Casting Capability Eliminates Molds

FKM-USA (Frankfort, IL) offers its rotary casting process, which can shorten production time and help decrease cost in the highly competitive metal processing industry. Rotary casting is based upon the application of highly reactive multiple-part urethanes directly onto a rotating roll core to create a solid roll cover in a matter of minutes. Because it eliminates the need for conventional poured molds and a secondary curing process, rotary cast rolls can be delivered in days instead of weeks, months or more. Further time and cost savings can be realized as rotary casting lends itself to coating the roll without having to first move the bearings from the roll journal.

FKM?s rotary casting process is far more flexible than standard mold-based technology, since FKM can direct cast different types of polyurethane materials onto any rotational-symmetric body, maintaining tight hardness tolerances while optionally varying the hardness of specific layers. FKM can also apply a single layer of a coating that protects the journals and end plates. The process can deliver a number of chemical systems including polyether urethane and polyester urethane.

With mold cast rolls, air pockets or other irregularities can occur in the polyurethane where the hardness uniformity can vary by + 5 ShA points across the roll, which can be detrimental to the end-user?s production process. With the rotary casting process, hardness uniformity is held consistently across the roll to within + 3 ShA points or better and the roll?s mechanical properties are typically superior. Roll sizes can be produced anywhere from 152 to 1800 mm (6 ? 71 in) diameter and up to12,000 mm (472 in) in length, making it well-suited for a variety of industries.

FKM designed and built its own rotary casting machine as well as custom-designing the accompanying controls software. The company has invested in in-house CNC lathes and grinding systems to offer complete roll finishing. ?With this machine, we?ve been able to cast rolls in minutes,? said FKM General Manager Jim Rusczyk. ?This casting process will benefit our customers in the metals industry, offering them efficiency and cost as a competitive advantage.?

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