HYBRID ROLLING MILL

Abstract

A hybrid rolling mill includes at least one work stand and a lubrication system. The at least one work stand includes an upper work roll and a lower work roll. The lubrication system includes a first lubricant applicator and a second lubricant applicator. The first lubricant applicator is configured to supply a first lubricant at an entry side of the work stand in a first rolling mode. The second lubricant applicator is configured to supply a second lubricant at the entry side of the work stand in a second rolling mode.

Description

REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/684,437, filed on Jun. 13, 2018 and entitled HYBRID ROLLING MILL, the content of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

This application relates to a rolling mill for rolling a metal substrate and, more particularly, to a hybrid rolling mill that may be run as a hot rolling mill, warm rolling mill, cold rolling mill, or any combination thereof.

BACKGROUND

Rolling is a metal forming process in which metal stock, such as aluminum or aluminum alloys, is passed through one or more pairs of work rolls of a rolling mill to reduce the thickness of the metal stock and/or to make the thickness more uniform. Depending on the desired properties of the final metal product, the metal stock may be hot rolled, cold rolled, and/or warm rolled. Hot rolling generally refers to a rolling process where the temperature of the metal is above the recrystallization temperature of the metal. Cold rolling generally refers to a rolling process where the temperature of the metal is below the recrystallization temperature of the metal. Warm rolling generally refers to a rolling process where the temperature of the metal is below the recrystallization temperature but above the temperature during cold rolling. Due to the differences between hot rolling and cold rolling (such as installation space required), it is common to have a separate rolling mill dedicated to each rolling process.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

According to certain examples, a hybrid rolling mill includes a work stand and a lubrication system. The work stand includes an upper work roll, a lower work roll, an upper backup roll, and a lower backup roll. The lubrication system includes a first lubricant applicator and a second lubricant applicator. The first lubricant applicator is configured to supply a first lubricant at an entry side of the work stand in a first rolling mode, and the second lubricant applicator is configured to supply a second lubricant at the entry side of the work stand in a second rolling mode. In some examples, in the first rolling mode, the first lubricant applicator is activated and the second lubricant applicator is deactivated, and in the second rolling mode, the second lubricant applicator is activated and the first lubricant applicator is deactivated.

According to some examples, a hybrid rolling mill includes a work stand and a lubrication system. The work stand includes an upper work roll, a lower work roll, an upper backup roll, and a lower backup roll. The lubrication system includes a lubricant applicator and an injector. The lubricant applicator is configured to supply a first lubricant at an entry side of the work stand in a first rolling mode. The injector is configured to inject a second lubricant at the entry side of the work stand in the second rolling mode.

In certain examples, a method of rolling a metal substrate includes feeding a metal substrate through a roll gap between an upper work roll and a lower work roll of a work stand of a hybrid rolling mill and rolling the metal substrate in at least one of a first rolling mode or a second rolling mode. In some examples, rolling the metal substrate in the first rolling mode includes activating a lubrication system such that a first lubricant applicator supplies a first lubricant at an entry side of the work stand as the metal substrate is fed through the roll gap. In various examples, rolling the metal substrate in the second rolling mode includes activating the lubrication system such that a second lubricant applicator supplies a second lubricant at the entry side of the work stand as the metal substrate is fed through the roll gap. In some cases, in the first rolling mode, the first lubricant applicator is activated and the second lubricant applicator is deactivated, and in the second rolling mode, the second lubricant applicator is activated and the first lubricant applicator is deactivated.

Various implementations described in the present disclosure can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

FIG. 1 is a schematic diagram of a hybrid rolling mill in a first rolling mode according to aspects of the current disclosure.

FIG. 2 is a schematic diagram of one stand of the hybrid rolling mill of FIG. 1 in the first rolling mode.

FIG. 3 is a schematic diagram of the hybrid rolling mill of FIG. 1 in a second rolling mode.

FIG. 4 is a schematic of one stand of the hybrid rolling mill of FIG. 1 in the second rolling mode.

FIG. 5 is a schematic of the hybrid rolling mill of FIG. 1 with a first work stand in the first rolling mode, a second work stand in the second rolling mode, and a strip cooling system.

FIG. 6 is a schematic diagram of a hybrid rolling mill in a first rolling mode according to aspects of the current disclosure.

FIG. 7 is a schematic diagram of the hybrid rolling mill of FIG. 6 in a second rolling mode.

FIG. 8 is a schematic diagram of the hybrid rolling of FIG. 6 in a third rolling mode.

FIG. 9 is a schematic diagram of a hybrid rolling mill according to aspects of the current disclosure

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

Certain aspects and features of the present disclosure relate to a hybrid rolling mill for rolling a metal substrate in a hot rolling mode, a cold rolling mode, a warm rolling mode, or any combination thereof. Through the hybrid rolling mill, a rolling plant can produce both hot and cold rolled coils of metal at very high quality using the same mill, which allows for the production of a wide variety of products at a lower capital cost using less equipment. Moreover, the space saved by the hybrid rolling mill within the rolling plant can be used for other processing systems and/or additional hybrid rolling mills to increase the volume and productivity of the plant and/or can decrease the size requirements of the rolling plant.

Aspects and features of the present disclosure can be used with any suitable metal substrate, however may be especially useful when rolling aluminum alloys. Specifically, desirable results can be achieved when rolling alloys such as 1xxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, or 8xxx series aluminum alloys. For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

A hybrid rolling mill includes at least one work stand, and in some examples, the hybrid rolling mill may include multiple stands. For example, the hybrid rolling mill may include two stands, three stands, four stands, five stands, six stands, or any other number of stands as needed or desired. Each stand includes a pair of work rolls that are vertically aligned. In some cases, each stand includes a pair of backup rolls that support the pair of work rolls. In some examples, each stand also includes a pair of intermediate rolls. During rolling of the metal substrate, the metal substrate is passed through a roll gap defined between the work rolls. Rolling the metal substrate reduces the thickness of the metal substrate to a desired thickness and imparts particular properties on the metal substrate depending on the composition of the metal substrate. Depending on the desired properties or other considerations for the final metal product, the hybrid rolling mill may be run in a hot rolling mode, a cold rolling mode, a warm rolling mode, or any combination thereof. In some examples with the hybrid rolling mill, all stands may be run in the same mode, or at least one stand may be run in one mode and at least one stand may be run in another mode.

Hot rolling generally occurs at temperatures above the recrystallization temperature of the metal. For example, in some cases where the metal substrate is aluminum or an aluminum alloy, hot rolling may occur at a temperature greater than about 250° C., such as from about 250° C. to about 550° C. In other examples, various other temperatures for hot rolling may be used.

In contrast to hot rolling, cold rolling generally occurs at temperatures below the recrystallization temperature of the metal. For example, in some cases wherein the metal substrate is aluminum or an aluminum alloy, cold rolling may occur at a temperature less than about 200° C., such as from about 20° C. to about 200° C. In other examples, various other temperatures for cold rolling may be used.

In some cases, a metal substrate may also be rolled through a warm rolling process, which occurs at a temperature below the recrystallization temperature of the metal but above the cold rolling temperature. For example, in some cases where the metal substrate is aluminum or an aluminum alloy, warm rolling may occur at a temperature from about 200° C. to about 250° C. In other examples, various other temperatures for warm rolling may be used.

The hybrid rolling mill includes a lubrication system such that the hybrid rolling mill can be run in the hot rolling mode, the cold rolling mode, the warm rolling mode, or combinations thereof. The lubrication system also allows the hybrid rolling mill to quickly switch between rolling modes, such as switching from the hot rolling mode to the cold rolling mode.

In various examples, the lubrication system includes a first lubricant applicator that is configured to supply a first lubricant at an entry side of the work stand in a hot rolling mode and a second lubricant applicator configured to supply a second lubricant at the entry side of the work stand in a cold rolling mode. The lubrication system may include any number of first lubricant applicators or second lubricant applicators as desired. During hot rolling, the first lubricant applicator may be activated and the second lubricant applicator may be deactivated, while during cold rolling, the first lubricant applicator may be deactivated and the second lubricant applicator may be activated. In other examples, the first lubricant applicator may be activated during both hot rolling and cold rolling, and the second lubricant applicator may be activated during cold rolling but deactivated during hot rolling.

In certain examples, the hybrid rolling mill includes a work roll cooling system that is configured to apply a coolant on the outer surfaces of the work rolls to control a temperature of the work rolls. In some cases, the cooling system includes a roll cooling header at an exit side of the work stand and a coolant containment box.

In some examples, a strip cooling system is provided after at least one work stand and is configured to reduce a temperature of the metal substrate during processing. In various examples, the strip cooling system includes a strip cooling header that is configured to apply a coolant on at least one surface of the metal substrate to control the temperature of the metal substrate. In some examples, the strip cooling system also includes a coolant removal device for removing the coolant or drying the metal substrate before the metal substrate enters a work stand. In various examples, depending on the configuration of the hybrid rolling mill, any number of strip cooling headers and coolant removal devices may be utilized. The strip cooling system may be provided at various locations within the hybrid rolling mill such as before a first work stand, after a last work stand, between work stands, etc.

FIGS. 1-4 illustrate a hybrid rolling mill 100 according to various aspects of the present disclosure. The hybrid rolling mill 100 is shown with two work stands 102A-B. In other examples, the hybrid rolling mill 100 may include any desired number of work stands 102 such as one work stand 102, three work stands 102, four work stands 102, five work stands 102, six work stands 102, or any other number of work stands 102 as needed or desired.

Each work stand 102A-B includes an upper work roll 104A and a lower work roll 104B vertically aligned with the upper work roll 104A. Each work roll 104A-B has an outer surface 106. A gap 108 is defined between the upper work roll 104A and the lower work roll 104B that is configured to receive a metal substrate 110 during rolling of the metal substrate 110. During processing, the upper work roll 104A-B and the lower work roll 104A-B are configured to contact and apply a work roll pressure on the outer surfaces 112 and 114 of the metal substrate 110 as it passes through the gap 108. Each work stand 102A-B has an entry side 116 and an exit side 118. The entry side 116 is generally upstream from the exit side 118 relative to a direction of movement 120 of the metal substrate 110. In various examples, each stand 102A-B may include intermediate rolls and/or backup rolls 105A-B that support the work rolls 104A-B during processing. During rolling, as the metal substrate 110 moves in the direction of movement 120 through the hybrid rolling mill 100, the thickness of the metal substrate 110 is reduced to a desired thickness.

The hybrid rolling mill 100 includes a lubrication system 122. The lubrication system 122 includes first lubricant applicators 124 at the entry side 116 that are configured to selectively supply a first lubricant 128 (see FIG. 2) to each work stand 102A-B and second lubricant applicators 126 at the entry side 116 that are configured to selectively supply a second lubricant 130 (see FIGS. 3-4) to each work stand 102A-B. Any desired number of first lubricant applicators 124 and second lubricant applicators 126 may be provided for each work stand 102A-B, including only one first lubricant applicator 124 and only one second lubricant applicator 126. In some examples, in a hot rolling mode, the first lubricant applicators 124 are activated and the second lubricant applicators 126 are deactivated, and in a cold or warm rolling mode, the second lubricant applicators 126 are activated and the first lubricant applicators 124 are deactivated. In other examples, the first lubricant applicators 124 are activated during both the hot rolling mode and the cold or warm rolling mode.

The first lubricant 128 is a lubricant suitable for hot rolling including, but not limited to, various rolling oils, a mechanical mixture of oil and water, oil in water emulsions, vegetable oils, mineral oils, naturally occurring fatty acids or esters, synthetic esters, and base oils. The second lubricant is a lubricant suitable for cold or warm rolling including, but not limited to, various rolling oils, naturally occurring fatty acids, fatty esters, and fatty alcohols. In certain examples, the second lubricant is different from the first lubricant.

The lubricant applicators 124 and 126 are devices generally suitable for supplying the lubricants to the work stands such as various nozzles, headers, injectors, etc., although they need not necessarily be the same type of lubricant applicator. For example, the first lubricant applicators 124 and second lubricant applicators 126 may utilize the same or different lubrication application techniques (e.g., flood lubrication, direct lubrication, etc.) to supply the respective lubricants. The lubrication application techniques include, but are not limited to, flood lubrication (e.g., neat oil, emulsion, dispersion, chemical emulsion, flood, etc.), direct lubrication (e.g., neat oil), or other various suitable lubrication application techniques.

As one non-limiting example and as described in detail below, in FIGS. 1-4, each first lubricant applicator 124 is configured to directly apply the first lubricant 128 uniformly and as a thin layer on the outer surfaces 106 of the work rolls 104A-B when activated (“direct lubrication,” see FIG. 2), and each second lubricant applicator 126 includes a nozzle or header to spray the second lubricant 130 into the gap 108 at the entry side 116 of the work stands 104A-B (“flood lubrication,” see FIG. 3). In other examples, the first lubricant applicator 124 may utilize another suitable lubrication application technique (e.g., flood lubrication) to supply the first lubricant 128 during hot rolling. Similarly, in other examples, the second lubricant applicator 126 may utilize another suitable lubrication application technique (e.g., direct lubrication) to supply the second lubrication 130 during cold rolling. Therefore, depending on the lubrication application technique utilized, the type of lubricant applicator used for the first lubricant applicators 124 and/or the second lubricant applicators 126 may be modified. In other examples, the lubricant applicators 124 and 126 may utilize similar application techniques (e.g., both lubricant applicators utilize direct lubrication) (see FIGS. 6 and 7).

In some examples, the lubrication system includes valves or other regulators for rapid activation or deactivation of the first lubricant applicators 124 and the second lubricant applicators 126. In various examples, the valves may be controlled manually or through a controller.

In addition to the lubrication system 122, the hybrid rolling mill 100 includes a cooling system 132. The cooling system 132 includes cooling headers 134 at the exit side 118 of each work stand 104A-B that spray coolant onto the outer surfaces 106 of the work rolls 104A-B. In some examples, the coolant sprayed by the cooling headers 134 includes water, although various other coolants suitable for cooling the work rolls may be utilized such as emulsions or various surfactant mixtures. In some examples, the cooling system 132 includes coolant containment boxes 136, which are configured to keep the coolant from the cooling headers 134 from contacting the metal substrate 110. Any number of cooling headers 134 and coolant containment boxes 136 may be used with the cooling system 132. U.S. patent application Ser. No. 14/707,460 filed May 8, 2015 and titled “Hybrid Oil and Water Cooled Rolling” to Gaensbauer et al., the entirety of which is incorporated herein by reference, discloses examples of work roll cooling systems that may be used with the hybrid rolling mill 100.

In various examples, through the cooling system 132, the temperature of the work rolls 104A-B can be controlled while the metal substrate 110 can achieve desired temperatures and/or surface qualities (e.g., because the coolant is kept off of the metal substrate 110). In addition, by separating the cooling system 132 from the lubrication system 122, the coolant from the cooling system 132 may be kept separate from the lubricants from the lubrication system 122, which may simplify the processing of any fluids returning from the hybrid rolling mill 100. In some examples, separating the coolant from the lubricants also reduces lubricant consumption and may allow for a simplified coolant house design and operation. In various aspects, separating the coolant from the lubricants also allows for better control of the temperature of the sheet, which can improve the metallurgical properties of the sheet. Separating the coolant may further allow for the better selection of the lubricant for a particular rolling mode with a particular rolling profile.

Depending on desired properties or other considerations for the final metal product, the hybrid rolling mill 100 (or individual stands 102A-B of the mill 100) may be run in a hot rolling mode, a cold rolling mode, a warm rolling mode, or any combination thereof. In some examples, all stands 102A-B of the hybrid rolling mill 100 may be run in the same mode, or at least one stand 102A may be run in one mode and at least one stand 102B may be run in another mode.

FIGS. 1 and 2 illustrate the hybrid rolling mill 100 in the hot rolling mode. In the hot rolling mode, the metal substrate 110 advances in the direction of movement 120 while passing through the roll gap 108 defined between the work rolls 104A-B. As the metal substrate 110 advances in the direction of movement 120, the first lubricant applicators 124 of the lubrication system 122 are activated to supply the first lubricant 128 at the entry side 116 of the work stands 104A-B. In these examples, the second lubricant applicators 126 are deactivated while the first lubricant applicators 124 are activated, although they need not be. As discussed above, in one non-limiting example, the first lubricant applicators 124 are configured to utilize direct lubrication to directly apply the first lubricant 128 uniformly and as a thin layer on the outer surfaces 106 of the work rolls 104A-B when activated (see FIG. 2). In some examples, each first lubricant applicator 124 includes an applicator 138 that directly applies the thin lubricant layer 128 on the outer surfaces 106 of the work rolls 104A-B. In some examples, when the first lubricant applicators 124 are activated, the applicators 138 contact the outer surfaces 106 of the work rolls 104A-B (see FIGS. 1 and 2), although they need not. The applicators 138 may be various suitable devices or mechanisms for directly applying the thin layer of lubricant on the work rolls 104A-B, including, but not limited to, sprayers, wipers, roll applicators, electrostatic applicators, and various other types of applicators.

FIGS. 3 and 4 illustrate the hybrid rolling mill 100 in the cold or warm rolling mode where the second lubricant applicators 126 are activated to supply the second lubricant 130 at the entry side 116 of the work stands 104A-B. In these examples, the first lubricant applicators 124 are deactivated while the second lubricant applicators 126 are activated, although they need not be (see FIGS. 6 and 7). As referenced above, in one non-limiting example, the second lubricant applicators 126 are configured to utilize flood lubrication to spray the second lubricant 130 into the roll gap 108 as the metal substrate 110 advances in the direction of movement 120.

In some examples, to switch from the hot rolling mode of FIGS. 1 and 2 to the cold or warm rolling mode of FIGS. 3 and 4, the first lubricant applicators 124 are deactivated and the second lubricant applicators 126 are activated. In various examples, deactivating the first lubricant applicators 124 includes adjusting the position of the applicators 138 (see FIGS. 3 and 4) such that the applicators 138 are spaced apart from the work rolls 104A-B, although they need not be adjusted in other examples. Deactivating the first lubricant applicators 124 and activating the second lubricant applicators 126 may include opening and closing valves or flow regulators associated with the respective lubricant applicators 124 and 126. In various examples, switching between rolling modes also includes optionally changing the work rolls 104A-B. As one non-limiting example, in some cases, the work rolls 104A-B are changed from work rolls 104A-B more suitable for hot rolling to work rolls 104A-B more suitable for cold or warm rolling. In other examples, the work rolls 104A-B may not be changed to switch between rolling modes. As one non-limiting example, the work rolls 104A-B may not be changed when switching the hybrid rolling mill 100 from a warm rolling mode to a cold rolling mode.

In some examples, to switch from the cold or warm rolling mode of FIGS. 3 and 4 to the hot rolling mode of FIGS. 1 and 2, the second lubricant applicators 126 are deactivated and the first lubricant applicators 124 are activated. In some examples, activating the first lubricant applicators 124 includes adjusting the position of the applicators 138 (see FIGS. 1 and 2) such that the applicators contact the outer surfaces 106 of the work rolls 104A-B, although in other examples, the position may not be adjusted. Switching to the hot rolling mode may also include opening and closing valves or flow regulators associated with the respective lubricant applicators and optionally changing the work rolls 104A-B.

Referring to FIG. 5, in some examples, the hybrid rolling mill 100 optionally includes a strip cooling system 140 that is configured to control a temperature of the metal substrate 110 during rolling. Although the strip cooling system 140 is illustrated between the work stands 102A-B in FIG. 5, the strip cooling system 104 may be positioned at various other locations within the hybrid rolling mill 100. For example, the strip cooling system 140 may be before the first work stand 102A, after the last work stand 102B, or between adjacent work stands 102A-B. Any number of strip cooling systems 104 may be utilized with the hybrid rolling mill 100 and may be at various locations within the hybrid rolling mill 100. In various examples, the strip cooling system 140 may be used to control the temperature of the metal substrate 110 during hot rolling, cold rolling, and/or warm rolling. In some optional examples, the strip cooling system 140 may be utilized to reduce the temperature of the metal substrate 110 from hot rolling conditions to cold or warm rolling conditions for subsequent stands. As one non-limiting example, FIG. 5 illustrates a hybrid rolling mill 100 where the work stand 102A is in a hot rolling mode and the work stand 102B is in a cold or warm rolling mode, and the strip cooling system 140 is positioned so that it cools the metal substrate 110 from the hot rolling conditions to the cold or warm rolling conditions.

The strip cooling system 140 includes a nozzle 142 or header or other applicator that selectively sprays a coolant, such as water or other suitable metal substrate coolants such as emulsions or mixtures of surfactants on the metal substrate 110 as the metal substrate 110 advances in the direction of movement 120. In FIG. 5, the nozzles 142 are provided both above and below the metal substrate 110; however, in other examples, the nozzles 142 may only be provided on one side of the metal substrate 110 (e.g., only above the metal substrate 110 or only below the metal substrate 110). The strip cooling system 140 also includes coolant removal devices 144, which may be various suitable devices for removing the coolant from the metal substrate 110 including, but not limited to, squeegees, wipers, blowers, or various other suitable devices.

FIGS. 6 and 7 illustrate another example of a hybrid rolling mill 600. The hybrid rolling mill 600 is substantially similar to the hybrid rolling mill 100 described above except that in the lubrication system 122 of the hybrid rolling mill 600, the first lubricant applicator 124 is a header and the second lubricant applicator 126 is an injector. In a first rolling mode (such as the hot rolling mode) illustrated in FIG. 6, the first lubricant applicator 124 supplies the first lubricant 128 at the entry side 116 of the work stand 102A while the second lubricant applicator 126 is deactivated. As illustrated in FIG. 7, during a second rolling mode (such as the cold rolling mode), the second lubricant applicator 126 injects the second lubricant 130 at the entry side 116 of the work stand 102A. In one non-limiting example, in the hybrid rolling mill 600 of FIGS. 6 and 7, the first lubricant 128 may comprise a mechanical mixture of water and oil and the second lubricant 130 may comprise oil. In other examples, other lubricants may be used as discussed above.

FIG. 8 illustrates another example of the hybrid rolling mill 600 in a third rolling mode where both the first lubricant applicator 124 and the second lubricant applicator 126 are activated.

FIG. 9 illustrates another example of a hybrid rolling mill 900. The hybrid rolling mill 900 is substantially similar to the hybrid rolling mills 100 and 600 except that a single lubricant applicator 924 is provided. As illustrated in FIG. 9, the lubricant applicator 924 is in fluid communication with a first lubricant supply 928 and a second lubricant supply 930. A control valve 901 is configured to control the flow of the first lubricant and the second lubricant to the lubricant applicator 924. In one non-limiting example, the control valve 901 is activated such that during a first rolling mode (such as the hot rolling mode), only the first lubricant is supplied from the first lubricant supply 928 to the lubricant applicator 924. In a second rolling mode (such as the cold rolling mode), the control valve 901 is activated such that the second lubricant is injected into the first lubricant upstream from the lubricant applicator 924. In such an example, the first lubricant may be water and the second lubricant may be oil. Other lubricants may be used as discussed above. In other examples, in the second rolling mode, the control valve 901 may be activated such that only the second lubricant is supplied from the second lubricant supply 930 to the lubricant applicator 924.

In various examples, a method of rolling the metal substrate 110 with the hybrid rolling mill 100 includes feeding the metal substrate 110 through the roll gap 108 between the upper work roll 104A and the lower work roll 104B of the work stand 102A of the hybrid rolling mill 100 and rolling the metal substrate 110 in at least one of a hot rolling mode or a cold or warm rolling mode.

Rolling the metal substrate 110 in the hot rolling mode includes activating the lubrication system 122 such that the first lubricant applicators 124 supply the first lubricant 128 at the entry side 116 of the work stand 102A as the metal substrate 110 is fed through the roll gap 108. In some examples, supplying the first lubricant 128 includes applying a coating of the first lubricant 128 on the outer surfaces 106 of the work rolls 104A-B through a direct lubrication technique.

Rolling the metal substrate 110 in the cold or warm rolling mode includes activating the lubrication system 122 such that the second lubricant applicators 126 supply the second lubricant 130 at the entry side 116 of the work stand 102A as the metal substrate 110 is fed through the roll gap 108. In various examples, supplying the second lubricant 130 includes spraying the second lubricant 130 into the roll gap 108 between the upper work roll 104A and the lower work roll 104B.

In some examples, in the hot rolling mode, the first lubricant applicators 124 are activated and the second lubricant applicators 126 are deactivated, and in the cold rolling mode, the second lubricant applicators 126 are activated and the first lubricant applicators 124 are deactivated. In other examples, in the hot rolling mode, the first and second lubricant applicators 124 and 126 are both activated, and in the cold or warm rolling mode, the first lubricant applicators 124 are activated and the second lubricant applicators 126 are deactivated.

In certain examples, rolling the metal substrate 110 includes adjusting the work stand 102A between the hot rolling mode and the cold or warm rolling mode by: deactivating the previously activated first lubricant applicators 124 or the second lubricant applicators 126; activating the previously deactivated second lubricant applicators 126 or the first lubricant applicators 124; replacing the upper work roll 104A with a replacement upper work roll; and replacing the lower work roll 104B with a replacement lower work roll.

In various cases, rolling the metal substrate 110 also includes cooling the upper work roll 104A and the lower work roll 104B with a cooling system 132 by: applying a coolant on the outer surfaces 106 of the work rolls 104A-B with a pair of cooling headers 134 at an exit side 118 of the work stand 102A; and removing the coolant from the outer surfaces 106 of the work rolls 104A-B with a pair of coolant containment boxes 136 to keep the coolant off of the metal substrate 110. The coolant containment boxes 136 may be under vacuum in some examples, although they need not be.

In some aspects, the method includes, after the work stand 102A, feeding the metal substrate 110 through the roll gap 108 between an upper work roll 104A and a lower work roll 104B of a second work stand 102B of the hybrid rolling mill 100. The method also includes rolling the metal substrate 110 at the second work stand 102B in at least one of the hot rolling mode or the cold or warm rolling mode. In some examples, the first work stand 102A is in the hot rolling mode and the second work stand 102B is in the cold or warm rolling mode.

According to some examples, the method optionally includes reducing a temperature of the metal substrate 110 between the first work stand 102A and the second work stand 102B with the strip cooling system 140.

A collection of exemplary embodiments, including at least some explicitly enumerated as “ECs” (Example Combinations), providing additional description of a variety of embodiment types in accordance with the concepts described herein are provided below. These examples are not meant to be mutually exclusive, exhaustive, or restrictive; and the invention is not limited to these example embodiments but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

EC 1. A hybrid rolling mill comprising: a work stand comprising an upper work roll and a lower work roll; and a lubrication system comprising: a first lubricant applicator configured to supply a first lubricant at an entry side of the work stand in a first rolling mode; and a second lubricant applicator configured to supply a second lubricant at the entry side of the work stand in a second rolling mode, wherein in the first rolling mode, the first lubricant applicator is activated and the second lubricant applicator is deactivated, and wherein in the second rolling mode, the second lubricant applicator is activated and the first lubricant applicator is deactivated.

EC 2. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first rolling mode is a hot rolling mode and the second rolling mode is a cold or warm rolling mode.

EC 3. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first lubricant applicator is a direct lubrication lubricant applicator comprising an applicator configured to apply a coating of the first lubricant on an outer surface of at least one of the upper work roll or the lower work roll.

EC 4. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first lubricant is a hot rolling lubricant comprising at least one of oil or a mixture of oil and water.

EC 5. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the applicator comprises at least one of a sprayer, a wiper, a roll applicator, or an electrostatic applicator.

EC 6. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the second lubricant applicator is a flood lubrication lubricant applicator comprising a sprayer configured to spray the second lubricant into a roll gap between the upper work roll and the lower work roll.

EC 7. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the second lubricant is a cold rolling lubricant comprising at least one of oil or a mixture of oil and water.

EC 8. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first lubricant is different from the second lubricant.

EC 9. The hybrid rolling mill of any of the preceding or subsequent example combinations, further comprising a work roll cooling system comprising: a cooling header at an exit side of the work stand and configured to apply a coolant on an outer surface of at least one of the upper work roll or the lower work roll; and a coolant containment box configured to keep the coolant off of a metal substrate processed by the work stand during rolling.

EC 10. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the coolant is water, an emulsion, or surfactant mixture.

EC 11. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the coolant containment box is under vacuum.

EC 12. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the work roll cooling system comprises at least two cooling headers and at least one containment box at the top work roll.

EC 13. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the coolant containment box is not under vacuum.

EC 14. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the work stand is a first work stand and wherein the lubrication system comprises at least two first lubricant applicators and at least two second lubricant applicators, and wherein the hybrid rolling mill further comprises: a second work stand comprising an upper work roll and a lower work roll, wherein at least one lubricant applicator of the at least two first lubricant applicators of the lubrication system is configured to supply the first lubricant at an entry side of the second work stand in the first rolling mode; and wherein at least one lubricant applicator of the at least two second lubricant applicators of the lubrication system is configured to supply the second lubricant at the entry side of the second work stand in a second rolling mode.

EC 15. The hybrid rolling mill of any of the preceding or subsequent example combinations, further comprising a strip cooling system between the first work stand and the second work stand configured to reduce a temperature of a metal substrate during rolling.

EC 16. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein in the first rolling mode, the work stand is configured to roll a metal substrate having a temperature of at least 250° C., and wherein in the second rolling mode, the work stand is configured to roll a metal substrate having a temperature less than about 200° C.

EC 17. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the lubrication system comprises at least two first lubricant applicators and at least two second lubricant applicators, wherein a first of the at least two first lubricant applicators and a first of the at least two second lubricant applicators are positioned above a metal substrate during rolling and proximate to the upper work roll, and wherein a second of the at least two first lubricant applicators and a second of the at least two second lubricant applicators are positioned below the metal substrate during rolling and proximate to the lower work roll.

EC 18. The hybrid rolling mill of any of the preceding or subsequent example combinations, further comprising an upper backup roll and a lower backup roll, wherein the upper backup roll is configured to remove lubricant from the upper work roll and the lower backup roll is configured to remove lubricant from the lower work roll.

EC 19. A hybrid rolling mill comprising: a work stand comprising an upper work roll and a lower work roll; and a lubrication system comprising: a first lubricant applicator configured to supply a first lubricant at an entry side of the work stand in a first rolling mode; and a second lubricant applicator configured to supply a second lubricant at the entry side of the work stand in a second rolling mode, and wherein the second lubricant applicator is deactivated in the first rolling mode.

EC 20. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first rolling mode is a hot rolling mode and the second rolling mode is a cold or warm rolling mode.

EC 21. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first lubricant comprises oil, and wherein the second lubricant comprises a water and oil mixture.

EC 22. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first lubricant is different from the second lubricant.

EC 23. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the lubrication system comprises at least two lubricant applicators, wherein a first of the at least two lubricant applicators is positioned proximate to the upper work roll, and wherein a second of the at least two lubricant applicators is positioned proximate to the lower work roll.

EC 24. The hybrid rolling mill of any of the preceding or subsequent example combinations, further comprising an upper backup roll and a lower backup roll, wherein the upper backup roll is configured to remove lubricant from the upper work roll and the lower backup roll is configured to remove lubricant from the lower work roll

EC 25. A method of rolling a metal substrate comprising: feeding a metal substrate through a roll gap between an upper work roll and a lower work roll of a work stand of a hybrid rolling mill; and rolling the metal substrate in at least one of a first rolling mode or a second rolling mode, wherein rolling the metal substrate in the first rolling mode comprises activating a lubrication system such a first lubricant applicator supplies a first lubricant at an entry side of the work stand as the metal substrate is fed through the roll gap, and wherein rolling the metal substrate in the second rolling mode comprises activating the lubrication system such that a second lubricant applicator supplies a second lubricant at the entry side of the work stand as the metal substrate is fed through the roll gap, wherein in the first rolling mode, the first lubricant applicator is activated and the second lubricant applicator is deactivated, and wherein in the second rolling mode, the second lubricant applicator is activated and the first lubricant applicator is deactivated.

EC 26. The method of any of the preceding or subsequent example combinations, further comprising adjusting the work stand between the first rolling mode and the second rolling mode by: deactivating the previously activated first lubricant applicator or second lubricant applicator; activating the previously deactivated second lubricant applicator or first lubricant applicator; replacing the upper work roll with a replacement upper work roll; and replacing the lower work roll with a replacement lower work roll.

EC 27. The method of any of the preceding or subsequent example combinations, wherein the first rolling mode is a hot rolling mode and the second rolling mode is a cold or warm rolling mode.

EC 28. The method of any of the preceding or subsequent example combinations, wherein the first lubricant applicator is a direct lubrication lubricant applicator, wherein the first lubricant applicator comprises an applicator, and wherein supplying the first lubricant comprises applying a coating of the first lubricant on an outer surface of the upper work roll or the lower work roll.

EC 29. The method of any of the preceding or subsequent example combinations, wherein the first lubricant is a hot rolling lubricant comprising at least one of oil or a mixture of oil and water.

EC 30. The method of any of the preceding or subsequent example combinations, wherein the applicator comprises at least one of a sprayer, a wiper, a roll applicator, or an electrostatic applicator.

EC 31. The method of any of the preceding or subsequent example combinations, wherein the second lubricant applicator is a flood lubrication lubricant applicator, wherein the second lubricant applicator comprises a sprayer, and wherein supplying the second lubricant comprises spraying the second lubricant into the roll gap between the upper work roll and the lower work roll.

EC 32. The method of any of the preceding or subsequent example combinations, wherein the second lubricant is a cold rolling lubricant comprising at least one of oil or a mixture of oil and water.

EC 33. The method of any of the preceding or subsequent example combinations, wherein the first lubricant is different from the second lubricant.

EC 34. The method of any of the preceding or subsequent example combinations, further comprising cooling the upper work roll or the lower work roll with a cooling system by: applying a coolant on an outer surface of the upper work roll or the lower work roll with a cooling header at an exit side of the work stand; and removing the coolant from the outer surface with a coolant containment box to keep the coolant off of the metal substrate.

EC 35. The method of any of the preceding or subsequent example combinations, wherein the coolant is water.

EC 36. The method of any of the preceding or subsequent example combinations, wherein the coolant containment box is under vacuum.

EC 37. The method of any of the preceding or subsequent example combinations, wherein the coolant containment box is not under vacuum.

EC 38. The method of any of the preceding or subsequent example combinations, wherein the work stand is a first work stand, the first lubricant applicator is a first work stand first lubricant applicator and the second lubricant applicator is a first work stand second lubricant applicator, and wherein the method further comprises: feeding the metal substrate through a roll gap between an upper work roll and a lower work roll of a second work stand of the hybrid rolling mill; and rolling the metal substrate at the second work stand in at least one of the first rolling mode or the second rolling mode, wherein rolling the metal substrate in the first rolling mode comprises activating the lubrication system such that a second work stand first lubricant applicator supplies the first lubricant at the entry side of the work stand as the metal substrate is fed through the roll gap, and wherein rolling the metal substrate in the second rolling mode comprises activating the lubrication system such that a second work stand second lubricant applicator supplies the second lubricant at the entry side of the work stand as the metal substrate is fed through the roll gap.

EC 39. The method of any of the preceding or subsequent example combinations, further comprising reducing a temperature of the metal substrate between the first work stand and the second work stand with a strip cooling system.

EC 40. The method of any of the preceding or subsequent example combinations, wherein in the first rolling mode, the work stand rolls the metal substrate having a temperature of at least 250° C., and wherein in the second rolling mode, the work stand rolls the metal substrate having a temperature less than about 200° C.

EC 41. A hybrid rolling mill comprising: a first work stand comprising a first upper work roll and a first lower work roll; a second work stand downstream from the first work stand and comprising a second upper work roll and a second lower work roll; and a lubrication system comprising: a first lubricant applicator configured to supply a first lubricant at an entry side of the second work stand in a first rolling mode; and a second lubricant applicator configured to supply a second lubricant at the entry side of the second work stand in a second rolling mode, and wherein the second lubricant applicator is deactivated in the first rolling mode.

EC 42. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first rolling mode is a hot rolling mode and the second rolling mode is a cold or warm rolling mode.

EC 43. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first lubricant comprises oil, and wherein the second lubricant comprises a water and oil mixture.

EC 44. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the first lubricant is different from the second lubricant.

EC 45. The hybrid rolling mill of any of the preceding or subsequent example combinations, wherein the lubrication system comprises at least two first lubricant applicators and at least two second lubricant applicators, wherein a first of the at least two first lubricant applicators and a first of the at least two second lubricant applicators are positioned proximate to the second upper work roll, and wherein a second of the at least two first lubricant applicators and a second of the at least two second lubricant applicators are positioned proximate to the second lower work roll.

EC 46. The hybrid rolling mill of any of the preceding or subsequent example combinations, further comprising an upper backup roll adjacent to the second upper work roll and a lower backup roll adjacent to the second lower work roll, wherein the upper backup roll is configured to remove lubricant from the second upper work roll and the lower backup roll is configured to remove lubricant from the second lower work roll

The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims that follow.

Claims

1. A hybrid rolling mill comprising:

a work stand comprising an upper work roll and a lower work roll; and

a lubrication system comprising: a first lubricant applicator configured to supply a first lubricant at an entry side of the work stand in a first rolling mode; and a second lubricant applicator configured to supply a second lubricant at the entry side of the work stand in a second rolling mode, wherein in the first rolling mode, the first lubricant applicator is activated and the second lubricant applicator is deactivated, and wherein in the second rolling mode, the second lubricant applicator is activated and the first lubricant applicator is deactivated.

2. The hybrid rolling mill of claim 1, wherein the first rolling mode is a hot rolling mode and the second rolling mode is a cold rolling mode or a warm rolling mode.

3. The hybrid rolling mill of claim 2, wherein:

the first lubricant applicator is a direct lubrication lubricant applicator comprising an applicator configured to apply a coating of the first lubricant on an outer surface of at least one of the upper work roll or the lower work roll; and

the second lubricant applicator is a flood lubrication lubricant applicator comprising a sprayer configured to spray the second lubricant into a roll gap between the upper work roll and the lower work roll.

4. The hybrid rolling mill of claim 3, wherein the first lubricant is a hot rolling lubricant comprising at least one of oil or a mixture of oil and water, and wherein the second lubricant is a cold rolling lubricant comprising at least one of oil or a mixture of oil and water.

5. The hybrid rolling mill of claim 3, wherein the applicator comprises at least one of a sprayer, a wiper, a roll applicator, or an electrostatic applicator.

6. The hybrid rolling mill of claim 1, wherein the first lubricant is different from the second lubricant.

7. The hybrid rolling mill of claim 1, further comprising a work roll cooling system comprising:

a cooling header at an exit side of the work stand and configured to apply a coolant on an outer surface of at least one of the upper work roll or the lower work roll; and

a coolant containment box configured to keep the coolant off of a metal substrate processed by the work stand during rolling.

8. The hybrid rolling mill of claim 7, wherein the coolant is water, an emulsion, or surfactant mixture.

9. The hybrid rolling mill of claim 1, wherein the work stand is a first work stand and wherein the lubrication system comprises at least two first lubricant applicators and at least two second lubricant applicators, and wherein the hybrid rolling mill further comprises:

a second work stand comprising an upper work roll and a lower work roll,

wherein at least one lubricant applicator of the at least two first lubricant applicators of the lubrication system is configured to supply the first lubricant at an entry side of the second work stand in the first rolling mode; and

wherein at least one lubricant applicator of the at least two second lubricant applicators of the lubrication system is configured to supply the second lubricant at the entry side of the second work stand in a second rolling mode.

10. The hybrid rolling mill of claim 1, wherein in the first rolling mode, the work stand is configured to roll a metal substrate having a temperature of at least 250° C., and wherein in the second rolling mode, the work stand is configured to roll a metal substrate having a temperature less than about 200° C.

11. A hybrid rolling mill comprising:

a work stand comprising an upper work roll and a lower work roll; and

a lubrication system comprising: a first lubricant applicator configured to supply a first lubricant at an entry side of the work stand in a first rolling mode; and a second lubricant applicator configured to supply a second lubricant at the entry side of the work stand in a second rolling mode, and wherein the second lubricant applicator is deactivated in the first rolling mode.

12. The hybrid rolling mill of claim 11, wherein the first rolling mode is a hot rolling mode and the second rolling mode is a cold or warm rolling mode.

13. The hybrid rolling mill of claim 11, wherein the first lubricant is different from the second lubricant.

14. The hybrid rolling mill of claim 11, wherein the lubrication system comprises at least two lubricant applicators, wherein a first of the at least two lubricant applicators is positioned proximate to the upper work roll, and wherein a second of the at least two lubricant applicators is positioned proximate to the lower work roll.

15. The hybrid rolling mill of claim 11, further comprising an upper backup roll and a lower backup roll, wherein the upper backup roll is configured to remove lubricant from the upper work roll and the lower backup roll is configured to remove lubricant from the lower work roll.

16. A method of rolling a metal substrate comprising:

feeding a metal substrate through a roll gap between an upper work roll and a lower work roll of a work stand of a hybrid rolling mill; and

rolling the metal substrate in at least one of a first rolling mode or a second rolling mode,

wherein rolling the metal substrate in the first rolling mode comprises activating a lubrication system such a first lubricant applicator supplies a first lubricant at an entry side of the work stand as the metal substrate is fed through the roll gap, and

wherein rolling the metal substrate in the second rolling mode comprises activating the lubrication system such that a second lubricant applicator supplies a second lubricant at the entry side of the work stand as the metal substrate is fed through the roll gap,

wherein in the first rolling mode, the first lubricant applicator is activated and the second lubricant applicator is deactivated, and

wherein in the second rolling mode, the second lubricant applicator is activated and the first lubricant applicator is deactivated.

17. The method of claim 16, further comprising adjusting the work stand between the first rolling mode and the second rolling mode by:

deactivating the previously activated first lubricant applicator or second lubricant applicator;

activating the previously deactivated second lubricant applicator or first lubricant applicator;

replacing the upper work roll with a replacement upper work roll; and

replacing the lower work roll with a replacement lower work roll.

18. The method of claim 16, wherein the first rolling mode is a hot rolling mode and the second rolling mode is a cold or warm rolling mode.

19. The method of claim 18, wherein:

the first lubricant applicator is a direct lubrication lubricant applicator;

supplying the first lubricant comprises applying a coating of the first lubricant on an outer surface of the upper work roll or the lower work roll;

the second lubricant applicator is a flood lubrication lubricant applicator; and

supplying the second lubricant comprises spraying the second lubricant into the roll gap between the upper work roll and the lower work roll.

20. The method of claim 16, wherein the work stand is a first work stand, the first lubricant applicator is a first work stand first lubricant applicator and the second lubricant applicator is a first work stand second lubricant applicator, and wherein the method further comprises:

feeding the metal substrate through a roll gap between an upper work roll and a lower work roll of a second work stand of the hybrid rolling mill; and

rolling the metal substrate at the second work stand in at least one of the first rolling mode or the second rolling mode,

wherein rolling the metal substrate in the first rolling mode comprises activating the lubrication system such that a second work stand first lubricant applicator supplies the first lubricant at the entry side of the work stand as the metal substrate is fed through the roll gap, and

wherein rolling the metal substrate in the second rolling mode comprises activating the lubrication system such that a second work stand second lubricant applicator supplies the second lubricant at the entry side of the work stand as the metal substrate is fed through the roll gap.