Carbon fiber rollers - Addax.com

carbon fiber rollers

The Addax Advantage SM
Markets and Applications Served
by Addax Carbon Fiber Rollers
Manufacturing, Slitting,
Coating and Laminating
of Foil, Film, Non-Wovens
and Paper
• Idlers
• Load Cells
• Lay-On Applications
• Nip Rollers
• Tensioning Rollers
• Draw Rollers
Offset Printing Industry
• Web Guides
• Idlers
• Inking Rollers
• Damping Rollers
2 800.827.9228
The premier choice for carbon
fiber roller applications
Addax was founded in 1985 by a collaboration of
defense and aerospace professionals who recognized the
revolutionary role advanced composite materials could play
in industrial applications. Advanced Composites were
originally developed for the aircraft and aerospace
industries where weight reduction and high strength were
paramount—at any cost.
Since our inception, the Addax mission has been to
apply the benefits of this advanced technology to commercial
industry, and to do so economically. The result has been a
string of commercial innovations. Addax has successfully
designed, manufactured and supplied a long list of products
using ingenious adaptations of proven composite technology.
Addax has extended the boundaries of mechanical properties
previously limited by metals and, ultimately, made the
impossible…Possible.
In the late 80s and early 90s, Addax recognized the
growing demand for faster printing and converting
machines. Addax responded with the introduction of some
of the first carbon fiber rollers. To date, Addax has become
one of the world’s largest suppliers of carbon fiber idler
rollers and the first to offer the significant benefits of
carbon fiber rollers at prices that are competitive with
conventional alloy alternatives.
Today, Addax looks confidently to the future. We pledge
to you, our customers and colleagues, that we will continue
to expand the boundaries of advanced composite technology
while providing products that yield significant benefits at
competitive prices.

why addax carbon fiber rollers?
Addax Carbon Fiber Rollers
Offer an Excellent ROI
Increased Web Quality
• Less Web Deflection
• Less Web to Roller Slip
• Less Web Breaks and
With Addax Carbon Fiber Rollers, you
Web Wrap-ups
get increased quality through less web
Increased Machine
deflection, slippage and breaking because
Addax Rollers have a lower rotational inertia Output
than metal rollers; increased production via
• Faster Web Speeds
• Wider Web Widths
faster line speeds, because Addax Rollers
have higher critical speeds than metal rollers;
wider web widths because Addax Rollers • Longer Bearing Life
can span longer distances than metal rollers • Eliminate Drive
while providing equal or increased stiffness;
Mechanisms
and reduced operating and maintenance
• Excellent Roller
Corrosion Resistance
costs because Addax Rollers provide
significantly better corrosion resistance,
longer bearing life, and can even eliminate drive mechanisms, because their
lower rotational inertia often allows the web to drive the roller instead of
motors, gear drives or belts.
As the trendsetter of the carbon fiber roller market, Addax has set
a new bar for the industry. We are leading the industry towards the
obsolescence of metal rollers. All Addax Rollers are manufactured using the
filament winding process. Filament winding provides the best manufacturing
method for producing high-strength, fatigue-resistant, high-performance
composite components at affordable prices. While carbon fiber composite
products are generally more expensive than those made from metal, Addax
has been able to refine the process to significantly reduce the cost
differential. Bottom line, Addax carbon fiber rollers are affordable for
most applications.
Addax is committed to providing quality Carbon Fiber Rollers for a variety
of applications in the converting, printing, and other web-based manufacturing
processes. We have designed a standard product line with specific
roller design options depending upon application requirements such as: roller
deflection, rotational inertia, operating speed, rubber and plasma coverings,
air release, web surface friction, and roller expansion/contraction caused by
temperature fluctuations. Applying Addax Carbon Fiber Rollers within your
operation will provide you and your customers with Increased Product
Quality, Increased Machine Output and a Reduction in Overall
Operating Costs. Ultimately, Addax Carbon Fiber Rollers present one of
the best methods to increase ROI that is currently available to the industry.
Reduced Operating Costs
Carbon Fiber to Metal
Comparisons
Density
• 20% weight of steel
• 60% weight of aluminum
Stiffness (Modulus)
• Stiffness equal to
4 times aluminum
• 20% increase in stiffness over steel
CTE (Coefficient of Thermal
Expansion)
• Dimensionally stable over a wide
range of temperature changes
www.Addax.com 3

How Carbon Fiber Rollers?
Addax Rollers are available
in three unique end fitting
configurations
Journaled/Live Shaft
• Bolt-In 12L14 CF Steel Journals
(Integral Journal for Roller
Diameters ≤ 4.00")
• 6061-T6 Aluminum Header
• Grade 8 Fasteners
Dead Shaft/Through Shaft
• 12L14 CF Steel Bearing
Housings
• 1018 CF Steel, Turned, Ground
and Polished Through Shafts
• ER (Free Running) Style Bearings
Dead Shaft/Double Bearing
Stub Roller
• 6061-T6 Aluminum Header
• High tensile strength, ground
and polished Stub Shaft
• 12L14 CF Steel Bolt-In
Bearing Carrier
• Dual Single Row, Deep Groove,
Shielded Ball Bearings
• Grade 8 Fasteners
4 800.827.9228
Our selection software allows you to input specific
application details and choose the appropriate
Addax Carbon Fiber Roller. Visit www.Addax.com
In the past, the selection and proper application of carbon fiber
rollers was somewhat of an art form. Fundamentally, the attention of
the industry was focused towards the lightweight properties of carbon
fiber composites and how a low weight and low rotational inertia roller
would benefit specific machine operation. Although low weight and low
rotational inertia is obviously important, there are many other
factors that must be considered when investigating the
application of carbon fiber rollers. As an example, other
factors to consider are: roller deflection, surface
finish/treatments, machine tolerances and roller
critical speed.
Addax has simplified the entire process by first,
designing a standard product offering utilizing
a) various types of carbon fiber materials,
b) standard tube outside diameters, c) standard
tube wall thickness; and finally, d) various surface finishes. The next
step was the development of standardized pricing depending upon
roller style, roller diameter, face length, surface finish and overall roller
strength/stiffness. From there, Addax designed and developed the first
and only computer-aided carbon fiber roller selection software
available to the industry. The selection software allows the user to input
specific application details and choose the appropriate Addax Carbon
Fiber Roller depending upon their application requirements, such as
web deflection, roller rotational inertia, roller critical frequency, roller
diameter, total roller weight and finally, roller cost. At last, the
development of these tools allows Addax’s customers to take full
advantage of the features of carbon fiber rollers, by using the
selection software found on our website: www.Addax.com.
In many applications an Addax Carbon Fiber Roller of a smaller
outside diameter can meet or exceed the same performance properties
of a conventional metal roller, with one exception…the Addax Roller will
be lower in weight and rotational inertia. Inherently, Addax’s carbon
fiber composite material is 1/5 the weight of steel and approximately
1/2 the weight of aluminum; therefore, a decrease in roller diameter
simply increases the weight and rotational inertia differential between
the Addax Roller and a metal roller. Ultimately an Addax customer no
longer needs to design around the limitations of metals.

Addax Standards and Conventions
Web Deflection and Roller Stiffness
To ensure that web wrinkling and web troughing is kept to a
minimum, each Addax Roller is selected specifically to an exacting roller
deflection requirement dictated by the application. Web Wrap, Web
Tension and Web Direction, or Nip Pressure and Nip Direction apply a
force or load to the roller. This load directly affects the amount a given
roller will flex or bend. Excessive bending or flexing by a roller is
a direct cause of web wrinkles or gaps between nipped rollers. As a
standard minimum requirement, Addax has adopted a Class B
roller/web deflection classification as discussed by Dr. David Roisum
in his book The Mechanics of Rollers, published and copyrighted by
Tappi Press, 1996.
Addax Carbon Fiber Tube Options
Addax’s standard roller product line is available in outside roller
diameters of: 3.00", 4.00", 4.50", 5.00", 5.50", 6.00", 8.00" and
10.00". Depending upon the amount of applied load and the deflection
requirements of the application, each roller diameter is available in a
choice of three unique Carbon Fiber Tube options;
1 x Standard Modulus — Light Load Applications
1 x Ultra High Modulus — Medium Load Applications
2 x Ultra High Modulus — Heavy Load Applications
Furthermore, each carbon fiber tube is available with a Standard
Operating Temperature Rating of 180° F (220° intermittent) or in an
Optional Operating Temperature Rating of 300° F (350° intermittent).
Coefficient of Thermal Expansion (CTE)
of Addax Carbon Fiber Rollers
Addax Carbon Fiber Rollers remain dimensionally stable over a wide
range of temperatures. As an example, the use of Addax Carbon Fiber
Rollers will reduce axial bearing loads in applications with fluctuating
operating temperatures.
Addax Roller Coatings and Coverings
Unless otherwise specified by application requirements, customers
may choose between three types of Abrasion-Resistant Coatings.
Essentially, carbon fiber composite material is a plastic material,
therefore each Addax roller will be provided with a coating or covering
to increase the abrasion resistance of the roller surface and to protect
the integrity of the carbon fiber structure. Furthermore, coating or
covering the surface offers an additional benefit by way of sealing the
roller surface to encapsulate any minute carbon fibers. In effect, this
encapsulation ensures that no small fibers are offset to the web or to
other components within the machine.
Class B: (Addax Standard)
< 0.0015" web deflection for
each inch of web width
• Most idler/guide rollers, commonly
used in the converting industry
For those applications that require
more stringent web deflection requirements,
Addax suggests that our customers follow
Dr. Roisum’s Class A deflection;
Class A:
< 0.00008" web deflection for
each inch of web width
• Precision applications,commonly
used in printing applications
Standard Modulus Carbon Fiber Roller
• Longitudinal Direction:
2.1 x 10 -7 in/in/deg.F
• Diametrical Direction:
3.7 x 10 -6 in/in/deg.F
Ultra High Modulus Carbon Fiber Roller
• Longitudinal Direction:
- 4.5 x 10 -7 in/in/deg.F
• Diametrical Direction:
3.8 x 10 -6 in/in/deg.F
www.Addax.com 5

The Addax Advantage SM :
Standard Addax HAR (High
Abrasion Resistant) Coatings
• Smooth HAR:
Surface Finish of 64 to 90 µin Ra
• Fine Grit HAR:
Surface Finish equal to 100 grit
sandpaper, 50% open space
between particles
• Coarse Grit HAR:
Surface Finish equal to 60 grit
sandpaper, 50% open space
between particles
• Abrasion Resistance:
16.1mg average loss, Taber
abrasion test CS-17 wheel,
1,000g weight, 1,000 cycles
Optional Coatings and Coverings
(including but not limited to)
• Plasma /Thermal Sprayed
Coatings
• Aluminum oxide
• Chrome oxide
• Tungsten Carbide
• Ceramics
• Elastomer Coverings
• EPDM
• Hypalon
• Neoprene
• Polyurethane
Addax Roller
Standard Packaging
• Wood crating provided as standard
for all Addax Rollers in quantities
of six or more and over 4.00"
in diameter
• Wood crating provided as standard
for all Addax Rollers with
elastomeric coverings.
• Reinforced plastic tubing provided
for all other shipments
6 800.827.9228
With this in mind, Addax developed a specialized High Abrasion
Resistant (HAR) coating system that is provided as a standard on each of
our rollers. Customers may choose between three types of surface finish
depending upon the application. Optional coatings and coverings are
available as an option if specific properties are required for the application.
Addax Roller Conductivity
Unless otherwise specified by the application, every Addax Carbon
Fiber Roller is electrically conductive as defined by the Electronics Industry
Association. This ensures safe operation in cases where static dissipation
is paramount.
• Addax Roller Surface Resistivity < 25,000 ohm/square
Addax Roller Assembly Tolerances
• Roller Body Machine Tolerances
■ Surface Profile: 0.002" — defined per ASME Y14.5M-1994
■ Circular Runout (bearing seat to roller OD):
0.005" — defined per ASME Y14.5M-1994
• Bearing Fit Tolerances:
■ Bearing Housing Bore Tolerance: M7 — ANSI standard for fits
recommended by Anti-Friction Bearing Manufacturers Assoc,
(AFBMA)
■ Journal/Bearing Seat Tolerance:
• Ø 0.500" to Ø 1.9375": + 0.0000/- 0.0005"
• Ø 2.000" to Ø 3.500": + 0.0000/- 0.0010"
• Bearing Surface Finish: 63 µin Ra—Per Roller Bearing Institute
Recommendation
Addax Roller Machine Options
• Crowned Rollers (negative and positive crowns)
• Grooved Rollers (adds 0.070" to nominal diameter of roller)
■ Spiral Air Release Groove
• Standard Addax Groove Profile Dimensions:
1/16" wide x 1/32" deep
■ Chevron Groove
• Standard Addax Grove Profile Dimensions:
3/8" wide x 1/32" deep
• Perforated
Addax Balance Specification
• Addax Standard Balance Specification
■ Two plane (dynamic) balance in accordance with ISO 1940 G6.3
• Optional Balancing
■ ISO 1940 G2.5
■ ISO 1940 G1.0

fundamentals of filament winding
The Process
High-speed precise positioning of continuous
reinforcement fiber in pre-determined patterns is the basis
of the filament winding method for manufacturing Addax
carbon fiber rollers. It is a process in which continuous
resin-impregnated rovings or tows (gathered strands of
carbon fiber) are wound over a rotating cylindrical mandrel.
The reinforcement fiber may be wrapped either in adjacent
bands or in repeating bands that eventually cover the entire
mandrel surface. This technique has the ability to vary the
winding tension, wind angle, or resin content in each layer
of reinforcement until the desired thickness and resin
content of the composite are obtained with the required
direction and strength.
The filament winding process enables the designer
to custom engineer components by placing the exact
mechanical characteristics where needed which allows
the roller design to be optimized for weight, stress concentrations
and fatigue. Torsional stiffness, axial stiffness,
Young’s modulus, tensile strength, proportional elastic limit,
hardness, abrasion and wear resistance, bearing stress
and other properties which may be customized by filament
winding the fiber/resin matrix.
Thermoset resins are used as the binders for the
reinforcements and are applied to the dry roving at the time
of winding. This process is referred to as “wet winding.”
The filament wound carbon fiber is then cured at elevated
temperatures, without any additional step for compaction.
Mandrel removal, cut-to-length, and other finishing
operations complete the roller assembly process.
Addax’s largest CNC (Computer Numerically Controlled)
multi-axis winding machine will produce parts 60 inches in
diameter and 46 feet in length. Our CNC filament winding
machines are extremely versatile and accurate. They are
supported by both wind control and pattern generation
software so that any pattern may be programmed,
optimized and set up in the winder in a matter of minutes.
Advantages of Filament Winding
• Accurate repeatability of placement from layer to
layer and from part to part
• Capacity to use continuous fibers over a
whole component area (no joints or
splices) and to orient fibers easily
in the load direction
• Large structures can be produced
• High fiber volume in finished parts
is obtainable
• Lowest manufacturing costs for
large quantities
• Low material costs because the fibers and resins can
be used in their lowest cost form
The limitations of filament winding have been overcome
by continued advancements in computer-controlled winders,
wind software and manufacturing techniques. Overall,
filament winding is the best manufacturing method for
producing high-strength, fatigue-resistant, high-performance
carbon fiber rollers at affordable prices.
www.Addax.com 7

Addax Carbon Fiber Rollers
Features & Benefits
• Low Weight
■ Reduce Bearing Loads
■ Less Vibration
■ Ease of Handling
■ Reduced Bearing Size/Cost
• Corrosion Resistant
■ Suitable for Harsh Environments
■ No Rust Build-Up
• Better Covering/Coating Adhesion
• Low Rotational Inertia
■ Allows for Lower Web Wrap Angles
■ Faster Speed Changes
• Less Web Damage
• Eliminate/Reduce Web Wrap-ups
• Safer and Faster E-Stops
■ Reduce/Eliminate Drive Mechanism
■ Reduce/Eliminate Web
Stretching/Scratching
• Idler Rollers Spin at or Closer to
Web Speed ‚ No “Stalled” Rollers
Addax
6040 Fletcher Ave.
Lincoln, NE 68507
Phone: 402.325.6000 Toll Free: 800.827.9228
Fax: 402.325.6406
Visit us on-line at www.Addax.com
Bulletin No. 4608
• High Specific Stiffness
■ Longer Roller Length
• Wider Web Widths
■ Less Roller Deflection
• Less Web Deformation
■ Reduced Whip Run Out
• Reduces Web Flutter
■ Decreased Roller Diameter
• Reduces Rotational Inertia
• Higher Critical Speed
■ Faster Line Speeds
• More Production
• Thermal Stability
■ Dimensional Stability over a Wide Range
of Temperatures
©2003 Addax, Inc. 4/01 Printed in USA