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

PROCESS

• The Process of Manufacturing Large Rings Requires Two Main Forming Operations:

• Forging: Upset Forging/Punching

• Rolling: Ring Rolling Process

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

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

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.

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.

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

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

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.

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.

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

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.

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.

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

SERIES 6000 HIGH SPEED SLEWING RING

• Applications:

• Log-Debarking Machines

• Coil Winders

• Pay-Off Reels

• High-Speed Capstans

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

THANK YOU