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Forging rolls complex


Forging rolls complex for rolling of blanks is intended for preliminary forming of blanks by rolling method for hot closed—die forging of the crankshaft and front axle beams forgings made in the automatic mode from steel piece billets.

Delivery Set

Forging rolls complex for rolling of billets

Delivery includes the following:

  • closed-type forging rolls of 400t capacity;
  • forging rolls manipulator with loading device;
  • hydraulic equipment;
  • electric equipment (electric equipment installed on the equipments, control cabinet, control desk).

    Specification Of Forging Rolls Complex

    Forging rolls complex for rolling of billets

    Basic technical characteristic:

    Nominal distance between axes — 1000 mm

    Nominal capacity — 400 tf

    Fit places under tool:

    -diameter — 550 mm

    -length — 1000 mm

    Rolls rotation frequency — 30 min-1

    Maximum torque — 43 tm

    Adjustment value of distance between axes — 25 mm

    Maximum diameter of initial billet — 200 mm

    Maximum length of rolled billet — 2100 mm

    Main electric motor power — 160 kW / 1000 min-1

    Maximum loading capacity of the manipulator — 230 kg

    Manipulator longitudinal stroke — 3000 mm

    Manipulator lateral stroke — 750 mm

    Gripper rotation stroke — 0°; 45°; 90°

    Rolling positions number — 4 pcs

    Distance between rolling positions —  210… 250 mm

    Lateral and longitudinal positioning accuracy — ±1 mm 

    Gripper rotation accuracy — ±1°

    Drive for longitudinal and lateral movement — electric


    Drive for gripper clamping and rotation — hydraulic

    Control — controller PLC («Siemens» S7 —  300)

    Frame has welded construction. It consists of the frame housing and welded upright having the possibility to move using the special mechanism. The forging rolls drive is mounted in the frame housing.

    Drive consists of the electric motor, V-belt transmission and single straight gearing. On one end of the high-speed shaft of the straight gearing there is a flywheel connected with the shaft through the pneumatic clutch. The other end of the high-speed shaft is connected with the pneumatic brake and through the overrunning clutch it is connected with the hydraulic motor.

    Hydraulic drive of the forging rolls is intended for slow feed of the working rolls to the billet. It consists of the hydraulic motor, hydraulic-pneumatic accumulator and panel. Hydraulic distributor and the consumption regulator is placed on the panel. Pressure-gauge is installed for control of the hydraulic drive operation.

    Mechanism of the forging rolls adjustment is intended for change of the distance between the rolls. Adjustment is carried out by rotation of the eccentric axle boxes of the lower roll using the drive of the motor-reducer.

    Mechanism for movement of the frame upright is designed for movement of the upright at mounting and dismounting of the profile sectors from the working forging rolls. Movement of the upright is carried out from the motor-reducer through the lead screw and nut.

    Mechanism for balancing of the lower roll is used for taking aside of the upright.

    Working stand consists of the rolls having parallel arrangement. The profile sectors of 4 rolling grooves are attached to the central part of the rolls. If according to the production process one requires rolling in two grooves only, then all at the same time one is able to install the profile sectors for two different billets on the rolls. Thus at change over to manufacture of another billets there is no need to change the sectors, one should only choose new positions for rolling.

    Forging rolls are equipped with he automatic grease lubrication system.

    Rolls manipulator with the loading device.

    Loading device.

    Loading device is designed for feed of the heated billets to the tongs of the forging rolls manipulator. It consists of the base fastened on the foundation, movable frame having possibility to move front and up, hydraulic cylinder performing lifting and lowering of the frame using the levers rotated on the axles. In the upper part of the movable frame the chain conveyer is arranged. The pusher helping to push a billet in the tongs of the manipulator is attached to the chain of the conveyer. The drive of the conveyer is carried out from the electric motor and gearing.


    Manipulator is intended for clamping, tilting and movement of a billet along the rolling grooves. The manipulator frame has welded construction. It consists of the following main mechanisms: mechanism for clamping and tilting of the tongs, mechanism for longitudinal and lateral movement. Clamping and tilting of the tongs with a billet by 45° and 90° is carried out from the hydraulic cylinders. Longitudinal movement of the manipulator carriage is performed from the electric motor through the rack gearing. Lateral movement of the carriage is carried out from the electric motor through the bevel gearing along the frame guides.

    Hydraulic equipment

    Hydraulic equipment is intended for actuation of the actuation mechanisms operating from the cylinders. It consists of the hydraulic station, hydraulic blocks, pipeline, hydraulic motor and power hydraulic cylinders. The hydraulic drive has the pump-accumulator type helping to decrease the driven power. The hydraulic drive has two lines:

  • line of drive of the loading mechanism and drive of slow stroke of the rolls forward;
  • line of drive of the manipulator tongs clamping and tilting by 45° and 90°.

    Both lines for pumping of working fluid under pressure have individual independent systems for pressure holding and are provided with the hydraulic station.

    Complex is included with the following complete sets:

    — main motor with phase rotor and block of resistors — Russian manufacture;

    — control from PLC S7—300 and operator’s panel — «SIMENS»;

    — relay — contact equipment, buttons, switches, alarm lamps, automated switches — «TELEMECANICUE»;

    — electric cabinet and panel of type — «RITTAL»;

    — Cam Switch — «BALLUFF»;

    — servo-motors — «SIEMENS»;

    — hydraulic equipment — «REXROTH»;

    — pneumatic system- «ROSS»;

    — lubrication system — «TRABON».