CN105312540A - Technique and device for manufacturing composite roller with recyclable roller core - Google Patents
Technique and device for manufacturing composite roller with recyclable roller core Download PDFInfo
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Abstract
The invention discloses a technique and device for manufacturing a composite roller with a recyclable roller core. The technique comprises the steps that a thick-walled hollow steel pipe core rod which is installed on a combined type water-cooling crystallizer is integrally heated to the temperature of 800-1000 DEG C by means of a induction heater; roller shaft working layer melt is poured; heating continues to be conducted for 10-15 minutes; a lifting device is started to lift the heater upwards at a certain speed; the heater rises to a heat preservation ring and stops 5-15 minutes later; heating continues to be conducted for 10-15 minutes; feeding is conducted on a dead head; and water is introduced for cooling for 30 minutes to 24 hours after heating is stopped. According to the technique and device for manufacturing the composite roller with the recyclable roller core, a composite roller sleeve and a mandrel are connected into a whole through a heat inlaying technique, the technique is simple, the production efficiency is high, safety and reliability are achieved, and the service life is long. Recycling of the roller core is achieved, the utilization rate of the roller core is over 60%, waste of materials and energy resources is reduced, and environmental pollution is reduced.
Description
Technical field
The invention belongs to metal-pressed machine technical field, particularly a kind of composite roll manufacturing process of reusable edible roller core and equipment, be applicable to the manufacture of composite roll in Steel-rolling Industry.
Background technology
Roll is described as " mothers of steel ", be steel, the rolling metal such as aluminium, copper makes metal material produce the instrument of plastic deformation in producing, it is the important large component determining milling train production efficiency and mill bar quality and economy, be the indispensable critical piece of mill milling and topmost large consumable part, its consuming cost is about 5% ~ 15% of Rolling production cost.If consider that the production brought because of roll consumption is shut down, fallen the factors such as product and plant maintenance increase, then the proportion of production cost shared by it can be higher.
Milling train is the visual plant during metal-pressed machine is produced, and is the distinctive marks of the national Iron & Steel Development technical merit of measurement one.And roll is the chief component of milling train, it is a large amount of critical component consumed in Rolling production, being the basic guarantee determining a national rolling technique development level, is the embodiment directly perceived of the basic industries comprehensive technical levels such as national metal material design, forming materials technology, processing and manufacturing and a heat treatment.In steel rolling industrial production, each stocking none be not rely on the rolling of roll and be shaped, in other words " good-for-nothing without roller ", so, the quality of roll and act on most important.
Roll quality is not only related to Rolling production cost and milling train production operational availability, also affects mill bar quality to a great extent.Along with the development of steel rolling technology, rolling mill speed and automaticity improve constantly, and the breaker roll quality particularly wearability of roll, intensity and toughness etc. is had higher requirement.Further raising roller performance, to adapt to the needs of milling train, realizes the energy-saving and cost-reducing production of iron and steel material shaped, is the fresh target that roll development person faces.
China's roll manufacturing industry is through the development of decades and growth, and become roll output big country of the world at present, there is very large development roll manufacturing technology and material kind aspect.In roll material, develop into present acicular constituent spheroidal graphite cast-iron, high alloy infinitely chilled ductile cast iron, rich chromium cast iron, carbide alloy, semi-high speed steel and high-speed steel etc. from spheroidal graphite cast-iron, alloy infinitely chilled ductile cast iron.In casting technique also from routine cast single material and press over system casting composite, develop into centrifugal compound casting process.Current domestic roll deliverability has reached more than 1,000,000 tons, manufactures and designs ability and can reach 120 ~ 1,500,000 tons.Along with the transformation of China's rolling equipment with constantly from the external milling train introducing advanced person, milling train is to automation, serialization, heavy-duty future development, and the structure and properties of breaker roll is had higher requirement.
But the metallurgical roller rolled steel mean consumption that China develops voluntarily still has larger gap compared with developed countries.From the recent statistics of China Steel association, within 2014, China's steel output has reached 1,125,570,000 tons, accounts for global output of steel more than 40%, calculates according to loss per ton steel roll 1.0 ~ 1.2kg/t steel, more than 110 ~ 130 ten thousand tons, year consumption roll, year consumes roll fund more than 20,000,000,000 yuan.In order to meet the actual needs of Rolling production, China all needs to spend a large amount of foreign exchange import roll every year, only about more than 3.0 ten thousand ton, import high-quality roll in 2010, consumes foreign exchange about more than 200,000,000 dollar.A large amount of consumption of China's roll, cause the huge waste of resource and the energy.In addition, external roll Year's consumption also more than 1,000,000 tons, the huge market demand.So large learies no matter from the rolling cost of steel rolling mill, or is all a huge waste from the viewpoint of the energy of China and resource consumption, exerts heavy pressures on to environment and resources.Therefore, improve roll quality, extend roll campaign, can not only save a large amount of foreign exchange, but also can save a large amount of roll materials, exploitation high-quality long-life roll material and forming technique thereof, not only can meet domestic demand, but also can realize foreign exchange earning.
Current domestic and international existing roll, adopts overall cast steel roll and grain roll mostly.Grain roll is compared with cast steel roll, and its wearability is better, but intensity is poor, easy roll breakage.In order to improve roller surface hardness, apply the centrifugal casting technique of roll in recent years, the roll surface of centrifugal casting roll and roll centre adopt the metal casting of heterogeneity respectively, in the hope of the unification of roller surface hardness and roll barrel intensity.Because the manufacturing cost of this roll is high, roll is disposable scraps the reasons such as the significant wastage causing material, and the application of centrifugal roller is extremely restricted.Subsequently, there is composite (back-up) roll, assembly roller is to a certain degree solving the problems such as waste of material, and assembly roller adopts antifriction alloy roller shell, roll campaign improves a lot, but connecting mode many employings key connecting of its roll shaft and roller shell or welding manner, in actual production, the accidents such as cover, scroll key that collapse frequently occur.In addition, after the roll that existing invention technology obtains all also exists cladding material wearing and tearing substantially, roller core only has melting again could realize the problem recycled, and causes the waste of material and the energy.
The existing roll structure of current China is except the roll of fraction special shape is as universal mill horizontal roller, edger roll, line segments roll, section steel straightening roller, cantilever rolling mill roll adopt and recycle outside Split type structure roll, and all types of rolls of more than 90% are all overall structures.Cause the significant wastage of roll material.
For produced problem in assembly roller practical application, China Patent No. CN1142993A discloses a kind of high-energy assembly roller, overcomes present combination roll the deficiencies in the prior art, well solves in assembly roller use procedure and collapse cover, the problem of peeling off.It mainly describes a kind of is that the effective working position of benchmark breaker roll inputs energy according to pressure rolling power in manufacture and assembling process, makes it improve the high-energy roll of intensity, rigidity, resistance to flaking and wearability to greatest extent.But through factual survey, this high-energy roll rarely has application aborning, because it exists following shortcoming: the roller shell of this high-energy assembly roller and the assembly manipulation process complexity of roll shaft; The unloading difficulty of roller shell is large; Assembling and unloading all will rely on the hydraulic test of special product design for this reason, and the hydraulic test due to the whole series makes production cost significantly raise; Because of Long-term Vibration in this high-energy assembly roller course of work, when roller shell deformation (energy) reduces, roll must be unloaded and ressemble, waste time and energy; Easily cause the scratch of roll shaft outer surface and roll sleeve inner surface during roll sleeve unloading, greatly shorten the service life of roll shaft.Chinese patent CN2129657Y " prestressing combination roll ", CN1059482A " iron and steel cementing-combined roller technology ", CN1092992A " combined hollow roll and manufacture method thereof ", ZL02223546.9 " Roller ring composite roller " etc. also individually disclose and manufacture bushing composite roll technology; Antifriction alloy collars (roller shell) and mandrel link together by these combined-type roll collars (roller shell) roll in a variety of different ways.They all do not mention collars must be " outer hard interior tough ", thus is guaranteeing to improve service life under the prerequisite that roll is used safely, and these rolls can exist phenomenons such as collapsing cover, destruction in actual use, thus do not have spread.
Along with the continuous progress of Steel-rolling Industry technology, in order to ensure work roll cooling security, require roll in use core to have higher toughness; Meanwhile, in order to improve steel output and product surface quality, the service life of iron and steel enterprise's breaker roll and the requirement of wearability also improve day by day, and this just needs roll working lining to adopt the high-abrasive material that hardness is high.For this reason, domestic and international scientific worker is doing the discuss and practice work of ring roller always.Develop bushing composite roll.
Compound Bushing Rolls is one of roll type., after the body of roll and roller core and roll neck two parts are differently made respectively, adopt cast setting technique to be assembled into one by hot charging interference fit, the performance requirement of wearability and these two kinds of contradictions of resistance to fracture can be met simultaneously.The roller core accounting for total amount more than 60% can cycle applications, and account for the roll sleeve of the roll sleeve of whole roll weight below 40% through more renewing after reaching Rejection standard both can recycle applications.Compared with traditional solid roll, compound is bushing to be manufactured roll more not only quality is good but also can also reduce the cost of roll.
Domestic and international developed composite ring manufacturing process at present, adopts the manufacture of centrifugal composite casting method mostly, and due to the restriction by manufacturing process, manufactured compound roller shell inner layer material is spheroidal graphite cast-iron, there is no the internal layer that legal system makes steel material.And adopt imbedding process mostly to adopt compound roller shell inner layer material is preheated to 300 ~ 800 DEG C in heating furnace; put into molding sand; then mould assembling pours into roller shell outer layer of composite material; the major defect of this technique is: heat in heating furnace; because the heat time is long; heated object is oxidizable, although can, by protecting the surface of solids not oxidated at surface of solids coating protective agent, thoroughly prevent the oxidation of the surface of solids very difficult.In addition, because pre-warmware is fetched into cast from heating furnace, the time in the middle of this is generally wayward, and before causing compound, the actual temperature change of pre-warmware is comparatively large, stably cannot ensure the quality of compound interface.And adopting high-temperature liquid metal to wash away for a long time solid portion, the efficiency of heating surface is very low, has both wasted the unnecessary waste that a large amount of high-temperature metals causes the energy and material.Simultaneously due to the chilling action of solid portion, the liquid metals near solid portion after liquid metals pours into casting mold solidifies at the surface of solids immediately, and the metal of this layer of rapid solidification very easily occurs crackle, crackle diffusion in practical application.
Summary of the invention
The object of the invention is to the deficiency having technology for oneself, composite roll manufacturing process and the equipment of a kind of reusable edible roller core that a kind of production technology is simple, equipment investment is little, production efficiency is high, cost is low, performance is good are proposed, simplify compound roller shell manufacturing process, improve compound roller shell performance and production efficiency, reduce production cost and equipment investment.
The equipment scheme solving its technical problem is: this equipment has a planer-type region directional solidification jacking equipment 16, planer-type region directional solidification jacking equipment 6 is provided with lifting platform 17, electromagnetic induction heater 8 is installed on lifting platform 17, rotating lifting screw 15 or hydraulic test by lifting motor 14 drives lifting platform 17 to move up and down with set speed, in the side of planer-type region directional solidification jacking equipment 16, electromagnetic induction electrical power control cabinet 19 is installed, two outputs of electromagnetic induction electrical power control cabinet 19 are connected by the two ends of water-cooled cable 20 with electromagnetic induction heating device 8, a base support is had in the bottom of planer-type region directional solidification jacking equipment 16, base support 13 is provided with support plinth 12, Water-cooled bottom water tank 11 is installed on support plinth 12, the center of end water tank 11 is manhole, the center that is provided with on end water tank 11 is the bottom board 10 of manhole, Combined water cooling crystallizer 7 is installed on bottom board 10, on the top of water mold 7, insulation ring 6 is installed, roll shaft plug 5 is by support plinth 12, the center hole of end water tank 11 and bottom board 12 is fixed on the center of crystallizer 7, casting runner 3 is connected with in the side of bottom board 10, casting runner 3 to be arranged on base support 13 and to sit brick 4 with cast and is connected, cast is sat brick 4 and is provided with feed trumpet 2 above, at the top of feed trumpet, sprue cup 1 is installed, pouring ladle 18 is had on depositing funnel 1.
Water inlet pipe 23 and outlet pipe 24 is had respectively in the side of Water-cooled bottom water tank 11; Water mold 7 is made up of the fourplatemold arc water-cooled box assembly 7 at crystallizer circumferentially equally distributed 2 or 3 integral multiples, water inlet pipe 21 is connected with in the bottom of each arc water-cooled box assembly 7, be connected with outlet pipe 22 on the top of each arc water-cooled box assembly 7, by attachment bolt 9, arc water-cooled box assembly 7 connected into drum-shaped entirety; Insulation ring 6 is manufactured by refractory material or fiber reinforcement refractory material; Electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, and frequency is 500Hz ~ 3000Hz.
Solve the process technology scheme that its technical problem adopts: needed for first that manufacture is good, oil removing is carried out on the thick-wall hollow steel pipe inner layer material surface of material and size, after processing of rust removing, one deck antioxidizing paint is applied at its surface uniform, put into after heating furnace carries out being preheating to 500 DEG C ~ 700 DEG C, pass through support plinth, the center hole of end water tank and bottom board is fixed on the center of crystallizer, starting region directional solidification lowering or hoisting gear, electromagnetic induction heater is dropped to the bottom of crystallizer, to fetch boiling water the water inlet pipe and water outlet pipe of cooling crystallizer and end water tank, start electromagnetic induction heating power supply, by the induction heater being arranged on water mold outside, surface heating is carried out to thick-wall hollow steel pipe inner layer material, to be heated to after 800 DEG C ~ 1000 DEG C, the roll compound roller shell outer sphere molten metal of composite parts needed for having smelted is poured in pouring ladle, molten metal in pouring ladle is passed through depositing funnel according to predetermined cast program, feed trumpet, casting runner pours in the space in crystallizer and between thick-wall hollow steel pipe inner layer material, in casting process, electromagnetic induction heater does not stop heating, after pouring metal melt, induction heater proceeds heating 10 ~ 50 minutes, make poured into a mould molten metal within the regular hour, keep liquid, to increase the liquid-solid time, interface is made to form metallurgical binding, electromagnetic induction heater upwards promotes with certain speed by starting region directional solidification lowering or hoisting gear, the roller shell composite bed progressively departing from electromagnetic induction heating successively consecutive solidification from bottom to top, and in different regions, control the different rates of climb according to quality requirement, forming region directional solidification, be raised to insulation ring place to stop through 5 ~ 15 minutes, continue to carry out heating 10 ~ 50 minutes to insulation ring, to postpone insulated feeder setting time, feeding is carried out to rising head, gas in composite-layer metal liquid and field trash are fully floated, eliminate composite-layer metal casting flaw, heating is stopped after reaching the scheduled time, continue water flowing and cool 30 minutes ~ 24 hours, be high abrasion resisting material by the skin cast, internal layer is high tenacity, the bimetallic compound roller shell of high-strength material takes out in crystallizer,
By machined to finished size for the compound roller shell of founding, composite roll cover is heat-treated, then 100 ~ 200 objects are had many ribs wedge angle and the particle that stiff dough is tough, binding agent is adopted to be bonded to the bore area of compound roller shell and the outer surface of mandrel respectively uniformly, roller shell is preheating to lower than roller shell temperature 400 ~ 550 DEG C, temperature retention time was directly press fit on mandrel after 8 ~ 12 hours, many ribs wedge angle and the tough particle of stiff dough embeds roller shell internal layer and the outer field surface of mandrel after roller shell cooling, improve interface bond strength, make compound roller shell and mandrel be coupled to an organic whole and form roller shell roll, composite roll after assembling enters stove and cools to room temperature with the furnace.
The composite roll of described reusable edible roller core is outer by composite roll roller shell, composite roll roller shell internal layer and mandrel three part form, roll working lining cladding material be spheroidal graphite cast-iron, graphitic steel, nickel-chrome-molybdenum alloy cast iron, rich chromium cast iron, cast steel with high chromium, alloy cast steel, high boron alloy steel, high-speed steel, mould steel high-abrasive material; Roller shell inner layer material is rolling, the mild steel of forging or casting, low-alloy steel, medium carbon steel or spheroidal graphite cast-iron, alloy cast iron.
Described mandrel adopts the various material roll or steel-casting or forged steel pieces or ironcasting scrapped.
Described interference fit adopts H7/s6 interference fit.
Described many prismatics wedge angle and the particle that stiff dough is tough is SiC, WC, Al2O3 or mullite.
Described fourplatemold both can realize the adjustment within the specific limits of fourplatemold inner diameter size by the arc water-cooled box assembly adding or reduce different size, meet the manufacture of different different-diameter size compound roller shell, thus reduce mould expense.
The composition of described mandrel surface antioxidizing paint is that Na2B407, Si02, Na20, K20, A1203, CaO one or more one-tenth are wherein grouped into.
beneficial effect
The bushing formula composite roll of sharp roller core capable of circulation of the present invention and manufacture, compared with prior art its main feature is:
1, this invented technology is used to manufacture compound roll shaft, because special casting method makes the metal of melting solidify from bottom to top, be conducive to the feeding of liquid metals, overcome the defect that centre spinning easily produces microstructure segregation, manufactured composite roll shaft material does not have gravity segregation, and crystalline structure is excellent, even tissue, the tiny density of crystal grain is high, and the production of the material can not produced by centre spinning before making becomes possibility.The range of choice of plug and composite material is wide, forging varying strength can being selected freely to require according to different instructions for uses or the composite material of rod cast thereby material and different performance, skin of the roll can adopt high alloy material, makes it have good red hardness and high temperature abrasion resistance.
2, electromagnetic induction heater breaker roll mandrel before cast is adopted directly to carry out preheating in crystallizer, after cast, breaker roll mandrel is incubated with the molten metal poured into a mould, decrease the temperature difference between roller core and outer sphere molten metal, be conducive to the good compound of bimetallic material, there is good mechanical performance.On the other hand in order to reduce casting flaw, metallic composite is allowed to realize to lower and upper consecutive solidification, molten metal flowing from top to bottom automatically, be conducive to molten metal feeding from top to bottom, thus shorten the length in feeding district, decrease casting flaw, form the fine and close composite roll without shrinkage cavity; Continue to carry out electromagnetic induction heating to composite in casting process, can reduce by the preheat temperature of composite, reduce the oxidation of composite, the liquid-solid time can be increased, impel the diffusion of two phase material more abundant, function composite by electromagnetic stirring can be utilized simultaneously, increase liquid metals to washing away by mandrel material surface, promote that the matter and energy between two phase material exchanges, composite bed interface is made to be easy to control, thus greatly improving the bond strength at interface, interface quality is good, can realize good metallurgical bonding interface.
3, the present invention adopts water mold substituted metal type shaping, in roller shell forming process, because roller shell outer sphere molten metal is cooled and solidified in water mold, cooling velocity is high, nucleation ability is strong, the solidified structure that crystal grain is tiny can be obtained, dense structure's degree is high, hardness is even, mechanical property is good, improve obdurability and the thermal fatigue resistance of roll, there is higher wearability and cold-resistant, the properties possessed needed for thermal fatigue and modern roll working layer, and there is excellent machinability, casting and forging can be realized, improve the service life of roll, thus meet the requirement of modern rolling steel industry to high-performance roll.Compound roller shell single through this manufacture technics exceedes former material used new roll more than 20 ~ 30% service life.Comprehensive life improves more than 50%.
4, adopt water mold substituted metal type shaping, the technique recovery rate of foundry goods is high, and liquid metals consumption reduces, and comparable permanent mold casting saves 15 ~ 30%, and using rate of metal is high, has saved material.
5, owing to adopting water mold shaping, the mold use life-span even several ten thousand times up to several thousand times, save Modeling Material greatly, reduce die cost, due to without sand molding, when having saved a large amount of molding sand and moulder, improve efficiency.Save a large amount of manufacturing expenses, reduced manufacturing cost, decrease the waste of resource and the energy and the pollution of environment.
6, adopt the method for castingin to realize the firm compound of the body of roll of high abrasion and high tenacity, high tensile steel tube lining, avoid faying face to ftracture.Roller shell then can be guaranteed overall through hardening, harden, and thus service life is higher, and effect of rolling is better.And when after outer material of roll wearing and tearing, as long as change compound roller shell, roller core is without the need to changing, turn waste into wealth, existing a large amount of useless roll can be recycled, its utilization rate is more than 60%, achieve recycling of roller core, save the waste of material and the energy, decrease environmental pollution.
7, adopt many ribs wedge angle and the tough particle of stiff dough embeds and adds interference fit connecting process, roll structure is stablized, and connecting mode is simple, interface bond strength is high, and security reliability is high, there will not be loosening, the fracture phenomena of roller shell in using, thus simplify processing technology, reduce production cost.
8, cannot guarantee thermal effectiveness because solid roll volume is large, roller shell then can be guaranteed overall through hardening, harden, thus by a relatively large margin improve roll working life, effect of rolling is better.
9, the selection of roll working lining overcoat high-abrasive material and scope of design wider, even with same material, service life is higher; When manufacture for new roll, the range of choice of mandrel material is wide, can adopt the forged steel of high strength, high tenacity, cast steel material, thus improves roll shock resistance, makes without roll breakage in Rolling production, solves the easy roll breakage difficult problem of alloy cast iron roller core.
10, use this technology and equipment to manufacture composite roll cover and there is the production efficiency higher than centrifuging process, and the component segregation overcome existing for Centrifugal compound foundry process and the drawback that cannot manufacture forged steel roll neck roll, controllable process parameters is few, production technology is simply easy to operation, and production efficiency is high, and power consumption is little, production cost is lower than electroslag remelting process by 1/2, lower than submerged arc bead welding method by 2/3, equipment is simply invested little, applied widely.
11, energy-saving and cost-reducingly dirt is subtracted.Because roller shell weight is only 1/3 of solid roll weight, compared with solid roll, often produce one ton of roll, foundry goods will reduce 60%.If plug reuses three times, compared with solid roll, every rolling one ton of steel roll is mutually measured and is reduced 70%.China's ironcasting energy utilization rate is 15 ~ 25%, and the energy consumption of often producing 1 ton of qualified ironcasting is that 500 ~ 700kg marks coal, accounts for 15% of production cost.Whole nation roll output about 1,200,000 tons, the energy saved thus and the pollution of minimizing are huge.
Accompanying drawing explanation
Fig. 1 is present device installation diagram, wherein 1 is depositing funnel, 2 is feed trumpet, 3 is cast runner, 4 is cast seat brick, 5 is roll shaft plug, 6 is insulation ring, 7 is fourplatemold, 8 is electromagnetic induction heater, 9 is attachment bolt, 10 is bottom board, 11 is end water tank, 12 is support plinth, 13 is base support, 14 is lifting motor, 15 is lifting screw, 16 is planer-type region directional solidification jacking equipment, 17 is lifting platform, 18 is pouring ladle, 19 electromagnetic induction electrical power control cabinets, 20 is water-cooled cable, 23 is end tank inlet pipe, 24 is end radiator drain.
Fig. 2 is fourplatemold structure chart of the present invention, and wherein 7 is fourplatemold.
Fig. 3 is fourplatemold arc water-cooled casing modular construction top view of the present invention, and wherein 21 is fourplatemold water inlet pipe, and 22 is fourplatemold outlet pipe, and 7 is crystallizer arc water-cooled box assembly.
Fig. 4 is end cisten mechanism figure of the present invention, and wherein 11 is end water tank, is water inlet pipe, is outlet pipe.
Fig. 5 is the end of the present invention cisten mechanism top view, and wherein 11 is end water tank, and 23 is end tank inlet pipe, and 24 is end radiator drain.
Fig. 6 is composite roll noose composition of the present invention, and wherein 25 is that composite roll roller shell is outer, and 26 is in composite roll roller shell.
Fig. 7 is roller structure figure of the present invention, and wherein 27 is composite roll mosaic coating, and 28 is composite roll mandrel.
Detailed description of the invention
By reference to the accompanying drawings, embodiments of the invention are provided as follows:
Embodiment 1: at Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, in Fig. 7, this equipment has a planer-type region directional solidification jacking equipment 16, planer-type region directional solidification jacking equipment 6 is provided with lifting platform 17, electromagnetic induction heater 8 is installed on lifting platform 17, rotating lifting screw 15 or hydraulic test by lifting motor 14 drives lifting platform 17 to move up and down with set speed, in the side of planer-type region directional solidification jacking equipment 16, electromagnetic induction electrical power control cabinet 19 is installed, two outputs of electromagnetic induction electrical power control cabinet 19 are connected by the two ends of water-cooled cable 20 with electromagnetic induction heating device 8, a base support is had in the bottom of planer-type region directional solidification jacking equipment 16, base support 13 is provided with support plinth 12, Water-cooled bottom water tank 11 is installed on support plinth 12, the center of end water tank 11 is manhole, the center that is provided with on end water tank 11 is the bottom board 10 of manhole, Combined water cooling crystallizer 7 is installed on bottom board 10, on the top of water mold 7, insulation ring 6 is installed, roll shaft plug 5 is by support plinth 12, the center hole of end water tank 11 and bottom board 12 is fixed on the center of crystallizer 7, casting runner 3 is connected with in the side of bottom board 10, casting runner 3 to be arranged on base support 13 and to sit brick 4 with cast and is connected, cast is sat brick 4 and is provided with feed trumpet 2 above, at the top of feed trumpet, sprue cup 1 is installed, pouring ladle 18 is had on depositing funnel 1.
Water inlet pipe 23 and outlet pipe 24 is had respectively in the side of Water-cooled bottom water tank 11; Water mold 7 is made up of the fourplatemold arc water-cooled box assembly 7 at crystallizer circumferentially equally distributed 2 or 3 integral multiples, water inlet pipe 21 is connected with in the bottom of each arc water-cooled box assembly 7, be connected with outlet pipe 22 on the top of each arc water-cooled box assembly 7, by attachment bolt 9, arc water-cooled box assembly 7 connected into drum-shaped entirety; Insulation ring 6 is manufactured by refractory material or fiber reinforcement refractory material; Electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, and frequency is 800Hz.
When work starts: first the low carbon steel thick hollow steel pipe mandrel surface of the required size manufactured is carried out oil removing, after processing of rust removing, one deck antioxidizing paint is applied at its surface uniform, put into after heating furnace carries out being preheating to 550 DEG C, pass through support plinth, the center hole of end water tank and bottom board is fixed on the center of crystallizer, starting region directional solidification lowering or hoisting gear, electromagnetic induction heater is dropped to the bottom of crystallizer, to fetch boiling water the water inlet pipe and water outlet pipe of cooling crystallizer and end water tank, start electromagnetic induction heating power supply, by the induction heater being arranged on water mold outside, surface heating is carried out to thick-wall hollow steel pipe plug, to be heated to after 890 DEG C, the roll compound roller shell outer sphere molten metal of the Ni-Cr-Mo composition smelted is poured in pouring ladle, molten metal in pouring ladle is passed through depositing funnel according to predetermined cast program, feed trumpet, casting runner pours in the space in crystallizer and between thick-wall hollow steel pipe plug, in casting process, electromagnetic induction heater does not stop heating, after pouring metal melt, induction heater proceeds heating 12 minutes, make poured into a mould molten metal within the regular hour, keep liquid, to increase the liquid-solid time, interface is made to form metallurgical binding, electromagnetic induction heater upwards promotes with certain speed by starting region directional solidification lowering or hoisting gear, the roll shaft composite bed progressively departing from electromagnetic induction heating successively consecutive solidification from bottom to top, and in different regions, control the different rates of climb according to quality requirement, forming region directional solidification, be raised to insulation ring place to stop through 6 minutes, continue to carry out heating 15 minutes to insulation ring, to postpone insulated feeder setting time, feeding is carried out to rising head, gas in composite-layer metal liquid and field trash are fully floated, eliminate composite-layer metal casting flaw, heating is stopped after reaching the scheduled time, continue water flowing and cool 14 hours, be high abrasion resisting material by the skin cast, internal layer is high tenacity, the bimetallic compound roller shell of high-strength material takes out in crystallizer,
By machined to finished size for the compound roller shell of founding, after composite roll cover is heat-treated, then 80 objects are had many ribs wedge angle and the particle that stiff dough is tough, binding agent is adopted to be bonded to the bore area of compound roller shell and the outer surface of mandrel respectively uniformly, roller shell is preheating to lower than roller shell temperature 450 DEG C, temperature retention time was directly press fit on mandrel after 8 hours, many ribs wedge angle and the tough particle of stiff dough embeds roller shell internal layer and the outer field surface of mandrel after roller shell cooling, improve interface bond strength, make compound roller shell and mandrel be coupled to an organic whole and form roller shell roll, composite roll after assembling enters stove and cools to room temperature with the furnace.
Embodiment 2: at Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, in Fig. 7, this equipment has a planer-type region directional solidification jacking equipment 16, planer-type region directional solidification jacking equipment 6 is provided with lifting platform 17, electromagnetic induction heater 8 is installed on lifting platform 17, rotating lifting screw 15 or hydraulic test by lifting motor 14 drives lifting platform 17 to move up and down with set speed, in the side of planer-type region directional solidification jacking equipment 16, electromagnetic induction electrical power control cabinet 19 is installed, two outputs of electromagnetic induction electrical power control cabinet 19 are connected by the two ends of water-cooled cable 20 with electromagnetic induction heating device 8, a base support is had in the bottom of planer-type region directional solidification jacking equipment 16, base support 13 is provided with support plinth 12, Water-cooled bottom water tank 11 is installed on support plinth 12, the center of end water tank 11 is manhole, the center that is provided with on end water tank 11 is the bottom board 10 of manhole, Combined water cooling crystallizer 7 is installed on bottom board 10, on the top of water mold 7, insulation ring 6 is installed, roll shaft plug 5 is by support plinth 12, the center hole of end water tank 11 and bottom board 12 is fixed on the center of crystallizer 7, casting runner 3 is connected with in the side of bottom board 10, casting runner 3 to be arranged on base support 13 and to sit brick 4 with cast and is connected, cast is sat brick 4 and is provided with feed trumpet 2 above, at the top of feed trumpet, sprue cup 1 is installed, pouring ladle 18 is had on depositing funnel 1.
Water inlet pipe 23 and outlet pipe 24 is had respectively in the side of Water-cooled bottom water tank 11; Water mold 7 is made up of the fourplatemold arc water-cooled box assembly 7 at crystallizer circumferentially equally distributed 2 or 3 integral multiples, water inlet pipe 21 is connected with in the bottom of each arc water-cooled box assembly 7, be connected with outlet pipe 22 on the top of each arc water-cooled box assembly 7, by attachment bolt 9, arc water-cooled box assembly 7 connected into drum-shaped entirety; Insulation ring 6 is manufactured by refractory material or fiber reinforcement refractory material; Electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, and frequency is 800Hz.
When work starts: first the low-alloy steel thick-wall hollow steel pipe mandrel surface of the required size manufactured is carried out oil removing, after processing of rust removing, one deck antioxidizing paint is applied at its surface uniform, put into after heating furnace carries out being preheating to 650 DEG C, pass through support plinth, the center hole of end water tank and bottom board is fixed on the center of crystallizer, starting region directional solidification lowering or hoisting gear, electromagnetic induction heater is dropped to the bottom of crystallizer, to fetch boiling water the water inlet pipe and water outlet pipe of cooling crystallizer and end water tank, start electromagnetic induction heating power supply, by the induction heater being arranged on water mold outside, surface heating is carried out to thick-wall hollow steel pipe plug, to be heated to after 990 DEG C, the roll compound roller shell outer sphere molten metal of the Ni-Cr-Mo composition smelted is poured in pouring ladle, molten metal in pouring ladle is passed through depositing funnel according to predetermined cast program, feed trumpet, casting runner pours in the space in crystallizer and between thick-wall hollow steel pipe plug, in casting process, electromagnetic induction heater does not stop heating, after pouring metal melt, induction heater proceeds heating 15 minutes, make poured into a mould molten metal within the regular hour, keep liquid, to increase the liquid-solid time, interface is made to form metallurgical binding, electromagnetic induction heater upwards promotes with certain speed by starting region directional solidification lowering or hoisting gear, the roll shaft composite bed progressively departing from electromagnetic induction heating successively consecutive solidification from bottom to top, and in different regions, control the different rates of climb according to quality requirement, forming region directional solidification, be raised to insulation ring place to stop through 7 minutes, continue to carry out heating 20 minutes to insulation ring, to postpone insulated feeder setting time, feeding is carried out to rising head, gas in composite-layer metal liquid and field trash are fully floated, eliminate composite-layer metal casting flaw, heating is stopped after reaching the scheduled time, continue water flowing and cool 18 hours, be high abrasion resisting material by the skin cast, internal layer is high tenacity, the bimetallic compound roller shell of high-strength material takes out in crystallizer,
By machined to finished size for the compound roller shell of founding, after composite roll cover is heat-treated, then 80 objects are had many ribs wedge angle and the particle that stiff dough is tough, binding agent is adopted to be bonded to the bore area of compound roller shell and the outer surface of mandrel respectively uniformly, roller shell is preheating to lower than roller shell temperature 500 DEG C, temperature retention time was directly press fit on mandrel after 10 hours, many ribs wedge angle and the tough particle of stiff dough embeds roller shell internal layer and the outer field surface of mandrel after roller shell cooling, improve interface bond strength, make compound roller shell and mandrel be coupled to an organic whole and form roller shell roll, composite roll after assembling enters stove and cools to room temperature with the furnace.
Embodiment 3: at Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, in Fig. 7, this equipment has a planer-type region directional solidification jacking equipment 16, planer-type region directional solidification jacking equipment 6 is provided with lifting platform 17, electromagnetic induction heater 8 is installed on lifting platform 17, rotating lifting screw 15 or hydraulic test by lifting motor 14 drives lifting platform 17 to move up and down with set speed, in the side of planer-type region directional solidification jacking equipment 16, electromagnetic induction electrical power control cabinet 19 is installed, two outputs of electromagnetic induction electrical power control cabinet 19 are connected by the two ends of water-cooled cable 20 with electromagnetic induction heating device 8, a base support is had in the bottom of planer-type region directional solidification jacking equipment 16, base support 13 is provided with support plinth 12, Water-cooled bottom water tank 11 is installed on support plinth 12, the center of end water tank 11 is manhole, the center that is provided with on end water tank 11 is the bottom board 10 of manhole, Combined water cooling crystallizer 7 is installed on bottom board 10, on the top of water mold 7, insulation ring 6 is installed, roll shaft plug 5 is by support plinth 12, the center hole of end water tank 11 and bottom board 12 is fixed on the center of crystallizer 7, casting runner 3 is connected with in the side of bottom board 10, casting runner 3 to be arranged on base support 13 and to sit brick 4 with cast and is connected, cast is sat brick 4 and is provided with feed trumpet 2 above, at the top of feed trumpet, sprue cup 1 is installed, pouring ladle 18 is had on depositing funnel 1.
Water inlet pipe 23 and outlet pipe 24 is had respectively in the side of Water-cooled bottom water tank 11; Water mold 7 is made up of the fourplatemold arc water-cooled box assembly 7 at crystallizer circumferentially equally distributed 2 or 3 integral multiples, water inlet pipe 21 is connected with in the bottom of each arc water-cooled box assembly 7, be connected with outlet pipe 22 on the top of each arc water-cooled box assembly 7, by attachment bolt 9, arc water-cooled box assembly 7 connected into drum-shaped entirety; Insulation ring 6 is manufactured by refractory material or fiber reinforcement refractory material; Electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, and frequency is 800Hz.
When work starts: first the low carbon steel thick hollow steel pipe mandrel surface of the required size manufactured is carried out oil removing, after processing of rust removing, one deck antioxidizing paint is applied at its surface uniform, put into after heating furnace carries out being preheating to 650 DEG C, pass through support plinth, the center hole of end water tank and bottom board is fixed on the center of crystallizer, starting region directional solidification lowering or hoisting gear, electromagnetic induction heater is dropped to the bottom of crystallizer, to fetch boiling water the water inlet pipe and water outlet pipe of cooling crystallizer and end water tank, start electromagnetic induction heating power supply, by the induction heater being arranged on water mold outside, surface heating is carried out to thick-wall hollow steel pipe plug, to be heated to after 950 DEG C, the roll compound roller shell outer sphere molten metal of the Ni-Cr-Mo composition smelted is poured in pouring ladle, molten metal in pouring ladle is passed through depositing funnel according to predetermined cast program, feed trumpet, casting runner pours in the space in crystallizer and between thick-wall hollow steel pipe plug, in casting process, electromagnetic induction heater does not stop heating, after pouring metal melt, induction heater proceeds heating 18 minutes, make poured into a mould molten metal within the regular hour, keep liquid, to increase the liquid-solid time, interface is made to form metallurgical binding, electromagnetic induction heater upwards promotes with certain speed by starting region directional solidification lowering or hoisting gear, the roll shaft composite bed progressively departing from electromagnetic induction heating successively consecutive solidification from bottom to top, and in different regions, control the different rates of climb according to quality requirement, forming region directional solidification, be raised to insulation ring place to stop through 7 minutes, continue to carry out heating 20 minutes to insulation ring, to postpone insulated feeder setting time, feeding is carried out to rising head, gas in composite-layer metal liquid and field trash are fully floated, eliminate composite-layer metal casting flaw, heating is stopped after reaching the scheduled time, continue water flowing and cool 24 hours, be high abrasion resisting material by the skin cast, internal layer is high tenacity, the bimetallic compound roller shell of high-strength material takes out in crystallizer,
By machined to finished size for the compound roller shell of founding, after composite roll cover is heat-treated, then 80 objects are had many ribs wedge angle and the particle that stiff dough is tough, binding agent is adopted to be bonded to the bore area of compound roller shell and the outer surface of mandrel respectively uniformly, roller shell is preheating to lower than roller shell temperature 450 DEG C, temperature retention time was directly press fit on mandrel after 8 hours, many ribs wedge angle and the tough particle of stiff dough embeds roller shell internal layer and the outer field surface of mandrel after roller shell cooling, improve interface bond strength, make compound roller shell and mandrel be coupled to an organic whole and form roller shell roll, composite roll after assembling enters stove and cools to room temperature with the furnace.
More than show and describe general principle of the present invention, principal character and advantage of the present invention.The technical staff of the industry should understand; the present invention is not by the restriction of step embodiment; the just principle of the present invention described in step embodiment and description; without departing from the spirit and scope of the present invention; design of the present invention can be implemented to use by other various forms; also have various changes and modifications, these changes and improvements equally all fall in the claimed scope of the invention.Application claims protection domain is defined by appending claims and equivalent thereof.
Claims (9)
1. the composite roll manufacturing process of a reusable edible roller core, it is characterized in that: first oil removing is carried out on the thick-wall hollow steel pipe inner layer material surface of material needed for having manufactured and size, after processing of rust removing, one deck antioxidizing paint is applied at its surface uniform, put into after heating furnace carries out being preheating to 500 DEG C ~ 700 DEG C, pass through support plinth, the center hole of end water tank and bottom board is fixed on the center of crystallizer, starting region directional solidification lowering or hoisting gear, electromagnetic induction heater is dropped to the bottom of crystallizer, to fetch boiling water the water inlet pipe and water outlet pipe of cooling crystallizer and end water tank, start electromagnetic induction heating power supply, by the induction heater being arranged on water mold outside, surface heating is carried out to thick-wall hollow steel pipe inner layer material, to be heated to after 800 DEG C ~ 1000 DEG C, the roll compound roller shell outer sphere molten metal of composite parts needed for having smelted is poured in pouring ladle, molten metal in pouring ladle is passed through depositing funnel according to predetermined cast program, feed trumpet, casting runner pours in the space in crystallizer and between thick-wall hollow steel pipe inner layer material, in casting process, electromagnetic induction heater does not stop heating, after pouring metal melt, induction heater proceeds heating 10 ~ 50 minutes, make poured into a mould molten metal within the regular hour, keep liquid, to increase the liquid-solid time, interface is made to form metallurgical binding, electromagnetic induction heater upwards promotes with certain speed by starting region directional solidification lowering or hoisting gear, the roller shell composite bed progressively departing from electromagnetic induction heating successively consecutive solidification from bottom to top, and in different regions, control the different rates of climb according to quality requirement, forming region directional solidification, be raised to insulation ring place to stop through 5 ~ 15 minutes, continue to carry out heating 10 ~ 50 minutes to insulation ring, feeding is carried out to rising head, heating is stopped after reaching the scheduled time, continue water flowing and cool 30 minutes ~ 24 hours, be high abrasion resisting material by the skin cast, internal layer is high tenacity, the bimetallic compound roller shell of high-strength material takes out in crystallizer,
By machined to finished size for the compound roller shell of founding, composite roll cover is heat-treated, then 100 ~ 200 objects are had many ribs wedge angle and the particle that stiff dough is tough, binding agent is adopted to be bonded to the bore area of compound roller shell and the outer surface of mandrel respectively uniformly, roller shell is preheating to lower than roller shell temperature 400 ~ 550 DEG C, temperature retention time was directly press fit on mandrel after 8 ~ 12 hours, many ribs wedge angle and the tough particle of stiff dough embeds roller shell internal layer and the outer field surface of mandrel after roller shell cooling, improve interface bond strength, make compound roller shell and mandrel be coupled to an organic whole and form roller shell roll, composite roll after assembling enters stove and cools to room temperature with the furnace,
The composite roll of described reusable edible roller core is made up of composite roll roller shell skin, composite roll roller shell internal layer and mandrel three part, and composite roller operational layer material is spheroidal graphite cast-iron, graphitic steel, nickel-chrome-molybdenum alloy cast iron, rich chromium cast iron, high chrome, alloy cast steel, high boron alloy steel, high-speed steel, mould steel high-abrasive material; Inner layer material is rolling, the mild steel of forging or casting, low-alloy steel, medium carbon steel or spheroidal graphite cast-iron, alloy cast iron;
Described mandrel adopts the various material roll or steel-casting or forged steel pieces or ironcasting scrapped.
2. one kind realizes the equipment of the composite roll manufacturing process of reusable edible roller core, it is characterized in that: this equipment has a planer-type region directional solidification jacking equipment, planer-type region directional solidification jacking equipment is provided with lifting platform, on lifting platform, electromagnetic induction heater is installed, rotating lifting screw or hydraulic test by lifting motor 14 drives lifting platform to move up and down with set speed, in the side of planer-type region directional solidification jacking equipment, electromagnetic induction electrical power control cabinet is installed, two outputs of electromagnetic induction electrical power control cabinet are connected by the two ends of water-cooled cable with electromagnetic induction heating device, a base support is had in the bottom of planer-type region directional solidification jacking equipment, base support is provided with support plinth, Water-cooled bottom water tank is installed on support plinth, the center of end water tank is manhole, the bottom board that center is manhole is installed on end water tank, Combined water cooling crystallizer is installed on bottom board, on the top of water mold, insulation ring is installed, roll shaft plug passes through support plinth, the center hole of end water tank and bottom board is fixed on the center of crystallizer, casting runner is connected with in the side of bottom board, casting runner to be arranged on base support and to sit brick with cast and is connected, cast is sat above brick and is provided with feed trumpet, at the top of feed trumpet, sprue cup is installed, pouring ladle is had on depositing funnel.
3. the equipment of a kind of composite roll manufacturing process of reusable edible roller core according to claim 2, it is characterized in that: water mold is made up of the fourplatemold arc water-cooled box assembly at crystallizer circumferentially equally distributed 2 or 3 integral multiples, water inlet pipe is connected with in the bottom of each arc water-cooled box assembly, be connected with outlet pipe on the top of each arc water-cooled box assembly, by attachment bolt, arc water-cooled box assembly connected into drum-shaped entirety.
4. the equipment of a kind of composite roll manufacturing process of reusable edible roller core according to claim 2, it is characterized in that: electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, frequency is 500Hz ~ 3000Hz.
5. the equipment of a kind of composite roll manufacturing process of reusable edible roller core according to claim 2, is characterized in that: insulation ring is manufactured by refractory material or fiber reinforcement refractory material.
6. the equipment of a kind of composite roll manufacturing process of reusable edible roller core according to claim 2, it is characterized in that: described fourplatemold both can realize the adjustment within the specific limits of roll inner diameter size by the arc water-cooled box assembly adding or reduce different size, meet the manufacture of different different-diameter size compound roll shaft.
7. the equipment of a kind of composite roll manufacturing process of reusable edible roller core according to claim 2, is characterized in that: have water inlet pipe and outlet pipe respectively in the side of Water-cooled bottom water tank.
8. the composite roll manufacturing process of a kind of reusable edible roller core according to claim 1, is characterized in that: the composition of described mandrel surface antioxidizing paint is that Na2B407, Si02, Na20, K20, A1203, CaO one or more one-tenth are wherein grouped into.
9. the composite roll manufacturing process of a kind of reusable edible roller core according to claim 1, is characterized in that: described many prismatics wedge angle and the particle that stiff dough is tough is SiC, WC, Al2O3 or mullite.
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Application publication date: 20160210 Assignee: Taizhou Haitian Machinery Parts Co., Ltd Assignor: DANYANG HENGQING COMPOSITE MATERIAL TECHNOLOGY Co.,Ltd. Contract record no.: X2020320000006 Denomination of invention: Technique and device for manufacturing composite roller with recyclable roller core Granted publication date: 20171222 License type: Exclusive License Record date: 20200325 |
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