Richmond has a large capacity to design, create and mass produce high performance rollers and wheel components. The engineering machine shop at Richmond offers state of the art CNC based equipment that is used to create Moulding Dies, individual components and specialised parts for many different industries. Richmond manufactures rollers in many ways and has utilized many ingenious methods to create sensational results for our clients.
The first step is to create a die using our precision milling machines, then the products are loaded into CNC turning centres to finish the roller shaping and balancing. The finished product can be seen below with the roller mounted in it's frame set with precision bearing housings allowing for ultimate roller performance at the rated tonnage.
Richmond can perform die making services for products of any size and for any purpose. Recently a client commissioned Richmond to design and manufacture very large rollers for the required purpose. With only a limited number of rollers required, keeping the tooling costs for such a job to a minimum was the major concern.
The rollers the client needed were over 1400mm in width with a rolling diameter of over 1 metre, leaving little chance of the dies being re-used at a later date for any other purpose. The overall weight of each roller would also be in excess of 150kg.
The object was to design a solution that allowed the engineers of Richmond to create a cost effective moulding die to complete the initial phase of the roller manufacturing process. A design was generated for the roller using Solid Works design software and the clients specifications. Once the axle and rolling steel components were machined to the exacting tolerances required, a new concept "wooden die" was chosen as the best and most cost effective option for the initial moulding of the rollers.
The timber blocks were milled in a stack to create a bi-sectional die that was strapped tightly together prior to axle insertion and pouring of the polyurethane roller. The roller was then placed in our high temperature oven and cooked for more than 40 hours prior to being unwrapped from the mould and allowed to cool. The roller was then sent back to our CNC machine shop for final turning, precision sizing and balancing. The completed product is then wrapped and loaded for delivery to our client.
The final product is an exceptional piece of engineering, with the final roller precision milled to exacting tolerances and prepared for shipping to our client for installation. Our engineers are extremely proud of the inventive, unique and ingenious concepts they are able to deliver to our clients.