Understanding your choice of forged rings options
In industrial applications, forged rings are essential for many different types of machinery. These rings are used in everything from power generation equipment to aerospace components, and they come in a wide range of sizes and materials. If you are in the market for forged rings, it is important to understand the different solutions available to make an informed decision. In this article, we will explore the various solutions for forged rings and help you choose the best one for your needs.
When choosing a forged ring solution, several factors must be considered, including the application, the material, and the cost. If you need a ring that can withstand high stress and extreme temperatures, an upset forged ring may be the best choice. A machined forged ring may be the way to go if you need a strong and reliable ring that requires a smooth finish. And if you need a strong and durable ring that doesn’t require the same level of precision as the other two solutions, a seamless rolled ring may be the best option.
In addition to considering the type of forged ring, you should also consider the material it is made from. Different metals have different properties; some are better suited for certain applications. For example, stainless steel is often used in applications where corrosion resistance is important, while titanium is used in aerospace applications because of its high strength-to-weight ratio.
Finally, the cost is always a factor when choosing a forged ring solution. While the upfront cost of a machined forged ring may be higher than a seamless rolled ring, the precision and finish of the machined ring may make it a better long-term investment. It is important to weigh the cost against the benefits of each solution to determine the best choice for your needs.
What are forged rings?
Forged rings are circular forgings that apply external force to metal billets and shape them into suitable compression forces through plastic deformation requirements. This force is typically achieved through the use of a hammer or pressure. The forging process builds exquisite particle structures and improves the physical properties of the metal.
Materials Used in Forged Rings
Forged rings can be made from various materials, each with unique properties suited for specific applications. Some common materials include:
|Titanium forged rings||ASTM B381 / ASME SB381, Titanium Gr. 1, Titanium Gr. 2, Titanium Gr. 4, Titanium Gr. 5, Titanium Gr. 7, ASTM R50250/GR.1| R50400/GR.2 | R50550/GR.3 | R50700/GR.4 | GR.6 |R52400/GR.7 | R53400/GR.12 | R56320/GR.9 |R56400/GR.5|
|Copper forged rings||T1, T2, C10100, C10200, C10300, C10400, C10500, C10700, C10800, C10910,C10920, TP1, TP2, C10930, C11000, C11300, C11400, C11500, C11600, C12000,C12200, C12300, TU1, TU2, C12500, C14200, C14420, C14500, C14510, C14520, C14530, C17200, C19200, C21000, C23000, C26000, C27000, C27400, C28000, C33000, C33200, C37000, C44300, C44400, C44500, C60800, C63020, C68700, C70400, C70600, C70620, C71000, C71500, C71520, C71640, etc|
|Copper Nickel forged rings||ASTM / ASME SB 61 / 62 / 151 / 152, Copper Nickel 90/10 (C70600 ), Cupro Nickel 70/30 (C71500), UNS C71640|
|Carbon Steel forged rings||ASTM/ASME A/SA105 A/SA105N & A/SA216-WCB, DIN 1.0402, DIN 1.0460, DIN 1.0619, Die Steel, ASTM A105 / ASME SA105, A105N, ASTM A350 LF2 / ASME SA350, High Yield CS ASTM A694 / A694 (F52 F56 F60 F65 F70 F80)|
|Stainless Steel forged rings||ASTM/ASME A/SA182 F304, F304L, F316, F316L, ASTM/ASME A/SA351 CF8, CF3, CF8M, CF3M, DIN 1.4301, DIN 1.4306, DIN 1.4401, DIN 1.4404, DIN 1.4308, DIN 1.4408, DIN 1.4306, DIN 1.4409|
|Alloy Steel forged rings||ASTM A182 / ASME SA182 F5, F9, F11, F12, F22, F91|
|Hastelloy forged rings||ASTM B564 / ASME SB564, Hastelloy C276 (UNS N10276), C22 (UNS N06022), C4, C2000, B2, B3, X|
|Brass forged rings||3602 / 2604 / H59 / H62 / etc.|
|Inconel forged rings||ASTM B564 / ASME SB564, Inconel 600, 601, 625, 718, 783, 690, x750|
|Monel forged rings||ASTM B564 / ASME SB564, Monel 400 (UNS No. N04400), Monel 500 (UNS No. N05500)|
|Duplex forged rings||S31803 / S32205 A182 Gr F51 / F52 / F53 / F54 / F55 / F57 / F59 / F60 / F61|
|Super Duplex forged rings||S32750 / S32760 A182 Gr F51 / F52 / F53 / F54 / F55 / F57 / F59 / F60 / F61|
|Alloy 20 forged rings||ASTM B462 / ASME SB462, Carpenter 20 Alloy, Alloy 20Cb-3|
|Aluminium forged rings||5052 /6061/ 6063 / 2017 / 7075 / etc.|
|Nickel forged rings||ASTM B564 / ASME SB564, Nickel 200, Nickel 201, Nickel 205, Nickel 205LC|
|Nimonic forged rings||Nimonic 75, Nimonic 80A, Nimonic 90|
|Other forged ringsmaterial||Tin bronze, Alumunum bronze, Lead bronze|
|Incoloy forged rings||ASTM B564 / ASME SB564, Incoloy 800, 800H, 800HT (UNS N08800), 825 (UNS N08825), 925|
|254 Smo forged rings||ASTM A182 / ASME SA182, SMO 254/6Mo, UNS S31254, DIN 1.4547|
Dimensions of Forged Rings
The dimensions of forged rings play a critical role in determining their performance and compatibility with other components. Here, we discuss the key dimensional factors you need to consider when selecting forged rings:
Outer Diameter (OD): The outer diameter is the measurement from one end of the ring to the other, passing through the center. It is a crucial parameter for determining the ring’s overall size and load-carrying capacity.
Inner Diameter (ID): The inner diameter measures the space within the ring. It is essential for ensuring a precise fit with other components in an assembly.
Thickness (T): The thickness of a forged ring refers to the measurement between the inner and outer diameter surfaces. It directly impacts the strength, weight, and durability of the ring.
Cross-Sectional Area (CSA): The cross-sectional area measures the material in a specific ring section. It is vital in determining the ring’s mechanical properties, such as tensile strength and fatigue resistance.
Height (H): A forged ring’s height is measured from the bottom to the top surface. It influences the ring’s overall size, weight, and stability in an assembly.
The Forging Process of Forged Rings
The forging process of forged rings, from blanking to packaging and delivery. Understanding these processes will give you insights into the precision, dedication, and expertise required to create high-quality forged rings.
Blanking → Heating (including tempering) → Forging → Rough turning → Solution treatment → Pre strengthening precision machining → Cold deformation hydraulic bulging strengthening → Residual stress relief heat treatment → Physical and chemical testing → Nondestructive testing after finishing → Packaging and delivery
1. Blanking: The First Step in Forged Ring Production
Blanking is the initial step in the forging process of forged rings. It involves cutting a piece of metal, often called a “blank,” to the desired size and shape. The required final dimensions of the forged ring determine the blank’s dimensions. This process ensures the material is accurately sized, reducing waste and ensuring an efficient forging process.
2. Heating and Tempering: Preparing the Metal for Forging
Before the actual forging process can begin, the metal blank must be heated to a specific temperature, making it more malleable and easier to shape. This process, known as heating, is done in a furnace that can reach temperatures between 1,100°C and 1,200°C (2,012°F and 2,192°F). The metal is heated until it reaches its optimal forging temperature.
Tempering is an essential process that occurs after heating. It involves controlled cooling of the heated metal, which helps to reduce its internal stresses and improve its overall strength and toughness. This process ensures that the forged ring will have the desired mechanical properties and can withstand the pressures and forces it will face during its service life.
3. Forging of Forged Rings: Shaping the Metal
The steel ingot is heated to around 1150-1240 ℃ and removed from the heating furnace. Then, the operator places it into an air hammer or an electro-hydraulic hammer. According to the steel ingot’s size and forging ratio requirements, corresponding processes such as pier thickness and elongation are carried out, and the forging size is monitored in real-time. An infrared thermometer controls the forging temperature.
The forging difficulty of large ring forgings is much greater than that of ordinary ones. The commonly used forging processes in producing large ring forgings include extrusion, punching, core shaft expansion, elongation, and closing forging.
First of all, let’s talk about punching. Punching is the process of pressing a punch into a roughened disc to form a central hole at the center of the billet. Through holes can be formed by punching the entire section with a solid or hollow punch. Punching can be completed using a solid punch for relatively unimportant large circular forgings. Hollow punches should be used for relatively important large ring forgings to ensure that the center of the segregated forging is punched out, thereby reducing the defect rate of large ring forgings.
Next, let’s talk about expanding the core shaft. When expanding the core shaft, the size of the hole diameter and outer diameter of the ring forging can be increased to the desired value while the length remains unchanged. The typical hollow large annular forgings produced by expanding the core shaft mainly include high-pressure vessels, retaining rings, gear rings, and boiler barrels.
Next, let’s talk about mandrel elongation. Mandrel elongation is inserting a mandrel into a hole in forging and placing it on a lower V-shaped anvil to forge a circular forging. During forging, the wall thickness and outer diameter of the circular forging continue to decrease, and the length continues to increase, but the size of the central hole remains unchanged. Typical forgings forged using the mandrel elongation process mainly include cylindrical forgings, flange plates, and some high-pressure vessels.
4. Expanding ring
Use the ring expanding tool to expand the central hole of the billet mentioned above until the thickness and diameter of the central hole of the annular casting billet meet the requirements, that are, meet the size requirements of the forging ring. Specifically, first use a smaller diameter core rod to expand the ring, then use a larger core rod to expand the ring. After one heat, if it is not flat, the radial height of the circular ingot blank can be increased accordingly until it is flat.
The difference in compression deformation direction of ring-shaped parts during the rolling process can be divided into two methods: radial rolling and radial and axial rolling.
1) Radial rolling. The ring wall is compressed radially during the rolling process, and the metal extends along the tangent direction. Even if the rolling roller does not limit the axial direction, the width of the ring wall is still very small. The radial rolling process mainly applies to rectangular sections, groove sections, and ten square section rings. The construction used in this process is simple, and due to the surface deformation characteristics of metal deformation, there are pits on the end face of the ring forging.
2) Radial and axial rolling. Radial rolling is a ring rolling process in which end face rollers are added to the base of radial rolling to cause axial deformation. It uses a pair of radial rollers and an axial roller to roll the wall thickness and height of the ring. The rolled circular ring has a flat end face, and the number of mold changes is small, greatly saving the mold. This process mainly applies to circular forgings with larger wall thicknesses or complex planting surfaces.
Due to the differences in groove forms on the expanding machine, the rolling process can be divided into two types: open rolling and closed rolling.
- 1) Open rolling. Open rolling accepts flat rollers and is mainly used for expanding holes in large rectangular sections of circular parts. Its advantage is that different sizes of rings can be rolled using the same pair of rollers. To avoid widening caused by uneven deformation, two pairs of free-rotating conical forgings can be added to the expanding machine to obtain a certain size of the billet in height. This environment can also be called semi-open rolling.
2) Closed rolling. The closed rolling roller groove is designed according to the requirements of the workpiece section style and can be used for the expansion forming of various circular parts with different sections.
3) The differences in applied rolling construction can be divided into vertical rolling and horizontal rolling.
5. Rough Turning of Forged Rings: Refining the Shape
After the forging process, the forged ring must undergo a rough turning process. This step involves removing excess material from the ring’s outer and inner surfaces, ensuring it meets the required dimensions and tolerances. The rough turning process is typically carried out using a lathe or a similar machine, allowing for precise control and accuracy.
6. Solid Solution Treatment of Forged Rings: Enhancing the Microstructure
Solid solution treatment is a vital step in the forging process, as it helps to improve the metal’s microstructure and overall properties. This heat treatment process involves heating the forged ring to a specific temperature and holding it at that temperature for an extended period. Afterward, the metal is cooled rapidly, usually by quenching in water or oil. This process helps to dissolve and redistribute the metal’s alloying elements, resulting in a uniform and fine-grained microstructure that enhances the ring’s mechanical properties.
7. Fine Machining Before Strengthening: Achieving the Final Dimensions
Once the solid solution treatment is complete, the forged ring undergoes a fine machining process. This step further refines the ring’s dimensions and surface finish, ensuring it meets the required tolerances and specifications. Fine machining often involves turning, milling, and grinding operations using advanced CNC machines, guaranteeing high precision and accuracy.
8. Cold Deformation Hydraulic Bulging Strengthening: Enhancing the Forged Ring’s Mechanical Properties
Cold deformation hydraulic bulging strengthening is a technique used to improve the mechanical properties of forged rings, such as their yield strength, tensile strength, and hardness. This process involves subjecting the ring to hydraulic pressure, which causes the metal to deform plastically to a specific shape. The cold deformation process refines the metal’s grain structure, improving mechanical properties and overall performance.
9. Heat Treatment to Eliminate Residual Stress: Ensuring Structural Integrity
After the cold deformation process, the forged ring undergoes heat treatment to eliminate residual stress. Residual stress can lead to deformation, cracking, or even failure of the forged ring under certain conditions. Heat treatment typically involves heating the ring to a specific temperature, holding it at that temperature for a specified time, and then cooling it at a controlled rate. This process helps to redistribute and relieve the internal stresses within the metal, ensuring structural integrity and long-lasting performance.
10. Physical and Chemical Testing: Verifying the Forged Ring’s Quality
To ensure the quality of the forged ring, it must undergo rigorous physical and chemical testing. These tests may include tensile, hardness, and impact testing to verify the ring’s mechanical properties. Chemical analysis, such as spectroscopy, is also performed to confirm the alloy’s composition and ensure it meets the required specifications. These tests guarantee that the final product is of the highest quality and ready for use in demanding applications.
11. Non-Destructive Testing after Finishing: Ensuring Reliability and Safety
Non-destructive testing (NDT) is performed on the forged ring after finishing to detect any potential defects or flaws that could compromise its performance or safety. NDT methods, such as ultrasonic testing, radiographic testing, and magnetic particle inspection, enable the detection of internal and surface defects without damaging the ring. This process is crucial for ensuring the reliability and safety of the forged ring in its intended application.
12. Packaging and Delivery: Protecting the Forged Ring during Transit
Once the forged ring has passed all the necessary tests and inspections, it is ready for packaging and delivery. The ring is carefully packaged to protect it from damage during transportation, ensuring that it arrives at its destination in perfect condition. Proper packaging materials and techniques are used to prevent scratches, dents, or other damage that could affect the ring’s performance.
Application areas of forged rings
The application areas of forged rings are:
Diesel engine forged rings: a kind of diesel engine forgings; the diesel engine is a kind of power machinery often used for engines. For large diesel engines, for example, the forgings used are the cylinder head, main journal, crankshaft end flange output end shaft, connecting rod, piston rod, piston head, crosshead pin shaft, crankshaft drive gear, gear ring, intermediate gear and dye oil pump body and more than ten kinds.
Marine forged rings: Marine forgings are divided into three categories, host forgings, shaft forgings, and rudder system forgings. The main engine forgings are the same as diesel engine forgings. Shaft forgings have a thrust shaft, intermediate shaft, rigid shaft, etc. Rudder system forgings are rudder rod, column, pin, etc.
Weapons forged rings: forgings occupy an extremely important position in the weapons industry. By weight, there are 60% forgings in the tank. Artillery barrels, muzzle reducers, gun tails, infantry weapons with a rifled barrel and three-pronged bayonet, rocket and submarine depth charge launchers and fixed seats, nuclear submarine high-pressure coolers with the stainless-steel valve body, artillery shells, gun shells, etc., are forging products. In addition to steel forgings, other materials are used to manufacture weapons.
Petrochemical forged rings: forgings have a wide range of applications in petrochemical equipment. Such as spherical storage tank maintenance hole, flange, heat exchanger required for a variety of pipe plates, butt welding flange catalytic cracking reactor of the whole forging cylinder (pressure vessel), hydrogenation reactor used in the cylinder section, fertilizer equipment required for the top cover, bottom cover, head, etc. are forgings.
Mining forged rings: the proportion of forgings in mining equipment is 12-24% by equipment weight. Mining equipment is mining equipment, winding equipment, crushing equipment, grinding equipment, washing equipment, and sintering equipment.
Nuclear power forged rings: nuclear power is divided into two categories: pressurized water reactor and boiling water reactor. The large main forgings for nuclear power plants can be divided into two categories: pressure shells and internal components of the reactor. The pressure shell contains a barrel flange, nozzle section, nozzle, upper barrel, lower barrel, barrel transition section, bolts, etc. Heap components are in high temperature, high pressure, strong neutron amplitude illumination, boric acid water corrosion, scouring and hydraulic vibration, and other severe work conditions, so choose 18-8 austenitic stainless steel to make.
Thermal power forged rings: thermal power generation equipment has four key forgings: the turbine generator rotor, guard ring, and impeller and turbine rotor.
Hydroelectric forged rings: There are important forgings in hydroelectric power plant equipment, such as hydraulic turbine shaft, hydraulic generator shaft, mirror plate, and thrust head.
How to Measure Forged Rings?
To ensure the optimal performance of forged rings, accurate measurements are crucial. Precise measurements ensure proper fit, alignment, and functionality, minimizing the risk of failure and prolonging the ring’s service life. With this in mind, let’s delve into measuring forged rings.
Step-by-Step Guide to Measuring Forged Rings
1. Preparing for Measurements
Before you begin, ensure that the forged ring, measuring tools, and work area are clean and debris-free. This will help prevent inaccurate measurements due to dirt or contaminants. Gather the necessary tools, such as calipers, micrometers, tape measures, and a surface plate.
2. Measuring the Outer Diameter (OD)
Place the forged ring on a flat, stable surface. Using a caliper or a tape measure, measure the outer diameter of the ring by placing the measuring tool across the widest part of the ring. Ensure the tool is parallel to the surface plate for accurate readings. Record the measurement in your preferred unit.
3. Measuring the Inner Diameter (ID)
To measure the inner diameter, use a caliper or a tape measure and place it across the narrowest part of the ring’s interior. Ensure the tool is parallel to the surface plate for accurate readings. Record the measurement in your preferred unit.
4. Measuring the Ring Width
Using a micrometer, measure the width of the ring by placing the micrometer’s anvil on one side of the ring and the spindle on the other. Ensure both the anvil and spindle are perpendicular to the ring’s surface. Gently tighten the micrometer until it makes contact with the ring, avoiding over-tightening. Record the measurement in your preferred unit.
5. Measuring the Ring Thickness
To measure the thickness of the ring, use a micrometer and place it on the top and bottom surfaces of the ring. Ensure the micrometer is perpendicular to the ring’s surface. Tighten the micrometer gently until it makes contact with the ring, avoiding over-tightening. Record the measurement in your preferred unit.
6. Inspecting for Surface Defects and Irregularities
Examine the forged ring for visible surface defects or irregularities, such as cracks, pits, or warping. These defects could compromise the ring’s performance and should be addressed before installation.
7. Verifying Measurements and Tolerances
Compare your measurements to the manufacturer’s specifications or engineering drawings. Ensure the forged ring meets the required tolerances for your specific application. If the measurements are outside the acceptable range, consult the manufacturer or engineer for guidance on addressing any discrepancies.
8. Documenting and Archiving Measurement Data
Document your measurements and inspection results in a comprehensive report, including any deviations from the required tolerances. Archive the data for future reference and traceability. This information is essential for quality control, warranty claims, and continuous improvement initiatives.
9. Repeating the Process for Additional Rings
Repeat the steps outlined above for each ring if you have multiple forged rings to measure. Consistency in measurement and documentation is vital to ensure the quality and performance of all rings in your application.
10. Implementing a Quality Control Program
Implement a robust quality control program that includes regular inspection and calibration of measuring tools, ongoing training for personnel, and periodic audits to ensure adherence to established procedures and tolerances. This will help maintain the accuracy and reliability of your forged ring measurements and contribute to the overall success of your projects.
How to purchase the correct forged rings?
Purchasing the correct forged rings involves carefully considering various factors, including material, size, shape, tolerance, straightness, surface finish, heat treatment, quality certifications, and budget. By considering these factors, you can make an informed decision and select the ideal forged rings for your application. Partner with a reputable manufacturer that adheres to strict quality standards and offers comprehensive services to ensure the best possible results.
Material of Forged Rings
It is crucial to select the appropriate material for your forged rings, as it directly impacts their performance and durability. Common materials used for forging rings include carbon steel, alloy steel, stainless steel, and other specialized metals. Consider the application requirements and environment the rings will operate in to make an informed decision on the material.
Size and Shape of Forged Rings
The size and shape of your forged rings are essential factors in meeting specific application needs. Accurate measurements of the inner and outer diameters and the height will ensure a perfect fit. In addition, consider the cross-sectional shape of the ring, which can be round, square, or rectangular, depending on the application.
Tolerance and Straightness of Forged Rings
Tolerance and straightness are crucial factors in the functionality of forged rings. The manufacturing process should adhere to strict quality standards to maintain tight tolerances and straightness. Look for manufacturers that utilize state-of-the-art equipment and skilled technicians to produce high-quality, precision-engineered forged rings.
Surface Finish of Forged Rings
The surface finish of forged rings affects their performance, particularly in applications where friction and wear are critical factors. Smooth surface finishes minimize friction and prolong the service life of the rings. Opt for a manufacturer that offers various surface finishes, such as machined, as-forged, or ground, to accommodate the specific requirements of your application.
Heat Treatment of Forged Rings
Heat treatment plays a vital role in enhancing the mechanical properties of forged rings. This process includes annealing, normalizing, quenching, and tempering. The heat treatment can improve the ring’s hardness, ductility, and impact resistance. Ensure that the manufacturer follows industry standards for heat treatment to guarantee optimal performance and longevity.
Quality Certifications of Forged Rings
Quality certifications testify to the manufacturer’s commitment to producing high-quality forged rings. Look for certifications such as ISO 9001 and other relevant industry-specific certifications. These certifications ensure that the manufacturer adheres to strict quality management systems and produces forged rings that meet or exceed industry standards.
Budget and Pricing of Forged Rings
Budget and pricing are crucial aspects to consider when purchasing forged rings. While finding a cost-effective solution is essential, don’t compromise on quality. Compare prices from different manufacturers, taking into account the material, size, and additional services like heat treatment and surface finishing. Opt for a manufacturer offering competitive pricing without compromising quality and performance.
How to select forged rings manufacturer?
Choosing a forged ring manufacturer is important for any enterprise requiring high-quality and reliable ring solutions. The wrong choice may lead to project delays, increased costs, and potential hazards. What factors should we consider when selecting forging ring manufacturers, how do we evaluate their reputation, and what other services that you should we be looking for?
Factors to Consider when Selecting a Forged Rings Manufacturer
Quality is the top priority when selecting a manufacturer. The rings must meet or exceed industry standards to ensure longevity and reliability. Inquire about the materials used, the manufacturing process, and any quality control measures in place. A reputable manufacturer should be fine providing detailed information about their product quality.
Experience is a significant factor in determining a manufacturer’s expertise in forged rings. An experienced manufacturer will know the materials, processes, and industry standards extensively. Look for a company with a proven track record and a history of successful projects.
Choose a manufacturer with the capacity to handle your project requirements. This includes the volume of rings needed and the ability to meet deadlines and handle any unexpected changes in demand. A manufacturer with a flexible production schedule can help avoid delays and keep your project on track.
Customization is essential if you require unique specifications for your rings. A manufacturer offering customization options can ensure that the rings meet your requirements. Customization may include varying ring sizes, materials, or finishes.
Certification is another crucial factor when selecting a manufacturer. Look for a company with relevant certifications from recognized industry organizations. These certifications testify to the manufacturer’s commitment to quality, safety, and environmental standards.
While pricing should not be the sole determining factor, finding a manufacturer that offers competitive pricing without compromising quality is essential—request quotes from multiple manufacturers to compare their offerings and make an informed decision.
The location of the manufacturer can impact the delivery time and shipping costs. A local manufacturer may offer faster delivery and lower transportation costs. However, weighing these benefits against other factors like quality and experience is essential.
Evaluating a Manufacturer’s Reputation
Customer reviews can provide valuable insights into a manufacturer’s quality, reliability, and customer service. Look for reviews from other businesses in your industry to ensure a fair comparison. Remember that no company is perfect, so consider the overall trend in the feedback.
Industry recognition, such as awards and commendations, can also help you gauge a manufacturer’s reputation. These accolades indicate a company’s commitment to excellence and innovation in the forged rings sector.
Additional Services Offered
In-house testing ensures the rings meet quality and safety standards before leaving the manufacturer’s facility. This can save you time and money by reducing the risk of defects and potential hazards. A manufacturer with a robust in-house testing program demonstrates their commitment to quality and customer satisfaction.
On-time delivery is critical for any project, as delays can increase costs and disruptions. Choose a manufacturer with a proven track record of meeting deadlines and a clear communication process to keep you updated on the progress of your order.
After-sales support is an essential aspect of a successful business relationship. A manufacturer that offers comprehensive after-sales support, such as technical assistance, warranty, and maintenance services, will ensure you get the most out of your investment in their products.
Why Choose Guanxin to Be Your forged ring Supplier?
At Guanxin, we pride ourselves on providing top-notch forged rings that meet industry standards. Our state-of-the-art manufacturing facilities and experienced team of engineers ensure that every forged ring we produce is exceptional, with precise dimensions and impeccable surface finish. By choosing Guanxin as your forged ring supplier, you can be confident that you are receiving products that will exceed your expectations and stand the test of time.
Wide Range of Materials and Sizes
Our extensive selection of materials and sizes sets us apart from other forged ring suppliers. We offer a diverse range of metals, including stainless steel, alloy steel, carbon steel, and superalloys, to meet the unique requirements of various industries. Our forged rings are available in various diameters and lengths, ensuring we can fulfill any order, no matter how specialized or demanding.
Tailored Solutions for Your Specific Needs
At Guanxin, we understand that each customer has unique requirements and challenges. That’s why we offer customized solutions tailored to your specific needs. Our skilled engineers will work closely with you to develop and produce forged rings that meet your specifications. Whether you require a particular material, size, or surface finish, we have the expertise and resources to deliver the perfect solution for your project.
Competitive Pricing and Exceptional Value
We know that cost is crucial when selecting a forged ring supplier. At Guanxin, we are committed to providing our customers with competitive pricing without compromising quality. Our streamlined manufacturing processes and extensive industry experience allow us to offer exceptional value, ensuring that you receive the best possible product at a fair price.
Fast Lead Times and Reliable Delivery
In today’s fast-paced business world, time is of the essence. We understand the importance of delivering your forged rings promptly and reliably. Our efficient production processes and well-established logistics network ensure that your order will be completed and delivered on time every time. By choosing Guanxin as your forged ring supplier, you can rest assured that your project will stay on track and schedule.
Unparalleled Customer Support
Customer satisfaction is at the core of our business. Our dedicated customer support team is always available to answer any questions or address any concerns. From the moment you place your order to the final delivery of your forged rings, we will be with you every step to ensure a seamless and hassle-free experience.
Environmentally Conscious Manufacturing
At Guanxin, we recognize the importance of protecting the environment and are committed to sustainable manufacturing practices. Our eco-friendly production processes and adherence to strict environmental regulations ensure that our forged rings are produced with minimal environmental impact. By choosing Guanxin as your forged ring supplier, you can be confident that you are partnering with a company that values and prioritizes environmental responsibility.
Global Presence and Reputation
As a leading global forged ring supplier, Guanxin has established a strong presence and reputation in the international market. Our extensive network of satisfied customers and partners is a testament to our commitment to quality, innovation, and customer service. By partnering with Guanxin, you can be assured that you are working with a company with the expertise and resources to support your business globally.
State-of-the-Art Research and Development
Innovation is at the heart of our success at Guanxin. Our research and development team is constantly exploring new materials, technologies, and manufacturing techniques to improve the performance and durability of our forged rings. By staying at the forefront of industry advancements, we can offer our customers cutting-edge products that set the standard for quality and performance. When you choose Guanxin as your forged ring supplier, you can be sure that you are receiving products incorporating the latest industry innovations.
Strict Quality Control and Assurance
To guarantee the highest quality forged rings, we have implemented a rigorous quality control and assurance system at every stage of the production process. From selecting raw materials to the final inspection and testing finished products, our experienced quality control team ensures that every forged ring meets our strict quality standards. By maintaining our unwavering commitment to quality, we can provide our customers with forged rings they can trust to perform reliably in even the most demanding applications.
Certifications and Compliance
As a leading forged ring supplier, Guanxin is fully committed to complying with all applicable industry standards and regulations. We hold various certifications, including ISO, demonstrating our dedication to maintaining the highest levels of quality and safety in our products and processes. By choosing Guanxin as your forged ring supplier, you can be certain that you are partnering with a company that values compliance and adheres to the strictest industry standards.
Long-Term Partnerships and Collaboration
At Guanxin, we believe in building long-lasting relationships with our customers and partners. By fostering a collaborative environment and maintaining open lines of communication, we can better understand your needs and work together to achieve your goals. Our commitment to long-term partnerships ensures we can provide ongoing support and resources to help your business grow and succeed.
Experience and Expertise
With years of experience in the forged ring industry, our team of skilled professionals has the knowledge and expertise to provide you with the best possible solutions for your projects. Our in-depth understanding of various industries unique requirements and challenges enables us to offer expert guidance and advice to help you make the best decisions for your business.
Guanxin is the ideal choice for your forged ring supplier due to our commitment to quality, innovation, customer satisfaction, and environmental responsibility. Our extensive range of products, tailored solutions, competitive pricing, fast lead times, and exceptional customer support make us the preferred partner for businesses worldwide. By choosing Guanxin as your forged ring supplier, you can be confident that you are working with a company dedicated to your success.
Forging process solution for automated ring forgings
The forging line of ring forging is long, and the forgings are heavy. Considering personnel safety issues, production tempo, and output, the automated forging line replaces the conventional manually operated forging line. To meet the requirements of automated forging, each equipment unit must have automated production capacity; the traditional air hammer billet making and hydraulic press-free forging billet making will not meet the requirements. Therefore, according to the requirements of the automated production process, we will use the reverse design idea to select the equipment type and develop the process parameters.
1. Final forging process development and equipment selection
According to the final forging billet positioning requirements, there are two ways to position the inner and outer diameter, finite element simulation analysis of the two ways to select the appropriate final forging billet positioning method and forging equipment.
The simulation parameters were selected as follows: die temperature 250°C, billet temperature 950°C, external environment temperature 25°C, convective heat exchange coefficient between billet and environment 0.02N/(sec.mm.C), heat exchange surface between environment and the outer surface of billet, heat transfer coefficient between billet and die 0.2N/(sec-mm-C), and the modeling schematic is shown in Figure 1 and Figure 2.
Fig.1 Inner diameter positioning
Figure.2 Outside diameter positioning
Inner diameter positioning result analysis: positioning by inner hole, the inner hole will have longitudinal burr, rounding at maximum outer diameter is not easy to fill, forging bottom surface has the risk of generating folding, forging forming force 5500t, forming energy 600kJ.
Analysis of outer diameter positioning results: positioning by outer hole, good metal flow, forging will not produce folding, forging forming force 6000t, forming energy 520kJ.
To summarize, according to the forming force and energy requirements, choose to forge forming on J58K-4000 electric screw press (electric screw press percussion force can be long-term overload 1.6 times). The outer diameter positioning method is selected for the final forging blank.
2. Rolling ring reaming process development and equipment selection
We can determine the blank size before rolling the ring according to the requirements of rolling the ring, which is blank after punching. The maximum outer circle size after ring rolling is less than 408mm, so D51K-500B CNC vertical ring rolling machine is used (the full outer circle can be rolled to 500mm).
3. Punching, extrusion, and upsetting process and equipment selection
According to the same drawing of the blank after punching, we can design the blank for extrusion. Then according to the mass conservation, we can calculate the upsetting height, and the upsetting size can be determined. After the simulation analysis of DEFORM simulation software, it was calculated that the upsetting force is 450t, the extrusion force is 1800t, and the punching force is 400t, so it is possible to choose one piece of equipment to do three stations of blank making, which saves both cost and space.
4. Heating and underfeeding process development and equipment selection
According to the IF furnace selection rules, you can choose the appropriate power IF furnace according to the product weight and capacity. The bar material with a larger weight is usually directly connected to the IF furnace by underfeed sawing machine to ensure the stability of the IF furnace feeding. The suitable IF furnace can be selected according to the bar material diameter and production beat. The final process and equipment selection are shown in Table 1.
Table.1 Process and equipment selection
|Working Procedure||Blanking||Heating||Jumping-up||Squeezing hole||Punching||Rolling ring||Forming|
|Equipment||Circular saw||Kgps||Quick die forging hydraulic press||Ring rolling machine||Electric Screw Press|
5. Design of mold dies frame.
Design of three-station die holder mold for 2000t hydraulic press
The design of the structure of the three-station billet-making die frame for the hydraulic press is shown in Figure 3.
Figure.3 Three-station blank making die.
The difficult part of the three-station die is the unloading of the punching station. The unloading structure of the punching station adopts the upper unloading so that the forgings stay in the uniform position of the lower die, which is convenient for the clamping of the manipulator. The advantage of the rectangular spring is that it is relatively high temperature resistant, but the unloading force provided is limited, and the required unloading stroke is large. Nitrogen springs provide a larger unloading force (a single one can be selected with an elastic force of 6t to 10t and an initial elastic force of 6t).
6. Design of 4000t final forging die holder dies.
The structure design of the final forging die, holder, and die is shown in Figure 4.
Fig.4 4000t electric die holder die structure.
The final forging equipment is a 4000t electric screw press; the advantage of this press is that the striking energy is controllable, the equipment comes with a hydraulic three-point ejector system, the ejector of the forging adopts the ring structure, the equipment comes with three-point ejector for the cross-shape ejector plate, the ejector structure is highly adaptable and suitable for different diameter ring parts.
7. Production verification
Fig. 5 shows the ring blank obtained from three stations before ring rolling, Fig. 6 shows the blank obtained after ring rolling and reaming, and Fig. 7 shows the finished forgings obtained after final forging. After mass production, the subsequent machining of the forgings reached the expected target, and Figure 8 shows the machined product.
Figure.8 Ring blank obtained from the first three working positions of ring rolling
Figure.9 Blank obtained after ring rolling and hole expanding
Figure.10 Finished forgings obtained after final forging
Figure.11 Machined Products
Our forging product types
|Item||Type||Section size/mm||Length/Height mm||Weight/ton|
|1||Circle/step axis class||Ø100-Ø1500||≤15000||≤15|
|4||Pie type class||Ø200-Ø2400||≤700||≤12|
|5||Valve box/valve body type||Ø250-1200||≤2000||≤12|
|Shaft flange type|
|7||Cross axis class||≤Ø2000||≤500||≤10|
Export Country For Forged Rings
|MIDDLE EAST||AFRICA||NORTH AMERICA||EUROPE||ASIA||SOUTH AMERICA|
|Oman||Sudan||Trinidad And Tobago||Spain||South Korea||Ecuador|
|Turkey||The Republic Of Congo||Bahamas||Netherland||Sri Lanka||Paraguay|