large diameter ring manufacturing | metal forming operations
TRANSCRIPT
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LARGE DIAMETER RING MANUFACTURING
TAREK GEDDAWI 84MOHAMED KHAMIS 128KARIM ESSAM 112MOHAMED ABDEL-MONEIM 141MOHAMED EMAD 146AHMED SAAD 21
MOHAMED SHERIF 126MOHAMED HASSAN 126MOHAMMED FOUAD 148MOHAMED MAHMOUD 153MOHAMED EMAD 147
PRESENTED TO: DR. MOHAMED A. DAHA
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PROCESS
• The Process of Manufacturing Large Rings Requires Two Main Forming Operations:
• Forging: Upset Forging/Punching
• Rolling: Ring Rolling Process
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FORGING
• Upset Forging: Inreases Work Piece Diameter by Compressing Length
• Producing The Ring Shape is Done Using Open Die Forging
• Punching: Creates Hole in Work Piece via Shearing
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Stock is First Rounded, Then Upset to Achieve Structural Integrity and Directional Grain Flow.
Stock is Pierced in Order to Achieve Preform Needed for Ring Rolling Process.
Completed Preform
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ROLLING
• The Preform is Heated to Forging Temperature, then Placed Between Two Rolls, One is Called the Idler Roll, while the Other is Called the Driven Roll.
• Pressure is Applied to The Wall by the Idler Roll
• The Cross Sectional Area is Reduced and the Inner and Outer Diameters are Expanded
• In Ring Rolling, Rolls are of Different Diameters.
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Ring Rolling Begins With Idler Roll Applying Pressure on Drive Roll.
Continuous Pressure Increases Ring Diameter. Axial Rolls Control Preform Height.
Process Continues Until Desired Size is Achieved.
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RING ROLLING
• Ring Rolling Produces Rings Varying in Size From a Few Inches to Over 8 Meters in Diameter and to About 3 Meters in Height.
• Equipment can be Fully Automated from Billet Handling through Post-Forge Handling.
• Advanced Ring Rolling Allowing for Excellent Weight Reduction, Material Saving and Reduced Machining Cost
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RING ROLLING
• The Rolls Can Be Shaped to Form Various Cross Sectional Shapes
• Rings Have Tangential Strength and Ductility, and Are Less Expensive Than Similar Closed Die Forgings
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RING ROLLING
• A Typical Ring Rolling Process has Two Sets of Rolls: Radial to Control Thickness and Axial to Control Width.
• During the Process, the Main Deformation Occurs Between the Driven (Main) Roll and the Idler (Mandrel) Roll.
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RING ROLLING
• As the Rolling Process Starts, the Idler roll applies pressure so the Cross Section of the Ring Continually Decreases and the Gap Between The Driven and Idler Roll Continually Decreases.
• As The Cross Section Decreases, The Diameter Increases due to Incompressability of The Material.
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APPLICATIONS
• Common Applications Include Roller and Ball Bearings, Turbines, Aerospace Applications, Pipes and Pressure Vessels.
• Titanium and Super Alloy Rings Are Used and Housing Parts for Jet Engines in the Aerospace Industry
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ADVANTAGES AND DISADVANTAGES
• Advantages:
• Uniform Quality
• Smooth Surface Finish
• Close Tolerance
• Short Production Time
• Relatively Small Material Loss
• Disadvantages:
• Ring Rolling is Poor in Filling the Roll Cavities
• Some Formed Rings Require Trueing and/Or Machining Operations to be Used.
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PRACTICAL CASE STUDY
• Rotek Inc. Manufactures Slewing Bearings Used In a Wide Range of Applications including: Wind Energy Turbines, Underwater Turbines and Solar Energy Plants.
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SERIES 6000 HIGH SPEED SLEWING RING
• High Speed Radial Ball Slewing Rings
• Specifications:
• Stamdard Models from 12’ to 180’ (Up to 4.5m)
• Capacities:
• Thrust: 1,000,000 lb
• Moment: 2,500,000 ft.lb
• Radial: 244,000 lb
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SERIES 6000 HIGH SPEED SLEWING RING
• Applications:
• Log-Debarking Machines
• Coil Winders
• Pay-Off Reels
• High-Speed Capstans
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REFERENCES
• http://thelibraryofmanufacturing.com/ring_rolling.html
• https://www.forging.org/system/files/field_document/UBETRingRolling.pdf
• http://thelibraryofmanufacturing.com/ring_rolling.html
• http://patent.ipexl.com/GB/877579ZZDASHZZA.html
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THANK YOU