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SUMMARY
General
The completion date of the project was postponed by one year, due to delays in the development of the
industrial stress measurement system by BFI at EKO-Stahl.
With the industrial coiling stress developed by BFI and implemented at EKO-Stahl, we
expected to study the links between 3 things: defect apparition, coiling stresses and parameters
influencing the coiling stresses (namely the coiling tension, the thickness profile and the flatness).
Without any reliable measurement, this was impossible, and no longer was useful the comparison with
existing models for coiling stresses and thermal stresses.
Arcelor Research (formerly IRSID) was in charge of the simulation of sticking and scratching
on narrow coils on its laboratoryrolling mill pilot.
This also began by the development of a simulation method for the defects.
For sticking, this includes the preparation of the coils (roughness, coiling tension), the
annealing in an small industrial batch annealing plant, and the characterisation of the sticking intensity.
After several attempts, sticking could be obtained by coiling at above 50 MPa, with Ra 0.5 m, and
annealing at 700C. A measurement method for sticking intensity was developed that consists in
measuring the un-coiling tension while the un-coiler was let free turning. It was clearly seen that
sticking marks appear as coil breaks at the exit of the un-coiler that cannot be rubbed out by the temper
mill.
We could see the evolution of the sticking intensity along the coils as a gaussian curve with its
maximum at mid-radius of the coil. The sticking force varies linearly with the coiling tension. A very
strong decrease of the sticking was seen with higher roughness (between Ra 0.5 m and 3.7 m) and
lower annealing temperature (650C to 700C). An attempt was made to test the effect of an excess of
oil on the strip, with no clear conclusion due to bad conditions of trial.
For scratching, the simulation seemed at first sight easier than for sticking. Scratching could be
tested at first without intermediate annealing. Scratching sensitivity was characterised by the un-coiling
tension that provokes, nearly statically, the deviation of a straight radius line marked on the coil.
Scratching marks have been observed at microscope: 1.5 mm long, 0.15 mm wide, 15 m above and
under the surface.
For a coil prepared at room temperature, the un-coiling tension that provokes scratching is
about 6 times the coiling tension. This is in contradiction with common industrial belief which would
have stated it at the same value. We have not been able to get scratching after the annealing of the coils,
although we would have forecasted easier scratching. We got sticking instead. We took care of potential
unexpected perturbations (coil history, mandrel expansion) on this result. We studied the effect of the
roughness and presence of oil: only the oil had a clear effect on scratching promotion in our conditions
of test.
An important result came from the coils annealed that were only slightly stuck, when we tried
to unstick a length of 300 mm in two different modes: tangentially (in fact shearing ie the scratching
sollicitation) or radially (in fact peeling ie the normal uncoiling). Only 3 N was enough to un-stick the
strip by peeling, while 10000 N were unable to do it by shearing. This means that to get scratching, the
coil must be absolutely not stuck.
The BFI, with some support of FQZ and EKO-Stahl, was in charge of the development and the
use of an industrial coiling stress measurement system, able to study the effect of both strip thickness
profile and flatness.
This development began by experiments on a laboratory coiling simulator with strip of 350 mm
wide. The mandrel coiler has been equipped with 5 radial piezo force sensors inserted below its surface.
It could be got very good signals, with the expected general form of curve for the stress evolution with
the radius. Even each winding addition could be seen by a sudden rise in the signal. The difference
between the measurement across the width could be attributed to the coil flatness.
It was decided to assess the potential risk of high thermal stresses arising during the contraction
of a warm coil over a cold mandrel. This was done by a special trial where the strip was heated by
radiant heater just before the coiling. Even if no tremendous over-stresses were detected during this
trial, a doubt subsisted due to the very slow coiling (2 m/min) and it was decided to limit the force
transmitted to the sensors by a geometric means, and by the way of to limit the sensitivity too.
Another trial was made to test the sensitivity of the system to changes in thickness profile,
which was simulated with adhesive tape, and the conclusion was very good.
One segment of the coiler at the exit of the reversing mill of EKO-Stahl was implemented with
15 sensors over its width. This implementation suffered some delay and a mechanical break of the
electronic boxes. A reliable solution was found to these problems proved by 6 months of operation
without problem.
The signals of 14 coils were analysed. For the finishing pass with normal coiling tension, the
signal of some sensors, if not perfect, had a rather logical shape. Others delivered no signal, while a
static test proved that it was not a sensor defect. For the intermediate passes with 5 times the normal
tension, the signals raised quickly then curiously decreased below zero. Several explanations were
imagined and tested. Some raised possible ways of improvement: loose windings at the start of the coils
due to a thicker part, sensor drift. But the main explanation of the very surprising behaviour came from
finite element calculation, which showed an important deformation of the segment in which the sensors
were inserted. This deformation was caused by a discontinuous support of the segment (which can be
considered as a beam). This discontinuous support is inherent to the classical wedge-shape piece that is
commonly used for the expansion of the mandrel.
Consequently, the expected correlation of the coiling stresses along the width, with sticking and
scratching defects on one hand, flatness and thickness profile on the other hand could not be pushed
further on.
If it had to be done again, one should take better care of the possible deformation of the coiler.
In fact, even on the coiler of the reversing mill of EKO-Stahl, they were locations (above the punctual
supports of the segment) where deformation was acceptable. Moreover, one should come back to the
design used at the BFI laboratory coiler for the head that insures pressure transmission to the sensor, in
order to improve sensitivity, since the expected thermal stresses were not so important.
FQZ was in charge of several industrial studies among which a statistical correlation between
the defect occurrence and process parameters.
Globally, rather poor correlation rates were determined.
With increasing strip thickness the scratching defect increases. This is evident for both rolling
plants, especially with material thicker than 2.0 mm. A possible explanation for this is the limitation of
the maximum strip tensions at both rolling plants.
The used annealing regimes show a growth of the sticking defect rate when the soaking
temperature is increasing, while at the same time the scratching defect rate drops.
When one of the examined defects occurred in a coil, one or more of the same defects occurred
in coils rolled shortly beforehand or afterwards. It can therefore be concluded that a possible direct
influence of the rolling mill, as far as the materials have about the same properties.
Individual steel grades (electro steel grades, IF steel) show comparatively low defect rates, but
since many parameters are different in the treatment of these steel grades, this does not prove any
metallurgical effect.
As expected, no influence was found for the annealing places and the annealing hoods. The
same is true of the influence of the coil position in the stack.
FQZ also tried to develop a defect detection device based on the sound analysis. The treatment
was initially based on the noise intensity, from which the occurrence of sticking or scratching could be
related to an increase or decrease in the signal level. But making the difference between the two defects
was sometimes difficult. No correlation could be made with the coiling tension variations observed at
the tandem mill.
Another measurement was implemented at the coiler of the tandem mill which intended to
correlate the vibrations observed at this place and the defects. No correlation could be made.
Conclusions
The pressure between windings during annealing is confirmed as a major ingredient for
sticking, both on trials on samples (direct pressure applied during one hour), and narrow coils (coiling
tension). We have not the confirmation of this fact on industrial coils. The effect of the pressure on
sticking (measured by sheering or peeling force) is nearly proportional.
An increase of the soaking temperature pushes the sticking up, as was striking on narrow coils,
confirmed by statistical studies on industrial coils, and also seen on sticking of pressured samples.
Sticking is also promoted by a factor 3 when the roughness is increased from 0.5 m to 1 m
then 3.5m, as was shown on narrow coils. This confirms result from bibliography [1] on samples.
Investigations on sticking of samples at the laboratory showed an increase of the surface
oxidation with wet atmosphere, HNx rather than H2 atmosphere, or high Mn or Si content of the steel
grade composition. But no real influence on adherence was seen. CO2 injections as a sticker prevention
brought either no effect, or a remaining oxidation.
A dedicated statistical study together with a model showed that localized irregularities of the
thickness profile is correlated to sticking when their height is positive and greater than 3 m, especially
when the thickness profile is flat (less than 5m of crown).
Scratching was reproduced readily after coiling. The un-coiling tension necessary to get
scratching of the coil was found 5 times more than the coiling tension. Scratching could not be obtained
after annealing of the prepared coil, although we would have expected easier scratching under these
conditions.
But it was seen that very slight adherence between windings is sufficient to avoid scratching, or
said in another way, that scratching can occur only when absolutely no adherence by sticking exits
between the windings. This is somewhat confirmed by a statistical study which shows higher sticking
and lower scratching rates for high temperature annealing cycles, and the reverse for low annealing
temperature.
An industrial measurement of the coiling stresses was developed and installed on the coiler of
the reversing mill at EKO-Stahl. It was aimed at studying the correlation of the stress repartition across
the width with the thickness profile, the flatness profile, and the scratching and sticking defects rates.
Unfortunately, the signals obtained with the system were not good enough to be exploited, mainly due
to severe deformation of the industrial mandrel itself. In a possible future re-development, more care in
the location of the force sensors should make the measurement work in a much better way.
Table of Contents
i Summary
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19
1. Introduction
21
1.1.
21
1.2.
22
1.3.
22
25
25
25
25
25
2.3.2. Effect of dew point on sticking of various steel grades (Mn, Si) on sticking 26
2.3.3. Applicability of CO2 injection as sticking prevention
26
27
29
29
29
29
29
29
30
30
30
31
31
32
32
33
33
33
33
34
34
34
35
37
37
37
37
38
38
38
39
40
40
41
41
42
42
42
43
43
44
45
45
46
10
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47
47
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49
49
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50
50
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51
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52
53
53
53
5.2.3.1. Generalities
53
54
54
54
11
55
56
56
57
57
57
57
58
58
5.5.3. Global results on sticking and scratching over the whole project period
58
6. Conclusions
59
59
59
61
158
12
Table 3:
Figure 4:
Figure 5:
Influence on sticking of the pressure applied during the first hour of the cooling (C0.1%Mn).
Figure 6:
Figure 7:
Figure 8:
Influence on sticking of the pressure applied at two different dew points (DP) during
the first hour of the cooling
Figure 9:
Figure 10: Influence of the soaking temperature, for a 5MPa compression stress, during
annealing in 100% H2 in various dew points on sticking (measured by a lap shear
test)
Figure 11: Influence of the soaking temperature, for a 1 MPa compression stress, during
annealing in 100% H2 in various dew points on sticking (measured by a lap shear
test)
Figure 12: SEM view of the C-1.1%Mn 0.2%Si samples after strip de-cohesion at different
magnification (left pictures: area not affected by sticking right pictures: area
affected by sticking) Annealing at 720C / dew point 50C with an applied stress of 5
MPa
Figure 13: Auger analysis made on the area not affected by sticking (Sample C-1.1%Mn 0.2%Si
/ 720C / DP-50C)
Figure 14: SEM view of the C-1.1%Mn 0.2%Si samples after strip de-cohesion at different
magnification (left pictures: area not affected by sticking right pictures: area
affected by sticking) Annealing at 720C / dew point +10C with an applied stress of 5
MPa
Figure 15: Auger analysis made on the area not affected by sticking (Sample C-1.1%Mn 0.2%Si
/ 720C / DP+10C)
Figure 16: SEM view of the C-1.2%Mn samples after strip de-cohesion at different
magnification (left pictures: area not affected by sticking right pictures: area
affected by sticking) Annealing at 720C / dew point -50C with an applied stress of 5
MPa
13
Figure 17: SEM view of the C-1.2%Mn samples after strip de-cohesion at different
magnification (left pictures: area not affected by sticking right pictures: area
affected by sticking) Annealing at 720C / dew point +10C with an applied stress of 5
MPa
Figure 18: Influence of CO2 injection at the end of the soaking on sticking
Figure 19: Influence of soaking time on sticking
Figure 20: Influence of the H2 amount during annealing at different soaking temperature on
sticking
Figure 21: Influence of surface cleanliness before annealing on sticking
Figure 22: Scheme for the sticking force and the uncoiling tension
Figure 23 : Pictures of the strip uncoiled from a strongly stuck coil on Arcelor Research pilot
mill
Figure 24: Uncoiling behavior of a strongly stuck coil on our pilot mill
Figure 25: Uncoiling of stuck coils wound after rolling at different tension levels
Figure 26: Coiling tension influence on sticking intensity
Figure 27: Uncoiling of stuck coils of different roughnesses and wounded at a same coiling
tension
Figure 28: Influence of the roughness on sticking intensity
Figure 29: Uncoiling of stuck coils annealed at different temperatures
Figure 30: Uncoiling of stuck coils with different amounts of oil
Figure 31: Observation of 2 scratching marks with interferometry microscope
Figure 32: Evolution of a radius mark on coil side after scratching during trials
Figure 33: Stress distribution upon the coiler resulting from different thickness profiles of the
strip
Figure 34: Radial stress distribution upon the coiler resulting from different types of flatness
defects
Figure 35: Schematic view of the tension roller plant
Figure 36: Overall view of the tension roller plant
Figure 37: Piezo transducer with integrated cable
Figure 38: Sensor installation at the laboratory coiler with electronic unit mounted on the face of
the mandrel body
Figure 39: Measuring laboratory coiler with installed force tranducers across the axis and
transmitter unit
14
Figure 63: Measured distribution of radial forces over the barrel length of the measuring coiler
(final pass no.7)
15
Figure 64: Course of the radial force during coiling measured by sensor 7 (final pass no.7)
Figure 65: Course of the radial force during coiling measured by sensor 8 (final pass no.7)
Figure 66: Course of the radial force during coiling measured by sensor 4 (final pass no.7)
Figure 67: Course of the radial force during coiling measured by sensor 11 (final pass no.7)
Figure 68: Measured distribution of radial forces over the barrel length of the measuring coiler
(pass no.1)
Figure 69: Appearance of the force signal (sensor 9, pass no. 1)
Figure 70: Course of the measured radial force during coiling and subsequent uncoiling
Figure 71: Course of the measured radial force during coiling with clamped thick and thin strip
head end
Figure 72: Basic positions of the pressure sensors in the mandrel viewed from top
Figure 73: Results of measurement of the 15 pressure sensors at static pressure 176.5 N
Figure 74: Example sensor 14 with high sensor sensitiveness and problems with reproduce the
range
Figure 75: Example sensor 14 with to high drift
Figure 76: Mesh structure of sensor area
Figure 77: Wedge shaped supporting surface of reel sleeve segment
Figure 78: Contact zone between sensor and bolt
Figure 79: Contact zone between sensor and reel sleeve segment
Figure 80: Contact zone between bolt thread and reel sleeve segment
Figure 81: Constant pressure distribution upon surface of sleeve segment and sensor cap
Figure 82: Total displacement of reel sleeve segment
Figure 83: Total displacement of reel sleeve segment, sensor area detailed
Figure 84: Displacement in z-direction of reel sleeve segment
Figure 85: Displacement in z-direction of reel sleeve segment, sensor area detailed
Figure 86: Stress distribution of sensor in z-direction
Table 87 : Statistics of defect coils depending on steel grade (year 2001)
Figure 88: Share of defects at quarto tandem mill classified by steel grade
Figure 89: Share of defects at 6 rolls reversing mill classified by steel grade
Table 90:
16
Figure 94: Share of defects at quarto tandem mill classified by coil width
Figure 95: Share of defects at 6 rolls reversing mill classified by coil width
Table 96:
Figure 97: Share of defects at quarto tandem mill classified by coil weight
Figure 98: Share of defects at 6 rolls reversing mill classified by coil weight
Table 99:
Statistics of defect coils depending on the annealing regime (1st half of year 2002)
17
18
List of References
[1]
[2]
de Groen, Jan-Hein, E.E. Schoone: Recent developments in technological and practical measures
in the field of stickers and scratches at CORUS cold rolling mill 2 Ijmuiden,
LOI Internat.
Customer Convention on Heat Treatment of Steel Strip and Wire, LOI Thermprocess Essen,
Bonn, DE, 12.-15. May, 2004
[3]
Sims, R. B., J. A. Place: The stresses in the reels of cold reduction mills. British Journal of
applied Physics 4 (1953), pp. 213-216
[4]
Wilkening, H.: Die Ermittling der radialen Haspelbelastung beim Wickeln von bandfrmigem
Gut. Dr.-Ing. Diss. RWTH Aachen 1965
[5]
Leifgen, Uta, A. Sinter: Sticker prevention in batch annealing - StickerMod: basics and results,
LOI Internat. Customer Convention on Heat Treatment of Steel Strip and Wire, LOI
Thermprocess Essen, Bonn, DE, 12.-15. May, 2004
19
1. Introduction
1.1.
Batch annealing remains a significant workshop in cold plants. Two of its major problems are
sticking and scratches, both defects of surface aspect unacceptable for automotive industry.
When cold-rolled strip is annealed in tight-coil batch annealing furnaces, it can happen that coil
wraps adhere or stick together. The adhering wraps in question then offer greater resistance when the
wound strip is uncoiled, e.g. in temper mills. This can cause discontinuities or also cross breaks in the
surface of the rolled material that are referred to as strip sticker marks. Even where the cohesion is the
same, the separation of adhering or stuck-together wraps can lead to various surface defects. Thinnergauge strips, because of their lower bending rigidity, tend to form cross breaks, whereas thicker-gauge
strips are more likely to suffer local surface damage [1].
Another surface defect besides strip sticker marks can be caused when batch-annealed strip is
uncoiled, and appears in the form of scratches. Unlike the formation of stickers, scratches are more
likely to come about if there is little adhesion, in other words little or no sticking, between the wraps. In
this case there is a danger of interwrap slip in the body of the coil.
A multitude of operating-related factors ranging from the geometry of the hot strip to the
uncoiling conditions at the temper mill, and their interaction, are responsible for the occurrence of strip
sticker formations. In the cold rolling as example the strip transverse thickness profile, coiling tension,
surface roughness and rolling oil residues are important influencing parameters.
The mechanism of two surfaces adhering together can be compared to joining methods such as
pressure welding, sintering or diffusion welding. The most important parameters that influence these
methods are temperature, time, pressure, surface condition and reactivity. It is possible for individual
wraps to adhere or stick together in batch annealing furnaces. The mentioned parameters of pressure,
temperature and time then appear as a radial stress field or in the anneal heat-treatment cycle curve, i.e.
the temperature-time gradient of the anneal. The anneal heat-treatment cycle curve influences adhesion
directly through temperature and time as well as indirectly through the thermal stresses resulting from
the temperature field.
Reactivity is dependent on the catalysing or retarding effect of the cleanness of the strip surface.
The presence of strip deposits such as emulsion residues, oxide layers, iron abrasion fines and antisticking agents is governed by whether the strips are degreased or whether anti-sticking agents are used.
Such contaminated surfaces can have a retarding influence on the reactions and, as a result, generally
reduce the likelihood of wraps adhering or sticking together [1,2].
Significant importance is also attributed to the surface topography of the rolled material. A
reduction of the cohesion is achievable particularly through high vertical roughness values such as Ra
and Rt.
Besides the thermal stresses resulting from the temperature field during the annealing process, the
level of strip tension under which the strip is coiled also determines the radial stress field within wound
coils. The radial loading of the coiler mandrel and, consequently, the compression of the wraps grow
continually during the coiling process. The authors in [3,4] perceive the coiling process as a successive
shrinking-on of individual, concentric 'rings'. The shrinking-on of each wrap increases the surface
pressure between the underlying wraps by a steadily diminishing amount until a radius limit value is
reached, i.e. from a certain coiling radius onward, additional strip wraps do not lead to any notable
increase in the radial loading of the mandrel.
Differences in tensile stress over the strip width can lead to excessive stresses locally. The cause
of these irregular stress distributions is flatness defects, whereas strip thickness profile defects cause
geometrical deviations in the wound coil. Both defects, consequently, bring about irregular radial stress
distributions over the strip cross-section in the wound coil.
There are, in principle, three approaches for avoiding or reducing strip sticker marks.
21
22
An important part of the report will deal with the development of an industrial measurement of
the coiling stresses. This equipment was aimed at studying the correlation of the stress repartition across
the width with the thickness profile, the flatness profile, and the scratching and sticking defects rates.
Unfortunately, this development did not reach the expected level of success.
In another part, we will present statistical studies on an industrial plant about cross relation
between defects and various parameters. A special focus will be made on the occurrence of localized
over-thicknesses. This will be completed with an attempt of development of defect detection device
based on the sound analyse, which would have facilitated the statistical studies, and a special study of
the vibrations at the up-coiling stage after tandem mill.
23
25
Other trials were carried on various steel grades, which confirmed a linear effect of the stress
applied during annealing (Figure 6). However, a saturation was observed when the duration for this
stress application was increased (Figure 7).
2.3.2. Effect of dew point on sticking of various steel grades (Mn, Si) on sticking
A first set of trials have been made to determine the influence on sticking of the hydrogen and
water vapour amounts during the same annealing cycle for the C-Mn0.3 steel grade.
Figure 8 summarises the influence of the applied stresses on the sample sticking for two amounts
of water injection:
Dry hydrogen: dew point around 30C depending on water desorption from the furnace
Wet hydrogen: dew point of 0C
The different trials indicate that a dew point of 0C does not influence the strip sticking, which
should be explained by a low surface coverage by external selective oxidation. Indeed, if the surface is
covered by an oxide, no sticking can be made due to the fact that sticking needs metallic bonds for
sintering. In our case the low coverage of the surface by Mn selective oxides could be explained by the
nodular shape of that kind of oxides. Moreover, the increase of the dew point should promote internal
selective oxidation, which will limit surface oxidation. That higher dew point during annealing
promotes however the strip decarburation according to the gas metal reaction: Csteel + H2O CO +
H2, as it is illustrated on Figure 9.
Further trials have been made on different steel chemistries. It appears that even if the Mn
amount in the steel increases up to 1.2 wt % and the silicon amount up to 0.2 wt %, no influence of the
dew point (between 50C and +10C) or of the soaking temperature (660C or 720C) can be observed
if a pressure of 5 MPa is applied on the samples during cooling (see Figure 10). Moreover, if the
pressure is applied during the whole thermal cycle, the same important sticking is observed on the
different steel grades (Figure 7). For the thin (0.52 mm) low carbon steel grade (C-0.3%Mn), the
sticking force ( 3000 N) can be greater than the yield point elongation.
Scanning Auger analysis, made on the samples after their separation by a tensile test, indicates
that sticking occurs on some small over-thickness (Figure 12, Figure 14, Figure 16, Figure 17).
Between the areas, where sticking occurs, a homogeneous Mn, Si and Al external selective oxidation is
observed when the annealing is made at a low dew point (-50C) (Figure 13). At a higher dew point
(+10C) the selective oxidation coverage is less homogeneous (Figure 15) and highly oxidizible
elements (Al, Si) are less present on the top surface. The same kind of results is observed on another C1.2%Mn steel grade (Figure 16 and Figure 17). If the continuous surface selective oxidation, observed
on high alloyed steel grades, is not sufficient to avoid iron diffusion and strip sticking, it can be
imagined that sticking can not be avoided on classical steel grades, alloyed with less elements.
If the pressure, applied during cooling, decreases down to 1 MPa, a significant reduction of the
sticking force is however observed. Here again, no clear influence of the steel chemistry on strip
sticking can be observed. The reduction of the soaking temperature seems however to slightly reduce
sticking, probably due to a decrease of the iron diffusion kinetic. That means however, that a reduction
of sticking can be obtained by a decrease of the cooling rate in the batch annealing furnace (decrease of
the thermal stresses) with however a decrease of productivity.
To avoid that productivity loss, the effect of a total oxidation before cooling was tested by CO2
injection at the end of the soaking. Indeed, as sticking is due to the presence of metallic iron when
26
stresses are applied, the growth of a controlled iron oxide layer should strongly reduce sticking. The
Figure 18 does not show clear evidence of such treatment, even if the oxidation is made during the last
2 hours of the soaking, which means that the reduction kinetic is too rapid in pure hydrogen.
Indeed, if the iron oxide is too quickly reduced, sticking will again occur. Moreover, the porous
iron layer, made by the oxidation / reduction process will probably promote sticking. If the CO2
injection is made during the beginning of the cooling, the sticking is strongly reduced but iron oxide
remains on the surface.
All these results seems to indicate that it is difficult to control the CO2 injections to reduce
sticking while avoiding residual iron oxide on the top surface. That study does however not take into
account the diffusion of the gases between the turns in an industrial configuration. Indeed, an industrial
trial has shown that the scale, on an hot rolled strip, can not be reduced on the strip axes in an industrial
batch annealing, even in a pure hydrogen atmosphere. The strip edges were only reduced on a length of
20 cm, probably due to water vapour diffusion problems.
Finally, the application of the compressive stresses at the end of the heating also induces strong
strip sticking. That result seems to indicate that the strip is already sufficiently clean to allow iron selfdiffusion and sticking.
The increase of the soaking time to increase the amount of selective oxidation has only a very
limited effect on sticking (Figure 19). That result seems to indicate that at low temperature (660C), the
diffusion kinetic of the alloying elements is too slow to increase sufficiently the thickness of the
selective oxidation layer.
27
Size:
Thickness: 0,8 mm
29
30
31
We intended to anneal the second coil at 730C. Unfortunately, it was impossible to find an
agreement with our subcontractor for such a high temperature annealing. Since the great influence of
the soaking temperature was established between 650C and 700C, we decided to give up this trial,
and used the prepared coil as reference coil for the test of oil influence below.
3.2.2.4. Influence of the oil quantity on sticking
One coil was prepared in the following conditions:
Roughness: Ra 0.47 grounded
Coiling tension: 150 MPa
For all the other trials, the chemical state of the surface was what it came from the exit of the
industrial tandem mill (with grounded rolls on the last stand).
No measurement of the oil quantity was made on these as-coming coils, since the rolling date
(December 2000) was too old when we interested in it. Nevertheless, it should be classical, that is
between 150 and 300 mg/m2.
During the coiling process, we sprayed pure oil on the strip, and controlled the deposit with our
wiping installation (air knives and scrapers). Nevertheless, too much oil was left on the coil, since the
coil was dripping, even after several coiling/wiping passes.
We measured for this coil the amount of oil on samples cut off at the end of the last
coiling/wiping pass, close to the coiler. The measurement says: 2100 mg/m2, which is pretty much.
The coil was then left on the ground with its axis vertical for dripping. After one week, the
dripping had stopped. It was turned upside down every 2 weeks before annealing, to avoid oil
accumulation on one side (not the same amount along its 60 mm width) as says our experience.
Then, the oily coil was annealed in a same stack with a reference coil. The annealing conditions
were planned to be 700C, 12 hours, on top of the stack in a small industrial batch-annealing unit
(ETILAM), H2 atmosphere, no insulation of the sides of the coils.
Unfortunately, a mistake was done about the soaking temperature set to 650C instead of 700C.
The result is that the coils were only a bit stuck, with some sticking marks happening during their
uncoiling.
The Figure 31 shows the resulting unsticking force versus remaining diameter for the two coils.
On the same figure is represented the curve for the coil previously annealed on purpose at 650C from
2.2.2.3. . One can see that the results are reproducible. Only a small difference can be seen between
the oily coil and the other ones, in the range 800-700 mm of remaining diameter, where the oily coil
exhibits a higher unsticking force, in good agreement with the sticking marks observations. Anyway,
we are at the limit of accuracy of our method, and we do not consider it as a proof of an effect of the oil
quantity on sticking.
No further test could be attempted, thanks to increasing difficulties to work with our
subcontractor.
32
33
Even if there are quantitative differences between this third trial and the first one, it can be related
to simple deviation. But the second trial shows a great influence of the history of the coil, say its coiling
history. Perhaps, the unstudied parameter behind the coil history effect is the roughness, or something
related to it. Or the scratching marks produced during the first slipping make grappling points between
the laps. Anyway, this made things a bit more difficult for the following of the study.
34
Then the coil was unwinded, then rewinded under a lower tension (1000 N = 12,5 MPa). This
time, scratching occurred for 8700 N.
370 mm
not stuck
300 mm
stuck
Strip
cut
out !
Strip
weight
- 500 mm of strip in cantilever (weight : 3,1 N) produces auto-unsticking of the remaining strip.
The equivalent force is 31 N/m width with a torque of 7,7 N.m/m width exerted on the unsticking line
- 10000 N (105 N/m width) exerted tangentially are unable to unstick a length of stuck strip of
300 mm.
The ratio between the forces necessary to unstick the strip, depending on their direction is
tremendous: at least 3000. In one case, we speak of peeling, in the other pure shear. The first one is the
case of the sticking mark formation, the second one of the scratching formation.
So we better understand why we could not get scratches on our lightly stuck coil. We can even
make the assumption that scratching can only occur when absolutely no adherence exists between the
laps.
35
influence of the force application on the un-sticking force: by sheering (stress solicitation in case of
scratching) the force to unstuck was at least 10000 times more than by peeling (normal uncoiling). This
brings to the conclusion that, unless absolutely non stuck, a coil should not scratch!
36
37
38
windings is the interference of the mandrel clamping cone, which causes heterogeneities during the
coiling of the first wraps.
Figure 41 shows the measurement results from a second trial sequence for an entire coil when a
strip was coiled under a constant mean back tension of 55 N/mm2. The strip data were as follows:
steel grade:
LC DDQ
strip width:
300 mm
strip thickness: 0.4 mm
strip length:
1206 m
number of wraps:
600
coil inner diameter:
400 mm
coil outer diameter:
880 mm
Because of the clamping conditions, the strip did not cover sensor A. The course of the radial
forces measured on the coiler is therefore illustrated for sensors B, C, D and E as a function of the
number of windings, for approx. 576 revolutions of the coiler. The diagram relates to two different
states: the dynamic state during the coiling process, and the static state describing the holding time
under tension when the equipment had come to a stop.
The course of the forces recorded by sensors B, C, D and E clearly show different levels. Sensors
D and C, positioned at the strip centre, indicate the highest level of stress for the entire strip length.
Sensors B and E gathering the data at the strip edges supply the lowest radial pressure values. In the
latter case, however, the intersection point of curves E and B, corresponding to approx. 310 windings,
indicates an additional elongation of local strip fibres, e.g. during cold rolling, at the strip edge position
represented by sensor B. A lower tension is thus induced locally. This relationship is illustrated in
Figure 42, which shows schematically the possible length distribution of strip for two measuring
positions before and after the point of intersection.
From the course of the curves in Figure 41 it can basically be deduced that the technique
employed to measure the radial pressure on the coiler mandrel is able to detect local radial force
deviations distinctly. The trials show differences of approx. 6 kN in the measured forces (corresponding
to a deviation of 45%) between sensors B and D, even when the strip is completely wound (values for
approx. 570 wraps).
No disturbances are expected during data collection due to a loss of charge of the piezo sensors in
use. This is supported by the course of curves measured within a period (approx. 60 min) in which the
bridle was held under tension, as illustrated in Figure 41. The slight drop in the measured forces will be
insignificant with regard to considerably shorter rolling times per pass at industrial installations.
39
The test schedule (Table 43) shows the operating conditions set for the trials.
Figure 44 documents the points for radial force and temperature measurement and the procedure
for the "profile trial" described in the test schedule.
The local stress distribution across the strip width was recorded continuously over the coiled strip
length by the stressometer roll, which is installed upstream of the coiler. The analysis of these data
shows that the tested strip had a virtually identical flatness or stress profile over its entire length, as seen
in Figure 45 for the strip head-end, strip center and strip tail-end. The coiled strip can be regarded as
almost free from flatness defects. The initial strip thickness profile in Figure 46 does not show any
irregularities.
To simulate different coiler and strip temperatures, the strip was heated to around 120C using a
heating unit (Figure 47) equipped with 20 quartz radiation heaters. The coiler was at room temperature
(23C) before coiling the first strip winding.
The trial was conducted in two stages. First, the strip and coiler temperatures and the radial forces
acting on the coiler were measured during coiling. The second stage involved a cooling phase during a
holding period of about 240 minutes after the equipment had been brought to a stop.
Figure 48 shows the temperature progression for the strip and the coiler during the coiling phase
of 122 minutes, which corresponds to 157 strip windings. As expected, the strip temperature drops
rapidly from about 120C to around 30C during the winding of the first wrap due to radiation and
convection. This rapid loss of temperature within a single revolution is assisted by the low winding
velocity of the equipment, corresponding to 15 sec/wrap, and the low mass of the strip in relation to the
coiler. The coiler temperature steadily rises with increasing coiling time (no. of windings) and
approaches the strip surface temperature of about 30C. In cases where no further heating energy is
introduced into the coiled strip/coiler system via the coiled hot strip windings, the coiler and strip centre
temperatures initially converge quickly, then decrease continuously, as shown in Figure 49.
Figures 50 and 51 show, similar to the temperature plots, the progression of the radial coiler
loading as measured by the pressure sensors, again for the coiling phase and the holding period after the
equipment was brought to a stop. The 300-mm-wide test strip was clamped in the coiler in such a way
that sensors A to D were completely covered. During coiling, sensors B and C, which were covered by
the strip center, registered a virtually identical increase in tension over the number of windings. The
individual sensors registered values between 14.5 kN and 18 kN for the radial force acting on the coiler.
The tension readings for coiler loading in the strip edge zones (sensors A and D) diverged greatly. The
strip side facing the drive (i.e. the trace for sensor A) showed a considerably lower rise in tension.
A temperature-related tension progression during a holding period of about 250 minutes is
illustrated in Figure 51. In the first 13 minutes after the coiler has been stopped, the radial stress rises
significantly. After around 26 minutes, a sudden settling of the coiler mandrel evidently influenced the
force progression measurement. This incident was accompanied by a loud bang. The gradual increase in
radial force after this incident was reversed after about 100 minutes of the holding time, and the force
decreased slowly thereafter.
When strips that have a non-rectangular thickness profile over their width are coiled, this leads,
similar to the situation of strip having larger flatness defects, to an irregular stress distribution across the
strip width and hence to varying radial loading of the coiler.
40
To simulate different thickness profiles over the strip width, tapes with a width of 50 mm and a
thickness of 0.1 mm were fed in at different locations across the strip width and coiled along with the
strip, so that they lay between the windings. Starting with the strip centre, 20 windings were coiled with
the tape (Figure 52). The tape was then shifted to the drive side (29 coiled windings) and finally to the
operator side (28 coiled windings) and coiled on top of the previously coiled windings
The radial coiler loading resulting during this trial is plotted in Figure 53. The coiling locations
are shaded in colour in the graph.
Sensors C and D registered the greatest increase in radial force, as expected, when the tape was
fed in at the strip centre (windings 11 to 30). When coiling was continued with the tape shifted to the
drive side, there was a redistribution of stress in the strip region around sensor B, combined with a clear
increase in stress from windings 31 to 58. This effect extends to the region around sensor C. Sensors E
and D, positioned on the operator side, registered a simultaneous decrease in stress. The relationships
change when the tape is wound in the strip edge zone on the operator side, and the strip longitudinal
stress are redistributed in the strip section around sensor E. Sensor E registers the steepest rise in radial
forces, as expected, in strip windings 59 to 85. Sensor D, unlike the other sensors, shows a steady
decrease in stress from winding 30 onwards. This can be attributed to the fact that, when the tape is
being fed in, there is a redistribution of stress at the strip centre and the strip edge on the operator side,
concentrated at neighbouring sensor regions C and E. As shown by the course of the radial forces
starting from winding 86, the influence of local thickness deviations remains effective, although the
strip has been coiled without feeding in more tape until the coiler is stopped at winding 111.
In addition to the trials described above, a conventional coiling trial was conducted without strip
heating or tapes interleaving. The radial forces registered in this case by sensors A to D for a total of
211 strip windings rise to values between 17.5 kN and 28 kN (Figure 54).
41
period at point in time "0" and progresses for around 13 min., is consequently attributable to the
cooling-related contraction strains in the coil. This is confirmed by the cooling temperature curves of
the coil shown in Figure 49. The coiling temperature remains almost constant during the considered
period, such that it is possible to rule out any coiling-related influence on the radial loading of the force
sensors.
The effect of thermally induced stresses exerted by the coiler on the sensor will play a
significantly greater role in high-speed industrial installations, e.g. when re-starting a rolling line after a
stoppage, than has been possible to simulate in the laboratory facility. Given the low maximum strip
speed that the bridle unit can handle, the strip and coiling temperature already converge as a result of
thermal radiation losses once the winding process has started.
The coiling trials involving locally wound tape showed that the sensors used are clearly able to
register and resolve the thus induced redistribution of tension over the strip width. This also holds true
when existing tension profiles are redistributed during coiling. This is illustrated by the response of
sensor E in Figure 53 during the transition from winding 59 to 85. Limited changes in the thickness
profile over the length of the strip continue to have a strong influence on the formation of the radial
stresses in subsequent, defect-free coil wraps. The radial stress gradient, for example, is preserved
over all the wraps ranging from 85 to 111, even when no further changes in coil geometry are induced
by the introduction of additional foil.
42
43
signal into a voltage signal that is proportional to the measured physical value. Conversion takes place
via a charging amplifier, which basically consists of an inverse voltage amplifier with a high inner
amplification and capacitive negative feedback.
15 such charging amplifiers are installed in the signal converter module. The measurement
signal delivers an output voltage in the range of 5 V.
Each charging amplifier has three measurement ranges for improved resolution of the physical
measurand.
Measurement range 1:
10,000 pC/V
Measurement range 2:
2,500 pC/V
Measurement range 3:
625 pC/V
With a sensitivity of 4.3 pC/N for the employed force sensors, 1 V is equivalent to
2325 N:
in measurement range 1
581 N:
in measurement range 2
145 N:
in measurement range 3
The measurement ranges can be selected automatically or via a stator-sided control signal. An
angle-of-rotation-synchronous impulse, which at the same time is used as a control signal for the reset
procedure of the charging amplifier, must be employed for the automatic range selection.
Control and transmission module
The control and transmission module contains:
the control system for selection of the measurement ranges
the control system for the residual signal
the A/D converter for the 15 measurement signals
the codification module for the digital transmission signals and
a radio module for the transceiver (transmitter and receiver)
The radio module has the following technical specifications:
carrier frequency
2.4 GHz
data rate approx.
192 kbit/s
transmitting power
10 mW
Receiver module
The receiver module has a transceiver, which has the same technical data as the radio module in
the control and transmission module. The output signal of the receiver module is transmitted to Ethernet
10base T-connection with TCP/IP protocol via a converter RS232, from where it is transmitted to the
data processing unit (PC).
Power and charge module
The power module that provides the supply voltage for both the signal converter module and the
control and transmission module has an exchangeable storage battery set consisting of three Li-ionic
storage batteries, each of which have a rated voltage of 7.5 V. The operating period of the storage
batteries is 8 hrs. The required charging time of the storage batteries is 1 hour.
Operating conditions for the signal conversion transmission unit
The high coiler speed of max. 10 1/s and the relatively large radius of 0.26 m, on which the
modules are attached to the front of the coiler, lead to accelerations of approx. 1000 m/s2.
During the development and construction of the components for the signal conversion
transmission unit, particular consideration had to be given to the extremely high centrifugal forces. A
test stand on which every structural component was tested was therefore built for simulation of the
actual velocity conditions inside the reversing mill.
44
period of the measuring coiler. These measures were necessary for enhanced protection of the
electronics. For this purpose the holding device is equipped with pockets for inserting the protective
boxes containing the charge amplifier and transmitter unit electronics. The protective boxes are securely
fixed by two retaining rings. This modification included a different routing of the sensor cables, which
now no longer exit the coiler mandrel through an opening in the face as show in Figure 60. Figure 61
illustrates the installed measuring coiler with mounted holding device for the electronics.
45
remains in the gripper slot during the reversing winding operations. The rotation-dependent measuredvalue dynamics then diminishes considerably when the non-rolled hot strip head-end is separated and
the strip in the thickness being rolled at the time is used for the start of coiling. In contrast to the
flexurally resistant thick hot strip, the thinner cold strip fits snugly around the circumference of the
coiler mandrel in the region of the gripper slot as early as the first strip wrap. This avoids any local
formation of hollow spaces between the coiler mandrel and inner wraps of the coil which, in case of the
thicker strip, leads to dynamic, rotation-dependent flexing processes.
In parallel to the modification and testing of the system by BFI at the reversing mill, and since
the results of the campaign were far from the results expected, FQZ carried out checking of the 15
pressure sensors. The order of the sensors in the mandrel is shown in Figure 72.
All sensors one after another were subjected to a pressure of 176.5 N (static state).
The results were satisfactory and the basic functionality of the sensors could thus be
demonstrated (Figure 73).
Deviations with the reproduce of pressure and scale graduation were recognized (Figure 74), but
they did not keep on examining.
One sensor did not keep on being able to be used (too high drift of the measurement signal,
Figure 75).
Even if the installation did not work perfectly, the problems detected could not by themselves
explain the strange behaviour of the signals of Figures 63 and 68.
46
to avoid any overloading of the sensors under any operating conditions, e.g. due to thermally induced
radial stress increases.
The above-described differences in design between the laboratory and industrial coiler
consequently give rise to two fundamentally different influences to which the sensors are exposed. The
sensors installed in the industrial coiler are subjected to loads and stresses reduced in a ratio of 1:12
compared with the laboratory coiler, while the radial stress between coil and coiler is identical. Elastic
deformations are triggered in the coiler segment due to its low bending rigidity which, depending on the
loading condition, have an effect on the sensor-securing elements and diminish its tightening force. The
sensor is thereby relieved counter to the radial force exerted by the strip. This effect can lead to a
situation where the sensor displays measured values, as a function of the strip coiling tension and buildup height, that seems to show a reduction of the radial stresses in the coil as the wound diameter
increases. This deformation influence can assume dimensions that lead to negative measured values.
During the subsequent unwinding of the coil from the coiler, the deformations previously introduced in
the coiler segment recede.
It has been possible to demonstrate this by means of FE calculations.
47
48
To examine the influence of the utilised steel grades on the frequency of the defects scratching
and sticking in the year 2001, the steel grades were summarised under the following steel grade groups
in order to improve the informative value of the statistics and enhance comparability:
In the Table 87, the evaluated coils (total number and number of defective coils) are shown for
the individual steel grade groups. Production at the two rolling mills was examined separately.
The evaluation results are summarised in Fig. 88 and 89.
The first evaluation of the results shows that the examined defects occur at both rolling units. It
appears that the frequency of scratching is higher at the four-high tandem, and the frequency of strip
sticking is higher at the reversing mill. The statistical comparability of the data sets must be taken into
account. What is interesting is that at both rolling units electrotechnical steel shows a very low number
of defects. Possible reasons for this could lie in the low roughness of these grades, as well as in the
more even strip cross-section.
49
The IF steels rolled at the four-high tandem also show a high quality standard, which could be the
result of increased technological inspections.
A further examination was carried out on the defect behaviour in regard to strip thickness. For
this, 8 thickness categories were created for both rolling units, which are statistically summarised in
Table 90. The visual illustration of the statistical analysis is shown in Fig. 91 and 92.
The interrelationships of defect frequency in regard to the strip thicknesses rolled at the four-high
tandem (Fig. 91) show that with increasing strip thickness the danger of scratching increases, while
sticking is reduced. A possible explanation for the development trend of scratching is that the
maximum strip tension of the coiler at the rolling mill is limited to 130 kN. Due to the unit-related
restrictions of the coiler performance, this tendency cannot be counteracted.
The same explanation applies for the conditions at the reversing mill, which also has a limited
coiler tension (156 kN).
The coil mass was analysed as a further influential factor on the frequency of sticking and
scratching.
These examinations become significant in the context of the planned examinations of the
distribution of stresses in the coil during the coiling process by BFI.
Table 96 shows the statistical figures, the visual evaluation is shown in the Figures 97 & 98.
In regard to the conditions at the four-high tandem, it can be discerned that with increasing coil
mass the defect frequency of strip scratching tends to increase (Fig.9). Although this trend is not equally
detectable at the reversing stand, it does exist in principle.
Apparently this statistical influence demonstrates the significance of complying to stable
geometrical and cinematic coiler conditions over a large coiling height.
50
point sticking
edge sticking
surface sticking
bulb sticking
defect 40
defect 69
coiler scratching
coiler marking
}
}
sticking
}
}
}
scratching
5.1.2.1. Annealing regime statistical analysis (based on data of 1st semester 2002)
Table 99 as well as Figure 100 show the evaluated coils in terms of the applicable annealing regime.
To verify whether the annealing regimes affect defect accumulation, identical/similar annealing regimes
were classed under annealing regime groups (Figure 101).
Figure 102 shows the measured correlation between defect frequency and annealing temperature. One
can see an growth of the sticking defect rate when the soaking temperature is increasing, while at the
same time the scratching defect rate drops.
In Tables 103 and 104 the statistical figures on the influence of the annealing place on the
development of the examined defects are compiled.
The annealing places 1-30 are equipped with Nassheuer furnaces and the annealing places 31-62
with furnaces manufactured by Fa. Ebner.
The distribution of the recorded coils across the annealing places is almost equal. According to
the visual illustration in Fig. 105 and 106, no furnace-specific distinctions in regard to defect frequency
can be discerned.
The results of the statistical evaluation of the defects sticking and scratching in regard to the
utilised annealing hoods are shown in Table 107 and Figure 108.
No statistical interconnections can be deduced from this examination.
51
A further analysis investigated whether the position of the coil in the annealing stack has an
influence on the frequency of defects.
The illustration of the position of the coils in the stack during the annealing process in the furnace
(Tab. 109 and Fig. 110) shows that the furnaces are predominantly operated with 3 coils. Positions 4
and 5 are occupied less frequently. Due to the low number of coils, a significant statistical statement
cannot be made for position 5 (top position).
Although the various heat-up and cooling conditions of the coils in the annealing stack would
lead to the expectation that the position of the individual coil has an influence, no unambiguous
connection can be established. The result of the analysis carried out, moreover, allows the assertion that
with the evaluated coils the furnace position has no influence on the defect frequency.
52
To take also these parameters into account, calculations have be performed to determine the
influence of irregularities in the strip profile on radial stresses. To achieve that goal, the study was
separated in three steps:
a) Simulation of the influence of artificial irregularities distributed along the strip width on
radial stress calculated at a distance of 400 mm from the coil axis (see Figure 112).
b) Study of the influence of real profile irregularities on radial stress repartition.
c) Validation of the model
5.2.1. Influence of irregularities in the strip profile on radial stresses after cold rolling
The results are summarised on Figure 113 to Figure 116. It appears that:
For important strip profiles (Figure 113), only the defects located on strip centre influence
significantly the radial stresses repartition. In that case, the influence of the defect width, contained
between 50 mm and 100 mm, can be neglected. Moreover, the change from a constant (curves with the
label C) coiling tension of 40N/mm to a decreasing (curves with the label D) coiling tension above a
radius of 600 mm, does not influence significantly the radial stresses repartition.
When the strip profile becomes flatter (Figure 114 and Figure 115), the defects closer from
the strip edges are more and more important for the local radial stresses. The height of the different
defects is of course very important as it can be seen from the comparison of Figure 115 and Figure
116.
The most detrimental defect is the very local peaks, which induce a sharper increase of the
radial stresses. The presence of shaft in the profiles seems to be less detrimental for the sticking
problem.
The influence of real profile irregularities on radial stress repartition is summarised on Figure
117 and Figure 118. These results mainly confirm the previous simulations indicating that shafts in the
optimal profiles are less important that peaks for the increase of the local radial stresses.
53
The Figure 120 compares the radial stresses calculated without inserting a tape, at the position of
the 4 sensors.
These results are to be compared to the measurements after the 10 first windings:
- The calculations give a lower value for the sensor C ; that is due to the fact that the strip is a
little thinner in that region
- After the winding 10, the calculated values for the sensors D and C do not differ from the
values E and B. It is the case for the measured values. A possible explanation would be the existence of
a small crown for the mandrel.
54
Strip natural vibration was measured directly on exit from the rolling line prior to up-coiling at
the four-stand cold rolling mill of EKO Stahl with the aim of detecting possible interrelations with the
occurrence of sticking and scratching defects.
Following successful feasibility tests, the strip vibration measuring system was applied for
recording data on in all 277 coils.
The measurements used a measuring set-up consisting of the following components:
Laser with cooling frame
OVF Controller for the laser vibrometer
PC with monitor for data storage
The Figures 123 and 124 show a sketch and a photograph of the installation site and the
measuring environment. On account of a number of restrictions (installation site, mechanical parts), the
measurement covered only a portion of the potential angle of 10 at which the laser may be aimed at
the strip, in order to achieve still usable readings. In addition, emulsion vapours had a detrimental effect
on the measuring laser. To guarantee that the laser operated according to specification, it was housed in
an air-cooled protective casing (Figure 125).
Within the trial period, a host of measurement data was recorded. A usability assessment showed
71 data sets to be suitable for further vibration analysis. These data sets show that 7 coils are subject to
sticking and 5 coils to scratching.
Figure 126 offers a model diagram of the records and evaluations. In addition to the actual
measured value, the diagram shows the result of an FFT analysis of the vibration signal.
However, this value is applicable only until the beginning of the continuous roll process, as this is
normally the time limit for the availability of measured values. This insight and the amplitude height of
the vibrations do not provide information about the defects to be evaluated, however. Even in coils
where this pattern was not clearly discernible, there was no indication of or tendency to sticking and
scratching. This is due to the fact that the length of the data sets in relation to the coil length does not
suffice to make a representative statement on the overall coil. Most recordings come to an end before
the plant goes into continuous roll mode. The area where, as known from experience, most defects
occur was rarely registered or not covered at all.
A thorough analysis of the records revealed that the data at hand give no clue to any relationship
between statistic characteristics of the measured values and the occurrence of sticking and scratching
defects.
The data records only suggested that the up-coiling was accompanied by vibrations whose
frequencies lay in the region from 15 to 25 Hz depending on the strip geometry.
The design of the device installed at EKO Stahl precluded recording of measured values over the
coil sections where the defects were known to occur. The data collected are limited to the top section of
any coil.
Because of high costs to be involved in required mechanical modification and adjustment, no
further measurements were performed.
55
56
In the period January to December 2001, tests to optimise the technology were carried out
especially at the four stand cold-rolling mill to detect causes and remove defects of the quality
problems, i.e. to reduce strip sticking and coiler scratching.
The following important modifications to the processes and equipment were made that were
supposed to affect occurrence of sticking and scratching defects.
Product-bound increase in set-up coiling tension values to improve coil progress at the temper
mill entry (loose turns)
Product-bound decrease in set-up coiling tension values to prevent sticking
(These changes in coiling tension set-up values were all limited to a range of
1 ... 4 %.)
Adjustments on the flushing mode were undertaken in order to improve strip cleanliness (a
slight decrease in the flushing rate at the heating stage, followed by rate redistribution over the holding
period and initial cooling step and accompanied by saving of hydrogen).
With thicknesses of 0.7 mm, a 6 h long cooling step (slow air cooling under heating bell with
switched-off burners), previously restricted to some selected annealing modes, was adopted in all cases
to reduce sticking defects.
57
Increasing the coiling tension at strip top to 135 % of the set-up value (for a denser coil core)
5.5.3. Global results on sticking and scratching over the whole project period
Batch annealed coils of second and third quality are routinely checked for defect rates during
final quality inspection. The results are logged and later summarised in daily analyses and monthly and
annual quality reports. A current and regular overview is thus always available at EKO Stahl.
The monthly summaries gave rates of 0.03 to 0.21 % for sticking defects and between 0.6 and
1.47 % for scratching defects in the course the project. The scratching marks were therefore about 10
times as frequent as the sticking defects.
Based on the respective rolled product quantities subjected to batch annealing, the rates of
sticking and scratching defects alike were about 5 times more frequent at the four-high tandem mill than
at the reversing mill.
The defect rates could be kept at about the same level during the entire project time.
In the periods of more frequent occurrence, actions to reduce defect rates were taken that
involved appropriate technical and process engineering measures (mainly changes in set-up values of
coiling tension at the four-high tandem mill). In spite of work by specialist teams, the elucidation of
exact causes during such defect prevention campaigns proved impossible.
58
6. Conclusions
6.1. Main results of the research
The pressure between windings during annealing is confirmed as a major ingredient for
sticking, both on trials on samples (direct pressure applied during one hour), and narrow coils (coiling
tension). We have not the confirmation of this fact on industrial coils. The effect of the pressure on
sticking (measured by sheering or peeling force) is nearly proportional.
An increase of the soaking temperature pushes the sticking up, as was striking on narrow coils,
confirmed by statistical studies on industrial coils, and also seen on sticking of pressured samples.
Sticking is also divided by a factor 3 when the roughness is increased from 0.5 m to 1 m then
3.5m, as was shown on narrow coils. This confirms result from bibliography [1] on samples.
Investigations on sticking of samples at the laboratory showed an increase of the surface
oxidation with wet atmosphere, HNx rather than H2 atmosphere, or high Mn or Si content of the steel
grade composition. But no real influence on adherence was seen. CO2 injections as a sticker prevention
brought either no effect, or a remaining oxidation.
A dedicated statistical study together with a model showed that localized irregularities of the
thickness profile is correlated to sticking when their height is positive and greater than 3 m, especially
when the thickness profile is flat (less than 5m of crown).
Scratching was reproduced readily after coiling. The un-coiling tension necessary to get
scratching of the coil was found 5 times more than the coiling tension. Scratching could not be obtained
after annealing of the prepared coil, although we would have expected easier scratching under these
conditions.
But it was seen that very slight adherence between windings is sufficient to avoid scratching, or
said in another way, that scratching can occur only when absolutely no adherence by sticking exits
between the windings. This is somewhat confirmed by a statistical study which shows higher sticking
and lower scratching rates for high temperature annealing cycles, and the reverse for low annealing
temperature.
An industrial measurement of the coiling stresses was developed and installed on the coiler of the
reversing mill at EKO-Stahl. It was aimed at studying the correlation of the stress repartition across the
width with the thickness profile, the flatness profile, and the scratching and sticking defects rates.
Unfortunately, the signals obtained with the system were not good enough to be exploited, mainly due
to severe deformation of the industrial mandrel itself. In a possible future re-development, more care in
the location of the force sensors should make the measurement work in a much better way.
59
One should pay attention to coils whose thickness profile presents a localized over-thickness
greater than 3m. These coils should be diverted from good aspect use or coiled at a lower tension. If a
lot of these cases exist, one should consider increasing the target crown at hot rolling mill.
60
61
Strength
Thermocouple
Stainless
steel inserts
Thermocouple
Samples
Strength
Thermocouple
62
Steel number
Mn
Ti
Nb
Al
Si
C- 0.1%Mn
26
128
52
C- 0.3%Mn
70
315
11
40
IF-0.4%Mn +P
410
14
19
70
34
3.2
750
27
25
77
41
17
C-1.2% Mn
137
1250
12
44
14
C-1.1%Mn 0.2%Si
92
1105
16
12
39
202
63
700
600
500
4
400
3
H2
300
GAS FLOW
H2O x 100
200
T (C)
100
0
0
10
15
20
25
T IME (H OU R S )
700
1500
F (N)
600
T (C)
1000
500
500
400
300
200
-500
100
-1000
0
0
10
15
20
25
T IME (H OU R S)
64
35
30
25
20
15
10
5
0
0
7000
6000
C-0.3%Mn
5000
IF 0.4%Mn +P
4000
IF 0.8%Mn +P,B
3000
2000
C-1.2%Mn
1000
C-1.1%Mn 0.2%Si
0
0
10
65
7000
6000
C-0.3%Mn
5000
IF 0.4%Mn +P
4000
3000
IF 0.8%Mn +P,B
2000
C-1.2%Mn
1000
C-1.1%Mn 0.2%Si
0
0
10
40
35
30
25
20
15
10
5
0
DP (0C)
DP (0C)
DP (bottle)
DP (bottle)
66
0.3
700
CO wet
CO dry
0.25
600
T (C)
500
0.2
400
0.15
300
0.1
200
0.05
100
0
0
10
15
20
25
T IME (H OU R S )
67
Decohesion strength (N
DP-50C
3000
DP0C
DP+10C
2000
1000
0
P
Si
n+
.2%
n
%M
P,B
0
4
.
n
0
n+
%M
Mn
M
IF
%
%M
1.2
%
1
.
8
.
1
C
0.3
0
CC
F
I
DP+10C
DP0C
DP-50C
6000
5000
4000
DP-50C
DP+10C
3000
2000
1000
0
+P
i
%S
Mn
,B
0.2
n
+P
. 4%
n
0
n
M
F
%M
M
I
Mn
2
%
.
%
1
.
-1
.8
.3%
C
0
0
C-1
IF
C
DP+10C
DP-50C
68
6000
5000
4000
DP-50C
3000
DP0C
DP+10C
2000
1000
0
P
Si
n+
.2%
n
%M
P,B
0
4
.
n
0
n+
%M
Mn
M
IF
%
%M
1.2
%
1
.
8
.
1
C
0.3
0
CC
F
I
DP+10C
DP0C
DP-50C
6000
5000
4000
3000
DP-50C
DP0C
2000
DP+10C
1000
0
+P
i
%S
Mn
,B
%
0.2
+P
.4
Mn
n
0
n
Mn
M
F
2%
M
I
.
%
1
%
1
.3%
.
.8
C
0
1
0
C
C
IF
DP+10C
DP0C
DP-50C
69
O1
Al2
Si2
Mn1
Fe3
52.47
7.24
18.13
10.09
12.08
GRAIN AREA 1
52.82
8.62
12.66
10.29
15.61
JOINT PT2
32.44
8.98
21.48
34.07
3.02
JOINT PT3
41.96
5.07
14.4
28.38
10.19
61.3
23.81
Figure 12: SEM view of the C-1.1%Mn 0.2%Si samples after strip decohesion at different magnification (left pictures: area not affected
by sticking right pictures: area affected by sticking) Annealing at
720C / dew point 50C with an applied stress of 5 MPa
70
Al
SEM
Fe
Mn
Si
Figure 13: Auger analysis made on the area not affected by sticking
(Sample C-1.1%Mn 0.2%Si / 720C / DP-50C)
71
C1
O1
Al2
Si2
Mn1
Fe3
0
3.86
5.64
3.38
66.83
62.23
57.04
62.66
0
0
0
0
6.26
5.65
6.32
3.88
21.24
26.55
18.62
27.2
5.67
1.7
12.38
2.88
16.44
11.17
12.92
8.59
7.19
59.52
61.87
60.78
45.08
48.36
0
1.26
1.11
3.23
2.66
0
0
0
9.15
9.25
2.68
0
0
16.71
14.89
21.36
25.7
25.19
17.24
17.64
Figure 14: SEM view of the C-1.1%Mn 0.2%Si samples after strip decohesion at different magnification (left pictures: area not affected
by sticking right pictures: area affected by sticking) Annealing at
720C / dew point +10C with an applied stress of 5 MPa
72
Al
SEM
Fe
Si
Mn
Figure 15: Auger analysis made on the area not affected by sticking
(Sample C-1.1%Mn 0.2%Si / 720C / DP+10C)
73
C1
O1
Al2
Si2
Mn1
Fe3
9.84
0
0
50.86
53.99
58.68
10.02
11.27
5.61
6.63
5.74
4.83
10.96
12.94
25.21
11.69
16.05
5.68
15.05
11.82
11.01
7.71
10.39
59.01
60.64
61.31
58.02
41.65
0
0
0
3.18
5.67
0
0
0
0
7.5
2.56
2.24
1.42
16.55
16.81
23.38
25.3
26.26
14.54
17.99
Figure 16: SEM view of the C-1.2%Mn samples after strip decohesion at different magnification (left pictures: area not affected
by sticking right pictures: area affected by sticking) Annealing at
720C / dew point -50C with an applied stress of 5 MPa
74
C1
O1
Al2
Si2
Mn1
Fe3
FULL
AREA 1
PT2
0
0
0
70.61
71.67
68.35
0
0
0
0
0
0
16.42
7.87
22.1
12.97
20.46
9.55
FULL
AREA 3
PT4
15.46
11.18
11.19
59
62.17
49.93
0
0
8.53
0
0
0
4.49
1.01
17.44
21.06
25.63
12.9
Figure 17: SEM view of the C-1.2%Mn samples after strip decohesion at different magnification (left pictures: area not affected
by sticking right pictures: area affected by sticking) Annealing at
720C / dew point +10C with an applied stress of 5 MPa
75
Decohesion strength (N
6000
5000
4000
3000
2000
1000
.4
IF 0
1H
n
%M
+P
.1
C-1
0
Mn
.2 %
Si
.8
IF 0
n
%M
B
+P ,
.2
C-1
Mn
.3
C-0
CO2
2H
n
%M
Decohesion strength (N
5H
3000
1H
2000
1000
0
1H
P
i
n+
%S
%M
P ,B
0 .2
4
.
n
0
Mn
n+
n
M
IF
M
2%
%
.
%
1
1
.
%M
8
.
3
.
C
0
0
C-1
IF
C-
76
5H
Decohesion strength (N
6000
5000
4000
3000
2000
1000
720C-5%H2
720C-100%H2
660C-5%H2
0
.4
IF 0
P
i
n+
%S
,B
%M
0.2
n
+P
n
%M
Mn
Mn
%M
%
1
.
8
-1.2
.
1
.3%
C
0
C
IF
C- 0
660C-100%H2
6000
5000
4000
3000
2000
1000
0
0
10
20
40
80
160
320
77
(a) :
(b) :
(c) :
= 0 ; T = F
0 ; Fr = T sin
= 90 ; Fr = T sin
Figure 22: Scheme for the sticking force and the uncoiling tension
78
Figure 23 : Pictures of the strip uncoiled from a strongly stuck coil on Arcelor
Research pilot mill
79
Figure 24: Uncoiling behavior of a strongly stuck coil on our pilot mill
80
Figure 25: Uncoiling of stuck coils wound after rolling at different tension
levels
81
82
83
84
85
86
87
Ra = 0,4 m
Figure 32: Evolution of a radius mark on coil side after scratching during
trials
88
89
Figure 33: Stress distribution upon the coiler resulting from different thickness profiles of the strip
90
Figure 34:
Radial stress distribution upon the coiler resulting from different types of flatness defects
91
92
93
94
Figure 38: Sensor installation at the laboratory coiler with electronic unit mounted on the face of the
mandrel body
95
Figure 39: Measuring laboratory coiler with installed force tranducers across the axis and transmitter unit
12
Sensor E
Radial force in kN
10
8
6
c
4
2
0
a
0
Revolutions
50
15000
20000
25000
a
revol. i
: 0
220
revol. i+1
360
220
96
97
Radial forces in kN
0
200
Number of windings
400
Transducer C
Transducer E ( OS )
Transducer D
Coiling
Transducer B
600
Force tra
nsducer
Holding time
Figure 41: Measured course of radial forces in dependence of the number of windings
12
16
20
24
Sensor
a)
D
C
E
Radial force
Measuring position 1
Measuring position 2
Start
End
Number of windings
b)
B
Length distribution
Measuring position 2
C
D
Measuring position 1
Strip width
98
Table 43: Schedule for test series with the laboratory coiler
99
Figure 44: Positions for temperature measuring and arrangement of the strip position for simulating local thickness deviations
100
Figure 45: Stress distribution across the strip width during coiling
101
102
103
104
105
Figure 49: Course of strip- and coiler temperature during cooling time
106
Figure 50: Measured course of radial forces in dependence of the number of windings (during coiling a heated strip)
107
Figure 51: Measured course of radial forces in dependence of the holding time
Figure 52: Feeding tape for simulating strip thickness deviations at strip center;
a) initial state and
b) final state
108
109
Figure 53: Measured course of radial forces in dependence of the number of windings (during coiling a
strip with simulated thickness deviations)
110
conventional coiling)
Figure 54: Measured course of radial forces in dependence of the number of windings (during
111
Figure 55: Design of industrial coiler and mounting position of the sensors
112
Figure 56: Design of industrial coiler and mounting position of the sensors
113
Figure 57: Gradients of measured radial forces for determination of the amplifier measuring ranges
114
115
116
Figure 60: Milled recess on the face of the reel mandrel for picking up the measuring cables
117
Figure 61: Installed measuring coiler in the reversing mill at EKO Stahl GmbH
118
119
120
Figure 68: Measured distribution of radial forces over the barrel length of
the measuring coiler (pass no.1)
121
Figure 70: Course of the measured radial force during coiling and
subsequent uncoiling
122
Figure 71: Course of the measured radial force during coiling with
clamped thick and thin strip head end
B side
A side
1
1
Rolling
directi
Figure 72: Basic positions of the pressure sensors in the mandrel viewed from
top
123
Scale graduation
500
450
+
+
400
+
+
+
+
+
350
300
A vera ge
3 86.2
250
200
150
100
50
1
10
11
12
13
14
15
S e n so r n u m b e r
high sensor
sensiti eness
Problem with reproduce
=176.5 N
Figure 74: Example sensor 14 with high sensor sensitiveness and problems with
reproduce the range
124
High drift
defect
=176.5 N
125
126
Figure 79: Contact zone between sensor and reel sleeve segment
Figure 80: Contact zone between bolt thread and reel sleeve segment
127
128
Figure 83: Total displacement of reel sleeve segment, sensor area detailed
129
130
IF steels
0
85
0
23
14
271
4
0
20
131
0
195
33
1449
91
0
3879 4856 1299 4190 2906 34504 16276 214
3859 4640 1299 3972 2859 32784 16181 214
0
5
1393
1388
0
1
100
99
8
2
1859
1849
4
2
240
234
28
21
1763
1714
45
65
3047
2937
7
4
638
627
0
1
25
24
4%
sticking
2%
high strength
IF steels
IF steels
soft
unalloyed
steel grades
high strength
microalloyed
steel grades
soft
unalloyed
steel grades
Electro steel
grades
soft
unalloyed
steel grades
structural
steel grades
0%
Figure 88: Share of defects at quarto tandem mill classified by steel grade
share of defects at "6-rolls reversing mill"
classify to grade of steel
8%
6%
w ithout defects
4%
scratching
sticking
2%
high strength
IF steels
IF steels
soft
unalloyed
steel grades
high strength
microalloyed
steel grades
soft
unalloyed
steel grades
Electro steel
grades
soft
unalloyed
steel grades
structural
steel grades
0%
131
>2.00mm
>1.75-2.00mm
>1.50-1.75mm
>1.25-1.50mm
>1.00-1.25mm
>0.75-1.00mm
>0.50-0.75mm
<0.50mm
27
81
174
44
37
2
25
7
13
65
241 161 417
40 386 596
2131 10453 23104 8630 9514 1757 7971 5660
2091 10307 22689 8425 9060 1715 7560 5057
16
18
3220
3186
23
15
2760
2722
40
27
2085
2018
8
11
461
442
5
18
885
862
0
1
36
35
0
5
180
175
0
6
281
275
scratching
sticking
3%
>2.00mm
>1.752.00mm
>1.501.75mm
>1.251.50mm
>1.001.25mm
>0.751.00mm
>0.500.75mm
<0.50mm
0%
9%
w ithout defect
scratching
6%
sticking
3%
>2.00mm
>1.752.00mm
>1.501.75mm
>1.251.50mm
>1.001.25mm
>0.751.00mm
>0.500.75mm
<0.50mm
0%
>1.5m
>1.4-1.5m
>1.3-1.4m
>1.2-1.3m
>1.1-1.2m
>1.0-1.1m
>0.9-1.0m
=0.8-0.9m
scratching
sticking
2%
>1.5m
>1.41.5m
>1.31.4m
>1.21.3m
>1.11.2m
>1.01.1m
>0.91.0m
0.80.9m
0%
Figure 94: Share of defects at quarto tandem mill classified by coil width
share of defects at "6-rolls reversing mill"
classify to width
8%
6%
w ithout defects
4%
scratching
sticking
2%
>1.5m
>1.4-1.5m
>1.3-1.4m
>1.2-1.3m
>1.1-1.2m
>1.0-1.1m
>0.9-1.0m
0.8-0.9m
0%
133
>31.0t
>27.5-31.0t
>24.0-27.5t
>20.5-24.0t
>17.0-20.5t
>13.5-17.0t
>10.0-13.5t
=7.0-10.0t
2
3
11
86
102
123
48
22
8
23
66
218
499
727 237 140
409 1599 3372 13502 14992 22406 9469 3424
399 1573 3295 13198 14391 21556 9184 3262
2
4
10
25
26
20
5
0
1
4
5
14
29
27
13
8
116 271 475 1614 3193 3017 938 266
113 263 460 1575 3138 2970 920 258
scratching
sticking
2%
1%
>31.0t
>27.531.0t
>24.027.5t
>20.524.0t
>17.020.5t
>13.517.0t
>10.013.5t
7.0-10.0t
0%
Figure 97: Share of defects at quarto tandem mill classified by coil weight
share of defects at "6-rolls reversing mill"
classify to weigth
5%
4%
w ithout defect
3%
scratching
2%
sticking
1%
>31.0t
>27.531.0t
>24.027.5t
>20.524.0t
>17.020.5t
>13.517.0t
>10.013.5t
7.0-10.0t
0%
defect 24
defect 25
30
0
0
4
1
11
0
16
2
0
0
0
17
6
0
0
0
4
0
0
0
0
0
1
0
0
0
0
0
0
0
20 804 474
0
0
0
0
0
0
8
45 20
1
6
2
11 31 13
0
0
0
12 39 15
1
8
3
0
2
0
0
0
0
0
1
0
10
1
0
5
60 20
0
6
0
0
2
0
0
0
0
0
28 10
1
9
2
0
0
0
0
16
2
0
11
4
1
17
7
2
23
8
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
% defect scratching
defect 23
10
0
0
1
0
1
0
3
0
0
0
0
0
4
1
0
0
0
0
0
1
0
0
1
0
0
0
0
0
0
0
% defect sticking
defect 22
1
0
0
0
0
1
0
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
defect 69
number of coils
10413
0
10
1385
821
1057
0
1145
220
42
67
19
747
1227
124
18
15
914
302
26
182
95
350
946
0
0
0
42
167
296
7
defect 40
0,59
0,00
0,00
0,87
0,24
2,27
0,00
2,62
1,36
0,00
0,00
0,00
3,61
1,39
0,81
0,00
0,00
0,44
0,33
0,00
0,55
0,00
0,29
0,42
0,00
0,00
0,00
0,00
0,00
0,00
0,00
7,72
0,00
0,00
3,25
0,73
2,93
0,00
3,41
3,64
4,76
0,00
5,26
0,13
4,89
4,84
11,11
0,00
3,06
2,98
0,00
8,79
11,58
4,86
2,43
0,00
0,00
0,00
0,00
0,60
0,00
0,00
The defects sticking and scratching were split up of EKO for a better evaluation. In the case
of the defect sticking decides the position and the appearance about the classification. The
difference between defect 40 and 69 lies in the appearance of the defect.
Defect 22:
point sticking
defect 40:
scratching
Defect 23:
edge sticking
defect 69:
surface mark
Defect 24:
surface sticking
Defect 25:
ridge sticking
Table 99: Statistics of defect coils depending on the annealing regime (1st
half of year 2002)
135
20,00
15,00
sticking
scratching
10,00
5,00
181
180
176
175
172
170
165
160
155
150
149
148
147
145
140
137
135
120
116
115
112
110
102
101
100
0,00
12
scratching
sticking
10
0
100
110
115
120
125
135
140
147
148
150
155
160
165
180
136
181
15
sticking
scratching
12
2
sticking [%]
scratching [%]
R = 0,6655
R = 0,2914
-1
590
600
610
620
630
640
650
660
670
680
690
0
700
Figure 102: Correlation between the annealing cycle soaking temperature and
sticking and scratching defects
137
% defect scratching
% defect sticking
0 9 6 40 1 2,15 6,15
0 4 1 31 1 0,71 4,40
2 5 1 37 1 1,22 5,64
0 6 2 23 4 1,19 3,42
3 6 4 26 0 2,01 4,01
1 3 3 20 2 0,93 3,10
1 4 6 26 3 1,65 3,91
2 8 1 41 0 1,31 5,99
2 7 2 28 1 1,68 4,28
9 3 2 30 0 2,12 4,55
0 2 2 33 0 0,60 4,95
1 2 2 33 3 0,74 4,90
1 2 1 29 2 0,58 4,19
1 10 3 25 1 2,06 3,68
0 8 0 29 1 1,19 4,33
1 13 0 29 2 2,08 4,30
2 7 0 34 0 1,28 5,45
0 2 2 19 0 0,64 3,05
0 5 1 27 0 0,79 4,29
0 1 0 29 3 0,16 4,55
0 2 1 29 0 0,48 4,68
2 4 3 19 0 1,16 3,16
3 3 3 27 1 1,35 4,05
0 3 3 19 4 0,88 2,78
1 3 3 27 1 0,94 4,23
1 5 3 24 2 1,19 3,57
4 4 1 27 5 1,36 4,09
0 4 1 31 3 0,74 4,56
0 8 4 32 3 1,67 4,86
1 0 4 26 3 0,75 3,87
2 6 3 32 1 1,80 5,23
1 5 3 26 0 1,40 4,05
defect 69
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
defect 40
defect 23
650
704
656
673
648
645
665
685
654
660
667
673
692
679
670
674
624
623
630
637
620
602
667
683
639
672
660
680
659
671
612
642
defect 25
defect 22
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
defect 24
number of coils
annealing place
% defect scratching
% defect sticking
defect 69
defect 23
2 2 1 35 1 0,79 5,54
2 9 3 32 1 2,08 5,12
1 2 0 32 2 0,48 5,14
1 1 1 42 2 0,47 6,61
4 3 3 31 4 1,56 4,84
2 4 3 44 4 1,18 6,50
6 2 4 29 0 2,01 4,87
2 3 0 30 2 0,74 5,54
0 3 2 28 4 1,00 4,68
2 13 1 40 4 2,45 6,13
5 2 2 35 4 1,55 6,04
2 4 0 34 0 0,92 5,22
6 3 0 14 1 1,69 3,37
4 1 2 23 1 1,63 5,36
5 2 0 22 0 1,75 5,50
2 0 0 28 2 0,42 5,94
2 3 0 21 3 1,12 4,72
2 3 2 15 2 1,40 3,01
3 6 1 34 0 1,90 6,45
3 3 0 40 1 1,19 7,94
4 1 3 34 3 1,32 5,61
1 2 3 35 3 0,96 5,58
2 2 4 17 0 1,50 3,65
1 4 2 35 0 1,11 5,54
5 6 2 38 1 2,02 6,40
6 3 3 33 2 1,91 5,26
5 4 2 36 1 1,87 6,12
4 1 1 25 3 0,90 3,76
6 3 1 30 1 1,58 4,74
3 2 4 35 3 1,32 5,12
defect 40
defect 22
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
defect 25
number of coils
632
625
622
635
640
677
596
542
598
653
579
651
415
429
400
471
445
499
527
504
606
627
466
632
594
627
588
665
633
683
defect 24
annealing place
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
138
7,00
6,00
5,00
sticking
4,00
scratching
3,00
2,00
1,00
26
21
16
11
0,00
7,00
6,00
5,00
sticking
4,00
scratching
3,00
2,00
1,00
61
56
51
46
41
36
31
0,00
139
annealing hood
number of coils
defect 22
defect 23
defect 24
defect 25
defect 40
defect 69
% defect sticking
% defect scratching
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
2382
2337
2311
2423
2330
2177
2335
2299
2294
2403
2321
2365
2303
2270
2263
1139
1190
1129
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
1
0
13
7
12
9
7
9
12
7
7
10
7
6
7
7
7
4
1
2
13
10
20
17
16
19
7
20
17
12
16
23
11
13
10
9
11
7
6
6
11
4
6
14
8
5
10
6
11
2
9
6
9
1
4
3
100
105
99
139
127
121
103
123
106
100
132
95
105
113
119
56
45
47
7
9
2
4
8
10
4
7
3
2
7
6
10
2
11
3
6
2
1,26
0,90
1,77
1,16
1,24
1,93
1,11
1,26
1,48
1,17
1,34
1,31
1,13
1,15
1,15
1,23
1,26
1,06
4,20
4,49
4,28
5,74
5,45
5,56
4,41
5,35
4,62
4,16
5,69
4,02
4,56
4,98
5,26
4,92
3,78
4,16
5,00
4,00
sticking
3,00
scratching
2,00
1,00
18
17
16
15
14
13
12
11
10
0,00
1
6,00
number of hood
140
defect 40
defect 69
% defect sticking
% defect scratching
defect 25
defect 24
defect 23
defect 22
number of coils
annealing position
1 11482 0 32 79 39
2 11483 0 47 77 27
3 11477 1 36 63 31
4 3671 1 19 29 23
5 164 0 0 3 1
556
564
545
162
8
35
29
28
11
0
1,26
1,25
1,09
1,93
2,44
4,84
4,91
4,75
4,41
4,88
5,00
4,00
sticking
3,00
scratching
2,00
1,00
0,00
number of position
Profile (m)
Over-thickness (m)
Sticking
12_01
12_02
12_03
12_04
12_05
12_06
12_07
12_08
12_09
12_10
14
14
7
10
6
23
2
10
11
2
1
3
6
15
8.5
2
2
4
3.5
6
OK
NOK
NOK
NOK
NOK
OK
OK
NOK
NOK
NOK
141
0.775
0.775
Peak - 50 mm
Peak - 100mm
p121
p111
0.770
p211
p221
0.770
p321
p311
p112
0.765
p122
0.765
p222
p212
p312
0.760
p322
0.760
p123
p113
p213
0.755
p223
0.755
p313
p323
0.750
0.750
0.745
0.745
0
0.775
400
800
1200
1600
0.775
Shaft - 50 mm
400
800
1200
Shaft - 100mm
p124
p114
0.770
p214
p224
0.770
p324
p314
p115
0.765
p125
0.765
p225
p215
p315
0.760
p325
0.760
p126
p116
p216
0.755
p226
0.755
p316
p326
0.750
0.750
0.745
0.745
0
400
800
p117
0.775
1200
1600
Positive step
p328
p119
0.760
p219
p129
p229
p319
0.755
0.750
0.750
0.745
0.745
400
Negative step
p228
0.765
p318
1600
p128
p218
0.755
1200
p327
0.770
p118
0.760
800
p227
p317
0.765
400
p127
0.775
p217
0.770
1600
800
1200
1600
p329
400
800
1200
1600
142
-15
-15
Stress (N/mm2)
Stress (N/mm2)
-35
-55
111
112
-75
113
-35
-55
116
115
-75
-95
114
-95
-115
1
11
13
15
-115
17
-15
-15
-35
-35
-55
119
11
13
15
17
118
-75
100
-55
129
128
-75
117
127
-95
-95
-115
-115
1
7
9
11
Along the with
13
15
17
-15
-15
-35
-55
100-0mm
-75
114-50mm
-95
7
9
11
Along the with
11
13
15
17
100- C
100- D
-75
111- C
111- D
-95
111-50mm
121-100mm
-115
1
-55
-115
1
-35
124-100mm
Influence of peaks
and shaft width
Stress (N/mm2)
Stress (N/mm2)
Stress (N/mm2)
Stress (N/mm2)
13
15
17
11
13
15
17
143
-15
-15
-35
-55
Stress (N/mm2)
Stress (N/mm2)
211
212
-75
213
-95
-35
216
-55
215
-75
214
-95
-115
-115
1
11
13
15
17
11
13
-15
-15
-35
-35
-55
17
219
-75
200
-55
229
228
-75
218
227
217
-95
-95
-115
1
7
9
11
Along the with
13
15
17
-15
-15
-35
-35
Stress (N/mm2)
Stress (N/mm2)
15
Stress (N/mm2)
Stress (N/mm2)
-55
200-0mm
-75
214-50mm
Influence of peaks
and shaft width
-95
7
9
11
Along the with
13
15
17
200- C
-55
200- D
211- C
-75
211- D
224-100mm
-95
211-50mm
221-100mm
-115
-115
1
7
9
11
Along the with
13
15
17
7
9
11
Along the with
13
15
17
144
-15
-15
-35
-55
Stress (N/mm2)
Stress (N/mm2)
311
312
-75
313
-95
-35
-55
316
315
-75
314
-95
-115
-115
1
11
13
15
17
-15
-15
-35
-35
-55
319
-75
11
13
15
318
300
-55
329
328
-75
327
317
-95
-95
-115
-115
1
7
9
11
Along the with
13
15
17
-15
-15
-35
Stress (N/mm2)
Stress (N/mm2)
17
Stress (N/mm2)
Stress (N/mm2)
300-0mm
314-50mm
-55
324-100mm
311-50mm
-75
7
9
11
Along the with
13
15
17
-35
300- C
-55
300- D
311- C
-75
311- D
321-100mm
Influence of peaks
and shaft width
-95
-95
-115
1
7
9
11
Along the with
13
15
17
7
9
11
Along the with
13
15
17
145
-15
-15
Stress (N/mm2)
Stress (N/mm2)
-35
-55
311
312
-75
313
-35
-55
316
315
-75
-95
314
-95
-115
1
11
13
15
17
-15
-15
-35
-55
319
318
-75
11
13
17
-35
300
-55
329
328
-75
317
327
-95
-95
-115
1
11
13
15
17
-15
-15
-35
-55
300-0mm
314-50mm
-75
324-100mm
11
13
15
17
-35
300- C
300- D
-55
311- C
311- D
-75
311-50mm
Influence of peaks
and shaft width
-95
Stress (N/mm2)
Stress (N/mm2)
15
Stress (N/mm2)
Stress (N/mm2)
-95
321-100mm
-115
-115
1
11
13
15
17
11
13
15
17
146
0.775
0.77
0.765
0.76
0.755
00
16
00
14
00
12
00
10
0
80
60
0
40
20
0.75
5
-15
1_2
2_2
3_2
4_2
-35
-55
-75
1
7 9 11 13 15 17
Along the with
147
148
-6
B
C
D
E
-5
-4
-3
-2
-1
0
0
10
20
Number of windings
30
40
-7
E
D
C
B
-6
-5
-4
-3
-2
-1
0
0
10
20
30
Number of windings
40
149
Radial forces in kN
wrapped up foil
Transducer C
without
wrapped
up foil
5
4
Transducer D
longitudinal
strip tension:
9.8 kN
3
2
Transducer E
(OS)
Transducer B
1
0
0
10
20
30
Number of windings
40
place of installation
Laser
holder
holder
rolling direction
coiler
coil
Sundwigroller
driving table
Figure 123: Sketch for the test set-up of the vibration measurement
with Laser-vibrometer
150
nd
Possible 2 place of
laser installation
Place of Laser
installation
Laser
Area of measurement
Coiling
mandrel
driving table
Figure 124: Picture of the installation site and the measuring environment
Supply for
blow off lens
Cooling input
151
Header and
processing data
measured
value
strength
FFT analysis
(frequency range 5-40 Hz)
152
Figure 127: Result of process capability analysis of the coiler tension at the
tandem mill (Example for November 2004)
Figure 128: Partial high noise level of coil nr 338544 at temper mill with
peaks (tendency to sticking) and the coiler tension at tandem mill
153
Figure 129: A normal noise level of coil nr 337301 at temper mill and the
coiler tension with strong variations at tandem mill
Figure 130: Noise level of coil nr 301640 with differences in level at temper
mill and the normal tension at tandem mill
154
Figure 131: Noise level of coil nr 310405 with valleys (slack windings ?) and
differences in level at temper mill and the normal tension at tandem mill
Figure 132: Noise level of coil nr 305983 with valleys (slack windings ?) at
temper mill and normal tension at tandem mill
155
G_Pegel [dB]
Bd-Nr: 244375
RNR: 19432
115
110
105
100
Geruschpegel am Dressiergerst
95
90
BZ G4-Aufh [kN]
85
90
80
70
Haspelzug am Quartotandem
60
50
40
30
2500
2000
1500
1000
500
A h
[]
Figure 133: Very high noise level of coil nr 244375 at temper mill and normal
tension at tandem mill. This coil was recorded as sticking coil
Bild: QTB12
Aut: QT_MESSEN_V6
DAC: MPL QT_V6
H-Strom [kA]
Haspelzug [kN]
0
100
Haspelzug
100 % Haspelzug
80
Soll : 41 kN
Ist : 41.6 kN
60
40
20
0
0
500
1000
1500
2000
Qualittsanalyse
Quartotandem
2500
Bandlnge [m]
HGA-Bund
x-Raster: 3.65 m
Bd-Nr: 244375
0.97 mm x 1260 mm
St-M: 313
Figure 134: It is the same coil as previous figure. Set points (red points and
green line) and actual values (black line) are normally at tandem mill.
Beginning and end of coiler tension is reflected to previous figure
156
0,80
0,60
scratching
sticking
0,40
0,20
dec
nov
oct
sep
aug
jul
jun
mai
apr
mar
feb
jan
0,00
point sticking
0,15
edge sticking
surface sticking
0,10
ridge sticking
0,05
dec
nov
oct
sep
aug
jul
jun
mai
apr
mar
feb
0,00
jan
0,20
157
ANNEX 1
1. OBJECTIVES
Batch annealing remains a significant workshop in cold plants. Two of its
major problems are sticking and scratches, both defects of surface aspect
unacceptable for automotive industry. One can think that sticking and scratching are
strongly related.
One objective of the present project is to enlarge the scope of previous
studies on sticking, generally done on sheet samples, both with other parameters
(atmosphere, steel composition), and by changing size of samples (laboratory tests
on narrow coils, industrial tests) .
The change in size for sticking experiments will allow to validate previous
results on sheet sample and to experimentally quantify the effect of parameters
inaccessible on sheet samples such as coiling tension, thermal stresses, flatness,
thickness and thickness profile (global and localized).
Another objective is to investigate and quantify scratching phenomenon,
particularly as a counterpart of sticking. This can only be made using coils and is
easier at laboratory scale (narrow coils).
We also aim at defining connection between force adherence inside coil and
sticking or scratching apparition. These relationships will be established with the
help of a model assessing coiling stresses and thermal stresses , validated by a
stress measurement at the inner wrap level of industrial coils at their coiling stage.
The possibility of very high soaking temperature for new products with very
low yield stresses will be analysed as regards sticking problems.
All the laboratory tests will be validated on industrial trials and statistical
studies made at EKO Stahl which encounters fair amount of sticking and even more
scratching problems, so the conclusions get more foundations.
158
159
160
The amount (50, 100, 200 mg/m2) as well as the degradation of the oil will be
studied. The oil, which can distillate during heating, will be condensed at the exit of
the furnace. Moreover, the evolution of the gas composition (H2, CO2, CO, H2O,
CH4, and C2H4) in the chamber will be monitored continuously.
2.2.2. Industrial trials on localized overthicknesses
2.2.2.1. Correlation between size of the over-thicknesses
after hot rolling and sticking
On industrial line, localised over-thickness observed and measured at the
exit of the hot rolled mill will be classified in function of their shape and their
influence on sticking will be established. That study should determine the critical
size of the defect, which leads to sticking problems.
2.2.2.2. Sampling of typical defects for characterization (size,
composition, texture,)
Depending on these results, some typical over-thicknesses on the hot rolled
strip will be more precisely studied. Indeed, some coils will be put on an inspection
line at different production step (after hot rolling, pickling, cold rolling and annealing)
for sampling and better characterising the defect (size, composition, texture,) and
its origin.
strip thickness,
161
162
163
164
5. Time Schedule
sem
1
IRSID
Material preparation
sem
2
sem
1
Material preparation
sem
4
sem
5
sem
6
sem
3
sem
4
sem
5
sem
6
CRM
sem
3
sem
2
sem
3
sem
4
sem
5
sem
6
BFI
Theoretical studies (Modelling) (232)
Developing an stressometer for coiler (2331)
Trial plan at EKO
sem
1
sem
2
X
X
X
X
X
X
165
X
X
sem
1
EKO
sem
2
sem
3
sem
4
sem
5
sem
6
X
X
X
X
9. Results
The results of the project will be the subject of a publication in the Technical
Research series .
The research described above will be placed in the area covered by the Executive Committe
(or the Expert Group) : D2 Rolling - flat product
166