Ring Forging Services

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Understanding Ring Forging Techniques

Ring forging is typically executed in a heated setting, where the grooves of the rolls are intricately designed to shape the component to its specified dimensions.

The forging configuration for the rings utilized in the creation of metal components is only discernible on a small fraction of the ring's overall diameter. A mere segment of a complete circular rotation is essential to forge the intended workpiece.

In the industrial sector, the forging geometry present on the rings often occupies between one-quarter to three-quarters of the total circumference of the ring.

The Steps Involved in the Ring Forging Procedure

The first phase of the roll forging technique involves upsetting a billet, usually in the form of a cylinder. This upsetting process reshapes the workpiece by altering its diameter, height, and overall structure, effectively enlarging its cross-sectional area. High pressure is applied horizontally to the workpiece via a hydraulic press during this deformation process.

Utilizing upsetting dies, the workpiece is compacted while remaining at its plastic deformation temperature, allowing it to expand beyond the confines of the press. This is categorized as an open die method in which an upper and lower die compress the cylinder, and this can be executed either hot or cold. The upsetting process is key for maintaining the integrity of the grain structure, a common byproduct of forging.

In seamless rolled ring forging, the central portion of the workpiece must be extracted. This specific action is referred to by various terms, including punching. The outcome of this stage is a circular 'donut' shape.

Unlike conventional drilling, piercing does not bore through the workpiece; rather, a punch is utilized to substantially displace the metal, leaving a thin web at the base of the punched hole.

The piercing phase is finalized through shearing, which eliminates the metallic web at the base of the pierced aperture. Consequently, this yields a completed hole that extends through the entire workpiece, primed for the rolling ring forging procedure.

The piercing and shearing steps ensure that the hole created is adequately sized to fit over a mandrel, a blunt rod instrumental in shaping the donut hole. Mandrels are typically composed of steel or medium carbon steel. Before being positioned on the mandrel, the workpiece is heated to just below its recrystallization temperature.

The shaping process initiates as the prepared donut shape begins to rotate. The mandrel applies pressure to the inner surface of the donut during its rotation, forcing it against the primary roller. This interaction causes the diameter and walls of the workpiece to thin out.

As the mandrel and the main roller increase the diameter while thinning the walls, the axial rollers concurrently reduce the height of the cross-section of the workpiece. The rotation of the main roller and the mandrel, along with the functioning of the axial rollers, is a consistent and progressive action that safeguards the grain structure of the workpiece.

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The workpiece continues its rotation and transformation until achieving the desired specifications. This technique is termed seamless rolling ring forging because it does not involve cutting, welding, or traditional forging methods in the creation of the final product.

The item remains an unbroken single metal piece throughout the entire process.

Ring Forging Applications and Benefits

• Applications in Wind Energy

  Components produced from seamless rolling ring forging can be found in all aspects of wind turbine construction. They play a critical role in wind turbine design, as these parts are renowned for their accuracy, robustness, and durability, which are vital for ensuring optimal performance of wind turbines.

• Utilization in Automotive Engineering

  Multiple components within automobiles must endure significant stress and load, necessitating the employment of parts constructed from seamless rolled ring forging. Every vehicle, whether it’s a truck or a car, contains seamlessly forged pieces such as crankshafts, camshafts, clutches, braking systems, gears, and couplings. These high-quality components are capable of withstanding the routine wear, pressure, and strain of standard vehicle operation, while also being lightweight, versatile, and resilient to continuous torque.

Selecting the Right Ring Forging Manufacturer

To ensure a successful experience when sourcing ring forgings from a manufacturer, it is crucial to evaluate multiple companies utilizing our directory of ring forging suppliers. Each manufacturer’s profile provides insights into their expertise and capabilities, along with a contact form for direct communication to request more information or quotes. Leverage our patented website previewer to quickly comprehend each company’s specialization. Afterward, use our straightforward RFQ form to reach out to various ring forging manufacturers using a single inquiry.

As specialists operating within a custom forge shop, we seldom encounter two forgings that are identical. Here are some key checklist items to consider when obtaining a forging:

• Will you need heat treatment for your components?

• What specific testing requirements must be met?

• Do you need a quote for as-forged, rough machined, or finish machined items?

• Which specifications must your products adhere to for certification?

These inquiries only scratch the surface of what you might require from your forging. If you are unfamiliar with the procurement process or metal forming, the experience can often feel overwhelming.

For additional information, please consult High-performance copper forging.