Calculation of % Slip in Mill During Rolling by Ajmal (10.09.2014)

CALCULATION OF % SLIP
IN MILL DURING ROLLING
02.07.2010
CALCULATION OF % SLIP IN MILL

DURING ROLLING
SLIP
During rolling there is always present a factor known as
slip.
Slip is the difference between work roll circumferential
speed and the linear speed of the bar , it depends on
many factors such as entry and exit cross-section, back
and front metal tension and friction condition.
Slip are of two types
1. Forward slip if the linear speed of the material is
greater than roll circumferential speed the slip is forward
slip.
2. Backward slip if the linear speed of the material is
less than roll circumferential speed the slip is backward
slip.
2
Copyright 2010 Jindal Steel & Power Ltd.
CALCULATION OF % SLIP IN MILL DURING

ROLLING
ROOT
CAUSE
Slip continuously varies based on many types of physical
condition. Following are the broadly categorized physical
conditions.
1.Wear & tear of roll.
2.Tension in between stands.
3.Temperature of material.
EFFECT
OF THE
SLIP be
DURING
1. What lead speed
percentage
should
kept forROLLING
ARE:
intermediate and braking pinch rolls, so that there
should be no fluttering in the material flow and divide
cut should be proper and clear.
2. The crop length (head cut & tail cut) in Shear#1 was
not consistent with respect to operators editable data
in HMICopyright
Screen.
2010 Jindal Steel & Power Ltd.

ROLLING
What lead speed percentage should be kept for

intermediate and braking pinch rolls, so that there
should be no fluttering in the material flow and
divide cut should be proper and clear.

ROLLING
INTRODUCTION
Pinch rolls are provided to create proper tension in the
material so that material easily travels through water boxes
and there should be enough proper tension for divide shear
to
take proper and clear cut.
MEASUREMENT
We actually calculate the actual linear velocity of the
material with the help of two HMDs (12 and 14). And we
have the linear velocity of NTM, with the help of these
two quantity we calculate the slip of the material. This
slip in turn becomes the lead of the first intermediate
pinch roll. ( First pinch roll after NTM)
5

ROLLING
CALCULATION
Distance between HMD 12 to 14
NTM linear velocity
= 30 m/s
= 49.5 mts
Time taken by material to travel from HMD 12 to 14

captured by logic in PLC
= 1.57 sec
So actual velocity of material
= 49.5/1.57
= 31.528 m/s
So the forward slip of material = 31.528/30
= 1.0509
In percentage
= 5.09 %
6

ROLLING
So the lead for the first intermediate pinch roll should be
slightly
greater than the calculated value.
Calculated is 5.09% so it should be kept around 5.1%. For
next pinch
roll this should slightly higher then the first.
This calculation is automatically done in the plc and displayed
in the
HMI.
This becomes the reference for the operator.
If physical condition changes so the slip and the lead should
also be
changed to match the actual speed of the material.
7

ROLLING

ROLLING

ROLLING
The crop length (head cut & tail cut) in Shear#1

was not consistent with respect to operators
editable data in HMI Screen.
10

ROLLING
In SIROLL (Siemens rolling Technology) for any rolled product the

cross section of the material at stand#6 remains constant
irrespective of any size (8mm to 40mm) of material to be rolled.
Based on that SIROLL (Siemens rolling Technology)
has adopted a fixed slip factor of 2% in the mill logic.
We have observed that the slip continuously varies from 2%-8%
based on many types of physical condition. Following are the
broadly categorized physical conditions.
1.Wear & tear of roll.
2.Tension in between stands.
3.Temperature of material.
WHAT DONE TO MAKE IT CONSISTENT
CAPTURING THE ACTUAL MATERIAL
SLIP
It was necessary to measure the slip for every billet for cut
length consistency.
For this we required two physical location and the reference
11
velocity
of stand#6, the two physical locations are Stand#6 and

ROLLING
CONCEPT
Based on this slip calculation the speed of the material is

determined at the shear. And as the HMD 05 senses the
head it calculates the time to trigger the shear. Since the
slip is not the same in every billet as discussed above so
the trigger time also varies to make the head cut
consistent.
12

ROLLING
Mathematical calculation
Consider
Velocity reference of stand#6
m/s (from plc)
Distance between stand#6 to HMD 05
Time to travel between stand#6 and HMD 05
=V
=Dm
= T sec.
Now the slip is calculated as

Actual material velocity
=Vact m/s (say)
= D/T
% slip
(Vact/V))*100
13
This
slip is now multiplied to stand#6 velocity to make
= (1-

ROLLING
Suppose operator sets the head cut length
=
X m
Distance between HMD05 to SH 01
=
Y m
So total length passed when shear blade bites the material to cut
x mtr
from HMD 05
= X+Y m
Time required for x mtr material passes from the SH01 position
(T1)
= (X+Y)/Z
Suppose time taken by the shear to travel from pass line position
to cut position
= T2
So Sh01 trigger time after HMD 05 head senses
14
(T)
Thank you

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CALCULATION OF % SLIP

IN MILL DURING ROLLING

CALCULATION OF % SLIP IN MILL

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

CALCULATION OF % SLIP IN MILL DURING

What lead speed percentage should be kept for

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

Time taken by material to travel from HMD 12 to 14

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

The crop length (head cut & tail cut) in Shear#1

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

In SIROLL (Siemens rolling Technology) for any rolled product the

CALCULATION OF % SLIP IN MILL DURING

Based on this slip calculation the speed of the material is

Copyright 2010 Jindal Steel & Power Ltd.

CALCULATION OF % SLIP IN MILL DURING

Now the slip is calculated as

CALCULATION OF % SLIP IN MILL DURING

Copyright 2010 Jindal Steel & Power Ltd.

Copyright 2010 Jindal Steel & Power Ltd.

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