Paper or Papermaking

Paper Mills Forge Ahead with Complex Forged Parts

In the pulp and paper industry, large drive and tending heads, rollers, drive shafts, gears, and other components are essential in producing pulp, paper, board, and other cellulose-based products.

These precision-forged parts are often found in applications where it is critical to withstand challenging conditions. Open die forgings and seamless rolled rings have a greater lifespan than other products due to their strength and durability, and are less prone to cracking or warping, making them the ideal option for critical components requiring high tensile strength. Depending on the metal and alloy, the rings are also resistant to thermal and chemical damage, which further extends longevity while reducing the need for maintenance, repair, and replacement.

seamless rolled rings are structurally
Seamless rolled rings are structurally sound because they create a circular grain flow in the material, following the shape of the ring.

Seamless rolled rings can be used in the manufacture of rolling and calendering equipment to promote precise, consistent paper production; in drying systems to provide the strength and durability required for efficiency; and in conveyor systems to ensure the smooth transport of paper products during processing.

However, for the pulp and paper industry, obtaining large heads and seamless rolled rings in a timely manner remains a significant challenge. Currently, it may take many months to receive the forged components after placing an order. This delay can have a severe impact on the production and maintenance schedules of companies that depend on replacement parts.

Rings are typically provided with a rough surface finish, which necessitates the use of computer numerical control (CNC) machining to achieve the required level of smoothness. This poses a challenge for machine shops with a high workload, as allocating machine time for finishing inevitably leads to a decrease in production speed and an increase in costs, ultimately impacting the end-use cost or profitability.

Fortunately, pulp and paper machinery manufacturers can rely on industry-leading forging specialists capable of producing large, custom, seamless rolled rings, or contoured, seamless rolled rings with the required surface finish, in under two months. One example, All Metals & Forge Group (AMFG), is an ISO 9001:2015 and AS9100D manufacturer of custom and standard open die forged parts and seamless rolled rings. The company can cost-effectively deliver these components with the required finish within 8-10 weeks.

AMFG’s range of forged products includes rings, discs, hubs, blocks, shafts (including step shafts or with flanges), sleeves, gear blanks, cylinders, flats, hexes, rounds, plates, and custom shapes. Carbon steel, alloy steel, stainless steel, nickel, titanium, and aluminum are among the materials used for forging. These forgings meet rigorous industry specifications such as ASTM, AMS, AISI, ASME, Boeing, SAE, GE, DIN, ASME B 16.5, ASME B 16.47, and API 6A. When speed and quality are essential, the pulp and paper industry can reap the advantages of an accelerated process for obtaining flawless rolled rings.

THE BENEFITS OF OPEN DIE FORGINGS

One chief advantage of open die forging is the customization it offers in the forged parts and seamless rolled ring manufacturing process.

Open die forging is ideal for providing large, custom parts. As an example, AMFG can produce seamless rolled rings or contoured rolled rings up to 200 inches in outside diameter, and custom forgings up to 40 feet long or 80,000 lbs. The company, which has been manufacturing and selling open die forgings and seamless rolled rings for more than 50 years, can also produce forgings for drive and tending ends, and large cylinders in diameters that cover the sizes needed.

While open die forging is typically associated with larger, simpler-shaped parts like bars or blanks, the process enables the creation of “custom-designed” metal components. Open die forging facilitates the production of seamless rolled rings to exact specifications with optimized mechanical properties and structural integrity. The rings can be produced in a variety of alloys, sizes, and shapes specific to the requirements. Forged parts finish-machined by machine shops are equally sound in structural integrity and required physical properties.

The forging of seamless or contoured rolled rings is also cost-effective, since the process reduces material waste and manufacturing costs. Because the rings are constructed from a single metal piece using a specialized ring rolling machine, there is no need for welding or assembly, saving time and labor. The seamless rolled rings are also more structurally sound because they create a circular grain flow in the material, following the shape of the ring, which increases strength and integrity, creating a refined grain structure. This can enhance the material’s fatigue resistance and overall performance, resulting in a stronger, more durable final product compared to other methods of ring making, such as cutting from plate or rolled and welded.

NEAR-NET- SHAPED PARTS WITH FINER SURFACE FINISH

Typically, when heads, cylinders, shafts, or seamless rolled rings are forged, they are often left in an unprocessed state with a rough surface measured at approximately 500 RMS. As a result, significant CNC machining time is required to achieve a smoother surface for the finished machined part. This poses a challenge for machine shops as the allocation of machining time for finishing these rough parts directly affects production efficiency, cost, and delivery time to the client.

To optimize efficiency and reduce costs, AMFG frequently provides near-net-shaped forged parts with more refined surface finishes. Typically, the company provides a 250 RMS surface finish. However, it can provide 125 RMS, drill holes, and even do contour forgings as needed.

Some forge shops only offer raw, unmachined parts. In contrast, AMFG produces a rough machine part, saving machine shop time and equipment wear and tear, since they have already taken the first rough cuts off the ring or forged parts.

In addition, the company conducts ultrasonic testing at zero expense to the customer to guarantee the absence of internal cracks, pits, or voids. This instills the utmost confidence in the quality of the parts, according to Tim Grady, management consultant for AMFG. “In many cases, All Metals & Forge Group can offer ultrasonically tested parts that are more affordable than raw forged rings,” says Grady.

STREAMLINING DELIVERY

In today’s market, the procurement of forged seamless rolled rings usually takes a considerable amount of time, from 20 weeks to as much as a year, due to long lead times in receiving the necessary steel from mills.

“When replacement parts are required, a delay of a year or more is not acceptable,” says Grady. “Even 20-plus weeks is a serious issue.”

To expedite the process for customers, AMFG has established strategic partnerships within the industry, enabling the company to deliver many custom forgings in a timeframe of eight to 10 weeks. Furthermore, to minimize any potential production downtime for machine shops, the company strives to provide accurate quotes within 48 hours.

The need to acquire seamless rolled rings will only increase in industries like pulp and paper that require high-quality, custom-forged components that can safely withstand extreme forces with minimal repair or replacement. In these cases, working with an expert forger who can expedite the process will convey a significant advantage.

Del Williams is a technical writer based in Torrance, CA. For more information about custom forging, contact All Metals & Forge, LLC toll-free at (800) 600-9290 or visit steelforge.com. The company is headquartered in Fairfield, NJ.

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