Analysis of coil slumping

Abstract

Steel strip is usually stored as a coil, which will slump to some degree after the removal of the mandrel. More often than not, the amount of slumping is so minor that it is assumed not to have occurred. Occasionally, the amount, though minor, is sufficient to compromise the integrity of the cylindrical bore which compromises subsequent handling of the coil. In extreme situations, the slumping progresses to a complete collapse of the coil. Such a collapse is rare. It occurs when a coil cannot hold up its own mass and loses its circular cross-section. It is thought to be principally associated with the size and weight of the coil, inappropriate coiling tensions and/or poor re-coiler equipment design. Strip properties, especially inter-strip contact characteristics, have been demonstrated experimentally to be crucial determinants of whether or not coil collapse is likely to occur.

The particular kind of slumping/collapse of interest to BlueScope Steel, who proposed this Study Group problem, is the minor slumping that compromises cylindrical bore integrity. It is referred to as coil slump.

The Study Group was asked to investigate and model the phenomenon of coil slumping, and, if possible, to quantify the effect of critical parameters, especially coil mass, strip thickness and inter-strip friction. In particular, it was suggested that deliberations should aim to characterize the geometry of slumping and to predict the deformation profile at the innermost and outermost wraps.

For BlueScope Steel, the long term objectives are:
(1) the formulation of the governing equations for the stresses in a coil under self-weight,
(2) the identification of analytical solutions and/or numerical schemes for the final coil shape after slumping, and
(3) the formulation of exclusion rules-of-thumb which predict when a particular form of slump (oval or triangular) is likely to occur.

The Study Group made some progress with (1), limited progress with (2) and most progress with (3). Though various computer programs were written to explore different force and energy balance scenarios, they only scratched the surface with regards to (2). Success with it is heavily dependent in substantial progress being made with (1). As explained in detail in the sequel, the Study Group’s deliberations resulted in an improved understanding of the coil slumping/collapse problem by identifying a number of specific issues that should be of direct assistance to BlueScope Steel’s future management of coil slumping/collapse.

In particular, such issues included the need, from a modelling perspective, to draw a clear distinction between minor slumping and major slumping which can subsequently lead to collapse; the formulation of a heuristic hypothesis about the dynamics of coil slumping/collapse which can be compared with historical data and act act as a conceptualization guide for further investigations; the identification of a “tension-weight ratio” (R) as the relevant dimensionless group which represents an indicative rule-of-thumb which can be applied in practice; and proposed, on the basis of the hypothesis, an efficient procedure for recording collapse events and statistically identifying possible collapse situations.