This second mill will have a very similar configuration to the first including a Quarto fixed frame and movable cassette design , continuous feeding section and a twin planetary gearbox mass balancing system .
The main advantages of the Quarto mill are an extremely rigid mill stand design capable of resisting high separating forces , a continuous and precise shell feeding section with CNC machine solutions ( profiled guide ways , a recirculating ball screw supported on both ends , a water cooled servomotor ) and a vibration-free mass balancing system designed to reduce foundation works and to minimize the overall CAPEX of the project .
Tube cold pilgering is one of the most important manufacturing technologies for seamless tubes . The process is unique in the rolling scenario : a simultaneous reduction of internal and external diameter and wall thickness is achieved ; an appropriate elongation ( from three to seven times depending on cross-section reduction and material ) can also be generated . Therefore , for these reasons , the coupled effect of the roll and mandrel shape on the final tube tolerance and properties is an important objective in the tooling design and process .
Two CPM orders for nuclear seamless tube applications from the same customer in a short time-span demonstrate the competitivity of DWK in this niche market segment . Simplified , cost effective configurations are also available for commodity tube producers .
Starting from India we are now targeting worldwide customers interested in Danieli CPM solutions developed thanks to an innovative Q-Pilger approach based on three pillars : tooling design knowledge , unbeatable ratio between mill quality and CAPEX and tailored after-sales services based on an in-depth understanding of the cold rolling process .
Tooling design using sophisticated 2D and 3D FEA techniques allows simulating the rolling process and estimating the separating forces on the rolls and retaining load on the mandrel in advance . This is a crucial aspect for the closed loop mill design . In the Quarto CPM configuration , load cells can be used to monitor separating forces on-line during production offering DWK the possibility to close the loop even during operation with a proper mill set up .
From our perspective , the Q-Pilger approach is the most modern and cost effective solution for increasing knowledge and parameters on the tube cold pilgering process . It avoids a costly trial and error approach , which has a very high impact on budget and scheduling when developing new products .
In a very tough market characterized by overcapacity , our mission is not only to supply new CPM mills to customers with the necessary resources for new investments but also to help tube producers use existing mills more efficiently by installing Technological Packages specifically developed to revamp existing CPMs .
Our cornerstone is process knowledge , which enables us to produce more with cost effective solutions utilizing optimal tooling design and reduced OPEX .
TN JANUARY 2017 10