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1、Goals,Technical solution,Execution of Tests,Goals,Technical Solution,Execution of Tests,10/22/2018,1,Goals,Reducing Tooling Costs,Increasing the lifetime of plugs (Example: 200 passes 13Cr steel billets instead of only 5 passes). Keeping the cost of plugs low (Using normal hot working steel as plug
2、material) Reconditioning of used plugs,Ensuring Faultless Piercing,Thanks to higher lifetime and higher stability the plugs do not fail at an early stage and can safely be removed for reconditioning. In addition the surface condition can be scanned during production.,Eliminating the Plug Changing De
3、vice,The mechanism of the plug changer can be deranged and cause mill down time. A plug with inside cooling needs no or much fewer mechanical manipulation.,Minimizing the Production Cycle Time,Over hundreds of passes no plug change is necessary and according idle time is avoided. For low cycle time
4、an effective cooling must be installed.,Goals,Technical Solution,Execution of Tests,10/22/2018,2,Goals,Technical Solution,Execution of Tests,Technical Solution,General,Reference,10/22/2018,3,Goals,Technical Solution,Execution of Tests,Piercer: 3-roll piercer Mill: mandrel mill Plug surface: pre-surf
5、ace coated Cooling system: internally and externally Internally Water Pressure: 20bar Billet material: 13% Cr steel Hollow bloom length: 8 m Piercing time: 10 s Delay time: 5 s Life time of the piercer plugs: 200 passes,Technical Solution,General,Reference,10/22/2018,4,Technical Solution,General,Ref
6、erence Complex solution,Goals,Technical Solution,Execution of Tests,Reference Complex solution,General,Technical Solution,5,High strength No plastic deformation No severe cracks Thermal shock resistance Suitability for oxidation Preformed condition,Wear resistance Heat isolation Decisive for rolling
7、 time Low friction Separating properties,Outside, inside cooling Plug changing system Cooling system Cooling parameters,Minimization of thermal loads Technological demands Bore design,Goals,Technical Solution,Execution of Tests,10/22/2018,6,Technical Solution,General,Reference Complex solution Main
8、factors,Goals,Technical Solution,Execution of Tests,Barrier against heatingBarrier against chemical and physical attacksEffective cooling,10/22/2018,7,Technical Solution,General,Reference Complex solution Main factors,Improved Properties of Piercer Plugs,PQSC plugs,Goals,Technical Solution,Execution
9、 of Tests,8,Deformation resistance,Temperature,Choice of steel grade,Goals,Technical Solution,Execution of Tests,Improved Properties of Piercer Plugs,PQSC plugs,9,Goals,Technical Solution,Execution of Tests,Improved Properties of Piercer Plugs,PQSC plugs,10,Advantages:No pre-rolling of short billets
10、 necessaryCost reduction thanks to high lifetimeHigh process security,Goals,Technical Solution,Execution of Tests,Improved Properties of Piercer Plugs,PQSC plugs,Impact-resistant oxide layers with thickness up to 1.5 mm,11,Goals,Technical Solution,Execution of Tests,Improved Properties of Piercer Pl
11、ugs,PQSC plugs,Tailor-made coating layers can be provided,October 18,12,Additional Properties of the PQSC Layer:,High Hardness,Thermal Shock Resistance,Strong Bonding to the Basic Material,No Material Adhesion,Low Friction,Self-Regeneration,Goals,Technical Solution,Execution of Tests,Improved Proper
12、ties of Piercer Plugs,PQSC plugs,10/22/2018,13,Technical Solution,General,Reference Complex solution Main factors,Improved Properties of Piercer Plugs,PQSC plugs Options for TPCO,Goals,Technical Solution,Execution of Tests,1. Purchase PQSC Plugs from SMS Meer 2. Own development,*) Assumed price for
13、PQSC Plugs for TPCO with OD 168 mm: 500 per plug (incl. 2 reconditions),*),10/22/2018,14,Technical Solution,General,Reference Complex solution Main factors,Improved Properties of Piercer Plugs,PQSC plugs Options for TPCO,Cooling System,Reference and experience,Goals,Technical Solution,Execution of T
14、ests,15,Goal: Retain high strength of the basic material in order to avoid plastic deformation.,Background: Technological know-how is based upon R&D and production knowledge from the MM-plant of Tube Investment LTD, Wolverhampton, GB Cooperation with our customers,Cooling System,Reference and experi
15、ence,Goals,Technical Solution,Execution of Tests,16,Cooling System,Reference and experience,Goals,Technical Solution,Execution of Tests,Vaporizing has to be avoided securely because it would reduce heat conductivity drastically.,10/22/2018,17,Cooling System,Reference and experience,Water pressure in
16、 bar (1 bar = 14.5 psi),Boiling temperature in C,Goals,Technical Solution,Execution of Tests,High pressure helps to avoid vaporizing.,10/22/2018,18,Cooling System,Reference and experience,Goals,Technical Solution,Execution of Tests,High pressure helps to ensure high velocity of the coolant. Pressure
17、 losses amount to approx. 10 to 15 bar. Accordingly high should be the applied input pressure.In addition turbulent flow has to be established because it increases the cooling efficiency.Alternative cooling methods like air-water spraying should be put on hold until having reconstructed the original solution.,
