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Cross-wedge rolling and Helical-rolling line

Cross-wedge rolling line WRL13025TS

The WRL 13025 TS cross-wedge rolling line (with two flat moving tools) is designed to produce forgings of the type of bodies of revolution with a diameter of 48-130 mm and a large length (up to 725 mm) by hot rolling. It is used in the production of a large range of parts, mainly for subsequent stamping or mechanical processing in the production of suspension parts and gearbox shafts for trucks and automotive equipment.

Cross-wedge rolling line WRL 13025 TS
Diameter of rolled parts, mm	48 - 130
Maximum length of rolled parts, mm	90-725
Productivity for single rolling with INU 1600 kW forgings, pcs/hour* - with initial workpiece weight up to 17 kg - with initial workpiece weight from 17 to 25 kg	140...180 60...70
* With paired or triple rolling, productivity is doubled or tripled

Rolling mill capacity - 400 kW (working mode is 35-40% less);

• Length of the forming part of the tool - 2500 mm;

• Time for tool changes - 10-15 minutes (the line uses an automatic tool change system with tool fixation using hydraulic clamps, controlled from the operator panel and a manipulator for extracting the tool from the line);

• The control system based on PLC (Mitsubishi) consists of a control panel and an electrical cabinet (upon request, it is possible to use controllers from other manufacturers - Siemens, Omron, Allen Bradley). Design of control systems in accordance with the region of operation (CIS, USA, etc.)

• Adjustment of the closed height using a remote control during operation;

• Rolling is carried out from individual blanks - a heated blank is fed into the machine from the side by the machine loading mechanism. The machine, using a tool, rolls - forms a forging. After rolling, the finished forgings are removed to a container along the tray.

• The slider drive is hydraulic. The machine is equipped with a system for maintaining a constant thermostatic rolling mode (tool cooling).

• The control system, based on a programmable controller, allows the line to operate in setup and automatic modes with all settings displayed on the operator panel;

• Operator diagnostics and assistance system (internal continuous diagnostics);

• High degree of automation. Ensures uninterrupted and stable operation of the line with full control of all parameters (including in combination with an induction heater, control of the heating temperature of the blanks and rejection or feeding the line, a system for cyclic feeding of blanks from a slide hopper, rolling of forgings and transfer to the next stage);

Included with an induction heating unit with a thyristor frequency converter with a capacity of 1600 kW 1000 Hz and 5 sets of replaceable inductors. The inductors are made in a two-strand parallel design. Each thread is loaded automatically from a common storage slide hopper. The loading mechanism drive is hydraulic. When replacing one inductor size with another, quick changeover is provided (connection of water-cooled pipes with quick-release nipples, fastening of the inductor with quick-release latches). The inductor design (lining) is disassemblable and repairable. Water-cooled guides are provided for moving the workpieces along the inductor.

The installed capacity of the entire equipment complex is 2000 kW. The equipment uses an original dual-circuit cooling system for the main working units of the tool, rolling machine, hydraulic stations, inductors and TFC. Cooling of heated units and line elements is forced water with continuous water supply at a pressure of 0.25...0.4 MPa. Cooling of the TPC is dual-circuit with a heat exchanger. The primary closed circuit with a heat exchanger is connected to the cooling system of the TPC cabinet, the secondary circuit is connected to the process water supply system. The coolant of the primary TPC cooling circuit is distilled water.

The induction heating unit ensures the delivery of heated in the range of +1100˚С - +1250˚С blanks with a diameter of up to 130 mm with a capacity of up to 3100 kg/hour.

The loading unit of the rolling machine ensures automatic delivery of heated blanks from the inductor to the working area of the machine. A device for monitoring the temperature of the blank (pyrometer) is used with the output of its readings to the control panel and a mechanism for removing underheated or overheated blanks coming from the outlet section of the inductor. The installation for loading blanks into the rolling machine includes a sorting mechanism, which ensures the separation of blanks rejected by temperature into underheated and overheated ones into appropriate containers.

When rolling forgings with a flat tool on the WRL13025TS line, we have the following advantages:

higher accuracy of the resulting forgings.
quick tool change due to fixing the rolling tool on the WRL13020TS line using hydraulic clamps controlled from the central control panel (the time to change a set of tools weighing about 3500 kg is 15-20 minutes).
installation of the tool does not require additional basing and setting parallelism.
the tool has a cooling system to stabilize the temperature mode of the line in automatic mode.
flat tool of the WRL and WRL TS mills is easier to manufacture and maintain during resharpening (only part of the replaceable wedges requires repair, when resharpening a round tool, the entire surface of the roll (roller) is resharpened).
automatic adjustment of the closed height from the control panel of the rolling line for switching from one diameter of rolled blanks to another.
equipment for 2-3 shift operation.

Cross-wedge rolling line WRL13025TS-01

Rolling machine, sorting mechanism, machine loading device, induction heater, inductor loading device, central control panel

Mechanism for sorting and monitoring the temperature of a heated workpiece with automatic feeding into the line

Double-inductor induction heating unit for workpieces / view without covers

Automatic inductor loading device / Automatic blank feed device from storage bin

Thyristor frequency converter (TFC) / Control cabinets

Hydroelectric power stations

Tool changer

Sets of replacement inductors 5 sizes

For rolling forgings for stamping or metalworking (ball pins of all sizes, lever forgings, stepped shafts and other types of products) at your production and the production of your partners, we offer the implementation of automatic rolling lines (together with heating of blanks) of our own design and production. We also invite you to visit our company to familiarize you with the specified technology and equipment in detail.

To justify the economic efficiency upon request, we are ready to prepare a technical and economic proposal in accordance with the drawings of parts planned for production provided by you.

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