1、Designation: A 649/A 649M 09Standard Specification forForged Steel Rolls Used for Corrugating Paper Machinery1This standard is issued under the fixed designationA 649/A 649M; the number immediately following the designation indicates the yearof original adoption or, in the case of revision, the year
2、 of last revision. A number in parentheses indicates the year of last reapproval.A superscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope*1.1 This specification2covers two kinds of rolls used inmachinery for producing corrugated paperboard. Rolls arefabri
3、cated of forged bodies and trunnions. The trunnions maybe bolted or shrink assembled on one or both ends of the body.A seal weld may be made at the body/trunnion interface. Rollshells are made of carbon/manganese, or low alloy steel ashereinafter described, and are heat treated prior to assembly.Pre
4、ssure rolls may be ordered surface hardened as ConditionH, or without surface hardening as Condition S. Provision ismade in Supplementary Requirement S1 for the optionalsurface hardening of corrugating rolls.1.2 Corrugating and pressure rolls made to this specificationshall not exceed 30 in. 760 mm
5、in inside diameter. The wallthickness of the roll body shall not be less than112 of theinside diameter or 1 in. 25 mm, whichever is greater, but shallnot exceed 4 in. 100 mm. The wall thickness of thecorrugating roll is measured at the bottom of the corrugationsin the location of the trunnion fit. T
6、he maximum designtemperature (MDT) of the roll is 600F 315C and themaximum allowable working pressure (MAWP) is 250 psi 1.7MPa. The minimum design temperature shall be 40F 4Cfor roll wall thicknesses up to 3 in. 75 mm. For roll wallthicknesses over 3 in. 75 mm to 4 in. 100 mm, the minimumdesign temp
7、erature shall be 120F 50C. The maximumstresses on the roll bodies from the combined internal andexternal loading are limited to 18 750 psi 129 MPa for theClass 2 pressure roll bodies, and 20 000 psi 138 MPa forClass 1A, 1B, or 5 pressure or corrugating roll bodies in Grades1 or 2. For the trunnions,
8、 the maximum stresses from thecombined internal and external loading are limited to 15 000psi 103.4 MPa for Classes 3 or 4, or 20 000 psi 138 MPafor Classes 1A, 1B, or 5 in Grade 2 only. The Grade 1 strengthlevel is not permissible for trunnions.1.3 Referring to Table 1, material to Classes 1A, 1B,
9、or 5shall be used for the manufacture of corrugating or pressureroll shells, and Class 2 shall be used only for pressure rollshells. Trunnions shall be made from forgings in Classes 1A,1B, or 5 in Grade 2 strength level as restricted by Footnote Bin Table 2 or in forgings in either Class 3 or 4.1.4
10、The values stated in either SI units or inch-pound unitsare to be regarded separately as standard. The values stated ineach system may not be exact equivalents; therefore, eachsystem shall be used independently of the other. Combiningvalues from the two systems may result in non-conformancewith the
11、standard.1.5 Unless the order specifies the applicable “M” specifica-tion designation, the material shall be furnished to the inch-pound units.1.6 Except as specifically required in this standard, all of theprovisions of Specification A 788/A 788M apply.2. Referenced Documents2.1 ASTM Standards:3A 2
12、75/A 275M Practice for Magnetic Particle Examinationof Steel ForgingsA 370 Test Methods and Definitions for Mechanical Testingof Steel ProductsA 788/A 788M Specification for Steel Forgings, GeneralRequirementsE 165 Test Method for Liquid Penetrant Examination3. Ordering Information3.1 Material suppl
13、ied to this specification shall conform tothe requirements of Specification A 788/A 788M, which out-lines additional ordering information, manufacturing require-ments, testing and retesting methods and procedures, marking,certification, product analysis variations and additional supple-mentary requi
14、rements.3.2 In addition to the ordering requirements of SpecificationA 788/A 788M, the purchaser shall include the maximumdesign temperature (MDT), if lower than 600 F 315 C, andthe maximum allowable working pressure (MAWP), if lowerthan 250 psi 1.7 MPa as allowed in 1.2 of the Scope.1This specifica
15、tion is under the jurisdiction of ASTM Committee A01 on Steel,Stainless Steel and Related Alloys and is the direct responsibility of SubcommitteeA01.06 on Steel Forgings and Billets.Current edition approved Feb. 15, 2009. Published March 2009. Originallyapproved in 1971. Last previous edition approv
16、ed in 2008 as A 649/A 649M 08.2For ASME Boiler and Pressure Vessel Code applications see related Specifi-cation SA-649/SA-649M in Section II of that Code.3For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMS
17、tandards volume information, refer to the standards Document Summary page onthe ASTM website.1*A Summary of Changes section appears at the end of this standard.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.3.3 When ordering pressure
18、 rolls the purchaser shall stipu-late the required condition, either surface hardened (ConditionH) or as heat treated (Condition S). In the event that thecondition is not specified the default condition is H.3.4 If the requirements of this specification are in conflictwith the requirements of Specif
19、icationA 788/A 788M, then therequirements of this specification shall prevail.4. Materials and Manufacture4.1 Forging Process:4.1.1 Roll body forgings may be made as solid forgings andsubsequently bored.4.1.2 Trunnions or gudgeons which are to be subsequentlyassembled to form the roll shall be made
20、as a solid forging orwhere practical upset from segments cut from billets or bars.4.2 Heat Treatment:4.2.1 Heat Treatment for Mechanical Properties (Require-ments do not apply to surface treatment):4.2.1.1 MachiningThe forged roll body shall have allsurfaces rough machined, including boring, prior t
21、o heattreatment for mechanical properties and be tested in accor-dance with 6.1.2.1. The manufacturer may opt to bore afterheat treatment for mechanical properties instead provided theforging is tested in accordance with 6.1.2.2.4.2.1.2 Roll bodies shall be normalized, liquid quenched,and tempered t
22、o produce the required mechanical properties,except that for Class 2 forgings, and when Grade 2 strengthrequirements are specified, a normalize and temper heattreatment may be applied.4.2.1.3 The trunnions shall be normalized and tempered orannealed to produce the required mechanical properties.4.2.
23、2 Surface Hardening of Pressure Roll ForgingsForCondition H the working face of pressure rolls shall be surfacehardened either before or after fitting the trunnions, at themanufacturers option. Surface hardening by weld overlays isnot permitted for Condition H or (subsequently) for ConditionS.4.3 As
24、sembly and WeldExcept for integrally forged orbolted-on trunnions, the assembly shall be made by shrinkfitting trunnions into the prepared body ends. If used, weldingof the trunnion to the roll body is restricted to a38 in. 9.5 mmmax. seal weld, made with low hydrogen materials. A mini-mum preheat o
25、f 400F 205C and a minimum post weld heattreatment of 850F 455C for 8 h shall be used. Themaximum post weld heat treatment shall be not higher than t 50F t 28C where t is the final tempering temperature.Allwelds shall be machined or ground for the final magneticparticle or liquid penetrant examinatio
26、n.5. Chemical Composition5.1 The steel shall conform to the requirements for chemicalcomposition prescribed in Table 1.6. Mechanical Properties6.1 Tensile Requirements:6.1.1 The material shall conform to the requirements fortensile properties prescribed in Table 2 when tested in accor-dance with Tes
27、t Methods and Definitions A 370. Tension testspecimens shall be the standard round12-in. 12.5 mmdiameter, 2-in. 50 mm gage length. The yield strengthprescribed in Table 2 shall be determined by the 0.2 % offsetmethod.6.1.1.1 Tests for acceptance shall be made after the heattreatment of the forgings,
28、 for mechanical properties in accor-dance with 4.2.1.6.1.2 Number, Location, and Orientation of Test Specimens:6.1.2.1 Roll Body ForgingsA full-size prolongation shallbe provided on a roll body forging representing each heat ofsteel in each heat-treatment furnace charge. One longitudinaltension test
29、 specimen shall be taken from the prolongation andthe axis of the specimen shall be located midway between theinner and outer surfaces of the wall body.6.1.2.2 If bored after heat treatment per 4.2.1.1, the centrallong axis of the longitudinal test specimen shall be located atTABLE 1 Chemical Requir
30、ementsComposition, %Class 1A Class 1B Class 2 Class 3 Class 4 Class 5Carbon 0.450.60 0.400.60 0.55 max 0.35 max 0.35 max 0.500.60Manganese 0.551.05 0.600.95 0.500.90 0.400.70 0.601.05 0.901.50Phosphorus 0.025 max 0.025 max 0.025 max 0.025 max 0.025 max 0.025 maxSulfur 0.025 max 0.025 max 0.025 max 0
31、.025 max 0.025 max 0.025 maxSiliconA0.150.35 0.150.35 0.150.35 max 0.150.35 0.150.35 max 0.150.35Nickel . 1.552.00 . . . 0.60 maxChromium 0.801.15 0.650.95 . 0.801.15 . 0.30 maxMolybdenum 0.150.50 0.200.45 . 0.150.25 . 0.15 maxAWhen vacuum carbon deoxidation (VCD) is used the silicon content shall b
32、e 0.10 % maximum.TABLE 2 Tensile RequirementsClass GradeYield Strength, minATensile Strength, minElongation in 2 in.or 50 mm, %, minReduction ofArea, %, minksi MPa ksi MPa1A, 1B or 5 1 130 890 150 1030 12.0 301A, 1B or 5 2B65 450 100 690 14.0 302 . 37.5 260 75 515 20.0 50.03 or 4 . 30 205 60 415 22.
33、0 55A0.2 % offset.BFor trunnion application, a maximum tensile strength of 125 ksi 860 MPa applies for Grade 2 of Classes 1A, 1B, or 5.A 649/A 649M 092the inside diameter of the bore dimension, with the specimenmid-length located at a minimum of T from the end face, whereT is the original heat-treat
34、ed outer diameter of the solidforging.6.1.2.3 TrunnionsTest material shall be provided fromeach heat of steel in each heat-treatment furnace charge. Onelongitudinal tension specimen shall be taken from each testpiece and the axis of the specimen shall be located at any pointmidway between the center
35、 and surface of the solid forging.6.2 Hardness:6.2.1 Roll body forgings shall have a Brinell hardness from352 HB to 415 HB (Grade 1) or 207 HB to 285 HB (Grade 2).No less than three hardness determinations shall be made oneach roll. The hardness readings are to be taken on the outsideof the roll bod
36、ies using care to prepare locations for tests thatare free of decarburization but not so deep as to affect theusefulness of the material.6.2.2 The surface hardened pressure roll body forgings inCondition H shall have a hardness of 58 to 65 HRC orequivalent. No less than three hardness determinations
37、 shall bemade on each roll. The hardness depth shall not exceed14 in.6 mm.7. Retreatment7.1 If the results of the mechanical tests of any forging donot conform to the specified requirements, the manufacturermay retreat the forging one or more times, but not more thanthree additional times without ap
38、proval of the purchaser.8. Magnetic Particle Examination8.1 The entire surface of the roll, including the seal weldarea, shall be examined by either a wet continuous method inaccordance with Practice A 275/A 275M or by a liquid pen-etrant method in accordance with Test Method E 165 aftermachining or
39、 grinding. The use of prods in the magneticparticle method is not permitted.8.2 Only indications with major dimensions greater than18in. 3.2 mm are considered relevant.8.3 Acceptance StandardsThe following relevant indica-tions are unacceptable:8.3.1 Any linear indications greater than316 in. 4.8 mm
40、long.8.3.2 Rounded indications greater than316 in. 4.8 mm.8.3.3 Four or more indications in a line separated by116 in.1.6 mm or less edge to edge.8.3.4 Ten or more indications in any 6 in.238.71 cm2ofsurface.9. Hydrostatic Testing9.1 The machined roll assembly shall be hydrostatic testedat 112 times
41、 the maximum allowable working pressure(MAWP). The MAWP pressure shall be furnished by thepurchaser.9.2 The recommended minimum hydrostatic test tempera-ture is 70F 21C.10. Marking, Packaging, and Loading10.1 In addition to the marking requirements of Specifica-tionA 788/A 788M, the MDTand the MAWPs
42、hall be includedtogether with any required application code marking.10.2 Packaging and loading shall be done so that the forgingis not damaged during shipment to the purchaser.10.3 For pressure roll forgings the marking and certificationshall include the applicable condition letter, H or S.11. Keywo
43、rds11.1 internal pressure; machinerycorrugating; rollassemblyforged; rollscorrugating; rollspressure; steelforgingsalloy; steel forgingscarbon; steel rolls; surface-hardened; trunnionsbolted; trunnionsshrink-fittedSUPPLEMENTARY REQUIREMENTSThe following supplementary requirements shall apply only wh
44、en specified by the purchaser on theorder and agreed to by the manufacturer:S1. Surface-Hardened Corrugating RollsS1.1 After all surfaces have been machined, the outersurface of the corrugating rolls may be surface-hardened to asurface hardness of Rockwell 53 HRC to 65 HRC. The depthof hardness shal
45、l not exceed38 in. 9.5 mm. A minimum ofthree hardness determinations shall be made on the surface.Additional hardness tests shall be made to establish the depthof hardness. The hardened surface shall be magnetic particletested (see Section 8).S2. Notch ToughnessS2.1 For applications where minimum no
46、tch toughnesslimits are required, impact testing shall be specified for bothroll bodies and trunnions. The following requirements shall bespecified:S2.1.1 Type of impact specimen and test standard (forexample, Test Methods and Definitions A 370 specimen TypeA or B).S2.1.2 Minimum value for absorbed
47、energy or lateral ex-pansion.S2.1.3 Test temperature.S2.1.4 Frequency of testing.S2.2 Trunnion and pressure rolls may be liquid quenchedand tempered instead of the heat treatments specified in 4.2when impact testing is required.A 649/A 649M 093SUMMARY OF CHANGESCommittee A01 has identified the locat
48、ion of selected changes to this standard since the last issue(A 649/A 649M 08) that may impact the use of this standard. (Approved Feb. 15, 2009.)(1) Revised pressure roll references in 1.1, 4.2.2, and 6.2.2.(2) Added 3.3 and 10.3.Committee A01 has identified the location of selected changes to this
49、 standard since the last issue(A 649/A 649M 04) that may impact the use of this standard. (Approved Oct. 1, 2008.)(1) Revised 4.2.1.1 and added 6.1.2.2.ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentionedin this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the riskof infringement o
