Forging is a process of metal processing that gives optimum results in regards to quality and cost efficiency. It is especially suitable for industries involving critical technology and need for specialized forging products.
The processes that forging utilizes are open die forging, impression die forging, ring-rolling, extrusion, piercing and secondary processes. All these processes involve plastic deformation to shape the metal. The temperature used for these pressures varies greatly. Depending on the requirement of the finished products, forgings can use cold, warm, or hot metal. Forging is drastically different from casting as the metal is never fully melted and poured into a die; instead, exertion of pressure is used to shape metal.
In ring rolling, a ring of small diameter is rolled into a ring of a diameter enlarged according to requirement having a decreased cross section. For executing this process, a driven and an idle roller is used on either side of the cross-section of the ring. To ensure a constant width throughout the operation, edging rollers are generally used. The finished product will have almost the same volume, meaning that wastage of raw material is minimal. The reduction in thickness is compensated by the increase in diameter. Rings produced by this method are called seamless. In addition to flat rings, this process can be used to produce rings with customized cross sections.
Some Benefits of Ring Rolling Process:
- As compared to plate products, ring rolled products use almost 66% less material. Therefore, there is a significant scope of economic savings.
- The time taken to finish a product by the ring rolled process is very less. Therefore, more products can be produced in less time, resulting in less manpower, more savings and more profits.
There are visibly no tooling charges.
- Easily controlled grain flow leads to the resulting products being superior in structural strength and impact. This happens because forging processes can include drawing out or squeezing metal to increase length and decrease cross-section or decrease length and increase cross-section.
- The most important benefit of this process is the incredible capabilities that the forging process gives its products. Especially in the industries related to power generation, all forging products be it end rings or specialty bearings prove an important asset. Other industries that have critical applications of forging products are mining, heavy equipment, and aerospace. The availability of forging products in nonferrous alloys of aluminum, copper, titanium, and nickel is important for these industries.
Some examples of ring rolled products are machinery rings, turbines, rollers, ball bearing races, and pressure vessels. Forging products impart a greater quality to whatever machinery or operation it is utilized in.
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