Rotary Casting Process accelerates PUR roll production.

Press Release Summary:

Eliminating need for poured molds and secondary curing, rotary casting process reduces production time and enables delivery of polyurethane (PUR) rolls in days. Service can direct cast different types of materials onto any rotational-symmetric body, consistently maintaining hardness uniformity across roll to within +3 ShA points or better while optionally varying hardness of specific layers. Rolls can be produced in diameters from 6-71 in. and lengths up to 472 in.

Original Press Release:

FKM-USA Offers High-Tech Polyurethane Roll Production

New Rotary Casting Capability Eliminates Molds to Reduce Production Time and Cost

Frankfort, Ill., May 22, 2008 --- FKM-USA, a fabricator of industrial roll products, has announced its new rotary casting process, which 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 journals.

The rotary casting process is far more flexible than standard mold-based technology since FKM can direct cast different types of 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 and 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 to produce a roll that typically has superior mechanical properties. Roll sizes can be produced anywhere from 152 to 1800mm (6 - 71") diameter and up to 12,000mm (472") 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 capability will benefit our customers as well as opening the door to new markets for us."

FKM is a fabricator of industrial roll products. FKM rolls are configured for diverse applications such as rolls for the steel and flat rolled metal industry, rolls for the paper industry, support for tailor welded blank systems, and wash rolls within sheet metal blank washers. The FKM product line includes non-woven roll covers, lightweight carbon fiber roll core technologies rotary cast polyurethane rolls.
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