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ISO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Product Speed Control
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DANIELI SERVICE
Training Center
ISO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
As the product elongates it must increase in speed, if we
consider the volume of material remains constant throughout
the rolling process then;
Area x Working Diameter (WD) x RPM of rolls = Constant (C)
Therefore the RPM at each stand can be calculated from;
RPM = C / (Area x WD)
Where C always remains constant
Area varies as stock reduces
WD (Working Diameter) varies with pass shape and diameter
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DANIELI SERVICE
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ISO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Modern continuous mills have a speed control system for
control and continuous adjustment of individual stand speeds.
In the roughing and intermediate groups this is a tension
control system while the finishing stands will have a loop
control system performing the stand speeds.
As we said earlier, the volume of steel going through each
stand must be the same to avoid tension or compression.
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ISO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
So if F1, F2, F3 etc. are the successive cross-sectional areas of
the bar in each stand and V1, V2, V3 etc, are the peripheral
speeds of the corresponding stands, then:
F1 V1 = F2 V2 = F3 V3 = Constant
Constant = Area (mm2) x speed (m/sec)
Calculations of Rolling Speeds
Decide on the rolling speed required at the finishing stand, (say
stand 18). We can now calculate our constant factor which is
the area of the bar in stand 18 x speed of stand 18 (meters/sec).
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ISO 9001 Cert. No 0218
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Constant factor = stand 17 speed m/sec
Area stand 17
Constant factor = stand 16 speed m/sec
Area stand 16
Constant factor = stand 15 speed m/sec
Area stand 15
And so on as far back as stand no. 1
This gives us the speeds (in meters per second) at which the
bar should leave each of the individual stands.
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ISO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Now we must use the above to calculate the motor speeds from
the formula:
Vr = x De x n
60 where:
Vr = Roll peripheral speed (m/sec)
De = Effective diameter in meters
n = Roll R.P.M.
The value Vr is now multiplied by the individual gear ratio to
arrive at motor speed
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ISO 9001 Cert. No 0218
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We see the term effective diameter, also called working diameter.
It is the position or diameter, at which the roll peripheral speed is
equal to the exit speed of the bar.
When rolling through two plain rolls the working diameter is
quite obviously equal to the roll diameter. However, for a shaped
pass, there are a number of diameters to choose from.
The diameter at the roll face will be greater than the diameter
at the bottom of the pass. In practice, the effective diameter is
somewhere in between these two diameters.
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DANIELI SERVICE
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ISO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Lennox’s method of calculating effective diameter is known,
as the equivalent rectangle method and is used by Danieli’s
roll designers, for rolling speed calculations.
In short, Lennox’s method of determining working diameter
is based on the formula:
Working diameter = roll diameter + gap - Area/width
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ISO 9001 Cert. No 0218
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Example:
Roll diam = 350 mm Bar = 30 mm
Roll gap = 2 mm Bar area = 706.5 mm2
Then:
WD = Roll Diam + Gap - Area / Width
= (350 + 2) - (706.5 / 30)
= 352 - 23.55
= 328.45
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This formula can be used to determine a groove factor for each
groove this groove factor does not change, even if the roll gap
is changed.
(Roll diameter – Working diameter is called Groove factor)
so in our earlier example the groove factor would be:
Roll diameter – working diameter
350 mm - 328.45 mm
Groove factor = 21.55
Modern speed control systems do the speed matching
calculation for the mill, once a groove factor is given.
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DANIELI SERVICE
Training Center
ISO 9001 Cert. No 0218
EN 729-2 Cert. No 0717
Speed Control Questions
An important point is that speed control systems all cascade
‘downstream’ i.e., back to stand number 1.
Why is this?
In our modern high speed mill three factors may alter or
adjust the speed of rolling stands.
What are these three things and what is the control priority
status for each of these?
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