COLD ROLLING

This was possible thanks to the ingenuity of operators and the discovery of their inventions, reaching levels showing that increased speeds actually had a negative impact in terms of production both in terms of quality and quantity.
Needless to say, increasing the speed of a material as it goes through a die (drawing) or through paired or staggered rollers arranged in cascade (rolling or straightening) or though rotating tools (peeling), the immediate effect is to increase the output, but if the speed increase is not coupled with suitable entry and exit services, the effect diminishes until it negatively affects the overall process.
OCN S.p.A., which for over 30 years has been making cold-working machines for ferrous and non-ferrous materials in bars or tubes, has carefully followed the evolution in the production aspect of this sector and, while enhancing the performances of its machines, has also pursued the goal of optimizing its services for the specific purpose of bringing the overall speed of the production process closer to the speed of each machine.
For example, starting with a combination of one or more process units, each one capable of running at 100 m/1’, the design goal is to “turn out” bars or tubes in bundles or coils at an overall speed that is as close as possible to the above-mentioned limit, maximizing the efficiency of the facilities.
In order to reach this goal, OCN has fitted its machines with special devices which, working automatically or at least with less operating personnel, minimize all the downtimes interspersed throughout the process.
The combined operating units basically use starting bars in various lengths or coils in various weights.
In the case of bars, it goes without saying that by reducing the spaces between the tail of one bar and the head of the next, the feed speed comes close to the constant speed of the line itself.
It is obvious that to accomplish this the preparation operations of each subsequent bar, such as bundle singling out, pointing, introduction of the point, must be done in the shadow of the previous bars. This also applies to coil feeding.
The design also focuses on the facilities located downstream the process, such as the finishing area for bar and tube ends, the bundle forming area, the strapping or packing area, the weighing area, the labelling area and storage area. These are all operations that have to be carried out without penalizing the line speed set in relation to the product section being produced.
But even if the above-mentioned production quantity targets have been met, this does not mean that the quality target has been reached.
In this respect OCN has perfected various quality control devices, such as:
– Servo-assisted die adjustment usable during the drawing process with storage of values
– Recording of values and drawing forces
– Dimensional checking of the product
– Checking for surface defects on the product
– Checking product straightness
– Servo-assisted adjustment of the straightener with storage of data
– Checking the eccentricity and thickness of tubes
– All the adjustments and checks that always have to be done without penalizing the process speed that the line is capable of reaching.
It is obvious that to obtain these results the lines have to be equipped with more or less sophisticated devices that inevitably involve a considerable increase in the investment. On the other hand, however, their advantage is that they do not require a larger number of operators.
Therefore, the use of these advanced technologies is especially advantageous to users in developed western countries and not to those in developing countries, as long as they can count on much lower manpower costs.

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