Danieli designed the Rotoforge process for maximum flexibility in operation at ABS. Cast blooms are heated at 100 mt/h in walking-beam furnace (hot charging from the caster is an option), and ingots are staged in a pit furnace directly ahead of the Rotoforge stand.
Italian Prime Minister Matteo Renzi attended the Rotoforge ribbon-cutting ceremony in September, joining Danieli and ABS executives.
The Danieli concept for forge-rolling centers on a reversing stand for blooms up to 850 mm diameter, and achieving a reduction ratio of >1:3 across the entire product range.
The Rotoforge stand uses hydraulic cylinders on the bottom roll as part of the system for in-line adjustment of rolls and guides.
Flexibility and Speed
The Rf stand is one of three options installed for rolling blooms at ABS, each option linked to a separate two-high reversing stand, providing maximum rolling flexibility and quick changing times.
Fine-Grain Structure, Low Soundness
The Rf stand imparts the same material strain to blooms via rolling that is achieved by forging. Rotoforged material has a fine-grain structure and low soundness (FBH < 2 mm), with surface quality and productivity typical of long-product rolling.
Fully Automatic Rolling
For ABS, the Rf stand operates in a fully automatic rolling mode, connected to a higher level of process automation guided by control algorithms that make the process smooth and repeatable, reducing head and tail deviation and enhancing bar straightness.