 | DESIGN AND DEVELOPMENT
Thistle Roller's Quality Control Program is very successful due to the professionalism of our work force and the direct communication with our clients. Communication requires listening to the customer and focusing on their needs. These needs will establish guidelines. For example: any new policies, instructions or specs. These factors will ensure the quality of all manufactured or serviced products. In addition, our "Quality Control Department" works closely with the production floor to ensure all rolls confirm to the highest quality standards and procedures.
Apex Rolls (India) Pvt. Ltd. is a quality driven company with focus on total customer satisfaction. Apex Rolls (India) Pvt. Ltd. has always dedicated a lot of resources for the maintenance of ultimate quality of its products. Years of experience in the business, dedication of foundry men, and careful selection of high grade, tested raw materials ensure that all rolls coming out of our production lines are of the highest quality.
Regular quality checks, thorough testing of rolls during each stage of manufacturing - casting, machining or finishing is carried out. Microprocessor based equipment is installed for testing of the composition, hardness and dynamic balancing of rolls. The data generated is stored and analyzed regularly. These steps ensure that all rolls are uniform in hardness, chill depth, adequate ductility, high wear resistance and consistency of the hardened layer, ensuring that the rolls we supply meet the stringent quality requirements of our valued customers.
Our concerted efforts in the process of research and development have resulted in production of rolls of the highest quality at reasonable prices. Apex Rolls (India) Pvt. Ltd. finds great pride in the fact that our rolls have been highly appreciated by customers from across the globe.
Machine & Testing
The rolls meeting all the stringent tests to our complete satisfaction are then sent to the rest of the machine-shop, comprising high precision lathes, radial drill machines, boring machines wobbler milling & grinding machines, etc. Special purpose milling machines for accurate machining of wobbles and the driving end, and Roll Grinders equipped with special concave and convex device, capable of grinding roll necks (both tapered and straight) to extremely close tolerances are the essential part of our work-shop.
The high precision boring machines guarantee highest accuracy in regard to roundness and concentricity of the bore. In our machines one would find a mix of some of the best Indian & International names for precision machining, grinding and drilling.
Meanwhile all the steel rolls require heat treatment. The hardening and tempering furnaces are provided with temperature control microprocessors and the required rolls are subjected to various heat treatment cycles. Stress relieving of special S.G. IRON ROLLS is also done here. Metallurgical tests in respect of grain size and microstructure are carried our after heat treatment and eventually the ultrasonic testing is done, where required, to ensure the overall internal soundness of the roll.
Hollow rolls are dynamical balanced at different RPM to ensure their friction free movement.
Proper temperature control during the course of the heat and at the roll is exercised with the help of immersion and optical pyrometers. Both sample of each melt is analysed for composition and determination through the latest model of German Spectrometer. Every Possible precaution is taken to minimize hydrogen. The process guarantees uniform structure & mechanical properties over the particular zone.
Rolls then move to our large machine-shop, where each roll first passes through a series of heavy roll-turning lathes for proof machining. At this stage, various tests are carefully carried out to determine if the roll is zero-defect and qualifies for further processing. A series of metallographic and mechanical tests monitor the structural homogeneity and ensure that rolls are free form cracks, blow holes, gas holes, etc. hardness is measured using the Shore, Vikers, & Dynamics Hardness Testers.
Finally rolls, as required are tested by means of non-destructive testing methods like ultrasonic, magnetic particle inspection and dye-penetrant test and the best possible quality of roll without surface and internal defects is ensured. For large or critical rolls, samples are removed from the rolls to carry out tensile and impact tests and to carry out micro structure. These tests are made to ensure optimum properties in service. Roll material and the groove design are major factors affecting rolling performance and roll life.
After series of tests and quality control process that we finally present our rolls for the ultimate inspection, approval and delivery. Rolls are always dispatched with the identity number engraved on the drive-end wobbler face.
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