Innovative Solutions for Metals Processing Technology
At Osborn, we understand the problems you face when it comes to metal finishing. We know the challenges of surface contamination that can crop up when rolling steel, aluminum, stainless steel or other primary metals. And, we appreciate the need to improve repeatability while increasing process times.
No matter what issues you have to deal with, we’re here to provide the right solutions for your requirements. From descaling and cleaning to surface prep regardless of material, we offer the best recommendations to meet and exceed your specific needs- whether it’s on steel, stainless steel, aluminum or other.
If your process line is experiencing inconsistent finishing or chatter marks, it might be the brushes. Or, it could be the bearings. But how would you know which? Our engineering experts will analyze and evaluate your process. We might recommend using the existing shaft construction, or we could suggest installing complete brush roll assemblies.
At Osborn, our forte is the development of new solutions that eliminate performance and reduce costs. We work closely with our customers to design products that address their exact requirements. The solutions we’ve developed are tailored to meet precise specifications. Whether it’s a brush used to clean the surfaces of coils or a furnace roll used to move material, Osborn solutions are custom-made and based on proven technology.
HDL® Brush Rolls
Osborn HDL® brush rolls are used in cold strip lines. Applications such as washing, degreasing and cleaning of strips, activation of strip surface, polishing and finishing of strip surface as well as scale removal after hot and cold mill processes are most common. HDL® brush rolls can have multi-filaments and special mono-filaments with or without an abrasive load as single bristle or mixture filaments. Accordingly steel, stainless steel, aluminum and non-ferrous metals can be treated. Advantages are a higher life-time, a siginificant higher ability to degrease and clean the strip surface. This enhances the quality of the final product and speeds up the total manufacturing process.
Helimaster® Brush Rolls
Osborn's Helimaster® brush rolls are perfect for cleaning work and as back-up rolls in wet or dry operated rolling and skin-pass mills. They remove oxides, dirt and rolling residuals. They are either wire-filled or abrasive. Each brush is neutrally grounded and either gets a cylindrical camber ground or - for offsetting the computed roll deflection - a positive and/or negative camber ground. Depending on the process, steel, stainless steel and aluminum can be treated. It is important that the brush tools are perfectly matched to the operational and process parameters. Especially the repeatability of the specified agressiveness and brush effect as well as a constant performance quality until the exchange of the roller need to be ensured.
Osborn offers furnace rolls for HHT furnaces and for high temperature applications. Aluminum plates can for example be transported through the heat treatment process. An optimum heat transfer between plate and transport roll is guaranteed; a damage to the plate surface and scale pick-up and spot-formation on the roller-surface can be avoided. After manufacturing the rollers the later route of the sheets is being simulated in our own test facilities. This way we can guarantee an exact sheet-routing within tight tolerances even before the rollers are being put into the furnace. In high temperature processing areas we use roller coverings out of extremely dense stainless steel wires with special heat resistant alloys. The rollers can be used in different horizontal heat treatment lines for stips of steel, stainless steel or non-ferrous metals. Excellent performance and a long life-time without scale pick-up up to 1.100°C can be achieved.
Brush transport rolls can also be used for noise-reduction. When transporting sheets onto rolling tables, extreme noise levels may occur in cross cutting lines after the shearing process. A level of 110 dB can easily be reached. By coating the naked transport rollers with brush sections, the noise level can be reduced to approx. 70 dB, which significantly minimizes hearing damages and other health risks triggered through noise.
Lipprite® Abrasive Non-woven Rolls
Osborn's Lipprite® abrasive rolls are an alternative to conventional brush rolls. Besides finishing applications they are used for working-roll cleaning, surface activation and de-scaling. The rolls are manufactured from abrasive non-woven flaps through radial adhesion to a core. The abrasive grit is made of silicon carbide or aluminum oxide. The aggressiveness of the roll is individually determined by the density of the material, e.g. the number of flaps. Through optional impregnation the service-life and aggressiveness can be enhanced. Lipprite® abrasive rolls can be used in wet and dry applications.
Osborn Non-woven Rolls
Osborn non-woven rolls are being used in all cold strip lines and rolling mills for steel, aluminum, stainless steel and non-ferrous metals. Among them are pickling and annealing lines, coating process, cleaning and degreasing lines, as well as skin-pass mills, to name just a few. They can have totally different functions such as bridle rolls, tension rolls, steering rolls or deflector rolls, as braking and squeezing rolls, as oiling/applicator rolls, tension, transporting or carrying rolls. Compared to rubber or polyurethane, Osborn non-woven rolls offer clear advantages: The spongy character in combination with the large pore volume makes the material highly compressible, resistant to cuts and it can absorb small particles of residue, oil and grease. The surface itself stays mainly free of contamination and so ensures a high-quality manufacturing process.
Osborn has a value-add-cooperation with company NCCM, River Falls (WI/USA) for manufacturing and service of high-tech Non-Woven Mill Rolls. Since 2009 NCCM has the exclusive rights to the original premier yellow non-woven material from 3M Company anywhere in the world. NCCM own a unique technology in the manfacturing of roll coverings using the original 3M high-tech material. The NCCM Premier Yellow Neutral Mill Rolls are top-quality and have a lifetime which is up to 100 times higher than common rubber rolls. Further advantages: Under pressure an adhesion effect occurs in the area where sheet and roll touch each other. When the pressure is decreased, a capillary or suction effect occurs, which reduces the amount of residual moisture that is present in squeezing applications.
All in all Osborn Non-Woven Rolls have a much higher life-time than PU- or rubber rolls. They achieve high-quality results, minimize downtime and therefore contribute to the economic efficiency of the total process. Due to the high-quality material and the special manufacturing process, Osborn non-woven rolls have in average a 30% longer service life than non-woven rolls from other manufacturers.
Free Finishing Analysis
When it comes to surface treatment and finishing, the best solutions depend on a lot of factors: the type of treatment/finishing work to be done…the equipment being used…the speed of that equipment…the surface profile of the work piece…and the kind of finish required.
So how do you know which solution is best for your job? That’s where Osborn’s technical expertise and experience with primary metals and automotive stamping blanks come in. Our engineering experts and application technicians will analyze your needs and offer the solutions that match your requirements.
We will provide recommendation on what type of products you should be using and what types of finishes you can expect. We’ll also work with you to develop custom finishing solutions. Don’t go it alone by trying to guess which products you need to achieve the results you’re looking for. To take advantage of a free finishing analysis, contact an Osborn technical field engineer.