Manufacturing Co.

K1DEADJUSWlENrFORGINGROLLS

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FORGINGROLLS

Ajax Forging Rollswith the sammade Ajax amachinery.Theseuncosigns toforging

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22'12" Diameter DieBillet Roll for Preform-ing Blanks for Press orHammer Forgings.

WHATROI FORGINGCAN DO

In roll forging, two curved dies rotating inopposite directions "squeeze" the stock as itis pulled through the rolls much like cloththrough a wringer. The forging stock deformsunder the force exerted by the rigid dies andmachine frame to make a part, whose shape isdetermined by the shape and contour of the dies.

Since there is essentially only rolling contactbetween the forging and the dies, roll forging isan efficient method of producing large reductionsin a cross sectional area at minimal loads.

When used to produce preforms for conventionalpress or hammer forging, roll forging can provideseveral advantages which become especiallyimportant with the high cost of energy andmaterials.

AJAX FORGING ROLLS CAN. . .

1. Increase die life, decrease machine loadingand energy consumption by minimizingmaterial deformation in subsequent forgingoperation.

2. Help to produce more uniform quality products.

3. Reduce rejects and save material.

4. Increaseproductivity.In addition, roll forging does not require skilledoperators or great manual effort. The operatormerely grasps one end of the heated stock withtongs, and inserts it between the rolls at the"open" position. Die rotation rolls the stocktoward the operator who repeats the operation fora specified number of passes.

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L£.~~~ WIDEADJUsrNlE~ FORGINGROIS

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Ajax Forging Rolls, with combination roll shafts, air clutchand brake, are designed to optimize all the advantages ofthe roll forging process for the production of straight,tapered or irregular forgings. Ajax "Wide Adjustment"Forging Rolls embody refinement and innovation in designwhich has been occurring since Ajax introduced theforging roll in 1898.

The proven design features a patented gearing arrange-ment which increases roll adjustment capability to sixtimes that of earlier designs. The "Wide Adjustment"feature permits numerous die redressings to decreaseproduction costs. It also permits the use of deep impres-sion dies, which when combined with the Ajax AirClutch and Brake for stop-motion operation, makes iteasy to handle stock with accurate registry for successive,severe breakdown passes.

Built in ten standard sizes, these "Wide Adjustment"Forging Rolls can produce forgings ranging from tapered

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automotive spring leaves, pointed coil spring ends andrear axle drive shafts, to long tapered blanks used onfork lift trucks and irregular shaped blanks from which Ibeam front axles can be forged.

Ajax Forging Roll versatility is increased because of self-contained construction which facilitates moving the smallersized rolls to forging presses, hammers, or other forgingequipment.

Pages 12 and 13 illustrate some of the many forgings thathave been produced on Ajax Rolls with the speed, accuracyand economy the industry has come to expect from allAjax equipment.

So that your Ajax Forging Roll will be designed best forthe production of your work, we suggest that blueprints,samples or sketches be submitted to our Engineering De-partment for recommendations based on stock size, lengthof reduced stock and finished forging accuracy.

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For maximum production versatility, Ajaxoffers two types of forging rolls: theDOUBLE HOUSING ROLL and the OVER-HANGING ROLL. Each of these machinesis suited to a particular type of roll forging.

The double housing roll is best suited toproduce shorter pieces requiring largedeformation, while the overhanging rollcan best produce very long forgings.

THEDOUBLEHOUSINGROLLRoll dies in the double housing roll aremounted between massive steel housings.Great width and rigidity permit the use ofwide dies with multiple impressions forforgings requiring large deformation or forproducing several different forgings. Toproll housings are cast steel, tongue-guidedin the main housings, and are verticallyadjustable to compensate for die dressing.Provisions are made for taking up roll shaftend play to prevent axial die mismatch.

Two types of roll dies, the flat backed seg-mental and the semi-cylindrical, can beused on the double housing roll.

FLAT BACKED SEGMENTAL DIES, SEMI-CYLINDRICAL DIES,

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used for rolling short lengths,are the most economical rollforging dies. These lightweight dies are bolted andkeyed to the roll shafts andcan be easily changed andset. Segmental dies are inex-pensive because a minimumamount of material is usedand grooves can be machinedon both dies simultaneously.Atter machining, heattreating may follow forhardening, and the backsurfaces ground to correctfor warpage.

for medium length work, are available onall forging roll sizes. Like the flat backedsegmental dies, semi-cylindrical dies arebolted to the roll shafts between thehousings and can be easily changed. Thetwo halves can be machined simultaneous-ly. For additional economy, when the workis not too long, both ends of the impres-sions can be mouthed out to make the diesreversible. Cast steel dies of the samealloy used in rolling mill service, havebeen used with great success.

THEOVERHANGINGROLLRoll dies on the overhanging roll are out-board-mounted. All the design featuresdescribed under the Double Housing Rollapply, including the exclusive Ajax "WideAdjustment" feature. These rolls havemassive roll shafts, and bearings mountedfar apart for superior rigidity. For specialhigh deformation parts or wide dies, aremovable outboard bearing support isavailable. Roll shaft extensions for usingfull round dies on Double Housing ma-chines are available only on machinesequipped with Air Brake and Clutch.

Overhanging full rounddies mounted on roll shafts.

FULL ROUND DIESare especially suited for long work, andare mounted on the overhanging ends ofthe roll shafts. Made most economicallyas rings, a cutaway section large enoughto permit stock feeding must be provided.Because they are supported on one endonly, width and therefore the number ofgrooves, must be limited. Full round dieshave the advantage of easy changing.

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FEATURES

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These design features, common toall Ajax Forging Rolls, add to theiroperating ease and efficiency.

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DIE LEADADJUSTMENT

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Adiustment 1 ;1= - ~ ... A die lead adjustment is pro-

vided on the upper roll shaftto compensate for die mismatch.Intricate, shouldered impres-sions can easily be brought intoperfect match by the rotationaladjustment provided.

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"WIDE ADJUSTMENT"BETWEEN ROLLS

In the patented Ajax Wide Adjustment GearingSystem, the top roll shaft gear is adjustedtangentially to the gear which drives it, sothat gear mesh deviates a minimum amountthroughout the entire roll adjustment. Forexample, as much as four inches of adjust-ment can be made on the NO.2 roll, withminimum increase of backlash. The result isenough adjustment for many die redressingswith all three types of dies.

The increased number of die redressingspermitted by this wide range of adjustmentresults in improved economy for all depthdies. With the "Wide Adjustment" capability,roll forging is economical for types of workwhere die costs were once prohibitive.

In the rugged drive mechanism, roll gearsoverlap and are staggered allowing use ofmaximum diameter gears which are designedto clear the bottom roll shaft at the lowestadjustment point. For smooth operation, heavypitch gears are used, and the small requiredtooth clearance which might be detrimentalon exacting work, is taken up with an ec-centric brake on the top roll shaft. This brakeis automatically set at the part of the cyclewhere the weight of the top die tends to causethe top roll shaft to "run ahead" then is re-leased for the rest of the cycle. The eccentricbrake is not required with full round dies.

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ALLOY BRONZEBEARINGS, PRESSURELUBRICATED

Bearings in Ajax Forging Rolls arespecially designed for rugged service.Bearings on all shafts are bronzealloy, particularly suitable for rollingmill service. The main roll neck

bearings are provided with a laby-rinth guard to keep out all scale andcooling water, if used. Very conserva-tively rated flywheel bearings aresmooth running anti-friction rollerbearings.

All Ajax rolls are equipped with anautomatic pressure lubrication sys-tem for all but the roller bearings.

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~ RUGGED STEELGEARING, COMPLETELY HOUSED

All machine gearing is high strength steel withmachine cut teeth. Overlapping gears with verylarge teeth drive the roll dies, contributing tolower tooth load and longer gear life.

The gearing mechanism is housed in a heavycasting and is covered with sheet steel guards toprotect the gears from abrasive scale and dirt.

. This housing also protects personnel, but is de-signed for maximum accessability to all internaladjustments.

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SHORT CENTERV-BELT MOTOR DRIVE.

The motor is supported on an ad-justable, hinged motor bracket.

Mounted above the gearingmechanism, the motor is pro-

tected from scale, is readilyaccessible, and occupies no floor

area. The motor sheave, V-beltsand guard are supplied with themachine. The motor is supplied

by the customer, or furnishedby Ajax at extra cost.

BRAKE AND AIR CLUTCH FOR STOP-MOTION OPERATION

The proven Ajax Air Clutch and co-actingBrake, used on Ajax Forging Machinesand Presses, is an available option onall Forging Roll sizes, and is standardequipment on all rolls with extensionsfor overhung dies. The air clutch andbrake gives the operator complete con-trol over machine operation, easing thehandlfng of heavy work and making itpossible to align stock into perfectregister in multiple deep or intricatedie impressions. This option also in-creases the variety of pieces that canbe rolled.

The Air Clutch is a multiple disc,friction type clutch. The pneumatically

operated clutch requires compressed air(60 to 100 psi) in small volumes. Thestopping brake is a band type, air-released and spring-set, and ismounted on an extension of the highspeed shaft.

On stop motion rolls, an electric footswitch is normally used to start a rollingcycle. The foot switch in sequence re-leases the brake, then engages the clutch.

At a predetermined point in the cycle,a rotary cam switch mechanism releasesthe clutch then sets the brake, effec-tively stopping the roll in preparationfor the next rolling operation.

SAFETY FRICTION-SLIP FLYWHEEL

The flywheel on continuousrunning rolls has the mass tosupply abundant energy forlong, large reduction rolling.On rolls not equipped with AirClutch and Brake for stop-mo-tion, the flywheel is clampedbetween friction discs at its hubto prevent damage frommisplaced stock. The torque atwhich the flywheel will slip isadjustable by means of clamp-ing studs which control thepressure between flywheelclamping discs. Clamping studdiameter, reduced below thethread root diameter to provideelasticity without distorting thethreads, is typical of attentionto engineering detail in Ajaxequipment. Flywheel frictionslip arrangement is not used onmachines equipped with an airclutch since the clutch providesthe same protection.

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HORIZONTALFRONT PRESS

When a forging requires side-squeezing after rollpasses, as in pointing coil springs and taperingchisel blades, a front press located close to therolls for rapid production, can be provided.The squeezing dies can be set to various loca-tions in order to distribute wear to other areasof the roll dies. The cross slide carries themoving die at the center and has widely spacedbearings which are well protected from scale.The slide is actuated by an eccentric on thelower roll shaft, and no miter gears are used.A safety pitman with breaker bolt in tensionis used to prevent accidental damage.

GUIDES AND GAUGES

Front and rear guides and gauges maintainperfect stock alignment in the die grooves toinsure accuracy. Front guide tables are availablefor handling long work.

MOTOR AND CONTROLS

Motors, controls, and other electrical equipmentare specified by The Ajax Manufacturing Companyand are available as optional equipment.

PRINCIPALDIMENSIONS

ROLLSIZES

Min. Usable Die PeripheryHalf Roun"dFlat Back

Overhung

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No. 0 BLANKFORMING

ROLLSNo.O

ROLLSNO.1

ROLLS

NO.2

ROLLSNo 3

ROLLSNO.5

ROLLS

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10 to 30 20 to 40

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NO.6 AJAXFORGING ROLLat 100 tons

NO.1 AJAXFORGING ROLLat 10 tonsIllustrates wide sizerange of Ajax Forgingrolls.

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SpecialBillet Roll

SpecialBillet Roll

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I Beam Front Axle

Twist Drill Blank

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Universal Joint Cross

Sector Shaft Arm

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Rocker Arms

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OpenEndWrenches

Leaf Spring

Tapered Endof Fork forLift Truck

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ROIPRODUCTS

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AutomotiveSpring

Blade Blank

Typical Preformed Blank

Clay Spade

Wood Chisel

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1441 Chardon Rd., North 8 Cleveland, Ohio 44117PHONE (216) 531-1010 FAX (216) 481-6369

FORGINGMACHINES

FORG INGPRESSES

Printed in USA

WIRE DRAWING &CUT-OFF EQUIPMENT

FORGINGROLLS