2/28/2022

Refresher Training on Roller Guides Setting

& Assembly Process

Suman Kanti Dey

Date: 27th Feb, 2022

Production (Re-heating furnace and Rolling

Department
Module) BSRM MILLS

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What is the rolling mills guides?

 The rolling mill guides are one of the main components.
 It can make the rolling mill accurately entering into the grooved of the Roll,
 The different shape of steel can be obtained.
Main use to rolling mill guides……
 Accurately put the rolled piece into the grooved roller.
 Make sure the steady deformation of rolled piece in groove, and obtain the
demanded shape and size of steel.
 Successfully derive the rolled piece from groove, prevent cobbling.
 Control and force the rolled piece twist or inflect, and deformation, and
movement on the basis of a definite direction.

Guides

Entry Exit

Static Roller Static Roller

AEC AEM AEL FRS SR MDR/DR30 AUM AUC AUT AUV RTC CTR MSL

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SR Series Guide
General Information:
1. The SR stands for single pair
roller guide.
2. The roller adjustment is
made with a rotating cam wheel
via the worm screw.
3. SR guide enables precise
symmetrical and simultaneous
adjustment is self locking.
4. The guide are mounted
either is a cassette or an a
conventional base.

SR Series Guide
Name of components

1. Body
2. Roller holder
3. Setting screws
4. Worm screw
5. Spring
6. Locking screw
7. Entry halves
8. Roller
9. Bearing
10. Pin
11. Washer

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Cam Wheel Setting DR / SR Series Guide

Cam wheel position Max. limit Cam wheel position Min. limit Cam wheel position Center limit

DR30 Entry Guide

General Information:
1. The DR30 stands for double
pair roller guide.
2. The roller adjustment is made with a
rotating cam wheel via the worm screw.
3. DR30 Modified guide assembled with
Stabilizer unit.
4. Single pair Horizontal roller.
5. DR guide enables precise symmetrical
and simultaneous adjustment is self
locking.
6. The guide are mounted either is a
cassette or an a conventional base.

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ROLLERS AND BEARINGS ASSEMBLY

1) Check the condition of the
bearings and of the Nilos-Rings,
then make up the roller units by
assembling the parts as shown in
Fig.

2) Usually, between roller and

bearing there is a clearance fit;
in most cases it is therefore
possible to insert the bearings into
their housing on the roll by hand.

3) If necessary, should there be a

transition fit, use a plastic
hammer.

ROLLERS AND BEARINGS ASSEMBLY

4) In order to deform the Nilos-Ring
correctly, tighten the stud on the lower
bushing to adjust the clearance of the
bearings properly.

5) Now you have to loosen again the stud

and check the rotation of the roller by
hand. With the 6-mm Allen wrench
gradually loosen the stud,
While trying to rotate the roller with
your hand.

6) As soon as you can rotate the roller

effortlessly, it means that the stud
position is correct.

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ROLLERS AND BEARINGS ASSEMBLY

 Always by hand, check the axial movement
of the roller.

 By trying to move it upwards and downwards

in the direction of its axis, make sure the
roller does not move.

 If there was too much free of rotation, it

means that the clearance on the bearings
should be reduced by tightening the stud
gradually again,

 Always remembering that the roller rotation

by hand should be rather free.

 The ideal condition will be obtained when there

are no axial movements and the roller is free
to rotate.

Rollers Alignment & Failure Video

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ADJUSTMENTS OF DR30 GUIDE

Adjustment of each roller independent center distance

 The adjustment has to be carried out on each single roller

show in Fig. Note: for DR boxes, always adjust intermediate
rollers first (12a) and then the exit ones (12b).
 To carry out the center distance adjustment proceeds as
follows:
a. Make sure that the fine center distance adjustment cam is
at about half of its stroke;
b. Unscrew the set screw locking nuts (14) with a socket
wrench or with a Allen wrench;
c. Operate on the set screw (15) with a socket head wrench
until the roller profile coincides with the suitable template
(Optical bench) or visualize (Hiline );
d. Once the rollers alignment has been carried out, lock the
adjustment screws by means of the locking nuts (14);
e. Proceed with the same sequence on the other rollers.

ADJUSTMENTS OF DR30 GUIDE

Adjustment of each roller independent height

 DR boxes are equipped with each roller independent height

adjustment.
 Once the macro adjustment of rollers center distance has been
carried out, if there are misalignments in roller height, proceed
as follows:
a. Operate on the “B” set screws with a socket wrench, until
obtaining a correct alignment.
b. This can be checked visualizing rollers profile with a
suitable template (Optical bench) or electronically (Hiline)
c. The maximum stroke is ± 0.5 mm with reference to the
position of the holder in nominal middle.
d. The set screw operates directly on the pivot that is in
contact inside the holder.
e. Holders are kept in position by means of cup springs (11).

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DR30 Assembly Process

>> Roller and Roller holder
align with the centering
template.

>>Center the Cam Wheel

>>Then tight the all locking

screw

>>then Set required gap by

using the adjusting screw /
worm screw.

DR Guide Roller Alignment

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DR Guide Roller Alignment

DR Guide Roller Alignment

All Guide Roller Should be
identical and perfectly
centered.

If any one roller out of

center that means miss
align it may occurred a
cobble.

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Pass sequence and guide schedule for slit rolling

DELIVERY ROLLER GUIDE FOR SLIT ROLLING ”MSL”

Four-roller entry guide type DR4BP of 1000-series in

combination with 4- or 5-strand slit guide type MSL45

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DELIVERY ROLLER GUIDE FOR SLIT ROLLING ”MSL”

Arrangement of MSL45 with flip opening conveying Slitting Action

through to looper

DELIVERY ROLLER GUIDE FOR SLIT ROLLING ”MSL”

Original MSL Stripper Modified MSL Stripper

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DELIVERY ROLLER GUIDE FOR SLIT ROLLING ”MSL”

In 5-strand slitting the multiple strand
separating guide, type MSL45, is used.

This guide is a combination of a 2- and a 3-

strand slitting system, again incorporated in
one unit.

In stage one sections 1 and 5 are separated,

and
In stage two sections 2, 3 and 4 are
separated

Resulting in five separate bars of false

round to be delivered to the finishing
section of the rolling mill.

Slitting Roller Stage - 1 Slitting Roller Stage - 2

DELIVERY GUIDE FINISHING STAND #20-H ”AUM”

Modified Design AUM Guide Nose Comparison between Regular Vs Modified

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DELIVERY GUIDE FINISHING STAND #20-H ”AUM”

Comparison between Regular Modified Nose After use

Vs Modified Nose

Corrective Action for further improvement

Profile Roller Guide, PRG
The profile roller guide has been designed in a compact
design,
without loosing strength, and is equipped with
simultaneous setting.
The two lower pair of rollers.
The third roller, top, is set by means of a screw easy
accessible on top of the guide.
PRG guides are equipped with the possibility for axial
adjustment of the top roller.
This possibility is an advantage for accurate positioning
of the roller with reference to the bottom rollers and is a
must when rolling asymmetrical sections such as
unequal angles.
As shown on the picture to the right the complete
side is removable for quick and reliable change
of rollers.

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Flat and profile roller guide, PRD
The PRD type of guide is a 4-roller entry guide used in
positions where an accurate entry of the flat section is
important.
The four rollers guide the material straight into the stand that
result
into a high quality final product.
Another major advantage for using this type of guide is the
prevention of scratches on the rolled material.
The distance between the rollers is set by one central screw
adjustment. When the distance is set the sides of the entry
funnel follows automatically.
The guide is provided with inner wear plates and
nose pieces, easily exchangeable, which increase
the guiding in open passes and in addition protect
the guide housing for eventual wear.
The base of the guide is made according to each
specific arrangement in respect of width.

PREVENTIVE MAINTENANCE PROGRAM

Preventive maintenance operations of the DR roller guides.
The following operations must be carried out in the workshop:

1. Remove any dirt and dust from the DR roller guides, especially from rollers, by means of
a jet of compressed air. If there are sports of grease, wash with oil-solvents.

2. Check the condition and the extent of wear of the strippers and entry funnel where the
bar rides. Remove with grinding wheel any scale attached to the groove.

3. Check the bearings provided on the rolls. For this check it is sufficient to move the rolls in
the two directions of rotation checking their smooth sliding without excessive noise.
Excessive noise can be due to insufficient lubrication.
If necessary, remove the component involved and carry out the following checks:
 Proper position of the bearings inside and outside rings
 Cleanliness of the bearing
 Condition of the casings containing the rotating components
 Onset of signs of damage on bearing races (by rotating the shafts slowly)
 Axial movement in the roll

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PREVENTIVE MAINTENANCE PROGRAM

4. Check the condition and the extent of wear of the rolls.
 If necessary, remove them and proceed with redressing operations.
 Before starting the operation, remove the two bearings and the relevant spacer.

5. Check for correct operation of single-point adjustment used to adjust the rolls.

6. Check entry guide half for excessive wear.

7. Using compressed air, check that the cooling water parts are open and free of scale.

8. Make sure that, during the lubrication phase, a grease ring forms around the bearing
being lubricated. Otherwise it is necessary to clean the point in the roll shaft.

9. Remove any dirt and dust from the roller guide, especially from rollers, by means of a jet
of compressed air. If there are spots of grease, wash with oil-solvents.

PREVENTIVE MAINTENANCE PROGRAM

10. Check the tightening of the bolts fastening the guide to the base plate and the base plate
to the rest bar. (Production & Workshop Team)

11. Check the proper operation of the water cooling system and make sure that the water
supply is constant to ensure a regular cooling of the rollers. (Production & Workshop Team)

12. Check the condition of the water cooling hoses. If damage, replace them. (Production & Workshop
Team)

13. Lubricate all the components that require (Production & Workshop Team)
Lubrication is meant to assure the working efficiency of every machine and plant component,
and to prevent breakdowns and failures.

Before using a hand pump, clean the grease nipple area and pump in grease until it comes
out of the bearing. Remove any excess grease.

14. Guide must be Change as scheduled. (Production Team)

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THANK YOU

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