Double Gears through Friction Welding Technology

 

Rolex Rings know-how to provide added value to Power Transmission industry

Rolex Rings – one of the global leading players in manufacturing forged, rolled, turned and heat-treated rings for both bearings and automotive industries – developed in the past years specific know-how to produce double gears by rotary friction welding technology.

Friction welding refers to joining two metallic surfaces by the frictional heat generated at their interface due to relative motion applied between them. The parts being joined are held under high compressive load. As the frictional heat starts to soften the materials at the interface, the applied compressive load creates a hot forging type action that forms a metallurgical bond between the two surfaces. The joint thus produced has a narrow heat affected zone in the plastically deformed zone adjacent to the joint, but no fusion zone. If there is any flash or extruded material on the sides, it can be removed by a later operation.

Rolex Rings applied such technology to produce double gears through a manufacturing process that includes the following steps:

  • Forging
  • Pre-machining
  • Friction welding
  • ISO Thermal annealing
  • Final turning

Special procedures for the operations and for the controls and testing have been developed by process engineering and quality team of Rolex Rings to be in condition to supply hundreds of thousands of components made by such technology during the last few years.

Advantages for the customer and the applications are several with respect to the traditional production process. However, the main ones can be summarized as it follows:

  • Drastically reduced input material (much lower manufacturing cost);
  • Better fibres flow, resulting in a longer life in endurance tests.

With 3 manufacturing units located in Rajkot (Gujarat) in India, Rolex Rings is public company whose shares are traded at Mumbai stock market and exports about 70% of its total turnover in more than 17 countries between Europe and America. Thanks to 6 high speed hot formers between Sakamura and Hatebur, 18 vertical hot forging presses with hot rolling unit, 30 cold rolling units, 590 CNC turning machines, 41 heat treatment furnaces, 4 induction furnaces and other machinery (including special friction welding operation), Rolex Rings is able to satisfy in competitive and reliable way the demand of large multinational companies in several application fields.


More information about Rolex Rings products can be received getting in touch with Rolex Rings engineers, calling at +39 (0)121 376811 or writing to
[email protected].  

 

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