The Making of a Plate. This second part of the presentation describes the Study Task and the Starting Information provided What You Are Going to Do Starting.

The Making of a Plate

This second part of the presentation describes the Study Task and the Starting Information provided

What You Are Going to Do

Starting Information

Deliverables

Planning the Group Project

What You Are Going To Do

Schedule ProductionRoll in The MillTest the Product

Despatch the Product

You are going to do it ….

You are going to make a plate

We want to place an order for a finished plate, specifying dimensions and mechanical properties and quality standards.

You are going to decide whether you can fulfil this order, and then you’re going to quote us to supply it.

If we give you the order, you are going to schedule production, and then supervise the rolling and the testing of the product.

Just as in real business, you have to get this right two ways :

• You have to make the product successfully

• And you have to make money

Program :

Today : Receipt of starting information (including ordered plate specification and slab inventory)

Week 5 : Intermediate PresentationsVenue: University of SheffieldEach Group presents (45 mins presentation, 30 mins questions) their cost model and ‘price’ for the order.Each group also hands over their slab-choice and their proposed rolling schedule.

Week 7 or 8 :Each Group sends representatives to the mill to witness rolling of their slab, and to monitor deviations from their specified practice. During this visit, groups hand over their test-house instructions. Time of day no object!

Week 10 or 11 :Test feedback. Spare material supplied to the Groups for metallography

Week 12 : Final Presentations Venue : VAI Sheffield Office

Over the coming weeks, you will need to make the following choices :

Slab Choice -You’ve received an inventory and you can choose one slab from it. Both the metallurgy and dimensions must be right.

Schedule Choice -There are various standard rolling practices for making the product. You have to learn about these and select the best one.

Price Choice -You have to work out how much it will cost to make this plate and price it accordingly.

Over the coming weeks, you will need to make the following choices :

Test Choice- You have to find out what the test-house does, and what’s appropriate for the product in question. Then you have to instruct the test-house to perform the tests.

Team Choices -You have to select your representatives for the rolling and inspection supervisory exercises, as well as sharing out the total workload.

The following steelmaking aim chemistries are available for rolling (all wt%);

C Si Mn P S Al Nb N Cr Mo Ni Cu V B Ti A .13

.14 .36 .40

1.37 1.42

.015

.005

.030

.040 .030 .040

.012

.060 .070

.001

.003 .020 .030

B .09 .11

.22

.26 .47 .52

.025

.015

.012

C .14 .16

.37

.41 1.36 1.40

.012

.012

.025

.040 .024 .028

.009

D .23 .27

.19

.23 .70 .80

.010

.010

.003

.008

.012 1.00 1.10

.20

.25

E .12 .14

.40

.44 1.41 1.45

.015

.005

.025

.040 .024 .028

.005

.010

F .10 .12

.33

.37 1.07 1.11

.020

.010

.025

.040

.012 .43 .48

.18 .23

.30

.35 .050 .070

Slab Choice - Inventory

Price Choice – This May Help

Plate Costs (£/t) is standard plate manufacturing costs ex.works

Schedule Choice – A Typical Drafting Schedule

Price Choice – This May Help

Sheffield University / VAI / Corus 2004 M Eng. Project

Option A

Yellow Goods Company (xxx) kindly request Corus to supply the following RMP items; 2 Plates : Grade S355J2G3 according to EN10025:1993 10000mm x 2500mm x 25mm Supply Condition as per EN10025 Table 1 Maximum CEV as per EN10025 Table 4 All dimensional tolerances according to EN10029:1991 Flatness Class N Surface Condition to EN10163:1991 Class A Sub-Class 3 Certification as per EN10204 3.1b

Test Choice – Note the Standards

Timeline for Corus/VAI/UoS Group Industrial Project 2004

Week 7 or 8: Individual sub-groups (perhaps 2 students per group) on the mill to witness rolling of their slab, and to monitor deviations from their specified practice. Another pair of students could visit plate inspection. During this visit, groups hand over their test house instructions. (Time of day should be no object.) Week 10 or 11: Spare plate material passed to groups for metallography by the students at Uni. Tests carried out and results relayed to groups (sub-group representation at the Corus Test House can be arranged if the students want it, but this is not essential).

Team Choice – Note these Activities

Your Starting Information consists of :• Presentation material fromkick off meeting(all also on CD-ROM)• Order plate specification (2 Versions)• Project program and milestones• ‘Rolling Rules’ document (notes for guidance about mill scheduling)• ‘Plate Products and Range of Sizes’ (Corus document.)• Conditions for works visit (Safety Form)• Summary of relevant course content

Additional Information (for interest)“The World of VAI Technology” Brochure“Corus Steel Plate”

Deliverables:

• Presentations in weeks 5 and 12 (Microsoft PowerPoint)

• Final written report, including :• reasons for slab choice, schedule choice and price choice• compliance with original plate specification, explaining deviations

(NB – detailed requirements of these reports to be elaborated further)

You will need to decide how to organise your time and resources to complete the whole Study Task.

Your academic supervisor can help you here – an early discussion (as soon as you’ve assimilated the problem) is advisable.

Mill Visit

This afternoon you will visit both the mill and the test-house

Try to relate what you see to the ideas you’ve met in this morning’s presentations

There won’t be much opportunity for questions at the end, so take the chance to ask them as you go

Above all, make note of things you see that seem important, and that you think you might need to understand more fully

Information and Reporting: Suggested Basis

There is a fuller program of meetings within the information pack. The weekly activities are indicated. The day, time and sometimes location of meetings will need to be negotiated.

Within this framework, there will be opportunities at least every two weeks to report progress and raise/discuss issues

Issues at other times to your university tutors please (These will get relayed to VAI/Corus too, but we can’t have open contact – we’ve other things to do as well!)

…anyway, this makes it more like the Real World of dealing with an industrial customer

Today’s Itinerary

09:30 – Welcome (Brief Presentation on Corus C+I and VAI-UK)Context Presentation – the World of Steel Plate

10:30 – Coffee Break

10:45 – 12:00Explanation of the Team’s Task - Handover of Basic Information

12:00 – Lunch

12:45 – Safety Induction

13:45 – Plate Mill Visit

15:45 – Test House Visit

16:30 – Tea, and Departure for Sheffield

Thermo-Mechanical Control Process (1)

Austenite

Ferrite

Pearlite

Conventional Rolling (eg C-Mn grades, Solid Solution Strengthening)

1000°C

500°C

Martensite

AR3

Hot Rolling to Final Gauge

Slab reheating

Air coolingFerrite + Pearlite

Temp.

Time

Bainite

Thermo-Mechanical Control Process (2)

Ferrite + Bainite

Austenite

Ferrite

Pearlite

TMCR : Typical of C-Mn-Nb Grades, Precipitation Strengthening

1000°C

500°C

Martensite

AR3

Primary Hot Rolling

Slab reheating

CR Hold

Temp.

Time

Bainite

The “Hold” takes the stock temperature down to a level where recrystallisation between passes is substantially suppressed

Low Temperature Finish Rolling