Cross-wedge rolling line WRL6012

The new WRL6012 cross-wedge rolling line is designed for rolling forgings for stamping with a diameter of 10-60 mm and a length of up to 350 mm. It is intended for the production of parts such as bodies of revolution using cold, semi-hot and hot rolling methods. The line includes an 250 kW induction heating unit (options). Two types of automation of feeding workpieces into the inductor. It is also possible to supply only the rolling line (the heating of the blanks is carried out by the customer)

Cross-wedge rolling line WRL 6012
Diameter of rolled parts, mm	10-60
Maximum length of rolled parts, mm	350
Productivity for single rolling (depending on the power of the high-frequency heating), pcs/hour	360-514
The WRL 6012 machine is designed to produce parts such as bodies of revolution by cold, semi-hot (t = 500-700 C°) and hot (t = 1000-1250 C°) rolling. Cold rolling is used in the mass production of short stepped parts of small diameters of 1-5 mm made of steel and non-ferrous alloys (various types of pins, valves, fingers, axles, pins, etc.). It should also be taken into account that cold and semi-hot rolling can produce finished products with minimal finishing grinding (parts of car headlights, ball pins, etc.). Semi-hot rolling is advisable when it is necessary to obtain with a final surface or minimal allowances for further mechanical processing (grinding). The accuracy of dimensions and quality are slightly inferior to the values achieved with cold rolling, but the list and size of manufactured parts is larger. Hot rolling allows to obtain parts of complex geometric shape, with a large number of transitions and a reduction ratio of 4 - 5 per pass. The accuracy of dimensions and surface quality are determined by wider tolerances than in cold or semi-hot rolling and, as a rule, require further mechanical processing. The machines manufacture large parts, parts of complex configuration, high-precision parts, parts made of material that is difficult to deform: - the machine beds are an extremely rigid pre-stressed closed frame assembled using special wedges, pins and pre-heated studs. - the supporting surface of the frame at the tool attachment point is reinforced with a hardened forged plate. Under the action of the load, the bed is deformed very slightly and is a stable base for the manufacture of high-precision parts. The WRL series machines are characterized by the presence of one (upper) movable tool. The machine ram is mounted on roller bearings with automatic clearance selection, which ensures minimal friction losses and no gaps in the guides when the ram is heated during rolling. All machine elements that come into contact with the hot workpiece have intensive water cooling, which minimizes the time of thermodynamic stabilization of the scale on the workpiece, allows for high-precision control of the workpiece temperature and, accordingly, for obtaining high-precision products. The ram has a long guide base, which ensures a rigid and very precise direction of its movement even with uneven load distribution. The use of high-precision pre-loaded rolling elements as guides ensures no gap and minimal force for moving the ram, as well as insignificant wear of the guides over a long period of time. A smoothly adjustable hydraulic drive allows for each part to select the required force and deformation speed, and during setup to move the ram forward or backward at a slow speed. All machine elements that come into contact with the hot workpiece have intensive controlled cooling, which reduces the time of thermodynamic stabilization of the process to a minimum. A pyrometer adapted to the conditions of scale on the workpiece allows for high-precision control of the workpiece temperature and, accordingly, for obtaining high-precision products.

Dear colleagues!

The WRL6012 cross-wedge rolling line is designed to work with replaceable sets of flat rolling tools (upper movable and lower fixed). The movable tool drive is hydraulic. The rolling machine operates using one hydraulic station, which controls one hydraulic drive of the working and return stroke of the upper slider with the upper rolling tool, as well as other hydraulic mechanisms of the line (precise adjustment of the closed height, which changes the distance between the upper and lower tools).

№	Type
1	Cross-wedge rolling line – WRL6012-01 (manual change die tool set, changeover time 20-30 minutes by line operator). This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Without heater.
2	One tool set WRL6012-01 (standard fixing with bolts on the line). Including design and production.
3	Cross-wedge rolling line – WRL6012-02 (automatic hydraulic change die tool set, changeover time 5-10 minutes by (change control from the line operator panel). This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Without heater
4	One tool set WRL6012-02 (fixing automatic tool changed system). Including design and production.
	Options
6	Induction heating 250 kW (maximum automatic) of workpieces and automatic feeding of workpieces from a storage hopper volume 2500 kg. This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Heating cycle 9-10 seconds
8	Induction heating 250 kW (simplified automation) feeding blanks from a storage tray with a capacity of 10-15 blanks. (loading of the workpiece tray by the operator according to consumption). This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Heating cycle 9-10 seconds

The final cost of the equipment depends on the delivery package and the agreed list of drawings of the products planned for production.

• Production time of the line and one set of rolling tools: 9-10 months

• The equipment and control system complies with USA standards or (Europe, Russian or needed)

• Payment terms: 30% - prepayment, 60% - during the entire production period, 10% - after signing the acceptance certificate on the territory of AMT (before shipment);

• Offer validity period: 20 days;

• Delivery terms: "FCA" Minsk (INCOTERMS-2020) (pickup at the customer's expense);

• Commissioning works are not included in the cost of the equipment and are performed under a separate agreement. These lines are tested on the customer's material before shipment and after delivery, as a rule, in addition to connection, they do not require lengthy commissioning works, and with experience in working with forging and pressing equipment, they allow Customers to independently put them into operation.

Accompanying technical documentation (in English)

• Operation and maintenance manual; a layout solution is provided for the preparation of the production site by the Customer, indicating the locations and requirements for the communications necessary for the line operation.

• General technical drawings (assembly drawings of the main groups);

• Electronic and electrical, pneumatic, hydraulic diagrams;

• To avoid unauthorized changes to the software, the source code of the line control program is transferred after the end of the equipment warranty. Remote service support for the software is provided during the warranty period.

• List of spare parts.

Aesthetic, ergonomic requirements

• Frame RAL 5005 blue; moving parts and protective screens: RAL1023 (yellow); Enclosures of cabinets and control panels of the electrical part: RAL7035 (gray) (we do not paint in other colors). It is possible to paint the frame and protective screens (except for cabinets and control panels) in another color (as an option: the color of the frame and painted parts of the equipment - anthracite gray RAL 7016. The color of the moving parts and safety elements - bright orange RAL 2008)

• Line control in automatic mode from the setup and central control panels.

• Standart ambient temperature oC -10oC +50oC.

• Storage temperature oC Max. 70°C (for 24 h)
• Relative humidity % 80

Rolling is carried out from individual blanks - the heated blank is fed into the machine from the side by the machine loading mechanism. The machine includes a device for automatic feeding of the heated blank into the machine. The machine rolls and forms the forging using the tool. After rolling, the finished forgings are removed along the tray into the container. The machine can be supplied with an automatic feed unit from the storage bin, including induction heating and temperature control before rolling. In the proposed version, the heating of the blanks occurs on the customer's equipment.

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

High degree of automation. Provides 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 into the line, a system for cyclic feeding of blanks from a slide hopper, rolling of forgings and transfer to the next production stage);

Technical data line WRL6012 without induction heater:

· Production cycle: 6-7 sec ( Line output capacity: single rolling – more 514 parts/hour;

· Line power –100-120kW; (3 phase 480 V 60Hz ). The billet heating unit is not included in the line set

· Cooling water consumption 0,2…0,4 МPa, m3 / h - up to 20 (not more ≤25°С)

· Compressed air 0,4…0,6 МPa, m3 / h – not less than 25 m³ / hour. Use components «Festo», «Camozzi»

· Parameters for adjusting the closed height of the tool, mm: 158…164

· Movable die length – 1200 mm;

· Die tools forming length – 1200 mm;

· Die tools forming width – 500 mm;

· Time for tool changing – 10-20 minutes (bolt fixed scheme) or 5-10 with automatic hydraulic change die tool set, (change control from the line operator panel)

· Blank diameter, mm – 10…60 mm;

· Blank length, mm – 60…350 mm;

· Rolling part diameter, mm –10…60 mm;

· Working with heated workpieces heated to temperatures C˚: 900...1200;

· Control System PLC-based, HMI panel (Allen Bradley) consists of a mobile control unit and electric cabinet (on request it is possible to use controllers from other manufacturers);

· Electric cabinet and control panel cabinet “RITTAL”, engress protection: IP65.

· Switching equipment from high quality companies «Telemecanique», «Allen Bradley», «Siemens», «ABB», «Schneider electric»,. Wire – Helukabel ;

· Gearmotors – «Siemens», hydraulic components – «Parker»;

· Shut height adjustment capability with the remote control during operation;

· Management system that is based on a programmable controller, allows the line to work in the adjustment and automatic modes with the withdrawal of all the settings on the operator panel;

· High degree of automation. Provides smooth and stable operation of the line, with full control of all parameters;

· Weight lines, kg – 11 000

The line WRL6012 includes

Rolling machine;
Block for feeding blanks into the machine;
Conveyor for removing rolled parts from the machine;
Pneumatic equipment;
Hydraulic equipment (hydraulic station, communications connections);
Control system (control cabinet, control panel, communications connections);
Tool changer;
Operation manual, electrical, pneumatic diagrams, etc.
Induction heater blank (option)
Accumulating bin with automatic feeding of blanks (option)

3D model complete delivery WRL6012 (without heater)

Lines WRL6012 use an efficient automatic cooling system for die rolling tool set:

Container load planning – WRL6012 and one tool set without induction heater

Planning Lines WRL6012-01 without heater

Lines WRL6012-01 without heater (include load blank mechanism in rolling machine)

Planning Lines WRL6012-01 with Induction heating 250 kW (simplified automation)

Lines WRL with heating 250kWt or simplified automation -

Planning Lines WRL6012 with heating and full automatic loading blank from vibration bin

Line WRL with a die tool set

Rolling process

Real foto the process of forming one cycle a part from a heated workpiece (end process view / side process view). The upper part of the tool moves from left to right, forcing the workpiece to rotate along the surface of the stationary lower part of the tool and the movable upper part, coming into contact with a set of wedge elements that give the workpiece the shape of the required part.

The universal rolling line allows you to work with a large number of changed tools.

We are looking forward to mutual beneficial cooperation!

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Cross-wedge rolling line WRL6012

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