Rolmak Döküm Sanayi ve Limited Şirketi
Karabük · Merkez
Rolmak Döküm Sanayi ve Limited Şirketi
Foundry in Karabük OSB with 7000 m2 closed area producing rolling mill rolls and rings; 10-ton melting capacity.
About
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United States
Factory gallery
Products
Rod-Coil Rolling Mill Rolls
Casting rolls used for rod and coil rolling mills, known as spherical (sphero) rolls in the industry, are classified as ferritic, perlitic and acicular. These rolls contain high alloys and can be used on all rolling steps, from preparation groups to finishing stands. Spherical graphite in the microstructure gives high breaking strength and blocks internal microcracks; high thermal conductivity dampens thermal stresses and delays thermal cracking. For rod-coil mills, preparation uses RDP 47-32 and RDP 57-41; middle group RDP 57-41 and RDP 65-47; post-finish RDP 67-48, RDAC 67-48 and RDAC 76-53; finish RDP 67-48, RDP 70-50, RDAC 74-52 and RDAC 83-57. The rolling mill layout may vary according to working conditions and the products to be drawn.
Rolling Mill Rings and Straightening Balls
Rings are used in middle-group and finish lines as a price-performance product; when used under suitable conditions, the increase in product amount per pass is significant. Before packaging, the straightening process removes linearity problems of the finished product. Rolmak produces straightening balls in hardness and microstructures prepared by its experienced teams so that maximum efficiency can be obtained. Rings and straightening balls are molded, cast, heat-treated and machined at the Karabük plant before shipment.
Angle-Profile Rolling Mill Rolls
Sphero rolls for angle and profile rolling mills have high tensile strength and thermal conductivity because of the spherical graphite they contain. They take their mechanical strength from the spherical graphite in their metallographic structure. After heat treatment these microstructures are suited to preparation, middle and finish groups. For angle-profile mills, preparation uses RDP 47-32 and RDP 57-41; middle group RDP 57-41 and RDP 67-48; post-finish RDP 67-48, RDAC 67-48 and RDAC 70-50; finish RDP 67-48, RDP 70-50, RDAC 70-50 and RDAC 76-53. The rolling mill layout may vary according to working conditions and the products to be drawn.
Services
CNC and Workshop Machining
All rolling mill rolls manufactured by the plant are machined in-house on the workshop machines according to the specified technical drawings. Equipment includes conventional lathe, CNC lathe, CNC double columns, vertical lathe, 150-ton press, radial drill, shaper, vertical mill, vertical band saw, universal mill, CNC boring mill and universal boring mill. Machining is applied after casting and heat treatment to bring roll geometry to the customer drawing.
Heat Treatment
The plant has two thermal process ovens running at full capacity. Each produced roll undergoes heat treatment for internal microstructure homogenization, and further thermal processes are applied according to the duty to increase roll performance. The company catalogue states that heat treatment for rolls is stress-relief annealing.
Ductile Iron Casting
Model moldings for rollers, rings and machine spare parts are made with mixers that have a total sand dispensing capacity of 70 tons/h. Chill moulds used in roller casting are designed to raise roller and ring quality. Melting is done in one double-pot induction furnace; up to 11 tons of metal can be melted in one heat. Chemical analyses are taken from each furnace and liquid-metal temperature is controlled; furnaces have ventilation and filtration to remove dust and smoke. Roll designs use special calculation methods to minimize casting-originated errors.