IMPROPER ROLLING PARAMETER SETTINGS
Excessive Rolling Force
Arbitrarily increasing rolling force without considering material properties and roll capacity
Causes pressure exceeding design limits, leading to elastic/plastic deformation
Compromises roll shape accuracy and accelerates surface wear
Example: Forcing thick-to-thin gauge reduction without proper parameter adjustment
Overspeed Operation
High rolling speeds generate excessive strip-roll friction
Requires increased rolling force to maintain stability, creating overload conditions
Generates excessive heat causing thermal expansion and additional pressure
Example: High-speed rolling exacerbates forward/backward slip phenomena
Improper Tension Control
Excessive strip tension creates additional radial pressure on rolls
Causes uneven friction distribution and localized overloading
Leads to irregular wear patterns and potential roll deformation
Example: Incorrect tension settings in continuous rolling lines
EQUIPMENT MALFUNCTION HANDLING ISSUES
Strip Deviation Problems
Uneven pressure distribution from misaligned strips
Continuous operation without correction causes localized overload
Results in asymmetric wear and roll deformation
Example: Material accumulation on one side creating pressure imbalance
Foreign Material Intrusion
Contaminants (metal chips, tools) entering roll gap cause instant force spikes
Lack of detection systems or delayed response exacerbates damage
Creates impact damage including surface pitting and cracking
Example: Insufficient protection systems for foreign object detection
PRODUCTION PLANNING DEFICIENCIES
Continuous Over-capacity Rolling
Scheduling thick, hard, or wide materials beyond roll specifications
Sustained high-load operation causes cumulative fatigue damage
Maintains rolls in excessive stress states beyond design parameters
Example: Extended processing of ultra-thick high-strength alloy strips