...to the Spring 2017 issue of our

Members’ Bulletin. Well, we’ve done

it; Brexit is triggered and we now

must carry on working to meet the

challenges - and take advantage of

the opportunities - that the process

will present.

Our last issue reported some encouraging

signs in the UK steel industry and I’m pleased

to say that continues to be the case; particularly

delighted to report that the ownership of

Speciality Steel Group has now been settled as

it becomes part of Liberty Steel.

Another positive move comes as two of the

steel industry’s most influential players combine

forces; a new partnership between Danieli

Centro Recycling and Turkey’s largest private

iron and steelmaker, Tosyali, looks set to storm

new markets.

Elsewhere throughout this issue, member

companies continue to demonstrate the

innovation, skills and resourcefulness which

enables them to buck trends and enter new

markets.

Finally, welcome to two new BMPCA

members; Siemens and Premier Hytemp -

each will bring valuable new skills, services

and expertise to our network.

Welcome

Issue 28 | March 2017

p2

p3

p7

www.bmpca.org.uk

...get the full story on page 4

p10

BMPCA welcometwo new members

Da Vinci’s design for arolling mill

Using the science ofmeasurement

Welcome from our newchairman Andy Orme

Danieli Centro

Recyclingforges

historic route toChina

2

The doomsday predictionsthat were prevalent during therealisation that the UK had votedfor Brexit have so far proved tobe pessimistic and we are stillfacing an improvement in theeconomy with growth beingaffected only marginally but withinflation looking as if it will peakaround 3% in the coming yeardue partially to the GBPexchange rate weakening againstthe US Dollar and Euro.

Both the FTSE 100 and 250indices have been at record highlevels this year and the latestpredictions are that interest rateswill not increase until the end of

next year. This doesn’t give theimpression of a doomsdayscenario unfolding as weapproach Brexit, although I feelsure that as events unfold in theBrexit negotiations there will besignificant swings in any forwardpredictions.

Since our last bulletin therehave been some stabilisingdevelopments in the UK steelindustry with Liberty SteelGroup concluding the agreementwith Tata Steel to acquire theSpeciality Steel Group. Also theagreement of the Tata Steelworkers to accept significantchanges to their pension in order

to secure jobs and £1bn infunding for the Port Talbot worksmodernisation over the next 10years. There are reports that theproposed merger talks betweenTata Steel and Thyssen have beenput off but as of now these havenot been confirmed by the TataSteel MD.

I look forward to the yearahead and welcoming newmembers to the BMPCA, bothSiemens and Premier Hytemphave joined since our last bulletinand we welcome them into ourassociation.

Message from the Chairman

Association News

Andy Orme Chairman‘‘

‘‘

Members please keep your news

articles coming in. Please visit us at

www.bmpca.org.uk

As this issue of the BMPCA Bulletin is produced the trigger is being

pulled on initiating the UK’s withdrawal process from the European Union.

There will no doubt be many ups and downs as this process waxes and wanes

between possible outcomes during the negotiation period but we can only hope

that the initial timetable of establishing a basic withdrawal treaty by the end of

2017 and a final withdrawal treaty by October 2018 is maintained. If so then a

degree of certainty should return to our future outlook as the earliest possible

date for the UK to leave the EU approaches in March 2019

Global operating Industrial

Automation & Control Ltd., of

Queensway Meadows, Newport, is

the UK’s leading independent systems

integrator of PLC systems, variable

speed drives and Scada.

Alcumus SafeContractor is a

leading third party accreditation

scheme which recognises extremely

rigorous standards in health and

safety management amongst

contractors. It is used by thousands of

organisations in the UK including

SMEs and FTSE 100 companies.

IAC Ltd, which employs 75

people and has an annual turnover of

£8.5m, undertakes complex

integration projects both in the UK

and overseas, for a huge range of

industries including paper, metals

pharmaceuticals, materials handling,

food, chemicals, printing, textiles,

water and nuclear power.

IAC Ltd’s clients include major

players such as Tata Steel, AMEC

Foster Wheeler, Dupont, Eastman,

Evoqua Water Technologies, and

Primetal Technologies Ltd. The

company’s application for

SafeContractor accreditation was

driven by the need for a uniform

standard across the business.

SafeContractor accreditation will

enhance the company’s ability to win

new contracts, and its commitment

to safety will be viewed positively by

its insurers when the company

liability policy is up for renewal.

Gemma Archibald, Director of

Alcumus SafeContractor said: "Major

organisations simply cannot afford to

run the risk of employing contractors

who are not able to prove that they

have sound health and safety policies

in place.

"More companies need to

understand the importance of

adopting good risk management in

the way that IAC Ltd. has done. The

firm’s high standard has set an

example which hopefully will be

followed by other companies within

the sector.

“SafeContractor plays a vital role in

supporting our clients in meeting

their compliance needs, whilst

working with their contractors as

they progress through the

accreditation process.”

IAC Ltd Marketing and HR

Director Kath Lewis, said: “Health and

safety in the workplace is of utmost

importance to everyone at and

associated with IAC Ltd. We are very

pleased to have been recognised with

this accreditation award.

“Safecontractor is a universally

acknowledged and recognised

endorsement which we’re confident

will further enhance IAC Ltds’ stature

and ability to successfully attract new

contracts and new work for our

business.”

for Industrial Automation & Control

Top Safety AccreditationLEADING UK automation and controls business IAC has

been awarded accreditation from Alcumus SafeContractor for

achieving excellence in health and safety in the workplace.

BACkgrounD ToSieMenS

Siemens is a globalpowerhouse focusing onthe areas of electrification,automation anddigitalisation.

As of September 30, 2016,Siemens had around 351,000employees in more than 200countries. In fiscal 2016, theygenerated revenues of €79.6 bn.

In the UK, Siemens have beenactive for over 170 years and infiscal 2016, generated revenuesof £5bn, employing around15,000 people, including about5,000 in the manufacturingsector, with 14 manufacturing

sites and more than 25 majoroffices.

We provide innovativesolutions to help tackle the UK’smajor challenges in Industry,providing digital solutions to helpmanufacturers to increaseproductivity, efficiency and createprogressively innovativeproducts to drive thetransformation towards thedigital enterprise.

Siemens integrated solutionscan improve manufacturingefficiency along the entire valuechain using intelligent industrysoftware to help simplify themanufacturing process, fromconception to execution.

BACkgrounD ToPreMier HyTeMP

Premier Hytemp is anapproved global supplier ofcomponents for wellheads,trees and downhole toolingto the major originalequipment manufacturersand leading servicecompanies in the oil andgas industry.

Our reputation is foundedupon our engineered solutionsto complex supplyrequirements, innovativeprocessing of materials and ourability to consistently meetchallenging lead times, all ofwhich have been established

over four decades. Today, theability to manufacture andmanage materials andcomponents across the wholesupply chain is at the heart oftheir investment and growthprogramme. Their specialitiesinclude Finished Machining, First Stage Machining, MaterialsManagement, and HeatTreatment

Premier Hytemp haveoperational sites in England,Scotland and the Far East.

3

Members News

The Director wishes to welcome Siemens and Premier Hytemp to

membership of the BMPCA. This is a great way to start 2017.

Siemens and Premier Hytemp reinforce our aim of providing a strong

network of manufacturers providing a wide range of services, skills and

expertise to plant manufacturers globally.

BMPCA Directorwelcomes two new members

Forgemasterssecures investment funding

The LEP is providing £650,000from its £52 million BusinessInvestment Fund towards newmachinery at Forgemasters'Brightside Lane machine shops tofacilitate further development intothe advanced manufacture offorgings and castings.

Forgemasters will install twonew machines; a five-axis millingmachine, and a vertical turning latheto enable the three-dimensionalmachining of increasinglycomplicated, ultra-large cast andforged shapes for industries such ascivil nuclear power and defence.

Sir Nigel Knowles, chair at theLEP, said: “We are working on anumber of technology-driveninitiatives and the BusinessInvestment Fund was set up to helpcompanies, such as SheffieldForgemasters and also smallerenterprises to achieve growth.

“It is no secret thatForgemasters sits at the fore-frontof technological developmentswithin the field of large-scaleengineering and this grant will helpthe business to advance itscapabilities even further, placingSheffield City Region at the leadingedge of manufacture into civilnuclear, defence, power generationand innovative projects such as theproposed Swansea Bay tidallagoon.”

The majority of the £6.5 millioninvestment will be fromForgemasters' own developmentbudget, but having pledged suchhigh levels of investment, thecompany qualified for the LEPBusiness Investment Fund grantwhich makes up ten per cent of theoverall project value.

James Tate, chief finance officerat Sheffield Forgemasters, said: “We

are delighted that the Sheffield CityRegion LEP has granted this fundingtowards what is a milestoneinvestment for the company andone which will create greaterefficiencies for future projects aswell as allowing for furtheradvanced machining techniques.

“The company has placed inwardinvestment high on its list ofpriorities since the managementbuyout in 2005 and we still investsignificantly more in research anddevelopment as a percentage ofturnover than most UKmanufacturers.

“There is no doubt that Sheffieldis a centre of excellence foradvanced manufacturing and thisinvestment will help us to deliver anincreasing volume of milling andturning work for defence andpower generation contracts usinginternal facilities to maintain high

tolerances and manufacturingstandards.”

The LEP brings togetherbusiness leaders and localpoliticians to make decisions thatdrive economic growth and createnew jobs within the SCR. The Boardis made up of 19 members – tenbusiness leaders and nine localauthority leaders.

Sheffield City Region comprisesof a core city, towns and markettowns, open countryside and asignificant rural economy. The CityRegion encompasses more than 1.8 million people andapproximately 700,000 jobs.

It is made up of the nine localauthority areas of Barnsley,Bassetlaw, Bolsover, Chesterfield,Derbyshire Dales, Doncaster, NorthEast Derbyshire, Rotherham andSheffield.

Engineering specialist Sheffield Forgemasters has secured funding from the Sheffield City Region'sLocal Enterprise Partnership (LEP) towards a £6.5 million investment.

Members News

4

Steel master Danieli Centro Recycling

European steel expertDanieli Centro Recyclinghas forged a path to newmarkets, securing its firstshredder sale in China

forges historic route to

With a factory and service

department already established

in Shanghai, the sale of the DCR

6290 to the Valuda Group marks

a new phase for the company,

bringing 25 years of experience

and European quality engineering

to the emerging Chinese scrap

processing industry.

Engineering Group Leader

Terry Keyworth said the deal

demonstrated Danieli Centro

Recycling’s commitment to

offering the highest

manufacturing standard on the

market. “With over 50 machines

in operation throughout the

world, we were keen to apply

our expertise to Chinese

operations. Although aspects of

the industry differ to our more

traditional home market, the

Members News

5

China

machine we have supplied works

to the same basic principles of

precision manufacturing with

wear parts designed for optimum

life and minimum downtime.”

The DCR 6290 is an entry-

level machine designed to

process relatively small volumes

of up to 30 tonnes per hour.

Based in Guangzhou, the Valuda

Group aims to utilise the

machine to treat end of life

vehicles (ELVs). In common with

Danieli Centro Recycling, it has

ambitious plans to expand across

China and recently won a

contract for the processing of

municipal waste in Shanghai. The

arrival of the new shredder

coincides with the company’s

plans to take scrap processing a

step further, from manual sorting

of non-ferrous materials to an

automated ELV processing

operation.

Keyworth says the Danieli

Lynxs shredding machine offers a

range of features that help it to

stand out from the competition

and which will ensure longevity

with low cost maintenance.

Perhaps the key point is Danieli

Centro Recycling’s approach to

wear parts. Instead of treating the

hard-working, fully machined

rotor as a consumable, it is

considered an integral part of the

machine, with wear parts such as

caps added to help balance the

rotor, reduce the cost of

replacing parts, and aid power

consumption with a design that

provides more inertia.

Keyworth added: “Our rotor is

a very highly precision-made

piece of equipment with spider

arms and end disks heated and

shrink fitted to the shaft. Similarly,

I believe we are alone in

supplying welded radial stiffeners,

which support the grids at four

points of contact. These provide

extra stiffness to castings and

bracing to the machine itself.”

In addition, the shredder

features independent hydraulic

cylinders for the kick-out door,

allowing the door to operate

independently to the machine in

an emergency, and single shaft

compression feed roller, which

helps to regulate the feed flow.

Keyworth said: “The feeding

system is linked to a completely

automated HMI (human machine

interface) system which monitors

rotor RPM, motor amps, and the

compression feed roller motor

and adjusts the settings by the

second.” Keyworth concluded:

“This is the first plant of its kind

in China and we are looking

forward to bringing a new level

of design and operation to the

market. We have a large factory

with 3,000 people working in

Shanghai and are fully equipped

to supply complete support to

the Valuda Group.

“We fully expect to be an

integral driver in Valuda’s plan to

both increase and improve ELV

processing capability, and to offer

China the benefit of our

specialised know-how and

manufacturing expertise.”

With over 50 machines in

operation throughoutthe world, we werekeen to apply ourexpertise to Chinese operations.

‘‘ ‘‘

The Oran site produces over onemillion tonnes of liquid steel peryear from its electrical furnace. Thearrival of the shredder is expectedto improve profit yields throughgreater flexibility on scrappurchasing, and a reduction infurnace transformation costs.

Davide Braga, Executive Manager,Technical Sales at Danieli CentroRecycling described the company’sexperience as a steelmaker ascrucial to the sale: “The mostfamous Danieli slogan sums it upperfectly: We know the art ofsteel. - We know exactly what asteelmaker is looking for in aproduct. We are not only sellingrecycling equipment, we alsoprovide added value in terms of know-how.”

The DCR 2227 – a 4,000 hpmachine prides itself on an outputof up to 100 tonnes per hour, with ayearly capacity of up to 400,000tonnes of shredded scrap. Itincludes, as standard, features suchas a high inertia, long-life, enclosedand capped rotor, heavy-duty rotorbearing housings, and a single unifiedbase structure to increase strengthin the vicinity of the anvil.

The shredder offers lower KWhpower consumption per tonneproduced and, in order to cutmaintenance time and the need toreplace expensive parts, DanieliLynxs has developed an innovativehammer pin puller.

However, Braga says that flexibilityin terms of feedstock purchasing isthe greatest benefit.

“When a customer invests, theywant to know how soon they canrecover outlay costs. In general,when producing one tonne of steelwith an electrical furnace, 80 percent of the total production costcomes from the cost of rawmaterials. Sourcing less expensivescrap, shredding, and raising thequality of your final producttherefore impact enormously onprofitability.

“In Algeria, standard scrap tendsto be of low yield and density, soinvesting in a shredder gives theopportunity to source cheaperfeedstocks and produce fresh scrapcompared with imported materialwhich may have lost one per cent ofits yield through oxidization duringstorage or transport. Our technicalteam recommends a density ofbetween 0.9 and 1.1. If the materialbecomes too dense, it can lead toinclusions within the scrap. A moreopen feedstock will have a higherheat exchange, which results in ashorter melting time.”

He concludes: “Theseconsiderations are very importantto the final material, and thereforevery important factors in the designof the mill – and in the design of thegrids and hammers. Our dedicatedresearch and development team hasproduced a range of grids and

hammers to suit all applications, andthanks to our subsidiary DanieliRiverside Products, which suppliesspare parts, Danieli CentroRecycling is able to apply itsexperience in shredderconsumables to each sale.”

Danieli Centro Recycling alreadyoperates four shredders acrossAfrica and three in the Middle East.However, the deal with Tosyali is afirst. The choice of Danieli CentroRecycling for Algeria confirms us asthe first choice in that market.Turkey, meanwhile, produces morethan 30 million tonnes of liquid steelper year, making it one of thehighest producing countries in theworld. We are extremely keen tobuild on our relationship withTosyali, using our knowledge andexperience to support such a majorplayer.

6

Members News

Tosyali & Danieli team upto install the first scrap shredding plant in Algeria

Two of the steel

industry’s most

influential players have

combined forces to

storm new markets.

The sale of Danieli

Lynxs’ DCR 2227

shredder to Turkish

giant Tosyali’s plant in

Oran, Algeria, marks

the first partnership

between recycling

equipment

manufacturer and

steelmaker Danieli

Centro Recycling and

Turkey’s largest private

iron and steelmaker.

7

Members News

by Mark Rewaj

Figure 1. Da Vinci’s design for a rollingmill with backup rolls (copyright Science Museum/Science &Society Picture Library)

Figure 2. Poster advertising the Taylor & Farley factory, 1888 (www.gracesguide.co.uk)

An eASier WAyTo forM MeTAl

Early metal workers found thatforging a shape with hammersfrom a simpler cast shape createdobjects far stronger than thoseformed by casting alone. However,hand hammering was laboriouseven for soft metals, so pressuregrew to create machines to assistwith the forming process.

eArly equiPMenTfor MeTAlrolling

The equipment that followed tocreate sheet products proved tobe of very simple design.

It is not known who created thefirst rolling mill. However, one ofthe earliest drawings is byLeonardo da Vinci. It even showsthe need for larger diameterbackup rolls to support longer,smaller diameter work rolls, Figure 1.

15TH – 17THCenTury

In the middle of the fifteenthcentury small mills produced goldlace, and other decorative work, insoft metals.

However, as these techniquesbecame more widely known,demands for products comingfrom metal rolling increased. Thereis evidence for rolling of lead andtin on simple 2-high mills withcast-iron rolls at the beginning ofthe seventeenth century.

At this point rolling mills did notprocess the high volumes of metalthat we see today. In addition, therequired quality of these earlyproducts was ‘poor’ if we measureit by today’s exacting standards.However, no-one had developedthe applications that needed higherquality material. Energy was also abig consideration if this technologywas to be expanded further.

By the end of the seventeenthcentury, it was possible to castlarger iron rolls and thereforebuild heavier mills. Horses andthen water wheels drove thesemills.

18TH – 20THCenTury

During the eighteenth century,4-high designs appeared (300years after da Vinci). This wasbecause people discovered thatsmaller diameter rolls requiredless load to reduce the metalthickness. Consequently, it waspossible to use a lighter frame.

At the end of the eighteenthcentury, with the availability ofsteam power, the mills started toresemble their moderncounterparts. During thenineteenth century and into thetwentieth century, the size andpower of mills increased with littlechange to the main design. Steamengines were capable of deliveringin excess of 10,000 hp. Oneexample of this is the 12,000 hp(8.9 MW) River Don Engine builtby Davy Brothers in 1905 to rollarmour plate. However, moreefficient electric motor technologyslowly replaced steam power inthe twentieth century.

Interestingly, we have our ownconnection with eighteenth

century metal rolling here atInnoval. Dr Tom Farley‘s greatgrandfather, Reuben Farley, starteda company in 1861 whichmanufactured rolling mills and rollsin West Bromwich, UK. Thecompany was “Taylor and Farley”.

Tom Farley is our expert inrolling mill vibration. I’m sureReuben Farley would be veryproud to know that metal rollingexpertise still exists within theFarley family.

A brief historyOF METAL ROLLING FOR SHEET & PLATE PRODUCTS

On the first day of our

Aluminium Rolling

Technology Course I run

a session entitled

“Machinery and Process

Overview”. Part of this

covers the history of

metal rolling from the

first known drawings of a

mill to the state-of-the-

art rolling equipment

available today. Metal

rolling has an interesting

history...

8

Members News

ToDAy’S rollingMillS

The basis of design for today’sequipment is not too dissimilar toearly designs, particularly whenyou consider a basic 2-high mill. Itjust uses different types ofmaterials and designs of rollstacks. However, today’s mills arenow designed for processing amultitude of metals for extensiveend-user applications. In somecases there are more than 20 rollsin the roll stack. This clearlydemonstrates that mill designs andtheir requirements have movedon substantially from the earlybasic designs.

Today we produce much higherquality products which haveexacting standards in dimensionalaccuracy, surface and materialproperties. All of these need to beconsidered in the design of newmills, be it for plate or coilproducts.

The mill in Figure 3 has thecapability to produce high qualitythick and thin plate and sheet(coil) products. The belt wrappersin this case are located on both

entry and exit sides of the mill.These belt wrappers are designedto move in and out as and whenrequired to produce either plateor coil products. With capacities inexcess of 200 Kt per annum, thisdesign represents a major leap intechnology from where it allstarted back in the time ofLeonardo Da Vinci.

AluMiniuMrollingTeCHnologyCourSe

Our Aluminium RollingTechnology Course covers all thekey aspects of hot and cold rollingof aluminium flat products. Mycolleagues and I write and deliverthe modules. Between us we havea huge amount of industryexperience. We’re very familiarwith the day-to-day issues of arolling plant, and we’ve createdthis course to help you solvethem. Many of the presentationsare supplemented with hands-onworkshop sessions.

The course takes place twice ayear here in Banbury. The nextone is 15-19th May 2017. You can

download a registration form(which contains the timetable andinformation about the cost) here.Finally, you might be interested toknow that the course isrecognised by the Institute ofMaterials, Minerals & Mining(IOM3) as ProfessionalDevelopment.

Mark Rewaj the author:Mark is one of our rolling expertsand he is part of our ProcessImprovement team. He has 30years’ experience in rolling plantoperations, optimisation ofprocesses, organisationalefficiencies and material flow.

Figure 3. A ‘simple’ combination single stand 4-high reverse roughing and finishing milldesign from Danieli

Figure 1. The ingot (green) at the start of the simulationwith the normal work roll (light blue), centre plane of

symmetry (dark blue) and edge roll (orange).

Figure 4. Timetable from our AluminiumRolling Technology Course

FEA MODELS FOR OPTIMISING A ROLLINGPROCESSHere we cover some of the computer basedmethods we use to get the most out ofaluminium rolling and finishing processes. Usingcomputer models, such as Finite Element Analysis(FEA) models, increases understanding andreduces the number of online trials. As a result,they reduce the cost of process optimisation. It’strue to say that FEA models are a significant partof our ‘tool box’

by Rade Ognjanovic

9

feA MoDelS ToPreDiCTAlligAToring

We use FEA models of rollingmills, such as the one in Figure 1,to predict things like alligatoring ofingots (Figure 2). In this case, weonly need to model one quarterof the ingot due to symmetryplanes.

It’s possible to minimisealligatoring by adjusting the rollingschedule. This is importantbecause less alligatoring meansless of the ingot is cropped off.Consequently, waste is minimised.

Figure 3 shows a full 3Dsimulation of the whole ingot atthe end of the ninth pass. Thealligator opens up as it moves intothe roll bite before closing onceit’s in the roll bite.

feA MoDelS AnDTHe innovAlrolling MoDel

Innoval also has an accurate fast-running analytical rolling model topredict roll loads, torques and otherphysical quantities. We have usedFEA models to develop our rollingmodel by predicting, for example,forward slip. This is how much fasterthe slab exits the roll bitecompared to the roll surface speed.Two dimensional FEA simulationspredict the forward slip as afunction of friction, Figure 4.

We use the same FEA modelsto study the velocity of materialthrough the roll bite at threepoints. These are the roll biteentry, the exit and the neutralpoint, Figure 5. The neutral pointis where the ingot surface speed

matches the roll speed. The rollsurface speed is 1 m/s in thisexample. Understanding this typeof behaviour helps us to developmore accurate analytical models.

Typically the mill should run in amode that is optimum for theprocess as a whole. This meansthe processes upstream anddownstream of the mill need tobe considered. This is where wecan use some of our many otherprocess modelling tools to findthe optimum conditions for theline or product.

feA MoDelS forTenSionlevelling

A levelling process is oftencarried out after rolling and wehave two models that cansimulate this. These are the InnovalTension Leveller Model and anFEA simulation of a roller leveller.Figure 6 shows a screen shot ofthe Innoval Tension LevellerModel. The geometry of the rollsand strip are in the top window.The bottom window shows thestrip through thickness stressesand strains. It’s an extremely fastand user friendly model.

The FEA model of a rollerleveller in Figure 7 shows a sheetentering a series of rolls alongwith the contact forces. It canpredict the properties of sheetexiting the leveller which helps theoperator set up the machine.

ProCeSS CoSTMoDelS

Finally, when there are anumber of machines to optimise

in a process chain, understandingand calculating the costs canbecome very complicated. Whilstour Process Cost Models are notFEA models, they are often used inconjunction with them to optimisean entire process. Furthermore, wehave experienced specialists whocan calculate the costs to assist inmaking strategic financial decisions.

If you would like to find outmore about our modellingcapabilities please contact us.

Rade Ognjanovic theauthor: Rade is one of ourProcess Improvement consultants.His background is in chemistry andpolymer science and he has 26years’ experience in processmodelling

Figure 4. Forward slip as a function offriction as predicted by the FEA model.

Figure 7.FEAsimulationof a rollerleveller with(lowerpicture) andwithoutcontactforcevectorsdisplayed.

Figure 5. The velocity distributionthrough the ingot thickness at the rollbite entry and exit, and also at theneutral point

Figure 6. The InnovalTensionLevellerModel.

Figure 2. An alligatoron the endof an ingot.

Figure 3. A full 3D FEA simulation of the ingot alligator entering the roll bite.The ingot is moving from left to right.

Members News

10

Using the science of measurement for your engineering needs, sometimes you just need to know the factsbefore making an educated decision...

The Metalock MetrologyDepartment are flexible andresponsive. They can performaccurate surveys in almost anyenvironment anywhere in theworld. If you require accuratedimentional data related to alltypes of plant and equipment inany industry we can provide thatservice.

For example in the steelmanufacturing industry

The Metalock metrologydepartment have already travelledto many steel mills around theworld and surveyed steel millstands and related equipmentwhich have provided ourcustomers with a detailed surveyreview and analyse informationprior to them making keydecisions related to future capitalexpenditure. We can pick up onlong lost datum’s on even themost dated mills. Even withoutphysical references in the way of

landmarks, using laser technologyour survey department has beenable to determine the pass line ofthe material and centre line of themill and individual stands byanalysing the surveyed data.

• Laser alignment and surveying has become an invaluable asset relating to our onsite machining services

• Allowing all stands to be machined in relation to the datum’s and each other within0.01mm or 0..004”

• Tolerances as tight as 0.05mmor 0.002” can be achieved across the stand window

• Stand machined perpendicularto gravity within 0.05mm or 0.002”

• Permanent reference systems installed during a full survey have many benefits

• All work carried out after the survey will be relevant to the mill datum’s survey

• Our equipment can be reset to the same datums each timeso that the condition of the plant can be monitored at regular intervals.

• Periodic inspection can map the degradation of the mill over time

ACCURATEMEASUREMENTS INALL ENVIRONMENTS

Laser tracking is now anindustry standard in all types ofengineering, the ability to produceaccurate measurements in alltypes of environments, to createand leave a permanent referencesystem that will allow the lasertracker to position its self in thesame place, time after time. This isbecoming a key feature for

customers that requirepermanent reference points towork from months or even yearsinto the future. This enables thecustomer to collect measurementdata at regular intervals that willestablish the level of wear,movement or deterioration of alltypes of plant and equipment.

Using the latest laser surveyingequipment Metalock are able tomeasure even the most obscurecomponents and structures andprovide accurate images and datathat can assist the customer inmaking educated decisions priorto any capital investment.

More details about the variedwork done in the UK and aroundthe world, by Metalock since1947 is available on thecompany’s websitewww.metalock.co.uk

Metalock Engineering

UK Ltd, established in

1947 and part of the

Midroc Europe Group,

works with some of the

largest, most sophisticated

and complex equipment

and serves a diverse

range of highly specialised

industries including

petrochemicals,

processing, steel and

paper making, pressing

and forging, power

generation and marine

and offshore.

11

IAC manufacture control systems for industry. We integrate equipment manufactured by the worlds leading electrical manufacturers into tailor made solutions.

We have a varied and extensive electrical engineering background based on solid, wellfounded experience and continuous development.

At the present moment, IAC are, without question, the leading independent variable speeddrive system integrator in the country.

What do we do...?

IAC are now well known for supplying drive systems and automation and control solutions,but we are able to offer a whole range of services...

Email: sales@iac-ltd.co.uk Telephone: 01633 293000 Visit: www.iac-ltd.co.uk

What else do we do...?

What can iAC do for you…

For further details contact:

R. RuddlestoneDirector BMPCAC/O EEFAdvantage HousePoplar WayCatcliffeRotherham S60 5TR

Tel: 44(0)7753 866127

email: bob.ruddlestone@mpiuk.com

www.bmpca.org.uk Designed & Produced byQ2CREATIVEwww.q2creative.co.uk

BMPCA 2017Meeting & Social Events Calendar

Chesterfield Special Cylinders

CISDI

Corewire Ltd

Danieli Ltd

Davy Markham

Industrial Automation & Control Ltd

Innoval Technology Ltd

Metalock Engineering UK Ltd

MII

Oldham Engineering

Premier Hytemp

Ross Controls

Sarclad Ltd

Siemens

Sheffield Forgemasters Engineering

Thermo Fisher Scientific

BMPCA members

6th April Business Meeting – KTC at the AMP Catcliffe followed by a visit to the Metalysis Research Centre. Dinner in the evening at the Cutlers Hall, Sheffield

July 6th Business Meeting to be held at SKF in Luton

October 5th AGM and Business Meeting

November 16th Annual Lunch at the Painters Hall London