Troubleshooting Steel Pile-Ups in Wire Rod Rolling

During wire rod production, steel pile-ups may occasionally occur. Below are the possible causes and corresponding solutions based on where the pile-up happens.

1. Steel Pile-Up at the Head of the Rolled Piece

Possible Causes:

1. Insufficient friction in the roller groove, causing the workpiece head to slip;
2. The head of the workpiece bends upward after exiting the stand;
3. Foreign objects in the rolling or guide groove;
4. Billet fails to enter the rolling mill;
5. The billet pushes out the guide or wraps around the roller;

Solutions:

1. Increase groove friction when replacing the roller or groove by grinding the groove with a grinding machine or applying spot welding;
2. Regularly check for loose guide bases; ensure the rolling line is centered and replace worn guides promptly;
3. Remove oxide scale in a timely manner during operation;
4. Reject defective billets; if the billet forks, immediately trigger an emergency stop to prevent production delays.

2. Steel Pile-Up in the Middle or Tail of the Rolled Piece

Possible Causes:

1. Improper roller gap setting;
2. Billet defects such as inclusions or bubbles causing it to break during rolling;
3. Inappropriate rolling speed design;
4. Sudden motor speed changes (increase or decrease);
5. Roller fracture or severe damage to front-pass guides;

Solutions:

1. Accurately match roller diameters and speeds to minimize speed mismatch;
2. Strictly inspect billet quality before rolling;
3. Properly adjust tension between stands;
4. Check electrical systems and replace any faulty components;
5. Monitor steel temperature and cooling water volume; avoid rolling steel at low temperatures or with “black heads”.

3. Steel Pile-Up Between Finishing Mill Stands

Possible Causes:

1. Guide wheel malfunction or bearing burnout
2. Rolled piece is forked or split;
3. Incorrect installation of guide or roller rings;
4. Improper gap setting or oversized/undersized workpiece;
5. Roller ring fracture;

Solutions:

1. Replace the guide and ensure proper installation;
2. Inspect billets and increase cutting head length if needed;
3. Recheck and adjust gap settings between guides and rollers;
4. Replace damaged roller rings and inspect associated cooling pipes.