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CUTTING

&
EDGE PLANNING

PROCEDURE FOR MARKING, CUTTING AND CHECKING OF


SHELL PLATES
SHELL
PLATE

4 UNITS

K2

TS
NI

ROLLING DIR.

5U

SA 516 GR
70 24357
9262 /
3

K1

3 UNITS

L
TOLERANCE
L - + 1 mm / M, Max. 3 mm., &
K1 - K2 = + 1 mm / M,

W - + 1 mm / M, Max. 3 mm

Max. + 5 mm

IDENTIFICATION MARKING
TO ROLLING DIRECTION.
L - NOMINAL CIRCUMFERENCE = MEAN DIA. X

3.1415926535897932384626433832792...

GENERAL WEP
WHEN JOINING PLATES OF DIFFERENT THICKNESS

T1

T2

FORMING

ROLLING DEPENDS
Provide necessary allowance ( 1.5 to 2 times the
thickness)

Gas cut

Wastage of the material

increased cycle time

Edge breaking to remove out peak out


Not feasible for all the thickness
Pressure required is more

ROLLING
THE PROCESS OF STRETCHING BEYOND THE YIELD
POINT OF THE METAL

METHODS

PINCH ROLLING

PYRAMID ROLLING

COLD ROLLING

WARM ROLLING

HOT ROLLING

NORMAL ROLLING

PINCH ROLLING
BENDING AT THE PLATE ENDS
BOTTOM ROLLER SHIFTED FROM CENTRE TO EITHER
LEFT OR RIGHT

PRESSURE APPLIED > NORMAL ROLLING PRESSURE

PYRAMID ROLLING
NORMAL ROLLING
TOP
ROLLER

BOTTOM
ROLLER

BOTTOM
ROLLER

COLD ROLLING
ROLLING AT NORMAL ROOM TEMPERATURE

WARM ROLLING
PLATE HEATED BELOW ITS CRITICAL TEMPERATURE
BEFORE ROLLING .

WHY?
PLATE THICKER THAN THE CAPACITY OF THE ROLLING M/C
PLATE MATERIAL HAS HIGHER YIELD POINT

HOT ROLLING
PLATE HEATED BEYOND UPPER CRITICAL TEMP.
BEFORE ROLLING .

WHY?
PLATE THICKER THAN THE CAPACITY OF THE ROLLING M/C
PLATE MATERIAL HAS HIGHER YIELD POINT

NORMAL ROLLING

PLATE PLACED BETWEEN TOP AND BOTTOM


ROLLERS AND PRESSURE APPLIED SLOWLY ON
TOP ROLLER TO ROLL THE REQUIRED DIAMETER.

CHECKING SHELL OVALITY AND CIRCUMFERENCE


OVALITY

ACTUAL THK.

= ID max - ID min
= 0.5 % of Nominal ID

P
M
TE

D/
4

4
D/

PEAK OUT

TE
M
P

I/D CHECK IN HP PLANE

PEAK IN

TEMPLATES
TO CHECK THE INSIDE DIAMETER
MADE OUT OF 3-4MM THICKNESS PLATES
D/4 TO D/8 TEMPLATES

R
D/4

PEAK IN / PEAK OUT


ID

WHY?
OVER / UNDER BENDING DURING
EDGE BREAKING OPERATION

PRECAUTIONS

PROPER CARE

RE ROLLING

< 152
MM
457
MM
914

Allowed gap
Pick in /
out
0.8 MM
< 305

1.2
<

1.6 MM
< 610
2.4
<
3.2 MM
< 1219

4.0 MM
< 1524
4.8
MM
<
1905
5.6 MM
< 2133
6.4 MM

SKEW
Rollers not aligned
Plate edges not kept parallel to roller axis plate
diagonals not checked

SKEW
15 TO 20MM AND LOW THICKNESS

SKEW
HIGH THICKNESS

SKEW
TURN BUCKLES

PRECAUTIONS

PROPER DEVELOPMENT & MARKING OF CONE

CHECK THE DIAGONALS

EDGE BREAKING WITH CARE ( D/4 LENGTH )

KEEP SUITABLE RADIUS GAUGE (HANDY)

ENSURE THE GENERATOR LINE OF THE CONE IS


PARALLEL TO THE TOP ROLLER

TO AVOID FLARE, INCREASE PREISURE SLOWLY

GOOD ENGINEERING PRACTICES


( FOR ROLLING )
Check diagonals of the plates to be rolled.
Stamp identification mark on the outer surface of
the width so that, when the plate is rolled in to a
shell the identification mark can be seen from
outside.

Identification mark should be stamped parallel to


the width of the plate

GOOD ENGINEERING PRACTICES


( FOR ROLLING )
Always pain rolling direction with an arrow on the
plate to be rolled
Remove burrs, dust, dirt from the edges of the plate
before it is fed in to rolling machine
While edge breaking a very long plate, hold one
end of such plate with crane while other end is
being edge broken

While edge breaking a very long plate, hold one end


of such plate with crane while other end is being
edge broken.

GOOD ENGINEERING PRACTICES


( FOR ROLLING )
Always refer capacity chart of a particular rolling
machine before attempting any bending/rolling on
that machine
Check alignment of the rollers, before rolling is
attempted.
Ensure that required templates are available before
rolling is taken up.
Before taking up s.s plate for rolling, the rollers
must be thoroughly cleaned with wire brush.

TOLERANCES ON CIRC. OF SHELLS, DENDS , CONES &


BELLOWS
THE REQUIRED CIRCUMFERENCE SHALL BE COMPUTED
BY THE FOLLOWING METHOD.

REQUIRED CIRCUMFERENCE = ( ID + 2T ) * PIE


WHERE,I.D = INSIDE DIA. AS SPECIFIED IN DRAWINGS
T

= ACTUAL THICKNESS MEASURED AT ENDS

PIE = VALUE OBTAINED FROM CALCULATOR


MEASURE THE ACTUAL CIRCUMFERENCE ON THE JOB.
ONLY CALIBRATED TAPES SHOULD BE USED FOR MEASUREMENT.
COMPARE THESE TWO VALUES OF CIRCUMFERENCE AND CHECK THE
ACCEPTABILITY BASED ON BELOW GIVEN TOLERANCE CHART.