THE Long Rolling Advanced

Long Rolling Advanced

The Long Rolling Advanced course provides an in-depth understanding of the long rolling process used in metal manufacturing. This course covers the principles of metal deformation, equipment operation, and the techniques necessary for producing high-quality rolled products. Students will learn about the various types of rolling mills, roll configurations, and the impact of processing parameters on material properties. By the end of the course, participants will be equipped with the knowledge and skills to effectively operate and optimize long rolling processes in a production environment, ensuring efficiency and quality in metal fabrication.

PROGRAM

This course provides a comprehensive understanding of the long rolling process for steel products, focusing on advanced metallurgical principles, process optimization, equipment operation, quality control, and troubleshooting techniques. Combining theoretical knowledge with practical on-site experience whenever possible, the program ensures a well-rounded and hands-on approach to mastering the process. Designed for professionals involved in steel rolling operations, it is ideal for Process Engineers, Production Managers, Metallurgists, Maintenance Engineers, Quality Control Professionals, and Technical Consultants seeking to enhance their expertise and optimize plant performance.

Metallurgical Fundamentals in Long Rolling

  • Steel Grades and Their Behavior in Rolling
  • Effect of Chemical Composition on Rolling Performance
  • Microstructure Evolution During Deformation
  • Phase Transformations and Cooling Strategies
  • Influence of Temperature on Steel Flow and Defects

Equipment and Technology in Long Rolling Mills

  • Components of a Long Rolling Mill:
    • Reheating Furnace
    • Roughing, Intermediate, and Finishing Mills
    • Rolls and Guides
  • Cooling Beds and Finishing Lines
  • Advanced Drive and Automation Systems
  • High-Speed Rolling Mills vs. Conventional Mills
  • Role of Sensors and AI in Modern Rolling

Process Optimization in Long Rolling

  • Pass Design and Roll Pass Sequences
  • Deformation Zones and Load Distribution
  • Energy Efficiency and Cost Reduction Strategies
  • Minimizing Roll Wear and Optimizing Roll Life
  • Impact of Lubrication and Cooling on Process Efficiency

Defects in Long Rolling and Troubleshooting

  • Common Rolling Defects (Laps, Fins, Cracks, Overfills, Undersized Products)
  • Root Cause Analysis of Defects
  • Influence of Rolling Speeds, Temperature, and Material Composition
  • Case Studies of Defect Prevention and Corrective Actions

Advanced Quality Control and Inspection Techniques

  • In-Line and Off-Line Quality Monitoring
  • Non-Destructive Testing (NDT) Methods for Long Products
  • Dimensional and Surface Quality Control
  • Automation and AI in Quality Inspection

Thermomechanical Processing and Controlled Cooling

  • Role of Controlled Cooling in Microstructure Refinement
  • Thermomechanical Rolling of High-Strength Steels
  • Advanced Cooling Bed Technologies
  • Heat Treatment and Post-Rolling Processes (Quenching, Tempering)

Digitalization and Industry 4.0 in Long Rolling

  • Smart Sensors and IoT in Rolling Mills
  • Digital Twin Technology in Process Simulation
  • Predictive Maintenance Using AI and Machine Learning
  • Case Studies of Digital Transformations in Steel Rolling

Safety, Sustainability, and Environmental Considerations

  • Occupational Safety in Rolling Mills
  • Emission Control and Energy Efficiency Measures
  • Sustainable Practices in Rolling Mill Operations
  • Recycling and Waste Reduction in Steel Rolling

Educational Requirements

1. Basic Education (Mandatory)

High School Diploma or Equivalent: A minimum qualification required for entry, particularly for courses related to engineering and manufacturing.

2. Technical Qualifications (Not Always Required)

  • Mechanical or Metallurgical Engineering: Beneficial for courses that involve in-depth technical concepts.
  • Diploma or Degree in Manufacturing or Industrial Technology: Provides a strong foundation in manufacturing processes, materials science, and mechanics.


3. Mathematical Knowledge

Basic knowledge of mathematics, particularly in areas like geometry and physics, is often required, as these are used in rolling mill calculations for material flow, temperature control, etc.

Work Experience Requirements

1. Manufacturing or Production Experience (Preferred)
  • Prior experience in a manufacturing environment, particularly in metalworking, steel production, or related industries, is advantageous.
  • Entry-Level Candidates: For beginner-level courses, experience in roles such as machine operator, assistant, or general worker in a manufacturing plant is beneficial.

2. Understanding of Metallurgical Processes (Beneficial)
  • Prior experience or knowledge of the basic metallurgical processes (like casting, forging, and rolling) is an asset as it provides context for how rolling mills fit into the broader production process.

3. Technical Skills
  •  Familiarity with operating machinery, reading technical drawings, or using tools and instruments related to manufacturing would be advantageous.
  •  Experience in operating or maintaining machines (even outside of rolling mills) might be required in some courses.

4. Safety Knowledge
  •  Exposure to industrial safety protocols in a manufacturing or metalworking environment is highly valuable.
  •  Understanding of safety practices is crucial, as rolling mills and related equipment pose potential hazards.

Instructor: Giuliano Pegorin
Rolling Mill Expert

With over five decades of experience in the rolling mill and long products industry, Giuliano brings a wealth of knowledge and expertise.

He has held key positions at Siemens and Pomini, where he managed technical proposals and was responsible for major projects across the Far East. Currently, he leads his own consultancy, offering specialized services in process engineering and equipment analysis to clients worldwide, including in Azerbaijan, Belgium, and Egypt.

His deep understanding of rolling mill processes, combined with strong leadership and team management skills, make him an ideal guide for this course.