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Rolled ring forging is a manufacturing process that involves shaping metal into a circular ring. This method is widely used across various industries to create durable and high-quality rings in critical applications such as aerospace components, power generation, oil and gas, and the automotive industry. Rolling ring forging involves several steps, including cutting, piercing, heating, and forming the metal into a ring shape. In this post, we’ll look at how rolled ring forging works and why it’s an important technique for creating robust and reliable rings for industrial applications.
Rolled ring forging is a metal shaping process involving extreme pressure and heat to form seamless circular rings. This technique results in products with superior strength, enhanced grain structure, and better fatigue resistance compared to other manufacturing methods. It is commonly used in the aerospace, automotive, and energy industries for producing high-quality components such as gears, bearings, flanges, and shafts. Unlike traditional machining processes, Rolled Ring Forging allows for the production of complex shapes with minimal material waste. In addition to its durability and versatility, this technique offers cost-effectiveness due to its ability to produce large quantities faster than other methods.
The roll ring forging process’s first step involves preparing the metal for shaping. The raw material is usually a thick metal plate that undergoes cutting and piercing. The plate is cut into a round shape and then pierced to create a central hole, which will become the ring’s centre. The cutting and piercing process can be done with tools like saws, lasers, or waterjets.
Once the metal has been cut and pierced, it must be heated to make it more malleable. The temperature required depends on the material being forged but typically ranges between 1100 to 1250 °C. Heating is done in a furnace specifically designed for the rolled ring forging process. Once the metal reaches the desired temperature, it is ready for the next phase.
In this phase, the heated metal is placed on a mandrel, a circular tool that creates the ring’s inner diameter. A hydraulic press then applies force on the heated metal, causing it to flow around the mandrel and take on a ring shape. The pressure gradually increases, and the metal is rotated to create a uniform ring shape. The metal cools and hardens during this process.
Once the ring has taken shape, it is quenched in water or oil to expedite the cooling and reduce the risk of warping or cracking. The ring is then removed from the mandrel and undergoes a finishing process to remove any burrs or excess material. The ring may undergo additional processing, such as heat treatment or final machining, depending on the application requirements.
Rolled ring forging is a versatile and reliable process for producing high-strength rings in various industrial applications. One of the primary advantages of rolled ring forging is that it can create seamless rings, which have higher structural integrity and are better suited for critical applications. Additionally, the metalwork produced through rolled ring forging typically has optimal grain structure, which makes the rings more resistant to wear and tear and corrosion.
Rolled ring forging is an essential manufacturing process for creating reliable and robust rings used in critical applications across various industries. Understanding the steps involved in this process, including cutting, piercing, heating, forming, and finishing the metal, highlights the critical aspects of ensuring the end product’s quality and integrity. Rolled ring forging is popular due to its advantages in creating seamless rings, impeccable grain structure, and unique physical properties. These rings are ideal for heavy-duty machinery, aerospace components, and other applications requiring high tolerance and safety standards.
Abstract:
Ring rolling has advanced but versatile rolling process as it can be performed on the material at high temperatures and also at ambient temperatures.
The main applications of the process are for the production of railway tyres, anti-friction bearing races, and a range of ring shaped components used in the automotive and aerospace industries.
Rolling is continuous forming of metal between a set of rotating rolls whose shape or height is incrementally reduced to produce desired section through imposing high pressures for plastic deformation. It is the process of reducing thickness, increasing length without increasing the width markedly. The ring rolling process can be performed with the material at high temperature (hot) or initially at ambient temperature (cold). Ring rolling is an advanced technique to manufacture seamless rings with flexible cross-sectional shape, improved grain structure, and minimal scrap.
The process and equipment are similar in principle to rolling mills used for plate production. Indeed in both processes the metal is rolled between two rolls which move toward each other to form a continuously reducing gap. In ring rolling, the rolls are of different diameters and geometries.
The ring rolling process is basically used in the production of railway tyres, anti-friction bearing races and different ring shaped work pieces for automotive and aerospace applications. The advantages of the ring rolling process include short production time, uniform quality, close tolerances and considerable saving in material cost.
Moreover the main advantage of the work pieces produced by ring rolling process, compared to other technological processes, is given by the size and orientation of grains, especially on the worked surface which give to the final product excellent mechanical properties. In figure 1 the main production steps of the ring rolling process are summarized.
As shown in figure 1, it begins with a forged bar that has been upset (a) and pierced (b) to obtain a hollow circular preform. The preform is placed over the idle roll that is forced toward the driven roll (c). At the same time, the axial rolls apply pressure in a direction parallel to the ring axis. So the idle roll reduces the width while the axial rolls reduce the height of the ring cross section.
The coupled idle and axial rolls movement imparts the desired shape to the cross section and increase the ring diameter. The work piece starting section could have a rectangular or complex shape. As can be observed from figure 1, due to the nature of the process different rolling mills (driven roll, idle and axial roll) are involved and the correct selection of the process parameters is not so feasible.
Also, the ring rolling process is widely used to produce seamless rings by forming by a continuous but gradual process with various outer ring diameters for power generation plants, aircraft engines and large cylindrical vessels. Advantages of the ring rolling process compared to the ring forging process are the fast working time with the grain flow being formed continuously which is favorable by nature.
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Date Published: Mar-2014
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