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FORGE-Cold Roll Work Roll
ETERNAL
Forged steel work rolls are core spare parts in aluminum plate and strip rolling production lines that directly contact aluminum blanks and apply rolling force. Typically used in conjunction with backup rolls, they are widely deployed in the cold rolling and finishing processes of aluminum plates, and play a decisive role in controlling the thickness accuracy, surface quality and flatness of aluminum plates and strips.
Forged steel work rolls of ETERNAL can been supplied to world's top steel manufacturer :
German:SMS Group,Achenbach
Italy:Danieli,Mino
Japan:Hitachi
Austria:Andritz,etc.
Parameter | Specification |
Brand | ETERNAL |
| Raw Material | ESR ingot |
| Material | Forged steel |
| Production Process | Electric slag remelting → forging → heat treatment → lathe machining |
| Heat Treatment | Normalizing; spheroidizing annealing; Oil quenching+ high-temperature tempering |
| Surface Treatment | Double-frequency quenching; cryogenic treatment;low-temperature tempering |
| Surface Hardness | HRC 58-62 |
| Depth of Hardened Layer | 10-50 mm |
Inspection Test | 100% UT/MT according to standards such as EN 10228 series |
ETERNAL determines the material of rolls in accordance with customer requirements. At present, forged steel rolls are generally made of materials such as Cr2, Cr3 and Cr5 series, and the raw materials are produced by electricslag remelting method.
ETERNAL strictly controls the content of harmful elements such as P/S and the longitudinal section of electroslag remelted ingot presents herringbone crystallization. White spots, internal cracks, shrinkage cavities, laps and naked-eye visible non-metallic inclusions are not permitted.
High Temperature Forging
ETERNAL adopts free forging, with multiple upsetting and elongation processes to break down coarse grains in the cast state, allowing for continuous distribution of metal fibers and improving overall strength and impact resistance.
Pre-heat treatment After Forging
The rolls will be spheroidization annealed to soften the matrix, refining grains, facilitating subsequent mechanical processing, while eliminating internal stresses during forging.
Rough Machining
The outer circle of rolls will be turned to remove surface scale, leave machining allowance, and take samples for composition analysis and metallographic test.
ETERNAL will perform overall oil quenching and high-temperature tempering on the rolling mill rolls,surface quenching on the roll body, cryogenic treatment and low-temperature tempering.
The purpose of heat treatment is to obtain high hardness and deep quenched hard layer on the working surface of the roll body, retain high toughness in the roll neck and core, and prevent roller breakage and cracking in the roller neck.
Quenching&Tempering Surface Quenching Cryogenic Treatment
1.Quenching and tempering is an extremely important preliminary heat treatment prior to the final induction heating quenching of cold rolling work rolls, which aims to improve the mechanical properties of roll necks and roll cores. After quenching and tempering, its metallographic structure consists of tempered sorbite plus granular carbides. All carbides in the matrix shall be granular and uniformly distributed. Cold rolling rolls with carbides in such a state feature high wear resistance and excellent accident resistance, capable of meeting the demands of cold rolling mills.
2.Surface heat treatments for rolls include medium-frequency continuous induction quenching, high-frequency continuous induction quenching, and power-frequency continuous induction quenching.
3.Cryogenic treatment is a process performed between surface induction quenching and low-temperature tempering,which can increase the depth of the hardened layer. It cools the working layer of the roll barrel to below 0 °C by using liquid nitrogen or dry ice mixed with ethanol, and the workpiece is generally held at a temperature range of -70 °C to -85 °C for a certain period of time.
4.Low-temperature tempering is mainly used to relieve stress and achieve the specified hardness value.
Final Machining
The rolling mill rolls need to have better accuracy. Therefore, fully CNC machining equipments and grinding machines are used to meet the requirements of size, roundness, and roughness step by step.
Quality Inspection
Before delivery, all rolls must undergo the following strict quality inspections:
1.Hardness and hardened layer depth inspection
2.Metallographic structure analysis
3.Grain size test
4.UT/MT test
5.Inspection of mechanical dimensions and geometric tolerances
Regular Grinding: Periodically remove fatigue layers and micro-defects on the roll surface to restore roll contour accuracy.
Surface Repair: Rolls with minor damage can be repaired by technologies including chrome plating and laser cladding.
Condition Monitoring: Timely identify roll abnormalities through monitoring parameters such as vibration, temperature and rolling force.
Service Life Assessment: Comprehensively evaluate the roll replacement timing based on rolling tonnage, surface condition, dimensional variations and other indicators.
| Manufacture drawing | √ | Process schedule with ETD date | √ |
| Raw material chemical specification test 100% | √ | Forging temperature control 100% | √ |
| Heat treatment after forging 100% | √ | UT test after forging 100% | √ |
| MT test after heat treatment 100% | √ | Metallographic test is optional | √ |
| Forging sample cutting is optional | √ | Sample mechanical property test is 100% | √ |
| Finish machining is optional | √ | Mechanical property test report | √ |
| Mill test report | √ | The third party Checking | √ |
| Photos &videos of each process | √ | ISO 9001,45001,14001 certificates | √ |
| Safety export packing 100% | √ | Warranty Time | √ |
Eternal Heavy Industry Co.,Itd covers the space 15000 square meters,8000 square meters heavy duty workshop was builted. Its max lift height is 16 Meters and designed max loading capacity is 75 tons.
Eternal Heavy Industry Co.,Itd has advanced manufacturing equipment including vertical CNC machining centers, frame type CNC machining centers, CNC lathes, heavy duty horizontal lathes, display boring and milling machines,etc. Testing equipment includes computer tensile testing machine,low temperature impact tester,UT tester,MT detector,etc.
Pre-sales service: According to the actual working conditions and needs of customers，ETERNAL recommends suitable materials and can develop and design products according to needs. Customized services can also be provided.
Strict quality control: From raw materials to the production process and before leaving the factory, all performance indicators are strictly tested, and the professional QC team controls according to the process.
After-sales service: Resolution of any issues and free maintenance and replacement of parts during the warranty period.
Raw material workshop Forging workshop Heat treatment workshop Machining workshop
Machining workshop Machining workshop Assembly workshop Finished product workshop
ETERNAL has been exported to Europe, U.S.A , South Africa, Russian, Mexico, Brazil, Peru, Chile, Korea, Vietnam, Indonesia, Middel East, etc more than 80 countries.
Our quality is accepted by customers. In future we would devote ourselves to deep research and new market, and we expect to make a better co-operation with our customers.
Electroslag remelting (ESR) can purify molten steel, drastically reduce the content of internal inclusions in steel, refine grains, homogenize carbide distribution, and eliminate casting defects such as porosity and segregation. Consequently, it improves the hardness uniformity of work rolls, avoids cracking caused by localized stress concentration during service, and makes the rolls suitable for rolling high-end, high-precision aluminum sheets.
① Hot rolling / Roughing: Prioritize 9Cr2Mo and Cr5 grades. They feature excellent thermal fatigue resistance and are less prone to thermal cracks under high-temperature rolling conditions.
② Cold rolling / Finishing / Aluminum foil rolling: Prioritize electroslag remelted (ESR) 8Cr3Mo and 9Cr3Mo steels. These steels boast high purity, superior roll surface finish and outstanding wear resistance, capable of meeting the production requirements for high-precision aluminum products.
