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