SEAMLESS ROLLED RINGS

State-of-the-art solutions for the wind power industry

 WIND POWER TURBINES
Climate-neutral, customised solutions

fossil fuel
Dwindling fossil fuel resources
resourcesand andglobal
globalwarming
warming tional radial-axial
radial-axial ring machines,
ring rolling rolling machines,
mainly mainly
withoutwith-
consequences of
– two consequences of climate
climatechange
changethat
thatnow
nowcall
call out profiSMS
profiles. les. SMS
group,Meer, however,
however, offers
offers the rolling
the rolling
widespread use
for the more widespread use of
ofrenewable
renewableforms
formsofof of profiled
of profiled rings.
rings.The
The result
resultisisaasignificant
significantsavings
savings
energy. Among
Among other
other technologies,
technologies,wind
windturbines
turbinesthat
that potential with
potential withrespect
respectto toinput
inputweight
weightand andmechanical
mechani-
generate electric
electric power
powerare arerapidly
rapidlygaining
gainingimportance.
importance. cal machining
machining time,time, particularly
particularly for tower
for the the tower flanges
flanges
Countries all
all over
over the
theworld
worldare
areconstantly
constantlyincreasing
increasing and slewing
and slewing rings.
rings.This
This represents
representsan animportant
importantcom-
com-
their capacities
capacities for
for producing
producingwindwindelectricity.
electricity. petitive advantage
petitive advantageininaahighly
highlycontested
contestedmarket.
market.

installation needs
A wind power installation needsnumerous
numerousrolled
rolled Thanks to
Thanks to newly
newlydeveloped
developedproduction
productiontechnologies,
technologies,
(connecting flanges,
rings (connecting flanges, slewing
slewingrings)
rings)and
andpower
power such as
such as axial
axial profiled
profiledrolling
rollingand
and2-step
2-stepradial
radialprofiled
profiled
components (bearing
train components (bearing races
racesand
andgear
gearrings).
rings).Until
Un- rolling,this
rolling, thiscan
canbebeachieved
achievedononmodern,
modern,specially-
specially-
til now,
now, these
these rings
rings havehave been
been produced
produced on on conven-
conventional designed ring
designed ringrolling
rollingmachines
machinesandandplants.
plants.

BENEFITS AT A GLANCE

„ significant savings in material,

energy and machining costs of
up to 30%
„ a wide range of different tower
flange sizes
„ competitive advantage for
plant operators
„ ability to be retrofitted in
modern machines

4
2
 SMS group is a globally leading partner for the metal industry. As a family-owned business head-
quartered in Germany, quality and innovation is in our DNA. We are committed to the success of our
Steelworks
customers / striveTube
and & Pipe
to add Longthe
value along Products
entire valueForging
chain Plants
of the global industry. Heat Treatment
metalPlants
NF Metal
Continuous Casting Plants Plants Technology

Electric Arc Seamless Section and Hydraulic Induction

Alu minium Plants
Furnaces Tube Plants Billet Mills Presses Technology

EXTENDED
Secondary PORTFOLIO Light Section
Welded Tube Plants Extrusion Presses Copper Plants Furnace Plants
RingsMetallurgy
and wheels large and small – these are Mills
the
pivot points of progress. They come in a very wide
Ironmaking plants
rangeContinuous
of different profiles Wire Rod Hardening
Spiral and
Tubematerials.
Plants Without Closed Die Forging
Casting and Bar Mills Machines
rings and wheels, for example, global mobility as
we know it would come to a standstill. SMS group
Finishing Plants Bright Steel Quench and
offers tailor-made solutions for demanding
and Machines applica-Lines
Processing
Ring Rolling Metallurgical plants and
Temper Lines
tions requiring rings and wheels. The portfolio
environmental technology
extends from individual machines such as ring Service
blank presses, rolling machines and ring expan-
ders to complete plants.
Flat product plants

Long product plants

Processing lines and

furnace technology
EXTENDED PORTFOLIO
Rings and wheels large and small – these are the
pivot points of progress. They come in a very wide
range of different profiles and materials. Without
Forging plants
rings and wheels, for example, global mobility as we
know it would come to a standstill. SMS Meer offers
tailor-made solutions for demanding applications re-
quiring rings and wheels. The portfolio extends from
Electrical and
individual machines such as ring blank presses, roll-
automation systems
ing machines and ring expanders to complete plants.

Production facilities

Technical service

3
5
ROLLING INTO RINGS
Successful combination of established
machinery and new technologies

RING ROLLING MACHINES MACHINES FOR FOR

A WIDE VARIETY OF SIZES AND
SHAPES
The task of SMS group
Meer ring rolling machines is to
enlarging the
produce rings by enlarging the diameter
diameter of of ring
ring
purpose, the
blanks: for this purpose, the blanks
blanks are
are heated
heated up up
temperature. With radial
to forging temperature. radial ring
ring rolling,
rolling, their
their
wall thickness is reduced by usingusing a main
main roll
roll and
and aa
mandrel. With radial-axial
radial-axial ring
ring rolling,
rolling, two
two additional
additional
reduce the
axial rolls reduce the height
height of
of the
the blanks
blanks simultane-
simultane-
ously.

MEETING MARKET REQUIREMENTS REQUIREMENTS

WITH RING BLANK PRESSES PRESSES
SMS group
Meer ring
ring blank
blank presses are the synthesis of
150 years of rolling and forging experience
experience withwith new
new
automation andand process
process techniques.
techniques. Plant
Plant operators
operators
reliable, future-proof
benefit from reliable, future-proof ring
ring blank
blankpresses
presses
with up to 100 MN press force. Thanks to their
design, ring
modular design, ring blank
blank presses
presses can
can be
be efficiently
efficiently
adapted at any time to changing plant plant demands
demands or or
requirements. Depending
market requirements. Depending on on the
the ring
ring and
and lot
lot
sizes, the lines operate
operate using
using different
different concepts
concepts in in
arrangement of
terms of the arrangement of the
the press
press cylinder
cylinder and
and
process.
ram for the forging process.

4
6
SAVING MATERIAL, TIME AND
COSTS WITH RING EXPANDERS
Ring expanders from SMS group are used for hot,
warm and cold expanding. All forgeable materials
can be expanded. SMS group designs and supplies
ring expanders suitable for the ring rolling machines.
These expanders consist of a hydraulically movable
expanding cone with the expanding jaws fitted
against the cone: these cause the ring to become
plastically deformed. The control system automati-
cally takes up the ensuing spring-back and compen-
sates this during the following expanding stroke.
An integrated turning device helps to improve the
precision of the expanded rings. For operation in an
automated plant, SMS group can supply expanders
which calibrate the ring in just one expanding stroke.

TECHNOLOGY SOFTWARE FOR

PROFESSIONAL PLANNING AND
OPTIMISATION
The technological interdependencies and their impact
on the product play a key role when manufacturing
rings. Misjudgments during production planning and
production itself can lead to instability of the product
and result, in turn, in economic disadvantages. In order
to avoid this, SMS group offers a complete package
that includes ROLLTECH Rings. ROLLTECH Rings from
SMS group is a software package that measurably
increases the profitability and product quality obtained
from radial and radial-axial ring rolling machines. The
self-contained software system guarantees the opera-
tor the best possible manufacturing results. By means
of customised, user-friendly databases, quick and easy
simulations and a high degree of internal automation,
ROLLTECH Rings simplifies operation significantly.

5
 PROFILING TECHNOLOGY
LATEST PROFILING TECHNOLOGY

SMS Meer
group installed
installed two
two ring
ringrolling
rollinglines
linesfor
fortower
towerflflange
ange production
productionatatFRISA
FRISAForjados
Forjados(Mexico)
(Mexico)– –among
among
those a ring blank presspress of
of type
type PL
PL 8000
8000 and
and ring
ring rolling
rolling machine
machineof oftype
typeRAW
RAW500/400.
500/400.TheThefully
fullyauto-
automated
mated
ring ring line
rolling rolling line consists
consists of a ringof blank
a ringpress
blank PL
press
5000 PLand
5000 and
ring ring rolling
rolling machinemachine RAW 315/200.
RAW 315/200. Withtwo
With the
new lines, FRISA saves material, machining costs and energy. The production capacities cover all sizesalland
the two new lines, FRISA saves material, machining costs and energy. The production capacities cover
sizes and
types types of connector
of connector flanges. flanges.

6
8
FLANGES FOR WIND TOWERS
Significant material savings thanks to
profiling technologies

Top flange

Middle flange

Base flange

7
9
TOP FLANGE

Sleeve type ring

Tall neck at the outside diameter

Material savings

Weight in kg In %
Rectangular 1,674 100
Radial profiled 1,251 75
Savings 423 25

MIDDLE FLANGE

Washer type ring; Neck at the outside diameter Material savings

Weight in kg In %

Rectangular 4,169 100

Axial profiled 3,097 75

Savings 1,072 25

Rectangular rolled shape Material savings by profiling Machine shape

8
10
BASE FLANGE

Washer type ring; Neck at the mean diameter Material savings

Weight in kg In %

Rectangular 4,336 100

Axial profiled 3,090 70

Savings 1,246 30

9
11
NEW AXIAL PROFILING
TECHNOLOGY
TECHNOLOGY
Integrated solutions from SMS group
Meer

Meer ring
SMS group ring rolling
rolling machines and lines are
radial and
capable of both radial and axial
axial profiling
profiling of
of the
the rings.
rings. NEW TECHNOLOGY AT A GLANCE
modification and
Machine modification and upgrade
upgrade possibilities
possibilities
viability for
ensure future viability for plant
plant operators,
operators, too.
too.This
This „ Upper profiled axial roll and two pressure
upgraded inexpen-
allows even older models to be upgraded inexpen- rollers
demands.
sively to meet new demands. „ Control software for rolling of axial profiles
(CARWIN, ROLLTECH, CNC program,
State-of-the-art software packages measurably
State-of-the-art software packages measurably PLC program)
increase the profitability and product quality.
increase the profitability and product quality. „ Modified hydraulic axis for axial stand
movement
„ Technology software for rolling of axial profiles
„ Economic production thanks to one universal
upper axial roll for all types of flanges and rings
with rectangular or radial profiled cross section

10
12
 THE
THECUSTOMER´S
CUSTOMER´SPERSPECTIVE
PERSPECTIVE

“The
“Themachines
machinesand
andplants
plantsfrom
from SMS
SMS group are of
Meer are of aa very
veryhigh
highquality.
quality.They
Theyare
areprecise,
precise,sturdy
sturdy and
and flexible.”
flexible.”

Mikel
MikelRedín
RedínPérez
Pérezde
deNanclares,
Nanclares,Owner
OwnerofofEuskal
EuskalForging
ForgingSA,
SA,Spain
Spain

One of Europe’s
Europe’s biggest
biggest tower
towerflange
flangeproducers,
producers,
Euskal Forging
Forging (Spain),
(Spain),chose
choseSMSSMSgroup
Meerto
toretrofit
retrofit
the existing ring rolling
existing ring rollingmachine
machineRAW RAW500/400
500/400with
with
the newest axial
axial and
and radial
radialprofiling
profilingtechnology.
technology.

EUSKAL FORGING ORDERS FIFTH

EUSKAL FORGING ORDERS FIFTH
RING ROLLING MACHINE
RING ROLLING MACHINE
Shortly after, Euskal ordered a further ring rolling
Shortly after, Euskal ordered a further ring rolling
machine from SMS group – the second most power-
machine from SMS Meer – the second most pow-
ful ring rolling machine that SMS group has ever
erful ring rolling machine that SMS Meer has ever
built. With the new radial-axial ring rolling machine
built. With the new radial-axial ring rolling machine
of type RAW 1000 (1250) / 1000 (1250), the Spanish
of type RAW 1000 (1250) / 1000 (1250), the Span-
company is extending production to include rings of
ish company is extending production to include
up to 50 tons in weight with a maximum ring dia-
rings of up to 50 tons in weight with a maximum
meter of 10 meters and a maximum ring height of
ring diameter of 10 meters and a maximum ring
1,700 millimeters.
height of 1,700 millimeters.
Euskal is meeting the market demands for larger
Euskal
rings foristower
meeting the market
flanges, demands
as higher for larger
wind turbines
rings for tower
with larger flanges,
generators ofasuphigher
to 7.5 wind turbines
MW and more
with larger generators
are needed, particularly of
forup tooffshore
the 7.5 MW sector.
and more
are needed, particularly for the offshore sector.

BENEFITS AT A GLANCE

„ Improved competitiveness
„ New production technology covers middle
and base flanges in the medium and large
size range

13
11
12
NEW RADIAL PROFILING
TECHNOLOGY
Improving competitiveness with new technologies

India – one of the largest wind markets

markets worldwide.
worldwide.
To meet the high market requirements,
requirements, SE SE Forge,
Forge, NEW TECHNOLOGY AT A GLANCE
a well-known supplier to the power, oil and gas and and
transportation industry,
industry, installed
installed aa fully
fullyautomated
automated „ Mandrel with straight and profiled section
ring rolling line from SMS group.
Meer. The
The Indian
Indian company
com- „ Control software for rolling of radial profiles
was
panythe
wasfirst
theuser
first of SMS
user Meer’s
of SMS new technologies
group’s new techno- (CARWIN, ROLLTECH, CNC program,
for tower
logies for fltower
ange flange
production.
production. PLC program)
„ Additional stroke for mandrel lifting and
The scope of supply comprises
The scope of supply comprises lowering device
a ring blank press PL 5000
„ a ring blank press PL 5000 „ Modified mandrel retraction sleeve
a ring rolling machine RAW 200/250
„ a ring rolling machine RAW 200/250 „ Modified hydraulic axis for the mandrel lifting
a ring expander RKP 1000
„ a ring expander RKP 1000 and lowering device
and the latest profiling technologies.
„ and the latest profiling technologies.

ROLLING SEQUENCES
1 With straight section of the mandrel 2 With profiled section of the mandrel

Lowered position of the upper

mandrel bearing assembly

13
15
REFERENCES
Selected seamless rolled ring plants

STATUS CUSTOMER MACHINES/LINES

In production „ SE Forge, India „ RiWa 5000/200/1000
„ Unison, ROK „ RAW 160/125
„ FRISA, Forjados, Mexico „ RiWa 8000/500
„ FRISA Forjados, Mexico „ RiWa 5000/315
„ Euskal Forging, Spain „ RAW 500/400 (retrofit)
„ Taewoong, ROK „ RAW 630/400 (retrofit)
„ ASFO, Italy „ RAW 400/400

Orders on hand „ Bohai, PRC „ RAW 800/630

„ Euskal Forging, Spain „ RAW 1000/1000

IMPRINT
SMS Meer, Corporate Communications, Dr. Peter Heimerzheim (Director)
Ohlerkirchweg 66, 41069 Mönchengladbach, Germany, Phone: +49 2161 350-2600, Fax: +49 2161 350-1862
14 [email protected], www.sms-meer.com 19
SMS group GMBH
Business Unit Forging Plants

Stockumer Strasse 28

58453 Witten
P-335E . 01/17 . Printed in Germany

Germany

Phone: +49 2302 7098-3370

Fax: +49 2302 7098-3356

[email protected]

www.sms-group.com

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics
as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obliga-
tion to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.