Seamless Rolled Ring Forging is one of xem truc tiep bong da toc do cao key processes for manufacturing high-strength, high-precision annular structural parts, and is widely used in aerospace, energy, military, chemical, rail and other engineering fields. Compared with cast or welded rings, seamless rings have better structural density, mechanical properties and dimensional stability, and are xem truc tiep bong da toc do cao preferred material form for many high-end structures.
This article will systematically introduce xem truc tiep bong da toc do cao manufacturing process, process path and forming method of seamless rolled ring forgings to help you deeply understand its core advantages and accurately meet actual application needs.
What is Rolling Ring Forging?
Ring forging is a metalworking technique that begins by forging a circular preformed piece of metal. This initial piece is first upset and then punched to form a donut-like shape, also known as a torus. It is then heated to a temperature above its recrystallization point and placed on a mandrel or idler.
xem truc tiep bong da toc do cao idler pulley guides xem truc tiep bong da toc do cao perforated ring structure to xem truc tiep bong da toc do cao drive roller, which continuously rotates to reduce xem truc tiep bong da toc do cao wall thickness of xem truc tiep bong da toc do cao ring body while uniformly expanding its inner and outer diameters. This process ultimately produces a product called a seamless rolled ring.
xem truc tiep bong da toc do cao roll ring forging method can produce seamless metal rings of various sizes, which are ideal for machine tools, turbines, pipes and pressure vessels. This technology greatly improves xem truc tiep bong da toc do cao mechanical properties of xem truc tiep bong da toc do cao forged metal and maintains its grain structure.
Standard manufacturing process for seamless rolled rings
xem truc tiep bong da toc do cao manufacturing of seamless rings is not a simple rolling operation, but a rigorous process system covering multiple high-temperature deformations, structural adjustments and precision machining. Chalco adopts an integrated path of "free forging + CNC ring rolling", supplemented by heat treatment, processing and quality control systems, to complete xem truc tiep bong da toc do cao closed-loop manufacturing from raw materials to finished products. xem truc tiep bong da toc do cao following is a detailed explanation of Chalco's standardized manufacturing process:
Raw material preparation
We use high-purity aluminum, titanium, and steel ingots, cut them to specific lengths based on process requirements, and manage them with unified numbers to enable traceability.
Free forging blank - roughing
xem truc tiep bong da toc do cao initial stage of xem truc tiep bong da toc do cao rolled ring forging process involves taking a blank (usually cylindrical) and subjecting it to an upset operation. Upset forging prepares xem truc tiep bong da toc do cao workpiece by deforming it to xem truc tiep bong da toc do cao desired diameter, height and shape, thereby increasing its cross-sectional area. This deformation is achieved by applying a large horizontal pressure through a hydraulic press, which forces xem truc tiep bong da toc do cao workpiece to expand along its length axis.
During upsetting, xem truc tiep bong da toc do cao die compresses xem truc tiep bong da toc do cao workpiece beyond xem truc tiep bong da toc do cao limits of xem truc tiep bong da toc do cao press while it is at its plastic deformation temperature. This open die process involves pressing a cylindrical body between upper and lower dies and can be hot or cold.
Heating a workpiece for upsetting causes a change in xem truc tiep bong da toc do cao metal's grain structure because heating affects xem truc tiep bong da toc do cao metal's crystallographic phase. When heated past xem truc tiep bong da toc do cao austenite phase, xem truc tiep bong da toc do cao metal changes from a body-centered cubic lattice to a face-centered cubic lattice. In xem truc tiep bong da toc do cao austenite phase, xem truc tiep bong da toc do cao metal becomes soft and ductile, making it easy to form.
Upset forging is a common forging method that can be used to quickly and efficiently form multiple workpieces. Upset forging is a method used to form bolt heads during xem truc tiep bong da toc do cao cold forging process. An upsetting machine has a punch that moves horizontally against xem truc tiep bong da toc do cao workpiece. xem truc tiep bong da toc do cao result of xem truc tiep bong da toc do cao horizontal stroke is an increase in xem truc tiep bong da toc do cao volume and shape of xem truc tiep bong da toc do cao workpiece.
Piercing – forming a ring shape
During xem truc tiep bong da toc do cao seamless rolled ring forging process, xem truc tiep bong da toc do cao center of xem truc tiep bong da toc do cao workpiece needs to be removed. This step is referred to by various terms such as punching or shearing and involves creating a hole in xem truc tiep bong da toc do cao middle of xem truc tiep bong da toc do cao workpiece. xem truc tiep bong da toc do cao spacing between xem truc tiep bong da toc do cao die and xem truc tiep bong da toc do cao punch is determined by xem truc tiep bong da toc do cao thickness and strength of xem truc tiep bong da toc do cao workpiece, which also affects xem truc tiep bong da toc do cao load or pressure applied to xem truc tiep bong da toc do cao tool cutting edge.
xem truc tiep bong da toc do cao piercing process produces a circular, annular workpiece. Unlike drilling, piercing does not cut into xem truc tiep bong da toc do cao workpiece, but rather creates an opening by pushing a punch, which deforms xem truc tiep bong da toc do cao metal radically, leaving a thin web at xem truc tiep bong da toc do cao bottom of xem truc tiep bong da toc do cao hole. This is classified as a forging technique because it involves deformation, rather than drilling or grinding xem truc tiep bong da toc do cao surface.
There are several types of piercing processes, including slitting, skiving, cutting off, and slicing off. To prepare xem truc tiep bong da toc do cao workpiece for rolled ring forging, xem truc tiep bong da toc do cao method used is called punching because it involves punching through xem truc tiep bong da toc do cao center of xem truc tiep bong da toc do cao blank. xem truc tiep bong da toc do cao removed portion is considered scrap and can be reused to make additional blanks.
xem truc tiep bong da toc do cao shape of xem truc tiep bong da toc do cao workpiece after punching is similar to a "donut", which is xem truc tiep bong da toc do cao basic prototype of a seamless ring.
Shearing – removing xem truc tiep bong da toc do cao bottom web residue
Shearing, in addition to being used in ring forging, is also used to trim and remove unwanted metal parts in preparation for further processing. This cold working method uses various tools. In ring forging, xem truc tiep bong da toc do cao punch is used as a shearing tool to complete xem truc tiep bong da toc do cao piercing process by removing xem truc tiep bong da toc do cao web at xem truc tiep bong da toc do cao bottom of xem truc tiep bong da toc do cao hole.
In order for xem truc tiep bong da toc do cao workpiece or ring to fit perfectly onto xem truc tiep bong da toc do cao mandrel or idler, its inner surface must be smooth and free of any obstructions. xem truc tiep bong da toc do cao shearing tool moves along xem truc tiep bong da toc do cao length of xem truc tiep bong da toc do cao pierced hole and removes xem truc tiep bong da toc do cao bottom web in one go. This creates a complete hole, ready for xem truc tiep bong da toc do cao workpiece for xem truc tiep bong da toc do cao roll ring forging process.
Mandrel and preheating
xem truc tiep bong da toc do cao piercing and shearing process creates a hole in xem truc tiep bong da toc do cao workpiece so that it can be placed on a mandrel, a blunt rod that is used to shape xem truc tiep bong da toc do cao annular hole. xem truc tiep bong da toc do cao mandrel, also called a saddle or idler, is usually made of steel or medium carbon steel and has xem truc tiep bong da toc do cao strength and durability required to apply xem truc tiep bong da toc do cao necessary force and withstand xem truc tiep bong da toc do cao stress of xem truc tiep bong da toc do cao workpiece compression.
xem truc tiep bong da toc do cao workpiece is heated to a temperature slightly below its recrystallization temperature before being placed on xem truc tiep bong da toc do cao mandrel. It is then rotated in incremental steps to forge xem truc tiep bong da toc do cao ring to its final size and shape. xem truc tiep bong da toc do cao mandrel, saddle, or idler presses xem truc tiep bong da toc do cao annular workpiece against xem truc tiep bong da toc do cao drive rolls, increasing its inner and outer diameters to xem truc tiep bong da toc do cao desired final dimensions.
Main roll and ring rolling (core step)
xem truc tiep bong da toc do cao forming process begins with xem truc tiep bong da toc do cao gradual, progressive rotation of xem truc tiep bong da toc do cao preformed donut shape by xem truc tiep bong da toc do cao main rollers. As xem truc tiep bong da toc do cao donut rotates, xem truc tiep bong da toc do cao mandrel presses on its inside, pushing it against xem truc tiep bong da toc do cao main rollers. This combined rotation and pressure expands both xem truc tiep bong da toc do cao inside and outside diameter of xem truc tiep bong da toc do cao workpiece while thinning xem truc tiep bong da toc do cao wall.
In xem truc tiep bong da toc do cao picture below, you can see xem truc tiep bong da toc do cao main rollers to xem truc tiep bong da toc do cao left of xem truc tiep bong da toc do cao yellow workpiece and xem truc tiep bong da toc do cao mandrel to xem truc tiep bong da toc do cao right of xem truc tiep bong da toc do cao main rollers inside xem truc tiep bong da toc do cao workpiece. xem truc tiep bong da toc do cao mandrel presses xem truc tiep bong da toc do cao ring of xem truc tiep bong da toc do cao workpiece against xem truc tiep bong da toc do cao main rollers. This process is done slowly and with high precision to achieve xem truc tiep bong da toc do cao correct size and shape.
Axial roller
xem truc tiep bong da toc do cao mandrel and main rollers increase xem truc tiep bong da toc do cao diameter of xem truc tiep bong da toc do cao workpiece and reduce xem truc tiep bong da toc do cao wall thickness, while xem truc tiep bong da toc do cao axial rollers reduce xem truc tiep bong da toc do cao height of xem truc tiep bong da toc do cao cross-sectional area of xem truc tiep bong da toc do cao workpiece. xem truc tiep bong da toc do cao main rollers and mandrels provide a continuous, gradual rotation of xem truc tiep bong da toc do cao workpiece, which combined with xem truc tiep bong da toc do cao movement of xem truc tiep bong da toc do cao axial rollers ensures that xem truc tiep bong da toc do cao workpiece retains its grain structure.
Axial rollers are tapered rollers mounted horizontally opposite xem truc tiep bong da toc do cao mandrel and main rollers, which are displaced vertically. Their function is to compress and adjust xem truc tiep bong da toc do cao height of xem truc tiep bong da toc do cao workpiece as it slowly rotates between xem truc tiep bong da toc do cao idler and main rollers. xem truc tiep bong da toc do cao combined motion of xem truc tiep bong da toc do cao idler and axial rollers shapes xem truc tiep bong da toc do cao cross section of xem truc tiep bong da toc do cao workpiece into xem truc tiep bong da toc do cao desired shape.
Complete rotation
xem truc tiep bong da toc do cao process of turning and forming xem truc tiep bong da toc do cao workpiece continues until xem truc tiep bong da toc do cao final dimensions are reached. This process, called seamless ring forging, involves forming xem truc tiep bong da toc do cao metal without cutting, welding or further forging. Throughout xem truc tiep bong da toc do cao process, xem truc tiep bong da toc do cao workpiece remains a solid, uninterrupted metal part.
Heat treatment and tempering
Standard heat treatments such as T6, T651, annealing, quenching and tempering, solution + aging can be performed to improve mechanical properties and release residual stress.
Rough/finishing and structural preparation
It includes vertical/horizontal turning, drilling, chamfering, keyway and other processing to control dimensional tolerance and improve assembly adaptability.
Inspection and delivery
All workpieces support UT flaw detection, metallographic analysis, dimension measurement, mechanical property testing, and provide third-party inspection reports.
Types and comparison of ring rolling forming methods
xem truc tiep bong da toc do cao ring rolling process, as xem truc tiep bong da toc do cao core and decisive step in xem truc tiep bong da toc do cao manufacturing process of seamless rings, largely determines xem truc tiep bong da toc do cao dimensional accuracy, organizational streamline and mechanical properties of xem truc tiep bong da toc do cao product.
Although xem truc tiep bong da toc do cao overall manufacturing process is basically xem truc tiep bong da toc do cao same, Chalco can provide a variety of ring rolling process paths according to specific application requirements to adapt to different structures, load levels and precision control requirements. xem truc tiep bong da toc do cao main methods include:
| Forming method | Deformation Control | Features | Applicable product types |
| Radial rolling | Wall thickness control | Simple structure and fast processing | Medium size rings, normal load parts |
| Radial-axial composite rolling | Wall thickness + height | Control thickness and height simultaneously with high precision | High-end aviation and military parts |
| Vertical Ring Rolling | Multi-directional controlled | Suitable for heavy/direction-restricted parts | Large diameter, thick wall, heavy duty structural ring |
| Horizontal Rolling Ring Forming | Radial main control + auxiliary axial | Strong versatility, easy operation, and adaptable to various specifications | General structural parts, medium strength annular components |
Each rolling method deforms xem truc tiep bong da toc do cao workpiece in a specific way, resulting in a unique shape and grain structure. In addition, these methods are suitable for producing a variety of annular profiles, including flanges, pulleys and anti-friction rings. Chalco mainly adopts radial-axial composite forming solutions and is equipped with a closed-loop CNC system to ensure full dimensional consistency of inner and outer diameters, wall thickness and height.
Radial rolled ring forgings
Radial Rolled Ring Forging, also known as Hot Radial Rolled Ring (HRRR) Forging, is a method used to manufacture medium-sized bearing rings. In this process, xem truc tiep bong da toc do cao main rolls of xem truc tiep bong da toc do cao HRRR mill provide rotation and linear feed, while xem truc tiep bong da toc do cao mandrel facilitates passive rotation. xem truc tiep bong da toc do cao guide roll is located on xem truc tiep bong da toc do cao exit side of xem truc tiep bong da toc do cao main rolls and xem truc tiep bong da toc do cao signal roll is located on xem truc tiep bong da toc do cao other side. xem truc tiep bong da toc do cao process ends when xem truc tiep bong da toc do cao outer diameter of xem truc tiep bong da toc do cao ring contacts xem truc tiep bong da toc do cao guide roll.
During xem truc tiep bong da toc do cao entire rolling process, xem truc tiep bong da toc do cao ring wall is compressed radially, causing xem truc tiep bong da toc do cao metal to expand tangentially. xem truc tiep bong da toc do cao metal is not restricted in xem truc tiep bong da toc do cao axial direction by xem truc tiep bong da toc do cao rolls. This method is particularly effective for producing rectangular cross-sections, groove shapes and cross-shaped rings.
Radial-axial composite rolling
Radial axial ring rolling is xem truc tiep bong da toc do cao classic form of ring roll forming. As xem truc tiep bong da toc do cao mandrel squeezes xem truc tiep bong da toc do cao workpiece, xem truc tiep bong da toc do cao main roll rotates and idles due to xem truc tiep bong da toc do cao friction of xem truc tiep bong da toc do cao contact surface. xem truc tiep bong da toc do cao axial rolls rotate at xem truc tiep bong da toc do cao opposite speed and retract as xem truc tiep bong da toc do cao ring diameter increases. As xem truc tiep bong da toc do cao diameter increases, xem truc tiep bong da toc do cao upper tapered axial roll slides axially toward xem truc tiep bong da toc do cao lower one, causing xem truc tiep bong da toc do cao height of xem truc tiep bong da toc do cao ring to decrease. xem truc tiep bong da toc do cao guide roll contacts xem truc tiep bong da toc do cao outer diameter of xem truc tiep bong da toc do cao ring to maintain its round shape.
xem truc tiep bong da toc do cao radial-axial rolling ring forging process requires precise control of all three sets of rolls to ensure xem truc tiep bong da toc do cao quality and performance of xem truc tiep bong da toc do cao final product. This control is achieved through a closed-loop system that utilizes a single-point laser ranging tool for precise monitoring and adjustment.
Vertical ring forging
xem truc tiep bong da toc do cao traditional method of ring forming is usually carried out on a horizontal ring forging machine equipped with radial and axial ring rolling mills. xem truc tiep bong da toc do cao vertical version of this machine has two main rolls, a mandrel and several restraining rolls. xem truc tiep bong da toc do cao axes of xem truc tiep bong da toc do cao main rolls are inclined at an angle of 20 to 30 degrees to xem truc tiep bong da toc do cao horizontal and are driven by electric motors. xem truc tiep bong da toc do cao mandrel is driven by xem truc tiep bong da toc do cao idle rotation of xem truc tiep bong da toc do cao ring being formed and is mounted on a lifting frame that is raised by a hydraulic control to press xem truc tiep bong da toc do cao ring. xem truc tiep bong da toc do cao position of xem truc tiep bong da toc do cao restraining rolls is carefully designed to conform to xem truc tiep bong da toc do cao diameter of xem truc tiep bong da toc do cao ring and ensure its roundness.
Horizontal rolling ring forming
Horizontal roll ring forming is xem truc tiep bong da toc do cao most traditional and widely used method. In this process, xem truc tiep bong da toc do cao workpiece is moved radially and a mandrel is placed on xem truc tiep bong da toc do cao inside of xem truc tiep bong da toc do cao ring to press against xem truc tiep bong da toc do cao ring wall. Axial rollers located on xem truc tiep bong da toc do cao upper and lower part or top and bottom of xem truc tiep bong da toc do cao ring control its height. Centering rollers help maintain xem truc tiep bong da toc do cao smoothness and roundness of xem truc tiep bong da toc do cao ring, operating as idler rollers driven by xem truc tiep bong da toc do cao movement of xem truc tiep bong da toc do cao forged ring.
Why choose Seamless Rolled Ring Forging?
Compared with castings, welded rings, and rolled plate cuttings, seamless ring forgings have xem truc tiep bong da toc do cao following advantages:
- xem truc tiep bong da toc do cao grains flow naturally in xem truc tiep bong da toc do cao circumferential direction, greatly improving xem truc tiep bong da toc do cao fatigue life
- No weld structure to avoid leakage, breakage and welding stress concentration
- High strength-to-lightweight ratio, meeting xem truc tiep bong da toc do cao lightweight requirements of various high-end structures
- High material utilization rate, reduced waste, and xem truc tiep bong da toc do cao yield rate can reach more than 80%
- A variety of alloy and size combinations can be quickly customized with strong adaptability
Chalco seamless rolled ring related products recommended
In order to quickly match your current project needs, Chalco simultaneously provides xem truc tiep bong da toc do cao following ring products and derivative structural parts, supporting internal link expansion and customization instructions:
- Aluminum alloy seamless rolled rings: provide high-strength aluminum materials (such as 6061, 7075, 2219, etc.), widely used in aviation, rail transit and equipment manufacturing
- Titanium alloy seamless rolled rings: suitable for high temperature, high strength, corrosion resistance applications, supporting typical models such as TC4, TA2, TC11, etc.
- Steel seamless rolled rings: low alloy steel, stainless steel, high strength structural steel, etc., used in xem truc tiep bong da toc do cao fields of petroleum, nuclear power, pressure vessels, etc.
- Forged flange: used for high-pressure connection parts, with stable structure and strong impact resistance
- Forged pipe fittings: used in conjunction with pipeline systems, with pressure adaptability and size controllability
- Forged ring/special-shaped ring: flange + keyway + bevel + asymmetric structure composite processing can be carried out according to xem truc tiep bong da toc do cao drawing
Summary: submit drawings and start engineering supporting cooperation
Chalco has a complete material system, ring rolling equipment, heat treatment platform and quality control mechanism. It is your long-term partner for seamless rings in projects such as aviation structures, energy engineering, and heavy equipment manufacturing.
You are welcome to submit your drawings and requirements via email, online form or phone. We will provide xem truc tiep bong da toc do cao most suitable material recommendations and processing solutions.