ABOUT 4 Hi MILL

Complete Name: 4 Hi cold rolling reversible CVC mill

4-Hi: it is the Latin word which means four horizontal rolls.
Reversible: The rolls of mill can rotate in both forward and reverse direction
CVC: CVC stands for continuous varying curve. It is named due to the profile of the rolls
Purpose: When the sheet is pickled then it is shifted to 4 Hi where it is process to increase its strength
and hardness by cold rolling.

SPECIFICATION OF 4 Hi Mill.
Total Length of Line

14m

Direction of line
Line Speed
Minimum reduce thickness

Right to Left
Max:120 mpm Min:40 mpm
0.25mm.

Line speed is variable and depends upon sheet dimension as well.

PRODUCTIVITY OF 4-Hi Mill

Yearly

Monthly

Weekly

Daily

25,00000 tons

23,000 tons

It is noted that weekly and daily production depends upon the thickness of sheets that are operational.
Greater thickness sheets have shorter length and may takes less time to rolled as compared to longer
thickness sheets,

Equipments List:

Mandrills

Hold down rolls

Pinch rolls

Peeler table

X-ray gauge

Strip press

Work rolls

Backup rolls

Shear cutter

PROCESS OF 4 Hi MILL

Storage Area:
From Pickling Department, coils that are perfect for further processing are shifted to the storage area of 4Hi where they are weighted and wrapped of for cold rolling.

ENTRY SIDE:
Uncoiler:
Pit Coil car raise the coil and assist the mandreal to grab the coil from its inside diameter.
Uncoiler mandreal is operated by Hurdraullic system drum.

Hold Down Roll:

It is cantilever mounted roll with the frame of uncoiler assembly. Its purpose is to help in feeding
the initial length of strip. It is operated by pneumatic cylinders. It is in open position during
feeding of sheet in line and it is at down position when sheet is starting to feed in line.
Slide Guide
It is used to adjust the central position of sheet. Side guide helps the sheet to move forward in the
same straight line

PROCESS SECTION :
The 4 Hi Cold Roll Mill is composed of two working rolls and two backup rolls for exerting
compressive stresses on the strip. The emulsion is sprayed on the incoming sheet of the
rolls while the outgoing of the cold roll is exposed to air in order to dry it.

Work rolls:
Work rolls are of diameter around400mm. The running life of work rolls is 300km-400km.,.
Work rolls are driven by motor. They can rotate in forward and reverse direction as per pass
Back up rolls
The life of backup rolls is 3000km. The diameter of backup roll is 1100mm.Back up rolls are idle
and not driven by any motor. X rays measure the thickness and send feedback to closed loop
system where compressive load is applied by hydraulic cylinder. The work rolls & the backup
rolls are changed when they complete their life and replaced, and the used ones are sent to the
roll grinding area where, rolls are grinded, and bring back into process.
Roll bite & pass line

The point of compressive stress on the sheet is called roll bite. The line under the cold rolling
process is called pass line
Wedge
Wedge is present at the bottom of mill. It is operated by hydraulic system. Its purpose is to adjust
it to maintain the pass line.
Thickness reduction & passes
The tensile force during the cold rolling is provided by the mandrels. The maximum tensile force
that can be achieved is 9200 kgf. The tension is given length wise so that when thickness is
reduced during rolling, the increment should come along the length & width of the sheet remains
constant. The pay off reel uncoils the pickled coils and supplies it to the reverse reel 2 with the
work rolls disengaged. When the reverse reel 2 coil it and the reverse reel 1 is mounted with the
other side of the coil then the first pass of the cold rolling process starts until the coil is majorly
shifted from reverse reel 2 to reverse reel 1. Then after which the process is reversed and is
called as a second pass and so on.
The works rolls and backup rolls at 4 HI are not completely flat. They have the CVC profile. The
maximum line speed that can be attaining at 4 HI mill is 1200 mpm. The percentage reduction in
the thickness is around 39% in the first pass and this percentage decreases as we move on
towards the next passes. The minimum thickness that can be achieved is 0.27mm and maximum
thickness from which we can start our process is 6mm.
X ray gauge:
There are two x rays gauges in the mill. One is at entry side and other is at exit side. It measure the
thickness of the sheet by emitting x rays on it

Flatness rolls:

Flatness roll is at the exit of mill. It has section slots at equal division throughout the roll length.
Sensors are placed in these slots. The portion of sheet that have greater thickness apply more
stress and this stress is converted into flatness

EMULSION SYSTEM
The emulsion used at 4 HI contains mineral oil 2-4%, with water. Emulsion is coming from base
oil tank. The Emulsion is used as a cooling agent, as a friction reducing agent for rolls and as a
cleaning agent. There are 8 headers inside the mill that sprayed through nozzles. Two of them are
backup roll and four headers are on work rolls and another two are on roll bite. Sprayed emulsion
is collected at pan where is pumped back to oil tank. Oil tank consists of two sections dirty
sections and clean sections. Iron particle is attracted by magnetic separator and after filtrartion it
is sent to clean section where agitator mix the oil and water properly. Desirable emulsion
temperature is 52 c in the mill and it is achieved by exchanging heat with steam

PRESSURE SYSTEMS
Low pressure system

Low pressure system operates on 140 bar maximum. All equipments other than mill is operated
by this system.
High pressure system;
It operates at 280bar as maximum pressure. It is used only on mill to apply pressure on top back
up roll
Center oil lubrication
All motors gear, other auxiliary are lubricated by this system.

Defects:

Rusty

Strip marks/ Burr/ Cutter marks/ Separator marks

Thickness variation/ waviness

Roll marks (Marks appearing due to 4 HI rolls)

HR marks

Reasons of roll changing

Run complete

Sheet break

Sheet paste

Roll marks

Cracks found

Maintenance:
Daily:

Work roll change

Checking of emulsion tank

Weekly:
Greasing of all parts
Check movement of coil car
Pass line adjustment
Inspection of mandrill assembly