Typical problems associated with metal rings can frequently
be traced to the metalforming process. A ring formed by the
casting process is often plagued with substandard strength
and integrity, while a ring cut from plate is susceptible
to fatigue and carries with it the price of the excess material.
In the cases below, these common problems were solved by switching
to the forging process.
Product/Application:
Previous Processing Problems:
Corrosion resistant profiled ring, 200" O.D. and 42"
face, for a submarine propulsor system
Material:
Nickel Aluminum Bronze
Three
different metalworking processes were attempted to
make one ring: a forging, a casting, and a rolled
and welded plate.
The cast ring failed
sonic requirements and had inclusion problems
which required excessive machining and weld
repair.
Extensive welding
on the fabricated ring reduced part integrity,
jeopardized corrosion resistance, and caused
distortion of the ring's shape.
Forging as the Solution:
A forged, profiled seamless
rolled ring produces unsurpassed structural integrity.
Overall strength is increased
through forging's directional grain flow.
With the absence of welding,
part integrity, corrosion resistance, and shape
are maintained.
Product/Application:
Previous Processing Problems:
Swing gear used for a mining
shovel
Material:
Alloy Steel
The part was previously produced as a cast ring, with high maintenance and repair costs.
The absence of grain
flow and directional strength caused part
integrity problems.
Gears were breaking
in the field due to fatigue failure, shortening
the service life of the product.
Forging as the Solution:
The designers turned to a rolled ring forging with a contoured I.D.
Forging yields improved
mechanical properties, reducing the risk of part
fatigue and breakage.
The continuous grain flow,
provided by the forging process, optimizes part
integrity and impact toughness.
Product/Application:
Previous Processing Problems:
Bearing application component
Material:
Alloy Steel
Ring Size:
95-7/8" O.D. X 40-5/8" I.D.
X 8-5/8" Thick
The
past production process involved torch cutting a
heavy wall ring from plate.
Excess
waste was substantial, since all corner
stock and the full center slug of the plate
were lost.
Desired plate sizes
and grades were sometimes difficult to obtain
due to ring thickness.
Parts were rejected
due to inclusions found on the polished
surface of the plate.
Forging as the Solution:
A custom forged rolled ring allows greater size
versatility while often-times reducing waste and
material costs.
Porosity, laminations,
and inclusions sometimes found in plate are eliminated
with forging.
A
copy of Successful Cases of Forged Rolled Rings is available
in pdf format.
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Successful Cases of Forged Rolled Rings
