 Capco® Turn-key Roll Shop at Norandal, Huntingdon, TN (click on image for larger view) |
 Capco® 50 Ton SuperGrinder™ at Norandal, Huntingdon, TN at Norandal, Huntingdon, TN (click on image for larger view) |
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Roll grinding is one of the most important operations in a rolling mill. The roll profile accuracy, surface quality and runout (TIR) directly affect the quality of the sheet produced in the rolling process. The roll grinding machines in the roll shop produce the rolls that are utilized in the rolling mill. Therefore the quality of roll grinding machines directly affects the quality of the sheet in the rolling process. The roll shop should be considered a profit center, not a cost center, as substantial profit can be generated by roll grinding machines that produce the highest accuracy roll profile, best surface quality and lowest runout (TIR). For example, higher quality rolls produce higher quality gage thickness and surface condition sheet that can be sold at a higher price which provides a higher profit for the overall rolling mill operation. Also, high quality roll grinds produce less scrap sheet that generate losses instead of profit. The objective of the roll shop should be to produce the highest quality rolls by ensuring the roll profile accuracy, correct uniform surface condition (Ra without any feedlines or chatter) and lowest runout (TIR) in the shortest time possible. Roll grinding machines that produce high accuracy roll profiles ensure that the rolling mill will produce exact gage thickness across the sheet. Roll grinding machines that provide the proper and consistent roll surface (Ra) across the roll face ensure the surface condition across the sheet is optimal. Roll grinding machines that produce the lowest runout (TIR) of the roll allow the mill to run at the highest production speeds, which again maximizes the profit of the rolling mill. Roll grinding machines that provide shorter grinding times lower the cost per grind and therefore again contribute to increasing profit of the rolling mill operation. The bottom line is: high quality roll grinders produce high quality rolls that produce higher quality sheet that will generate higher income and more profit for the rolling mill operation. Quantifying high quality rolls is a must for the roll shop and requires proper roll metrology equipment on the grinder and proper tracking of rolls from roll grinding through the rolling operation in order to monitor the performance of the rolls throughout the rolling process. Capco® manufactures heavy duty, high accuracy roll grinders that produce the proper roll profile, exact roll surface condition (Ra) and the lowest roll runout (TIR) in the shortest possible grinding time. Grinding performance is directly related to three factors: mass (m), stiffness (k) and dampening (c). Capco® SuperGrinders™ are of massive cast iron construction with up to 3 times the mass of other roll grinder designs. Capco® SuperGrinders™ also provide the maximum stiffness possible through the design principle of utilizing the least number of parts and closely coupled joints. The static system stiffness of a typical Capco® Model SG SuperGrinder™ grinding a hot or cold mill work roll is 1,500,000 lb/in. Finally, Capco® SuperGrinders™ provide the highest dampening through Capco®’s use of cast iron and proper design. By maximizing the mass, stiffness and dampening of the Capco® SuperGrinders™ mechanical design and combining this with the fastest all-digital drives and CNC controls, Capco® SuperGrinders™ grind rolls 3 to 4 times faster than any other roll grinding machines. Capco® utilizes an ABSOLUTE digital PC-based open architecture control (Capco® OAC 10.0) with Internet addressed CNC, PLC and HMI. The Capco® OAC 10 grinder controls can be directly connected to Capco®’s level II web-based internet connected Roll Shop Computer Management System (RSCS) that tracks all roll grinds including: grinding times, grinding programs, roll metrology reports, roll defects (cracks and bruises) reports, roll chock and bearing information, and performance of the roll in the mill (i.e., tons of sheet produced per roll grind). In addition, the Capco® OAC 10 can be connected to the Internet for on-line service and diagnostics. With Capco® SuperGrinders™ more roll shops can utilize the latest manufacturing technology to produce higher quality sheet and more profit for the rolling mill operation.
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