The Business of Rolling

• Economics of rolling
• Business cycles
• Future trends

Lubrication

• Friction and lubrication basic principles
• Interaction of rough surfaces
• Role of additives
• Hot and cold rolling oils
• System maintenance
• Filtration

Outline of the Sheet Rolling Process

Outline of the process routes and metal conditions at various stages from cast ingot to coil

Surface Quality

• Surface generation during rolling
• Oil entrapment
• Strip brightness control
• Scuffing
• Types of defect
• Reduction marks
• Surface inspection

Metallurgy

• Alloy choice
• Microstructure
• Strengthening mechanisms
• Annealing

Control Theory

• Open and closed loop control systems
• PID control and gain determination
• Ziegler-Nichols testing
• Use of feedback

Mechanics of Rolling

• Yield criteria
• Friction hill
• Factors determining rolling load
• Closed and open gap rolling

Profile Mechanics and Control

• Definition
• Effect on downstream process
• Changing profile in hot and cold rolling
• Importance of rolling sequence
• Strategies to control profile

The Machinery of Rolling

• Types of roll stacks
• Major components of reversing and hot tandem mills
• Cold mills
• Special actuators: VC, CVC, DSR, 6hi

Gauge Control

• Total gauge description
• Gauge control loops
• Measurement devices
• Different methods of gauge control in current use

Thermal Aspects of Rolling

• Heat sources and sinks
• Temperature distributions in rolls and strip
• Design of roll spray cooling systems
• Strip cooling

Flatness Mechanics and Control

• Definition
• I-units
• Different types of off-flatness
• Relation with stress
• On-line measurement
• Flatness control actuators
• Strategies to control flatness

Mechanics of Profile & Flatness

• Definitions of profile and flatness
• Sources of variation
• In-process specification and targets for control

Mill Vibration

• Main types of mill vibration
• Torsional, 3rd and 5th octave chatter
• Resonance modes of mills
• Self excitation
• Examples of solutions to vibration problems

Rolling Process Models

• Models of ingot preheating: temperature and energy aspects
• Roll gap models: Orowan homogeneous and inhomogeneous models
• Closed gap rolling: non-circular arc
• Modelling temperature distributions in coils during annealing

Condition Monitoring

• Maintenance strategies: reactive, preventive and predictive
• Reliability-centred maintenance
• Vibration detection
• Thermography and wear analysis