R5229 -58 :/, 62(9:0* (4+ 8;)),8 685+;*:054 · WALZEN IRLE 904*, 1693 Irle rolls for the plastic...

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Rolls for the plastic and rubber production

Transcript of R5229 -58 :/, 62(9:0* (4+ 8;)),8 685+;*:054 · WALZEN IRLE 904*, 1693 Irle rolls for the plastic...

Page 1: R5229 -58 :/, 62(9:0* (4+ 8;)),8 685+;*:054 · WALZEN IRLE 904*, 1693 Irle rolls for the plastic and rubber industry are produced by experienced and qualified specialists according

Rolls for the plastic and rubber production

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Rolls from

WALZEN IRLE since 1693

Irle rolls for the plastic and rubber industry are

produced by experienced and qualified specialists

according to most modern metallurgical and manu-

facturing guidelines.

Plastic calender rolls from WAlZeN Irle fulfill the

highest quality requirements of the plastic industry.

Our certified quality management ensures supervi-

sion and testing of all manufacturing steps thus con-

tributing to the excellent reputation of our rolls in

operations worldwide.

Our technically oriented sales specialists discuss solutions and developments for all sorts of

challenges of the plastic and rubber industry with our customers.

plant I: machine shop

plant II: foundry

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More than 300 years of foundry expertise,

about 200 years of roll casting experience

2006 erection of the large vertical spin casting machine

(up to 80 t casting weight)

2007 production start of the new vertical spin casting ma-

chine

2007 implementation of a complete new production line

for heavy rolls

2007 founding of a new company with the Indian partner

Kay Jay rolls in Panchkula, India, to produce small

rolls for the food industry and stretch reducingrolls

for the tube and wire industry

2009 More than 100 heavy plate mill rolls, produced with

the vertical spin casting machine, are already

running in customers mills worldwide

2010 WAlZeN Irle celebrates its 190st anniversary as

a roll manufacturer

1693 start of casting and machining of iron parts by

Johannes Irle

1820 founding year of the iron foundry in Marienborn

and casting of the first chilled cast iron roll

1848 purchase of the idle silver and lead works in Deuz,

today Irle plant I in Netphen Deuz

1854 founding year of the "Hermann Irle" company

1884 start of the production of paper calender rolls

1903 purchase of the idle flour mill on the outskirts of

Deuz, today Irle plant II

1906 start of production of heavy rolls

1920 casting of the first cast steel roll

1950 casting of the first nodular iron roll

1960 complete new construction of plant I

1972 building of state of the art foundry and modeling

shop

1981 market launch of the WAlZeN Irle material OrT®

for rolls for the food industry

1985 WAlZeN Irle introduces the peripherally drilled

roll to the paper industry

1989 development of coated thermal calender rolls made

of forged steel

1990 development of the WAlZeN Irle roll material

KSTV for high temperature applications

2000 variable edge insulation of thermal rolls

2000 development of the Irle-Auto-lock-System

2000 market launch of hot grinding procedures for paper

calender rolls

2000 market launch of hot balancing of paper calender

rolls

2001 Development of the WAlZeN Irle S-Technology

for optimization of the roll geometry under operating

conditions

2005 Introduction of the rapid service journal for calender

rolls

2005 Big investments at the Deuz plants in the pro-

duction of centrifugally casted work rolls for heavy

plate mills and roughing rolls as well as work rolls

for hot strip mills.

entrance into the production of spin casted work

rolls for heavy plate mills and roughing rolls for hot

strip mills (40-75 metric tons) and further expansion

of production of work roll for hot strip mills

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Applications

IRLE Thermo Rolls for the production of continuous plastic

sheets

Irle thermo calender rolls are used for the production of ABS foils, flooring, office supply

foils, roofing foils, decorative foils, landfill and pool foils and tarps, insulating foils, artificial

leather, truck canvas, coatings, packaging material, soft and hard PVC sheets etc. in 3

roll, 4 roll and 5 roll calenders or melting calenders. Depending on the application our

rolls are manufactured either from cast iron using the single or compound casting method,

statically or centrifugally casted, or from forged steel. They are equipped with different

heating or cooling systems by means of peripheral bores, they can have a coating or

hard chrome plating, ground according to the best surface smoothness.

IRLE Thermo Rolls for the production of rubber products

WAlZeN Irle supplies heated and cooled rolls for shredding, mixing and calendering

of rubber material for the production of tires, straps, bands, conveyor belts, rubber pro-

files, sealings, gaskets, hoses, mats, pads etc. Our rolls are in operation in breaker

stacks, mixing calenders and rubber calenders.

IRLE Thermo Rolls for the production

of gasket sheets

WAlZeN Irle supplies heated and cooled rolls for the production

of gasket sheets which are for example being used in the automo-

tive industry but also in the aerospace industry.

WALZEN IRLE plug

even though we can provide every type of sealing for the peri-

pheral bores the Irle plug is an especially reliable design.

FEA

WAlZeN Irle’s design engineering department utilizes the most

modern tools such as Finite element Analysis for supporting customers

already in the planning phase of a new machine or of the rebuild of

an existing one. Besides the creation of engineering drawings and

order documentation the following areas are covered as well:

∙ technical counseling and engineering support

∙ technical support of the sales department

∙ engineering of parts according to customer specification

∙ analysis of strength, toughness and stresses etc.

∙ optimization of parts according to customer requirements

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Plastic and rubber calender rolls

Calender rolls provide an important basis for the success of

a profitable rubber or plastic production.

A flawless and precise roll geometry, uniform temperature

distribution, accuracy of surface and mechanical characte-

ristics are the key factors for the runnability of the total pro-

duction machine and marketability of your product.

Being fully aware of these responsibilities, we work on the

metallurgy, on the design and on the machining and we

continuously develop advanced production methods and

procedures.

We develop and manufacture oil heated, water heated and

cooled thermo rolls with optimal properties as individual so-

lutions for customer specific requirements. Our range of roll

materials is based on technical expertise and experience

from about 200 years of research and development and

thousands of successful roll projects for plastic, rubber, pa-

per, steel and other roll applications.

each roll material is adjustable to match optimal the operat -

ing conditions of the customer’s individual application.

Close quality assurance

∙ surface hardness measurement according to leeB, Vik-

kers, Brinell and Shore C

∙ perthometer inspection for surface roughness

∙ equipment to measure bending and tensile strength pro-

perties

∙ a most modern dynamic balancer equipped for hot balan-

cing operations

∙ turning lathes and grinders (including hot grinding) equip-

ped with special devices for measuring concentricity, ru-

nout, roll shape, etc.

∙ close quality assurance according to DIN ISO 9001 by

German TÜV

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MonoTherm S

∙ application: two- or multi-roll calenders

∙ heating/cooling medium: mainly thermal oil or water

∙ flow principle: MonoPass system (peripheral bores close

to surface with integrated patented turbulators)

∙ max. surface temperature: 200 °C

∙ optimal temperature distribution over the circumference

∙ optimally adjustable temperature distribution over the

barrel width and the circumference due to S-Technology

(see page 15)

DuoTherm and DuoTherm S

∙ application: two- or multi-roll calenders

∙ heating/cooling medium: mainly thermal oil or water

∙ flow principle: DuoPass system (peripheral bores close

to the surface, in case of DuoPass S with integrated pa-

tented turbulators)

∙ peripheral drills far from roll surface

∙ max. surface temperature exceeding 200 ° C

∙ good temperature distribution over the barrel width

∙ optimally adjustable temperature distribution over the

barrel width and the circumference due to the optional

S-Technology (see page 15)

TriPass and TriPass S

∙ application: two- or multi-roll calenders

∙ heating/cooling medium: mainly thermal oil or water

∙ flow principle: TriPass system (peripheral bores either

close to the surface or farther inside, in case of TriPass S®

with integrated patented turbulators)

∙ peripheral drills far from or close to roll surface

∙ max. surface temperature 160 ° C

∙ optimally adjustable temperature distribution over the

barrel width and the circumference due to the optional

S-Technology (see page 15)

Heating and cooling concepts

IRLE Thermo Rolls

Thermo rolls from WAlZeN Irle with peripheral bores for the heating/cooling

medium with the proven flow principles MonoTherm S, DuoTherm or TriPass

are successfully operating in all calender types with two or more rolls.

The WAlZeN Irle S-Technology was developed in order to optimize the

sheet profile and create a most even temperature distribution on the roll sur-

face around the circumference and the barrel width of the plastic or rubber ca-

lender rolls.

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Materials

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Chilled Cast Iron (K)

Chilled cast iron rolls, single or compound material, casted statically

or centrifugally, consist of cementite, ledeburite and the metallic

base material matrix (Perlite). Surface hardness and wear resis-

tance is depending on the percentage of cementite in the matrix

and the constellation of the matrix.

Indefinite (I)

The main metallurgical feature of the statically or centrifugally ca-

sted indefinite rolls is the material matrix which is directed radially

from the roll surface to the core. Cementite and graphite are arran-

ged in arrays perpendicular to the roll surface. This makes indefinite

rolls best suitable for applications where high wear resistance, high

mechanical or thermal requirements are important.

Nodular Iron (KSTi)

Nodular iron rolls contain free graphite in spherical form which ma-

kes this material stronger and tougher than cast iron materials with

graphite in lamella form.

Depending on the required wear resistance KSTi rolls contain besides

the spherical graphite different amounts of cementite in the matrix.

An even higher wear resistance will be achieved by induction har-

dening.

Cast Steel (ST0i)

Depending on the chemical composition and the heat treatment

rolls from cast steel consist of a perlitic or bainitic matrix. This ma-

terial comes with a high strength and break resistance.

The rolls are being inductive hardened and annealed.

Forged Steel (FSi)

Forged steel rolls contain annealed martensite in the hardened

surface layer and a homogeneous tempered matrix in the core and

journal material. After forging, tempering and pre-machining the

rolls will be induction hardened and annealed.

K -560

100-x

I -640

100-x

KSTi-520100-x

ST0i-600100-x

FSi-560

100-x

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Surface and geometry optimization

Grinding specifications

Journals rolls

Grey Iron(G)

Nodular Iron(S)

Steel(ST+ FS)

Chilled CastIron(K)

Steel Cast (ST0)

Forged Steel(FS)

HardChrome

Cast

Grinding ra µm 0,5 0,5 0,8 0,20 0,20 0,20 0,15

Fine grinding ra µm 0,4 0,4 0,4 0,10 0,15 0,15 0,08

Special grinding ra µm 0,3 0,2 0,2 0,07 0,07 0,07 0,05

Superfinish ra µm 0,03 0,02 0,02 0,02

Hot grinding ra µm 0,3-0,4 0,5 0,6 0,7

Hot grinding with

Superfinish ra µm0,03 0,02 0,02 0,02

Surface quality

The surface quality of the roll is decisive for the product to be manufactured. rt,

rz and ra are the criteria to describe the surface finish of the roll.

Re-grinding

Depending on product quality, re-grinding operations become necessary

from time to time. WAlZeN Irle provides the full range of surface finishing

to achieve the required surface quality, shape and run-out tolerances of the

roll.

Certificates

WAlZeN Irle reports on all quality related properties, e.g. surface

roughness, roll shape and run-out values under cold and hot conditions.

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Mechanical machining

Hot grinding

In order to eliminate concentricity deviations and edge de-

formation of the thermo rolls during operation the hot grind-ing

process has been developed and implemented in our pro-

duction.

The rolls will be heated up to the respective operating tem-

perature of the production calender, will then be ground to

shape and finish machined at a temperature which reflects

the medium operating range of the calender.

Advantage: deviations of concentricity and shape at operating

temperature are reduced to a minimum.

Calenders running with rolls manufactured using this grinding

procedure show a higher performance and provide better qua-

lity products than with conventionally machined rolls.

Chrome plating / Thermal coating

If a surface coating or plating is required we can provide a

hard chrome plating or a thermal spray coating according

to customer’s application.

Roll service

We can ensure a continuously excellent performance by

frequently servicing your rolls. Besides cold or hot grinding

with or without crown control we perform necessary cleaning

of the flow system of the heating and cooling rolls, refurbis-

hing of bearing seats and fluting of roll surfaces.

A possible rebuild of older rolls to the S-Technology can

provide a much better temperature distribution on the sur-

face.

measured distance Im

(simplified formula)

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Innovations

WALZEN IRLE material ST0 i:

Calender rolls made of the material ST0i have characte-

ristics similar to those of forged steel. ST0i is characterised

by high strength and elongation resulting in a clearly im-

proved resistance against fracture. Furthermore this ma-

terial has a high thermal conductivity. The roll surface will

be induction hardened (i) and thereby shows a fine-grained

martensitic microstructure.

This microstructure is the basis for an extremely high initial

smoothness.

Typical applications for ST0i are calenders with high tem-

peratures and high requirements regarding run out beha-

viour and wear resisance.

ST0i can potentially substitute forged steel material in the

calender applications.

i-hardening

i-hardening is a special thermal process developed by

WAlZeN Irle for hardening of the roll surface in order to

achieve a quality improvement of the calender roll.

For i-hardening the roll materials KST, ST0, FS and FS

plus can be used.

Advantages of i-hardening are

∙ the induction hardening process provides a very homo-

geneous concentric hard layer which gives the roll an

excellent run out behaviour

∙ opposed to a hard coating or the hard layer of a standard

chilled cast iron roll the induction hardening procedure

will not create a thermal insulation

∙ reduced residual stresses

∙ potentially the roll can be re-hardened when the initial

layer is ground of

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WALZEN IRLE S-Technology

The impulse to develop the WAlZeN Irle S-Technology was to

further improve the transition of thermal energy from the peripheral

bores to the roll surface. The thermal transfer is improved by

spindles (turbulators) inserted into the peripheral bores which force

the heating medium into a spiral motion thus increasing the speed

of the fluid and the area it is passing by.

WAlZeN Irle S-Technology is applicable for every peripherally

drilled roll type as a basic feature and also for upgrading existing

rolls. Using the S-Technology tolerances for temperature and

shape accuracy can be reduced by up to 50% compared to con-

ventional peripherally drilled rolls.

material ST0i

i-hardening

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Material introductionStandard values according to FKM-guideline

The above mentioned proposals of roll materials for the individual applications are based on general ex-

perience and the production capabilities of WAlZeN Irle.

The optimum design and material may deviate depending on the specifics of the individual application.

Material

Chilled cast iron Indefinite Nodular iron Cast steel Forged steel

K I KSTi ST0i FSi

Applications l = suitable

Breaker mills (fluted rolls) l l

Mixing mills l l

Coaters and reverse roll coaters l l l

Gasket sheet calender l l

rubber calender l l l l

Plastic calender l l l

Melting calender l l

Specifics static mono or compound casting or spin casting

static mono or compound casting or spin casting

i-hardened spin casting, i-hardened i-hardened

Tensile strength core [N/mm2] core ≥ 160 core ≥ 400 core ≥ 600 core ≥ 900 core ≥ 950

Modulus of elasticity roll [N/mm2] ≥ 130** ≥ 170** ≥ 170 ≥ 200* ≥ 200*

Yield strength core [N/mm2] – – ≥ 390 ≥ 500 ≥ 500

Compression-tension fatigue strength core[N/mm2]

core ≥ 60 core ≥ 80 core ≥ 150 core ≥ 240 core ≥ 220

elongation at break core [%] < 1 < 1 ≥ 3 ≥ 5 ≥ 8

Hardness range HV 500-600 500-560 540-620 500-640 500-640

16 17

* depending on temperature **mean modulus

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Main production facilities foundry:

• 8 electric melting furnaces (induction), with 3 to 30

tons capacity

• 17 heat treatment furnaces

Casting facilities:

• static single and compound casting facilities,

max.casting weight: 130 tons per roll

• horizontal/vertical spin casting machines for rolls upto

12 m casting length

Machining:

• over 80 CNC controlled turning, milling, grinding,

boringand balancing machines in 12 workshop bays

Machining capacity:

• production capacity per month: about 1.500 tons

finished products

• maximum roll sizes:

- barrel length: up to 13 m

- diameter: up to 1,7 m

- finished weight: up to 120 tons per piece

Production monitoring

• determination of chemical composition

• hardness testing according to various test

procedures

• determination of mechanical properties (tensile, ben-

dingand fatigue strength, modulus of elasticity, etc.)

• determination of residual stresses

• ultrasonic tests

• crack tests

• microscopic and physical investigations of material

structures

• special investigations in cooperation with external

institutes

Production capacity

melting plant and foundry

mechanical processing

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The quality control mainly includes the process control and the individual testing of

products. The manufacturing process of rolls is subject to a number of influencing

factors whose interaction determines the quality of the rolls.

Main factors in the process are the precise chemical composition of the materials, the

melting- and casting process within a tight temperature- and time frame, specific heat

treatment- and hardening and tempering processes and the mechanical machining of

the rolls.

The quality assurance of the production process includes the permanent control of the

material by testing the chemical composition using a spectrometer, combustion analysis

of carbon and sulphur and the gas analysis of the contents of oxygen and nitrogen as

well as checking the mechanical properties and the metallography to ensure the correct

formation of the microstructure of our defined materials.

every single roll is subject to non-destructive tests which are carried out for example

by an ultrasonic test, surface hardness tests as well as colour penetrating or magnetic

particle testing. On certain roll qualities internal stress measurements are carried out.

The special scope of testing and tolerances are considerably stricter than the usual

DIN-eN-ISO standards.

recorded standard test results and customer specific special tests are carried out

respectively and are documented in test certificates according to eN 10204 - 3.1.

Customer orientation continues in the material research and development in our

metallurgic laboratory.

The high qualification of our staff in combination with our experience enables us to

realise tailor made solutions and customer specific improvements. We are continuously

optimising our work process according to the ISO 9001:2008 Quality Management, the

ISO 14001:2009 environment Management and the ISO 50001:2011 energy

Management Systems.

Quality department

Quality control, quality management,

research and development

2020 21

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The IRLE GROUP

Due to strategic decisions and developments the

structure of the Irle GrOUP had started with a

spin-off into Irle DeUZ GmbH and WAlZeN

Irle GmbH in the early 70´s of the last century.

In 2000 SIWACO GmbH was founded as a ser-

viceand trading company.

In 2007 Irle founded together with an Indianpart-

ner the Irle KAY JAY rOllS PVT lTD. in-

Panchkula, India.

In 2009 the Irle GrOUP acquired 80% of the

shares of the fast growing machine builder

GapCon GmbH in Willich. This opened a new entry

into the worldwide market for calender rolls.

Siwaco GmbH Huettenweg 2

57250 NetphenGermany

www.siwaco.com

WAlZeN Irle GmbH Hüttenweg 5

57250 Netphen Germany

www.walzenirle.com

GapCon GmbH Walzwerkstraße 20

47877 Willich Germany

ww.gapcon.com

Irle KAY JAY rOllS PVT lTD

India

www.ikjrolls.com

Irle DeUZ GmbH Huetenweg 5

57250 NetphenGermany

www.irle-group.com

23232222 23

Administrador
Cuadro de texto
Contacto: Ing. Benjamin Lozano G. e-mail: [email protected] Erika Angeles D. e-mail: [email protected]
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WALZEN IRLE GMbH

Huettenweg 5 ∙ 57250 Netphen ∙ Germany

Phone +49 (27 37) 504-0 ∙ Fax +49 (27 37) 504-111

www.walzenirle.com

A Company of the

IRLE GROUP