Steel plants play a crucial role in the manufacturing industry, producing high-grade steel strips and other specialized materials. One of the key processes in these plants is cold rolling, which ensures the precision and quality required for modern applications. However, achieving such precision relies heavily on the performance of backup rollers used in tension levellers. These essential components are subjected to extreme conditions, making their design, durability, and maintenance critical factors in ensuring optimal performance.
The Backbone of Cold Rolling: Backup Rolls
Backup rollers are indispensable in cold working machines, performing crucial tasks such as straightening, levelling, and flattening steel strips. These rollers endure high radial forces, often coupled with axial forces, necessitating robust design and material integrity. The evolving demands of the steel industry have led to advancements in backup roll technology, with manufacturers now offering application-specific designs that cater to diverse industrial requirements.
TTS, a leader in backup roll manufacturing, has been at the forefront of innovation for over 15 years. With the capability to produce backup rolls up to 400mm in shaft length, TTS continues to refine its designs to meet the industry’s ever-growing demands. The company’s technical department employs advanced modelling and analysis software, alongside precision measurement tools like Coordinate Measuring Machines (CMM) and roundness metrology systems, to ensure impeccable quality and performance.
Engineering Excellence and Customization
Backup rolls come in a variety of internal and external designs, tailored to specific applications. Depending on operational needs, they can be permanently lubricated or require periodic lubrication. Low starting torque is another crucial factor in their design, as it helps minimize friction and enhances efficiency.
Many of these rolls operate in harsh environments, frequently exposed to large quantities of water, oil, and industrial pollutants. Such conditions increase the risk of premature corrosion and wear, necessitating a robust sealing system. At TTS, meticulous attention is given to the selection of lubricants and sealing mechanisms, ensuring enhanced longevity and reliability in demanding applications.
In addition to standard backup rolls, TTS offers special surface coatings and manufacturing options using high-performance materials such as stainless steel. These enhancements not only extend the lifespan of backup rolls but also contribute to improved performance under extreme conditions.
Reconditioning and Sustainability
While backup rollers are designed for durability, their lifespan is often determined by the wear and tear on their outer rings rather than internal fatigue. Surface deterioration can negatively impact product quality long before the internal components show signs of failure. Recognizing this challenge, TTS has introduced a specialized revamping service for used backup rolls, catering to both its own products and those from other manufacturers.
The reconditioning process involves several meticulous steps:
- Disassembly, washing, and component identification
- Instrumental analysis to assess wear and dimensional integrity
- External diameter grinding of outer rings
- Replacement of damaged components
- Reassembly, final testing, and certification
This reconditioning service not only extends the lifespan of backup rolls but also delivers significant economic benefits to users while reducing environmental impact. By restoring the contact surface between work rollers and backup rollers, manufacturers can maintain high-quality production standards while optimizing resource utilization.
A Commitment to Quality and Innovation
At TTS, every stage of the backup roll production and reconditioning process is rigorously monitored by a dedicated quality control team. Dimensional and geometric measurements are performed using specialized instrumentation, ensuring each component meets the highest industry standards.
With a steadfast commitment to innovation and sustainability, TTS continues to lead the way in backup roll technology, providing cutting-edge solutions for the steel industry. By combining advanced engineering, meticulous quality control, and an environmentally responsible approach, TTS remains a trusted partner in optimizing cold rolling processes worldwide.
As the steel industry continues to evolve, the demand for precision, durability, and efficiency in backup rolls will only increase. With a clear focus on engineering excellence and sustainability, TTS is poised to shape the future of cold rolling technology, ensuring superior performance and reliability for years to come.
The technical department of TTS is always available for helping the users of back up rolls for revamping and designing new bearings tailor made as per their application.
They can be easily reached on [email protected]. For further information please visit the website.
