Production Engineering

RAMTM.-201O.February. 19-20,2010
Department, [adttopur University, Kolkata- 32

Slit Rolling Technology, To Increase Production of Rolling

Round Steel Bars
Prof. R. N. Patll", Mr. Achintya Mittal%
#Professor& H.O.D, Departmentof ProductionEngineering,BharatiVidyapeethUniversityCollegeof Engineering,
Pune, India, Pin-411046,E-mail:rnpatil@bvucoep.edu.in
% HegemonSteel, MIs. Mohit Ispat Limited,Office No. 712, 7thFloor,Cera's Imperium-I,Patto Plaza, Panjim,Goa,
India, Pin-403001,E-mail:achintyamittal@hotmail.com
Abstract: A method for producing steel bars wherein at least two individual bars are
rolled at the same time from a single billet. An apparatus for separation of the individual
elements of the multi-stranded bar is provided wherein the elements are separated at
several stages starting with the two outermost elements in the first stage and continuing in
the same order until the center elements are separated in the last stage. Slit rolling
technology can be implemented on the existing rolling mills, designed to produce single
stranded bar, at a predetermined velocity. It allows a considerable increase in the
production capacity of rolling small sized bars.
Keywords: Slit Rolling Technology, Multi Strand, Entry Guide, and Exit Guide.
1. INTRODUCTION
Presently round steel bars are produced from steel billets, generally having square section, which
are rolled in a sequence of passes through a multiple stand rolling mill, wherein each of the stand
is provided with a pair of rolls, each of which is formed on the outer circumferential
surface
thereof, with a groove for rolling. Cross section of the billet is gradually reduced and shaped in a
sequence of passes, until the final shape is obtained. 111 The final shaped bars are cut in a
particular length during in-line rolling process. This cutting is done to accommodate the finished
bar over the limited length of cooling bed.

Fig.1 Conventional Rolling {11

Fig.2 Slit Rolling

{21

Rolling productivity of small size bars is generally lower than that of large size. To eliminate the
imbalance in the production of rolled sections that are small in cross section, a technology of inline rolling and cutting has been further improved by increasing the number of strands that are cut
simultaneously. This new method of rolling is called S lit Rolling Technology. {31
With slit rolling technology at least two individual bars are rolled at the same time from a single
billet thus increasing the production capacity of typical existing rolling mills operating at a
predetermined
velocity. The invention allows the continuous rolling of billets into bars in the
minimum number of passes. The capital and operational costs of a rolling mill incorporating the
technology are consequently lowered. {21

1B9

RAMTM-201O, February, 19-20, 2010

Production Engineering Department, [adaopur University, Kolkata- 32

In principle the billet will be rolled to take the shape of a slab. Hereafter using special pass profile
rolls, square cross-section of billet is shaped into dog bone and then into individual strands
connected by a thin web of metal. These strands are separated from each other and are further
rolled into finished sizes.

I
I - -O-{)-D-o-O-O-{J-Q-O
0\"31

ROUJld

Fig.3 Conventional

2. BACKGROUND

Rolling Pass Sequence

[1]

.,

Fig.4 Double Strand Slit Rolling Pass Sequence

[3J

OF SLIT ROLLING TECHNOLOGY

The production of multiple sections from a single metal billet was proposed a long time ago in
1910, when a method was developed of producing wire from sheets or strips of soft metals,
subjected to rolling and pressing operation by which longitudinal parallel depressions or grooves
are formed along the sheet. The individual sections can then be readily manually torn along such
grooves or depressions. This early method discloses a general concept of longitudinally dividing
a metal piece into individual sections but was not addressed to the production of steel bars,
which presents other problems due to the hardness and very high rolling temperatures, nor does
it foresee the problems solved by the present technology. [21
Another method of rolling metal sections, such as round, angles, T's or channels in multiples of
two or more units, all formed at the same time from a billet of a larger size was developed in
1934. In the final pass, the sections are separated into individual units by means of rolls arranged
to vertically shear and thereby cut or tear the thin web of metal joining the sections, whereby a
plurality of units are simultaneously produced thus increasing the capacity of the mill. [21

-'i

I 1

.
I
I
:;

f""h;; (::l...
:r:h;f;~:""::J:-::'.-'':;;j

I
I

.'

I I~ -J,.j
i

J ,
Fig.5 ~littin9. by offsetting rolls vertically

[2}

This method does not deal with the problem of different tensional stresses between the inner and
outer sections, because the sections are rolled following parallel paths without significant
separation thereof in the horizontal direction. Another problem with this process is that the cutting
rolls are more expensive and SUbject to wearing of the cutting surfaces implying higher
operational and maintenance costs, [2
It has also been known to separate interconnected strands by passing them between a pair of
rolls which reduce the cross-sectional area of adjacent strands by different amounts (Fig.6), thus
causing them to exit from the roll stand at different velocities, the speed differential in turn
inducing a longitudinal force in the node which results in ruptures and strand separation. [21

190

Production Engineering

Fig.6 Slitting by variation in cross-section

RAMTM-201O, February, 19-20, 2010

Dcparttncut, [adaopur Unioersits), Kolkata> 32

Fig.7 Slitting by diverging the outer strand 12)

12)

This method is not well suited to modern continuous rolling mills because the separated strands
are not presented to subsequent stands in the desired form, namely simultaneously and at
substantially identical velocities. Also problem with this process is that the pass designing of
slitting roll is very difficult and if there are more than three strands then slitting cannot be done at
a single stage. A multi stage separation of strand is required.
Fig.7 shows one more proposal published in 1980, which discloses a method for slitting billets of
metal which are rolled to produce a double or triple stranded bar. The method comprises slitting a
multi-stranded bar of "no more than three strands", wherein each strand is longitudinally
interconnected to the adjacent strand and is divided into individual sections by diverging the two
outer strands. Applying on bar a compressive working force so as to produce equal crosssectional area reduction on each of strands and simultaneously create lateral tensile forces in
each connecting node causing each of nodes to rupture and causing a laterally outward shift of
the center of gravity of the outermost strands. (2) This patent, being limited to three strands, is
mute in respect to a four strand roller.
3.1 LATEST METHOD OF SLIT ROLLING
In the latest method a combination of entry guide, special pass profile rolls with designated exit
guide equipment are used to shape and longitudinally separate the incoming billet into two or
more individual strands which will then be further rolled into finished sizes. (2) A special Exit Guide
Box is used, where the edge of revolving circular wedge shaped knives are used to separate the
strands into individual bars.
H ,R""-II'I;

1.\....
~

!'H',\RXM\\;

r',\"'''

ELEVArTON

VlEW

Fig.8 Slit Rolling Using Entry Guide, Special Pass Profile Roll & Exit Guide

[2J. [3J

At the separating stand the forming pass must be precisely aligned into the separating pass.
Thus, it is most important to place an entry guides immediately before the separating pass to
provide precise guidance of the leader stock entering the separating pass & ensure equal stock
balance among all the passes between the separating rolls. The guide must have a fine
adjustment possibility for lateral positioning.

191

Production Enguieertng

RAMTM-2010, February, 19-20, 2010

Department, [adaopur Unioersib), Kolkntn - 32

,/"-

Fig.9 Alignment of stock from forming pass into separating pass using Entry Guide [31

According to this technology an apparatus as shown in Fig.10 is provided for separating the hot
state individual elements along grooves of a preformed multi-stranded stock, elements being
joined together by thin steel webs along grooves. This apparatus is called "Exit Guide Box".

i\

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Ll----"
---0_

. ..:

=AT...::

.- :::::~..-~

.:-::--bLC"--'~I

-._-..

Fig.10 Exit guide box and Schematic diagram of separating strands in exit guide box. [21. [31

The Exit guide box frame consists of first pair of circular members having a beveled periphery on
both sides defining a wedge shaped profile which forces the elements to be split when said
circular members guide the adjacent elements along its sides without cutting joining webs but
forces them to be torn apart. [31
Pair of circular members are located on first shaft rotatably mounted on frame aligned with the
outermost grooves of multi-stranded stock, and define a guiding space between circular members
to guide the remaining elements of said stock still joined and which will be separated by
subsequent circular members. Similar pair of circular members located on second shaft is
mounted on same frame and below first shaft so that circular members on first shaft cooperate
with those circular members of second shaft. [31
Third and fourth shafts have corresponding circular separating members, located downstream in
the direction of processing of multi-stranded stock & work in the same manner as first and second
shaft to separate the outermost elements of the remaining multi-stranded stock; and so on until
the number of pairs of shafts sum N/2 (rounded to previous number) and tile number of pairs of
circular elements sum N-1 for a multi-stranded stock of N elements. After the slitting operation the
stock continues rolling with multiple strands.

192

Production Engineering
3.2 SEPARATING

RA~IT:"1-201 ' February, 19-20, 2010

Department, JllrlllVl
Uuiccrsits). Kolkata - 32

TECHNIQUE

The separating pass consists of two or more major sections, which are I ,..Ill together by small
strips of material. During the slitting or separating process these sect. , s are divided into
separate bars of false round. The technique is that the separating wheels aPt. J diagonal forces to
the slitting section, resulting into lateral forces splitting or dividing the sn ,I strips of material
between the rounds. [21

Fig.11 Wedge separating technique

>.

The rollers in exit guide box do not revolve due to any special revolving for . ( energy. Moving
band impacts against the separating rollers, setting the rollers in rotation. 1 s r Jiving situation
reduces friction between the band and the rolls during slitting.
For more than 3-strand slitting, a multiple strand separating guide is used .. ','5 ~ Ie differs from
the 2 and 3-strand slit guide by having two sets of separating wheels .ncor:
t .: !l one unit. In
s in one unit. [31
principle the A-strand slit guide, is a combination of 2 and 3-strand sli.: ..lg 0
I,
1 J second stage
In the first stage sections 1 and 4 will be separated from the slitting puss ar
. spread into the
sections 2 and 3 are divided. As a result, four separate strands arc .lelivert.
S -uide .
correct strand distance by delivery channels situated at the end of tile separ.
s. '11, incorporated
In 5-strand slitting, the exit guide is a combination of a two 2-strarv! s ttin:
in one unit.
l

4.1 ADVANTAGES
1. Increased
Productivity:
- With the same output rolling speed, t .: pi
linearly with increase in number of strands. As there are less num. ..r ot
travelling time and rolling time at each stage is also reduced. The s oarate
also saved. [51

Multi-slit

s;
...c::

c
L

,Ii

I; is increased
Jfl stages, the
} cutting time is

rolling

.oJ

Conventional

>
....
.....

rolling

;:I

"0

s::
Q..

10

Fig.12 Productivity

13

16

19

22

25

Product size (mm )

improvement by slit rolling to "hne

'0

.I

[5]

2. Reduction of Number of Stands: - As it can be seen in Fig.3 pa . see .nc of conventional

process, that there are 19 stages of reduction & in slit rolling (F, :) I' ,;re .re 6 stages of

193

Production Engtuecring

RNvfl \ 1-2010, I'd 'liary, 19-20, 2010

Departmcnt.]
duopur UII r-sib}, Kolkuta - 32

reduction and one stage of slitting, there is a drastic drop in number Of reduction stages. As there
are less number of reduction stages in slit rolling process, number Jf 'tan S 11e very less as
compared to conventional rolling process.
3. Reduced Production
Cost:- Less investment as less number of stands, i.e. less investment in
stands, other accessories of each stand, rolls, motors, drive power, mamtenance, consumable,
machining cost, spare parts. No separate rotarylflying shear is requireo for in I 'le rutting of rolled
bars. 15]

4.2 CHALLENGES
1. The fin which appears on either side of bar after slitting, deter.o
Ill'.
~ quality of the
finished rolled stock: - During the slitting operation the divided bars will 'iav-. a little fin or fins of
material either on either side of the slit stock. During the transform.Jion ( thL.:'
I und stock into
an oval, these fins will be elongated. The fin on the final product ,.dS il epu:
t is accepted by
the standards. 14]

Fig.13 In~ctly

separated strands & Buck'ed strand

of the slitting wedge-shaped

rolls: - After nr
rollers to sep rate the strands, the rollers get worn out due to s
these rollers. the guide-box is to be replaced with the one 1. g
disadvantage of cost of rollers of guide box and the guide box' i: l~
3. Incorrect
jap between separating
rollers or improper
pi f
separation 0, strands from each other. Fig.13 shows the strands
rolling. The reason being. an incorrect gap between the separating I "
not assure the correct division of the extreme band strands. ri,' .1'
symmetrical strip input into slitting box with idle separating lUll .r:
strand. After buckling the external strand was moved into medial
caused by lapping on right median strand.
4. Complexi,
of control over the entry of stock: - Any error i' I
stock with respect to separating pass leads to unequal di -. ,
production wustaqe. A precise control over the entrance of fl
pass is requ
J, because if there is lateral position error 01 ~
slitting might tuxe place uneven. But. to a large extent this problc- IS I

2. Low durability

5. REFEREN

1)
2)
3)
4)

5)

'JI

(f.

I(

evit guide box

') . To change
. 'his gives a

c:f
cause lack of
IL::th ; parated during
S. TI.I' J!.er setting did
als
hows that non
~CI b. .llnq of external
!, c.' ( 'ie 1, which was
'f 'orrninq pass
" .l III pass and
into separating
sto
Iting pass, the
se:
d IS
l' entry guide.

ES

Repor Jil In-Plant Training at "HEGEMONSTEEL, GOA" By Mr. flc'nty

G. r--. r ,,11, ProductionDepartment,BharatiVidyapeethUniversit;
:ge
http:!
v.patentstorm.us/(a).5626044,(b).4193283(c).1977285
http:! .. I.morgardshammar.org!
Dele.ud. ation Of Slitting Criterion Parameter During The Multi
r; I
SebastianMroz, Piotr Szota, Henryk Dyja
http://www.nsc.co.jp!en!tech!reportlindex.html

nce of Prof. J.

.e 1d, f- . e.

e<

Jrzej Stefanik',

194