There are three reasons for forging a roll:

1. To create high compactness
2. To refine grain size
3. To produce longitudinal fibers

The forge process starts with a casting. This is done with a sufficiently large diameter to ensure a high forging ratio.

However, this is not possible for large rolls so they are first pressed length-wise which increases their diameter. This is called upsetting.   

The forging process takes place between approximately 1,100 degrees and 700 degrees C. Larger rolls cannot be made in one step and require re-heating, sometimes several times. The forging process is used to form the roll barrel and the necks. We operate two presses – one 4,000 ton press with a 100 ton-meter manipulator, (both computer operated), and one of 2,000 tons which is mainly used for ESR ingots.