ONE PIECE STEEL ROLLS

 

In manufacturing of this rolls  tempered steels,  tool steels, Stainless steels, steel alloys, wrought steels are used. Working surface are usually hardened by heat treatment. Rolls are produced on CNC  and universal lathes. Final dimension is achieved by grinding.

 

Due to working conditions surface can be strengthened with coating .Electrolytic hard chrome plating,Tungsten carbide and chrome carbide coating and ceramic coating with plasma spray are most common applications. Coated surfaces are grinded with cylindrical grinding machines.

 

STEEL CAST ROLLS

 

In these rolls, roll body materials are  cast steel and cast stainless steel. Preferred for homogenous heat transfer and minimum dimensional deformation is needed.  Roll body, flanges and  journals are machined with turning.  Roll components are assemblied within specific tolerances.  Roll body and flanges are bolted.  After assembled process, the roll is machined sheerly.

 

ELKAP  manufactures custom rolls for various industrial sectors.

 

 

• ALUMİNİUM INDUSTRY

 

Various types of slitting rolls, paint line rolls, deflector rolls production for sheet aluminium, plate, cylinder or foil production   plants.

 

• Prime Coater Pick Up Roll

 

Drawn steel body, St 52 steel journals and flanges,

         Welded assembly. Hard chrome plated surface. Grinding and super finishing.

 

• Cold Rolled Pass Line Rollers, Flattening  Rolls, Burr Masher Roll, Slitting Line Rolls

 

For roll body material  St 52 drawn steel pipes are used. Steel journals,  flange and body assemblies are welded assembly. Hard chrome plated surface,  grinding.

 

• Cold Rolled Tension Rollers

 

Body manufacturing with drawn steel pipe material, hard chrome plating and grinding,  shaft manufacturing with high quality steels, Body and shaft assembly with bearings.

 

• Foil Line Ironing Rolls

 

Body manufacturing with drawn steel pipe material, hard chrome plating and grinding,  shaft manufacturing with high quality steels, Body and shaft assembly with bearings.

 

• Pinch Rolls

 

Manufacturing with monolithic steel materials, induction hardening surface, hard chrome plating and grinding.

 

 

• TEXTILE INDUSTRY

 

• Manufacture of Transfer and Tension Rollers.

 

As body material St 52 drawn steel pipe material is used. Steel journal,  flange and body assemblies are welded assembly.

 

Surface coatings can be applied in different ways.

 

1. Hard chrome plating grinding and polishing
2. Nodular hard chrome plating and grinding
3. Ceramic coating and grinding

 

 

• STEEL INDUSTRY

 

Various roll type manufacturing for the needs of flat stell (sheet) production Cold Rolling Mills, Continuous Galvanizing Lines, Paint Lines and Steel Machining Centers.

• Bridle Rolls,  Idler Rolls, Driving Rolls

 

For roll body material drawn steel pipe materials ( ST 44 / 52 ) are used. For diameters that a standard pipe material cannot be found ( for maximum 1800 mm ) cylindrically formed steel sheet metals are used by means of bending and welding.   Journal and face flange materials are selected from high weldability steels.  Body, flanges and journals   are assembled by welding. Roll is shaped by turning and grinding. Roll work surface is hard chrome plated or tungsten carbide coated. Surface roughness values are achieved by coating or grinding following the coating process.

 

• Tension Meter Rolls,   Anti Crimping Rolls, Hold Down Rolls,  Pass Line Rolls, Deflector Rolls

 

As body material for this type of roll production, heat treatable such as SAE 1045 / 4140 tempered steel pipe materials are used. Following roll body hardening with heat treatment, additional surface hardness is achieved by induction hardening. Surface is hard chrome plated or tungsten carbide coated. Surface roughness values are achieved by coating or grinding following the coating process.

 

Assembly can be done with two different ways.

 

1. Body and the journals shrink fitting and after assembly with welding ( roll as a whole ).
2. Individually body and shaft manufacturing and after assembly with bearings ( rotary rolls ).

• Pinch Rolls

 

Welded manufacturing with solid steel material or  thick walled tempered steel pipe material such as SAE 1045 / 4140 . Following the body hardening with heat treatment, additional surface hardness is achieved by induction hardening. Surface is hard chrome plated or tungsten carbide coated. Surface roughness values are achieved by coating or grinding following the coating process.

 

• Deburring Rollers

 

Wrought steel is used in manufacturing. After hardening and tempering processes, induction hardening is done. Machined by turning, the roll is hard chrome plated and grinded.

 

• Back - up Roll for Cleaning Section

 

For roll body material drawn steel pipe materials ( ST 44 / 52 ) are used. Body, flanges and journals   are assembled by welding. Roll is shaped by turning and grinding. Roll work surface is hard chrome plated or tungsten carbide coated. Roll is grinded and super finish polished.

 

• Conductor Rolls

 

Body manufacturing with drawn steel pipe material. After journals and body shrink fitting , assembled by welding. Face and the body of the roll is copper plated. Over the copper plating also tungsten carbide is coated. Journals are hard chrome coated and grinded.

 

• Stabilizing Rolls  (Galvanizing Line Rollers)

 

Manufacturing with 316 L stainless steel material. Machining by turning and grinding. Tungsten carbide coating and seal application.

 

• Sink Rolls (Galvanizing Line Rollers)

 

Casted stainless steel base material, machining of all diameters and grooves by turning.

 

• Furnace Rolls

 

Casted stainless steel base material, machining of all diameters by turning. On grinded surface cermet thermal powder selection with respect to working temperature, plasma and HVOF applications.

 

• Painting Roller

 

Drawn steel body, St 52 steel journals and flanges, Assembly by welding. Hard chrome plating, surface grnding and super finish polishing..

 

PAPER INDUSTRY

 Industrial Rolls for Paper Mills

 

• Paper Guide Rolls / Wire Guide Rolls

 

• Shell manufacturing with drawn steel pipe material.
• Steel or steel cast journal manufacturing.
• Dynamic balancing.
• Chrome plating, ceramic or rubber coating.

 

• Breast Roll

 

• Shell manufacturing with drawn steel pipe material.
• Alloy steel journal manufacturing.
• Dynamic balancing.
• Chrome plating, ceramic or rubber coating.

 

• Suction Roll’s Shell  Manufacturing

 

• Manufactured with duplex stainless steel.
• Drilling the top holes by gun drilling method with ELKAP's 5 axis turning center.

 

• Suction Roll Manufacturing

 

• Shell manufacturing with duplex stainless steel.
• Inner mechanism and nozzle system fabrication.
• Flange and journal manufacturing with wrought steel.
• Wear and corrosion resistant ELKAP Suction Press Roll cermet coating and machining.

 

• Press Roll Manufacturing

 

• Shell manufacturing of Size Press and Counter  Shoe Press  Rollers with wrought steel.
• Journal manufacturng with wrought steels
• Cooling system rotary joints design and assembly.
• Dynamic balancing.
• Certification and QA/QC reports sharing with customers.

 

• Dryer Roll Manufacturing

 

Optional manufacturing is available as casting manufacturing or steel shell manufacturing.

 

Advantages of Steel Welded Shell Dryer Cylinders :

 

• With Steel Shell, same strength is achieved as Cast Shell with thinner walls. This improves heat transfer ability.
• With welded assembly of steel shells and flanges,  sealing effect is also achieved.  This eases cylinder maintenance services.

 

Advantages of Cast Shell Dryer Cylinders :

 

• Less dimensional deformation occurs in temperature changes on Cast Shell Dryers.
• Homogenous heat distribution.

 

ELKAP can deliver Dryer  Cylinders with Steam inlet equipment and Turbulence bars  mounted.

 

In addition to this, with ELKAP Dryer Roll Coating Application on  Dryer Rolls’ surface, roll can work effectively with proper Doctor Blade.

 

• Winder Roll Manufacturing

 

• Shell manufacturing with drawn steel pipe material.
• Journal manufacturing from steel.
• Dynamic balancing.
• By tungsten carbide coating, obtaining wear resistant surfaces  in specific roughness ranges with respect to paper types.