Development of satellite mill and trial rolling of profiled metal strip

A new type of compact continuous mill called the “Satellite mill” has been developed to produce profiled metal strip from flat strip. This mill consists of one large-diameter driven roll (central roll) and five smaller rolls (satellite rolls) arranged along the periphery of the central roll. A strip is continuously rolled at five gaps between the central roll and the satellite rolls. All rolls are driven at an equal roll peripheral speed to promote transverse metal flow or lateral spread. Guide shoes are provided between the adjacent satellite rolls and are supported with two adjacent satellite rolls. They prevent a strip from bulging or buckling. A test mill was constructed, and rolling experiments have been performed on the production of T-shaped or U-shaped profiled aluminum strip. The deformation- load characteristics were investigated and compared with those of conventional rolling. As a result, in the satellite mill rolling operation, elongation was suppressed. Lateral spread was enhanced, and the profile of the product cross section was significantly improved. Consequently, the new rolling process was found to be forming of profiled metal strip.