issue 28 |march 2017 - bmpca...primetal technologies ltd.the companyls application for...
TRANSCRIPT
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...to the Spring 2017 issue of our
Members’ Bulletin. Well, we’ve done
it; Brexit is triggered and we now
must carry on working to meet the
challenges - and take advantage of
the opportunities - that the process
will present.
Our last issue reported some encouraging
signs in the UK steel industry and I’m pleased
to say that continues to be the case; particularly
delighted to report that the ownership of
Speciality Steel Group has now been settled as
it becomes part of Liberty Steel.
Another positive move comes as two of the
steel industry’s most influential players combine
forces; a new partnership between Danieli
Centro Recycling and Turkey’s largest private
iron and steelmaker, Tosyali, looks set to storm
new markets.
Elsewhere throughout this issue, member
companies continue to demonstrate the
innovation, skills and resourcefulness which
enables them to buck trends and enter new
markets.
Finally, welcome to two new BMPCA
members; Siemens and Premier Hytemp -
each will bring valuable new skills, services
and expertise to our network.
Welcome
Issue 28 | March 2017
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p3
p7
www.bmpca.org.uk
...get the full story on page 4
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BMPCA welcometwo new members
Da Vinci’s design for arolling mill
Using the science ofmeasurement
Welcome from our newchairman Andy Orme
Danieli Centro
Recyclingforges
historic route toChina
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The doomsday predictionsthat were prevalent during therealisation that the UK had votedfor Brexit have so far proved tobe pessimistic and we are stillfacing an improvement in theeconomy with growth beingaffected only marginally but withinflation looking as if it will peakaround 3% in the coming yeardue partially to the GBPexchange rate weakening againstthe US Dollar and Euro.
Both the FTSE 100 and 250indices have been at record highlevels this year and the latestpredictions are that interest rateswill not increase until the end of
next year. This doesn’t give theimpression of a doomsdayscenario unfolding as weapproach Brexit, although I feelsure that as events unfold in theBrexit negotiations there will besignificant swings in any forwardpredictions.
Since our last bulletin therehave been some stabilisingdevelopments in the UK steelindustry with Liberty SteelGroup concluding the agreementwith Tata Steel to acquire theSpeciality Steel Group. Also theagreement of the Tata Steelworkers to accept significantchanges to their pension in order
to secure jobs and £1bn infunding for the Port Talbot worksmodernisation over the next 10years. There are reports that theproposed merger talks betweenTata Steel and Thyssen have beenput off but as of now these havenot been confirmed by the TataSteel MD.
I look forward to the yearahead and welcoming newmembers to the BMPCA, bothSiemens and Premier Hytemphave joined since our last bulletinand we welcome them into ourassociation.
Message from the Chairman
Association News
Andy Orme Chairman‘‘
‘‘
Members please keep your news
articles coming in. Please visit us at
www.bmpca.org.uk
As this issue of the BMPCA Bulletin is produced the trigger is being
pulled on initiating the UK’s withdrawal process from the European Union.
There will no doubt be many ups and downs as this process waxes and wanes
between possible outcomes during the negotiation period but we can only hope
that the initial timetable of establishing a basic withdrawal treaty by the end of
2017 and a final withdrawal treaty by October 2018 is maintained. If so then a
degree of certainty should return to our future outlook as the earliest possible
date for the UK to leave the EU approaches in March 2019
Global operating Industrial
Automation & Control Ltd., of
Queensway Meadows, Newport, is
the UK’s leading independent systems
integrator of PLC systems, variable
speed drives and Scada.
Alcumus SafeContractor is a
leading third party accreditation
scheme which recognises extremely
rigorous standards in health and
safety management amongst
contractors. It is used by thousands of
organisations in the UK including
SMEs and FTSE 100 companies.
IAC Ltd, which employs 75
people and has an annual turnover of
£8.5m, undertakes complex
integration projects both in the UK
and overseas, for a huge range of
industries including paper, metals
pharmaceuticals, materials handling,
food, chemicals, printing, textiles,
water and nuclear power.
IAC Ltd’s clients include major
players such as Tata Steel, AMEC
Foster Wheeler, Dupont, Eastman,
Evoqua Water Technologies, and
Primetal Technologies Ltd. The
company’s application for
SafeContractor accreditation was
driven by the need for a uniform
standard across the business.
SafeContractor accreditation will
enhance the company’s ability to win
new contracts, and its commitment
to safety will be viewed positively by
its insurers when the company
liability policy is up for renewal.
Gemma Archibald, Director of
Alcumus SafeContractor said: "Major
organisations simply cannot afford to
run the risk of employing contractors
who are not able to prove that they
have sound health and safety policies
in place.
"More companies need to
understand the importance of
adopting good risk management in
the way that IAC Ltd. has done. The
firm’s high standard has set an
example which hopefully will be
followed by other companies within
the sector.
“SafeContractor plays a vital role in
supporting our clients in meeting
their compliance needs, whilst
working with their contractors as
they progress through the
accreditation process.”
IAC Ltd Marketing and HR
Director Kath Lewis, said: “Health and
safety in the workplace is of utmost
importance to everyone at and
associated with IAC Ltd. We are very
pleased to have been recognised with
this accreditation award.
“Safecontractor is a universally
acknowledged and recognised
endorsement which we’re confident
will further enhance IAC Ltds’ stature
and ability to successfully attract new
contracts and new work for our
business.”
for Industrial Automation & Control
Top Safety AccreditationLEADING UK automation and controls business IAC has
been awarded accreditation from Alcumus SafeContractor for
achieving excellence in health and safety in the workplace.
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BACkgrounD ToSieMenS
Siemens is a globalpowerhouse focusing onthe areas of electrification,automation anddigitalisation.
As of September 30, 2016,Siemens had around 351,000employees in more than 200countries. In fiscal 2016, theygenerated revenues of €79.6 bn.
In the UK, Siemens have beenactive for over 170 years and infiscal 2016, generated revenuesof £5bn, employing around15,000 people, including about5,000 in the manufacturingsector, with 14 manufacturing
sites and more than 25 majoroffices.
We provide innovativesolutions to help tackle the UK’smajor challenges in Industry,providing digital solutions to helpmanufacturers to increaseproductivity, efficiency and createprogressively innovativeproducts to drive thetransformation towards thedigital enterprise.
Siemens integrated solutionscan improve manufacturingefficiency along the entire valuechain using intelligent industrysoftware to help simplify themanufacturing process, fromconception to execution.
BACkgrounD ToPreMier HyTeMP
Premier Hytemp is anapproved global supplier ofcomponents for wellheads,trees and downhole toolingto the major originalequipment manufacturersand leading servicecompanies in the oil andgas industry.
Our reputation is foundedupon our engineered solutionsto complex supplyrequirements, innovativeprocessing of materials and ourability to consistently meetchallenging lead times, all ofwhich have been established
over four decades. Today, theability to manufacture andmanage materials andcomponents across the wholesupply chain is at the heart oftheir investment and growthprogramme. Their specialitiesinclude Finished Machining, First Stage Machining, MaterialsManagement, and HeatTreatment
Premier Hytemp haveoperational sites in England,Scotland and the Far East.
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Members News
The Director wishes to welcome Siemens and Premier Hytemp to
membership of the BMPCA. This is a great way to start 2017.
Siemens and Premier Hytemp reinforce our aim of providing a strong
network of manufacturers providing a wide range of services, skills and
expertise to plant manufacturers globally.
BMPCA Directorwelcomes two new members
Forgemasterssecures investment funding
The LEP is providing £650,000from its £52 million BusinessInvestment Fund towards newmachinery at Forgemasters'Brightside Lane machine shops tofacilitate further development intothe advanced manufacture offorgings and castings.
Forgemasters will install twonew machines; a five-axis millingmachine, and a vertical turning latheto enable the three-dimensionalmachining of increasinglycomplicated, ultra-large cast andforged shapes for industries such ascivil nuclear power and defence.
Sir Nigel Knowles, chair at theLEP, said: “We are working on anumber of technology-driveninitiatives and the BusinessInvestment Fund was set up to helpcompanies, such as SheffieldForgemasters and also smallerenterprises to achieve growth.
“It is no secret thatForgemasters sits at the fore-frontof technological developmentswithin the field of large-scaleengineering and this grant will helpthe business to advance itscapabilities even further, placingSheffield City Region at the leadingedge of manufacture into civilnuclear, defence, power generationand innovative projects such as theproposed Swansea Bay tidallagoon.”
The majority of the £6.5 millioninvestment will be fromForgemasters' own developmentbudget, but having pledged suchhigh levels of investment, thecompany qualified for the LEPBusiness Investment Fund grantwhich makes up ten per cent of theoverall project value.
James Tate, chief finance officerat Sheffield Forgemasters, said: “We
are delighted that the Sheffield CityRegion LEP has granted this fundingtowards what is a milestoneinvestment for the company andone which will create greaterefficiencies for future projects aswell as allowing for furtheradvanced machining techniques.
“The company has placed inwardinvestment high on its list ofpriorities since the managementbuyout in 2005 and we still investsignificantly more in research anddevelopment as a percentage ofturnover than most UKmanufacturers.
“There is no doubt that Sheffieldis a centre of excellence foradvanced manufacturing and thisinvestment will help us to deliver anincreasing volume of milling andturning work for defence andpower generation contracts usinginternal facilities to maintain high
tolerances and manufacturingstandards.”
The LEP brings togetherbusiness leaders and localpoliticians to make decisions thatdrive economic growth and createnew jobs within the SCR. The Boardis made up of 19 members – tenbusiness leaders and nine localauthority leaders.
Sheffield City Region comprisesof a core city, towns and markettowns, open countryside and asignificant rural economy. The CityRegion encompasses more than 1.8 million people andapproximately 700,000 jobs.
It is made up of the nine localauthority areas of Barnsley,Bassetlaw, Bolsover, Chesterfield,Derbyshire Dales, Doncaster, NorthEast Derbyshire, Rotherham andSheffield.
Engineering specialist Sheffield Forgemasters has secured funding from the Sheffield City Region'sLocal Enterprise Partnership (LEP) towards a £6.5 million investment.
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Members News
4
Steel master Danieli Centro Recycling
European steel expertDanieli Centro Recyclinghas forged a path to newmarkets, securing its firstshredder sale in China
forges historic route to
With a factory and service
department already established
in Shanghai, the sale of the DCR
6290 to the Valuda Group marks
a new phase for the company,
bringing 25 years of experience
and European quality engineering
to the emerging Chinese scrap
processing industry.
Engineering Group Leader
Terry Keyworth said the deal
demonstrated Danieli Centro
Recycling’s commitment to
offering the highest
manufacturing standard on the
market. “With over 50 machines
in operation throughout the
world, we were keen to apply
our expertise to Chinese
operations. Although aspects of
the industry differ to our more
traditional home market, the
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Members News
5
China
machine we have supplied works
to the same basic principles of
precision manufacturing with
wear parts designed for optimum
life and minimum downtime.”
The DCR 6290 is an entry-
level machine designed to
process relatively small volumes
of up to 30 tonnes per hour.
Based in Guangzhou, the Valuda
Group aims to utilise the
machine to treat end of life
vehicles (ELVs). In common with
Danieli Centro Recycling, it has
ambitious plans to expand across
China and recently won a
contract for the processing of
municipal waste in Shanghai. The
arrival of the new shredder
coincides with the company’s
plans to take scrap processing a
step further, from manual sorting
of non-ferrous materials to an
automated ELV processing
operation.
Keyworth says the Danieli
Lynxs shredding machine offers a
range of features that help it to
stand out from the competition
and which will ensure longevity
with low cost maintenance.
Perhaps the key point is Danieli
Centro Recycling’s approach to
wear parts. Instead of treating the
hard-working, fully machined
rotor as a consumable, it is
considered an integral part of the
machine, with wear parts such as
caps added to help balance the
rotor, reduce the cost of
replacing parts, and aid power
consumption with a design that
provides more inertia.
Keyworth added: “Our rotor is
a very highly precision-made
piece of equipment with spider
arms and end disks heated and
shrink fitted to the shaft. Similarly,
I believe we are alone in
supplying welded radial stiffeners,
which support the grids at four
points of contact. These provide
extra stiffness to castings and
bracing to the machine itself.”
In addition, the shredder
features independent hydraulic
cylinders for the kick-out door,
allowing the door to operate
independently to the machine in
an emergency, and single shaft
compression feed roller, which
helps to regulate the feed flow.
Keyworth said: “The feeding
system is linked to a completely
automated HMI (human machine
interface) system which monitors
rotor RPM, motor amps, and the
compression feed roller motor
and adjusts the settings by the
second.” Keyworth concluded:
“This is the first plant of its kind
in China and we are looking
forward to bringing a new level
of design and operation to the
market. We have a large factory
with 3,000 people working in
Shanghai and are fully equipped
to supply complete support to
the Valuda Group.
“We fully expect to be an
integral driver in Valuda’s plan to
both increase and improve ELV
processing capability, and to offer
China the benefit of our
specialised know-how and
manufacturing expertise.”
With over 50 machines in
operation throughoutthe world, we werekeen to apply ourexpertise to Chinese operations.
‘‘ ‘‘
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The Oran site produces over onemillion tonnes of liquid steel peryear from its electrical furnace. Thearrival of the shredder is expectedto improve profit yields throughgreater flexibility on scrappurchasing, and a reduction infurnace transformation costs.
Davide Braga, Executive Manager,Technical Sales at Danieli CentroRecycling described the company’sexperience as a steelmaker ascrucial to the sale: “The mostfamous Danieli slogan sums it upperfectly: We know the art ofsteel. - We know exactly what asteelmaker is looking for in aproduct. We are not only sellingrecycling equipment, we alsoprovide added value in terms of know-how.”
The DCR 2227 – a 4,000 hpmachine prides itself on an outputof up to 100 tonnes per hour, with ayearly capacity of up to 400,000tonnes of shredded scrap. Itincludes, as standard, features suchas a high inertia, long-life, enclosedand capped rotor, heavy-duty rotorbearing housings, and a single unifiedbase structure to increase strengthin the vicinity of the anvil.
The shredder offers lower KWhpower consumption per tonneproduced and, in order to cutmaintenance time and the need toreplace expensive parts, DanieliLynxs has developed an innovativehammer pin puller.
However, Braga says that flexibilityin terms of feedstock purchasing isthe greatest benefit.
“When a customer invests, theywant to know how soon they canrecover outlay costs. In general,when producing one tonne of steelwith an electrical furnace, 80 percent of the total production costcomes from the cost of rawmaterials. Sourcing less expensivescrap, shredding, and raising thequality of your final producttherefore impact enormously onprofitability.
“In Algeria, standard scrap tendsto be of low yield and density, soinvesting in a shredder gives theopportunity to source cheaperfeedstocks and produce fresh scrapcompared with imported materialwhich may have lost one per cent ofits yield through oxidization duringstorage or transport. Our technicalteam recommends a density ofbetween 0.9 and 1.1. If the materialbecomes too dense, it can lead toinclusions within the scrap. A moreopen feedstock will have a higherheat exchange, which results in ashorter melting time.”
He concludes: “Theseconsiderations are very importantto the final material, and thereforevery important factors in the designof the mill – and in the design of thegrids and hammers. Our dedicatedresearch and development team hasproduced a range of grids and
hammers to suit all applications, andthanks to our subsidiary DanieliRiverside Products, which suppliesspare parts, Danieli CentroRecycling is able to apply itsexperience in shredderconsumables to each sale.”
Danieli Centro Recycling alreadyoperates four shredders acrossAfrica and three in the Middle East.However, the deal with Tosyali is afirst. The choice of Danieli CentroRecycling for Algeria confirms us asthe first choice in that market.Turkey, meanwhile, produces morethan 30 million tonnes of liquid steelper year, making it one of thehighest producing countries in theworld. We are extremely keen tobuild on our relationship withTosyali, using our knowledge andexperience to support such a majorplayer.
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Members News
Tosyali & Danieli team upto install the first scrap shredding plant in Algeria
Two of the steel
industry’s most
influential players have
combined forces to
storm new markets.
The sale of Danieli
Lynxs’ DCR 2227
shredder to Turkish
giant Tosyali’s plant in
Oran, Algeria, marks
the first partnership
between recycling
equipment
manufacturer and
steelmaker Danieli
Centro Recycling and
Turkey’s largest private
iron and steelmaker.
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7
Members News
by Mark Rewaj
Figure 1. Da Vinci’s design for a rollingmill with backup rolls (copyright Science Museum/Science &Society Picture Library)
Figure 2. Poster advertising the Taylor & Farley factory, 1888 (www.gracesguide.co.uk)
An eASier WAyTo forM MeTAl
Early metal workers found thatforging a shape with hammersfrom a simpler cast shape createdobjects far stronger than thoseformed by casting alone. However,hand hammering was laboriouseven for soft metals, so pressuregrew to create machines to assistwith the forming process.
eArly equiPMenTfor MeTAlrolling
The equipment that followed tocreate sheet products proved tobe of very simple design.
It is not known who created thefirst rolling mill. However, one ofthe earliest drawings is byLeonardo da Vinci. It even showsthe need for larger diameterbackup rolls to support longer,smaller diameter work rolls, Figure 1.
15TH – 17THCenTury
In the middle of the fifteenthcentury small mills produced goldlace, and other decorative work, insoft metals.
However, as these techniquesbecame more widely known,demands for products comingfrom metal rolling increased. Thereis evidence for rolling of lead andtin on simple 2-high mills withcast-iron rolls at the beginning ofthe seventeenth century.
At this point rolling mills did notprocess the high volumes of metalthat we see today. In addition, therequired quality of these earlyproducts was ‘poor’ if we measureit by today’s exacting standards.However, no-one had developedthe applications that needed higherquality material. Energy was also abig consideration if this technologywas to be expanded further.
By the end of the seventeenthcentury, it was possible to castlarger iron rolls and thereforebuild heavier mills. Horses andthen water wheels drove thesemills.
18TH – 20THCenTury
During the eighteenth century,4-high designs appeared (300years after da Vinci). This wasbecause people discovered thatsmaller diameter rolls requiredless load to reduce the metalthickness. Consequently, it waspossible to use a lighter frame.
At the end of the eighteenthcentury, with the availability ofsteam power, the mills started toresemble their moderncounterparts. During thenineteenth century and into thetwentieth century, the size andpower of mills increased with littlechange to the main design. Steamengines were capable of deliveringin excess of 10,000 hp. Oneexample of this is the 12,000 hp(8.9 MW) River Don Engine builtby Davy Brothers in 1905 to rollarmour plate. However, moreefficient electric motor technologyslowly replaced steam power inthe twentieth century.
Interestingly, we have our ownconnection with eighteenth
century metal rolling here atInnoval. Dr Tom Farley‘s greatgrandfather, Reuben Farley, starteda company in 1861 whichmanufactured rolling mills and rollsin West Bromwich, UK. Thecompany was “Taylor and Farley”.
Tom Farley is our expert inrolling mill vibration. I’m sureReuben Farley would be veryproud to know that metal rollingexpertise still exists within theFarley family.
A brief historyOF METAL ROLLING FOR SHEET & PLATE PRODUCTS
On the first day of our
Aluminium Rolling
Technology Course I run
a session entitled
“Machinery and Process
Overview”. Part of this
covers the history of
metal rolling from the
first known drawings of a
mill to the state-of-the-
art rolling equipment
available today. Metal
rolling has an interesting
history...
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Members News
ToDAy’S rollingMillS
The basis of design for today’sequipment is not too dissimilar toearly designs, particularly whenyou consider a basic 2-high mill. Itjust uses different types ofmaterials and designs of rollstacks. However, today’s mills arenow designed for processing amultitude of metals for extensiveend-user applications. In somecases there are more than 20 rollsin the roll stack. This clearlydemonstrates that mill designs andtheir requirements have movedon substantially from the earlybasic designs.
Today we produce much higherquality products which haveexacting standards in dimensionalaccuracy, surface and materialproperties. All of these need to beconsidered in the design of newmills, be it for plate or coilproducts.
The mill in Figure 3 has thecapability to produce high qualitythick and thin plate and sheet(coil) products. The belt wrappersin this case are located on both
entry and exit sides of the mill.These belt wrappers are designedto move in and out as and whenrequired to produce either plateor coil products. With capacities inexcess of 200 Kt per annum, thisdesign represents a major leap intechnology from where it allstarted back in the time ofLeonardo Da Vinci.
AluMiniuMrollingTeCHnologyCourSe
Our Aluminium RollingTechnology Course covers all thekey aspects of hot and cold rollingof aluminium flat products. Mycolleagues and I write and deliverthe modules. Between us we havea huge amount of industryexperience. We’re very familiarwith the day-to-day issues of arolling plant, and we’ve createdthis course to help you solvethem. Many of the presentationsare supplemented with hands-onworkshop sessions.
The course takes place twice ayear here in Banbury. The nextone is 15-19th May 2017. You can
download a registration form(which contains the timetable andinformation about the cost) here.Finally, you might be interested toknow that the course isrecognised by the Institute ofMaterials, Minerals & Mining(IOM3) as ProfessionalDevelopment.
Mark Rewaj the author:Mark is one of our rolling expertsand he is part of our ProcessImprovement team. He has 30years’ experience in rolling plantoperations, optimisation ofprocesses, organisationalefficiencies and material flow.
Figure 3. A ‘simple’ combination single stand 4-high reverse roughing and finishing milldesign from Danieli
Figure 1. The ingot (green) at the start of the simulationwith the normal work roll (light blue), centre plane of
symmetry (dark blue) and edge roll (orange).
Figure 4. Timetable from our AluminiumRolling Technology Course
FEA MODELS FOR OPTIMISING A ROLLINGPROCESSHere we cover some of the computer basedmethods we use to get the most out ofaluminium rolling and finishing processes. Usingcomputer models, such as Finite Element Analysis(FEA) models, increases understanding andreduces the number of online trials. As a result,they reduce the cost of process optimisation. It’strue to say that FEA models are a significant partof our ‘tool box’
by Rade Ognjanovic
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feA MoDelS ToPreDiCTAlligAToring
We use FEA models of rollingmills, such as the one in Figure 1,to predict things like alligatoring ofingots (Figure 2). In this case, weonly need to model one quarterof the ingot due to symmetryplanes.
It’s possible to minimisealligatoring by adjusting the rollingschedule. This is importantbecause less alligatoring meansless of the ingot is cropped off.Consequently, waste is minimised.
Figure 3 shows a full 3Dsimulation of the whole ingot atthe end of the ninth pass. Thealligator opens up as it moves intothe roll bite before closing onceit’s in the roll bite.
feA MoDelS AnDTHe innovAlrolling MoDel
Innoval also has an accurate fast-running analytical rolling model topredict roll loads, torques and otherphysical quantities. We have usedFEA models to develop our rollingmodel by predicting, for example,forward slip. This is how much fasterthe slab exits the roll bitecompared to the roll surface speed.Two dimensional FEA simulationspredict the forward slip as afunction of friction, Figure 4.
We use the same FEA modelsto study the velocity of materialthrough the roll bite at threepoints. These are the roll biteentry, the exit and the neutralpoint, Figure 5. The neutral pointis where the ingot surface speed
matches the roll speed. The rollsurface speed is 1 m/s in thisexample. Understanding this typeof behaviour helps us to developmore accurate analytical models.
Typically the mill should run in amode that is optimum for theprocess as a whole. This meansthe processes upstream anddownstream of the mill need tobe considered. This is where wecan use some of our many otherprocess modelling tools to findthe optimum conditions for theline or product.
feA MoDelS forTenSionlevelling
A levelling process is oftencarried out after rolling and wehave two models that cansimulate this. These are the InnovalTension Leveller Model and anFEA simulation of a roller leveller.Figure 6 shows a screen shot ofthe Innoval Tension LevellerModel. The geometry of the rollsand strip are in the top window.The bottom window shows thestrip through thickness stressesand strains. It’s an extremely fastand user friendly model.
The FEA model of a rollerleveller in Figure 7 shows a sheetentering a series of rolls alongwith the contact forces. It canpredict the properties of sheetexiting the leveller which helps theoperator set up the machine.
ProCeSS CoSTMoDelS
Finally, when there are anumber of machines to optimise
in a process chain, understandingand calculating the costs canbecome very complicated. Whilstour Process Cost Models are notFEA models, they are often used inconjunction with them to optimisean entire process. Furthermore, wehave experienced specialists whocan calculate the costs to assist inmaking strategic financial decisions.
If you would like to find outmore about our modellingcapabilities please contact us.
Rade Ognjanovic theauthor: Rade is one of ourProcess Improvement consultants.His background is in chemistry andpolymer science and he has 26years’ experience in processmodelling
Figure 4. Forward slip as a function offriction as predicted by the FEA model.
Figure 7.FEAsimulationof a rollerleveller with(lowerpicture) andwithoutcontactforcevectorsdisplayed.
Figure 5. The velocity distributionthrough the ingot thickness at the rollbite entry and exit, and also at theneutral point
Figure 6. The InnovalTensionLevellerModel.
Figure 2. An alligatoron the endof an ingot.
Figure 3. A full 3D FEA simulation of the ingot alligator entering the roll bite.The ingot is moving from left to right.
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Members News
10
Using the science of measurement for your engineering needs, sometimes you just need to know the factsbefore making an educated decision...
The Metalock MetrologyDepartment are flexible andresponsive. They can performaccurate surveys in almost anyenvironment anywhere in theworld. If you require accuratedimentional data related to alltypes of plant and equipment inany industry we can provide thatservice.
For example in the steelmanufacturing industry
The Metalock metrologydepartment have already travelledto many steel mills around theworld and surveyed steel millstands and related equipmentwhich have provided ourcustomers with a detailed surveyreview and analyse informationprior to them making keydecisions related to future capitalexpenditure. We can pick up onlong lost datum’s on even themost dated mills. Even withoutphysical references in the way of
landmarks, using laser technologyour survey department has beenable to determine the pass line ofthe material and centre line of themill and individual stands byanalysing the surveyed data.
• Laser alignment and surveying has become an invaluable asset relating to our onsite machining services
• Allowing all stands to be machined in relation to the datum’s and each other within0.01mm or 0..004”
• Tolerances as tight as 0.05mmor 0.002” can be achieved across the stand window
• Stand machined perpendicularto gravity within 0.05mm or 0.002”
• Permanent reference systems installed during a full survey have many benefits
• All work carried out after the survey will be relevant to the mill datum’s survey
• Our equipment can be reset to the same datums each timeso that the condition of the plant can be monitored at regular intervals.
• Periodic inspection can map the degradation of the mill over time
ACCURATEMEASUREMENTS INALL ENVIRONMENTS
Laser tracking is now anindustry standard in all types ofengineering, the ability to produceaccurate measurements in alltypes of environments, to createand leave a permanent referencesystem that will allow the lasertracker to position its self in thesame place, time after time. This isbecoming a key feature for
customers that requirepermanent reference points towork from months or even yearsinto the future. This enables thecustomer to collect measurementdata at regular intervals that willestablish the level of wear,movement or deterioration of alltypes of plant and equipment.
Using the latest laser surveyingequipment Metalock are able tomeasure even the most obscurecomponents and structures andprovide accurate images and datathat can assist the customer inmaking educated decisions priorto any capital investment.
More details about the variedwork done in the UK and aroundthe world, by Metalock since1947 is available on thecompany’s websitewww.metalock.co.uk
Metalock Engineering
UK Ltd, established in
1947 and part of the
Midroc Europe Group,
works with some of the
largest, most sophisticated
and complex equipment
and serves a diverse
range of highly specialised
industries including
petrochemicals,
processing, steel and
paper making, pressing
and forging, power
generation and marine
and offshore.
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11
IAC manufacture control systems for industry. We integrate equipment manufactured by the worlds leading electrical manufacturers into tailor made solutions.
We have a varied and extensive electrical engineering background based on solid, wellfounded experience and continuous development.
At the present moment, IAC are, without question, the leading independent variable speeddrive system integrator in the country.
What do we do...?
IAC are now well known for supplying drive systems and automation and control solutions,but we are able to offer a whole range of services...
Email: [email protected] Telephone: 01633 293000 Visit: www.iac-ltd.co.uk
What else do we do...?
What can iAC do for you…
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For further details contact:
R. RuddlestoneDirector BMPCAC/O EEFAdvantage HousePoplar WayCatcliffeRotherham S60 5TR
Tel: 44(0)7753 866127
email: [email protected]
www.bmpca.org.uk Designed & Produced byQ2CREATIVEwww.q2creative.co.uk
BMPCA 2017Meeting & Social Events Calendar
Chesterfield Special Cylinders
CISDI
Corewire Ltd
Danieli Ltd
Davy Markham
Industrial Automation & Control Ltd
Innoval Technology Ltd
Metalock Engineering UK Ltd
MII
Oldham Engineering
Premier Hytemp
Ross Controls
Sarclad Ltd
Siemens
Sheffield Forgemasters Engineering
Thermo Fisher Scientific
BMPCA members
6th April Business Meeting – KTC at the AMP Catcliffe followed by a visit to the Metalysis Research Centre. Dinner in the evening at the Cutlers Hall, Sheffield
July 6th Business Meeting to be held at SKF in Luton
October 5th AGM and Business Meeting
November 16th Annual Lunch at the Painters Hall London