Carbide composite rolls are widely used in various rolling processes due to their excellent wear resistance and high strength. However, to ensure their optimal performance and service life, a series of operating requirements and precautions must be strictly followed.
Correct selection of carbide grades
Choosing the right carbide grade is the key to ensuring the performance of the roll. According to the rolling requirements of different materials and the characteristics of each rack, choosing the right carbide grade can achieve the best match of each rack grade. This can not only improve rolling efficiency, but also extend the service life of the roll.
Assembly and hoisting requirements
Carbide composite rolls are brittle materials and must be installed with caution. During the assembly process, it is strictly forbidden to use a hammer or other heavy objects to hit the roll to avoid cracks or damage. Avoid collisions between rolls during hoisting, especially collisions between carbide rolls will aggravate damage and affect their performance.
Cooling water management
Cooling water is crucial to the use effect and life of carbide composite rolls. Ensure that the pressure of the cooling water is between 3-5 bar and the direction of the water spray should be radial, at an angle of 15-30 degrees to the placement direction of the roll. The water flow cannot be scattered or misted, and it must be ensured that the cooling water is directly injected into the rolling groove. Therefore, a small nozzle should be welded on the main water inlet elbow to allow the cooling water to be concentrated and sprayed to avoid waste.
In addition, the cooling water must be precipitated and purified to ensure that the content of suspended particles in the water is less than 30 mg/L. The flow rate of cooling water is required to be greater than or equal to 24 cubic meters/hour. This can not only effectively cool the carbide rolls, but also reduce the corrosion of the rolling mill and extend the service life of the entire production equipment.
Maintenance and grinding of the rolling groove
During the rolling process, it is common for microcracks to appear in the rolling groove, but when the depth of the crack reaches 0.3mm, it is necessary to grind or replace the rolling groove in time. Otherwise, cracks that have not been completely repaired may cause the roll to break or be damaged. Therefore, microcracks must be completely removed during grinding to avoid affecting the quality and safety of the next rolling.
After grinding, the groove should be passivated to eliminate the sharp edge at the junction with the die rib and make a smooth transition. This treatment can improve the service life of the groove and optimize the processing quality of the steel.
Avoid rolling low-temperature steel
The design and performance of carbide composite rollers are not suitable for rolling low-temperature steel. In order to better protect the rollers, it is recommended to perform two cuts during the rolling process, especially when processing the billet head. This is not only conducive to the use of carbide rollers but also improves the rolling quality.
Processing and turning recommendations
For turning carbide composite rollers, it is recommended to use cubic silicon carbide (CBN) or PCD (polycrystalline diamond) copy-turning tools for turning. These tool materials can effectively ensure processing accuracy and extend the service life of the tool. Use diamond grinding wheels during grinding to ensure sharpness and improve efficiency. When processing iron characters and engraved ribs, use cubic boron carbide or PCD tools and use kerosene as a coolant to reduce heat accumulation and tool wear.
Groove Rib Requirements
When regrooving the groove, avoid operating in the original position. Select the middle position between the original two ribs for staggered scoring.
This placement effectively avoids internal stress concentration in the carbide roll.
It also reduces the negative impact on roll life.
Reasonable rib position not only helps to improve the working efficiency of the roll but also prolongs its service life.
Summary
Carbide composite rolls are important equipment for improving rolling efficiency and quality, but their service life and performance depend on correct operation and maintenance. Accurately selecting the proper grade, strictly following assembly and hoisting procedures, optimizing cooling water management, and regularly inspecting and grinding the groove all help improve the performance of carbide composite rolls and extend their service life.
Contact Us
If you have any questions or needs about carbide composite rolls, please contact us. Our professional team will provide you with comprehensive technical support and solutions to help you optimize your production process and ensure the efficient operation of your equipment.