November 2024 Volume 6

EQUIPMENT & TECHNOLOGY A SINGLE-SOURCE SOLUTION FOR RING MANUFACTURING

S chuler Group (Schuler) has made significant strides in supplying forgers with innovative ring roller systems. This article explores technological advance ments for ring rolling and the industry impact forgers can expect with Schuler’s single-source solutions. The Ring Rolling Process Ring rolling is a forming technique that produces rings without weld seams, resulting in high-strength, defect-free components. The process involves several stages: 1. Material Preparation: Sections, or "billets," are cut to size, heated, and sometimes descaled.

Schuler offers complete systems for the production of seamless rings.

2. Preforming: Quality requirements can require preforming to occur in a hydraulic press. 3. Rolling: The ring is rolled to achieve the desired geometry, diameter, and shape. 4. Heat Treatment: An optional process dependent on the final application. Schuler dived into ring rolling about 11 years ago due to customer demand and the company’s success in train-wheel manufacturing. Several successful projects led to Schuler’s ability to deliver complete turnkey ring roller systems that can be seamlessly integrated into existing production lines. Schuler’s systems can handle both multistage and single-stage processes, catering to different customer needs and applications, and are designed to enhance quality and efficiency. Schuler’s series of ring rollers, for rings or bushings, include diameters of 1.25-4 meters and 8 meters. Key Innovations Include: 1. Integrated Systems: Schuler’s complete turnkey lines include ring rollers, heating systems, automation equipment, and more. Schuler is a member of the international technology group, ANDRITZ, and ANDRITZ Metals provides high-quality industrial furnaces as part of these turnkey lines. 2. Advanced Machine Design: Schuler’s ring rollers feature a motorized idler roll that rotates even during downtime, cooling the die evenly on all sides and reducing stress. The design also eliminates the needs for a conventional idler-roll lifting device— reducing machine height and simplifying die changes that

normally take an entire shift to just a few minutes. 3. Enhanced Control Systems: All machines in the process are controlled by a unified system for comprehensive monitoring and operation from any control unit. Advancements in ring rolling technology represent a significant leap forward in the production of seamless rings. Rings produced by Schuler’s system solutions are known for their high strength and toughness, making them ideal for applications that require durability and reliability (e.g., wind turbines). The material-saving and cost-effi cient nature of the process also makes the technology impactful for various industries such as aerospace, automotive, energy, and more. Schuler’s comprehensive product portfolio of forging presses range from 3,200 kN to 360,000 kN and enable the best economic solu tions for quality parts. The company also offers hammers and counter blow hammers ranging from 12 kJ to 1,400 kJ. Schuler’s capabili ties extend further to process and operation development, dies, and automation systems. About Schuler North America—www.schulergroup.com Schuler North America (Schuler), headquartered in Canton, Michigan, is the North American subsidiary of Schuler Group. Schuler provides new equipment, spare parts, and a portfolio of lifecycle services for all press systems—including preventative maintenance, press shop design and optimization, turnkey installations, retrofits for existing systems, and localized production and service. Schuler’s best-in-class position in the metalworking and materials industry serves automotive manufac turers and tier suppliers, as well as battery, home appliance, electronics, forging, and other industries.

FIA MAGAZINE | NOVEMBER 2024 15