High-Performance Rollers for Metals Processing

Transcription

High-Performance Rollers
for Metals Processing
Engineering expertise and manufacturing skills are
what set the Osborn brand apart. People experienced
in surface treatment solutions and finishing tools,
collaborating with cutomers to achieve optimum r esults.
Matching tough fi
nishing problems with the right
solutions when and where you need them.
Countries
United States
United Kingdom
Taiwan
Sweden
Spain
Singapore
Romania
Portugal
Mexico
India
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Germany
As the global leader in surface treatment and finishing
solutions, we have more patents on products and
processes than all other brush companies combined.
France
Since Osborn’s inception in 1887, success has always
been about ensuring that you finish first. Whether it was
last century, last week or in the last hour, customers like
you need the right solutions and count on us.
China
About Osborn
Brazil
Operations in
Offers access to new ideas, economies of scale, and new
techniques to master your surface treatment and finishing needs.
In addition to more than 10,000 standard products
sold in more than 120 countries, we offer local support
throughout the world. So, no matter where you or your
customers are located, you will always have access to
Osborn application expertise and the industry’s best,
most practical solutions.
When you start with Osborn, you finish first.
Sales offices in
23
2,000
Countries
Employees worldwide
Servicing more than
120
Countries
through numerous agencies and
strong distribution networks.
Providing insight into the customs
and best practices necessary to
succeed anywhere in the world.
Your Partner for High-Performance ROLLERS in Aluminum, Carbon Steel,
Stainless and Non-Ferrous Coil and Sheet Metals Processing
STRIP PROCESS LINES
HOT & COLD ROLLING
N STEEL
RBO
A
C
LESS STEE
L
M IN U M ALU
AIN
ST
N-FE RROUS
4
AUTOMOTIVE PRESS &
BLANKING LINES
NO
THERMOPROCESS FURNACES
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Hot & Cold Rolling
Hot & Cold Rolling
Hot & Cold Rolling
Application category
Metallurgic field
Process line
Carbon steel
Skin Pass Mill,
Temper Mill,
Continuous Hot-dip
Galvanizing Line
Roll cleaning
and polishing
Stainless steel
Skin Pass Mill,
Temper Mill
Aluminum
Cold Rollig Mill
Aluminum
Hot Reversing Mill, Hot
Reversing Finishing
Mill, Hot Finishing Mill
Non ferrous
Hot Continuous Mill
Roll coating control
Description of application OSBORN product range
Removal of oxides,
dirt and
rolling residuals
Control of the oxide
layer and removal of
oxides
Helimaster® Brush rolls,
abrasive or wire-filled;
Non-abrasive Brush rolls;
Lipprite® abrasive
Non-woven rolls
Helimaster® Brush rolls
abrasive or wire-filled
Brush Roll Applications
Almost 50 years ago, Osborn developed a revolutionary technology using brushes in the continuous rolling
process in order to optimally regulate the oxide film
on working and back-up rollers in hot rolling mills. As
a result hundreds of hot mills worldwide have been
equipped with Osborn technology.
To date, specially designed wire qualities, abrasive multifilaments, individually camber ground surfaces and
extensive experience in optimising the use of brushes in
numerous individual applications have secured a major
technological advantage for us in this field. The benefits
from this we can pass on to our customers worldwide.
In the meantime, with Lipprite® abrasive rollers, an
alternative technology, has also been developed and
manufactured in-house for skin-pass roller cleaning.
The brush roller itself is only part of the solution. This
technologically demanding application can only be
optimally implemented with a precise matching of
the brush tool to operational and process parameters.
The reproducibility of the specified corrosiveness and
brush effect as well as constant tool performance play
a crucial role from the first point of use to the exchanging of the roller.
Osborn’s Helimaster brush rolls are perfect for cleaning
work and back-up rolls in wet or dry operated rolling
and skin-pass mills. They have been fitted to technological developments worldwide for decades, both in
online lines integrated in strip lines as well as standalone off-line rolling stands.
The rollers can work sporadically or continuously when
designed as a wire or an abrasive brush. Each brush
is neutrally ground at the radius and gets axially. This
means that it gets either a cylindrical camber ground
or, for offsetting the computed roll deflection, a positive and/or negative camber ground.
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Hot & Cold Rolling
Hot & Cold Rolling
Non-woven Roll Applications
For the cleaning of deflector, shape control or thickness
measurement rolls, special wear-resistant non-abrasive
plastic filaments are used. They ensure an equally
thorough removal of solids and liquid materials without
damaging the roll surface or altering the roughness.
At the same time, the filament type and bristle diameter are dependent on the surface hardness and the
degree of pollution of the roll that requires cleaning.
The individually adapted camber ground of the brush
roller body is one of the most important prerequisites
for guaranteeing uniform brushing across the entire
width of the roll. Depending on the construction of
the working or back-up rollers to be brushed and the
calculation of the optimum crown, convex or concave
contours are ground. Osborn, of course, also grinds
brush rollers with a CVC contour on CVC technology
mills for roller gap adjustment.
NCCM® Premier Yellow Neutral Mill Rolls are the
finest general-purpose, Non-woven roll covering
for primary metal and original equipment manufacturer
(OEM) stamping operations.
NCCM® Premier Yellow Neutral Mill Rolls are porous
to absorb debris that can mar the metal strip surface.
Once absorbed, the roll heals over so fewer repairs that
reduce productivity are required. If a problem does occur, the rolls can be quickly and easily repaired instead
of replaced.
Porosity also makes the NCCM roll compressible which
maintains consistently tight contact across the metal
strip to wring uniformly. Chemical tank to tank carry-out
and the need for auxiliary drying is reduced. The rolls
have up to 24 times greater coefficient of friction compared to rubber or urethane rolls to improve material
control by reducing metal coil slippage and hydroplaning. One NCCM® Premier Yellow Neutral Mill Roll
can last as long as up to 100 rubber rolls making it an
exceptional value for the money spent, especially when
costly line downtime is taken into account.
NCCM® Mill Roll premium roll covering products optimize countless metal sheet processing applications in
primary metals and AOEM (automotive original equipment manufacturer) stamping plants. They also show
exceptional value In other industries such as lithography.
Individually adapted camber ground
NCCM® Mill Roll technology is designed to replace traditional roll coverings such as rubber, urethane, Non-wovens
and various fabrics. NCCM® Mill Roll technology has features and properties that no other Non-woven rolls offer.
Premier Yellow
Compared to Felt Wipes Rubber
or Cork, NCCM® Mill Wipes offer:
• Longer life
• Better cleaning, “scrubbing”, and wiping action
• Less waste
• Easier operation
• Best value
International Cooperation
DK Blue: PMS 301
C=94
M=34
Y=8
K=1
LT Blue: PMS 298
C=68
M=3
Y=0
K=0
Osborn has a value-add-cooperation with
company NCCM, River Falls/WI, United
States for manufacturing and service of high-tech
Non-woven Mill Rolls.
Yellow:
C=0
M=4
Y=100
K=2
Gray:
C=0
M=0
Y=0
K=80
Fonts:
Avant Garde
Neutraface Text
Since 2009 NCCM has the exclusive rights to
the original premier yellow non-woven material
from 3M Company anywhere in the world. NCCM
own a unique technology in the manufacturing of
roll coverings using the original 3M high-tech
material.
Osborn is engineering individually customized
High performance Non-woven Rolls for Quality
and Process improvement in Coil and Sheet Metal
processing in Strip Process Lines, Rolling Mills
and automotive press- and blanking systems,
using the leading NCCM technology in combination
with our comprehensive application know-how.
We are assembling, finishing and servicing
the original premier yellow rolls in our wide-face
Roller manufacturing centers around the world.
Neutral Mill Roll
NCCM® brand is a trademark of NCCM Company.
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Hot & Cold Rolling
Hot & Cold Rolling
CARBON STEEL
Cold Rolling Mill
BETTER FRICTION, HIGHER
TENSION, LESS SLIPPING
UNIFORM OIL FILM,
REDUCE CONSUMPTION
OF OIL
Non-woven Mill Roll
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Line-Diagrams for many different applications can be found online at:
Brush Roll
http://www.osborn.com/en-de/markets/primary-metals/primary-metals-applications/
Bridle S-Roll
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Hot & Cold Rolling
Hot & Cold Rolling
CARBON STEEL
Temper Mill
UNIFORM OIL FILM,
REDUCE CONSUMPTION
OF OIL
HIGH CLEANING PERFORMANCE, HIGH CONTACT
DENSITY
Non-woven Mill Roll
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Brush Roll
Bridle S-Roll
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Hot & Cold Rolling
Hot & Cold Rolling
Cold Reversing Mill
ALUMINUM
SNUBBER/PINCH ROLL,
LESS MARKING,
NO SLIPPING
WRINGER ROLL, HIGH ABSORBING
CAPACITY OF SOLUTION, AVOID
QUALITY CLAIM FOR SCRATCHES
Non-woven Mill Roll
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Furnace Brush Roll
Bridle S-Roll
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Thermoprocess Furnaces
Transport roll systems
for Horizontal Heat
Treatment Furnaces
Transport roll systems
for high temp
applications
Metallurgic field
Aluminum
Process line
Horizontal Heat
Treatment Plate
Furnaces
Carbon steel
Continuous Annealing Line,
Continuous Hot-dip
Galvanizing Line
Stainless steel
Bright Annealing Line,
Cold Strip - Annealing
Pickling Line, Continuous Annealing Line,
Hot Strip-Annealing
Pickling Line
Aluminum
Non ferrous
Transportation of hot
plates through the heat
treatment process;
optimized heat transfer;
Avoidance of transport
roll pick-up and surface
damages
Transportation of high
temp strip; Avoidance
of transport roll pick-up
and surface damages
Brush transport rolls;
Horizontal Heat
Treatment
brush transport roll
systems;
Furnace capacity
increase concepts
High temp brush
transport rolls; Brush
transport roll systems
With brush furnace transportation rolls, Osborn customers can today place their trust in several decades
of experience and well known global references. In
the complex production of the rolls, some with a
total length of over 6000mm and 4000mm of brush
length, the highest level of precision and reliability are
required in all manufacturing processes.
After the rolls have been manufactured, the later course
of the sheet is accurately simulated in advance in our factory. For roll assemblies in new furnace lines, this allows
Osborn to guarantee an optimum course of the sheet
within tight tolerances even when starting up the run.
Benefits
• Optimum heat transfer between the transportation roll and the plate
• Longstanding lifetime without significant wear
of the brushes
• Complete avoidance of scale pick-up and spot
formation on the surface of the roller, just as it
is the case with self-contained roller coverings
• Total-care transportation of the plates during
the heat treatment without damaging the surfaces
of the plates
Horizontal Heat
Treatment,
conveyor furnace
Applications
The tempering of hot mill plates made of precipitation hardening aluminum alloys through the process
of solution annealing, serves the purpose of attaining
higher strength and strain values along with a good
level of corrosion resistance. Today, this is required for
structural parts in aircraft in accordance with the strict
requirements of standards AMS 2750D, AMS 2750C
and AMS-H-6088.
The careful transportation of these aluminum plates in
‘hard metal and hard material technology’ roll hearth furnaces takes place as a batch or continuous process at tem-
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peratures of up to 600°C on brush transportation rolls. In
close cooperation with leading equipment manufacturers,
numerous furnaces around the world have been equipped
in recent years with Osborn’s sophisticated technology.
In the process, plates with thicknesses of up to 400mm,
lengths of 20 metres and weights of over 10 tonnes do not
present a problem for us. Tolerances have been continually
reduced and product features optimised, so that now more
than ever, the brush roller is an integral and technologically
superior component in the overall design of the line.
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No Pick Up with Osborn!
In order to guarantee the lowest possible sheet tracking
with the ‘re-brushing’ of entire furnace zones the transportation of the sheets is simulated on an in-house test
rig just like new lines.
This advanced technology provides a convincing argument for why brushing with heat resistant wires is increasingly establishing itself as a roller cover for furnace
transportation rolls.
Aside from the production of new rolls, the recovering
and replacement of worn brushes in older lines is also
one of our core competences.
By precisely measuring the course of the plate as well
as the state of the individual rolls within the furnace by
means of self-developed test equipment, we are able to
optimise plate tracking if needed, which maximizes the
output of the entire system.
PICK-UP WILL NOT FORM ON THE BRUSH SURFACE
Roll coverings made from extremely dense stainless
steel wires in special alloys and resistant to high temperatures provide specific product features and strong
advantages compared to uncoated transportation
shafts or furnace rollers with ceramic coatings. These
can be used in different horizontal heat treatment lines
for strips of steel, stainless steel or non ferrous metals.
PROPERTIES AND ADVANTAGES
Scale / Iron particles
•Temperature resistance of up to approx. 1250°C
•Shaft construction with internal cooling
•Extremely dense and accurate neutrally ground
surface of the rolls
•Significantly better heat transfer characteristics of the
tips of the wires in comparison to full metal surfaces
•No scale pick up (formation of spots) on account of the
absorption properties of the exposed brush surface
•Reduced maintenance
•Particularly careful transportation of the plates and
reduction of damage to the surface
•Very low wear to the rolls with significantly longer
lifespan than ceramic coatings or other roll coatings
OSBORN FURNACE ROLL
NO PICK UP
CAPACITY OPTIMIZATION AT OLDER FURNACE INSTALLATIONS
Plate tracking in initial state
Zone 1
Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
Zone 1
Zone 2
Zone 3
Zone 4
Plate tracking after optimization as per OSBORN recommendation
Zone 5
Zone 6
Platetracking
trackingafter
afteroptimization
optimizationas
asper
perOsborn recommendation
OSBORN recommendation
Plate
Zone 1
Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
Zone 1
Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
CONVENTIONAL FURNACE ROLL
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PICK UP PROBLEMS
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STAINLESS STEEL
ELIMINATES PICK-UP,
EXTENDED SERVICE LIFE
Non-woven Mill Roll
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Furnace Brush Roll
Bridle S-Roll
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Strip Process Line
Strip Process Line
Strip Process Lines
Degreasing, washing
and cleaning
Metallurgic field
Process line
Carbon steel
Continuous Hot-dip
Galvanizing Line,
Continuous Annealing
Line, Cleaning Line/
Degreasing Line,
Electrolytic Tinning Line
Aluminum
Tension Level Line, Slitting/Cross Cutting Line
Non ferrous
Cleaning Line, Descaling
Pickling Line, Annealing
Pickling Line,
Continuous Pickling Line
Carbon steel
Continuous Pickling
Line, Color Coating Line,
Electrolytic Galvanizing
Line, Electrolytic Tinning
Line
Strip surface activation
prior to coating
Aluminum
CM
Strip, sheet or plate surface preparation prior
to cladding, coating or
pressing
Non ferrous
Annealing Pickling Line,
Aluminum
Non ferrous
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Scale removal
Stainless steel
Carbon steel
Polishing Line,
Annealing Pickling Line,
Finishing Line
Metallurgic field
Process line
Carbon steel
Heavy duty descaling
prior to acid pickling
Hot Strip - Annealing
Pickling Line
Hot Strip Annealing Line,
Cold Strip Annealing
Line, Bright Annealing
Line,
Cleaning Line
Activation of strip
surface
Strip polishing and
finishing
Removal of oil, grease,
other protective
coatings,
rolling residues or dirt
from the strip/sheet
surface
Brush rolls, abrasive or
non-abrasive, OSBORN
HDL® Technology
Stainless steel
Non ferrous
Hot Strip - Annealing
Pickling Line
Heavy duty descaling
between acid tanks
Hot Reserving Mill
Scale and dirt removal
prior to rolling
Brush rolls abrasive
or wire-filled; Heavy
abrasive brush rolls;
OSBORN HDL®
Technology;
Lipprite® abrasive
Non-woven rolls
HDL Brush Roll Applications
Oxide removal, polishing
and finishing of hardened
and tempered strips
Oxide removal, polishing, finishing and
generating decorative
surfaces
The demands relating to the quality and the technical
product characteristics of flat rolled steel in the form
of cold rolled steel, tin plated steel, electrical steel,
galvanized strips or other refined surface materials are
steadily rising. Along with increasing processing speeds,
optimising the tempering, refinement or coating process
of the upstream strip cleaning section also increases.
With the development and introduction of the HDL®
brush roller, Osborn has found an answer to these
demands, in comparison to conventional brush rollers.
HDL® sets new standards in the degreasing and cleaning of strip surfaces. Through the consistent development of quality, by looking at fill material, brush
construction and fill density, we achieve significant
Brush rolls, abrasive or
wire-filled, OSBORN
HDL® Technology
Brush rolls abrasive or
wire-filled; Bessemerwire brush rolls;
OSBORN HDL®
Technology;
Lipprite® abrasive
Non-woven rolls;
UNIPOL® polishing
compounds
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Strip Process Line
Strip Process Line
COMPARISON CONVENTIONAL BRUSH VS. OSBORN HDL
improvements in terms of the brush lifetime / cleaning performance. This results in reduced operating
and maintenance costs for our customers.
For descaling strip surfaces after hot and cold mill
processes, our brush rollers have been setting standards
for years. OSBORN’s developments and innovations in
both brush constructions and filaments have in set the
international standards in annealing and pickling lines or
bright annealing lines for stainless steel strip.
Conventional Brush
Osbon HDL
(Mono-Filament)
(Multi-Filament)
Imprecise brushing
Very precise brushing
Low cleaning performance
High cleaning performance
Short life-time
Long life-time
Low contact density
High contact density
Irregular brushing
Even brushing
With the development of acid resistant fill materials, it
has been possible to achieve tremendous quality and
improvements relating to service life on numerous strip
lines. This results in substantial reduction of total cost for
our customer. The parallel optimisation of the brush /
shaft design and operational parameters through targeted assistance on site is another important Osborn
competence based on our long-standing worldwide
experience. Give us a challenge!
LIPPRITE® – THE ABRASIVE COMPLETION FOR A PERFECT SURFACE
When it comes to the optical finishing of strip surfaces
in the form of polishing, satinising, finishing or decorative grinding and brushing, you’re in good hands with
Osborn. Decades of experience in the machining of steel,
stainless steel, aluminum and other ferrous or non-ferrous surfaces have given us a technological advantage,
from which our customers benefit worldwide today.
Our Lipprite® product series represents a completion
to brush rollers with wire or abrasive bristle coating.
Different combinations of adhesive and abrasive together with nylon web generate diverse products to meet
different demands. An absolutely uniform fine final grind
and a corresponding homogeneous surface finish can
be achieved with the special web construction. With the
correct contact pressure, the flexible roller web adapts
to the surface like a suspension and is in a position to
offset any slight unevenness of the strip (spring action,
see picture below).
Various grades of synthetic fibre and abrasive grit are
combined and bonded with special resin, firmly fixing
the grit particles to the non-woven fibres. The result is
an open, flexible structure. The material is self-dressing
and suitable for wet and dry processes. New abrasive
OVERVIEW OF THE ROLLER COVERINGS AND MATERIAL SPECIFICATIONS FOR
LIPPRITE® ABRASIVE ROLLERS
Aluminum oxide abrasive grain (Al2O3)
A2
coarse
CRS
Grit 80
S4
medium
MED
Grit 100
A4
medium
MED
Grit 100
S6
fine
FN
Grit 180 (240)
A6
fine
FN
Grit 180 (240)
S7
very fine
VFN
Grit 280 (320)
A7
very fine
VFN
Grit 280 (320)
S8
super fine
SFN
Grit 500
For orientation, the following approximate values for
the achievable surface roughness (Rt) are:
• A4 (medium) = 3.3 - 3.9 μm
• A6 (fine) = 2.9 - 3.6 μm
• A7 (very fine) = 1.1 - 1.8 μm
RECOMMENDATIONS CONCERNING
THE USE OF ROLLERS:
S9
ultra fine
UFN
Grit 600 (800)
S10
micro fine
MFN
Grit 1000 (1200)
Roughness values vary depending on diameter,
pressure, cutting speed, feeding speed, density, etc.
Treatment with synthetic resin stiffens the LIPPRITE®
Roller improving performance and extending its suitability for a range of applications.
Abrasive Particles
Abrasive
• Use in wet or dry operations
• Optimum cutting speed 15-25 m/s
• Line (strip) speed or feed speed up to
30 m/min. (max.)
•Processing in the opposite direction to the
running direction of the material feed
• Optimum depth of immersion 2-6 mm,
depending on the roller diameter and hardness
• Oscillation improves the uniformity of the
machining profile
TECHNICAL DATA AND PRODUCT
CHARACTERISTICS
Resin
Fiber
Work Surface
3-Dimensional Open Web
Spring Action
Your advantages
• Standard roller width up to 2000 mm
• Standard roller diameter up to 450 mm
• Versions available with or without impregnation
• Rollers are dynamically balanced in accordance
with DIN EN ISO 1940
• Oversized rollers can be made per customer request
• uniform surface quality
• intense cleaning performance
• remains hard under wet conditions
• dynamic balancing
Examples of achieved finishing with standard Lipprite®:
particles are continually exposed to the surface for a
consistent and uniform finish.
GALVANIZED STEEL
BEFORE
BEFORE
BEFORE
Based on many years of experience or by individual tests
on our test lines, we are able to specify the right product
in a targeted way for almost any surface roughness
required. Contact our application engineers.
AFTER
FINE FINISH
Ra: 1.270µ Ra: 6.42µ
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Silicon carbide abrasive (SIC)
AFTER
MEDIUM FINISH
Ra: 1.370µ Ra: 6.96µ
AFTER
COARSE FINISH
Ra: 1.390µ Ra: 7.37µ
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Strip Process Line
Strip Process Line
Non-woven Applications
NON-WOVEN VERSUS RUBBER
Osborn Mill Rolls
Made with NCCM Materials Advantages
• Long Life – Compressible resist
cutting for more uptime
MATERIAL COMPRESSIBILITY
OF NON-WOVEN
Rubber Rollers
• Short life – Non compressible,
susceptible to cuts, causes more
downtime
• Line Speed – Porous, open surface
for consistent strip contact can allow
higher line speeds
• Can limit line speed due to
• Repairable for better return on
investment
• Non-repairable
• Self-healing for superior fluid control
• High coefficient of friction on many
surfaces, even wet, for better strip
control
hydroplaning because of non
porous, closed surfaces
Non-woven roll
• Cuts propagate causing excessive
fluid pass-through and reduced lie
Did you know?
• Low coefficient of friction on
wet/oiled surface conditions
Conventional rubber roll
LOAD RUNNERS
Heavy-Duty Idler Rollers and Rails for High-Capacity
Precision Load Handling
APPLICATIONS
Non-woven rolls can be used in all strip lines or
rolling mills for steel, stainless steel, aluminium
and non-ferrous metals. They include:
•
•
•
•
•
•
•
•
Hot-dip galvanizing lines
Continuous annealing lines
Annealing and pickling lines
Cold rolling mills
Skin-pass mills
Colour and/or organic coating systems
Electrolytic galvanizing lines
Cleaning or degreasing lines
and a whole range of other types of line. They also
significantly contribute to improving product and
process quality.
CO-EFFICIENT OF FRICTION
Material Condition
Osborn Mill Rolls
Rubber Rolls
Dry steel
0,52
0,36
Oiled steel
0,36
0,01
Dry aluminium
0,52
0,36
Oiled aluminium
0,23
0,01
Benefits
• Compressible
• Self-healing
• Porous
• Uniformity
• High Coefficient
Friction
• Solidity
• Repairable
Osborn designed the world’s first non-needle roller
bearing idler roller more than fifty years ago to solve
an internal manufacturing challenge on the company’s
foundry equipment. Today Osborn Load Runners® are
the ultimate heavy-duty load rail and idler roller solution in the industry, providing precision performance
across numerous applications. Load Runners are
specially designed to tolerate both radial and thrust
loads and are available in all standard configurations either metric or imperial, stud- or yoke-style – ranging
in rolling sizes up to 12 inches. Load Runners® help
reduce your design time and lower overall material
handling system costs.
Manufactured in the USA, Load Runners® feature
heat-treated specialty steel, precision bearings, a
maintenance-free lubrication and seal system. Osborn
Load Runners® are designed and manufactured using
exacting engineering principles with an emphasis on
achieving:
Benefits
•
•
•
•
•
•
Better balance
Increased bearing life
Less tread/outer shell wear
Reduced power consumption
Smoother operation
Quieter operation
Along with Osborn Load Rails, precut and drilled to
your specifications, Load Runners are the complete
solutions for linear motion control.
HEAVY-DUTY
IDLER ROLLER &
RAIL SOLUTIONS
Find more information and CAD-drawings/models for easy incorporation into
your designs on: www.loadrunners.de
Or have a look at our new catalogue at:
http://www.osborn.com/media/PDF/literature-en/Osborn-Loadrunners-English.pdf
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Strip Process Line
Strip Process Line
REDUCE CHEMICAL
SOLUTION ON STRIP, AVOID
CHEMICAL CARRY OUT,
LONGER LIFE TIME
CARBON STEEL
Continuous pickling
LESS MOISTURE ON STRIP,
EXTENDED SERVICE LIFE, REDUCED
DRYING ACTION = LOWER
ENERGY CONSUMPTION
UNIFORM OIL FILM,
REDUCE CONSUMPTION
OF OIL
Non-woven Mill Roll
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Brush Roll
Bridle S-Roll
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Strip Process Line
Strip Process Line
HIGH CLEANING
PERFORMANCE, EXTENDED
SERVICE LIFE, VERY
PRECISE BRUSHING
CARBON STEEL
Cleaning
REDUCE CHEMICAL
SOLUTION ON STRIP,
ENERGY CONSUMPTION
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Non-woven Mill Roll
Brush Roll
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Strip Process Line
Strip Process Line
CARBON STEEL
Annealing
HIGH CLEANING
PERFORMANCE, EXTENDED
SERVICE LIFE, VERY
PRECISE BRUSHING
EXTENDED SERVICE LIFE,
REDUCED DRYING ACTION =
LOWER ENERGY CONSUMPTION
DENSITY
TENSION, LESS
SLIPPING
Non-woven Mill Roll
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Brush Roll
Bridle S-Roll
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Strip Process Line
Strip Process Line
CARBON STEEL
Electro-galvanizing
TENSION, LESS
SLIPPING
EXTENDED SERVICE LIFE OF
HOLD DOWN ROLLS, HIGH
GRIP, BETTER WRINGER
REDUCE CHEMICAL
SOLUTION ON STRIP,
DENSITY
HELPS PASSIVATION
PROCESS
Non-woven Mill Roll
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Brush Roll
Bridle S-Roll
35
Strip Process Line
Strip Process Line
CARBON STEEL
Hot Dip galvanizing
REDUCE CHEMICAL
SOLUTION ON STRIP,
HIGH CLEANING
PERFORMANCE,
EXTENDED
SERVICE LIFE,
VERY PRECISE
BRUSHING
AVOID SLIPPING ON
BRIDLE ROLLS
BETTER FRICTION,
HIGHER TENSION
LESS MOISTURE ON STRIP, EXTENDED SERVICE LIFE,
REDUCED DRYING ACTION = LOWER ENERGY
CONSUMPTION, AVOID SLIPPING ON BRIDLE ROLLS
HIGH CAPACITY WRINGER JUST
AFTER SKIN PASS, LESS MOISTURE ON
STRIP, REDUCED DRYING ACTION =
Non-woven Mill Roll
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Brush Roll
Bridle S-Roll
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Strip Process Line
Strip Process Line
CARBON STEEL
Tinning
REDUCE THE QUANTITY
OF OIL TO AVOID
COLLAPSE DEGREASING
EXTENDED SERVICE LIFE OF
HOLD DOWN ROLLS, HIGH GRIP,
BETTER WRINGER
REDUCE CHEMICAL
SOLUTION ON STRIP,
BETTER FRICTION,
HIGHER TENSION,
LESS SLIPPING
Non-woven Mill Roll
38
Brush Roll
Bridle S-Roll
39
Strip Process Line
Strip Process Line
CARBON STEEL
Organic Coating
HIGHER TENSION, LESS
SLIPPING, AVOID QUALITY
CLAIMS FOR SCRATCHES
HELPS COATING PROCESS
Non-woven Mill Roll
40
Brush Roll
Bridle S-Roll
41
Strip Process Line
Strip Process Line
STAINLESS STEEL
Hot Annealing & Pickling
HIGH CLEANING
PERFORMANCE, HIGH
CONTACT DENSITY
ELIMINATES PICK-UP,
Non-woven Mill Roll
42
Brush Roll
Bridle S-Roll
43
Strip Process Line
Strip Process Line
STAINLESS STEEL
Cold Annealing & Pickling
HIGH CLEANING PERFORMANCE,
EXTENDED SERVICE LIFE, VERY
PRECISE BRUSHING
Non-woven Mill Roll
EXTENDED SERVICE LIFE, AVOID
SLIPPING ON BRIDLE ROLLS
Brush Roll
Bridle S-Roll
44
45
Strip Process Line
Strip Process Line
REDUCE CHEMICAL
SOLUTION ON
STRIP, EXTENDED
SERVICE LIFE
STAINLESS STEEL
Bright Annealing
HIGH CLEANING PERFORMANCE, EXTENDED
SERVICE LIFE , VERY
PRECISE BRUSHING
ENERGY CONSUMPTION
Non-woven Mill Roll
46
Brush Roll
Bridle S-Roll
47
Strip Process Line
Strip Process Line
NON-FERROUS
Copper & Brass Pickling
REDUCE CHEMICAL SOLUTION ON
STRIP, AVOID CHEMICAL CARRY
OUT, EXTENDED SERVICE LIFE
EXTENDED SERVICE LIFE, REDUCED DRYING
ACTION = LOWER ENERGY CONSUMPTION
48
EXTENDED SERVICE LIFE, REDUCED DRYING
ACTION = LOWER ENERGY CONSUMPTION
Non-woven Mill Roll
Brush Roll
49
Automotive Press & Blanking Lines
Osborn Non-woven material range
Material type
neutral/soft
neutral/medium
neutral/hard
chemical/soft
chemical/medium
Technical data
Basic fibre
Max. operating temperature
Max. line loading
PA
PA
PA
PP
PP
75°C
125°C
140°C
75°C
100°C
30 N/mm.
60 N/mm.
12 N/mm.
16N/mm.
20 N/mm.
Application data
Applicable for liquid categories
Main applications
APPLICATION
POSITION
Cleaning roll,
Degreasing
HDL Brush roll
Inside of
Cleaning
section or
Blank Washer
units
Non-woven and Brush Roll Applications
Blank washing units remove dirt and deposits from
the blanks and apply a protective film of oil. The Blank
washers are constructed with three to four pair of rolls
(6-8 total). The first pair of rolls are Non-woven Rolls
which are working as Feeder Rolls to control the blanks.
The center rolls are brush rolls and provide the cleaning
of the blanks. The exit rolls are Non-woven Rolls which
control the residual film thickness.
World-renowned quality and performance is what
makes our Neutral Mill Roll, made with NCCM Materials,
outperform all others.
Feeder Roll,
Brake roll,
Cycle Roll
The neutral roll is used in pH neutral environments and
oil applications. Our Rolls are made in variety of densities
and to your specification and roll processing need.
EXPECTED MAXIMUM RESIDUAL OIL
Osborn provides high performance Non-woven Wringer
Rolls for precise coating application of the lubrication
fluid and as Feeder Roll to pull in the blanks into the
machine as well as brush rolls for optimized cleaning of
blanks and sheets.
Our high-density Mill Roll material is considered the premium general-purpose roll covering for primary metal
and AOEM stamping operations.
Oiling Roll,
Blank Washer
Roll
Line speed: 130 m/min, Oil viscosity: 9-11 mm2/s (cStk)
Line Pressure
Roll hardness
Soft
Medium
Hard
11 N/mm
2,5 g/mm
15 N/mm
2,3 g/mm2
1,7 g/mm2
19 N/mm
2,1 g/mm
2
1,6 g/mm2
1,3 g/mm2
23 N/mm
1,8 g/mm2
1,5 g/mm2
1,2 g/mm2
1,3 g/mm
1,1 g/mm
27 N/mm
32 N/mm
Force
Bending X/Y - level
Too low force:
wet edges
Too high force:
wet centre
To specification:
uniform break
50
Too high force:
wet centre
To specification:
uniform break
0.2
0.1
0
-0.1
-0.2
-0.3
-0.4
-0.5
-0.6
-0.7
0.2
0.1
0
-0.1
-0.2
-0.3
-0.4
-0.5
-0.6
-0.7
ADVANTAGES
Osborn
Non-woven Rolls
Remove dust
from the sheet
before coating it.
Very high cleaning capacity,
Longer Life,
No marking,
no filaments
breaking
Rolls supply
back-tension so
tight finished
coils can be
wound.
Motion Rolls to
move the strip or
the blanks.
More Friction
(higher tension &
less slipping),
Longer Life,
Less Marking
Inside the
Blank Washing unit in
front of the
presses or
inside of oiler
unit
To apply an extremely light and
uniform coating
of lubricant to the
blank's surface.
This allows it to be
formed into parts
of a car's body or
protects the blanks
from the rust.
Much better
(lower) coating
weights. More
uniform and consistent coating
weights.
Longer Life.
Applicator roll
applying “chem
treat” fluids.
Chemical
wringer Rolls
LINES
SLITTING
LINES
Narrow strip
width are
produced
on lines of
longitudinal
shear or
slitting lines
from a Coil
CUT TO
LENGTH
Rectangular
or trapezoidal
blanks are
produced on
cut to length
lines from a
Coil
BLANKING
LINES
PRESS
LINES
Tailored
blanks
are only
produced
on blanking
lines using
a press and
blanking die
from a Coil
Press lines
are used for
body production parts
in a single
one or progressive
strokes. The
feeding material can be
steel sheets
or coils or tailored blanks
Provide Highly Engineered Film Thickness
• Maintain film thickness longer over life of the roll
• Reduce hydrostatic stamping defects
• Reduce part rework
• Reduce paint rework
0,9 g/mm2
Bending X/Y - level
BENDING X/Y-LEVEL
y
(mm)
PURPOSE
De-oiling
Cost Savings Advantages
Drastically Reduce Oil Usage
• Reduce welding smoke
• Save oil costs
• Better part transfer
• Reduce excess oil in production line
y
(mm)
Too low force:
wet edges
Oil and Emulsions Acid and Alkalines Acid and Alkalines
Wringer rolls,
De-oiling and
Tensioning rolls
2
FORCE
Force
Water and Oil
Towards exit
end of line
(brake rolls).
Before the
presses or the
shear (feeder,
Cycle roll).
2
2
Water and Oil
Wringer roll and
oiling roll
applications
x
(mm)
x
(mm)
Longer Life
• Best total value roll system
• More damage resistant
• More consistent performance
Global Network and Process Solutions Experts
Image courtesy MarkOne
51
CARBON STEEL
Blank Washer
HIGHER GRIP
52
UNIFORM OIL FILM, MINIMUM
THICKNESS OF OIL
Non-woven Mill Roll
Brush Roll
53
Download our full catalogue range
IT’S EASY
It’s quick and easy to download our Osborn special catalogue from the Osborn website.
If you have a smartphone or tablet PC, you can also scan the QR code with a reader app
to access the summary page.
www.osborn.com/en-de/support/literature.html
Highperformance machine brushes
Novofil Hightech brush
Solutions for woodworking
SnowProtec
Load Runners
Multizack
Top-quality machine and special brushes for
industrial applications
Abrasive nylon brushes with premium abrasives
such as diamond, zircon, aluminium oxide, etc.
Brushes and abrasives, tools and compounds
for high-gloss polishing (for power tools and
manual finishing)
Special solutions for rail traffic:
snow-protection system for points
Load-bearing rollers and heavy-load roller
guides
Stamped brushes for cleaning, deburring,
transporting, sorting, washing and guiding
ATB disc brushes with abrasive filaments
Micropolishing brushes
Novoflex-B
Solutions for the pipeline industry
Brushes for the mechanical finishing of PCBs
Retail and Distribution
Up to 4 times higher trim density than traditional disc brushes
Polishing tools and compounds for
micropolishing
Self-centring honing tools for smooth grinding
Brushes for weld seam cleaning and special
brushes for the pipeline industry (transport
brushes, contact brushes and cutback systems)
Brushes for deburring, cleaning/deoxydising,
removal of resin, finishing and cleaning of
sheet steel
Machine Brushes, Hand Brushes, Polishing tools
and compounds for Retail and Distribution.
Multistrip brushes
Polishing products
Products for agriculture
Strip and sealing brushes
Premium polishing tools, firm pastes and
emulsions
Professional sweeping solutions for farms and
livestock operations
54
55
Osborn Sells Solutions
Global Headquarters
North American Headquarters
Osborn International GmbH
Ringstrasse 10
35099 Burgwald
Germany
Tel.: +49 64515880
Fax: +49 6451588206
[email protected]
Osborn
2350 Salisbury Road North
Richmond, IN 47374
USA
Tel.: +1 765 965-5333
[email protected]
Osborn International Ltda.
Rua Lemos Torres,
150 - Jardim Gagliardi
09890-070 São Bernardo do Campo
Brazil
Tel.: +55 1143916559
Fax: +55 1143916550
[email protected]
Osborn International
Rm. 612, Tower R, Huiyuan Int. Apartment
No. 8 Beichen East Road,
Chaoyang District
Beijing, 100101
China
Tel.: +86 10 8498 6167
Fax: +86 10 6499 3009
[email protected]
Osborn Unipol SAS
Parc Mail – Bâtiment Orion
24B avenue de la Demi-Lune
CS 80006
95735 ROISSY CH. DE GAULLE CEDEX
France
Tel.: +33 134450600
Fax: +33 139936711
[email protected]
Osborn Lippert (India) Pvt. Ltd.
Plot No. E-66, MIDC Waluj
Aurangabad - 431 136
India
Tel.: +91 2402556538
Fax: +91 2402552530
[email protected]
Osborn Emilio Cárdenas No.211
Centro Industrial Tialnepantla
Tialnepantla Edo. México, 54030
Mexico
Tel: +52 5555659555
Osborn Unipol Lda
Rua de Pardelhas
4805-062 Brito-Guimarães
Portugal
Tel.: +351 253479550
Fax: +351 253576629
[email protected]
Osborn International SRL
Bd. Bucovina, Nr. 151
725300 Gura Humorului, jud. Suceava
Romania
Tel.: +40 230234212
Fax: +40 230531785
[email protected]
Osborn Singapore Pte Ltd
206 Tuas South Avenue 2
West Point Bizhub
Singapore 637208
Singapore
Tel.: +65 6863 0318
Fax: +65 6863 4318
[email protected]
Osborn - Unipol, S.L.
C/ Ronda Norte, 320
(Polígono Industrial) - Apartado 169
46470 Catarroja (Valencia)
Spain
Tel.: +34 961325876
Fax: +34 961324602
[email protected]
Osborn International AB
Huskvarnavägen 105
56123 Huskvarna
Sweden
Tel.: +46 36389200
Fax: +46 36133190
[email protected]
Osborn Unipol (UK) Limited
Avenue West
Newhouse Farm Industrial Estate
Chepstow NP16 6UD
United Kingdom
Tel.: +44 1291643200
Fax: +44 1291643298
[email protected]
Art.Nr. 6255310210, Printed 05/15. All items subject to change without notice.
The Global Leader in Surface
Treatment Solutions and Finishing Tools

High-Performance Rollers for Metals Processing

Transcription

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