R-Factor: What It Means and How To Use It To Roll The Mill

R-FACTOR
What it means and how to use it to roll the mill

R-Factor
 What does it stand for

 Reduction Factor
 It is also known as (AKA)
 E-Factor or Elongation Factor
 Because it is referred to as a “factor” it is unitless.
 Meaning it can be applied equally in similar situations.
Reduction
 When heated steel is passed between two counter

revolving rolls where the incoming height is greater
than the exiting height the change in Area of the
two shapes is referred to as the reduction.
 R-Factor = Area in vs. Area out
 R-Factor = Ain/Aout
 R-Factors will always be greater than 1
 The higher the number, the greater the reduction
Elongation
 The “reduction” in cross sectional area is directly

proportional to the change in length because of the
“Constant Volume Principle”
A 2 ton Billet yields 2 tons of product no matter the
shape of the product (minus any yield lost to crops or
scale)
 This is also directly proportional to the change in
speed of the bar.
R- Factor/Elongation Factor
 Assuming the bar is rolled
at constant volume.
 R-Factor represents the A1= 3 in2 A2= 2 in2
amount of change: L1=24 in
L2=36 in
 In the bars cross-sectional

area
V1= A1(L1) V2= A2(L2)
 It’s change in length V1= (3in2)(24in) V2= (2in2)(36in)
V1= 72 in3 V2= 72 in3
 And the change in bar speed.
Ratio 3:2
R-factor =1.5
Working Diameter
 The working diameter of the roll is the diameter
that that represents the speed of the bar
 The working diameter is calculated using the roll
diameter and the Groove factor (G-Corr)
 Roll Dia. – G-Factor = W-Dia
 Groove Factor is an empirical formula that uses
pass area, bar width and roll gap
 G-fact = Area/width-gap
Scheduled R- Factors
 Scheduled R-Factors are a blend of theoretical

values and historically consistent rolling's.
 Variations from schedule have a variety of
interpretations
 Bar size at the stand in question is wrong
 Bar size preceding the stand in question is wrong
 Speed mismatch
 Tension or Compression
 Interstand looper settings are incorrect
Out of Range Remediation
(Bar size)
 R-Factor out of range due to size

 R-Factor too high – bar is too small
 R-Factor too low – bar is too large
 R-Factor out of range due to barin (gazinta) size

discrepancy
 R-Factor too high – barin is too large
 R-Factor too low – barin is too small
Out of Range Remediation
(Speed)
 R-Factor out of range due to speed

 R-Factor too high - stands are considered “tight” Speed
the mill up in back
 R-Factor too low - stands are considered “soft” Slow the
mill down in back
Other Indications of R-Factor fails
 Groove Factor
 Roll Diameter
 Gear ratio
 Schedule is wrong
Tension Control
Rougher
 The mill is not rolling or

between bars:
 A new bar arrives and
bites at stand 1, the
current taken by the
motor is now being
measured and averaged
until just before the bar
strikes stand 2.
 This is the measured
period.
Tension Control
 The bar now bites at stand 2

and the current of stand 1 is
monitored, any change in load
pattern is acted upon through
the speed control system.
 If the current shows a decrease
then tension is evident
 The speed of stand 1 is
increased.
 So, an increase in current of
stand 1 (at this exact time)
indicates compression
 The speed of stand 1 is
decreased.
Scale Break
 The Scale Break is the

part of the bar that does
not touch the sides of the
pass.
 The appearance is rough
and scaly
 If the mill is in tension the
scale break
 Gets wider
 If the mill is in compression
the scale break
 Gets smaller
Loop Profiles
HOW DOES A CONTINUOUS MILL WORK ?
MILL CONSTANT IS BASED ON THE VOLUME CONSERVATION

PRINCIPLE
MEASURED IN CUBIC INCHES PER SECOND
FORMULA : AREA x SPEED = THE MILL CONSTANT (in3/sec)
AREA = PASS AREA (in2)
SPEED = WORKING DIA x Pi x ROLL RPM/60 (in/sec)

Pi = 3.1412
MILL CONSTANT
 Volume entry =Area entry x Speed entry =Area exit x Speed exit =Volume exit
• Take 13mm for an example. Nominal Area is .199 in2 , 5% light is .189 in2
• Shrink factor for steel is 6.5 x 10-6 per inch per degree Fahrenheit. Delta t
is 1830o (1900-70). This works out to 1.012, or .012” shrink per inch.
• The hot area is .191 in2. We are finishing at 2264 FPM or 452.8 inch/sec.
• The volume in in3/sec is: .191 x 452.8 = 86.62 in3/sec. This is the hot
volume going through each stand.
• How does this translate into TPH?
• A 1in3 piece of steel weighs .277# (hot).
• 86.62 x .277 x 3600 / 2000 = 43.19 full groove TPH.
MILL CONSTANT
 Working Diameter = Roll diameter – Groove Factor
 Groove factor = pass area / bar width – roll gap
GROOVE FACTOR (GF) FOR FINISHER

GF = 0.191 in2 / 0.504 - .093 = 0.286
GROOVE FACTOR (GF) FOR LEADER

GF = 0.264 in2 / 0.708 – 0.091 = 0.282
LEADER FINISHER
Roll dia = 13.400” Roll dia = 13.400”
CALCULATE ROLL RPM FOR THE FINISHER AND LEADER FOR 13mm Rebar
CALCULATE ROLL RPM FOR THE FINISHER FOR
13mm Rebar
WE SAID THAT VOLUME  AREA  SPEED

IF WE DEFINE SPEED IN THIS EQUATION WE REWRITE :
in 3
 AREAin 2  ROLL DIAMETER in  GF in     ROLL RPM / 60
sec
VOLUME
sec min
EXTRAPOLATE ' ROLL RPM'
VOLUME in 3  60 sec
ROLL RPM 
AREAin 2  ROLL DIAMETER in  GF in   
86.62  60
ROLL RPM 
0.191  13.400  0.268  
ROLL RPM  659.6

CALCULATE ROLL RPM FOR THE LEADER FOR
13mm Rebar
NOW CALCULATE THE ROLL RPM FOR THE LEADER

IF WE DEFINE SPEED IN THIS EQUATION WE REWRITE :
in 3
 AREAin 2  ROLL DIAMETER in  GF in     ROLL RPM / 60
sec
VOLUME
sec min
EXTRAPOLATE ' ROLL RPM'
VOLUME in 3  60 sec
ROLL RPM 
AREAin 2  ROLL DIAMETER in  GF in   
86.62  60
ROLL RPM 
0.264  13.400  0.282   
ROLL RPM  477.7

GEAR RATIO &
MOTOR SPEED
 Roll RPM * Gear Ratio = Motor RPM
 (motor RPM/Roll RPM = Gear Ratio)
 For Stand 16V Gear ratios are 2.2 and 4
 Motor RPM Stand 16V 1000min/2000max
– 659.6 * 4.0 = 2638 (too high)
– 659.6 * 2.2 = 1451
• For Stand 15H gear ratio is 3.3

– 477.7 * 3.3 = 1062
Expectations for Running on Schedule
 Consistency of operations
 Faster more repeatable start ups
 Better quality product

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R-FACTOR

What it means and how to use it to roll the mill

 What does it stand for

 When heated steel is passed between two counter

 The “reduction” in cross sectional area is directly

 In the bars cross-sectional

 Scheduled R-Factors are a blend of theoretical

 R-Factor out of range due to size

 R-Factor out of range due to barin (gazinta) size

 R-Factor out of range due to speed

 The mill is not rolling or

 The bar now bites at stand 2

 The Scale Break is the

MILL CONSTANT IS BASED ON THE VOLUME CONSERVATION

MEASURED IN CUBIC INCHES PER SECOND

FORMULA : AREA x SPEED = THE MILL CONSTANT (in3/sec)

AREA = PASS AREA (in2)

SPEED = WORKING DIA x Pi x ROLL RPM/60 (in/sec)

GROOVE FACTOR (GF) FOR FINISHER

GROOVE FACTOR (GF) FOR LEADER

WE SAID THAT VOLUME  AREA  SPEED

ROLL RPM  659.6

NOW CALCULATE THE ROLL RPM FOR THE LEADER

ROLL RPM  477.7

• For Stand 15H gear ratio is 3.3

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