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Danoil Brochure DANOIL DANIELI OIL FILM BEARINGS Latest generation for rolling mill equipment thanks to Danieli’s expertise in design and manufacturing processes for the metal industry INTEGRACTION SMART SERVICES FOR INTEGRATED SUPPORT DANOIL LATEST GENERATION FOR ROLLING MILL EQUIPMENT THANKS TO DANIELI’S EXPERTISE IN DESIGN AND MANUFACTURING PROCESSES FOR THE METAL INDUSTRY Introduction 3 Why choose DanOil bearings? 6 Engineering Research and Development DanOil main components 8 White Metal Welding of Bushings 10 White Metal Centrifugal Casting Process of Bushings 12 DanOil Sleeves 14 Sealing System L L I I 15 Seal End Plate (Nitreg process) 16 Locking Device 18 Bearing Lubrication Systems 20 Reconditioning Refurbishment and Repair DAN DAN 22 De-Chocker and Tilter Machines Customer Service 24 Traceability / Quality Certificate 25 Installation, Advisory Service and Training DanOil sizes 26 DanOil Bearing data table Danieli Service portfolio 28 High Technology Products 30 DanOil Bearing reference list 32 Danieli Service Centers and Danieli Workshops and Facilities SINCE 1962 1 DANIELI SERVICE DANOIL — Know-how — On-site Customer Being an integral part of Assistance Danieli, world leaders in rolling The Danieli philosophy of WHY CHOOSE mill innovation, ensures DanOil strong customer support is at bearings are at the forefront of the heart of DanOil bearing’s developments in all aspects of operating approach. We offer DANOIL BEARINGS rolling technology. comprehensive, worldwide technical support service for Rolling mill back-up rolls are designed to withstand the — Engineering Experience oil-film bearing users in all forces generated by the rolling process and therefore Our engineers have extensive aspects of design, operation, require bearings capable of carrying very high loads. knowledge and "hands on" maintenance and spare parts. To ensure the mill stand is as stiff, as possible the experience of the design, bearings also must be stiff and compact. manufacture, installation and — Safety and Application DanOil bearings satisfy this requirement-which is operation of all back-up roll We are able to offer new one of the reasons they are a well-proven design in oil-film bearings and rolling mill mechanical and hydraulic this field. DanOil bearings are located in the backup technology. locking designs to increase roll chocks and are connected to a re-circulating oil operator safety and to lubrication system, usually located in the mill cellar. — Reseach and Development simplify the assembly and Through our knowledge and installation procedure, with experience in the design and every unit specifically operation of oil-film bearings, designed for each customer’s we have identified and are actual requirements, ensuring committed to further there are no disruptions to improvement of the bearing rolling schedules. and associated equipment. — Competitive Pricing — 100% Interchangeable Our aim is to reduce mill Our standard range of bearings operating costs by providing is fully compatible with other the highest quality bearings manufacturers’ bearings, for and spares at low prices. which we offer a full range of Danieli's highly efficient spares. production techniques and strong buying power results — Forefront Manufacturing in very competitively priced Cells bearings and spare parts, Investment in state-of-the-art, without compromising the purpose-built machines will high finished quality to which ensure that all the components Danieli's customers have of DanOil bearings are become accustomed. manufactured to the highest possible standards and — DanOil Worldwide tolerances. The Danieli References Headquarters manufacturing In addition to a facility in Buttrio (Italy) is the comprehensive list of DanOil most modern in the industry, bearing customers, we also together with DanOil supply spare parts such as manufacturing workshops in new oil-film bearing sets for Changshu (China), in Chennai many hot-and cold-rolling (India), and coming soon in mills supplied by both Danieli Ashland (USA). and others. 2 3 DANIELI SERVICE DANOIL 1. Back-up roll 2. Bushing 3. Sealing system 4. Sleeve 5. Back-up roll chock 6. Sleeve ring 7. Thrust bearing 8. Chock end plate 9. Hydraulic locking unit 10. Outer end plate 11. End cover 1 2 3 4 5 6 7 8 9 10 11 — Bushing — Sleeve — Sealing system — Locking device — Sleeve ring — Chock End Plate, Outer — Bearing End covers — Thrust bearing End Plate and other rings The bushing is the static part The sleeve is the journal part To keep the roll coolant and Various types of locking The sleeve ring located in the Thanks to the skill and These items secure the A conventional double-row, of the bearing assembly and is of the bearing assembly; it is the bearing lubricant separate, devices are used to ensure outboard end bore of the experience of our engineers, components to the back-up taper roller bearing withstands located in the bore of the located on the taper neck of specially developed seals are that the sleeve and the other sleeve is used to transmit the Danieli can offer its customers roll chocks and form an the axial loads imposed on the back-up roll chock. The steel the back-up roll. located at the inboard end of components mounted on the axial force from the locking innovative, high-tech solutions oil-tight enclosure at the back-up roll and bearing by the shell of the bushing is lined The sleeve is made from the bearing. Danieli can supply roll are located in the right unit to the sleeve during for the other main components outboard end of the bearing rolling process. Traditionally with a special white metal (also high-quality forged alloy steel the innovative solutions for the position. mounting and also to transmit of the oil-film bearing. assembly. this bearing is mounted on the known as Babbitt). DanOil and is precision ground to coolant seal (stationary), the Danieli can offer two efficient any axial forces to the thrust operator side of the mill. Babbitt was carefully selected ensure roll eccentricity is aluminum seal inner ring and solutions as an alternative to bearing. For optimal control of the axial for its ability to reduce start-up minimized (the bearing surface neck seal (rotates). the traditional mechanical and movement of the bearing and friction and to withstand rolling is round and concentric to 3 Moreover Danieli has hydraulic locking systems. chocks, thrust bearings may forces, as well as to capture micron or better). developed a innovative solution be fitted to both ends of the small particles that otherwise for the Seal End Plate (with roll. Chock-spreader bars, their would damage the bearing. nitreg heat-treatment process), locating pods, and the solving the difficult working associated maintenance of conditions to which these these items are eliminated. components are exposed. 4 5 DANOIL ENGINEERING, RESEARCH AND DEVELOPMENT The DanOil system is a fundamental part of the technological equipment fitted to hot- and cold-rolling stands, and Danieli has a group of specialists who are fully dedicated to its design and development for continuous improvement of quality and service life, thus ensuring it maintains its top-level status. The Danieli Engineering Department backed by the Danieli Research and Development Center and based on feedback from its on-field technicians, focuses on conceptual design, customized solutions and standardization of oil-film bearing components, so as to develop first-class, reliable and innovative products at competitive prices. 1. 1. FEM allows us to simulate working conditions and to analyze the behavior of the sleeve and bushing in various loaded conditions. This ensures that we optimize the performance of each bearing component. 2. Danieli’s expertise in design, manufacturing and experience of rolling processes for long and flat mills, has ensured that the DanOil bearing technology has reached the same levels of 2. excellence for all types of rolling applications. 6 7 DANIELI SERVICE DANOIL White metal welding facilities WHITE METAL have been installed in our WELDING OF shops in Italy, China and India BUSHINGS to ensure that DanOil bushings are manufactured to the highest standards. This investment is proof of our commitment to control the production of key components. This new center is specifically dedicated to spinning the white metal linings onto the bushing shells of DanOil bearings. The maximum capacity is ø 2,000 x 1,500, with a maximum casting weight of 5,000 kg. In an air-controlled, covered area of more than 500 square meters, all the following 1. operations for this production process are performed: — heating and tinning to activate the bushing surface and facilitate the bonding of the white metal; QUALITY DANOIL — welding casting facility to distribute the white metal onto COMPONENTS: the bushing surface evenly; — accelerated cooling to TRACEABILITY obtain 100% bonding and OF THE ENTIRE achieve the specified bond strength; PRODUCTION — every bushing is ultrasonically tested in order CYCLE. to confirm no cracks on longitudinal welding and Chalmers test is performed to ensure bond strength value. 2. Advantages of plasma welding — Very fine microstructure for high compressive strength; — Uniform quality due to high reproducibility of the process parameters; — Environmental friendliness due to save resources; — Consistently thin layer even after repeated repairs. This installation, which complies with the UNI EN ISO 9001 standard, is 1. environmentally friendly: particular attention has been given to the fume treatment plant to ensure a safe working 3. environment. 1. Bushing welding booth with controlled atmosphere and temperature. 2. Bushing machine at the end of the white metal welding process. 3. Ultrasonic testing to determine bushing bond strength. 8 9 DANIELI SERVICE DANOIL A centrifugal casting facility WHITE METAL was installed in Changshu CENTRIFUGAL (China) to manufacture CASTING PROCESS DanOil white metal, high- OF BUSHING thickness bushings to the highest standards. This center is specifically dedicated to spinning the white metal linings onto the bushing shells of DanOil bearings. The maximum capacity is ø 2,000 x 1,400, with a maximum weight of 6,000 kg.
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