Bearing arrangement for rolls

in a 155 t calender for PVC floor coverings

Examples from Application Engineering

WL 03 503 GB-D

Manufacturer: Rodolfo Comerio Operator: Taraflex

In 1986, French company Taraflex commissioned a calender, The bearing concept is based on a solution which has
manufactured by Rodolfo Comerio, S.N.C., Solbiate Olona/Italy, been proven in other calender applications.
for PVC floor coverings. The rolling forces, distortions of roll body, roll neck and
The rolling bearings used in this bearing arrangement concept bearings, as well as the bearing temperatures reached
were supplied by FAG and have since been operating smoothly during processing of various types of plastics,
around the clock. The thermoplastic material passes through have also been taken into account.
the gaps between rolls 1 and 2, rolls 2 and 3 and rolls 3 and 4,
during which process its thickness is gradually reduced. In this bearing concept, the bearings meet all
Hot water flowing through the rolls heats their outside surfaces requirements, such as:
up to +220 °C, thereby achieving good processibility of the plastic • reliable accommodation of forces
mass. • good axial and radial guidance
The main bearings in rolls 1, 2 and 4 support the radial rolling • accommodation of the counterbending forces
forces. The main bearings in roll 3 are only subjected to the • extremely high running accuracy
difference between the rolling forces of rolls 2 and 4. • high temperature suitability and dimensional stability.
Rolls 1, 2 and 4 undergo flexing under the high forces in the
rolling gap. In order to keep the thickness tolerance of the rolled Type: Four-roll calender, F form
material in the micrometer range, flexing is compensated by Useful width: 3 600 mm
tilting the axes of rolls 1 and 3 and counterbending of rolls Roll diameter: 820 mm
2 and 4. Roll gap: 1st step 1,5 mm to 2 mm
The narrow thickness tolerance calls for an extremely high level 2nd step 1 mm to 1,5 mm
of bearing running accuracy and sufficiently clearance-free, 3rd step 0,25 mm to 1 mm
radial guidance of intermediate roll 3, which is only exposed to Roll speed: 6 rpm to 24 rpm
the low differential load. Roll mass: 18 000 kg
 Bearing system
The bearing system comprises:
• the main bearing arrangement for supporting radial and axial
forces, which is identical for all rolls
• the “roll bending bearing arrangement” in rolls 2 and 4 for
accommodating the counterbending forces
• the preload bearing arrangements for clearance-free guidance
of intermediate roll 3.

Main bearing arrangement

The bearing support load of rolls 1, 2 and 4 resulting from the
maximum gap load of 5 kN/cm and the roll mass is supported at
both ends by two double row cylindrical roller bearings.
A radially relieved deep groove ball bearing in the locating bearing
arrangement at the drive end guides the roll axially.
Angular misalignment due to shaft flexing (and possible roll
inclination) is compensated by a spherical cap between machine
frame and bearing housing.
As a result of the operating temperature, which under roll surface
temperatures of, for example, +220 °C can reach up to +160 °C
at the inner ring, all rolling bearings have to be appropriately heat
treated and dimensionally stable up to +200 °C.
The required high runout accuracy of the rolls of ≤ 5 μm is
achieved not only by high bearing precision
(P5 running accuracy) but also by finish-grinding the bearing inner
rings and roll bodies in one clamping operation at the anticipated
roll operating temperature of, for example, +220 °C.
The calculated finish-grinding dimension of the inner ring raceway
is defined such that the resulting radial internal clearance permits Roll arrangement in calender from Rodolfo Comerio, type F
a temperature gradient of +80 °C between outer and inner ring
without the risk of generating a radial preload during the heating
stage.
Lubrication
The lubricant is subjected to severe stress. Due to the
low speed, no elastohydrodynamic lubricant film can
Roll bending bearing arrangement form. The high operating temperature, which reduces
viscosity and accelerates the ageing of the oil,
Hydraulic cylinders at both ends of the roll apply a maximum
constitutes a further problem.
roll bending force of 345 kN to the roll necks, thus generating
The bearings constantly operate in the mixed friction
counterbending of the rolls. The force is transmitted from the
range and are exposed to increased wear.
hydraulic cylinders to the roll necks via the housing and spherical
Polyglycol oils, which exhibit high thermal stability and
roller bearings.
resistance to ageing, offer protection against wear and
have been used successfully under these conditions.
A central recirculating lubrication system with recooling
Preload bearings supplies all roll bearing arrangements with sufficient
The main bearings in roll 3 are subjected to the weight and the quantities of oil. For the cylindrical roller bearings,
difference between the rolling forces from gaps 2 and 3. the oil is fed through grooves in the housing and radial
The resulting force may act from above or below and may also be lubricating grooves in the end face of the outer ring,
relatively small. Uncontrolled radial roll movements under the as well as laterally for deep groove ball bearings and
so-called zero crossing and slippage conditions are prevented, centrally for the spherical roller bearings.
whereby the main bearings are generally subjected to a radial load
of 100 kN by the preload bearings. Schaeffler KG
Heavy Industries
Pulp & Paper
Georg-Schäfer-Strasse 30
Bearing system in a 155 t calender 97421 Schweinfurt (Germany)
(bearings per roll) Phone: +49 9721 91-0
A Main bearing arrangement, radial, at both ends of all rolls: Fax: +49 9721 91-3435
2 cylindrical roller bearing pairs comprising E-mail: pulp_paper@schaeffler.com
FAG Z-522028.RZL-N12BC-M15FC www.fag.com www.ina.com
with inner rings FAG Z-522028.LZL-J22NA
B Main bearing arrangement, axial, drive end of all rolls:
1 deep groove ball bearing FAG 61996-M-P6-C5
C Preload bearing arrangement, both ends of roll 3:
2 spherical roller bearings FAG 23888-K-MB-C5
D Roll bending bearing arrangement;
both ends of rolls 2 and 4:
2 spherical roller bearings FAG 23980-B-K-MB-C5
200909.5 / Printed in Germany

D C B A