Failure Analysis of Rollers in mill stand using Failure mode Effect Analysis

Rolling is an important steel production process. Productivity and quality improvements in metal rolling are possible by paying a detailed attention to the various roll failure modes.A proper understanding of the causes of roll failure modes is usually complex and depends on the metallurgical quality of rolls, improper mill usage practices and abnormal rolling conditions. The work rolls operate under severe condition and should posses excellent wear resistance and very little plastic deformation to withstand mechanical and thermal shocks. The objective of this study is to analyze different failures associated with rollers in the mill stand using Failure Mode Effect Analysis (FMEA). The values of severity, probability of occurrence and detection of each failure mode are taken according to the FMEA criteria and based on these values, Risk Priority Number of each failure mode is calculated. Based on the risk levels of each failure modes, remedies for the respective failure modes are presented. Thus it results in reduced risk of process failure, improved reliability and quality of the products.