CN101811379A - Rubber-coating roll with composite rubber-coating layer and method for preparing same - Google Patents
Rubber-coating roll with composite rubber-coating layer and method for preparing same Download PDFInfo
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Abstract
The invention discloses a rubber-coating roll with a composite rubber-coating layer. The rubber-coating roll comprises a cylindrical rotary body made of a metallic material; the rubber composite material layer is coated on the rotary body; and the rubber composite material layer is made of a composite material formed by embedding wear resistant alloy blocks in rubber. The rubber-coating roll has the advantages of high toughness and plasticity and impact resistance of rubber materials and high hardness and wear resistance of wearing resistant alloy; and the rubber-coating roll can be used under working conditions of bearing a bigger impact load, and overcomes the defect that the impact resistance of the wearing resistant alloy materials is low.
Description
Technical field
The present invention relates to a kind of rubber covered roll and preparation method thereof with composite rubber layer.
Background technology
Rubber covered roll is widely used in industries such as metallurgy, mine, electric power, chemical industry, printing, weaving, printing and dyeing, is divided into conveying roller, jockey pulley, slewing rollers, squeeze roll, backing roll etc.Rubber covered roll is also referred to as rubber and coats roll shaft, makes columniform revolving body with metal material, coats one deck elastomeric material on the surface of cylindrical revolving body then.The cylindrical revolving body that uses adopts the seamless steel pipe manufacturing more at present, and the revolving body of the rubber covered roll that part is small-sized also adopts the solid shafting structure.The encapsulate layer adopts abrasive rubber to make, and encapsulate layer structure can be divided into bilayer or individual layer, and general double-deck encapsulate internal layer is harder, and hardness is about 100 Shao Er A, and skin is softer, and hardness is about 85 Shao Er A, and internal layer is generally 5mm ~ 6mm, and skin is no more than 20mm.It is thick that the individual layer encapsulate generally is no more than 25mm, and hardness is about 85 ~ 95 Shao Er A.The metallurgical magazine in Jiangsu, the 6th phase of calendar year 2001 paper " rubber coats the application of roll shaft in the cold-strip steel unit " has been introduced the structure and the application thereof of rubber covered roll, and wherein the encapsulate of the rubber covered roll of Jie Shaoing is single elastomeric material, is not the composite that adopts.The elastic deformation that this encapsulate layer has rubber is big, and elastic modelling quantity is minimum, and Poisson's ratio is big, the almost constant advantage of volume during deformation, but its anti-wear performance can not show a candle to materials such as antifriction alloy.Physical and chemical inspection-physics fascicle magazine was rolled up the paper of the 10th phase paper " rubber covered roll cracking Analysis " in 2008 the 44th, and the encapsulate of the rubber covered roll of introduction also is single elastomeric material, was not the composite that adopts.By literature search, still do not adopt rubber composite to make the report of rubber covered roll encapsulate layer at present.
At present, antifriction alloy is used very extensive aspect resistance to wearing.Normal casting or the technique for overlaying of adopting made various rollers such as various rolls, conveying roller, backing roll and abrasion-proof backing block etc. with metal material.Having introduced a kind of core as the Chinese invention patent " a kind of manufacture method of steel-cored cast-iron compound roll " of patent No. ZL92113960.8 is steel, and the surface is a kind of roll of cast iron, has utilized the good advantage of cast iron anti-wear performance; Publication number is that the Chinese invention patent of CN1099075A discloses the method that adopts casting method production high strength and high chrome cast iron lining plate.Technique for overlaying then is to make the complex abrasion-proof steel plate with high-abrasive material is deposited to substrates such as mild steel, paper as " solder technology " magazine publication in 1996 " adds the application of powder bead-welding technology and hardfacing clad steel plate ", has introduced a kind of technology of preparing of complex abrasion-proof steel plate.It is generally acknowledged that the wearability of material improves along with the increase of its hardness, the toughness of metal, plasticity are significantly descended, be difficult to use in the operating mode of the load that withstands shocks but increase hardness.
The hardness of general abrasive rubber is far below antifriction alloy, but abrasive rubber has good toughness and plasticity, makes it have the excellent in impact resistance energy.Antifriction alloy has higher hardness, shows good abrasion resistance, be the material of wear-resistant grinding abrasion excellent performance as high-chromium cast iron alloy, but its shock resistance is relatively poor.If abrasive rubber and antifriction alloy combined make the encapsulate layer of composite as rubber covered roll, can give full play to both advantages separately, reach both wear-resisting, shock proof again purpose, thus prolong service life of encapsulate layer significantly.
Summary of the invention
Good based on elastomeric material toughness, plasticity, proportion is little, and deformability is strong, can absorb the advantage of large impact momentum, and antifriction alloy hardness height, and abrasion resistance is good, characteristics easy to manufacture.The invention provides a kind of rubber covered roll and preparation method thereof with composite rubber layer, the encapsulate layer of this rubber covered roll has adopted the composite rubber material of inlaying abrasion-resistant alloy piece in the rubber, make full use of two kinds of materials advantage separately, both had high wear-resistant, resisting strong impact, and can absorb the advantage of large impact momentum again by distortion.
The present invention adopts following technical scheme:
A kind of rubber covered roll with composite rubber layer, it comprises the columniform revolving body of making of metal material, on revolving body, coating the rubber composite layer, the rubber composite layer is for to be made by the composite of inlaying abrasion-resistant alloy piece in the rubber, the rubber composite layer adopts bonding agent to be connected with revolving body, perhaps the rubber composite layer is directly vulcanized to revolving body.
The diameter of described cylindrical revolving body, length determine arbitrarily that as required cylinder adopts hollow core structures or adopts real cored structure.Revolving body is made by metal material, preferred ferrous materials.In order to improve the bond strength of revolving body and rubber composite, can carry out following processing to the surface of revolving body: keep revolving body original surface shape, perhaps some grooves on revolving body surperficial prefabricated, perhaps prefabricated some pits.The degree of depth of the above groove is 0.5mm ~ 5.0mm, width is no more than 5mm, the distance of adjacent two grooves is no more than 10mm, groove cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, the angle of groove and revolving body cross section is 0 ° ~ 30 °, and perhaps the angle of groove and revolving body axis is 0 ° ~ 30 °.The degree of depth of the above pit is 0.5mm ~ 3.0mm, and volume is no more than 100 cubic millimeters, the pit cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, it distributes arbitrarily at revolving body surface.
The composite of inlaying abrasion-resistant alloy piece comprises the rubber substrate in the described rubber, described rubber substrate is provided with several blind holes, be inlaid with the wear-resisting alloy block that is complementary with the blind hole size in blind hole, the rubber substrate adopts tight fit or bonding the connection with wear-resisting alloy block.The thickness of rubber substrate is 5mm ~ 25mm, and blind hole depth is less than the rubber-based plate thickness, and the cross section of blind hole is circle or polygon or other regular shapes, and cross-sectional area is not less than 4 square millimeters, and the minimum range between the adjacent blind hole edge is not less than 3.0mm.The rubber substrate is selected one or more in natural rubber, butadiene-styrene rubber, butadiene rubber, acrylonitrile-butadiene rubber, neoprene, butyl rubber, EP rubbers, the polyurethane rubber for use.The preferred butadiene-styrene rubber of described rubber substrate or butadiene rubber or acrylonitrile-butadiene rubber.The length of rubber substrate and width are determined according to the surface size of revolving body.
The chemical composition of described wear-resisting alloy block (mass percent) is:
1) high-chromium alloy cast-iron: C is 2.0% ~ 5.5%, Mn is no more than 3.5%, Si is no more than 3.5%, Cr is 12.0%～35.0%, V is no more than 8.5%, and Ni is no more than 8.0%, Mo is no more than 6.5%, W is no more than 18.0%, B is no more than 4.0%, surplus is Fe;
Or 2) high chrome: C is 0.1% ~ 0.70%, Si is no more than 1.5%, Cr is 8.0%～18.0%, Ni is no more than 6.0%, Mo is no more than 3.0%, W is no more than 2.5%, Nb is no more than 0.6%, B is no more than 1.5%, surplus is Fe;
Or 3) Martensitic Alloy Pig Iron: C is 2.1% ~ 5.0%, Cr is no more than 6.5%, Mo is no more than 5.5%, W is no more than 15.0%, surplus is Fe;
Or 4) high-speed steel: C is 0.6%～1.5%, Cr is 3.6%～5.6%, V is 0.9%～1.6%, W is 15.0%～20.0%, surplus is Fe;
Or 5) Cr-W-Mo oxida-tion-resistant steel: C is 0.1% ~ 0.6%, Mn is no more than 2.5%, Si is no more than 1.2%, Cr is no more than 6.0%, Mo is 0.2% ~ 2.8%, V is no more than 1.0%, W is 0.25% ~ 11.0%, surplus is Fe;
Or 6) common low, medium alloy steel: C is 0.3% ~ 1.2%, Mn is 0.3% ~ 5.0%, Si is 0.1% ~ 1.2%, Cr is no more than 5.0%, Mo is no more than 3.0%, surplus is Fe.
Above-mentioned 1)～6) composition of six kinds of listed wear-resisting alloy blocks allows to contain a certain amount of other alloying elements that exist as impurity except the alloying element of above requirement, and its content is principle with the performance that does not influence wear-resisting alloy block.
Wear-resisting alloy block is rotary body or polyhedron or rotary body and polyhedral assembly, and rotary body comprises the assembly of round platform, cylinder, spheroid, hemisphere and above-mentioned rotary body, and polyhedron comprises terrace with edge, prism.Preferred round platform of revolving body or cylinder.The height of wear-resisting alloy block is 2mm ~ 20mm, and with the blind hole depth coupling, the volume of wear-resisting alloy block is not less than 8 cubic millimeters.In order to improve the bond strength of wear-resisting alloy block and rubber, following processing can be carried out in whole surface to the wear-resisting alloy block that contacts with rubber: the surface configuration that keeps former solid, perhaps some grooves prefabricated on the wear-resisting alloy block surface perhaps prefabricatedly some pits.The degree of depth of the above groove is 0.5mm ~ 3.0mm, width is no more than 5mm, the distance of adjacent two grooves is no more than 10mm, groove cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, the angle of groove and alloy block cross section is 0 ° ~ 30 °.The degree of depth of the above pit is 0.5mm ~ 3.0mm, and volume is no more than 100 cubic millimeters, the pit cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, it distributes arbitrarily on the wear-resisting alloy block surface.
A kind of preparation method with rubber covered roll of composite rubber layer, its step is:
(1) preparation revolving body, wear-resisting alloy block according to the dimensional requirement of revolving body, adopt existing mechanical processing method processing revolving body.And adopt prior art as required, some grooves revolving body surface is prefabricated, perhaps prefabricated some pits; Composition and dimensional requirement according to wear-resisting alloy block, adopt existing foundry engieering or PM technique or technique for overlaying or cold-drawn rolling technique to prepare the wear-resisting alloy block blank, be worked into machining process again and require size, and can go out groove or pit in the Surface Machining of wear-resisting alloy block as required;
(2) removal of impurities according to existing blasting craft or acid cleaning process or machining process, is removed impurity, the dirt of revolving body surface, use the chemical clean surface then, the preferred gasoline of chemical cleans the cleaning back and dries 10 ~ 30 minutes naturally, or dries up with blower fan; Wear-resisting alloy block for preparation, all surfaces that contact with rubber at them, handle according to existing blasting craft or acid cleaning process or machining process, remove impurity, the dirt on surface, use the chemical clean surface then, the preferred gasoline of chemical cleans the cleaning back and dries 10 ~ 30 minutes naturally, or dries up with blower fan;
(3) to the revolving body and the wear-resisting alloy block surface of step (2) preparation, evenly coat bonding agent as required, perhaps coating adhesive does not directly use;
The revolving body surface bonding agent is selected epoxide-resin glue, polyurethane adhesive, phenolic resin glue, SGA, inorganic glue or polymeric isocyanate glue for use, during coating adhesive, be coated with twice, whenever put 10 ~ 40 minutes all over cold at room temperature after being coated with, the adhesive coating gross thickness is 0.01mm ~ 0.5mm; The resin type bonding agent is selected on the wear-resisting alloy block surface for use, perhaps rubber-type bonding agent, the perhaps compound bonding agent that is made into by resin type bonding agent, rubber-type bonding agent, the bonding hot vulcanization agent of preferentially selecting for use is a polymeric isocyanate glue, when being coated with the bonding hot vulcanization agent, be coated with twice, whenever put 20 ~ 40 minutes all over cold at room temperature after being coated with, the adhesive coating gross thickness is 1mm ~ 100mm;
(4) raw material of rubber is produced in selection, according to existing rubber production technology plasticate, mixing, calendering back obtains the semi-finished product raw material, it is sizing material, the wear-resisting alloy block that step (3) is obtained is placed in the sizing material, adopts existing room temperature vulcanization technology or hot vulcanization process to vulcanize then and makes rubber composite; Perhaps break-in gold bullion that step (3) is obtained and the sizing material surface that is placed into revolving body is adopted existing room temperature vulcanization technology or hot vulcanization process to vulcanize then and is made rubber covered roll;
(5) rubber composite with step (4) preparation bonds to the revolving body surface that was coated with bonding agent that step (3) obtains, and makes rubber covered roll;
(6) with the rubber covered roll of step (4) or step (5) preparation, carry out removing surface and promptly obtain the rubber covered roll product.
The described sulfuration of step (4) adopts existing room temperature vulcanization technology or hot vulcanization process to vulcanize, preferred heat curing system.Hot vulcanization process is finished on forcing press, uses mould shape, and mould has mold and bed die.Earlier the semi-finished product sizing material is put into bed die, the wear-resisting alloy block that step (3) is obtained then is placed into the precalculated position of sizing material upper surface, covers mold.Mould is pushed between the flat board of forcing press, upper and lower two flat boards compress and vulcanize, and obtain to be inlaid with the rubber slab of wear-resisting alloy block.Perhaps, elder generation is placed into the revolving body that step (2) scribbles bonding agent in the bed die, again the semi-finished product sizing material is put into bed die, and the wear-resisting alloy block that step (3) is obtained is placed into the precalculated position on sizing material surface then, covers mold.Mould is pushed between the last lower platen of forcing press, upper and lower two pressing plates compress and vulcanize, and directly make rubber covered roll.
The invention provides a kind of rubber covered roll with composite rubber layer and preparation method thereof, the encapsulate layer of this rubber covered roll has adopted the composite rubber material of inlaying alloy block in the rubber, and its application and enforcement have following positive effect:
(1) the rubber covered roll encapsulate layer of inlaying abrasion-resistant alloy piece in the rubber, existing elastomeric material toughness plasticity is good, and shock proof advantage has antifriction alloy hardness height again, the strong point that anti-wear performance is good.Can be used for bearing the operating mode of greater impact load, overcome the not impact-resistant drawback of high-wearing feature alloy material;
(2) wear-resisting alloy block that adopts special construction to design is realized the bonding of alloy block and rubber in sulfuration, both bond strength height are not easy during use to come off;
(3) the present invention is used for rubber covered roll encapsulate layer with the rubber slab of inlaying abrasion-resistant alloy piece, can adopt bonding agent to bond on the revolving body of rubber covered roll, is suitable for the on-the-spot rubber covered roll of repairing wear out failure fast;
(4) the encapsulate layer of rubber covered roll of the present invention is inlaid with wear-resisting alloy block, has good wear-resistant grinding abrasion ability, is particularly suitable for the conveying of material under the strong abrasion of particles operating mode.
Description of drawings
The rubber covered roll surface of Fig. 1 for inlaying round table-like wear-resisting alloy block in the encapsulate layer rubber, wherein round table-like alloy block axis normal is in the revolving body axis.
Fig. 2 is for inlaying the rubber covered roll partial sectional view of round table-like wear-resisting alloy block in the encapsulate layer rubber, wherein round table-like alloy block axis normal is in the revolving body axis.
Fig. 3 is for inlaying the rubber covered roll partial sectional view of cylindric wear-resisting alloy block in the encapsulate layer rubber, wherein cylindric alloy block axis is parallel to the revolving body axis.
Fig. 4 is for inlaying the rubber covered roll partial sectional view of cylindric wear-resisting alloy block in the encapsulate layer rubber, wherein cylindric alloy block axis is parallel to the revolving body axis.
Wherein: 1 wear-resisting alloy block, 2 rubber substrates, 3 encapsulate roll shafts, 4 revolving bodies (wherein Fig. 1, Fig. 2 are real core revolving body, and Fig. 3, Fig. 4 are the hollow revolving body), 5 revolving body end faces, the spoke of 7 hollow revolving body encapsulate roll shafts.
The specific embodiment
The present invention will be further described below in conjunction with accompanying drawing and embodiment.
Among Fig. 1, Fig. 2, a kind of rubber covered roll with composite rubber layer, it comprises the columniform revolving body of making of metal material 4, on revolving body 4, coating the rubber composite layer, the rubber composite layer is for to be made by the composite of inlaying abrasion-resistant alloy piece in the rubber, the rubber composite layer adopts bonding agent to be connected with revolving body, perhaps the rubber composite layer is directly vulcanized to revolving body.
The diameter of described revolving body 4, length determine arbitrarily that as required cylinder adopts hollow core structures or adopts real cored structure.Revolving body 4 is made by metal material, preferred ferrous materials.In order to improve the bond strength of revolving body and rubber composite, can carry out following processing to the surface of revolving body: keep revolving body original surface shape, perhaps some grooves on revolving body surperficial prefabricated, perhaps prefabricated some pits.The degree of depth of the above groove is 0.5mm ~ 5.0mm, width is no more than 5mm, the distance of adjacent two grooves is no more than 10mm, groove cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, the angle of groove and cylindrical revolving body cross section is 0 ° ~ 30 °, and perhaps the angle of groove and cylindrical revolving body axis is 0 ° ~ 30 °.The degree of depth of the above pit is 0.5mm ~ 3.0mm, and volume is no more than 100 cubic millimeters, the pit cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, it distributes arbitrarily at cylindrical revolving body surface.
The composite of inlaying abrasion-resistant alloy piece comprises rubber substrate 2 in the rubber, offer several blind holes on the rubber substrate 2, in blind hole, be inlaid with the wear-resisting alloy block 1 that is complementary with the blind hole cross sectional dimensions, rubber substrate 2 adopts tight fit or bonding the connection with wear-resisting alloy block 1, the position of wear-resisting alloy block 1 cross-sectional area maximum is positioned at the rubber-based intralamellar part, perhaps at prefabricated upper groove in the side of the wear-resisting alloy block that contacts with rubber or pit, at sulfurating stage, these grooves or pit will be embedded into rubber, prevent that from structure wear-resisting alloy block from coming off.The thickness of rubber substrate 2 is at 5mm ~ 25mm, and blind hole depth is less than the thickness of rubber substrate 2.Rubber substrate 2 is selected a kind of in natural rubber, butadiene-styrene rubber, butadiene rubber, acrylonitrile-butadiene rubber, neoprene, butyl rubber, EP rubbers, the polyurethane rubber for use, perhaps selects with two or more of above-mentioned rubber rubber after mixing for use.Rubber substrate 2 preferred butadiene-styrene rubber or butadiene rubber or acrylonitrile-butadiene rubbers.The length of rubber substrate and width are determined according to the surface area of revolving body.The cross section of blind hole is circle or polygon or other regular shapes, and cross-sectional area is not less than 4 square millimeters, and the minimum range between the adjacent blind hole edge is not less than 3.0mm.The material of wear-resisting alloy block is selected above-mentioned high-chromium alloy cast-iron for use, high chrome, Martensitic Alloy Pig Iron, high-speed steel, Cr-W-Mo oxida-tion-resistant steel, a kind of in common low, the medium alloy steel.Wear-resisting alloy block is rotary body or polyhedron, and the height of wear-resisting alloy block is 2mm ~ 20mm, antifriction alloy tile height and blind hole depth coupling, and the volume of wear-resisting alloy block is not less than 8 cubic millimeters.
Embodiment 1:
(1) preparation revolving body, the diameter of revolving body is 100mm, and length is 2m, is real cored structure, and material selection Q345 steel adopts existing method for turning processing revolving body.Adopt existing turning technology to process groove in the side of revolving body, the degree of depth of groove is 1.0mm, width is 4mm, adjacent two groove distance are 8mm, groove cross section be shaped as rectangle, the angle of groove and revolving body cross section is 0 °, removes impurity, the dirt of revolving body surface, use the gasoline clean surface then, clean the cleaning back and dried naturally 10 minutes;
(2) to the revolving body surface of step (1) preparation, evenly coat the polymeric isocyanate glue bonding agent, be coated with twice, whenever put 25 minutes all over cold at room temperature after being coated with, the adhesive coating gross thickness is 50mm;
(3) the preparation wear-resisting alloy block adopts existing precision casting technology to prepare wear-resisting alloy block, and the solid of wear-resisting alloy block 1 is positive round platform, and the bottom surface diameter of positive round platform is 10mm, and the upper bottom surface diameter is 7mm, highly is 10mm.The material of wear-resisting alloy block 1 is a high-chromium alloy cast-iron, and its chemical composition (mass percent) is that 3.8%C, 0.5%Mn, 1.2%Si, 22.0%Cr, 1.8%V, surplus are Fe;
Handle according to existing blasting craft on wear-resisting alloy block surface to preparation, removes impurity, the dirt on wear-resisting alloy block surface, cleans the wear-resisting alloy block surface with gasoline then, cleans the cleaning back and dried naturally 20 minutes;
Evenly coat the agent of polymeric isocyanate glue bonding hot vulcanization on the wear-resisting alloy block surface of above-mentioned preparation, be coated with twice, whenever put adhesive coating thickness 30mm 30 minutes all over cold at room temperature after being coated with;
(4) selecting butadiene-styrene rubber is substrate, and the thickness of substrate is 20mm, selects to produce the raw material of butadiene-styrene rubber according to existing rubber production technology, plasticates, mixing, calendering back obtains semi-finished product raw material, i.e. sizing material.Elder generation is placed into the revolving body that step (2) scribbles bonding agent in the bed die, according to the thickness of rubber substrate the semi-finished product sizing material is put into bed die again, the wear-resisting alloy block that step (3) is obtained then, be placed into the sizing material surface, round table-like alloy block axis is radially consistent with revolving body, its upper bottom surface outwardly, wear-resisting alloy block is 10mm to the minimum range of revolving body end face 5, place 99 row's wear-resisting alloy blocks in revolving body axis direction, place 14 row's wear-resisting alloy blocks at circumferencial direction, place 99 * 14 wear-resisting alloy blocks altogether, the wear-resisting alloy block of above-mentioned both direction is evenly arranged, and covers mold.Mould is pushed between the last lower platen of forcing press, upper and lower two pressing plates compress and carry out heat cure, in the rubber substrate of wear-resisting alloy block embedding as the encapsulate layer, directly make rubber covered roll.
(5) with the rubber covered roll of step (4) preparation, carry out removing surface and promptly obtain the rubber covered roll product.
Embodiment 2:
(1) preparation revolving body, it is that 200mm, length are that 1m, wall thickness are the steel pipe of 20mm that revolving body adopts diameter, material selection Q235 steel, according to existing blasting craft, remove impurity, the dirt of revolving body surface, clean with gasoline then, clean the cleaning back and dry up with blower fan;
(2) to the revolving body surface of step (1) preparation, evenly coat the epoxide-resin glue bonding agent, be coated with twice, whenever put 20 minutes all over cold at room temperature after being coated with, the adhesive coating gross thickness is 30mm;
(3) preparation wear-resisting alloy block
Adopt existing cold-drawn technology to prepare the wear-resisting alloy block blank, blank is a wire rod, and diameter is 10mm, is cut to the cylinder of length 140mm behind the aligning.The material of wear-resisting alloy block 1 is common low, medium alloy steel, and its chemical composition (mass percent) is that 0.35%C, 0.8%Mn, 0.4%Si, 0.3%Cr, 0.2%Mo, surplus are Fe;
To the wear-resisting alloy block of preparation, handle according to existing blasting craft, remove impurity, the dirt on wear-resisting alloy block 1 surface, clean the wear-resisting alloy block surface with acetone then, clean the back and dry up with blower fan;
Evenly coat phenolic aldehyde-epoxy glue bonding agent XY502 on the wear-resisting alloy block surface of above-mentioned preparation, this bonding agent belongs to the resin type bonding agent; Be coated with twice, whenever put 20 minutes all over cold at room temperature after being coated with, the adhesive coating gross thickness is 10mm;
(4) selecting butadiene rubber is substrate, and the thickness of substrate is 25mm, selects to produce the raw material of butadiene rubber according to existing rubber production technology, plasticates, mixing, calendering back obtains semi-finished product raw material, i.e. sizing material.Elder generation is placed into the revolving body that step (2) scribbles bonding agent in the bed die, according to the thickness of rubber substrate the semi-finished product sizing material is put into bed die again, the wear-resisting alloy block that step (3) is obtained then, be placed into the sizing material surface, cylindric alloy block axis is parallel with the axis of revolving body, wear-resisting alloy block is 20mm to the minimum range of revolving body end face 5, place 6 row's wear-resisting alloy blocks in revolving body axis direction, place 15 row's wear-resisting alloy blocks at circumferencial direction, place 6 * 15 wear-resisting alloy blocks altogether, the wear-resisting alloy block of above-mentioned both direction is evenly arranged, and covers mold.Mould is pushed between the last lower platen of forcing press, upper and lower two pressing plates compress and carry out heat cure, in the rubber substrate of wear-resisting alloy block embedding as the encapsulate layer, directly make rubber covered roll.
(5) with the rubber covered roll of step (4) preparation, carry out removing surface and promptly obtain the rubber covered roll product.
Embodiment 3:
(1) preparation revolving body, it is that 400mm, length are that 1500mm, wall thickness are the steel pipe of 25mm that revolving body adopts diameter, material selection Q195 steel, according to existing blasting craft, remove impurity, the dirt of revolving body surface, clean with gasoline then, clean the cleaning back and dry up with blower fan;
(2) preparation wear-resisting alloy block
Adopt existing PM technique to prepare wear-resisting alloy block, the solid of wear-resisting alloy block 1 is positive truncated rectangular pyramids, and the bottom surface of positive truncated rectangular pyramids is that the length of side is the square of 12mm, and upper bottom surface is the square of length of side 8mm, highly is 6mm.The material of wear-resisting alloy block 1 is a high-speed steel, and its chemical composition (mass percent) is that 0.9%C, 4.1%Cr, 1.2%V, 18.0%W, surplus are Fe;
To the wear-resisting alloy block surface of preparation, handle according to existing blasting craft, remove impurity, the dirt on wear-resisting alloy block surface, clean the wear-resisting alloy block surface with gasoline then, clean the cleaning back and dried naturally 30 minutes;
Evenly coat phenolic aldehyde-epoxy glue bonding agent XY502 on the wear-resisting alloy block surface of above-mentioned preparation, this bonding agent belongs to the resin type bonding agent; Be coated with twice, whenever put 20 minutes all over cold at room temperature after being coated with, the adhesive coating gross thickness is 10mm;
(3) selecting butyl rubber is substrate, and the thickness of substrate is that 22mm, length are 1500mm, and width is 1325mm.Select to produce the raw material of butyl rubber according to existing rubber production technology, plasticate, mixing, calendering back obtains semi-finished product raw material, i.e. sizing material.Earlier the semi-finished product sizing material is put into bed die, the wear-resisting alloy block that step (2) is obtained then, be placed into the sizing material upper surface, positive truncated rectangular pyramids shape alloy block axis is vertical with the sizing material upper surface, upper bottom surface up, the foursquare both sides of upper bottom surface are parallel to the edge of substrate respectively, wear-resisting alloy block is 30mm to the minimum range of rubber-based panel edges, place 84 wear-resisting alloy blocks in length 1500mm direction, place 74 row's wear-resisting alloy blocks in width 1325mm direction, place 84 * 74 wear-resisting alloy blocks altogether, the wear-resisting alloy block of above-mentioned both direction is evenly arranged, and covers mold.Mould is pushed between the flat board of forcing press, upper and lower two flat boards compress and vulcanize, and obtain to be inlaid with the rubber slab of wear-resisting alloy block.
(5) to the revolving body surface of step (1) preparation, evenly coat the epoxide-resin glue bonding agent, the adhesive coating gross thickness is 0.2mm.
(6) rubber slab that is inlaid with wear-resisting alloy block with step (4) preparation bonds to the revolving body surface of step (5) preparation, and carries out removing surface, makes the rubber covered roll product.
Embodiment 4:
(1) preparation revolving body, it is that 400mm, length are that 1500mm, wall thickness are the steel pipe of 25mm that revolving body adopts diameter, material selection Q195 steel, according to existing blasting craft, remove impurity, the dirt of revolving body surface, clean with gasoline then, clean the cleaning back and dry up with blower fan;
(2) preparation wear-resisting alloy block
Adopt existing precision casting technology to prepare wear-resisting alloy block, the solid of wear-resisting alloy block 1 is positive round platform, and the bottom surface diameter of positive round platform is 12mm, and the upper bottom surface diameter is 9mm, highly is 10mm.Side at positive round platform adopts existing precision casting mold to cast out groove, and the degree of depth of groove is 1.0mm, and width is 4.0mm, adjacent two groove distance are 8.0mm, groove cross section be shaped as rectangle, the angle of groove and round platform upper surface is 0 °, groove evenly distributes in the side of round platform.The material of wear-resisting alloy block 1 is a Martensitic Alloy Pig Iron, and its chemical composition (mass percent) is that 3.5%C, 5.5%Cr, 2.8%Mo, 2.2%W, surplus are Fe;
Handle according to existing blasting craft on wear-resisting alloy block surface to preparation, removes impurity, the dirt on wear-resisting alloy block surface, cleans the wear-resisting alloy block surface with gasoline then, cleans the cleaning back and dried naturally 20 minutes;
Evenly coat the agent of polymeric isocyanate glue bonding hot vulcanization on the wear-resisting alloy block surface of above-mentioned preparation, be coated with twice, whenever put adhesive coating thickness 30mm 30 minutes all over cold at room temperature after being coated with;
(3) selecting acrylonitrile-butadiene rubber is substrate, and the thickness of substrate is that 25mm, length are 1500mm, and width is 1325mm.Select to produce the raw material of acrylonitrile-butadiene rubber according to existing rubber production technology, plasticate, mixing, calendering back obtains semi-finished product raw material, i.e. sizing material.Earlier the semi-finished product sizing material is put into bed die, the wear-resisting alloy block that step (2) is obtained then, be placed into the sizing material upper surface, just round table-like alloy block axis is vertical with the sizing material upper surface, upper bottom surface up, wear-resisting alloy block is 30mm to the minimum range of rubber-based panel edges, place 84 row's wear-resisting alloy blocks in length 1500mm direction, place 74 row's wear-resisting alloy blocks in width 1325mm direction, place 84 * 74 wear-resisting alloy blocks altogether, the wear-resisting alloy block of above-mentioned both direction is evenly arranged, and covers mold.Mould is pushed between the flat board of forcing press, upper and lower two flat boards compress and vulcanize, and obtain to be inlaid with the rubber slab of wear-resisting alloy block.
(5) to the revolving body surface of step (1) preparation, evenly coat the epoxide-resin glue bonding agent, the adhesive coating gross thickness is 0.25mm.
(6) rubber slab that is inlaid with wear-resisting alloy block with step (4) preparation bonds to the revolving body surface of step (5) preparation, and carries out removing surface, makes the rubber covered roll product.
Embodiment 5:
(1) preparation revolving body, it is that 600mm, length are that 3000mm, wall thickness are the steel pipe of 25mm that revolving body adopts diameter, material selection Q195 steel, according to existing blasting craft, remove impurity, the dirt of revolving body surface, clean with gasoline then, clean the cleaning back and dry up with blower fan;
(2) preparation wear-resisting alloy block
Adopt existing technique for overlaying to prepare wear-resisting alloy block.Selecting thickness for use is the Q345 steel plate of 8mm, select commercially available welding rod, the chemical composition of welding rod deposited metal (mass percent) is, C is 0.45%, Mn is 1.5%, Si is 0.5%, Cr is 3.1%, Mo is 1.8%, V is 0.5%, W is 6.0%, surplus is Fe, and deposited metal belongs to the Cr-W-Mo oxida-tion-resistant steel.Use above welding rod,, length and width thick at 8mm are respectively on the Q345 steel plate of 2m and 1m, adopt the wear-resistant alloy layer of existing processes built-up welding 4mm, and obtaining gross thickness is the 12mm clad steel plate.Use existing plasma cutting process, cut out cylinder on clad steel plate, cylindrical diameter 24mm highly is 12mm, and cylindrical axis normal is in the clad steel plate surface.
Wear-resisting alloy block to preparation with the side that lathe adopts the cylindric wear-resisting alloy block of existing turning process turning, is processed into diameter 20mm, the cylinder of height 12mm, and it is poor to go out the helix of a M20 in side turning.Impurity, the dirt on wear-resisting alloy block surface are removed in turning processing, clean the wear-resisting alloy block surface with gasoline then, clean the cleaning back and dry naturally 10 minutes.
Evenly coat the agent of polymeric isocyanate glue bonding hot vulcanization on the wear-resisting alloy block surface of above-mentioned preparation, be coated with twice, whenever put 20 minutes all over cold at room temperature after being coated with, the adhesive coating gross thickness is 50mm;
(3) selecting acrylonitrile-butadiene rubber is substrate, and the thickness of substrate is that 25mm, length are 3000mm, and width is 1963mm.Select to produce the raw material of acrylonitrile-butadiene rubber according to existing rubber production technology, plasticate, mixing, calendering back obtains semi-finished product raw material, i.e. sizing material.Earlier the semi-finished product sizing material is put into bed die, the wear-resisting alloy block that step (2) is obtained then, be placed into the sizing material upper surface, cylindric alloy block axis is vertical with the sizing material upper surface, overlaying surface up, wear-resisting alloy block is 50mm to the minimum range of rubber-based panel edges, place 111 row's wear-resisting alloy blocks in length 3000mm direction, place 71 row's wear-resisting alloy blocks in width 1963mm direction, place 111 * 71 wear-resisting alloy blocks altogether, the wear-resisting alloy block of above-mentioned both direction is evenly arranged, and covers mold.Mould is pushed between the flat board of forcing press, upper and lower two flat boards compress and vulcanize, and obtain to be inlaid with the rubber slab of wear-resisting alloy block.
(5) to the revolving body surface of step (1) preparation, evenly coat the epoxide-resin glue bonding agent, the adhesive coating gross thickness is 0.25mm.
(6) rubber slab that is inlaid with wear-resisting alloy block with step (4) preparation bonds to the revolving body surface of step (5) preparation, and carries out removing surface, makes the rubber covered roll product.
Embodiment 6:
Adopt prior art for preparing wear-resisting alloy block 1, the material of wear-resisting alloy block 1 is a high chrome, and its chemical composition (mass percent) is that 0.4%C, 0.7%Si, 16.0%Cr, 0.7%Ni, 1.2%Mo, surplus are Fe.The solid of wear-resisting alloy block 1 is positive round platform, and the bottom surface diameter of positive round platform is 12mm, and the upper bottom surface diameter is 9mm, highly is 10mm.Wear-resisting alloy block adopt prior art in its side prefabricated on depth capacity be the pit of 1.5mm, the pit shape of cross section is semicircle, the diameter of semicircle is 3.0mm, and minimum range and ultimate range between the adjacent semicircle center of circle are respectively 6.0mm, 10.0mm, distributes arbitrarily in the side of positive round platform.
All the other are identical with embodiment 4, repeat no more.
Embodiment 7:
Adopt existing mechanical processing method processing revolving body, the diameter of revolving body is 100mm, and length is 2000mm, is real cored structure, material selection Q345 steel.Adopt the existing machinery processing method to process pit in the side of revolving body, the pit depth capacity is 2.0mm, the pit shape of cross section is semicircle, the diameter of semicircle is 4.0mm, minimum range and ultimate range between the adjacent semicircle center of circle are respectively 7.0mm, 11.0mm, and pit distributes arbitrarily in the revolving body side.
All the other are identical with embodiment 1, repeat no more.
Claims (10)
1. rubber covered roll with composite rubber layer, it is characterized in that, it comprises the columniform revolving body of making of metal material, is coating the rubber composite layer on revolving body, and the rubber composite layer is for to be made by the composite of inlaying abrasion-resistant alloy piece in the rubber.
2. according to the described rubber covered roll of claim 1, it is characterized in that the surface of described revolving body is shaped on some grooves in advance, perhaps be shaped on some pits in advance with composite rubber layer.
3. according to the described rubber covered roll of claim 2 with composite rubber layer, it is characterized in that, the degree of depth of described groove is 0.5mm～5.0mm, width is no more than 5mm, the distance of adjacent two grooves is no more than 10mm, groove cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, the angle of groove and revolving body cross section is 0 °～30 °, perhaps the angle of groove and revolving body axis is 0 °～30 °; The degree of depth of described pit is 0.5mm～3.0mm, and volume is no more than 100 cubic millimeters, the pit cross section be shaped as rectangle, trapezoidal, triangle, one of semicircle, it distributes arbitrarily at revolving body surface.
4. according to the described rubber covered roll of claim 1, it is characterized in that the rubber composite layer adopts bonding agent to be connected with revolving body, perhaps the rubber composite layer is directly vulcanized to revolving body with composite rubber layer.
5. according to the described rubber covered roll of claim 1 with composite rubber layer, it is characterized in that, the composite of inlaying abrasion-resistant alloy piece in the described rubber, it comprises the rubber substrate, described rubber substrate is provided with several blind holes, be inlaid with the wear-resisting alloy block that is complementary with the blind hole size in blind hole, the rubber substrate adopts tight fit or bonding the connection with wear-resisting alloy block.
6. according to the described rubber covered roll of claim 5 with composite rubber layer, it is characterized in that described rubber substrate is selected one or more in natural rubber, butadiene-styrene rubber, butadiene rubber, acrylonitrile-butadiene rubber, neoprene, butyl rubber, EP rubbers, the polyurethane rubber for use.
7. according to the described rubber covered roll of claim 5, it is characterized in that the chemical composition of described wear-resisting alloy block is with composite rubber layer:
1) high-chromium alloy cast-iron: C is 2.0% ~ 5.5%, Mn is no more than 3.5%, Si is no more than 3.5%, Cr is 12.0%～35.0%, V is no more than 8.5%, and Ni is no more than 8.0%, Mo is no more than 6.5%, W is no more than 18.0%, B is no more than 4.0%, surplus is Fe;
Or 2) high chrome: C is 0.1% ~ 0.70%, Si is no more than 1.5%, Cr is 8.0%～18.0%, Ni is no more than 6.0%, Mo is no more than 3.0%, W is no more than 2.5%, Nb is no more than 0.6%, B is no more than 1.5%, surplus is Fe;
Or 3) Martensitic Alloy Pig Iron: C is 2.1% ~ 5.0%, Cr is no more than 6.5%, Mo is no more than 5.5%, W is no more than 15.0%, surplus is Fe;
Or 4) high-speed steel: C is 0.6%～1.5%, Cr is 3.6%～5.6%, V is 0.9%～1.6%, W is 15.0%～20.0%, surplus is Fe;
Or 5) Cr-W-Mo oxida-tion-resistant steel: C is 0.1% ~ 0.6%, Mn is no more than 2.5%, Si is no more than 1.2%, Cr is no more than 6.0%, Mo is 0.2% ~ 2.8%, V is no more than 1.0%, W is 0.25% ~ 11.0%, surplus is Fe;
Or 6) common low, medium alloy steel: C is 0.3% ~ 1.2%, Mn is 0.3% ~ 5.0%, Si is 0.1% ~ 1.2%, Cr is no more than 5.0%, Mo is no more than 3.0%, surplus is Fe.
8. according to the described rubber covered roll of claim 5 with composite rubber layer, it is characterized in that, wear-resisting alloy block is rotary body or polyhedron or rotary body and polyhedral assembly, rotary body comprises the assembly of round platform, cylinder, spheroid, hemisphere and above-mentioned rotary body, and polyhedron comprises terrace with edge, prism.
9. have the preparation method of the rubber covered roll of composite rubber layer, it is characterized in that, comprise the steps:
(1) preparation revolving body, wear-resisting alloy block according to the dimensional requirement processing revolving body of revolving body, and some grooves revolving body surface is prefabricated as required, perhaps prefabricatedly some pits; Composition and dimensional requirement according to wear-resisting alloy block prepare wear-resisting alloy block, and some grooves on wear-resisting alloy block surperficial prefabricated as required, perhaps preset some pits;
(2) revolving body, the impurity on wear-resisting alloy block surface, dirt are removed in removal of impurities, dry;
(3) to the revolving body and the wear-resisting alloy block surface of step (2) preparation, evenly coat bonding agent as required, perhaps coating adhesive is directly not standby;
(4) raw material of rubber is produced in selection, according to existing rubber production technology plasticate, mixing, calendering back obtains the semi-finished product raw material, be sizing material, the wear-resisting alloy block that step (3) is obtained is placed in the sizing material, vulcanizes then to make rubber composite; Perhaps wear-resisting alloy block and the sizing material that step (3) is obtained is placed into revolving body surface, vulcanizes then to make rubber covered roll;
(5) rubber composite with step (4) preparation bonds to the revolving body surface that was coated with binding agent that step (3) obtains, and makes rubber covered roll;
(6) with the rubber covered roll of step (4) or step (5) preparation, carry out removing surface and promptly obtain the rubber covered roll product.
10. according to the described preparation method of claim 9 with rubber covered roll of composite rubber layer, it is characterized in that, the bonding agent that step (3) is coated with on the wear-resisting alloy block surface is selected epoxide-resin glue, polyurethane adhesive, phenolic resin glue, SGA, inorganic glue or polymeric isocyanate glue for use, during coating adhesive, be coated with twice, cold was at room temperature put 10～40 minutes after being coated with for every time, and the adhesive coating gross thickness is 1mm～100mm; To the revolving body of preparation, the even coated with resins type bonding agent on its surface, perhaps rubber-type bonding agent, the perhaps compound bonding agent that is made into by resin type bonding agent, rubber-type bonding agent, the adhesive coating gross thickness is 0.01mm～0.5mm.
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