The Ring Rolling Process

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.

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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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A process called ring rolling forms seamless forged rings. The ring rolling method is carried out on machines referred to as rolling mills. These mills will generate rings that have an outer diameter varying from just a couple of inches up to 300 inches. The weight of these rings will also vary from approximately 1-lb all the way up to 300,000-lbs and over.

Seamless Rolled Ring Forging Process:

In this process, a circular metal component is pierced in order to form a hollow ring, something similar to a doughnut.

Once the hollow piece is formed, it is then heated to recrystallization temperatures. It is then placed onto an idler roll, that when under pressure, will move towards a drive roll. This step in the process causes rotating and then increases the diameter of the rolling rings, also decreasing the wall thickness.

Seamless rings can be produced using a variety of configurations. Whether it&#;s a tall cylindrical shape or a small washer-like part, the rings are usually in a rectangular cross section shape. Whether complex or customized shapes, seamless rolled rings can be manufactured by using a shaping tool.

What Are Seamless Rolled Rings Used For:

These rings can be used in many products, such as:

• Valves
• Bearings
• Flanges
• Robotics
• Gears
• Couplings
• Machines
• Glass-lined reactors
• Clutches and drives

Seamless rolled rings are used in the following industries:

military, power generation, mining, rock crushing, gear drives and presses, oil field, jet engines, wind mills, helicopter gearboxes, and railways.

They are also excellent tensile and yielding properties for heavy machinery, gears and bearings.

Over 200 grades of stainless steel products can be forged. Rings are produced using a host of different types of materials, like carbon steel, alloy steel, stainless steel and tool steel, as well as a number of metal alloys.

Sizes vary and can be pre-cut into either round, hexagon, or flat bar shapes.

Stainless Steel Forging Industries:

Stainless steel is versatile. Below you&#;ll find the many perks and benefits of using this amazing material:

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1. High Corrosion Resistance: Resistant to exposure in environments like petrochemical
2. Durable: Strong, extremely durable, stainless steel can withstand frequent cleaning procedures and holds up well for uses such as food processing, service equipment, and medical devices.
3. Heat Resistant: Stainless steel is highly tolerant to heat and works well with furnaces systems and ovens.
4. High Performance: Works very well in a high-stress environment, whether in landing gears and fittings or connectors and motor components.