What is a Seamless Rolled Ring Forging Process?

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Forging is still one of the most popular and economical metalworking processes used for manufacturing a wide range of industrial and mechanical components. While there are a number of forging processes, seamless rolled ring forging is integral as it not just helps in manufacturing a host of forged components but also offers a number of benefits when compared to other forging methods. No wonder it is one of the most popular processes used for manipulating the shape of metals and produced forged components

Let us have a look at the advantages of seamless rolled ring forging and how this process actually works.

Advantages of Seamless Rolled Ring Forging Process

Seamless rolled rings offer several benefits. Some of the most important ones are-

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&#; The process used high temperature to strengthen the metal which results in better strength and durability

&#; It is highly cost-efficient when compared to other forging methods

&#; As compared to other metalworking processes, rolled ring forging makes it easier to predict the effect of the process on metal, and this helps in reducing the manpower requirements

&#; Limited restrictions as compared to other processes

&#; It can be used for many kinds of metal

Seamless rolled ring forging process

Let us have a look at how this process works-

1. A large metal piece is punched with a round hole with the help of a hydraulic machine to form a donut-shaped cavity in the metal piece.
2. The metal donut is then heated above its recrystallization temperature before being placed on Mandler or idler roll.
3. Pressure is applied to the mandrel roll to make it move towards a rotating drive roll for reducing the thickness of the wall and increasing the inside and outside diameter of the ring as per the requirement and specific needs.

Uses of seamless rolled rings

As the seamless rolled rings created with this process are versatile, strong and highly cost-effective, they are used for several industrial applications. The rings are very commonly found in paper mills, jet engines, gearboxes of helicopters, windmills, and many other demanding environments.

Availability of Seamless rolled rings

With the advancements in forging technologies, forging companies in India now offer rolled rings in a number of sizes and weight range. You can easily find rolled rings of just 1&#;2 inches to more than 300 inches. As for the weight, it can range from 100kgs to kgs and even more, depending on the requirement and needs. Moreover, even the shape of the rings can vary. You can find tall cylindrical rings and even rings that are flat like washers.

There are forging companies in India that also offer custom rolled rings in complex shapes that feature contours on the inside and outside diameter. As compared to fabricated rings manufactured from steel castings and plates, these custom rolled rings are highly cost-efficient.

Seamless rolled rings offer a host of advantages making them extremely popular across various industries. Rely on a reputed forging company for such requirements to make sure that the final outcome is exactly as per your requirement.

Seamless rolled rings can be produced using an open die forging method or on a ring rolling mill. Seamless rings are extremely durable and are overall stronger rings because they generate circumferential grain structures, and they have no welded seam to fail. Using a seamless ring rolling mill is also a more cost-effective forging process than other methods because it requires less input material, and the end product has less material to remove, providing a double benefit and oftentimes does not require a final machining. Ring rolling, when used in combination with a ring expander, generates exceptionally round and durable ring products in any forgeable material. 

Open die forging of rings, typically done with the use of forging hammers, dates back hundreds of years. Achieving perfectly forged rings on a hammer and mandrel is a challenging task. The most common method involves heating the metal, punching a hole in it, and rolling the ring on a mandrel with intermittent flattening operations. While this method did create ring-shaped parts, the finished rings were often rough, and required extra material. One alternative method for producing rings is to cut plate, then roll and weld it into rings. While this solution can work in some applications and it is generally less expensive, it can often lead to mechanical failures and poor quality product, especially if the ring is under immense pressure and corrosion. 

In the mid-19th Century due to the growth of the railroads, people started to design equipment to produce round rings using less material. As technology advanced, different forging methods were created that greatly improved the final product. Eventually the seamless rolling mill was created &#; resulting in forged rings that were more consistent in size, they were strong and versatile, and were cheaper to produce than ever before. Seamless rolled rings can be produced in many different materials, including nickel-based superalloys, titanium, stainless steel, and copper.

Seamless rolled rings are commonly used in several different industrial applications. Seamless rolled ring parts are used for bearings, clutches, flanges, gears and connectors, valves and much more.

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