CN110202007B - Method for prolonging service life of roller - Google Patents
Method for prolonging service life of roller Download PDFInfo
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- CN110202007B CN110202007B CN201910606461.6A CN201910606461A CN110202007B CN 110202007 B CN110202007 B CN 110202007B CN 201910606461 A CN201910606461 A CN 201910606461A CN 110202007 B CN110202007 B CN 110202007B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B28/00—Maintaining rolls or rolling equipment in effective condition
- B21B28/02—Maintaining rolls in effective condition, e.g. reconditioning
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Abstract
The invention relates to the technical field of steel smelting, and discloses a method for prolonging the service life of a roller, which comprises the following steps: 1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture. 2) Detecting the loss degree: after the roller is disassembled, an ultrasonic flaw detector is used for penetrating the deep part of the roller by utilizing ultrasonic waves, and after the ultrasonic beams are led into the roller from the surface of the roller by a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, and pulse waveforms are formed on a fluorescent screen. According to the method for prolonging the service life of the roller, the wear degree of the working layer of the roller is detected, whether the working layer of the roller can be recycled or not is judged, then the working layer of the roller is subjected to precision machining, and the surface quality and hardness of the machined roller are improved through alloy powder, so that the roller is changed from a consumable product to a recyclable durable product, the production cost is greatly reduced, and the service life of the roller is prolonged.
Description
Technical Field
The invention relates to the technical field of steel smelting, in particular to a method for prolonging the service life of a roller.
Background
The roller is an important production tool for iron and steel production enterprises. In the rolling production, the roller is in direct contact with a rolled material, so that the deformation process of a rolled piece is participated in, meanwhile, the roller is worn and consumed and generates cracks, and the roller needs to be replaced after reaching a certain rolling tonnage, so that spare part consumption is generated and the operation rate is influenced. Therefore, the requirements of the roll, such as the external dimension, the internal structure, the structure and various properties, have very strict control standards, and for these reasons, the use condition of the roll directly affects the product quality and the production efficiency.
The roller can generate cracks, peeling and fracture failure modes after long-time work, and the roller is expensive, so that the direct scrapping and processing cost is too high, and the processing efficiency is influenced, so that a method for prolonging the service life of the roller is needed.
Disclosure of Invention
Technical problem to be solved
Aiming at the defects of the prior art, the invention provides a method for prolonging the service life of a roller, which has the advantages of prolonging the service life of the roller and improving the processing precision of the roller.
(II) technical scheme
In order to achieve the purposes of prolonging the service life of the roller and improving the processing precision of the roller, the invention provides the following technical scheme: a method of extending the useful life of a roll comprising the steps of:
1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture.
2) Detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating ultrasonic waves into the deep part of the roller, when the ultrasonic beams are led into the roller from the surface of the roller through a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged.
3) Preprocessing a roller: conveying the recyclable roller into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to program a machining program according to the track of the roller.
4) Roller calibration: after the roller is fixed in a hydraulic chuck of a numerical control machine tool, the distance between the roller and the chuck is measured by using a dial indicator, and then the roller is adjusted according to the size of the distance, so that the calibration is completed.
5) Turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method comprises the following steps that part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, main deflection angles of the mechanically-clamped tool holders are selected according to the length-diameter ratio of the rollers, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 7-13%, Si 20-25%, Mo 8-14%, W5-11%, Tic 27-31% and Fe 28-34%.
6) Detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, then spanning two measuring columns of the sine gauge over the concave center area on the flat surface to measure symmetry, and judging whether deviation exists.
Preferably, the alloy powder is replaced by the following raw materials in parts by weight: cr 6-12%, Si 16-22%, Mo 6-12%, W6-12%, Tic 27-33% and Fe 28-34%.
Preferably, the alloy powder is replaced by the following raw materials in parts by weight: cr 7-13%, Si 17-23%, Mo 7-13%, W7-13%, Tic 28-34% and Fe 29-35%.
Preferably, the alloy powder is replaced by the following raw materials in parts by weight: cr 5-11%, Si 15-21%, Mo 5-11%, W5-11%, Tic 26-32% and Fe 27-33%.
Preferably, the alloy powder is replaced by the following raw materials in parts by weight: cr 6-12%, Si 18-24%, Mo 4-10%, W6-12%, Tic 28-34% and Fe 27-33%.
Preferably, the alloy powder is replaced by the following raw materials in parts by weight: cr 7-13%, Si 16-22%, Mo 6-11%, W6-14%, Tic 27-31% and Fe 28-34%.
Preferably, the alloy powder is replaced by the following raw materials in parts by weight: cr 9-10%, Si 21-22%, Mo 9-13%, W6-10%, Tic 23-30% and Fe 25-32%.
Preferably, the alloy powder is replaced by the following raw materials in parts by weight: cr 8-12%, Si21.5-23%, Mo 9-13%, W6-10%, Tic 28-30% and Fe 12-27.5%.
(III) advantageous effects
Compared with the prior art, the invention provides a method for prolonging the service life of a roller, which has the following beneficial effects:
1. according to the method for prolonging the service life of the roller, the wear degree of the working layer of the roller is detected, whether the working layer of the roller can be recycled or not is judged, then the working layer of the roller is subjected to precision machining, and the surface quality and hardness of the machined roller are improved through alloy powder, so that the roller is changed from a consumable product to a recyclable durable product, the production cost is greatly reduced, and the service life of the roller is prolonged.
2. According to the method for prolonging the service life of the roller, the roller is processed through the high-precision numerical control machine tool, the roller is calibrated through the dial indicator before turning, and the roller is detected through the sine gauge, the knife edge ruler, the dial indicator and the magnetic gauge stand measuring tool after the processing is finished, so that the accuracy of the roller is improved, the roller is prevented from deviating, and potential safety hazards are prevented from occurring when the roller is used.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The first embodiment is as follows:
1. a method of extending the useful life of a roll comprising the steps of:
1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture.
2) Detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating ultrasonic waves into the deep part of the roller, when the ultrasonic beams are led into the roller from the surface of the roller through a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged.
3) Preprocessing a roller: conveying the recyclable roller into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to program a machining program according to the track of the roller.
4) Roller calibration: after the roller is fixed in a hydraulic chuck of a numerical control machine tool, the distance between the roller and the chuck is measured by using a dial indicator, and then the roller is adjusted according to the size of the distance, so that the calibration is completed.
5) Turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method is characterized in that a part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, a main deflection angle of the mechanically-clamped tool holder is selected according to the length-diameter ratio of the roller, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 7%, Si 20%, Mo 8%, W10%, Tic 27% and Fe 28%.
6) Detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, and then enabling two measuring columns of the sine gauge to span the concave center area on the flat surface to measure symmetry, so that the influence of the shape error of the flat surface on the shape and position error is avoided, the precision of measuring a roller is improved, and whether deviation exists is judged.
Example two:
1. a method of extending the useful life of a roll comprising the steps of:
1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture.
2) Detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating ultrasonic waves into the deep part of the roller, when the ultrasonic beams are led into the roller from the surface of the roller through a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged.
3) Preprocessing a roller: conveying the recyclable roller into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to program a machining program according to the track of the roller.
4) Roller calibration: after the roller is fixed in a hydraulic chuck of a numerical control machine tool, the distance between the roller and the chuck is measured by using a dial indicator, and then the roller is adjusted according to the size of the distance, so that the calibration is completed.
5) Turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method is characterized in that a part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, a main deflection angle of the mechanically-clamped tool holder is selected according to the length-diameter ratio of the roller, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 8%, Si 19%, Mo 8%, W9%, Tic 28% and Fe 28%.
6) Detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, and then enabling two measuring columns of the sine gauge to span the concave center area on the flat surface to measure symmetry, so that the influence of the shape error of the flat surface on the shape and position error is avoided, the precision of measuring a roller is improved, and whether deviation exists is judged.
Example three:
1. a method of extending the useful life of a roll comprising the steps of:
1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture.
2) Detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating ultrasonic waves into the deep part of the roller, when the ultrasonic beams are led into the roller from the surface of the roller through a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged.
3) Preprocessing a roller: conveying the recyclable roller into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to program a machining program according to the track of the roller.
4) Roller calibration: after the roller is fixed in a hydraulic chuck of a numerical control machine tool, the distance between the roller and the chuck is measured by using a dial indicator, and then the roller is adjusted according to the size of the distance, so that the calibration is completed.
5) Turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method is characterized in that a part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, a main deflection angle of the mechanically-clamped tool holder is selected according to the length-diameter ratio of the roller, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 5%, Si 21%, Mo 9%, W10%, Tic 26% and Fe 29%.
6) Detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, and then enabling two measuring columns of the sine gauge to span the concave center area on the flat surface to measure symmetry, so that the influence of the shape error of the flat surface on the shape and position error is avoided, the precision of measuring a roller is improved, and whether deviation exists is judged.
Example four:
1. a method of extending the useful life of a roll comprising the steps of:
1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture.
2) Detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating ultrasonic waves into the deep part of the roller, when the ultrasonic beams are led into the roller from the surface of the roller through a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged.
3) Preprocessing a roller: conveying the recyclable roller into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to program a machining program according to the track of the roller.
4) Roller calibration: after the roller is fixed in a hydraulic chuck of a numerical control machine tool, the distance between the roller and the chuck is measured by using a dial indicator, and then the roller is adjusted according to the size of the distance, so that the calibration is completed.
5) Turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method is characterized in that a part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, a main deflection angle of the mechanically-clamped tool holder is selected according to the length-diameter ratio of the roller, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 8%, Si 19%, Mo 4%, W11%, Tic 29% and Fe 29%.
6) Detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, and then enabling two measuring columns of the sine gauge to span the concave center area on the flat surface to measure symmetry, so that the influence of the shape error of the flat surface on the shape and position error is avoided, the precision of measuring a roller is improved, and whether deviation exists is judged.
Example five:
1. a method of extending the useful life of a roll comprising the steps of:
1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture.
2) Detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating ultrasonic waves into the deep part of the roller, when the ultrasonic beams are led into the roller from the surface of the roller through a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged.
3) Preprocessing a roller: conveying the recyclable roller into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to program a machining program according to the track of the roller.
4) Roller calibration: after the roller is fixed in a hydraulic chuck of a numerical control machine tool, the distance between the roller and the chuck is measured by using a dial indicator, and then the roller is adjusted according to the size of the distance, so that the calibration is completed.
5) Turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method is characterized in that a part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, a main deflection angle of the mechanically-clamped tool holder is selected according to the length-diameter ratio of the roller, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 7%, Si 18%, Mo 5%, W9%, Tic 28% and Fe 33%.
6) Detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, and then enabling two measuring columns of the sine gauge to span the concave center area on the flat surface to measure symmetry, so that the influence of the shape error of the flat surface on the shape and position error is avoided, the precision of measuring a roller is improved, and whether deviation exists is judged.
Example six:
1. a method of extending the useful life of a roll comprising the steps of:
1) selecting a roller: the rolls were disassembled with cracks, spalling and failure modes of fracture.
2) Detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating ultrasonic waves into the deep part of the roller, when the ultrasonic beams are led into the roller from the surface of the roller through a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged.
3) Preprocessing a roller: conveying the recyclable roller into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to program a machining program according to the track of the roller.
4) Roller calibration: after the roller is fixed in a hydraulic chuck of a numerical control machine tool, the distance between the roller and the chuck is measured by using a dial indicator, and then the roller is adjusted according to the size of the distance, so that the calibration is completed.
5) Turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method is characterized in that a part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, a main deflection angle of the mechanically-clamped tool holder is selected according to the length-diameter ratio of the roller, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 7%, Si 20%, Mo 7%, W7%, Tic 27% and Fe 32%.
6) Detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, and then enabling two measuring columns of the sine gauge to span the concave center area on the flat surface to measure symmetry, so that the influence of the shape error of the flat surface on the shape and position error is avoided, the precision of measuring a roller is improved, and whether deviation exists is judged.
In conclusion, the method for prolonging the service life of the roller judges whether the roller can be recycled or not by detecting the loss degree of the working layer of the roller, then carries out precision processing on the roller, improves the surface quality and hardness of the processed roller by alloy powder, enables the roller to be changed from a consumable into a recyclable durable product, greatly reduces the production cost, prolongs the service life of the roller, processes the roller by a high-precision numerical control machine, calibrates the roller by a dial indicator before turning, and detects the roller by matching with a sine gauge, a knife edge ruler, a dial indicator and a magnetic gauge stand measuring tool after finishing processing, thereby not only improving the precision of the roller, but also avoiding the deviation of the roller and preventing the potential safety hazard when the roller is used.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (8)
1. A method of extending the useful life of a roll, comprising the steps of:
1) selecting a roller: disassembling the roller with cracks, peeling and fracture failure modes;
2) detecting the loss degree: the roller is disassembled, an ultrasonic flaw detector is used for penetrating the deep part of the roller by utilizing ultrasonic waves, when ultrasonic beams are led into the roller from the surface of the roller by a probe, reflected waves are respectively generated when the ultrasonic beams meet defects or the bottom of the roller, pulse waveforms are formed on a fluorescent screen, automatic conversion is carried out according to the highest wave of the defects, and therefore the loss degree of a working layer of the roller is detected, and whether the working layer of the roller can be recycled or not is judged;
3) preprocessing a roller: conveying the roller capable of being recycled into a high-precision numerically controlled lathe, drawing a part map of the roller by using computer drawing software, sequentially capturing nodes, marking the size required during programming, and then utilizing interpolation functions (G00, GO1, GO2 and GO3), preparation functions (G98), cutter functions (T11 and T22), compensation functions (G42 and G40), auxiliary functions (M98, M99 and M30), feeding functions (G04) and multi-cycle functions (G71 and G70) of a machine tool numerical control system to compile a machining program according to the track of the roller;
4) roller calibration: after a roller is fixed in a hydraulic chuck of a numerical control machine tool, measuring the distance between the roller and the chuck by using a dial indicator, and then adjusting the roller according to the size of the distance so as to finish calibration;
5) turning a roller: and (3) replacing the cutter according to the material and hardness of the roller, wherein the common machine clamp cutter handle of the large roller is 40 x 40 square, and the angle of the common cutter rod is a machine clamp turning tool and an arc turning tool with 45 degrees. The method comprises the following steps that part of small-sized rollers adopt a 25-25 mechanically-clamped tool holder and a 32-32 mechanically-clamped tool holder, main deflection angles of the mechanically-clamped tool holders are selected according to the length-diameter ratio of the rollers, a long and thin roller is commonly used for a 90-degree or 75-degree mechanically-clamped turning tool, a robust roller is commonly processed by a 45-degree arc turning tool, alloy powder is sprayed on the surface alloy of the turned roller, the alloy powder is melted and combined with a roller substrate, and the alloy powder formula comprises the following components: cr 7-13%, Si 20-25%, Mo 8-14%, W5-11%, Tic 27-31% and Fe 28-34%;
6) detecting a measuring tool: the method comprises the steps of selecting a sine gauge and a knife edge ruler to be matched with a flat surface for measurement, using the knife edge ruler to check the flatness of the flat surface, finding out the concave center area of the whole flat surface, adsorbing a magnetic gauge seat provided with a dial indicator on a sinusoidal reference plane, then spanning two measuring columns of the sine gauge over the concave center area on the flat surface to measure symmetry, and judging whether deviation exists.
2. The method for prolonging the service life of the roller as claimed in claim 1, wherein the alloy powder is replaced by the following raw materials in parts by weight: cr 6-12%, Si 16-22%, Mo 6-12%, W6-12%, Tic 27-33% and Fe 28-34%.
3. The method for prolonging the service life of the roller as claimed in claim 1, wherein the alloy powder is replaced by the following raw materials in parts by weight: cr 7-13%, Si 17-23%, Mo 7-13%, W7-13%, Tic 28-34% and Fe 29-35%.
4. The method for prolonging the service life of the roller as claimed in claim 1, wherein the alloy powder is replaced by the following raw materials in parts by weight: cr 5-11%, Si 15-21%, Mo 5-11%, W5-11%, Tic 26-32% and Fe 27-33%.
5. The method for prolonging the service life of the roller as claimed in claim 1, wherein the alloy powder is replaced by the following raw materials in parts by weight: cr 6-12%, Si 18-24%, Mo 4-10%, W6-12%, Tic 28-34% and Fe 27-33%.
6. The method for prolonging the service life of the roller as claimed in claim 1, wherein the alloy powder is replaced by the following raw materials in parts by weight: cr 7-13%, Si 16-22%, Mo 6-11%, W6-14%, Tic 27-31% and Fe 28-34%.
7. The method for prolonging the service life of the roller as claimed in claim 1, wherein the alloy powder is replaced by the following raw materials in parts by weight: cr 9-10%, Si 21-22%, Mo 9-13%, W6-10%, Tic 23-30% and Fe 25-32%.
8. The method for prolonging the service life of the roller as claimed in claim 1, wherein the alloy powder is replaced by the following raw materials in parts by weight: cr 8-12%, Si21.5-23%, Mo 9-13%, W6-10%, Tic 28-30% and Fe 12-27.5%.
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| US5460023A (en) * | 1991-09-13 | 1995-10-24 | International Rolling Mill Consultants Inc. | Roll surface restoration system and method |
| CN103042038B (en) * | 2013-01-10 | 2015-06-10 | 北京首钢股份有限公司 | Method for prolonging service life of rolling bearing |
| CN105032939A (en) * | 2015-07-21 | 2015-11-11 | 首钢京唐钢铁联合有限责任公司 | Method for prolonging service life of hot-rolled plate belt roller bearing |
| CN107159714B (en) * | 2017-05-22 | 2018-11-30 | 河钢股份有限公司邯郸分公司 | The method that a kind of pair of cold rolling support roller working face carries out local reconditioning |
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