This document describes the process of manufacturing large diameter rings through forging and rolling operations. It discusses how the stock material is first upset forged and punched to create a preform, which is then heated and placed between rolls to be ring rolled. Ring rolling reduces the cross-sectional area and expands the inner and outer diameters to form the finished ring. Applications include bearings, turbines, and pipes. The advantages are uniform quality, smooth surface, and close tolerances, while disadvantages can include poor roll cavity filling and need for post-machining. A case study on high speed slewing rings for wind turbines is also presented.

1. LARGE DIAMETER RING
MANUFACTURING
TAREK GEDDAWI 84
MOHAMED KHAMIS 128
KARIM ESSAM 112
MOHAMED ABDEL-MONEIM 141
MOHAMED EMAD 146
AHMED SAAD 21
MOHAMED SHERIF 126
MOHAMED HASSAN 126
MOHAMMED FOUAD 148
MOHAMED MAHMOUD 153
MOHAMED EMAD 147
PRESENTED TO: DR. MOHAMED A. DAHA

2. PROCESS
• The Process of Manufacturing Large
Rings Requires Two Main Forming
Operations:
• Forging: Upset Forging/Punching
• Rolling: Ring Rolling Process

3. FORGING
• Upset Forging: Inreases Work Piece
Diameter by Compressing Length
• Producing The Ring Shape is Done Using
Open Die Forging
• Punching: Creates Hole in Work Piece via
Shearing

4. Stock is First Rounded,
Then Upset to Achieve
Structural Integrity and
Directional Grain Flow.
Stock is Pierced in Order to
Achieve Preform Needed
for Ring Rolling Process.
Completed Preform

5. ROLLING
• The Preform is Heated to Forging
Temperature, then Placed Between Two
Rolls, One is Called the Idler Roll, while the
Other is Called the Driven Roll.
• Pressure is Applied to The Wall by the Idler
Roll
• The Cross Sectional Area is Reduced and the
Inner and Outer Diameters are Expanded
• In Ring Rolling, Rolls are of Different
Diameters.

6. Ring Rolling Begins
With Idler Roll
Applying Pressure on
Drive Roll.
Continuous Pressure
Increases Ring
Diameter. Axial Rolls
Control Preform
Height.
Process Continues
Until Desired Size is
Achieved.

7. RING ROLLING
• Ring Rolling Produces Rings Varying in Size
From a Few Inches to Over 8 Meters in
Diameter and to About 3 Meters in Height.
• Equipment can be Fully Automated from
Billet Handling through Post-Forge
Handling.
• Advanced Ring Rolling Allowing for
Excellent Weight Reduction, Material
Saving and Reduced Machining Cost

8. RING ROLLING
• The Rolls Can Be Shaped to Form Various
Cross Sectional Shapes
• Rings Have Tangential Strength and
Ductility, and Are Less Expensive Than
Similar Closed Die Forgings

9. RING ROLLING
• A Typical Ring Rolling Process has Two
Sets of Rolls: Radial to Control Thickness
and Axial to Control Width.
• During the Process, the Main
Deformation Occurs Between the Driven
(Main) Roll and the Idler (Mandrel) Roll.

10. RING ROLLING
• As the Rolling Process Starts, the Idler roll
applies pressure so the Cross Section of the
Ring Continually Decreases and the Gap
Between The Driven and Idler Roll
Continually Decreases.
• As The Cross Section Decreases, The
Diameter Increases due to
Incompressability of The Material.

11. APPLICATIONS
• Common Applications Include Roller and
Ball Bearings, Turbines, Aerospace
Applications, Pipes and Pressure Vessels.
• Titanium and Super Alloy Rings Are Used
and Housing Parts for Jet Engines in the
Aerospace Industry

12. ADVANTAGES AND DISADVANTAGES
• Advantages:
• Uniform Quality
• Smooth Surface Finish
• Close Tolerance
• Short Production Time
• Relatively Small Material Loss
• Disadvantages:
• Ring Rolling is Poor in Filling the
Roll Cavities
• Some Formed Rings Require
Trueing and/Or Machining
Operations to be Used.

13. PRACTICAL CASE STUDY
• Rotek Inc. Manufactures Slewing
Bearings Used In a Wide Range of
Applications including: Wind
Energy Turbines, Underwater
Turbines and Solar Energy Plants.

14. SERIES 6000 HIGH SPEED SLEWING RING
• High Speed Radial Ball Slewing Rings
• Specifications:
• Stamdard Models from 12’ to 180’ (Up to 4.5m)
• Capacities:
• Thrust: 1,000,000 lb
• Moment: 2,500,000 ft.lb
• Radial: 244,000 lb

15. SERIES 6000 HIGH SPEED SLEWING RING
• Applications:
• Log-Debarking Machines
• Coil Winders
• Pay-Off Reels
• High-Speed Capstans

16. REFERENCES
• http://thelibraryofmanufacturing.com/ring_rolling.html
• https://www.forging.org/system/files/field_document/UBETRingRolling.pdf
• http://thelibraryofmanufacturing.com/ring_rolling.html
• http://patent.ipexl.com/GB/877579ZZDASHZZA.html

17. THANK YOU