trjwalcowa walcarka

Three-roll skew rolling mill RSP 14/40

     In December 2014, a new rolling laboratory (also for materials that are not so plastic and difficult to deform) was launched. The laboratory is equipped with the only three-roll skewed rolling mill in Poland - RSP 14/40 - produced by a Russian company, ZAO „ISTOK ML”. It’s a rolling mill that enables rolling of round bars with significant deformations. In case of rolling of round bars, the mill allows for applying great deformation in one pass, max. value of elongation coefficient - 3.

     The unique structure of a skew rolling mill enables analysing new materials, especially materials that are hard to deform, including high temperature resistant materials, hard alloys based on Fe, Cr, C, B, alloys with special magnetic properties – for example Fercalloy, high-strength materials based on W, W-Re, W-Ni-Fe, shape-memory alloys, in which the final shape is obtained by means of plastic working, or zirconium alloys. Finished products made of those materials are used in the key areas of economy, including the energy industry, and previously the nuclear industry. Currently, the Institute of Plastic Working and Safety Engineering is conducting works connected to rolling of magnesium and aluminium alloys in the three-roll skew rolling mill.    

Basic technical parameters of the rolling mill:

  • bevel angle of the roller axis: 18° (during rolling in traditional skew rolling mills the max. bevel angle of rollers is 16°)
  • feedstock diameter: from 20 to 40 mm
  • diameter of the finished product: from 14 to 35 mm, length of the finished product: up to 6000 mm
  • elongation coefficient: up to 3, efficiency: from 0.2 to 1.5 Mg/h
  • engine power: max. 3 x 11.5 kW

trjwalcowa walcarka


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DUO 300 rolling mill

      Basic technical parameters of the DUO 300 rolling mill:

  • working rollers with the diameter of 300 mm
  • length of the a roller: 300 mm
  • feedstock measurements up to: 50 x 80 mm
  • finished product measurements: 30 x 30 mm
  • rotational speed of the roller: 26 rpm
  • rolling speed: 0,45 m/s
  • engine power: 2 x 75 kW

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DUO 150 rolling mill

     Duo rolling mill with the roller diameter of 150 mm and the barrel length of 170 mm; it is also equipped with devices for measuring energy and strength parameters.


walcarka duo150DSCN4582

Hydraulic presses

     The laboratory is also equipped with two hydraulic presses:

  • The PWH-250R hydraulic press is intended for: embossing, extrusion, and forging etc.
  • The „Ponar-Żywiec” PHM 250C hydraulic press is intended for realization of embossing processes.

     The PWH-250R frame hydraulic press is intended for all kinds of plastic working processes involving metal, including embossing, extrusion, riveting etc. The press is equipped with a slider, which ensures more stiffness and parallelism of the upper table movement. It is being conducted with the use of eight guidable slide blocks. The main cylinder has a system for measuring pressure force and covered distance. The press has a hydraulic drive system with smoothly regulated pressure force and its characterised by the following technical parameters:

  • regulated pressure (I range): 130 kN¸ 2500 kN;
  • main cylinder reverse power: 1270 kN;
  • nominal pressure within the installation of the main cylinder: 328 bar;
  • min. stroke: 20 mm;
  • max. stroke: 500 mm;
  • downward movement speed (work): 5-40 mm/s;
  • upward movement speed (return): 77 mm/s;
  • clearance between the columns of the press: 960 mm;
  • surface area of the table: 800 x 800 mm;
  • press and power unit mass (without oil) ~11 000 kg;
  • pump engine power: 110 kW;
  • installed capacity: 111 kW;
  • adjustment to protective installation: TN-C or Tn-S;
  • main protection: 250A (time delay fuse)

     The machine is controlled with the use of the BERNECKER & RAINER programmable logic controller with an operator’s touch panel. The absolute measurement of location of the press guided plate and the bottom hydraulic cushion plate is conducted by the BALLUFF position transducer, which makes the measurement result available with the use of analogue signal. The result is displayed in a graphic and digital form on the screen of the operator’s panel. The press can operate in both automatic and manual cycles. Cylinder output stroke in the automatic cycle takes place in two stages. The first stage is a fast approaching movement, and the second one is a slow working movement. The cylinder goes back to its starting position at a steady pace. The upper position (starting), switching position form fast to slow motion, return pressure, working velocity, and the bottom return position of the cylinder are set on the operator’s panel. The press is equipped with a data recorder for the main cylinder pressure relative to the location.




      The 250C Żywiec hydraulic press is intended for hot and cold free forging, forming of plastics as well as hot and cold embossing. The pressure can be applied both by the upper working plate and the ejector. The press can be controlled automatically or manually. There’s a possibility of heating up the tools.

  • pressure force: 2500 kN
  • slider stroke: 30 mm/s
  • working feed: 10 mm/s
  • ejector stroke: 45 mm/s
  • ejector pressure force: 150 kN



Drawing machines

    The laboratory is also equipped with two drawing machines:

  • single drum drawing machine
  • draw bench machine

    A single drum drawing machine (D = 600 mm) enables drawing different wires, including those with the diameter in between 1.0 ÷ 5,5 mm. The drawing velocity of this machine can vary between 0.6; 1.1 and 1.6 m/s with the use of conventional or pressure dies. This work station is expected to expand in order to obtain the following possibilities:

  • draw force measurement
  • controlled rotation of the die in a drawing box
  • feed drawing

    A draw bench machine gives the possibility ofdrawing wires and tubes, as well as analysing the fatigue limit (rotational bending) of a wire.


One step wire drawing machine  Obraz4 Draw bench machine for tubes and bars

Chamber furnace
Additionally, the laboratory is equipped with two chamber furnaces for heating up analysed samples. The furnaces are adjusted to various heat treatment processes, in case of steel and other metals, reaching the temperature up to 1200 [°C]. They enable to precisely obtain necessary temperature and keep the materials in the required temperature for a long period of time.



 Thermographic camera ThermaCAM SC640 by FLIR Systems

kamera     Moreover, the laboratory is equipped with a ThermaCAM SC640 infrared camera produced by FLIR Systems. It’s a hand thermal imaging camera with an uncooled detector that generates high-resolution images (640 x 480 pixels). This camera is a perfect tool for professional thermographic research. Combined with the latest ThermaCAM Reporter™software, it is an extremely efficient solution for infrared inspections and ultimately provides an advanced report archiving conducted measurements. Integration of a thermal imaging camera, digital camera, additional lightning, and a laser pointer enables to conduct more measurements in a shorter period of time. Infrared and photography, together with other data registered by the ThermaCAM SC640 camera during a study, are completely integrated in the new ThermaCAM Reporter programme, which allows for an advanced analysis of temperature changes and automatic creation of reports. With the use of the camera it is possible to analyse a wide range of temperature distributions. It can be used in laboratory conditions as well as directly in mills. Thanks to the camera, temperature distributions can be analysed at every stage of the production process. The generated thermograms allow for an analysis of temperature distributions on the surface of a material, also on its length. The camera also enables to study cooling abilities of devices for faster cooling of a strand in a rolling line, for different cooling conditions. Moreover, it can help to determine roller temperature. The analysis of obtained thermograms can be followed by verification of temperature values assumed for numerical modelling of plastic working processes.

Laboratory supervisor: PhD, Eng. Tomasz Garstka
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