The seamless rolled ring forging process offers an ideal combination of strength, toughness and fatigue resistance through contoured grain flow.
The seamless rolled ring forging process begins by cutting a desired material’s starting stock to size before rounding it on the open die presses. The rounded piece is then upset and then pierced to make a preform. The preform is a donut-shaped forging ready to be placed on a ring rolling mill. On the ring rolling mill, there are axial rolls which control the height of the ring and an idler roll to apply pressure to the ring against a drive roll. The pressure of these forces decreases the wall thickness and height of the rolled ring while increasing the ring’s diameter…until the right size is achieved. Ringmasters forge seamless rolled rings from virtually limitless combinations of sizes and grades available including carbon and alloy steels as well as stainless steels and other customer specific grades.
When acquiring metal rings for any application, issues can often be traced to the metal forming process. Cast rings are often plagued with poor strength and integrity. Rolled and welded or cut rings from plate are susceptible to fatigue, and carry excess material and processing costs. Custom forging performed by Ringmasters experts, however, allows greater versatility and improved quality while reducing material cost. Other benefits include:
The unidirectional grain flow inherent in hot rolled plate produces exposed grain ends when cutting the ring shape. This renders the material more liable to fatigue and more sensitive to stress corrosion cracking. The forging process shapes the material to the desired ring size so there is no need to remove excess corner stock or center holes. Additionally, material availability and plate size for large burnout plates may be difficult to obtain. Overall, forging allows greater size versatility while minimizing material waste, often reducing costs.
Cast rings typically do not have a desired grain structure. This greatly impacts the impact toughness, ductility and fatigue strength of the ring and can lead to a potential crack or fracture. Forging provides controlled directional grain flow or increased strength and offers superior structural integrity, eliminating inclusions and porosity commonly found in castings.
Fabricated rings are susceptible to porosity and inclusions in the material. Extensive welding on a rolled and welded ring reduces part integrity, jeopardizes corrosion resistance and may cause distortion of the ring's shape. With the absence of welding through the seamless rolled ring forging process, part integrity, corrosion resistance, and shape can be maintained…ultimately achieving a stronger ring while reducing risk of part fatigue and breakage.
With our commitment to strict ISO 9001:2015 quality standards, Ringmasters consistently achieves customer acceptance rates of over 99% on product quality.