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Walzen irle rolls for plastic & rubber production
- 2. 3 oçääë=Ñêçã= t^iwbk=foib=ëáåÅÉ=NSVP 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 contributing 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. éä~åí=ffW=ÑçìåÇêó éä~åí=fW=ã~ÅÜáåÉ=ëÜçé
- 3. 54 jçêÉ=íÜ~å=PMM=óÉ~êë=çÑ=ÑçìåÇêó=ÉñéÉêíáëÉI ~Äçìí=OMM=óÉ~êë=çÑ=êçää=Å~ëíáåÖ=ÉñéÉêáÉåÅÉ 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 reducing rolls for the tube and wire industry 2009 worldwide already 100 heavy plate mill rolls, pro- duced with the vertical spin cast machine, are run- ning in customers mills 2010 WAlZeN Irle celebrates its 190th anniversary as a roll manufacturer 1693 start of casting and machining of iron parts by Jo- hannes 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 1854 founding year of the "Hermann Irle" company 1884 start of the production of paper calender rolls 1903 purchase of the idle flour mill at 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 1957 manufacturing of the first peripherally drilled roll for the plastic industry 1960 complete new construction of plant I 1969 purchase of the roll foundry of Krauss-Maffei, a machine builder for the plastic and rubber industry. This widened the entrance to the market of plastic and rubber rolls. 1972 building of state of the art foundry and moulding 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 2000 development of the Irle-Auto-lock-System 2000 market launch of hot grinding procedures and hot balancing for paper and plastic calender rolls 2001 development of the WAlZeN Irle S-Technology® to optimize the geometry of heated calender rolls under operating conditions 2005 extensive equipment investments for the pro- duction of spin casted heavy plate rolls, roughing rolls and for the production of hot strip rolls at the facility in Deuz 2006 assembly of the world's largest vertical spin cast- ing machine (up to 100 t casting weight) 2007 production start of the new vertical spin casting machine
- 4. ^ééäáÅ~íáçåë foib=qÜÉêãç=oçääë=Ñçê=íÜÉ=éêçÇìÅíáçå=çÑ=Åçåíáåìçìë=éä~ëíáÅ ëÜÉÉíë= 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 me- thod, statically or centrifugally casted, or from forged steel. They are equipped with dif- ferent 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. foib=qÜÉêãç=oçääë=Ñçê=íÜÉ=éêçÇìÅíáçå=çÑ=êìÄÄÉê=éêçÇìÅíë 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 profiles, sealings, gaskets, hoses, mats, pads etc. Our rolls are in operation in breaker stacks, mixing calenders and rubber calenders. foib=qÜÉêãç=oçääë=Ñçê=íÜÉ=éêçÇìÅíáçå= çÑ=Ö~ëâÉí=ëÜÉÉíë WAlZeN Irle supplies heated and cooled rolls for the production of gasket sheets which are for example being used in the auto- motive industry but also in the aerospace industry. t^iwbk=foib éäìÖ even though we can provide every type of sealing for the peri- pheral bores the Irle plug is an especially reliable design. cb^ WAlZeN Irle’s design engineering department utilizes the most modern tools such as Finite element Analysis for supporting custo- mers already in the planning phase of a new machine or of the rebuild of an existing one. Besides the creation of engineering draw- ings 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 6 mä~ëíáÅ=~åÇ=êìÄÄÉê=Å~äÉåÇÉê=êçääë 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 charac- teristics are the key factors for the runnability of the total production 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 solutions 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, paper, steel and other roll applications. each roll material is adjustable to match optimal the operat- ing conditions of the customer’s individual application. `äçëÉ=èì~äáíó=~ëëìê~åÅÉ ∙ 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 ba- lancing operations ∙ turning lathes and grinders (including hot grinding) equip- ped with special devices for measuring concentricity, runout, roll shape, etc. ∙ close quality assurance according to DIN ISO 9001 by German TÜV 7
- 5. 98 jçåçqÜÉêã=p∆ ∙ 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) aìçqÜÉêã® ~åÇ=aìçqÜÉêã=p® ∙ 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) qêám~ëë=~åÇ=qêám~ëë=p® ∙ 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) eÉ~íáåÖ=~åÇ=ÅççäáåÖ=ÅçåÅÉéíë foib=qÜÉêãç=oçääë 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 surface around the circumference and the barrel width of the plastic or rubber calender rolls.
- 6. NNNM 11 j~íÉêá~äë 10 `ÜáääÉÇ=`~ëí=fêçå=EhF Chilled cast iron rolls, single or compound material, casted stati- cally or centrifugally, consist of cementite, ledeburite and the me- tallic base material matrix (Perlite). Surface hardness and wear resistance is depending on the percentage of cementite in the ma- trix and the constellation of the matrix. fåÇÉÑáåáíÉ=EfF 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 indefi- nite rolls best suitable for applications where high wear resistance, high mechanical or thermal requirements are important. kçÇìä~ê=fêçå=EhpqáF Nodular iron rolls contain free graphite in spherical form which makes this material stronger and tougher than cast iron materials with graphite in lamella form. Depending on the required wear resistance KSTá 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. `~ëí=píÉÉä=EpqMáF 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. cçêÖÉÇ=píÉÉä=EcpáF 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. hJRSM NMMJñ= fJSQM NMMJñ== hpqáJROM NMMJñ pqMáJSMM NMMJñ cpáJRSM NMMJñ=
- 7. pìêÑ~ÅÉ=~åÇ=ÖÉçãÉíêó=çéíáãáò~íáçå Grinding specifications Journals rolls Grey Iron (G) Nodular Iron (S) Steel (ST+ FS) Chilled Cast Iron (K) Steel Cast (ST0) Forged Steel (FS) Hard Chrome 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 µm 0,03 0,02 0,02 0,02 pìêÑ~ÅÉ=èì~äáíó 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. oÉJÖêáåÇáåÖ 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. `ÉêíáÑáÅ~íÉë WAlZeN Irle reports on all quality related properties, e.g. surface roughness, roll shape and run-out values under cold and hot conditions. 1312 jÉÅÜ~åáÅ~ä=ã~ÅÜáåáåÖ eçí=ÖêáåÇáåÖ 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 production. 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 quality products than with conventionally machined rolls. `ÜêçãÉ=éä~íáåÖ=L=qÜÉêã~ä=Åç~íáåÖ 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. oçää=ëÉêîáÅÉ 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, refurbishing 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)
- 8. NQ1414 fååçî~íáçåë t^iwbk=foib ã~íÉêá~ä=pqMáW Calender rolls made of the material ST0á have characte- ristics similar to those of forged steel. ST0á 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 (á) and thereby shows a fine-grained martensitic microstructure. This microstructure is the basis for an extremely high initial smoothness. Typical applications for ST0á are calenders with high tem- peratures and high requirements regarding run out beha- viour and wear resisance. ST0á can potentially substitute forged steel material in the calender applications. áJÜ~êÇÉåáåÖ á-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 á-hardening the roll materials KST, ST0, FS and FS plus can be used. Advantages of á-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 15 t^iwbk=foib pJqÉÅÜåçäçÖó® The impulse to develop the WAlZeN Irle „S-Technology®“ was to further improve the transition of thermal energy from the peri- pheral 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. ã~íÉêá~ä=pqMá áJÜ~êÇÉåáåÖ
- 9. j~íÉêá~ä=áåíêçÇìÅíáçå Standard 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. j~íÉêá~ä `ÜáääÉÇ=Å~ëí=áêçå fåÇÉÑáåáíÉ kçÇìä~ê=áêçå `~ëí=ëíÉÉä cçêÖÉÇ=ëíÉÉä h f hpqá pqMá cpá 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 á-hardened spin casting, á-hardened á-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
- 10. 19 Main production facilities foundry: ∙ 8 electrical 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 up to 12 m casting length laboratory: ∙ determination of chemical composition ∙ hardness testing according to various test procedures ∙ determination of mechanical properties (tensile, ben- ding and fatigue strength, modulus of elasticity, etc.) ∙ determination of residual stresses ∙ ultrasonic tests ∙ crack tests ∙ microscopic and physical investigations of material structures (determination of the structure composition regarding type and content) ∙ special investigations in cooperation with external in- stitutes Machining: ∙ over 80 CNC controlled turning, milling, grinding, boring and balancing machines in 12 workshop bays Production 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 mêçÇìÅíáçå=Å~é~Åáíó ãÉäíáåÖ=éä~åí=~åÇ=ÑçìåÇêó ãÉÅÜ~åáÅ~ä=éêçÅÉëëáåÖ= 1818 19
- 11. 21 WAlZeN Irle’s quality assurance contains the control of the production process and testing of individual products. For some roll types the production process can be influ- enced by up to 400 different factors such as the precise chemical constellation of the material, the melting and cast- ing process in narrow temperature and time slots, individual heat treatment and annealing processes and mechanical and geometrical properties of the rolls. Ongoing testing of the materials during production is part of the quality assurance. Testing methods are: testing of chemical constellation by means of spectrometer, leCO and gas analysis of Oxygen and Nitrogen content as well as testing of tensile strength and microscopic testing for correct development of the material structural matrix. each roll will be checked with non-destructive testing me- thods such as ultrasonic for correct bonding of layers in compound casted rolls, surface hardness check, magnetic particle test and dye penetration test for cracks. For certain roll types residual stress measurements will be done using different testing methods. Standard test results and additional customer specific tests will be documented in the respective work certificates. Our research and development of new materials is always focussed on the customer. Besides the high skills of our personnel we have gathered lots of knowledge in several rolling processes of different industries which makes up a competent partner for tailor made solutions and innovations for our customers. Some of the developments are materials suitable for future requirements, combination of materials, optimisation of the Irle production under consideration of customer’s production and quality. Our special testing methods and tolerances are much stricter than DIN norm and TÜV certificate require. The QMS has to follow the Irle innovation level accordingly. Therefore it is continu- ously updated. nì~äáíó=ã~å~ÖÉãÉåíI êÉëÉ~êÅÜ=~åÇ=ÇÉîÉäçéãÉåí= 2020 21
- 12. OPOP qÜÉ=foib=dolrm 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 service and trading company. In 2007 Irle established together with an Indian partner 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 world wide calender market. 22 SIWACO GmbH Huettenweg 2 57250 Netphen Germany www.siwaco.com WAlZeN Irle GmbH Huettenweg 5 57250 Netphen Germany www.walzenirle.com GapCon GmbH Walzwerkstraße 20 47877 Willich Germany www.gapcon.com Irle KAY JAY rOllS PVT lTD India www.ikjrolls.com Irle DeUZ GmbH Huettenweg 5 57250 Netphen Germany www.irle-group.com 22 OP