Background
Vibremo engineers identified a persistent vibration issue in a roll grinder as the root cause of chatter marks observed on finished backup rolls. These imperfections directly impacted the quality of the aluminum sheet produced by the cold rolling mill, leading to similar markings on the coils.
Using our expertise in vibration analysis, we traced the source of the issue to the headstock chain - a critical component of the drivetrain system responsible for transmitting mechanical power from the motor to the roll.
Finding an effective solution to eliminate these vibrations became a priority to improve grinding performance, restore the quality of the rolls, and ultimately lead to satisfactory output aluminium sheet.
Solution
From experience, a measure to minimise the effect of significant vibration levels from a chain is to alter its tension, which is what we did by rotating the grinder headstock chain tensioner.
We determined an ideal adjustment as it resulted in a significant reduction of the vibration levels by carrying out running light tests – a specific experiment carried out with only the roll turning.
Outcome
To confirm the positive effect obtained by tightening the chain, our team performed more vibration measurements at various roll speeds during grinding operation. Vibration levels at the chain frequency were reduced at all tested roll speeds after adjusting the chain tension, with a maximum reduction of close to 70%!
It has been reported that the rolls ground after this investigation are now chatter-free, significantly improving the quality of rolls sent to the rolling mill.
This case study highlights the critical role of optimising chain tension in roll grinders to reduce vibrations and enhance roll quality. The significant improvement in grinding performance demonstrates the value of regular testing, proactive maintenance, and targeted adjustments. Addressing these mechanical issues early not only prevents defects but also boosts overall production efficiency and product reliability.
