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:
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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.
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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.
The ring rolling process starts with a circular preform of metal that has been previously upset and pierced (using the open die forging process) to form a hollow “doughnut.” This doughnut is heated above the recrystallization temperature and placed over the idler or mandrel roll. This idler roll then moves under pressure toward a drive roll that continuously rotates to reduce the wall thickness, thereby increasing the diameters (I.D. and O.D.) of the resulting ring.
Seamless rolled rings can be produced in configurations ranging from flat, washer-like parts to tall, cylindrical shapes, with heights ranging from less than an inch to more than 9 feet. Wall thickness to height ratios of rings typically range from 1:16 up to 16:1, although greater proportions can be achieved with special processing. The simplest and most commonly used shape is a rectangular cross-section ring, but shaped tooling can be used to produce seamless rolled rings in complex, custom shapes with contours on the inside and/or outside diameters.
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