Cast Mill Rolls for Bar/Rebar Mills

• Customization: Available
• After-sales Service: 24 Hours
• Warranty: 1 Year
• Model NO.: AS/AD/GS/SGP/SGA/IC/HSS
• Condition: New
• Certification: ISO9001
• Standard: DIN, GB, JIS, ANSI
• Customized: Customized
• Material: Cast Steel/Iron
• Application: Metal Processing Machinery Parts
• Automatic Grade: Automatic
• Power Source: Electric
• Type: Two-Roll Cold-Hot Mill
• Produced Products: Long Products
• Applied Mills: Long Products Mills
• Transport Package: Steel Pallets
• Specification: As Requirement
• Trademark: TSR Rolls
• Origin: China
• HS Code: 8455300000
• Production Capacity: 30000 Tons/Year

Product Description

Product Description

Alloy Cast Steel (AS)
Carbon contents of Alloyed Cast Steel range between 0.4 to 1.4 % depending of the hardness level. Additions of Cr, Ni, Mo and other alloying elements and the right heat treatment will develop a pearlitic or sorbitic structure. 
In case of deep channels and grooves, we recommend a pre-machining of the grooves before the final heat treatment allowing the hardness to penetrate down to the bottom of the grooves and developing a uniform hardness along the barrel

Application:
Roughing and BD stands of heavy section and medium section mills.
 

MATERIAL	GRADE	CHEMISTRY						BARREL HARDNESS (HSC)
		C	Si	Mn	Cr	Ni	Mo
Alloy Steel	AS60	0.55-0.65	0.20-0.45	0.90-1.20	0.80-1.20		0.20-0.45	35-50
	AS65 I	0.55-0.65	0.20-0.60	0.50-1.00	0.80-1.20	0.20-1.50	0.20-0.60	35-45
	AS70	0.65-0.75	0.20-0.45	0.90-1.20				32-42
	AS70 I	0.65-0.75	0.20-0.45	1.40-1.80				35-45
	AS70 II	0.65-0.75	0.20-0.45	1.40-1.80			0.20-0.45	35-45
	AS75	0.70-0.80	0.20-0.45	0.60-0.90	0.75-1.00		0.20-0.45	35-50
	AS75 I	0.70-0.80	0.20-0.70	0.70-1.10	0.80-1.50	≥0.20	0.20-0.60	35-50

 

		TYPICAL PHYSICAL PROPERTIES
Material	Neck Hardness (HSC)	Tensile Strength (N/mm^2)	Unevenness of Barrel Surface Hardness (HSC)
AS60	≤45	≥650	<5
AS65 I	≤45	≥650	<5
AS70	≤45	≥600	<5
AS70 I	≤45	≥600	<5
AS70 II	≤45	≥680	<5
AS75	≤45	≥680	<5
AS75 I	≤45	≥700	<5

Adamite (AD)
Adamite or Steel Base is a material with Carbon content and mechanical properties between Steel and Iron.The addition of Cr, Ni, Mo and other elements and a special heat treatment process will develop a high wear and fire cracking resistance together with a constant hardness along the working layer.

Application:
Intermediate and finishing stands of section mills.
Intermediate stands of bar mills.
Sleeves for Universal stands of heavy section mills.
Vertical Edgers of hot strip mills.
Work Rolls for roughing stands of heavy plate mills.
 

MATERIAL	GRADE	CHEMISTRY						BARREL HARDNESS (HSC)
		C	Si	Mn	Cr	Ni	Mo
Adamite	AD140	1.30-1.50	0.30-0.60	0.70-1.40	0.80-1.60		0.20-0.60	38-55
	AD140 I	1.30-1.50	0.30-0.60	0.70-1.10	0.80-1.20	0.50-1.20	0.20-0.60	35-50
	AD160	1.50-1.70	0.30-0.60	0.70-1.10	0.80-1.20		0.20-0.60	40-50
	AD160 I	1.50-1.70	0.30-0.60	0.80-1.30	0.80-2.00	≥0.20	0.20-0.60	40-60
	AD180	1.70-1.90	0.30-0.80	0.60-1.10	0.80-1.50	0.50-2.00	0.20-0.60	45-60
	AD190	1.80-2.00	0.30-0.80	0.60-1.20	1.50-3.50	1.00-2.00	0.20-0.60	55-65
	AD200	1.90-2.10	0.30-0.80	0.80-1.20	0.60-2.00	0.60-2.50	0.20-0.80	50-65

 

		TYPICAL PHYSICAL PROPERTIES
Material	Neck Hardness (HSC)	Tensile Strength (N/mm^2)	Unevenness of Barrel Surface Hardness (HSC)
AD140	≤45	≥590	<5
AD140 I	≤45	≥590	<5
AD160	≤50	≥490	<5
AD160 I	≤50	≥490	<5
AD180	≤50	≥490	<5
AD190	≤50	≥490	<5
AD200	≤50	≥490	<5

Graphitic Steel (GS)
The carbon content and matrix of graphite steel rolls are similar to that of adamite rolls, the main character is that it contains a small amount of fine graphite in its microstructure, which will increase its resistance to fire crack and prevent oxidized scales from adhering. 

Application: 
Intermediate and finishing stands of heavy section mills. 
Finishing stands of rails.
Pilger mills. 
Vertical Edgers of hot strip mills.
 

MATERIAL	GRADE	CHEMISTRY							BARREL HARDNESS   (HSC)
		C	Si	Mn		Cr	Ni	Mo
Graphite Steel	GS 140	1.30-1.50	1.30-1.60		0.50-1.00	0.40-1.00		0.20-0.50	36-46
	GS 160	1.50-1.70	0.80-1.50		0.60-1.00	0.50-1.50	0.20-1.00	0.20-0.60	40-60
	GS190	1.80-2.00	0.80-1.50		0.60-1.00	0.50-2.00	0.60-2.20	0.20-0.80	55-65

 

		TYPICAL PHYSICAL PROPERTIES
Material	Tensile Strength (N/mm^2)	Bending Strength(N/mm^2)	Elongation(%)
Graphite Steel	≥450	650-1000	0.2-0.6

 Pearlitic Nodular Cast Iron (SGP)
Pearlitic and Pearlitic / Sorbitic Nodular Iron are nodular grades alloyed with Cr, Ni, and Mo with Ni ranging between 1.50 % in the softer grades and 4 % in the harder grades. The right balance of Si and Cr will help to develop the adequate hardness level. The rolls can be cast static or spun cast depending of the size of the working layer and the mill conditions.

Application:
Roughing stands of bar, wire rod and medium section mills.
Intermediate stands of bar mills.
Sleeves of Universal stands.
 

MATERIAL	GRADE	CHEMISTRY						BARREL HARDNESS   (HSC)
		C	Si	Mn	Cr	Ni	Mo
Pearlite (SGP)	Pearlite I	2.90-3.60	1.40-2.20	0.40-1.00	0.10-0.60	1.50-2.00	0.20-0.80	45-55
	Pearlite II	2.90-3.60	1.20-2.00	0.40-1.00	0.20-1.00	2.01-2.50	0.20-0.80	55-65
	Pearlite III	2.90-3.60	1.00-2.00	0.40-1.00	0.20-1.00	2.51-3.00	0.20-0.80	62-72

 

	TYPICAL PHYSICAL PROPERTIES
Neck Hardness (HSC)	Tensile Strength (N/mm^2)	Unevenness of Barrel Surface Hardness (HSC)
35-55	≥350	<5

Bainitic nodular cast iron (SGA)
Bainitic and bainitic / martensitic nodular iron are nodular grades alloyed with Cr, Ni, and Mo with higher Cr and Ni contents. 
Compared to pearlitic irons, acicular irons show higher strength, toughness and wear resistance.
The rolls can be cast static or spun cast depending of the size of the working layer and the mill conditions.

Application:
Intermediate and finishing stands of bar, wire rod and medium section mills.
Forming, sizing, reducing and straightening rolls for pipe and tube mills.
Sleeves for Universal finishing stands (Horizontal & Vertical).
 

MATERIAL	GRADE	CHEMISTRY					BARREL HARDNESS   (HSC)
		C	Si	Mn	Ni	Cr
Bainite (SGA)	Bainite I	2.90-3.60	1.20-2.20	0.20-0.80	3.01-3.50	0.50-1.00	55-78
	Bainite II	2.90-3.60	1.00-2.00	0.20-0.80	3.51-4.50	0.50-1.00	60-80

 

	TYPICAL PHYSICAL PROPERTIES
Neck Hardness (HSC)	Tensile Strength (N/mm^2)	Unevenness of Barrel Surface Hardness (HSC)
32-45	≥350	<5

Alloy Indefinite Chilled Cast Iron (IC)
Alloy Indefinite Chilled Cast Iron is a material between chill cast iron and grey cast iron.The sizes, shapes and distributions of graphite and carbide are controlled by the chilling effect and the contents of alloy elements. The addition of alloy elements such as Manganese, Nickel, Chromium, and Molybdenum changes the matrix microstructure from pearlite, bainite to martensite. The present of small amount of fine graphite enhances the roll's resistance to spallling, thermal crack and wearability. This roll has small hardness gradient in the working layer of roll barrel and is suitable to medium and finishing stands for bar, wire and section mills.
 

MATERIAL	GRADE	CHEMISTRY									BARREL HARDNESS   (HSC)
		C	Si	Mn	Cr	Ni	Mo	V	W	Nb
Indefinite Chilled  (IC)	IC III	2.90-3.60	0.60-1.20	0.40-1.20	0.70-1.20	2.01-3.00	0.20-1.00				38-55
	IC IV	2.90-3.60	0.60-1.50	0.40-1.20	1.00-2.00	3.01-4.00	0.20-1.00				35-50
	IC V	2.90-3.60	0.60-1.50	0.40-1.20	1.00-2.00	3.01-4.80	0.20-2.00	0.20-2.00	0.00-2.00	0.00-2.00	40-50

 

		TYPICAL PHYSICAL PROPERTIES
Material	Tensile Strength (N/mm^2)	Bending Strength(N/mm^2)	Elongation(%)
IC	400-500	700-1000	0.2-0.5

High Speed Steel (HSS)
High-speed steel rolls are manufactured by centrifugal casting, the core material is spheroidal graphite cast iron. By adding vanadium, tungsten, niobium and other alloying elements and special heat treatment, the distribution of this material became martensite with good uniformity to ensure high hardness and hardness uniformity of Shell. High-speed steel materials perform high hardness and wear resistance at high temperature. It could be used for finishing stand to increase the operating time and improve the quality of the surface of rolling material.
 

MATERIAL	CHEMISTRY										BARREL HARDNESS(HSC)   (HSD)
	C	Si	Mn	p	s	Cr	Ni	Mo	V	W
High Speed Steel	1.50-2.20	0.30-1.00	0.40-1.20	≤0.030	≤0.025	3.00-8.00	0.00-1.50	2.00-8.00	2.00-9.00	0.00-8.00	75-95

 

		TYPICAL PHYSICAL PROPERTIES
Material	Neck Hardness (HSC)	Tensile Strength (N/mm^2)	Unevenness of Barrel Surface Hardness (HSD)
High Speed Steel	30-45	≥350	<5

 

Detailed Photos

 

Technology

--MELTING

TSR Rolls factory is equipped with a variety of smelting equipments, such as EBT electric arc furnace, LF double-bit refining furnace, VD-VOD vacuum furnaces and etc. Advanced smelting equipment supplemented by temperature control, component analysis and other testing equipment ensure that each furnace is in line with the requirements of molten steel.

Steel Foundry

• EBT Arc Furnace; Capacity 55T
• Ladle Furnace, Double position; Capacity 55 T Each
• Vacuum Degassing VD + VOD, 9 units; Capacity 90 T Each
• Medium Frequency Induction Furnaces, 2 sets; Capacity 20 T Each

Large Rolls Foundry

• 2 x 20 T Medium Frequency Induction Furnaces
• 2 x 10 T Medium Frequency Induction Furnaces
• 2 x 7 T Medium Frequency Induction Furnaces
• 2 x 3 T Medium Frequency Induction Furnaces

Small Rolls Foundry

• 2 x 3 T Medium Frequency Induction Furnaces
• 2 x 1.5 T Medium Frequency Induction Furnaces
• 2 x 1 T Medium Frequency Induction Furnaces

--CASTING

TSR Rolls applies advanced roll casting technology to first-class foundry equipment. Our main production processes use computers to control and select parameters automatically. So we can ensure that each batch of rolls has consistent production process control. Every step is traceable by our Electronic recording system. Whether it is static casting or centrifugal casting, our products have excellent performance.

7 Horizontal Spin Casters (Centrifugal Machines)

• 1 Unit Ø 1.600 mm x 4.500 mm B.L.
• 1 Unit Ø 1.400 mm x 3.000 mm B.L.
• 2 Units Ø 800 mm x 2.600 mm B.L.
• 1 Unit Ø 500 mm
• 2 Units Ø 300 mm

Plus a complete set of chills, chillers and moulding tackle to cast all kind of rolls including big section rolls with the barrel shaped with grooves and collars in as-cast condition.
 

--HEAT TREATMENT

During the manufacturing process of rolls, many materials need to pass one or more heat treatment to further achieve the most appropriate mechanical properties and good microstructure. The resistance furnace of TS ROLL can achieve multi-point precise temperature control to ensure uniformity of the furnace temperature. Between different furnaces, we use a unified computer control to achieve the furnace heating and cooling consistency in order to ensure the rolls from different furnaces with same microstructure and performance.

• Differential Heat Treatment Furnace Ø 1.600 mm x 2.800 mm B.L.
• Spray quenching machine, Maximum capacity: Ø1800mm rolls
• Electrical fumaces, Maximum capacity: 200T 18 sets - bogie type
• 7  sets - low-temperature
• 11 sets - high temperature

--MACHINING

TSR Roll has a machining shop of more than 15.000 square meters, including the lathe, boring machine, grinding machine and other modern processing equipment for rolls. Thanks for the first-class operator working on high-precision CNC equipment, it is easy to produce the rolls with various kinds of grooves and precise tolerances.

• CK61160 CNC Lathe, Maximum capacity: 32T
• MK84200 CNC Grinding machine, Maximum capacity: 50T
• C9125*6/63 Turing and Boring machine, Maximum capacity: 63T
• T6920D Boring machine

    
--QUALITY ASSURANCE  

The high performance requirements of today's mills require reliable rolls capable of remaining in the production cycle longer than ever while still assuring a high quality of the rolled products. TS Rolls has built a consistent quality control throughout the manufacturing process. Our aim is supplying the customer with reliable rolls capable to perform better, contributing to customer benefit, cost reduction and satisfaction.

Since the beginning TS Roll obtained the ISO 9001:2008 Quality Management System Certification. Based on our consistent adherence to the quality management, TS Roll products quality has been universally acclaimed by dozens of customers worldwide.

• Emission Spectrometer ARL - 3460; Two sets
• Carbon & Sulphur Analyzer CS-80
• Hydrogen & Oxygen Analyzers
• Thermal Analyzer
• Hardness Testers (Portable and Laboratory sets)
• Ultrasonic Testing Equipments (Several units)
• Material Testing Machine WAW-600
• Charpy Impact Test Machine JSB-300

 

Service & Support

At TSR Roll, we are focused on the roll service. Our Technical Service will help you to solve questions about roll maintenance, roll wear, roll damages, roll configuration, shape of the roll, surface hardness, roughness, temperature distribution and damage inspection among others. The aim is reducing the Total Cost of Operation for the customer by supplying reliable rolls and advanced roll service always with strict adherence to the delivery time.