Note: Descriptions are shown in the official language in which they were submitted.
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HYBRID ROLLING MILL
REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No.
62/684,437,
filed on June 13, 2018 and entitled HYBRID ROLLING MILL, the content of which
is
hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This application relates to a rolling mill for rolling a metal
substrate and, more
particularly, to a hybrid rolling mill that may be run as a hot rolling mill,
warm rolling mill,
cold rolling mill, or any combination thereof.
BACKGROUND
[0003] Rolling is a metal forming process in which metal stock, such as
aluminum or
aluminum alloys, is passed through one or more pairs of work rolls of a
rolling mill to reduce
the thickness of the metal stock and/or to make the thickness more uniform.
Depending on
the desired properties of the final metal product, the metal stock may be hot
rolled, cold
rolled, and/or warm rolled. Hot rolling generally refers to a rolling process
where the
temperature of the metal is above the recrystallization temperature of the
metal. Cold rolling
generally refers to a rolling process where the temperature of the metal is
below the
recrystallization temperature of the metal. Warm rolling generally refers to a
rolling process
where the temperature of the metal is below the recrystallization temperature
but above the
temperature during cold rolling. Due to the differences between hot rolling
and cold rolling
(such as installation space required), it is common to have a separate rolling
mill dedicated to
each rolling process.
SUMMARY
[0004] The terms "invention," "the invention," "this invention" and "the
present invention"
used in this patent are intended to refer broadly to all of the subject matter
of this patent and
the patent claims below. Statements containing these terms should be
understood not to limit
the subject matter described herein or to limit the meaning or scope of the
patent claims
below. Embodiments of the invention covered by this patent are defined by the
claims below,
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not this summary. This summary is a high-level overview of various embodiments
of the
invention and introduces some of the concepts that are further described in
the Detailed
Description section below. This summary is not intended to identify key or
essential features
of the claimed subject matter, nor is it intended to be used in isolation to
determine the scope
of the claimed subject matter. The subject matter should be understood by
reference to
appropriate portions of the entire specification of this patent, any or all
drawings, and each
claim.
[0005] According to certain examples, a hybrid rolling mill includes a work
stand and a
lubrication system. The work stand includes an upper work roll, a lower work
roll, an upper
backup roll, and a lower backup roll. The lubrication system includes a first
lubricant
applicator and a second lubricant applicator. The first lubricant applicator
is configured to
supply a first lubricant at an entry side of the work stand in a first rolling
mode, and the
second lubricant applicator is configured to supply a second lubricant at the
entry side of the
work stand in a second rolling mode. In some examples, in the first rolling
mode, the first
lubricant applicator is activated and the second lubricant applicator is
deactivated, and in the
second rolling mode, the second lubricant applicator is activated and the
first lubricant
applicator is deactivated.
[0006] According to some examples, a hybrid rolling mill includes a work stand
and a
lubrication system. The work stand includes an upper work roll, a lower work
roll, an upper
backup roll, and a lower backup roll. The lubrication system includes a
lubricant applicator
and an injector. The lubricant applicator is configured to supply a first
lubricant at an entry
side of the work stand in a first rolling mode. The injector is configured to
inject a second
lubricant at the entry side of the work stand in the second rolling mode.
[0007] In certain examples, a method of rolling a metal substrate includes
feeding a metal
substrate through a roll gap between an upper work roll and a lower work roll
of a work stand
of a hybrid rolling mill and rolling the metal substrate in at least one of a
first rolling mode or
a second rolling mode. In some examples, rolling the metal substrate in the
first rolling mode
includes activating a lubrication system such that a first lubricant
applicator supplies a first
lubricant at an entry side of the work stand as the metal substrate is fed
through the roll gap.
In various examples, rolling the metal substrate in the second rolling mode
includes
activating the lubrication system such that a second lubricant applicator
supplies a second
lubricant at the entry side of the work stand as the metal substrate is fed
through the roll gap.
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In some cases, in the first rolling mode, the first lubricant applicator is
activated and the
second lubricant applicator is deactivated, and in the second rolling mode,
the second
lubricant applicator is activated and the first lubricant applicator is
deactivated.
[0008] Various implementations described in the present disclosure can include
additional
systems, methods, features, and advantages, which cannot necessarily be
expressly disclosed
herein but will be apparent to one of ordinary skill in the art upon
examination of the
following detailed description and accompanying drawings. It is intended that
all such
systems, methods, features, and advantages be included within the present
disclosure and
protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The features and components of the following figures are illustrated to
emphasize the
general principles of the present disclosure. Corresponding features and
components
throughout the figures can be designated by matching reference characters for
the sake of
consistency and clarity.
[0010] FIG. 1 is a schematic diagram of a hybrid rolling mill in a first
rolling mode
according to aspects of the current disclosure.
[0011] FIG. 2 is a schematic diagram of one stand of the hybrid rolling mill
of FIG. 1 in the
first rolling mode.
[0012] FIG. 3 is a schematic diagram of the hybrid rolling mill of FIG. 1 in a
second rolling
mode.
[0013] FIG. 4 is a schematic of one stand of the hybrid rolling mill of FIG. 1
in the second
rolling mode.
[0014] FIG. 5 is a schematic of the hybrid rolling mill of FIG. 1 with a first
work stand in
the first rolling mode, a second work stand in the second rolling mode, and a
strip cooling
system.
[0015] FIG. 6 is a schematic diagram of a hybrid rolling mill in a first
rolling mode
according to aspects of the current disclosure.
[0016] FIG. 7 is a schematic diagram of the hybrid rolling mill of FIG. 6 in a
second rolling
mode.
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[0017] FIG. 8 is a schematic diagram of the hybrid rolling of FIG. 6 in a
third rolling mode.
[0018] FIG. 9 is a schematic diagram of a hybrid rolling mill according to
aspects of the
current disclosure
DETAILED DESCRIPTION
[0019] The subject matter of embodiments of the present invention is described
here with
specificity to meet statutory requirements, but this description is not
necessarily intended to
limit the scope of the claims. The claimed subject matter may be embodied in
other ways,
may include different elements or steps, and may be used in conjunction with
other existing
or future technologies. This description should not be interpreted as implying
any particular
order or arrangement among or between various steps or elements except when
the order of
individual steps or arrangement of elements is explicitly described.
Directional references
such as "up," "down," "top," "bottom" "left," "right," "front," and "back,"
among others are
intended to refer to the orientation as illustrated and described in the
figure (or figures) to
which the components and directions are referencing.
[0020] Certain aspects and features of the present disclosure relate to a
hybrid rolling mill
for rolling a metal substrate in a hot rolling mode, a cold rolling mode, a
warm rolling mode,
or any combination thereof. Through the hybrid rolling mill, a rolling plant
can produce both
hot and cold rolled coils of metal at very high quality using the same mill,
which allows for
the production of a wide variety of products at a lower capital cost using
less equipment.
Moreover, the space saved by the hybrid rolling mill within the rolling plant
can be used for
other processing systems and/or additional hybrid rolling mills to increase
the volume and
productivity of the plant and/or can decrease the size requirements of the
rolling plant.
[0021] Aspects and features of the present disclosure can be used with any
suitable metal
substrate, however may be especially useful when rolling aluminum alloys.
Specifically,
desirable results can be achieved when rolling alloys such as lxxx series,
2xxx series, 3xxx
series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, or 8xxx series
aluminum alloys. For
an understanding of the number designation system most commonly used in naming
and
identifying aluminum and its alloys, see "International Alloy Designations and
Chemical
Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or
"Registration Record of Aluminum Association Alloy Designations and Chemical
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Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,"
both
published by The Aluminum Association.
[0022] A hybrid rolling mill includes at least one work stand, and in some
examples, the
hybrid rolling mill may include multiple stands. For example, the hybrid
rolling mill may
include two stands, three stands, four stands, five stands, six stands, or any
other number of
stands as needed or desired. Each stand includes a pair of work rolls that are
vertically
aligned. In some cases, each stand includes a pair of backup rolls that
support the pair of
work rolls. In some examples, each stand also includes a pair of intermediate
rolls. During
rolling of the metal substrate, the metal substrate is passed through a roll
gap defined between
the work rolls. Rolling the metal substrate reduces the thickness of the metal
substrate to a
desired thickness and imparts particular properties on the metal substrate
depending on the
composition of the metal substrate. Depending on the desired properties or
other
considerations for the final metal product, the hybrid rolling mill may be run
in a hot rolling
mode, a cold rolling mode, a warm rolling mode, or any combination thereof. In
some
examples with the hybrid rolling mill, all stands may be run in the same mode,
or at least one
stand may be run in one mode and at least one stand may be run in another
mode.
[0023] Hot rolling generally occurs at temperatures above the
recrystallization temperature
of the metal. For example, in some cases where the metal substrate is aluminum
or an
aluminum alloy, hot rolling may occur at a temperature greater than about 250
C, such as
from about 250 C to about 550 C. In other examples, various other
temperatures for hot
rolling may be used.
[0024] In contrast to hot rolling, cold rolling generally occurs at
temperatures below the
recrystallization temperature of the metal. For example, in some cases wherein
the metal
substrate is aluminum or an aluminum alloy, cold rolling may occur at a
temperature less than
about 200 C, such as from about 20 C to about 200 C. In other examples,
various other
temperatures for cold rolling may be used.
[0025] In some cases, a metal substrate may also be rolled through a warm
rolling process,
which occurs at a temperature below the recrystallization temperature of the
metal but above
the cold rolling temperature. For example, in some cases where the metal
substrate is
aluminum or an aluminum alloy, warm rolling may occur at a temperature from
about 200 C
to about 250 C. In other examples, various other temperatures for warm
rolling may be used.
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[0026] The hybrid rolling mill includes a lubrication system such that the
hybrid rolling mill
can be run in the hot rolling mode, the cold rolling mode, the warm rolling
mode, or
combinations thereof The lubrication system also allows the hybrid rolling
mill to quickly
switch between rolling modes, such as switching from the hot rolling mode to
the cold rolling
mode.
[0027] In various examples, the lubrication system includes a first lubricant
applicator that
is configured to supply a first lubricant at an entry side of the work stand
in a hot rolling
mode and a second lubricant applicator configured to supply a second lubricant
at the entry
side of the work stand in a cold rolling mode. The lubrication system may
include any
number of first lubricant applicators or second lubricant applicators as
desired. During hot
rolling, the first lubricant applicator may be activated and the second
lubricant applicator may
be deactivated, while during cold rolling, the first lubricant applicator may
be deactivated and
the second lubricant applicator may be activated. In other examples, the first
lubricant
applicator may be activated during both hot rolling and cold rolling, and the
second lubricant
applicator may be activated during cold rolling but deactivated during hot
rolling.
[0028] In certain examples, the hybrid rolling mill includes a work roll
cooling system that
is configured to apply a coolant on the outer surfaces of the work rolls to
control a
temperature of the work rolls. In some cases, the cooling system includes a
roll cooling
header at an exit side of the work stand and a coolant containment box.
[0029] In some examples, a strip cooling system is provided after at least one
work stand
and is configured to reduce a temperature of the metal substrate during
processing. In various
examples, the strip cooling system includes a strip cooling header that is
configured to apply
a coolant on at least one surface of the metal substrate to control the
temperature of the metal
substrate. In some examples, the strip cooling system also includes a coolant
removal device
for removing the coolant or drying the metal substrate before the metal
substrate enters a
work stand. In various examples, depending on the configuration of the hybrid
rolling mill,
any number of strip cooling headers and coolant removal devices may be
utilized. The strip
cooling system may be provided at various locations within the hybrid rolling
mill such as
before a first work stand, after a last work stand, between work stands, etc.
[0030] FIGS. 1-4 illustrate a hybrid rolling mill 100 according to various
aspects of the
present disclosure. The hybrid rolling mill 100 is shown with two work stands
102A-B. In
other examples, the hybrid rolling mill 100 may include any desired number of
work stands
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102 such as one work stand 102, three work stands 102, four work stands 102,
five work
stands 102, six work stands 102, or any other number of work stands 102 as
needed or
desired.
[0031] Each work stand 102A-B includes an upper work roll 104A and a lower
work roll
104B vertically aligned with the upper work roll 104A. Each work roll 104A-B
has an outer
surface 106. A gap 108 is defined between the upper work roll 104A and the
lower work roll
104B that is configured to receive a metal substrate 110 during rolling of the
metal substrate
110. During processing, the upper work roll 104A-B and the lower work roll
104A-B are
configured to contact and apply a work roll pressure on the outer surfaces 112
and 114 of the
metal substrate 110 as it passes through the gap 108. Each work stand 102A-B
has an entry
side 116 and an exit side 118. The entry side 116 is generally upstream from
the exit side 118
relative to a direction of movement 120 of the metal substrate 110. In various
examples, each
stand 102A-B may include intermediate rolls and/or backup rolls 105A-B that
support the
work rolls 104A-B during processing. During rolling, as the metal substrate
110 moves in the
direction of movement 120 through the hybrid rolling mill 100, the thickness
of the metal
substrate 110 is reduced to a desired thickness.
[0032] The hybrid rolling mill 100 includes a lubrication system 122. The
lubrication
system 122 includes first lubricant applicators 124 at the entry side 116 that
are configured to
selectively supply a first lubricant 128 (see FIG. 2) to each work stand 102A-
B and second
lubricant applicators 126 at the entry side 116 that are configured to
selectively supply a
second lubricant 130 (see FIGS. 3-4) to each work stand 102A-B. Any desired
number of
first lubricant applicators 124 and second lubricant applicators 126 may be
provided for each
work stand 102A-B, including only one first lubricant applicator 124 and only
one second
lubricant applicator 126. In some examples, in a hot rolling mode, the first
lubricant
applicators 124 are activated and the second lubricant applicators 126 are
deactivated, and in
a cold or warm rolling mode, the second lubricant applicators 126 are
activated and the first
lubricant applicators 124 are deactivated. In other examples, the first
lubricant applicators
124 are activated during both the hot rolling mode and the cold or warm
rolling mode.
[0033] The first lubricant 128 is a lubricant suitable for hot rolling
including, but not limited
to, various rolling oils, a mechanical mixture of oil and water, oil in water
emulsions,
vegetable oils, mineral oils, naturally occurring fatty acids or esters,
synthetic esters, and base
oils. The second lubricant is a lubricant suitable for cold or warm rolling
including, but not
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limited to, various rolling oils, naturally occurring fatty acids, fatty
esters, and fatty alcohols.
In certain examples, the second lubricant is different from the first
lubricant.
[0034] The lubricant applicators 124 and 126 are devices generally suitable
for supplying
the lubricants to the work stands such as various nozzles, headers, injectors,
etc., although
they need not necessarily be the same type of lubricant applicator. For
example, the first
lubricant applicators 124 and second lubricant applicators 126 may utilize the
same or
different lubrication application techniques (e.g., flood lubrication, direct
lubrication, etc.) to
supply the respective lubricants. The lubrication application techniques
include, but are not
limited to, flood lubrication (e.g., neat oil, emulsion, dispersion, chemical
emulsion, flood,
etc.), direct lubrication (e.g., neat oil), or other various suitable
lubrication application
techniques.
[0035] As one non-limiting example and as described in detail below, in FIGS.
1-4, each
first lubricant applicator 124 is configured to directly apply the first
lubricant 128 uniformly
and as a thin layer on the outer surfaces 106 of the work rolls 104A-B when
activated ("direct
lubrication," see FIG. 2), and each second lubricant applicator 126 includes a
nozzle or
header to spray the second lubricant 130 into the gap 108 at the entry side
116 of the work
stands 104A-B ("flood lubrication," see FIG. 3). In other examples, the first
lubricant
applicator 124 may utilize another suitable lubrication application technique
(e.g., flood
lubrication) to supply the first lubricant 128 during hot rolling. Similarly,
in other examples,
the second lubricant applicator 126 may utilize another suitable lubrication
application
technique (e.g., direct lubrication) to supply the second lubrication 130
during cold rolling.
Therefore, depending on the lubrication application technique utilized, the
type of lubricant
applicator used for the first lubricant applicators 124 and/or the second
lubricant applicators
126 may be modified. In other examples, the lubricant applicators 124 and 126
may utilize
similar application techniques (e.g., both lubricant applicators utilize
direct lubrication) (see
FIGS. 6 and 7).
[0036] In some examples, the lubrication system includes valves or other
regulators for
rapid activation or deactivation of the first lubricant applicators 124 and
the second lubricant
applicators 126. In various examples, the valves may be controlled manually or
through a
controller.
[0037] In addition to the lubrication system 122, the hybrid rolling mill 100
includes a
cooling system 132. The cooling system 132 includes cooling headers 134 at the
exit side 118
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of each work stand 104A-B that spray coolant onto the outer surfaces 106 of
the work rolls
104A-B. In some examples, the coolant sprayed by the cooling headers 134
includes water,
although various other coolants suitable for cooling the work rolls may be
utilized such as
emulsions or various surfactant mixtures. In some examples, the cooling system
132 includes
coolant containment boxes 136, which are configured to keep the coolant from
the cooling
headers 134 from contacting the metal substrate 110. Any number of cooling
headers 134 and
coolant containment boxes 136 may be used with the cooling system 132. U.S.
Patent
Application No. 14/707,460 filed May 8, 2015 and titled "Hybrid Oil and Water
Cooled
Rolling" to Gaensbauer et at., the entirety of which is incorporated herein by
reference,
discloses examples of work roll cooling systems that may be used with the
hybrid rolling mill
100.
[0038] In various examples, through the cooling system 132, the temperature of
the work
rolls 104A-B can be controlled while the metal substrate 110 can achieve
desired
temperatures and/or surface qualities (e.g., because the coolant is kept off
of the metal
substrate 110). In addition, by separating the cooling system 132 from the
lubrication system
122, the coolant from the cooling system 132 may be kept separate from the
lubricants from
the lubrication system 122, which may simplify the processing of any fluids
returning from
the hybrid rolling mill 100. In some examples, separating the coolant from the
lubricants also
reduces lubricant consumption and may allow for a simplified coolant house
design and
operation. In various aspects, separating the coolant from the lubricants also
allows for better
control of the temperature of the sheet, which can improve the metallurgical
properties of the
sheet. Separating the coolant may further allow for the better selection of
the lubricant for a
particular rolling mode with a particular rolling profile.
[0039] Depending on desired properties or other considerations for the final
metal product,
the hybrid rolling mill 100 (or individual stands 102A-B of the mill 100) may
be run in a hot
rolling mode, a cold rolling mode, a warm rolling mode, or any combination
thereof. In some
examples, all stands 102A-B of the hybrid rolling mill 100 may be run in the
same mode, or
at least one stand 102A may be run in one mode and at least one stand 102B may
be run in
another mode.
[0040] FIGS. 1 and 2 illustrate the hybrid rolling mill 100 in the hot rolling
mode. In the hot
rolling mode, the metal substrate 110 advances in the direction of movement
120 while
passing through the roll gap 108 defined between the work rolls 104A-B. As the
metal
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substrate 110 advances in the direction of movement 120, the first lubricant
applicators 124
of the lubrication system 122 are activated to supply the first lubricant 128
at the entry side
116 of the work stands 104A-B. In these examples, the second lubricant
applicators 126 are
deactivated while the first lubricant applicators 124 are activated, although
they need not be.
As discussed above, in one non-limiting example, the first lubricant
applicators 124 are
configured to utilize direct lubrication to directly apply the first lubricant
128 uniformly and
as a thin layer on the outer surfaces 106 of the work rolls 104A-B when
activated (see FIG.
2). In some examples, each first lubricant applicator 124 includes an
applicator 138 that
directly applies the thin lubricant layer 128 on the outer surfaces 106 of the
work rolls 104A-
B. In some examples, when the first lubricant applicators 124 are activated,
the applicators
138 contact the outer surfaces 106 of the work rolls 104A-B (see FIGS. 1 and
2), although
they need not. The applicators 138 may be various suitable devices or
mechanisms for
directly applying the thin layer of lubricant on the work rolls 104A-B,
including, but not
limited to, sprayers, wipers, roll applicators, electrostatic applicators, and
various other types
of applicators.
[0041] FIGS. 3 and 4 illustrate the hybrid rolling mill 100 in the cold or
warm rolling mode
where the second lubricant applicators 126 are activated to supply the second
lubricant 130 at
the entry side 116 of the work stands 104A-B. In these examples, the first
lubricant
applicators 124 are deactivated while the second lubricant applicators 126 are
activated,
although they need not be (see FIGS. 6 and 7). As referenced above, in one non-
limiting
example, the second lubricant applicators 126 are configured to utilize flood
lubrication to
spray the second lubricant 130 into the roll gap 108 as the metal substrate
110 advances in the
direction of movement 120.
[0042] In some examples, to switch from the hot rolling mode of FIGS. 1 and 2
to the cold
or warm rolling mode of FIGS. 3 and 4, the first lubricant applicators 124 are
deactivated and
the second lubricant applicators 126 are activated. In various examples,
deactivating the first
lubricant applicators 124 includes adjusting the position of the applicators
138 (see FIGS. 3
and 4) such that the applicators 138 are spaced apart from the work rolls 104A-
B, although
they need not be adjusted in other examples. Deactivating the first lubricant
applicators 124
and activating the second lubricant applicators 126 may include opening and
closing valves
or flow regulators associated with the respective lubricant applicators 124
and 126. In various
examples, switching between rolling modes also includes optionally changing
the work rolls
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104A-B. As one non-limiting example, in some cases, the work rolls 104A-B are
changed
from work rolls 104A-B more suitable for hot rolling to work rolls 104A-B more
suitable for
cold or warm rolling. In other examples, the work rolls 104A-B may not be
changed to switch
between rolling modes. As one non-limiting example, the work rolls 104A-B may
not be
changed when switching the hybrid rolling mill 100 from a warm rolling mode to
a cold
rolling mode.
[0043] In some examples, to switch from the cold or warm rolling mode of FIGS.
3 and 4 to
the hot rolling mode of FIGS. 1 and 2, the second lubricant applicators 126
are deactivated
and the first lubricant applicators 124 are activated. In some examples,
activating the first
lubricant applicators 124 includes adjusting the position of the applicators
138 (see FIGS. 1
and 2) such that the applicators contact the outer surfaces 106 of the work
rolls 104A-B,
although in other examples, the position may not be adjusted. Switching to the
hot rolling
mode may also include opening and closing valves or flow regulators associated
with the
respective lubricant applicators and optionally changing the work rolls 104A-
B.
[0044] Referring to FIG. 5, in some examples, the hybrid rolling mill 100
optionally
includes a strip cooling system 140 that is configured to control a
temperature of the metal
substrate 110 during rolling. Although the strip cooling system 140 is
illustrated between the
work stands 102A-B in FIG. 5, the strip cooling system 104 may be positioned
at various
other locations within the hybrid rolling mill 100. For example, the strip
cooling system 140
may be before the first work stand 102A, after the last work stand 102B, or
between adjacent
work stands 102A-B. Any number of strip cooling systems 104 may be utilized
with the
hybrid rolling mill 100 and may be at various locations within the hybrid
rolling mill 100. In
various examples, the strip cooling system 140 may be used to control the
temperature of the
metal substrate 110 during hot rolling, cold rolling, and/or warm rolling. In
some optional
examples, the strip cooling system 140 may be utilized to reduce the
temperature of the metal
substrate 110 from hot rolling conditions to cold or warm rolling conditions
for subsequent
stands. As one non-limiting example, FIG. 5 illustrates a hybrid rolling mill
100 where the
work stand 102A is in a hot rolling mode and the work stand 102B is in a cold
or warm
rolling mode, and the strip cooling system 140 is positioned so that it cools
the metal
substrate 110 from the hot rolling conditions to the cold or warm rolling
conditions.
[0045] The strip cooling system 140 includes a nozzle 142 or header or other
applicator that
selectively sprays a coolant, such as water or other suitable metal substrate
coolants such as
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emulsions or mixtures of surfactants on the metal substrate 110 as the metal
substrate 110
advances in the direction of movement 120. In FIG. 5, the nozzles 142 are
provided both
above and below the metal substrate 110; however, in other examples, the
nozzles 142 may
only be provided on one side of the metal substrate 110 (e.g., only above the
metal substrate
110 or only below the metal substrate 110). The strip cooling system 140 also
includes
coolant removal devices 144, which may be various suitable devices for
removing the coolant
from the metal substrate 110 including, but not limited to, squeegees, wipers,
blowers, or
various other suitable devices.
[0046] FIGS. 6 and 7 illustrate another example of a hybrid rolling mill 600.
The hybrid
rolling mill 600 is substantially similar to the hybrid rolling mill 100
described above except
that in the lubrication system 122 of the hybrid rolling mill 600, the first
lubricant applicator
124 is a header and the second lubricant applicator 126 is an injector. In a
first rolling mode
(such as the hot rolling mode) illustrated in FIG. 6, the first lubricant
applicator 124 supplies
the first lubricant 128 at the entry side 116 of the work stand 102A while the
second lubricant
applicator 126 is deactivated. As illustrated in FIG. 7, during a second
rolling mode (such as
the cold rolling mode), the second lubricant applicator 126 injects the second
lubricant 130 at
the entry side 116 of the work stand 102A. In one non-limiting example, in the
hybrid rolling
mill 600 of FIGS. 6 and 7, the first lubricant 128 may comprise a mechanical
mixture of
water and oil and the second lubricant 130 may comprise oil. In other
examples, other
lubricants may be used as discussed above.
[0047] FIG. 8 illustrates another example of the hybrid rolling mill 600 in a
third rolling
mode where both the first lubricant applicator 124 and the second lubricant
applicator 126 are
activated.
[0048] FIG. 9 illustrates another example of a hybrid rolling mill 900. The
hybrid rolling
mill 900 is substantially similar to the hybrid rolling mills 100 and 600
except that a single
lubricant applicator 924 is provided. As illustrated in FIG. 9, the lubricant
applicator 924 is in
fluid communication with a first lubricant supply 928 and a second lubricant
supply 930. A
control valve 901 is configured to control the flow of the first lubricant and
the second
lubricant to the lubricant applicator 924. In one non-limiting example, the
control valve 901
is activated such that during a first rolling mode (such as the hot rolling
mode), only the first
lubricant is supplied from the first lubricant supply 928 to the lubricant
applicator 924. In a
second rolling mode (such as the cold rolling mode), the control valve 901 is
activated such
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that the second lubricant is injected into the first lubricant upstream from
the lubricant
applicator 924. In such an example, the first lubricant may be water and the
second lubricant
may be oil. Other lubricants may be used as discussed above. In other
examples, in the
second rolling mode, the control valve 901 may be activated such that only the
second
lubricant is supplied from the second lubricant supply 930 to the lubricant
applicator 924.
[0049] In various examples, a method of rolling the metal substrate 110 with
the hybrid
rolling mill 100 includes feeding the metal substrate 110 through the roll gap
108 between the
upper work roll 104A and the lower work roll 104B of the work stand 102A of
the hybrid
rolling mill 100 and rolling the metal substrate 110 in at least one of a hot
rolling mode or a
cold or warm rolling mode.
[0050] Rolling the metal substrate 110 in the hot rolling mode includes
activating the
lubrication system 122 such that the first lubricant applicators 124 supply
the first lubricant
128 at the entry side 116 of the work stand 102A as the metal substrate 110 is
fed through the
roll gap 108. In some examples, supplying the first lubricant 128 includes
applying a coating
of the first lubricant 128 on the outer surfaces 106 of the work rolls 104A-B
through a direct
lubrication technique.
[0051] Rolling the metal substrate 110 in the cold or warm rolling mode
includes activating
the lubrication system 122 such that the second lubricant applicators 126
supply the second
lubricant 130 at the entry side 116 of the work stand 102A as the metal
substrate 110 is fed
through the roll gap 108. In various examples, supplying the second lubricant
130 includes
spraying the second lubricant 130 into the roll gap 108 between the upper work
roll 104A and
the lower work roll 104B.
[0052] In some examples, in the hot rolling mode, the first lubricant
applicators 124 are
activated and the second lubricant applicators 126 are deactivated, and in the
cold rolling
mode, the second lubricant applicators 126 are activated and the first
lubricant applicators
124 are deactivated. In other examples, in the hot rolling mode, the first and
second lubricant
applicators 124 and 126 are both activated, and in the cold or warm rolling
mode, the first
lubricant applicators 124 are activated and the second lubricant applicators
126 are
deactivated.
[0053] In certain examples, rolling the metal substrate 110 includes adjusting
the work stand
102A between the hot rolling mode and the cold or warm rolling mode by:
deactivating the
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previously activated first lubricant applicators 124 or the second lubricant
applicators 126;
activating the previously deactivated second lubricant applicators 126 or the
first lubricant
applicators 124; replacing the upper work roll 104A with a replacement upper
work roll; and
replacing the lower work roll 104B with a replacement lower work roll.
[0054] In various cases, rolling the metal substrate 110 also includes cooling
the upper work
roll 104A and the lower work roll 104B with a cooling system 132 by: applying
a coolant on
the outer surfaces 106 of the work rolls 104A-B with a pair of cooling headers
134 at an exit
side 118 of the work stand 102A; and removing the coolant from the outer
surfaces 106 of the
work rolls 104A-B with a pair of coolant containment boxes 136 to keep the
coolant off of
the metal substrate 110. The coolant containment boxes 136 may be under vacuum
in some
examples, although they need not be.
[0055] In some aspects, the method includes, after the work stand 102A,
feeding the metal
substrate 110 through the roll gap 108 between an upper work roll 104A and a
lower work
roll 104B of a second work stand 102B of the hybrid rolling mill 100. The
method also
includes rolling the metal substrate 110 at the second work stand 102B in at
least one of the
hot rolling mode or the cold or warm rolling mode. In some examples, the first
work stand
102A is in the hot rolling mode and the second work stand 102B is in the cold
or warm
rolling mode.
[0056] According to some examples, the method optionally includes reducing a
temperature
of the metal substrate 110 between the first work stand 102A and the second
work stand
102B with the strip cooling system 140.
[0057] A collection of exemplary embodiments, including at least some
explicitly
enumerated as "ECs" (Example Combinations), providing additional description
of a variety
of embodiment types in accordance with the concepts described herein are
provided below.
These examples are not meant to be mutually exclusive, exhaustive, or
restrictive; and the
invention is not limited to these example embodiments but rather encompasses
all possible
modifications and variations within the scope of the issued claims and their
equivalents.
[0058] EC 1. A hybrid rolling mill comprising: a work stand comprising an
upper work roll
and a lower work roll; and a lubrication system comprising: a first lubricant
applicator
configured to supply a first lubricant at an entry side of the work stand in a
first rolling mode;
and a second lubricant applicator configured to supply a second lubricant at
the entry side of
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the work stand in a second rolling mode, wherein in the first rolling mode,
the first lubricant
applicator is activated and the second lubricant applicator is deactivated,
and wherein in the
second rolling mode, the second lubricant applicator is activated and the
first lubricant
applicator is deactivated.
[0059] EC 2. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first rolling mode is a hot rolling mode and the
second rolling
mode is a cold or warm rolling mode.
[0060] EC 3. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first lubricant applicator is a direct lubrication
lubricant applicator
comprising an applicator configured to apply a coating of the first lubricant
on an outer
surface of at least one of the upper work roll or the lower work roll.
[0061] EC 4. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first lubricant is a hot rolling lubricant
comprising at least one of
oil or a mixture of oil and water.
[0062] EC 5. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the applicator comprises at least one of a sprayer, a
wiper, a roll
applicator, or an electrostatic applicator.
[0063] EC 6. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the second lubricant applicator is a flood lubrication
lubricant
applicator comprising a sprayer configured to spray the second lubricant into
a roll gap
between the upper work roll and the lower work roll.
[0064] EC 7. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the second lubricant is a cold rolling lubricant
comprising at least one
of oil or a mixture of oil and water.
[0065] EC 8. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first lubricant is different from the second
lubricant.
[0066] EC 9. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, further comprising a work roll cooling system comprising: a
cooling header at
an exit side of the work stand and configured to apply a coolant on an outer
surface of at least
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one of the upper work roll or the lower work roll; and a coolant containment
box configured
to keep the coolant off of a metal substrate processed by the work stand
during rolling.
[0067] EC 10. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the coolant is water, an emulsion, or surfactant
mixture.
[0068] EC 11. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the coolant containment box is under vacuum.
[0069] EC 12. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the work roll cooling system comprises at least two
cooling headers
and at least one containment box at the top work roll.
[0070] EC 13. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the coolant containment box is not under vacuum.
[0071] EC 14. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the work stand is a first work stand and wherein the
lubrication
system comprises at least two first lubricant applicators and at least two
second lubricant
applicators, and wherein the hybrid rolling mill further comprises: a second
work stand
comprising an upper work roll and a lower work roll, wherein at least one
lubricant applicator
of the at least two first lubricant applicators of the lubrication system is
configured to supply
the first lubricant at an entry side of the second work stand in the first
rolling mode; and
wherein at least one lubricant applicator of the at least two second lubricant
applicators of the
lubrication system is configured to supply the second lubricant at the entry
side of the second
work stand in a second rolling mode.
[0072] EC 15. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, further comprising a strip cooling system between the first work
stand and the
second work stand configured to reduce a temperature of a metal substrate
during rolling.
[0073] EC 16. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein in the first rolling mode, the work stand is configured
to roll a metal
substrate having a temperature of at least 250 C, and wherein in the second
rolling mode, the
work stand is configured to roll a metal substrate having a temperature less
than about 200
C.
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[0074] EC 17. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the lubrication system comprises at least two first
lubricant applicators
and at least two second lubricant applicators, wherein a first of the at least
two first lubricant
applicators and a first of the at least two second lubricant applicators are
positioned above a
metal substrate during rolling and proximate to the upper work roll, and
wherein a second of
the at least two first lubricant applicators and a second of the at least two
second lubricant
applicators are positioned below the metal substrate during rolling and
proximate to the lower
work roll.
[0075] EC 18. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, further comprising an upper backup roll and a lower backup roll,
wherein the
upper backup roll is configured to remove lubricant from the upper work roll
and the lower
backup roll is configured to remove lubricant from the lower work roll.
[0076] EC 19. A hybrid rolling mill comprising: a work stand comprising an
upper work roll
and a lower work roll; and a lubrication system comprising: a first lubricant
applicator
configured to supply a first lubricant at an entry side of the work stand in a
first rolling mode;
and a second lubricant applicator configured to supply a second lubricant at
the entry side of
the work stand in a second rolling mode, and wherein the second lubricant
applicator is
deactivated in the first rolling mode.
[0077] EC 20. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first rolling mode is a hot rolling mode and the
second rolling
mode is a cold or warm rolling mode.
[0078] EC 21. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first lubricant comprises oil, and wherein the
second lubricant
comprises a water and oil mixture.
[0079] EC 22. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first lubricant is different from the second
lubricant.
[0080] EC 23. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the lubrication system comprises at least two lubricant
applicators,
wherein a first of the at least two lubricant applicators is positioned
proximate to the upper
work roll, and wherein a second of the at least two lubricant applicators is
positioned
proximate to the lower work roll.
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[0081] EC 24. The hybrid rolling mill of any of the preceding or
subsequent example
combinations, further comprising an upper backup roll and a lower backup roll,
wherein the
upper backup roll is configured to remove lubricant from the upper work roll
and the lower
backup roll is configured to remove lubricant from the lower work roll
[0082] EC 25. A method of rolling a metal substrate comprising: feeding a
metal substrate
through a roll gap between an upper work roll and a lower work roll of a work
stand of a
hybrid rolling mill; and rolling the metal substrate in at least one of a
first rolling mode or a
second rolling mode, wherein rolling the metal substrate in the first rolling
mode comprises
activating a lubrication system such a first lubricant applicator supplies a
first lubricant at an
entry side of the work stand as the metal substrate is fed through the roll
gap, and wherein
rolling the metal substrate in the second rolling mode comprises activating
the lubrication
system such that a second lubricant applicator supplies a second lubricant at
the entry side of
the work stand as the metal substrate is fed through the roll gap, wherein in
the first rolling
mode, the first lubricant applicator is activated and the second lubricant
applicator is
deactivated, and wherein in the second rolling mode, the second lubricant
applicator is
activated and the first lubricant applicator is deactivated.
[0083] EC 26. The method of any of the preceding or subsequent example
combinations,
further comprising adjusting the work stand between the first rolling mode and
the second
rolling mode by: deactivating the previously activated first lubricant
applicator or second
lubricant applicator; activating the previously deactivated second lubricant
applicator or first
lubricant applicator; replacing the upper work roll with a replacement upper
work roll; and
replacing the lower work roll with a replacement lower work roll.
[0084] EC 27. The method of any of the preceding or subsequent example
combinations,
wherein the first rolling mode is a hot rolling mode and the second rolling
mode is a cold or
warm rolling mode.
[0085] EC 28. The method of any of the preceding or subsequent example
combinations,
wherein the first lubricant applicator is a direct lubrication lubricant
applicator, wherein the
first lubricant applicator comprises an applicator, and wherein supplying the
first lubricant
comprises applying a coating of the first lubricant on an outer surface of the
upper work roll
or the lower work roll.
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[0086] EC 29. The method of any of the preceding or subsequent example
combinations,
wherein the first lubricant is a hot rolling lubricant comprising at least one
of oil or a mixture
of oil and water.
[0087] EC 30. The method of any of the preceding or subsequent example
combinations,
wherein the applicator comprises at least one of a sprayer, a wiper, a roll
applicator, or an
electrostatic applicator.
[0088] EC 31. The method of any of the preceding or subsequent example
combinations,
wherein the second lubricant applicator is a flood lubrication lubricant
applicator, wherein the
second lubricant applicator comprises a sprayer, and wherein supplying the
second lubricant
comprises spraying the second lubricant into the roll gap between the upper
work roll and the
lower work roll.
[0089] EC 32. The method of any of the preceding or subsequent example
combinations,
wherein the second lubricant is a cold rolling lubricant comprising at least
one of oil or a
mixture of oil and water.
[0090] EC 33. The method of any of the preceding or subsequent example
combinations,
wherein the first lubricant is different from the second lubricant.
[0091] EC 34. The method of any of the preceding or subsequent example
combinations,
further comprising cooling the upper work roll or the lower work roll with a
cooling system
by: applying a coolant on an outer surface of the upper work roll or the lower
work roll with a
cooling header at an exit side of the work stand; and removing the coolant
from the outer
surface with a coolant containment box to keep the coolant off of the metal
substrate.
[0092] EC 35. The method of any of the preceding or subsequent example
combinations,
wherein the coolant is water.
[0093] EC 36. The method of any of the preceding or subsequent example
combinations,
wherein the coolant containment box is under vacuum.
[0094] EC 37. The method of any of the preceding or subsequent example
combinations,
wherein the coolant containment box is not under vacuum.
[0095] EC 38. The method of any of the preceding or subsequent example
combinations,
wherein the work stand is a first work stand, the first lubricant applicator
is a first work stand
first lubricant applicator and the second lubricant applicator is a first work
stand second
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lubricant applicator, and wherein the method further comprises: feeding the
metal substrate
through a roll gap between an upper work roll and a lower work roll of a
second work stand
of the hybrid rolling mill; and rolling the metal substrate at the second work
stand in at least
one of the first rolling mode or the second rolling mode, wherein rolling the
metal substrate
in the first rolling mode comprises activating the lubrication system such
that a second work
stand first lubricant applicator supplies the first lubricant at the entry
side of the work stand as
the metal substrate is fed through the roll gap, and wherein rolling the metal
substrate in the
second rolling mode comprises activating the lubrication system such that a
second work
stand second lubricant applicator supplies the second lubricant at the entry
side of the work
stand as the metal substrate is fed through the roll gap.
[0096] EC 39. The method of any of the preceding or subsequent example
combinations,
further comprising reducing a temperature of the metal substrate between the
first work stand
and the second work stand with a strip cooling system.
[0097] EC 40. The method of any of the preceding or subsequent example
combinations,
wherein in the first rolling mode, the work stand rolls the metal substrate
having a
temperature of at least 250 C, and wherein in the second rolling mode, the
work stand rolls
the metal substrate having a temperature less than about 200 C.
[0098] EC 41. A hybrid rolling mill comprising: a first work stand comprising
a first upper
work roll and a first lower work roll; a second work stand downstream from the
first work
stand and comprising a second upper work roll and a second lower work roll;
and a
lubrication system comprising: a first lubricant applicator configured to
supply a first
lubricant at an entry side of the second work stand in a first rolling mode;
and a second
lubricant applicator configured to supply a second lubricant at the entry side
of the second
work stand in a second rolling mode, and wherein the second lubricant
applicator is
deactivated in the first rolling mode.
[0099] EC 42. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first rolling mode is a hot rolling mode and the
second rolling
mode is a cold or warm rolling mode.
[0100] EC 43. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first lubricant comprises oil, and wherein the
second lubricant
comprises a water and oil mixture.
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[0101] EC 44. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the first lubricant is different from the second
lubricant.
[0102] EC 45. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, wherein the lubrication system comprises at least two first
lubricant applicators
and at least two second lubricant applicators, wherein a first of the at least
two first lubricant
applicators and a first of the at least two second lubricant applicators are
positioned
proximate to the second upper work roll, and wherein a second of the at least
two first
lubricant applicators and a second of the at least two second lubricant
applicators are
positioned proximate to the second lower work roll.
[0103] EC 46. The hybrid rolling mill of any of the preceding or subsequent
example
combinations, further comprising an upper backup roll adjacent to the second
upper work roll
and a lower backup roll adjacent to the second lower work roll, wherein the
upper backup roll
is configured to remove lubricant from the second upper work roll and the
lower backup roll
is configured to remove lubricant from the second lower work roll
[0104] The above-described aspects are merely possible examples of
implementations,
merely set forth for a clear understanding of the principles of the present
disclosure. Many
variations and modifications can be made to the above-described embodiment(s)
without
departing substantially from the spirit and principles of the present
disclosure. All such
modifications and variations are intended to be included herein within the
scope of the
present disclosure, and all possible claims to individual aspects or
combinations of elements
or steps are intended to be supported by the present disclosure. Moreover,
although specific
terms are employed herein, as well as in the claims that follow, they are used
only in a
generic and descriptive sense, and not for the purposes of limiting the
described invention,
nor the claims that follow.
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