PEELING LINES Quality and productivity in bright steel production Bright steel processing lines Integrated solutions from a single source The bright steel industry is characterized by ever stricter quality and productivity requirements. As the world-wide leading supplier, the product unit Schumag & Copper of SMS Meer offers both high performance single units but also, interconnected systems with a maximum degree of automation. They are suitable for machining of round bars and thick walled tubes made of steel and steel alloys. Especially with the PM-series in diameter rage up to 250 mm and PMH-series in diameter range up to 600 mm SMS Meer introduces new standards in quality, productivity, and flexibility. 2 Special characteristics of the bright steel centre Depending on the machine configuration, bar–to–bar, coil–to–bar and coil–to–coil operation are possible for the manufacturing of cylindrical, tapered and/or double tapered bars. All common steel alloys, round cast, titanium and other non-ferrous materials can be processed. The product program specifically includes: Black bar straightening machines in multiple or two-roll design Complete bar loading device with unscrambling for bars as well as coil preparation systems, consisting of pay-off reel, coil end opener, pre-straightening and calibrating units for operation mode from coil. Peeling machines for highest performance and quality requirements Two-roll straightening and polishing machines for best straightening results and surface finishes Integration of non-destructive testing systems Single and double-sided bar end processing machines for the raw material and the finish product The individual units are configured as LH or RH machines, depending on the local conditions and the material flow required 3 Black Bar Straightening Two and Multi-Roll Straightener For straightening of rolled or forged round bars and thick walled tubes made of steel the product unit Schumag & Copper of SMS Meer supplies straightening machines in line with a bright bar centre or as a separate unit with handling equipment. Especially with straightness deviations of the raw material of more than 2 mm within 1 m of the measured length, straightening before peeling is recommended. Two-roll Straightener For high straightness requirements over the total bar length, incl. lead and trail ends, we recommend the use of a two-roll straightener. The main features of this machines are: Hydraulically movable upper roll to compensate the ovality of the black bar Scale discharge via emulsion Steel guide ledges with hardened wear segments for the surfaces in contact with material Good accessibility and easy maintenance thanks to vertically fitted straightener rolls MACHINE SIZES WRP 60S to WRP 160S Working rages Ø 10 mm to Ø 160 mm Throughput speed up to 60 m/min 4 Multiple–roll straightener 10-roll concept In order to meet the future requirements, SMS Meer has developed a multi-roll straightener with 10-rolls. The machines of the MWR series are characterized by the following features: Motor driven diameter adjustment with hydraulic clamping for all top rolls High performance roll and drive concept Good accessibility and high operating comfort Fast change of rolls and reduced down-times for tool change improved scale removal Environment and operator friendly due to integrated dust extraction and optimized sound insulation MACHINE SIZES MWR 40 to MWR 170 Working rages Ø 8 mm to Ø 170 mm Throughput speed up to 240 m/min 5 Raw Material Coil Pay-off reel For coil weights up to 3,500 kg pay-off reels in different designs and executions are available. Coil end opener Coil end openers to open and pre-straighten the leading coil end are available in three sizes and right/left versions. Feed device movable in cross direction Feed device, laterally movable to feed the leading coil end pre-straightened by the coil end opener into the pre-straightener. Manipulator Manipulator as an alternative to the coil end opener. Controllable five axes enable safe and flexible handling of the leading coil end from the moment of gripping it until it is taken over by the pinch rolls of the pre-straightener. The movement axes are controlled by “joy stick”. Horizontal and vertical pre-straightener Straightening combinations, consisting of Horizontal, driven pre-straighter Vertical, non-driven pre-straighter Calibrating unit The combination of the plastic deformation effect during the calibrating process and the simultaneous twist on the taut wire, removes kinks from even roll-hardened material. Therefore, it will straight and it can still roll and be unscrambled after peeling and cutting to size. The wire is twisted by the inclined pinch rolls. Rotary Straightener Depending on the quality of the raw material alternatively or additionally to the calibrating unit a rotary straightener can be installed. 6 Raw Material Bar Bar loading and unscrambling To supply bar material from bundles to the system, SMS Meer supplies tailormade loading systems with automatic downstream unscrambling. The transport to the subsequent units is done either by using discharge slopes or chain conveyors. 7 Peeling machine PM-Series The PM-series is suited to the most stringent performance, quality and flexibility requirements. Round solid materials and thick walled tubes of all common steel alloys, round cast, titanium and other non-ferrous materials can be processed. The common operating modes bar–to–bar and coil–to–bar for cylindrical, tapered- and double-tapered bars and the coil–to–coil mode are possible. The distinguishing characteristics of the PM-series are: Economic production of bright steel of the highest quality Rigid construction Use of vibration damping materials Use of quick-change systems High performance range Peeling quality up to IT8 8 Infeed unit Drive via multi-shaft distributor gearbox. High user-friendly design by axial plug-in unit movement Entry guide Easy diameter alignment of the guide rolls by central motor and rack and pinion gearing Multipoint guide in sturdy version Machine bed FEM-optimized machine bed Adjustment of cutter head tools High availability by wear-resistant, optimized contact surfaces SG iron housing with no-play, hydrostatic bearing, large radial rigidity and good vibration damping of the cutter head Low-friction diameter adjustment Setting of the tool adjustment using a position controlled axis Optimized labyrinth seals for high operational reliability Reinforced and FEM-optimized tapered bushing Exit guide The exit guide can be removed via the extraction carriage Push rod version Extraction carriage Smooth running characteristics due to the integration of linear guides in the machine bed Maintenance free drive system due to rack and pinion MACHINE SIZES PM 35 to PM 250 Working ranges Ø 5 mm to Ø 250 mm Throughput speed up to 60 m/min 9 Peeling machine PMH-Series This series is especially designed for peeling of rolled and particularly forged round bars in the upper range of diameters up to approx. 600 mm. The machine offers the following special features: Rigid construction with high vibration damping effect Highest peeling performance, also for high strength steels and nickel based alloys Cutting depths of maximum 15 mm by using appropriate tools 10 Adjustment of new bar diameter from operator control panel All tools cover the whole working range of the machine Infeed guide with large dimensioned rollers with easy centre alignment by separate motors Axial movable infeed guide for quick change of cutting tools Infeed guide precisely and reproducible fixed via Index bolts and hydraulically clamped during the peeling process OPTIONAL Separate polishing unit for improved surface quality Handling equipment for safe bar feeding and removal MACHINE SIZES PMH 320 to PMH 600 Working ranges Ø 75 mm to Ø 600 mm Throughput speed up to 6 m/min 11 BRIGHT BAR STRAIGHTENING WRP-Series To fulfill the highest performance requirements at high demanding material qualities, the two-roll straightening and polishing machine of the WRP type series are used. Their most noteworthy characteristics are: Optimum straightening effect, even with high strength materials Two-roll principle with concave upper roller and convex bottom roller to ensure that the ends are straightened Straightener rolls from alloyed and hardened chrome steel Lateral guidance of the bar to be straightened between the straightener rolls by special guide ledges 12 Height-adjustable traverses to adjust the guide ledges to the centre of the straightening gap Easy change of the guide ledges by swiveling the traverses outwards Easy and quick replacement of the entire roller pair using the integrated roll change device Long straightening roller life due to coolant lubrication WRP 250 Largest two-roll straightening machine in SMS Meer history and one of the largest in the world. Technical data: Height 7 m Weight 250 t Straightening force 8,000 kN MACHINE SIZES WRP 25BF to WRP 60BF Working ranges Ø 5 mm to Ø 60 mm Throughput speed up to 210 m/min Height adjustable Fixed upper roll MACHINE SIZES WRP 80B to WRP 250B Working ranges Ø 10 mm to Ø 250 mm Throughput speed up to 75 m/min Hydraulically cushioned upper roll 13 MATERIAL TESTING AND BAR END PROCESSING Undoubtedly the best quality Material testing A testing unit can be integrated into the line to ensure the required quality of the peeled and straightened bar. This can consist of the following components: Standard test coil according to the eddy current method for testing surface point errors Rotating test coil according to the eddy current method for testing surfaces for point and longitudinal errors Detection of internal material defects by ultrasonic Randomized measurement of the rod straightness Measurement of the diameter Grade and heat treatment verification Bar end Processing The machining of bar material in downstream machines such as automatic lathes often requires a certain bar end shape to ensure a trouble-free feed in the lathe. The relevant bar end machining operation with the FP-series can take place at the end of the line by machining the peeled and straightened bar, or to minimize cutting tool wear upstream of the peeling machine. The flexible machine concept enables a multitude of bar end machining options such as: Face turning Face milling Chamfering Trunnion turning Centering boring Sawing Some of the advantages of the SMS Meer concept for bar end machining are: High performance Facing/chamfering in one run Face-milling/chamfering with the same tool Quick tool replacement MACHINE SIZES FP2 to FP6 Working ranges Ø 5 mm to Ø 160 mm 14 PEELING MACHINES Automation concept of SMS Meer peeling machines The machine control system is designed according to the latest safety and ergonomic standards and is based on years of know-how of SMS Meer. Special features: Self-explanatory operating and diagnostic concept on the touch screen of the main control panels Powerful visualization helps the operator to achieve the high standards of production quality Documentation of quality-related product characteristics Constant bar diameter ensured through online measurement in combination with closed loop controlled tool positioning Integrated recipe management enables operatorindependent reproducibility of the machine setting Remote diagnosis via the standardized SMS Meer remote service supports the maintenance personnel and reduces downtimes Host IBM / Remote maintenance PLC S7, AB, Mitsubishi... Control levels Ethernet Laser measurement HMI 15 SMS Meer Product Unit Schumag & Copper Bright Steel Processing 52076 Aachen Germany Phone:+49 2161 350-1308 Fax: +49 2161 350-1874 [email protected] www.sms-meer.com MEETING your EXPECTATIONS IMPRINT SMS Meer, Corporate Communications, Dr. Peter Heimerzheim (Director), Ohlerkirchweg 66, 41069 Mönchengladbach, Deutschland Phone: +49 2161 350-2600, Fax: +49 2161 350-1862, [email protected], www.sms-meer.com The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract. D4201.03/14 en · Printed in Germany Nerscheider Weg 170
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