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Danieli Fröhling 6-high Diamond Mill
rolling speeds up to 1,800 m/min
4. Wide entry to exit thickness range, typical-
ly from 10 mm to less than 1 mm
3. Ability to handle and roll coil weights up to
or greater than 35 tonnes without a compromise
in rolling dimensionally smaller coils
4. Large rolling load range to cater for hard
alloys to Electrical Discharge Texturing (EDT)
and skin-passes on a single stand
5. Operational efficiency by reduction in coilto-coil
times and mill stop-time
6. Greater production flexibility by a wide
mill control range thus having <strong>the</strong> ability to
react to future market demands for new strip
products or requirements, i.e. a ‘future pro<strong>of</strong>’
mill
7. Environmental considerations such as electrical
power efficiency and fume recovery with
coolant re-generation
8. Improved working environment and practices
for mill operators.
Some existing cold mills can be modernised
to include some <strong>of</strong> <strong>the</strong> above latest requirements
and that a new 4-high single stand cold
mill <strong>of</strong> an advanced design may exactly meet
<strong>the</strong> specific market and commercial requirements
<strong>of</strong> a client, for example in <strong>the</strong> case <strong>of</strong>
<strong>the</strong> Danieli Fröhling a ‘4-high Diamond Mill’
being supplied to Nikkei Siam Aluminium
(NSA), Thailand, to roll primarily fin-stock
material. However, <strong>the</strong> majority <strong>of</strong> <strong>the</strong> latest
market requirements require an advanced
6-high mill stand solution ei<strong>the</strong>r as a single
stand or tandem mill configuration.
The Danieli Fröhling ‘6-High Diamond
Mill’ in a single stand configuration being
supplied to Aleris Europe is <strong>the</strong> latest generation
<strong>of</strong> state-<strong>of</strong>-<strong>the</strong>-art cold rolling mills and is
designed from inception to meet <strong>the</strong> current
and future market requirements. The superior
technology selected by Aleris and provided
by <strong>the</strong> Diamond Mill includes <strong>the</strong> following:
• 6-high roll stack configuration to ensure
mill stack stability with optimum sized
workrolls for <strong>the</strong> specified thickness range
whilst providing <strong>the</strong> highest level <strong>of</strong> strip flatness
performance across a wide strip range
that has a max / min width ratio <strong>of</strong> greater than
two. This configuration ensures flexibility <strong>of</strong>
scheduling current rolling products as well as
future products. The parallel roll design delivers
a practical operational solution with a
simple roll grind regime and has an effective
actuator control range to guarantee high qual-
Danieli Fröhling Advanced Slitter
ROLLING INDUSTRY
ity strip flatness.
• Hydraulic roll-gap adjustment, utilising
bottom mounted double-acting roll load cylinders
designed for a roll separation force with
an operational range that covers low load EDT
passes as well as high rolling load capability
for AA5xxx series hard alloys
• The Danieli Fröhling ‘Hi-Res’ coolant spray
concept with Hot Edge Sprays (HES) providing
precise <strong>the</strong>rmal control <strong>of</strong> <strong>the</strong> workrolls that
coupled with <strong>the</strong> dynamic work-roll and intermediate
roll bending and intermediate roll
side-shifting in order to meet Aleris’s stringent
product performance criteria
• Close attention to <strong>the</strong> design <strong>of</strong> all rolls in
contact with <strong>the</strong> strip and <strong>the</strong> coil handling to
maintain a defect free material surface finish
• DAN-ECO 2 fume cleaning and rolling oil
recovery system to meet <strong>the</strong> highest European
emission standards for <strong>the</strong> separation <strong>of</strong>
Volatile Organic Compounds (VOC) as well as
recovering <strong>the</strong> rolling oil to be fully re-used for
<strong>the</strong> rolling process
• DANPurity rolling oil filtration system to
maintain <strong>the</strong> original design specifications <strong>of</strong>
<strong>the</strong> rolling oil by <strong>the</strong> filtration <strong>of</strong> containments
thus ensuring high strip surface quality.
When <strong>the</strong> Aleris Diamond Mill starts producing
quality material at <strong>the</strong> end <strong>of</strong> 2012, it
will be one <strong>of</strong> <strong>the</strong> most advanced cold mills in
operation around <strong>the</strong> world.
Modern slitting and trimming technology
As <strong>the</strong> requirements for ‘totally’ flat material
with tight tolerances exists not only for fin-
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