1、Designation: A649/A649M 10Standard Specification forForged Steel Rolls Used for Corrugating Paper Machinery1This standard is issued under the fixed designation A649/A649M; the number immediately following the designation indicates the yearof original adoption or, in the case of revision, the year of
2、 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 arefabricat
3、ed 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.Pressu
4、re rolls may be ordered surface hardened as ConditionH, or without surface hardening as Condition S. Provision ismade in Supplementary Requirements S1and S3 for the op-tional surface hardening of corrugating rolls.1.2 Corrugating and pressure rolls made to this specificationshall not exceed 30 in. 7
5、60 mm 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
6、fit. The 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 minimumdesig
7、n temperature 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 trun
8、nions, 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
9、, 1B, 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
10、4.1.4 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-conformancewit
11、h the 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 A788/A788M apply.2. Referenced Documents2.1 ASTM Standards:
12、3A275/A275M Practice for Magnetic Particle Examinationof Steel ForgingsA370 Test Methods and Definitions for Mechanical Testingof Steel ProductsA788/A788M Specification for Steel Forgings, General Re-quirementsE165 Practice for Liquid Penetrant Examination for GeneralIndustry3. Ordering Information3
13、.1 Material supplied to this specification shall conform tothe requirements of Specification A788/A788M, which out-lines additional ordering information, manufacturing require-ments, testing and retesting methods and procedures, marking,certification, product analysis variations and additional suppl
14、e-mentary requirements.3.2 In addition to the ordering requirements of SpecificationA788/A788M, the purchaser shall include the maximum de-sign 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.
15、1This specification 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 April 1, 2010. Published May 2010. Originallyapproved in 1971. Last previous e
16、dition approved in 2009 as A649/A649M 09.DOI: 10.1520/A0649_A0649M-10.2For 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 s
17、erviceastm.org. For Annual Book of ASTMStandards 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,
18、United States.3.3 When ordering pressure 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 a corrugating roll is required to be surface
19、hardenedby the forging supplier, prior to forming the flutes by thepurchaser, the requirements of Supplementary requirement S1shall apply.3.5 If the requirements of this specification are in conflictwith the requirements of Specification A788/A788M, then therequirements of this specification shall p
20、revail.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 as a solid forging orwhere practical upset from segments cut from bille
21、ts 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 to heattreatment for mechanical properties and be tested in accor-dance
22、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 to produce the required mechanical properties,except that for Class 2 fo
23、rgings, 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.4.2.2 Surface Hardening of Pressure Roll ForgingsForCondition H the working
24、 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 Assembly and WeldExcept for integrally forged orbolted-on trunnions, the
25、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 of 400F 205C and a minimum post weld heattreatment of 850F 455C for 8 h
26、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 examination.5. Chemical Composition5.1 The steel shall conform to the requirement
27、s 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 Test Methods and Definitions A370. Tension testspecimens shall be the stan
28、dard 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, for mechanical properties in accor-dance with 4.2.1.6.1.2 Number, Locat
29、ion, 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 specimen shall be taken from the prolongation andTABLE 1 Chemical Requi
30、rementsComposition, %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
31、0.025 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
32、be 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.A649/A649M 102the 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.
34、1, the centrallong axis of the longitudinal test specimen shall be located atthe 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-treated outer diameter of the solidforging.6.1.2.3 TrunnionsTest material shall
35、 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 and surface of the solid forging.6.2 Hardness:6.2.1 Roll body forgings sh
36、all 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. After completion of heat treatment described in 4.2,the hardness readings are to be taken on the outside of the rollbodies using care to prep
37、are locations for tests that are free ofdecarburization but not so deep as to affect the usefulness ofthe 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 shall bemade on each
38、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 approval of the purchase
39、r.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 PracticeA275/A275M or by a liquid penetrantmethod in accordance with Practice E165 after machining orgrinding. The use of prods in
40、the magnetic particle method isnot 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 mmlong.8.3.2 Rounded indications
41、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 the maximum allowable working
42、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-tion A788/A788M, the MDT and the MAWP shall be includedtogether with
43、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. Keywords11.1 internal pressure; las
44、er hardened; machinerycorrugating; roll assemblyforged; rollscorrugating; rollspressure; steel forgingsalloy; steel forgingscarbon; steelrolls; surface-hardened; trunnionsbolted;trunnionsshrink-fittedSUPPLEMENTARY REQUIREMENTSThe following supplementary requirements shall apply only when specified b
45、y 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 shall not exceed38
46、 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 notch toughnessl
47、imits 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 DefinitionsA370 specimen TypeAor B).A649/A649M 103S2.1.2 Minimum value for absorbed ene
48、rgy 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.S3. Laser Hardened Flute TipsS3.1 After the flute profile of corrugating ro
49、lls has beenformed, the flute tips shall be laser hardened to a surfacehardness of 53 to 65 HRC. The dimensions of the hardenedprofile shall be as agreed between purchaser and supplier.S3.2 The hardened surfaces shall be examined by themagnetic particle method in accordance with Section 8.SUMMARY OF CHANGESCommittee A01 has identified the location of selected changes to this standard since the last issue(A649/A649M 09) that may impa
