the roll internal layer material 2B.
[0026] Further, bearing housings 13a to 13d are mounted on roll neck portions of the paired
upper and lower work rolls 2 via bearings (not shown). These bearing housings 13a
to 13d are furnished with bending cylinders 14a to 14d for imparting roll bending.
By so doing, roll bending is imparted to the work rolls 2.
[0027] Here, rolling load is imparted by the hydraulic cylinders 6a, 6b, and rolling torque
is transmitted to the work rolls 2 by spindles (not shown). The paired upper and lower
intermediate rolls 3 have roll shoulders 3a, whose roll diameter decreases, at the
positions of the roll barrel ends in vertical point symmetry with respect to the center
of the strip width of the strip 1.
[0028] The paired upper and lower intermediate rolls 3 are supported by bearing housings
15a to 15d via bearings (not shown). The paired upper and lower intermediate rolls
3 are axially movable by shifting devices (not shown) via the drive-side bearing housings
15c, 15d. Further, these bearing housings 15a to 15d are furnished with bending cylinders
16a to 16d for imparting roll bending. By so doing, roll bending is imparted to the
intermediate rolls 3.
[0029] Deflection of the work roll by the rolling mill inlet side-outlet side differential
tension will be described using Fig. 4 and Fig. 5.
[0030] As shown in Fig. 4, if the inlet-side tension of the rolling mill is designated as
Tb, and the outlet-side tension of the rolling mill is designated as Tf, differential
tension which is the difference between Tb and Tf is exerted on the work rolls 2.
Since the number of the bearings for the work roll is one each on the operating side
and on the drive side, the supporting conditions for simple support shown in Fig.
5 apply. Horizontal deflection δ s of the work roll in this case is expressed by the
following equation (2), where F represents the differential tension per unit length,
L represents the support spacing, Dc represents the diameter of the conventional work
roll 2, Ic represents the second moment of area of the conventional work roll diameter,
and Ec represents the modulus of longitudinal elasticity (21,000 kg/mm
2) of the material (special forged steel) for the conventional work roll:

where

[0031] A material with a high modulus of longitudinal elasticity is used for the paired
upper and lower work rolls 2. Deflection δ r in the horizontal direction of the work
roll 2 in this case is expressed by the following equation (3), where Dr represents
the diameter of the work roll 2 of Embodiment 1, Ir represents the second moment of
area of the diameter of the work roll of Embodiment 1, and Er represents the modulus
of longitudinal elasticity of the material for the work roll of Embodiment 1.

where Ir = π×Dr
4/64
Assuming that δr = δs, Dr is expressed by the following equation (4):

[0032] On the other hand, the minimum roll diameter of the work roll is intermediate between
the minimum diameter upper limit Dmax1 and the minimum diameter lower limit Dmin1,
and these parameters are expressed by the following equation (5):

where D4max; minimum diameter upper limit of conventional work roll with strip width
of 1,300 mm: 380 mm
B; strip width (mm)/1,300 mm
K; high longitudinal modulus material/conventional material ratio (modulus of longitudinal
elasticity of high longitudinal modulus material/modulus of longitudinal elasticity
of conventional material (21,000 kg/mm
2))
The minimum diameter upper limit Dmax1 per strip width in Embodiment 1 is shown in
Fig. 6. K=2.5, provided that the material for the work roll was a cemented carbide.

where D4min; minimum diameter lower limit of conventional work roll with strip width
of 1,300 mm: 180 mm
The minimum diameter lower limit Dmin1 per strip width in the present embodiment is
shown in Fig. 7. K=2.5, provided that the material for the work roll was the cemented
carbide.
[0033] In the present embodiment, as describe above, the work roll 2 composed of a cemented
carbide or a ceramic material as a high longitudinal modulus material is used in the
six-high mill having no supporting rolls inside and outside the rollable strip width
of the work rolls 2. Thus, the flexural rigidity of the work roll is ensured, and
the diameter of the work roll can be rendered small by an amount corresponding to
the high rigidity. Consequently, the strip 1 of high product quality can be obtained
with high productivity by the rolling of a hard material.
[0034] As shown in Figs. 8A and 8B, the work rolls 2 of the high longitudinal modulus material
may be offset variably, according to the magnitude of the inlet side-outlet side differential
tension (Tf-Tb)/2, toward the inlet side in the rolling direction in the horizontal
direction (see an offset amount α in Fig. 8A). By so doing, the inlet side-outlet
side differential tension (Tf-Tb)/2 is decreased by the offset horizontal component
force Fa of the rolling load Q, so that the total force in the horizontal direction
exerted on the work roll 2 is decreased. In Fig. 8B, Fb represents the offset vertical
component force of the rolling load Q.
[0035] As a result, the advantage that the deflection of the work roll 2 can be further
diminished is produced.
The total force Fw in the horizontal direction exerted on the work roll 2 is expressed
by the following equation (7):

where Dw represents the diameter of the work roll, and DI represents the diameter
of the intermediate roll.
[0036] As shown in Figs. 9A and 9B, the intermediate rolls 3 may be offset variably, according
to the magnitude of the inlet side-outlet side differential tension (Tf-Tb)/2, toward
the outlet side in the rolling direction in the horizontal direction (see an offset
amount β in Fig. 9A). By so doing, the inlet side-outlet side differential tension
(Tf-Tb)/2 is decreased by the offset horizontal component force Fa of the rolling
load Q, so that the total force in the horizontal direction exerted on the work roll
2 of the high longitudinal modulus material is decreased. In Fig. 9B, Fb represents
the offset vertical component force of the rolling load Q.
[0037] As a result, the advantage is produced that the deflection of the work roll 2 can
be further diminished.
The total force Fw in the horizontal direction exerted on the work roll 2 is expressed
by the following equation (8):

where Dw represents the diameter of the work roll, and DI represents the diameter
of the intermediate roll.
[0038] In the present embodiment, the paired upper and lower work rolls 2 are not structured
to be shifted in the axial direction. As will be described below, however, the work
roll 2 may have a structure in which it can be shifted in the axial direction. The
shift structure for the work roll is, for example, a structure as shown in Patent
Document 2.
[0039] As shown in Fig. 10, the upper and lower work rolls 2 as a pair have roll shoulders
2a, which taper, at the positions of the roll barrel ends in vertical point symmetry
with respect to the center of the strip width of the strip 1. Roll neck portions of
the paired upper and lower work rolls 2 are mounted with bearings (not shown) on the
operating side and on the drive side. The paired upper and lower work rolls 2 are
movable in the axial direction by shift cylinders (not shown) via the drive-side bearings
(not shown).
[0040] Next, an explanation will be offered for a method of decreasing edge drops by the
shift of the work roll 2 having the tapered roll shoulder 2a. The work rolls 2 are
provided with the tapered roll shoulders 2a in vertical point symmetry, and the distances
from the positions of the roll shoulders to the plate ends are designated as δw and
δd. A strip thickness gauge (not shown) is provided for measuring the strip thickness
at one point or a plurality of points in the vicinity of strip edge portions on the
operating side and the drive side on the outlet side of the rolling mill.
[0041] If the strip thickness at the one point or the plurality of points in the vicinity
of the strip edge portion, which has been measured on the operating side, is smaller
than a predetermined strip thickness, the upper work roll 2 is shifted in the direction
of the roll shaft width narrowing. That is, the upper work roll 2 is shifted in a
direction in which δ w is increased. Conversely, if the measured strip thickness at
the site in the vicinity of the strip edge portion is larger than the predetermined
strip thickness, the upper work roll 2 is shifted in the direction of the roll shaft
width broadening. That is, the upper work roll 2 is shifted in a direction in which
δw is decreased.
[0042] If the strip thickness at the one point or the plurality of points in the vicinity
of the strip edge portion, which has been measured on the drive side, is different
from the predetermined strip thickness, the lower work roll 2 is similarly shifted
so that the above strip thickness equals the predetermined strip thickness. Essentially,
the work roll diameter can be rendered small by applying the work roll 2 of the high
longitudinal modulus material. Thus, the rolling load can be decreased in conformity
with the small diameter. This makes it possible to curtail a sharp decrease in thickness
at the strip edge portion, which is called an edge drop becoming the cause of a decreased
yield.
[0043] The combined use of the small-diameter work roll and the work roll shift mentioned
above can minimize the tapered roll shoulder 2a or minimize the shift distance δw
or δd. This technology is preferred, in particular, for rolling of a brittle material,
such as an electromagnetic steel sheet, which is susceptible to these values and is
apt to splinter. Fig. 10 describes the mill of Fig. 1 as a representative, but the
mill with the variably offset work rolls in Figs. 8A, 8B or the mill with the variably
offset intermediate rolls in Figs. 9A, 9B may be used.
[0044] The present embodiment shows an example in which the paired upper and lower intermediate
rolls 3 have the roll shoulders 3a, which decrease in roll diameter, at the positions
of the roll barrel ends in vertical point symmetry with respect to the center of the
strip width of the strip 1. However, the paired upper and lower intermediate rolls
3 may be structured to have S-curved roll crowns in vertical point symmetry with respect
to the center of the strip width of the strip 1, and to be shifted in the axial direction,
as shown in Non-Patent Document 1. In this case, the ability to control shape is lower
than in the six-high mill having the roll shoulder 3a, but is higher than in the four-high
mill. Moreover, the aforementioned work roll shift shown in Fig. 10 may be applied
to this mill.
[Embodiment 2]
[0045] Fig. 11 is a front sectional view of a four-high mill showing Embodiment 2 of the
present invention. Fig. 12 is a sectional view taken along line XII-XII in Fig. 11.
Fig. 13 is an explanation drawing of a work roll shift of a four-high mill showing
an applied example of Embodiment 2.
[0046] The rolling mill of the present embodiment is a four-high rolling mill, and is configured
to remove the set of the paired upper and lower intermediate rolls 3, the bearing
housings 15a to 15d, and the bending cylinders 16a to 16d from the six-high rolling
mill which represents Embodiment 1, as shown in Figs. 11 and 12. In this case, the
plate shape control ability declines greatly, but the structure is further simplified.
[0047] In the present embodiment, the paired upper and lower work rolls 2 do not show a
structure for shift in the axial direction. As shown in Fig. 13, however, the work
rolls 2 may be structured to have roll shoulders 2a, which taper, at the positions
of the roll barrel ends in vertical point symmetry with respect to the center of the
strip width of the strip 1, and to be shiftable in the axial direction. According
to this configuration, edge drops can be decreased using a simpler structure.
[0048] The above-mentioned applied example is an example of a structure in which the paired
upper and lower work rolls 2 have the tapered roll shoulders 2a at the positions of
the roll barrel ends in vertical point symmetry with respect to the center of the
strip width of the strip 1, and are shiftable in the axial direction. However, the
paired upper and lower work rolls 2 may be structured to have S-curved roll crowns
in vertical point symmetry with respect to the center of the strip width of the strip
1, and to be shifted in the axial direction, as shown in Non-Patent Document 1. In
this case, the ability to control shape is higher than in the four-high mill shown
in Fig. 13.
[0049] If the rolling mill with the small-diameter work rolls according to the present invention
is applied to a tandem rolling mill, its application to No. 1 stand, as shown in Fig.
14, enables the small-diameter work rolls of the high longitudinal modulus material
to impart a great reduction in thickness. When it is applied to the final stand, i.e.,
No. 4 stand in the drawing, a thinner strip can be rolled by the small-diameter work
rolls of the high longitudinal modulus material. It goes without saying that the rolling
mills with the small-diameter work rolls according to the present invention may be
applied to all of No. 1 stand to No. 4 stand. This makes it possible to roll a thinner,
harder material. Fig. 14 illustrates the six-high mill as a representative of the
rolling mill with the small-diameter work rolls according to the present invention,
but a four-high mill can be applied similarly.
[Reference Signs List]
[0050]
- 1
- Strip
- 2
- Work roll
- 3
- Intermediate roll
- 4
- Back-up roll
- 5a, 5b
- Pass line adjusting device
- 6a, 6b
- Hydraulic cylinder
- 7a, 7b
- Housing
- 13a to 13d
- Work roll bearing housing
- 15a to 15d
- Intermediate roll bearing housing
- 17a to 17d
- Back-up roll bearing housing
- 14a to 14d
- Work roll bending cylinder
- 16a to 16d
- Intermediate roll bending cylinder