Nine independent and four dependent variables are used to build a response surface to calculate strip crown using the difference in the industry standard strip height measurements. The single element response surface in use provides the advantages of continuous derivatives and decouples rolling load from the determination of exit height. The data points to build the response surface are the product of a calibrated finite element model. The rolling dynamics in the finite element model creates a transient that requires nonlinear regression to find the system steady-state values. Weighted-least squares is used to build a response surface using isoparametric interpolation with the non-rectangular domain of the mill stands represented as a single element. The regression statistics, the 1-D projections, comparisons against other response surface models and the comparisons against an existing strip crown model are part the validation of the response surface generated. A four-high mill stand is modeled as a quarter-symmetry 3-D finite element model with an elastic-plastic material model. A comparison of the pressure distribution under the arc of contact with existing research supports the pressure distribution found with experiments conducted by Siebel and Lueg [16] and it also suggests the need for one improvement in the initial velocity for the strip in the finite element model. The strip exit heights show more sensitivity to change than strip exit crown in seven out of the nine independent variables, so a response surface built with the strip exit height is statistically superior to using the derived dependent variable strip exit crown. Sensitivity of strip exit crown and the strip exit heights to changes in work-roll crown are about equal. Backup-roll diameter sensitivity is small enough that oversampling for the mean trend has to be considered or ignore backup-roll altogether. Strip entry velocity is a new independent variable, unless the response surface is built from the derived variable, strip exit crown. A problem found is that the sensitivity of strip entry crown and work-roll crown requires a larger than typical incremental change to get a reliable measure of the change strip exit crown. A narrow choice of high and low strip entry crowns limits the usefulness of the final response surface. A recommendation is to consider the use of the strip cross-section as an exit crown predictor. / Master of Science

During the last decade, power quality has been recognised asa global problem. Among different types of power qualityproblems, voltage sags have been identified to be one of themost severe problems for different process industries. The mostcommon reason to voltage sags is lightning strikes in powerlines. Protection equipment, usually located at switchyards,disconnect faulted power lines as soon as possible, which isapproximately 100 ms. Thus, the duration of voltage sags areapproximately 100 ms. The sensitivity to voltage sags ofelectrical equipment in process industries can be observed asfor instance malfunction, automatic turnoff or damages. This thesis gives an overview of three metals processes withfocus on the sensitivity to voltage sags and interruptions. Theinherent energy in the process is used to find the sensitivity.This energy may also be used to obtain "ride-through" for theprocesses. The three metals processes are a blast furnaceprocess, a hot rolling mill process and a cold rolling millprocess. The main attention in this thesis is paid to the blastfurnace process, which is powered by a line-operatedsynchronous machine. The thesis shows that the protection equipment forelectrical machines can be adjusted to avoid unnecessaryshutdowns. It is also explained why there are high torque andcurrents during voltage sags as well as after voltage sags. Itis shown that the first peak torque and current during thevoltage sags is almost proportional to the voltage change, thatis the voltage magnitude before the voltage sag minus thevoltage magnitude during the voltage sag. The first peak torqueand current after the voltage sag depends sinusoidal-like onthe duration of the voltage sag and almost proportional to thevoltage change during the voltage sag. There is no fluxsaturation during voltage sags, however after voltage sagssaturation is very likely to occur. The thesis explains why andalso how the flux is changed during and after voltage sags. The duration of voltage sags is in many cases set by theprotection equipment located in switchyards. It is shown thatthe durations of voltage sags can be changed to durations thatwill cause less peak torque and current after voltage sags forline-operated AC-machines. It is also shown how this istheoretically achieved. <b>Keywords:</b>Rolling mill, Blast furnace, Power Quality,Synchronous machine, Asynchronous machine, Voltage sag, Voltageinterruption, Ride-through, Process disturbances, Simulation,Modelling

<p>During the last decade, power quality has been recognised asa global problem. Among different types of power qualityproblems, voltage sags have been identified to be one of themost severe problems for different process industries. The mostcommon reason to voltage sags is lightning strikes in powerlines. Protection equipment, usually located at switchyards,disconnect faulted power lines as soon as possible, which isapproximately 100 ms. Thus, the duration of voltage sags areapproximately 100 ms. The sensitivity to voltage sags ofelectrical equipment in process industries can be observed asfor instance malfunction, automatic turnoff or damages.</p><p>This thesis gives an overview of three metals processes withfocus on the sensitivity to voltage sags and interruptions. Theinherent energy in the process is used to find the sensitivity.This energy may also be used to obtain "ride-through" for theprocesses. The three metals processes are a blast furnaceprocess, a hot rolling mill process and a cold rolling millprocess. The main attention in this thesis is paid to the blastfurnace process, which is powered by a line-operatedsynchronous machine.</p><p>The thesis shows that the protection equipment forelectrical machines can be adjusted to avoid unnecessaryshutdowns. It is also explained why there are high torque andcurrents during voltage sags as well as after voltage sags. Itis shown that the first peak torque and current during thevoltage sags is almost proportional to the voltage change, thatis the voltage magnitude before the voltage sag minus thevoltage magnitude during the voltage sag. The first peak torqueand current after the voltage sag depends sinusoidal-like onthe duration of the voltage sag and almost proportional to thevoltage change during the voltage sag. There is no fluxsaturation during voltage sags, however after voltage sagssaturation is very likely to occur. The thesis explains why andalso how the flux is changed during and after voltage sags.</p><p>The duration of voltage sags is in many cases set by theprotection equipment located in switchyards. It is shown thatthe durations of voltage sags can be changed to durations thatwill cause less peak torque and current after voltage sags forline-operated AC-machines. It is also shown how this istheoretically achieved.</p><p><b>Keywords:</b>Rolling mill, Blast furnace, Power Quality,Synchronous machine, Asynchronous machine, Voltage sag, Voltageinterruption, Ride-through, Process disturbances, Simulation,Modelling</p>

This master thesis was done at Swerim AB in cooperation with SSAB and the Technical University of Luleå in the purpose of preventing spalling problems in hot rolling mills. Spallings are a fatigue damage that occurs on the rolls due to extreme loads and unfavorable conditions between the rolls in a mill. This report describes how the roughing mill, which is the first of a series of hot rolling mills is modelled and simulated in order to compute and improve the load distribution between the rolls. The load distribution tells a lot where the spalling problems occurs. By computer aided design and simulations with the finite element method a parametric computational model was created and used to simulate the load distribution between the work roll and backup roll with worn andfresh rolls. These simulations showed what the load distribution looks like when using new rolls and that the load distribution is especially bad when the work roll is worn. The computational model was used to simulate how the load distribution changes with different geometries on the backup roll to provide valuable input and suggest new designs on the backup roll currently used by SSAB Borlänge.

Diploma thesis "Gender and manpower in production companies in the Chomutov region" is focused on historically and sociologically oriented research of employment of men and women in production companies in the Chomutov region over last 50 and 70 years respectively. The main aspects which are included in the theoretical part of this work are gender relations in the production companies, that is the history of the employment of women, horizontal and vertical gender segregation including wages and salaries and employee education. The analyzed data are from the period of mid 20th century and the beginning of the 21st century and focus primarily on the production companies of The Tube and Iron Rolling Mill and their current successor Sandvik. By means of data analysis, the methodical part of the thesis describes differences and changes which have ocurred in the horizon of last 50 and 70 years in the manpower employment in production companies with respect to gender. KEYWORDS Gender, Feminism, Manpower, Socialism, The Tube and Iron Rolling Mill, Production, Chomutov

Le laminage est un procédé de mise en forme à chaud permettant d’obtenir des barres de différents diamètres en partant de blooms issus de la coulée continue. Dans les bruts de coulée se répartissent des inclusions qui sont de natures, de formes et de tailles différentes. Le laminage va permettre de réduire le diamètre de la barre et d’agir sur la microstructure du matériau, notamment, en fragmentant et dispersant les inclusions. L’objectif des travaux de thèse est de contribuer à la compréhension des effets du chargement thermomécanique sur l’évolution des défauts de coulée en laminage. Vu la dimension des installations, les investigations expérimentales directes sur les moyens industriels ne sont pas envisageables. L’idée développée dans les travaux de thèse concerne la mise en place et la validation d’un essai de caractérisation à échelle réduite reproduisant le chemin thermomécanique subi par la matière au cours du laminage. Pour ce faire la ligne de laminage industrielle est modélisé afin d’obtenir le chargement thermomécanique de la barre au cours du laminage. Seules les sollicitations ayant un rôle majeur sur le comportement des défauts sont reproduites. Un essai dit de « forgeage libre » a ainsi été conçu, réalisé, mis en place sur les moyens de mise en forme de la plateforme VULCAIN de l’ENSAM. L’essai a été utilisé avec des défauts artificiels présentant des similarités comme la malléabilité avec les défauts réels. Une campagne expérimentale paramétrique a été menée sur les différents types de défauts. Les échantillons forgés ont été analysés par des méthodes non destructives comme les ultrasons, la radiographie et la tomographie X. Ces analyses ont permis de suivre le comportement du défaut et d’observer certains phénomènes mis en évidence dans la littérature comme l’apparition de cavité à l’interface défaut-matrice. / Rolling is a hot forming process dedicated to manufacture bars with different diameters. The initial product is a bloom from the continuous casting. The bloom contains inclusions which have different forms, sizes and distributions. The rolling reduces the diameter of the bar and acts on the material microstructure by fragmenting and dispersing the inclusions. The aim of the thesis work is to understand the behavior of the inclusions with the rolling thermo mechanical loading effects. The direct investigations on the rolling mill are not possible because of the size of the installations. To address this problem, the solution is to develop and validate a small scale characterization test reproducing the thermo mechanical loading of the rolled bar. To achieve this, the rolling mill is modeled. Only the solicitations which have a major role on the behavior of the defects are reproduced. An open-die forging test is designed, manufactured and implemented on the VULCAIN installation of the ENSAM. The artificial defects which have a similar malleability to the real defects are integrated into the sample. A parametric experimental campaign has been conducted on the different defects. The forged samples have been analyzed with non-destructive methods such as ultrasound, radiography and tomography. These analyses allowed to follow the behavior of the defects and to observe certain phenomena illustrated in the literature such as the emergence of a cavity on the defect-matrix interface.

[pt] O desenvolvimento de um aço microligado para a produção de vergalhões nervurados, busca atender a modernização das estruturas de concreto armado e a industrialização na construção civil que solicitam novos desenvolvimentos nas técnicas de construção e nos materiais aplicados. As barras de aço nervuradas são um dos principais produtos empregados na produção de peças e estruturas de concreto armado sendo usadas largamente por todo o mundo. A otimização da aplicação final, a necessidade de manter baixos custos de produção e atender a combinação de alta resistência com grande ductilidade em um material com características de soldabilidade destinados a armaduras de concreto armado, se tornou um grande desafio para os produtores de vergalhões para a construção civil. Aplicando a tecnologia desenvolvida ao longo dos últimos 50 anos, este trabalho oferece a alternativa de se empregar aços microligados ao vanádio e nióbio para a produção em laminadores de alta produção de rolos de vergalhões capazes de atender a indústria da construção civil nos mais rigorosos atributos solicitados. Os experimentos foram realizados em escala industrial testando aços com faixa de 0,14 porcento a 0,20 porcento de vanádio e até 0,04 porcento de nióbio. Os resultados atendem as normas mais exigentes no mercado mundial. / [en] The development of microalloyed steel for the production of reinforcement bars (rebar) seeks to achieve the modernization of reinforced concrete structures and streamline industrialization in civil construction that demands new developments in techniques and applied materials. Rebar is one of the main products used in the production of reinforced concrete all over the world. The optimization of the final application and the necessity to keep production low costs while attempting to combine high resistance with great ductility in a material with weldability characteristics, became a great challenge for the producers of rebars. Applying the technology developed throughout the last 50 years, this work offers the alternative of using vanadium and niobium microalloyed steel to produce large quantities of rebars in rolling mills. Upon completion these rebar are used in coils capable of meeting the most rigorous demands of the civil construction industry. The experiments made in an industrial environment, applied steels with 0.14 percent to 0.20 percent of vanadium and up to 0.04 percent of niobium. The results met the most demanding standards in the world-wide market.

Le laminage est un procédé de mise en forme à chaud permettant d’obtenir des barres de différents diamètres en partant de blooms issus de la coulée continue. Dans les bruts de coulée se répartissent des inclusions qui sont de natures, de formes et de tailles différentes. Le laminage va permettre de réduire le diamètre de la barre et d’agir sur la microstructure du matériau, notamment, en fragmentant et dispersant les inclusions. L’objectif des travaux de thèse est de contribuer à la compréhension des effets du chargement thermomécanique sur l’évolution des défauts de coulée en laminage. Vu la dimension des installations, les investigations expérimentales directes sur les moyens industriels ne sont pas envisageables. L’idée développée dans les travaux de thèse concerne la mise en place et la validation d’un essai de caractérisation à échelle réduite reproduisant le chemin thermomécanique subi par la matière au cours du laminage. Pour ce faire la ligne de laminage industrielle est modélisée afin d’obtenir le chargement thermomécanique de la barre au cours du laminage. Seules les sollicitations ayant un rôle majeur sur le comportement des défauts sont reproduites. Un essai dit de « forgeage libre » a ainsi été conçu, réalisé, mis en place sur les moyens de mise en forme de la plateforme VULCAIN de l’ENSAM. L’essai a été utilisé avec des défauts artificiels présentant des similarités comme la malléabilité avec les défauts réels. Une campagne expérimentale paramétrique a été menée sur les différents types de défauts. Les échantillons forgés ont été analysés par des méthodes non destructives comme les ultrasons, la radiographie et la tomographie X. Ces analyses ont permis de suivre le comportement du défaut et d’observer certains phénomènes mis en évidence dans la littérature comme l’apparition de cavité à l’interface défaut-matrice / Rolling is a hot forming process dedicated to manufacture bars with different diameters. The initial product is a bloom from the continuous casting. The bloom contains inclusions which have different forms, sizes and distributions. The rolling reduces the diameter of the bar and acts on the material microstructure by fragmenting and dispersing the inclusions. The aim of the thesis work is to understand the behavior of the inclusions with the rolling thermo mechanical loading effects. The direct investigations on the rolling mill are not possible because of the size of the installations. To address this problem, the solution is to develop and validate a small scale characterization test reproducing the thermo mechanical loading of the rolled bar. To achieve this, the rolling mill is modeled. Only the solicitations which have a major role on the behavior of the defects are reproduced. An open-die forging test is designed, manufactured and implemented on the VULCAIN installation of the ENSAM. The artificial defects which have a similar malleability to the real defects are integrated into the sample. A parametric experimental campaign has been conducted on the different defects. The forged samples have been analyzed with non-destructive methods such as ultrasound, radiography and tomography. These analyses allowed to follow the behavior of the defects and to observe certain phenomena illustrated in the literature such as the emergence of a cavity on the defect-matrix interface.

[pt] A Manutenção Autônoma (MA) é parte de uma estratégia de manutenção que se centra na relação homem-máquina para efetuar de forma eficaz a limpeza, lubrificação, inspeção e pequenos reparos. Quando devidamente implementada, a MA pode melhorar significativamente a produtividade e a qualidade, bem como reduzir os custos, portanto é uma importante área da Gerência de Operações (OM). No entanto, a indústria tem sido desafiada com inúmeras barreiras para implementar com sucesso a MA, e o meio acadêmico pouco tem feito para ajudar a indústria a este respeito. Esta dissertação aborda essa atual lacuna entre pesquisa e prática, tendo como objetivo principal desenvolver um framework para a implementação da MA com as dimensões Humana, Tecnológica e Organizacional (HTO). O trabalho baseia-se numa pesquisa-ação, conduzida no âmbito de um estudo longitudinal, num processo de laminação de tiras a quente de uma usina siderúrgica. A adoção da abordagem HTO por pesquisadores da OM tem sido conduzida com sucesso em diferentes casos e está bem documentada na literatura. No entanto, o autor sugere que esta é a primeira pesquisa a utilizar esta abordagem dentro da MA. Os resultados da pesquisa indicam a aderência das dimensões HTO para corresponder aos desafios da implementação da MA e reforçar a necessidade de uma perspectiva holística e combinada destas dimensões para o desenvolvimento empresarial, resultando em ganhos de natureza quantitativa e qualitativa e que quatorze lições foram aprendidas com implicações práticas imediatas. Os gestores da indústria podem fazer um balanço das lições aprendidas no âmbito desta pesquisa-ação e utilizar o framework oferecido para ajudar à implementação com sucesso da MA nas suas operações industriais. / [en] Autonomous Maintenance (AM) is part of a maintenance strategy that focuses on the man-machine relationship to effectively carry out cleaning, lubrication, inspection and minor repairs. When properly implemented, AM can significantly improve productivity and quality, as well as reduce cost, therefore, it is an important area of operations management (OM). However, the industry has been challenged with numerous barriers to successfully implement AM and the academy has done little to help industry in this regard. This paper addresses this current research practice gap by offering as its main goal a framework for implementation of AM with the Human, Technological and Organizational (HTO) dimensions. It builds upon an action-research conducted within a longitudinal study in a rolling mill production process. The adoption of the HTO approach by OM scholars has been successfully conducted in different cases and is well documented in the literature. However, the author suggests that this is the first research to use this approach within AM. The research findings indicate the adherence of the HTO dimensions to match the AM implementation challenges and reinforce the need for a holistic and combined perspective of these dimensions for business development, resulting in gains of both a quantitative and qualitative nature and that fourteen lessons were learned with immediate practical implications. Practitioners can take stock of the lessons learnt within this action-research and the offered framework to aid the successful implementation of AM in their industrial operations.

Ways of rolling tubes on a continuous rolling mill considered in the work. Overview of three-roll continuous rolling mills are given. Technology for the production of pipes for pipe unit with 3 roller stand continuous mill developed. The geometric model of the process by scanning the tube sheet is constructed. Determination of the amount of deformation is made. Kinematically possible velocity field is constructed. Examples of calculations of a table rolling and modes of compression on a continuous three-roll mill is shown. / В работе рассмотрены способы прокатки труб на непрерывном стане, проведен обзор трехвалковых оправочных станов. Приведена технология производства труб на ТПА с 3-х валковой клетью непрерывного стана. Построена геометрическая модель обжатия путем развертки трубы в лист и проведено определение размера очага деформации. Построено кинематически-возможное поле скоростей. Приведены примеры расчетов таблицы прокатки и режимов обжатия на непрерывном трехвалковом стане.