LARGE DIAMETER PLANTS Meer. Forging rolls. RW/ARWS Series

Transcription

1 LARGE DIAMETER PLANTS Meer Forging rolls RW/ARWS Series

2 Committed to progress by tradition Forging rolls are characterized by their simple and clear construction. In everyday operation, this makes them highly reliable and constantly available machines. SMS group distinguishes between the manually operated machines of the RW series and the automatic ARWS plant. SMS group has supplied a total of over 900 forging rolls of all sizes, including around 25 percent as automatic plants. Ongoing development in their design and construction is today reflected in Higher output resulting from shorter cycle times Shorter setup times with quick-change systems for screwless rolling segment attachment WA change arm for easier rolling segment change, and change manipulator Programmable logic control for easier operation Exact standstill position monitoring and programmable cross transfer positioning 2

3 Applications and operation Forging rolls are used to produce a preform with a mass distribution very close to that of the blank that will subsequently be forged. The weight saved by reducing the flash ratio is just one of the numerous benefits for the user. Others include: Reduction in the necessary furnace capacity as a result of lower material input Improved surface quality of forged workpieces by descaling during rolling Die service life extended by optimized material distribution and descaling Improved grain flow in forgings Automatic forging rolls integrated in a forging line require no additional operator The high output of an automatic forging roll permits full use of downstream closed-die forging press capacity. 3

4 Construction and operation The forging roll comprises Frame with base plate Roll stand Countershaft with fl ywheel Clutch and brake Gear drive Top and bottom rolling cylinders with separate gear drive Automatic backlash compensation Automatic axial distance adjustment The fl ywheel is driven from the main motor by a belt drive. The top and bottom rolling cylinders turn when the clutch is engaged. When the operating sequence is complete, the coupling is disengaged and the brake applied. ARWS automatic forging roll AS automatic rocker arm transfer High capacity fl ywheel Length compensating cylinder Servo-electric cross transfer (programmable positioning) Crank rocker arm for AS drive Clutch with asbestos-free friction blocks Brake with water cooling and asbestosfree friction blocks Rolling cylinder drive with automatic backlash compensation Eccentric bearing of the bottom rolling cylinder for axial distance adjustment (optionally by electric motor) Feeder for transfer into the manipulator tongs 4

5 Process The forging roll reduces round or square starting materials in longitudinal direction to the required mass distribution. After the blank has been heated to forming temperature, it is first guided between the top and bottom rolling cylinders into a defined end position. The actual rolling process is then performed either manually or automatically. Positive or friction locking between the workpiece and the rolling segment ensure reliable transport of the workpiece during rolling cylinder rotation. The resulting rolled form is dependent on the shape of the rolling segments. The outer rolling cylinder journals on manually operated forging rolls can be used for additional ring-shaped rolling tools. 5

6 Automatic workpiece transfer The AS automatic rocker arm transfer is a longestablished and proven automation concept for RW 1 to RW 2a forging rolls. It makes it possible in many cases to reduce the number of personnel increase output improve quality and simplify operation. The top rolling cylinder drives a rocker arm fixed onto the crosshead. It transmits the rolling cylinder rotation into the linear motion of the tube carrying the tongs to guide the workpiece horizontally through the rolling gap. Rotation of the rolling cylinder is coupled to the linear transport to prevent damage to the tong tube holding the tongs by the rolling segments. The tong tube is telescopic to compensate elongation of the workpiece during rolling. A rotary cylinder on the tong tube turns the blank through 90 after every rolling pass. The servo-electrically driven cross transfer moves the workpiece from one rolling impression to the next. Positioning is programmable. Other automation concepts are also available, including automatic workpiece transfer by manipulator for the RWW 3 forging roll. This system is chiefly used in pre-rolling heavy crankshafts or axles. SMS group s product range also includes an automatic finish-rolling concept for ploughshares. 6

7 Cycle time example Prerolling passenger vehicle double connecting rods for forging makes it possible to achieve 100% output of up to 900 rods in four passes. Examples of pre-rolling on a forging roll: This equates to 1800 single connecting rods an hour and a cycle time of 4 seconds. A forging roll can also be used to preroll workpieces made of forgeable aluminium and titanium alloys. 7

8 SMS group GmbH Business Unit Forging Plants Closed-Die Forging Ohlerkirchweg Mönchengladbach Germany Phone: Fax: P-315E Published on Circulation 500 Printed in Germany KD The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.