Our Self-Developed Anti-Deformation Fixture for Large Forged Rings
In large-scale forging manufacturing, Heat Treatment can be considered a double-edged sword. While it significantly improves the mechanical performance of the material, it can also introduce a serious manufacturing risk — deformation.
This challenge becomes particularly critical for large-diameter thin-wall Bearing Rings. For example, a ring with an outer diameter of 3200 mm and a wall thickness of only 120 mm is extremely sensitive to distortion during heat treatment.
These components are expensive and have high material value. If deformation exceeds the machining allowance, the entire part may have to be scrapped.
To reduce this risk, manufacturers often increase machining allowances or perform secondary reshaping processes. However, these approaches significantly increase cost and extend production cycles.
To address this long-standing industry challenge, our engineering team developed and patented an Anti-Deformation Fixture designed to stabilize large bearing rings during heat treatment. The fixture maintains geometric stability during both heating and cooling, significantly reducing deformation and improving heat treatment yield.
Why Large Bearing Rings Are Prone to Heat Treatment Deformation
For bearing rings with diameters exceeding 2–3 meters, maintaining geometric stability during heat treatment becomes a major engineering challenge.
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- Large diameter combined with relatively thin wall thickness
- High heat treatment temperatures generating thermal stress
- Uneven cooling creating tensile stress within the material
- Non-uniform thermal expansion and contraction
As a result, even very small dimensional deviations can become significantly amplified in components with diameters of several meters.
Providing structural support during heat treatment to prevent collapse, ovalization, or wave deformation is therefore essential.
Our Solution: Temporary Internal Frame Anti-Deformation Fixture
To stabilize thin-wall bearing rings during high-temperature heat treatment, we developed a solution based on a temporary internal support frame.
Before heat treatment, an adjustable support structure is welded inside the ring. This internal frame allows the component to maintain its geometric shape throughout both heating and cooling stages.
Compared with traditional rigid support structures, our patented fixture provides several advantages:
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- Adjustable structure that accommodates thermal expansion and contraction
- Multi-point support instead of single-point suspension
- Reduced stress concentration that could affect the material structure
- Easy removal after heat treatment
Key Structural Features of the Fixture System
Main Support Unit
The main support unit forms the central structural channel, providing rigid support throughout the entire heat treatment process. Its modular design allows adaptation to rings of different diameters.
Adjustable Expansion Unit
The structure includes internal clearance that allows controlled movement during thermal expansion. This prevents excessive rigid constraints that may introduce secondary stress or reverse deformation.
Curved Multi-Point Support Plates
Curved support plates distribute load evenly along the inner surface of the ring. This design prevents localized pressure points and reduces the risk of wave-type deformation.
Together, these components form a lightweight three-dimensional support framework inside the ring, maintaining geometric stability throughout quenching, heating, and tempering processes.
Advantages Compared with Traditional Methods
1. Significant Reduction in Heat Treatment Deformation
In practical production, deformation levels are greatly reduced, especially for large-diameter rings commonly used in the Wind Power industry.
2. Adjustable Structure Prevents Locked-In Stress
Traditional rigid frames cannot adapt to thermal expansion at high temperatures. Our adjustable structure allows controlled expansion without restricting the material.
3. Strong Adaptability for Multiple Ring Sizes
The modular and detachable design allows the fixture to be used for rings with diameters ranging from Ø1500 mm to Ø3200 mm.
4. Easy Removal Without Affecting Machining
The fixture requires only limited welding points at controlled locations. After heat treatment, it can be removed easily, and only minor finishing is required before machining.
Typical Applications
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- Wind turbine bearing rings (Yaw Bearing / Pitch Bearing)
- Slewing rings for construction machinery
- Large Gearbox Components such as ring gears
- Thin-wall ring components used in heavy Industrial Equipment
This solution is particularly suitable for large rings requiring high-performance quenching and tempering with relatively thin wall sections.
Conclusion
Controlling heat treatment deformation remains one of the key technical challenges in large forging manufacturing.
With our self-developed Anti-Deformation Fixture, large bearing rings can maintain excellent geometric stability throughout the entire heat treatment process.
This significantly reduces scrap rates and improves manufacturing efficiency.
If you are looking for a reliable supplier of large forged rings or bearing rings with controlled heat treatment deformation, feel free to contact our engineering team.
