REDEX machinery TENSION LEVELING

1 – Why flatness defects ?

2 – What are in fact flatness defects ?
3 – How to improve the flatness of a strip ?

4 – General arrangement of a TL section

Entry and Exit Bridles
Driving Group
Leveler

Appendix

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 Tension Leveling
1 – Why Flatness defects ?
Flatness defects

Flatness defects are caused by

differential elongation and internal
stress across the product width
during rolling.

Origins of elongation differences

during rolling can be :
machinery

Examples of internal stress repartition across the product width

Roll gap variations and related usual visible flatness defects
Unsuitable crown adjustment
Unsuitable roll camber
Lubrication and cooling variations
Spraying variations
Roll temperature variations
Strip temperature variations
REDEX

Those various elongations means

different fiber lengths as well as
non visible internal stress. Long Center Herring- Quarter
edges buckles bone buckles

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 Tension Leveling
2 – What are in fact Flatness defects ?

Waves
L1
Sample cut after leveling
Full width h
h h
Length = 2 x width
L L L
machinery

Value in % Value in IU
For one wave :
Length difference between longer and
height = h, wave length = L shorter fibre x 10 000
h x 100 L1 - L
W (%) = __________ W (IU) = __________ x 100 000
L L
REDEX

For several waves : For several waves

considered as a sinusoidal
height = h, total length = L curve

Σ(h) x 100
W (%) = __________
π² h
W (IU) = ____ x ____ x 100 000
L 4 L

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 Tension Leveling

Longitudinal camber
S
Width
Sample cut after leveling L
Full width
Length = 1000 mm

Crossbow
h
Sample cut after leveling
machinery

Full width
Length = 2 x width
Width

Coil set
Sample cut after leveling
REDEX

Full width
L Length = 500 mm
Vertically oriented
The defect is the value of the
product deflection regarding the
vertical line

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 Tension Leveling
3 – How to improve the flatness of a strip ?

By bringing back all fibers at the same length

machinery

It is the goal of Tension Leveling !

The main principles to reach this goal will be developped on the
following pages.
REDEX

Continuous Tension + Alternate Flexion application

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 Tension Leveling

Let’s analyse an alternating

flexion on two rolls R1 and R2,
under tension (T2 – T0)
machinery

T0
R2
T2
R1
T1
REDEX

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 Tension Leveling
Section 1 : before roll R1

According to T0 value, the strip is submitted to a

uniform tension stress σ0, lower to yield point σe
All the strip is in the elastic zone

R2
machinery

th/2
σ0 R1
REDEX

th/2

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 Tension Leveling
Section 2 : during the pass on roll R1

The strip is subjected to tension and flexing superposition. In the upper

half thickness (h1), the strip is in extension in the plastic zone.
Length difference between fibers is reduced or cancelled.

R2
machinery

+σe
th/2 R1

h1 In the lower zone (g1),

the product is in
REDEX

compression in elastic
th/2

zone.
g1

-σe
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 Tension Leveling
Section 3 : between rolls R1 and R2

The product returns to a uniform state of stress σ1,

less than σ0

R2
machinery

th/2
σ1 R1
REDEX

th/2

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 Tension Leveling
Section 4 : between rolls R1 and R2

The same than section 2, but symmetrically oriented.

In the upper half thickness (g2), the product is in

compression in the elastic zone.
R2
machinery

-σe R1

g2
th/2

In the lower section (h2), the

product is in extension in the
REDEX

elastic zone. All fibres have

been brought to the same
th/2

h2
length.

+ σe
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 Tension Leveling
Section 5 : after the roll R2

The product has a uniform stress of

extension σ2 less than σe .

R2
machinery

th/2
σ2 R1
REDEX

th/2

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 Tension Leveling

CONCLUSION
According to the diameters R1, R2 and the intermesh,
h1 and h2 are greater than the half thickness :
all fibers have been elongated

Intermesh
T0
machinery

R2 According to (T2 – T0)

T2 compared with elastic limit
R1 of the strip, the length
difference between other
fibers has been reduced.

σ0 σ1 σ2
Then, the remaining
REDEX

length difference will be

reduced again on a
th/2

h1
following pair of rolls
h2
th/2

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 Tension Leveling

The basic parameters of Tension Leveling are :

‰ The gap of tension applied to the strip between

entry and exit of the process
machinery

Elongation control

‰ The quantity, dimension and arrangement of

the rolls
REDEX

Leveler

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 Tension Leveling
4 – General arrangement of a
Tension Leveling section

Elongation control

Driving group
machinery

Entry bridle Exit bridle

REDEX

Leveler

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 Tension Leveling

ENTRY and EXIT BRIDLES

The purpose of entry and exit tension bridles is to increase and decrease tension through
several rolls in order to bring it to the required value for the leveling operation.

Each bridles includes generally 4 rolls controlled by the driving group.

TU TD
machinery

The diameter of the rolls depends on the product thickness .

REDEX

The number of rolls depends on the amplitude between the required

leveling tension and upstream and downstream tensions (TU , TD ).

The leveling tension is directly bound to strip cross section and yield
strength (Ys).

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 Tension Leveling

Rolls arrangement depends on

available space and on the type Horizontal
of drives used.
machinery

Vertical

Rolls surface coating depends on the product quality :

REDEX

For product with fragile surface (such as copper, stainless steel, …),
polyurethane covered rolls are used.

For products like black steel or galvanized steel, steel rolls or carbide
covered rolls may be used.

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 Tension Leveling

DRIVING GROUP

The purpose of driving group is :

‰ To create the Leveling Tension level through the entry and exit bridles

TENSIONING

‰ To keep a difference of tension between exit and entry bridles of the

machinery

leveler, or even better, to keep a constant elongation without any risk of

strip breakage
ELONGATION CONTROL

Different designs :
REDEX

Full electric drive

Rigid mechanical drive
Torque controlled drive train
REDEX Differential mechanical drive

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 Tension Leveling

Full electrical drive (Driving group)

This is the most simple design for the rolls drive systems :

Each roll is individually driven by a DC motor

The elongation is
created by the speed T1 T2
difference motors M5
machinery

and M4 4 5
3 6

This speed control is

provided through the
actual tension applied
to the strip, by using a
tensiometer.
REDEX

It means that it is a
tension control system
and not an elongation M4 M3 M6 M5
control.

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 Tension Leveling

Rigid mechanical drive (Driving group)

This type of drive train lies in the tension bridles which are of solid cast iron rolls that have
been tempered and precision-machined. The rolls are linked through synchronising gears
for equal angular speeds.

Tensioning
To compensate the elastic
machinery

elongation effect imparted

to the strip and to prevent
strip slippage, there is a
difference in diameter
between successive roller
pairs.

Elongation control
REDEX

The mechanical link

ensures, via a differential,
different velocities between
the entry and exit bridles
corresponding to the
desired elongation.

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 Tension Leveling

Torque controlled drive train (Driving group)

This drive train is characterised by tension bridle rolls covered by polyurethane or suitable
equivalent. Each tension bridle features a pilot roll. The two pilot rolls are mechanically
interconnected as in the case of the rigid type drive train.

The other tension bridle

rolls, synchronised by the
machinery

strip, are torque-controlled

by means of a differential
gear unit, driven by :
either an electric motor,or
an hydraulic motor,or an
electromagnetic clutch

This arrangement ensures

REDEX

smooth running without risk

of strip/tension bridle roll
slippage, even with bridles
of different roll diameters.

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 Tension Leveling

REDEX Differential Mechanical Drive

General design

Torque
Sharing Gearbox 2
machinery

Torque
Sharing Gearbox 1

Elongation
Gearbox
REDEX

Leveler

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 Tension Leveling

REDEX Differential Mechanical Drive

Torque Sharing Gearbox
Same linear speed all along the
bridles :
The differential based design guarantee
the same linear speed on the rolls,
whatever is their actual diameter.
No slip
Easier maintenance
machinery
REDEX

Leveler

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 Tension Leveling
REDEX Differential Mechanical Drive
Elongation Gearbox

Perfectly constant elongation :

Independant from electric motor
quality and stability
Defined only by the mechanical Main
fixed ratio of the differential
motor

High accuracy elongation

machinery

setting :
Accuracy of elongation motor
divided by K Elongation
motor
(ex : 0.01% / 25 = 0.0004 %)

N1 : elongation
motor speed
N3 = ρ N2 + N1 / K
N2 : entry speed
REDEX

N3 : exit speed
N1

(ex : if N1 = 1007 RPM, ε = 0, 014 %)

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 Tension Leveling

REDEX Differential Mechanical Drive

Main advantages :

easy electrical installation easy rolls maintenance

flexibility to process all types low installed power
of products preservation of surface quality :
elongation accuracy no strip slip whatever is the wear of
the rolls
machinery
REDEX

Leveler

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 Tension Leveling
For Comparison : Energy consumption

REDEX Elongation & In a REDEX differential drive, the energy

Torque Sharing drive consumption is given by the difference
between entry and exit bridle rolls drive.

With, for instance, the following data :

Speed = 120 m / mn
T0=2000 T3=8000
T2=6000 T5 = 2000
Elongation = 1 %
machinery

REDEX
Pcons = 92,5 kW
REDEX

Full Electric
Electrical drive
Pcons = 137,1 kW

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 Tension Leveling

LEVELER

Two main types of Tension Levelers are used for the

leveling operation itself.

‰ Multiflex levelers, also called anti-fluting

levelers.
machinery

annealed, galvanized steel

or similar products
Thickness > 0.2 mm
Ys < 700 N / mm²

‰ Multiroll levelers
REDEX

any kind of products

Including very thin and hard
products

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 Tension Leveling

Multiflex levelers

This leveller is
composed with an
assembly of several Anti Anti
Flexing crosbow coil-set
groups of bending
unit unit unit
rolls.

The first roll ensures

machinery

approx. 80 % of the
elongation through
extensive bending of
the strip on a small
diameter roll thus
eliminating the
waves.

The second ensure

REDEX

the correction of
crossbow and the
third of the coil set.

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 Tension Leveling
REDEX Multiflex AR Series

Features :

6-high cassettes : a working roll,

two intermediate rolls supported
by 3 rows of back-up rolls
Small diameter working rolls to
avoid to mark the strip
machinery

Fast extraction of the cassettes

(via carriage), even during
processing
Allows easy maintenance

Digital remote control of the

intermesh
REDEX

Fast opening for joint and weld

pass in continuous lines

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 Tension Leveling
REDEX Multiflex MR Series

Specific design for

galvanizing lines

This MR is suitable for lower

and medium speed and offers
lower maintenance costs.
machinery

It is composed of 4 bending
rolls supported by rows of
back-up rolls.

The first two rolls are working

as the flexing unit, the third
one as the anti crossbow, and
edd
eenntte
the forth one as the anti coil
REDEX

set. PPaatt

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 Tension Leveling
REDEX Multiroll LR Series

Process much more progressive than in a

Multiflex : lower bending, with a greater
number of rolls.
Crown adjustment : leveling according to
entry strip defects profile.
Very large range :
machinery

From soft (160N/mm²), to very hard (2000

N/mm²)
Including thin products (as low as 0.05 mm).
Universal machine : limited only by its width
REDEX

The tooling (cassettes) is defined by the

product range, allowing the same machine
to work with very different products.

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 Tension Leveling
REDEX Multiroll LR Serie

LR Cassettes Range Thickness Major

For Stainless Steel YS up to [N/mm²]
Range
H25-12 0.02 Æ 0.10 2000

H23-16 0.03 Æ 0.80 2000

H21-18 0.05 Æ 1.00 2000

machinery

H21-25 0.20 Æ 1.50 2000

H17-25 0.20 Æ 1.50 1600

M19-16 0.05 Æ 0.60 1200

M17-20 0.08 Æ 0.80 1200

REDEX

M17-25 0.20 Æ 1.50 1200

M15-30 0.40 Æ 2.00 1000

M13-32 0.60 Æ 3.00 1000

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 Tension Leveling
REDEX Multiroll LR Serie

machinery
REDEX

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 Tension Leveling
REDEX Multiflex AR Serie

6 contacts
machinery

3 Settings with interaction

REDEX Multiroll LR Serie

Entry Exit
Intermesh Intermesh
REDEX

15 contacts
1 Setting : entry & exit
intermesh
Progressive action
High stifness

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 Tension Leveling

REDEX Global offer for Tension Leveling

2000

Yield
strength
[MPa]
LR
1500
machinery

1000

500
AR
MR
REDEX

0.5 1.0 1.5 2.0 2.5 3.0

Thickness [mm]

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 Tension Leveling

REDEX Global offer for

Tension Leveling
LR

AR
MR
machinery

Entry Strip LR AR MR

25 UI 2 UI 6 UI 6 UI

Waves 100 UI 4 UI 10 UI 10 UI

500 UI 6 UI 15 UI 15 UI

Coil Set 5mm / 500mm 20mm / 500mm 20mm / 500mm

REDEX

1% 0.10 0.20 0.20

Cross Bow
3Æ4% 0.30 0.35 0.35

Longitudinal
10mm / 3m 10mm / 3m 10mm / 3m 10mm / 3m
Camber
Speed 600 m/mn 400 m/mn 200 m/mn

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 Tension Leveling
CONTENTS 1 – Why flatness defects ?
2 – What are in fact flatness defects ?
3 – How to improve the flatness of a strip ?
4 – General arrangement of a TL section
Entry and Exit Bridles
Driving Group
Full electric drive
Rigid mechanical drive
Torque controlled drive train
machinery

REDEX elongation control

REDEX Tensioning by Torque sharing
Leveler
Multiflex levelers
REDEX Multiflex AR Series
REDEX Multiflex MR Series
REDEX Multiroll LR Series
REDEX

Appendix 1 : Two particular cases of « Tension Leveling »

Appendix 2 : Metallurgical state of sheet

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 Tension Leveling

machinery

F- 45210 Ferrieres France

Tel. +33 2 38 94 42 00
Fax + 33 2 38 94 42 99
REDEX

[email protected]
www.redex.fr

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 Tension Leveling
Appendix 2 : Two particular cases of “Tension Leveling”

Without Tension : Multi-rolls driven leveler

The product is deformed by a

succession of rolls, in a
selective manner in order to
machinery

elongate especially short fibres.

Rolls are motorised to drive the
strip.

This machine is especially

suitable for sheet stretched
medium to thick products.
REDEX

NOTE :
This device does not provide large elongation and it is not suitable for thin and
strain-hardened products as it would need working rolls with too small diameters.
Rolls number and the fact that they are driven makes the machine rather complex
from a maintenance point of view.

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 Tension Leveling
Appendix 3 : Metallurgical state of sheet S [kg/mm²]

In order to understand the different conditions of tension fig 1

leveling, it is important to compare the tension-
Ym = 22000 kg/mm²
deformation diagrams of various materials.

On the opposite diagrams, the first one -fig1- shows a

strain-hardened steel. It shows up the rupture strength, 0 10% E [%]
the yield strength, and the modulus of elasticity
(22.000 kg/mm²) corresponding to the original slope. S [kg/mm²]
machinery

The strength increases proportionally for elongation Ym = 22000 kg/mm²

values less than 10 %.
Stainless steel have a similar diagram. Yp
fig 2

The second diagram –fig2- corresponds to an annealed

steel. It is characterised by a yield point elongation
forming a little peak near 0,1 % of elastic elongation (this 0 0.1% 0.2% E [%]
diagram has been simplified to be more understandable).
S [kg/mm²]
REDEX

The third diagram –fig3- concerns an aluminum alloy.

The only important difference, with regard to the first one,
is the original slope which represents a modulus of
elasticity of approx. 7.000 kg/mm².
fig 3
Ym = 7000 kg/mm²
These differences between diagrams will define and
determine various methods of tension levelling. 0 0.2% E [%]

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