Maximising Mill Yield Through Measurement Systems

by Adrian R Jacobs, Neil J Fletcher

Publisher - Shape Technology Ltd, Long Products, Shape Technology Ltd

Category - General Novel

Maximum yield of first quality finished product should be the aim of every mill. As yield is affected by many different variables, there is no single 'quick and easy' fix to achieve this. This paper describes how three separate approaches currently in use can be combined to create a powerful new weapon in the constant battle to maximise yields in wire rod and bar mills. Roll pass design software has distilled the empirical and implicit knowledge of roll pass design engineers and translated it into specific recordable design rules to determine the most efficient mill configurations to produce the correct geometry on the end product. Various non-contact measurement systems used at key points in the rolling process can provide valuable information on actual dimensions during the rolling process. Statistical process control (SPC) assumes that any production process will produce products whose properties vary slightly from their design values, even when the production line is running normally, and these variances can be analysed statistically to control the process. However, by integrating all three approaches and using the results of SPC analysis to inform the roll pass design, a powerful new weapon is created in the constant battle to maximise yields.

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