CN114086068B - High-wear-resistance grinding roller and preparation method thereof - Google Patents

High-wear-resistance grinding roller and preparation method thereof Download PDF

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CN114086068B
CN114086068B CN202111367659.7A CN202111367659A CN114086068B CN 114086068 B CN114086068 B CN 114086068B CN 202111367659 A CN202111367659 A CN 202111367659A CN 114086068 B CN114086068 B CN 114086068B
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insert
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grinding roller
temperature
casting
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CN114086068A (en
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姜利坤
李银玲
亢同庆
石海川
孙佩佩
李勇
王卺
杜劲
王猛
苏国胜
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Qilu University of Technology
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C15/00—Disintegrating by milling members in the form of rollers or balls co-operating with rings or discs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C15/00—Disintegrating by milling members in the form of rollers or balls co-operating with rings or discs
    • B02C15/004—Shape or construction of rollers or balls
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/04—Making ferrous alloys by melting
    • C22C33/06—Making ferrous alloys by melting using master alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/06—Cast-iron alloys containing chromium
    • C22C37/08—Cast-iron alloys containing chromium with nickel
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/10—Cast-iron alloys containing aluminium or silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/001—Ferrous alloys, e.g. steel alloys containing N
    • C—CHEMISTRY; METALLURGY
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    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/42—Ferrous alloys, e.g. steel alloys containing chromium with nickel with copper
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/50—Ferrous alloys, e.g. steel alloys containing chromium with nickel with titanium or zirconium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/58—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding

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  • Food Science & Technology (AREA)
  • Crushing And Grinding (AREA)

Abstract

The invention relates to a high-wear-resistance grinding roller and a preparation method thereof, wherein the high-wear-resistance grinding roller comprises an insert A, an insert B and a base body, wherein the insert A and the insert B are both of a rod-shaped structure with one thick end and one thin end, the rod-shaped structure is embedded in the base body, the thin end surface of the rod-shaped structure is exposed on the surface of the base body and the surface of the base body to form a working surface of the grinding roller, and the thin end surfaces of the insert A and the insert B are uniformly distributed on the surface of the base body in a staggered manner at intervals; the insert A is made of medium and high alloy steel, the insert B is made of ultrahigh alloy cast iron, and the matrix is made of medium alloy steel. Firstly casting an insert A and an insert B, then pre-embedding the insert A and the insert B into a casting mold of a grinding roller, then pouring a base iron liquid of the grinding roller, metallurgically combining the base iron liquid with the insert A and the insert B to obtain a grinding roller blank, and annealing, quenching and tempering the grinding roller blank to obtain a finished grinding roller. The grinding roller has good safety and wear resistance, wide application range, difficult fracture and easy recycling.

Description

High-wear-resistance grinding roller and preparation method thereof
Technical Field
The invention relates to a grinding roller, and belongs to the technical field of metal materials and processing.
Background
The vertical mill is a grinding device applied to cement, glass fiber and other industries, and has the advantages of high yield, high efficiency, energy conservation and the like, so the vertical mill is widely applied in recent years. The grinding roller is a key part of the vertical grinding machine and is also an easily-worn and consumed part, the annual wear consumption is large, and the high-performance wear-resistant grinding roller can reduce the production cost of enterprises and promote energy conservation and emission reduction, so that the development of the high-wear-resistant grinding roller is of great significance.
In recent years, researchers have conducted a lot of research on improving the hardness, toughness, wear resistance, service life and performance of grinding rollers, and several grinding roller materials and products are developed domestically. At present, grinding rollers mainly comprise the following components:
patent CN110449559A discloses a bimetal Raymond machine grinding roller-grinding ring and a double-liquid centrifugal casting method thereof, the invention comprises the following steps: the bimetal Raymond machine grinding roller is cylindrical and is formed into a whole by a working layer and a base body, wherein the working layer and the cylindrical base body are metallurgically combined by a centrifugal casting process, the working layer is made of high-chromium wear-resistant cast iron or high-vanadium high-speed steel, the base body layer is made of nodular cast iron or low-carbon steel, and the material range of the working layer is as follows: the high-chromium wear-resistant cast iron is selected from KmTBGr9Ni5, KmTBGr12, KmTBCr15Mo, KmTBCr8, KmTBCr20Mo or KmTBNi4Cr 2; the high-vanadium high-speed steel has the trademarks of W6Mo5Cr4V2A, W18Gr4V, W6Mo5Cr4V2, W6Mo5Cr4V3, W10MoCr4Val or W6Mo5Gr4V1A 1. The material range of the substrate layer is selected from ZG230-450, ZG270-500, ZG310-570, ZG340-640, QT400-15, QT450, QT500-7 or QT 600. The grinding roller disclosed by the invention is subjected to annealing, quenching and tempering to obtain a finished product, the surface hardness of the working layer is HRC 58-64, the product does not have grinding pits and grooves in use, and the grinding roller is high in hardness and good in wear resistance. The invention mainly adopts cast steel or ductile iron as a matrix, and the surface of the matrix adopts high-chromium cast iron or high-vanadium high-speed steel as the surface using surface. The following disadvantages mainly exist: the base body is cast steel or ductile iron, the appearance is high-chromium cast iron or high-vanadium high-speed steel which are not materials, the expansion coefficients are difficult to be consistent, even if the two materials form metallurgical bonding, the expansion coefficients and the phase transformation points are inconsistent, and cracking under different conditions occurs in the subsequent heat treatment process, so the design structure of the material and the casting process have defects. In addition, although the patent has pictures, various cracking phenomena in the heat treatment process at the later stage are difficult to avoid. Secondly, the quenching process is 810-830 ℃, the temperature is kept for a period of time, then the quenching treatment is carried out, and no matter the material used by the base material (cast steel or ductile iron) or the surface (high-chromium cast iron or high-vanadium high-speed steel), the whole austenitizing is difficult at the temperature.
Patent CN210303870U discloses "coal pulverizer grinding roller", this kind of coal pulverizer grinding roller, grinding roller base member are cyclic annular, and several ceramic rod inlay in the surface of grinding roller base member, and the free end protrusion grinding roller base member of ceramic rod, convex height is 2 ~ 4mm, has increased the area of milling of grinding roller, has improved and has milled output, makes buggy fineness control range wider for the surface hardness of grinding roller is high, whole toughness is good. However, the toughness of the matrix is generally not high, namely 6 to 8j/cm, because the matrix is made of high-chromium cast iron2Second, high chromium cast iron is a metalThe ceramic block is a non-metal material, the ceramic block and the ceramic block are difficult to achieve metallurgical bonding, and the ceramic block is easy to lose effectiveness due to the falling of ceramic and other situations in the use process.
Patent CN 110935864A invented "a method for preparing a surface treatment ZTA particle reinforced steel-based composite grinding roller", which is characterized in that ZTA particles are plated with metal chromium on the surface, then ZTA is vacuum-dried to form a prefabricated body with a honeycomb structure, and the prefabricated body and high-chromium cast iron metal liquid are compositely cast to obtain the ZTA particle reinforced high-wear-resistance grinding roller. The patent states that: the ZTA particles are subjected to the steps of soaking in acetone, acid washing, deionized water washing, drying, low-speed ball milling treatment, surface micro-roughening of the ZTA particles, multi-arc ion plating of Cr, heating treatment of the preform in a low-temperature heat treatment furnace and the like to prepare the preform. And finally, casting the prefabricated body and the high-chromium cast iron liquid to form the composite grinding roller, wherein the prepared grinding roller has good wear resistance because the ceramic is embedded in the high-chromium cast iron matrix. The patent states that the thickness of the ZTA particle Cr layer is 9.6-19.7 μm. However, firstly, ceramics are non-metal, high-chromium cast iron is a metal material, and from the atomic bonding perspective, complete metallization of ceramic particles is difficult to achieve even if surface chromium plating is performed on the ceramic particles, the surface chromium plating is only performed on the surfaces of the ceramic particles, the nature of the ceramics in the ceramic particles is still unchanged, and the ceramics are still easy to peel off and lose efficacy under the conditions of high stress or high hardness in the use process of the grinding roller, so that a plurality of problems of ceramic particle reinforced steel-iron-based composite materials are still needed to be solved. Secondly, the matrix of the patent adopts high-chromium cast iron, and the high-chromium cast iron is selected as the matrix, so that the situation that the toughness is insufficient and the cracking is caused by the insufficient toughness can still be met in the use process.
Patent CN110142103A provides "grinding roller, mill and vertical mill with bulb stud", this invention relates to a grinding roller, mill and vertical mill with bulb stud, this grinding roller includes: a plurality of ball stud bolts are distributed in the plug holes which are uniformly arranged in the circumferential direction of the outer surface of the grinding roller body, and the increase of the surface stamping strength of the grinding roller is realized by plugging a plurality of ball stud bolts which are uniformly arranged on the outer surface of the grinding roller body along the outer surface of the grinding roller bodyThe grinding roller has the advantages that when the grinding roller works, effective gaps for discharging material gas are formed among the uniformly arranged ball stud nails, so that a stable material layer is formed and vibration is reduced more easily in the cement vertical mill. The ball stud is wear-resistant hard alloy steel, so the toughness of the ball stud is low, and the ball stud is generally 3-5 j/cm2Therefore, in the using process, if a harder material or a high stress condition exists, brittle failure can occur, the ball stud is easy to fall off, the grinding roller fails, and normal production is influenced. The material of the matrix is not explicitly stated as to how the spherical stud is specifically bonded to the matrix.
In summary, by comparing and analyzing the prior grinding roller technology, the following defects can be found in the prior technology related to the grinding roller:
firstly, in the selection of grinding roller materials, the focus of comparatively hot in recent years is the combination of grinding roller base body and ceramic material, so that the ceramic composite grinding roller is made, the grinding roller is made of non-metal (ceramic) and metal, the process has the defects that one is non-metal material and the other is metal material, the non-metal material and the metal material are difficult to be combined together, and ceramic particles are easy to fall off due to the infirm combination under the working condition of high stress or high hardness. Therefore, the ceramic and metal composite grinding roller needs to be perfected in many aspects, and the process has many defects.
Secondly, on the selection of the grinding roller substrate, most of the high-chromium cast iron is selected as the substrate, the toughness of the high-chromium cast iron is insufficient, and the impact property is generally 6-8 j/cm (unnotched sample)2The toughness is difficult to meet all working conditions, and the normal production is possibly influenced due to the fact that the toughness is insufficient under the high stress condition, so that the base body of the grinding roller is made of high-chromium cast iron, the using working condition of the grinding roller is limited, and the using range of the grinding roller is limited.
And thirdly, the hardness of the material of the working surface of the grinding roller is not very high generally, and the general surface hardness is HRC 58-64, so that the hardness is difficult to improve the wear resistance of the grinding roller. There is no systematic description of the heat treatment process of the grinding roller in the patent for the heat treatment process of the grinding roller.
Therefore, the development of a composite grinding roller with low cost, good performance, enough toughness of a matrix and enough hardness of a grinding roller insert material is urgently needed to adapt to more working conditions.
Disclosure of Invention
The invention aims to overcome the defects and provide the high-wear-resistance grinding roller and the preparation method thereof, and the all-metal composite grinding roller is used for solving the problems that a single metal grinding roller is not wear-resistant due to insufficient hardness or is fractured due to insufficient toughness, solving the problems that large-area chipping is easy to occur in metal ceramic composite and the grinding roller is invalid, and achieving the purpose of prolonging the service life of the grinding roller.
The technical scheme adopted by the invention is as follows:
a high-wear-resistance grinding roller comprises an insert A, an insert B and a base body, wherein the insert A and the insert B are respectively of a rod-shaped structure with one thick end and one thin end, the rod-shaped structure is embedded in the base body, the thin end surface of the rod-shaped structure is exposed on the surface of the base body and the surface of the base body to form a working surface of the grinding roller, and the thin end surfaces of the insert A and the insert B are uniformly distributed on the surface of the base body in a staggered mode at intervals; the insert A is made of medium and high alloy steel, the insert B is made of ultrahigh alloy cast iron, and the matrix is made of medium alloy steel.
The matrix is made of the following materials in percentage by weight: 0.38-0.48% of C, 1.10-1.37% of Si, 1.97-2.15% of Mn, 3.89-4.17% of Cr, 0.002-0.003% of B, 0.31-0.48% of V, 1.87-1.99% of Mo, 0.61-0.78% of Ni, 0.78-1.06% of Cu, 0.28-0.39% of Nb, 0.05-0.12% of N, 0.03-0.04% of Re, 0.0031-0.0066% of Ba, 0.00056-0.00151% of Zr, 0.021-0.043% of Al, S, P less than or equal to 0.031% of Fe and impurities, and the balance of Fe and impurities, wherein the total amount of impurities is less than or equal to 0.053%.
The insert A is made of the following materials in percentage by weight: 0.638 to 0.748 percent of C, 0.93 to 1.17 percent of Si, 0.87 to 1.15 percent of Mn, 6.89 to 7.27 percent of Cr, 0.003 to 0.004 percent of B, 2.31 to 2.48 percent of V, 1.97 to 2.39 percent of Mo, 0.81 to 0.88 percent of Ni, 0.88 to 1.08 percent of Cu, 0.38 to 0.39 percent of Nb, 0.06 to 0.12 percent of N, 0.53 to 0.64 percent of W, 0.03 to 0.04 percent of Re, 0.0023 to 0.2 percent of Ca, 0.0031 to 0.0066 percent of Ba, 0.00016 to 0.00035 percent of Zr, 0.011 to 0.033 percent of Al, S, P not more than 0.025 percent of impurities and the balance of Fe and impurities, wherein the total amount of Fe and impurities is not more than 0.049 percent.
The insert B is made of the following materials in percentage by weight: 3.838-4.348% of C, 0.83-1.05% of Si, 0.89-1.04% of Mn, 34.89-37.56% of Cr, 0.13-0.23% of B, 2.01-2.16% of V, 1.91-2.09% of Mo, 0.81-0.85% of Ni, 0.68-0.78% of Cu, 0.26-0.31% of Nb, 0.09-0.15% of N, 0.93-1.14% of W, 0.03-0.04% of Re, 0.022-0.045% of Al, S, P-0.032% of Fe and the balance of Fe and impurities, wherein the total amount of the impurities is less than or equal to 0.036%.
The size of the insert A is 15.1-35.8 mm in diameter and 41.3-59.8 mm in length, the diameter of one end of the insert A is 1.82-2.71 mm larger than that of the other end of the insert A, the thick end of the insert A is positioned in the grinding roller base body, and the thin end of the insert A is exposed on the surface of the grinding roller base body.
The size of the insert B is 3.61-8.28 mm in diameter and 41.3-59.8 mm in length, the diameter of one end of the insert B is 0.58-1.62 mm larger than that of the other end, the end with the larger diameter of the insert B is arranged in the grinding roller base body, and the end with the smaller diameter of the insert B is exposed on the surface of the grinding roller base body and forms a working surface of the grinding roller together with the end surface of the fine head of the insert A and the surface of the base body.
The preparation method of the high-wear-resistance grinding roller comprises the following steps: firstly casting an insert A and an insert B, then pre-embedding the insert A and the insert B into a casting mold of a grinding roller, then pouring a base iron liquid of the grinding roller, metallurgically combining the base iron liquid with the insert A and the insert B to obtain a grinding roller blank, and annealing, quenching and tempering the grinding roller blank to obtain a finished grinding roller.
The preparation method specifically comprises the following steps:
preparing an insert A
Preparing raw materials:
weighing scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, ferrotungsten, rare earth ferrosilicon, silicon barium, silicon calcium, aluminum wire and ferrozirconium material;
the modeling is as follows:
utilizing the metal mold to carry out modeling, preheating the metal mold in advance, wherein the preheating temperature is as follows: 158-236 ℃;
smelting raw materials:
smelting raw materials, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, when the temperature of molten iron reaches 1518-1556 ℃, carrying out pre-deoxidation treatment, firstly adding 0.52% ferromanganese, adding 0.23% ferrosilicon after 8-10 minutes, testing the chemical components of the molten iron, adjusting the chemical components of the molten iron to meet the requirements of the medium-high alloy steel, when the temperature of the molten iron in the furnace reaches 1625-1636 ℃, inserting 0.025% aluminum wires, and then discharging;
fourth, inoculation pouring:
and pouring the obtained molten iron into a casting ladle for inoculation, putting an inoculant into the casting ladle before tapping, pouring the inoculant into a metal mold, and cooling to room temperature to obtain the insert A.
(II) preparing the insert B
Preparing raw materials:
weighing pig iron, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, ferrochromium nitride, ferrotungsten, rare earth ferrosilicon and aluminum wires;
the modeling is as follows:
utilizing the metal mold to mold, preheating the metal mold in advance, wherein the preheating temperature is as follows: 138-196 ℃;
smelting raw materials:
smelting raw materials, wherein the smelting sequence is carried out according to the sequence of pig iron, scrap steel, alloy and precious metal, when the temperature of molten iron reaches 1468-1506 ℃, carrying out pre-deoxidation treatment, adding 0.61% ferromanganese, adding 0.03% ferrosilicon and 0.041% ferrochromium nitride after 6 minutes, then adjusting chemical components to ensure that the weight percentage of the chemical components meets the requirements of the ultrahigh alloy cast iron, continuing smelting, when the temperature of the molten iron reaches 1556-1566 ℃, preserving heat for 8-10 minutes, fully standing the molten iron, floating slag, and timely slagging, when the temperature of the molten iron is 1539-1546 ℃, inserting 0.018% aluminum wires, then discharging, and timely discharging the molten iron;
fourth, inoculation pouring:
and pouring the obtained molten iron into a casting ladle for inoculation, putting an inoculant into the casting ladle before tapping, pouring the inoculant into a metal mold, and cooling to room temperature to obtain the insert B.
(III) preparing the composite grinding roller
Preparing raw materials:
weighing scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, rare earth ferrosilicon, silicon barium, aluminum wire and ferrozirconium material.
The modeling is as follows:
welding the thin ends of the insert A and the insert B with nails respectively, then inserting the nails into the casting mold, and enabling the insert A and the insert B to be distributed on the working surface of the grinding roller in a staggered manner respectively, wherein the distance between the insert A and the insert A is kept to be 1.47-1.53 times of the diameter of the thin end of the insert A, the distance between the insert B and the insert B is kept to be 1.15-1.21 times of the diameter of the thin end of the insert B, the insert A and the insert B are uniformly distributed on the working surface, and before casting, the insert A and the insert B are preheated to 186-245 ℃;
smelting of base raw materials
Smelting raw materials, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, when the temperature of molten iron reaches 1548-1565 ℃, carrying out pre-deoxidation treatment, firstly adding 0.43% ferromanganese, adding 0.013% ferrosilicon after 10 minutes, testing the chemical components of the molten iron, adjusting the chemical components of the molten iron to meet the requirements of the medium alloy steel, when the temperature of the molten iron in a furnace reaches 1628-1635 ℃, inserting 0.023% aluminum wires, and then discharging the molten iron;
fourth, inoculation pouring:
pouring the obtained molten iron into a casting ladle for inoculation, putting an inoculant into the casting ladle before tapping, pouring the inoculant into a grinding roller casting mold, cooling to room temperature, and opening the mold;
and fifthly, cleaning and polishing to obtain a composite casting grinding roller blank.
(IV) Heat treatment of grinding rolls
Annealing: charging the obtained grinding roller blank and carrying out annealing treatment;
the annealing treatment process comprises the following steps: controlling the temperature of the casting entering the furnace to be below 185 ℃, controlling the heating rate to be 28-36 ℃/h below 300 ℃, keeping the temperature for 1 h at 300 ℃, controlling the heating rate to be 38-55 ℃/h between 300 ℃ and 650 ℃, keeping the temperature for 1.5 h at 650 ℃, controlling the heating rate to be 58-65 ℃/h between 650 ℃ and 1000 ℃, keeping the temperature for 3.5-5.5 h at 1000 ℃, properly adjusting the wall thickness of the casting, keeping the temperature at 1000 ℃, and cooling the casting in the furnace along with the furnace;
and (2) roughing: carrying out rough machining on the grinding roller obtained after annealing;
quenching: charging the grinding roller blank obtained by rough machining, and quenching;
the quenching treatment process comprises the following steps: controlling the temperature of a cast entering a furnace to be below 178 ℃, controlling the heating rate to be 38-45 ℃/h below 300 ℃, keeping the temperature for 1 h at 300 ℃, controlling the heating rate to be 48-56 ℃/h between 300 ℃ and 650 ℃, keeping the temperature for 1.5 h at 650 ℃, controlling the heating rate to be 65-71 ℃/h between 650 ℃ and 1020 ℃, keeping the temperature for 3.5-4.5 h at 1018 ℃ and 1020 ℃ of the cast, properly adjusting the temperature according to the wall thickness of the cast, discharging the cast and quenching the cast, wherein the quenching adopts an air cooling and spraying (water mist) mode, starting air cooling and spraying after the cast is discharged from the furnace, stopping spraying when the temperature of the cast is reduced to be below 698 ℃, continuing air cooling, cooling the cast to be below 396 ℃, stopping blowing and naturally cooling the cast in the air;
fourthly, tempering: re-charging the quenched casting, and tempering;
and (3) tempering process: controlling the charging temperature of the casting below 168 ℃, controlling the heating rate below 280 ℃ to be 38-45 ℃/h, preserving the heat at 280 ℃ for 5-8 h, discharging the casting after the heat preservation time is up, and naturally cooling the casting in the air;
and fifthly, carrying out finish machining on the tempered grinding roller according to the drawing requirements.
Sixthly, performing hardness and impact toughness detection on the finished product of the grinding roller by ultrasonic flaw detection.
And packaging and warehousing grinding roller finished products meeting the drawing requirements.
The inoculant adopted by the insert A in the preparation method is as follows: 0.151 percent of silicon calcium, 0.127 percent of silicon barium, 0.311 percent of rare earth ferrosilicon and 0.035 percent of zirconium iron are processed by a punching and packing method. The inoculant adopted by the insert B is as follows: 0.148 percent of ferroboron, 0.21 percent of ferrovanadium, 0.33 percent of rare earth ferrosilicon and 0.035 percent of ferrochromium nitride are processed by a punching and covering method. The inoculant adopted by the matrix is as follows: 0.13 percent of silicon-barium, 0.23 percent of ferrovanadium, 0.35 percent of rare earth ferrosilicon and 0.185 percent of ferrozirconium are processed by a punching and packing method.
The invention has the beneficial effects that:
(1) the grinding roller is made of metal materials, the grinding roller matrix is made of medium alloy steel, the insert A is made of medium alloy steel, the insert B is made of ultrahigh alloy cast iron, and the three selected materials are all made of metal materials.
(2) The abrasive resistance of the grinding roller is 2.5-3 times that of a single high-chromium cast iron grinding roller. Because of the medium chromium alloy steel (Cr4 series) for the matrix, the matrix hardness reaches: HRC 45.5-52.5, and the impact performance reaches: 171 to 238j/cm2(ii) a The insert A is made of medium and high alloy steel (Cr7 series), and the mechanical property of the grinding roller insert A is as follows: the impact toughness (no notch of the sample) is 19.5 to 32.5j/cm2(ii) a Hardness: HRC 58.5-61.5, which not only ensures enough toughness, but also ensures enough hardness; the insert B is made of ultra-high alloy cast iron (Cr35 series), and the mechanical property of the insert B is as follows: impact toughness (no notch in the test specimen): 6.5 to 13j/cm2Hardness: HRC 63.5-68.5, and enough hardness is ensured to improve the wear resistance of the grinding roller; the hardness of the grinding roller matrix reaches: HRC 45.5-52.5, and the impact performance reaches: 171 to 238j/cm2The grinding roller has certain hardness and enough toughness, and the use safety of the grinding roller is ensured.
(3) The insert A and the insert B adopt unique design structures, so that the falling off in the use process can be effectively prevented, the safe use is ensured, and the wear resistance is improved together; insert A, insert B is the thick stick-shaped structure of one end and one end thin, insert A diameter is greater than insert B, medium and high alloy steel has been selected as insert A during the design material, guarantee sufficient toughness, make insert A the condition that fracture can not appear, insert A and insert B all have certain toughness, more importantly insert A and insert B hardness rise step by step, insert B as the dispersion distribution hard particles in the middle of insert A, both cross distribution in base member surface, the intercrossing mutual complement, the grinding roller base member, insert A, insert B three mutually promotes not only has guaranteed the security, especially have had the improvement of matter at the wearability, insert A and insert B have reached the purpose that improves the grinding roller wearability jointly.
(3) Compared with the ceramic-metal composite grinding roller, the composite grinding roller has the advantages that the grinding roller is easy to recycle, and various problems can be encountered when the ceramic composite grinding roller is recycled after being used.
In conclusion, the grinding roller has good safety and wear resistance and wide application range. The grinding roller has excellent wear resistance, can cope with various complex working conditions, can cope with the phenomena of fracture, poor wear resistance and the like due to insufficient toughness and hardness of the grinding roller under the working conditions of high stress and hard materials, greatly improves the operating efficiency of a machine, reduces the replacement times, and has remarkable economic and social benefits and better market prospect and application range.
Table 1 shows the comparison of the indexes of several grinding rollers
Figure BDA0003361234330000071
Figure BDA0003361234330000081
Drawings
FIG. 1 is a schematic structural view of a high abrasion resistant grinding roller according to the present invention;
FIG. 2 is a schematic view of the local structural distribution of the working surface of the high abrasion resistant grinding roller of the present invention;
FIG. 3 is a view taken along line A-A of FIG. 2;
FIG. 4 is a metallographic structure (200 times) of a grinding roller substrate of the invention, after heat treatment, corroded with 4% nitrol;
FIG. 5 is a metallographic (200 times) representation of the structure of an insert A of the invention after 4% nitrol etching after heat treatment;
FIG. 6 is a metallographic (200 times) representation of the inventive insert B after 4% nitrol etching after heat treatment.
The novel high-strength high-.
Detailed Description
The following is a further description with reference to specific examples.
Example 1:
preparing an insert A
First, a raw material is prepared
Weighing scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, ferrotungsten, rare earth ferrosilicon, silicon barium, silicon calcium, aluminum wire and ferrozirconium.
The second step of modeling
Utilizing the metal mold to carry out modeling, preheating the metal mold in advance, wherein the preheating temperature is as follows: 188 ℃.
Thirdly, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, when the temperature of molten iron reaches 1556 ℃, carrying out pre-deoxidation treatment, adding 0.52% ferromanganese firstly, adding 0.23% ferrosilicon after 10 minutes, testing the chemical components of the molten iron, and adjusting the chemical components of the molten iron. When the temperature of the molten iron in the furnace reaches 1636 ℃, a 0.025 percent aluminum wire is inserted, and then the furnace is taken out.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.151 percent of silicon calcium, 0.127 percent of silicon barium, 0.311 percent of rare earth ferrosilicon and 0.035 percent of ferrozirconium, before tapping, the inoculant is placed into the casting ladle and is poured into a metal mold, and the insert A is obtained after cooling to room temperature.
The size of the insert A is a cylinder with the diameter of 35.8mm, the height of the insert A is 59.8mm, the insert A is of a rod-shaped structure, the diameter of one end of the insert A is 1.82mm larger than that of the other end of the insert A, the end with the larger diameter of the insert A is arranged in the parent body of the grinding roller, and the end with the smaller diameter of the insert A is exposed on the surface of the grinding roller.
The insert A comprises the following chemical components in percentage by weight: 0.698 percent of C, 0.99 percent of Si, 0.97 percent of Mn, 6.99 percent of Cr, 0.0035 percent of B, 2.35 percent of V, 2.19 percent of Mo, 0.85 percent of Ni, 0.98 percent of Cu, 0.381 percent of Nb, 0.08 percent of N, 0.57 percent of W, 0.035 percent of Re, 0.0026 percent of Ca, 0.0041 percent of Ba, 0.00018 percent of Zr, 0.021 percent of Al, 0.02 percent of S, 0.021 percent of P and the balance of Fe and impurities.
(II) preparing an insert B
First, a raw material is prepared
Weighing pig iron, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, ferrochromium nitride, ferrotungsten, rare earth ferrosilicon and aluminum wire materials. The second step of modeling
Utilizing the metal mold to carry out modeling, preheating the metal mold in advance, wherein the preheating temperature is as follows: 189 deg.C.
The third step, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of pig iron, scrap steel, alloy and precious metal, when the temperature of molten iron reaches 1488 ℃, carrying out pre-deoxidation treatment, adding 0.61% ferromanganese, adding 0.03% ferrosilicon and 0.041% ferrochromium nitride after 6 minutes, then adjusting chemical components, continuing smelting, when the temperature of the molten iron reaches 1558 ℃, keeping the temperature for 8 minutes, fully standing the molten iron, floating slag, and timely slagging, when the temperature of the molten iron is 1545 ℃ after 8 minutes, inserting 0.018% aluminum wires, then discharging, and timely discharging the molten iron.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.148% of ferroboron, 0.21% of ferrovanadium, 0.33% of rare earth ferrosilicon and 0.035% of ferrochromium nitride, before tapping, the inoculant is placed into the casting ladle and poured into a metal mold, and the insert B is obtained after cooling to room temperature.
The size of the insert B is a cylinder with the diameter of 8.28mm, the height of the insert B is 59.8mm, the insert B is of a rod-shaped structure, the diameter of one end of the insert B is 1.62mm larger than that of the other end of the insert B, the end with the larger diameter of the insert B is positioned in the parent body of the grinding roller, and the end with the smaller diameter of the insert B is exposed on the surface of the grinding roller.
The insert B comprises 3.988% of C, 0.99% of Si, 0.97% of Mn, 36.89% of Cr, 0.18% of B, 2.07% of V, 1.96% of Mo, 0.83% of Ni, 0.69% of Cu, 0.28% of Nb, 0.12% of N, 0.98% of W, 0.033% of Re, 0.026% of Al, 0.03% of S, 0.03% of P and the balance of Fe and impurities by weight percentage.
(III) preparing the composite grinding roller
First, a raw material is prepared
Weighing scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, rare earth ferrosilicon, silicon barium, aluminum wire and ferrozirconium material.
The second step of modeling
And (2) respectively welding the thin ends of the insert A and the insert B with nails, then inserting the nails into the casting mold, so that the insert A and the insert B are respectively and crossly distributed on the working surface of the grinding roller, wherein the distance between the insert A and the insert A is kept to be 1.5 times of the diameter of the insert A, the distance between the insert B and the insert B is kept to be 1.16 times of the diameter of the insert B, the insert A and the insert B are uniformly distributed on the working surface, and the insert A and the insert B are preheated to 216 ℃ before casting.
The third step, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, carrying out pre-deoxidation treatment when the temperature of molten iron reaches 1558 ℃, adding 0.43% ferromanganese, adding 0.013% ferrosilicon after 10 minutes, testing the chemical components of molten iron, adjusting the chemical components of the molten iron, inserting 0.023% aluminum wires when the temperature of the molten iron in the furnace reaches 1629 ℃, and then discharging.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.13% of silicon-barium, 0.23% of ferrovanadium, 0.35% of rare earth ferrosilicon and 0.185% of ferrozirconium, before tapping, the inoculant is placed into the casting ladle, poured into a casting mold, cooled to room temperature, and opened.
The grinding roller base body comprises, by weight, 0.42% of C, 1.11% of Si, 1.99% of Mn, 3.99% of Cr, 0.0021% of B, 0.36% of V, 1.97% of Mo, 0.67% of Ni, 0.88% of Cu, 0.34% of Nb, 0.08% of N, 0.033% of Re, 0.0036% of Ba, 0.00076% of Zr, 0.028% of Al, 0.03% of S, 0.03% of P, and the balance of Fe and impurities.
Fifthly, cleaning and polishing.
And cleaning and polishing the casting obtained in the fourth step to obtain the composite casting grinding roller blank.
(IV) grinding roller heat treatment
First step, annealing
And (4) charging the obtained grinding roller blank and carrying out annealing treatment. The annealing treatment process comprises the following steps: the temperature of the casting entering the furnace is controlled below 185 ℃ and below 300 ℃, the heating rate is controlled at 36 ℃/h, the temperature is kept at 300 ℃ for 1 h and 300-650 ℃, the heating rate is controlled at 55 ℃/h, the temperature is kept at 650 ℃ for 1.5 h and 650-1000 ℃, the heating rate is controlled at 65 ℃/h, the temperature of the casting is kept at 1000 ℃ for 5.5 h, and the temperature is properly adjusted according to the wall thickness of the casting. After the temperature is kept at 1000 ℃, the furnace is cooled in the furnace.
Secondly, rough machining
The grinding roller obtained after annealing is subjected to rough machining.
A third step of quenching
And (4) charging the grinding roller blank obtained by rough machining and quenching. The quenching treatment process comprises the following steps: the temperature of the casting entering the furnace is controlled below 178 ℃ and below 300 ℃, the heating rate is controlled at 45 ℃/h, the temperature is kept at 300 ℃ for 1 h and 300-650 ℃, the heating rate is controlled at 56 ℃/h, the temperature is kept at 650 ℃ for 1.5 h and 650-1020 ℃, the heating rate is controlled at 71 ℃/h, the temperature of the casting is kept at 1018-1020 ℃ for 4.5 h, and the temperature is properly adjusted according to the wall thickness of the casting. And after heat preservation, discharging, quenching, wherein the quenching adopts a mode of air cooling and spraying (water mist), the air cooling and spraying are started after the casting is discharged, the spraying is stopped when the temperature of the casting is reduced to below 698 ℃, the air cooling is continued until the temperature is reduced to below 396 ℃, the blowing is stopped, and the casting is naturally cooled in the air.
Fourthly, tempering
And (3) re-charging the quenched casting, tempering, and tempering: controlling the charging temperature of the casting below 168 ℃ and below 280 ℃, controlling the heating rate at 45 ℃/h, keeping the temperature for 8 h at 280 ℃, discharging the casting after the heat preservation time is up, and naturally cooling the casting in the air.
Fifthly, finely machining
And (4) carrying out finish machining on the tempered grinding roller according to the requirements of a drawing.
Sixthly, detecting quality
And (4) carrying out hardness, impact toughness and ultrasonic flaw detection on the grinding roller finished product.
Performance indexes are as follows: the mechanical properties of the matrix are as follows: impact properties (no specimen notch): 218j/cm2HRC 49.5. The insert A has the following mechanical properties: impact toughness (unnotched sample) 23.5j/cm2: hardness: HRC 59.5. The insert B has the mechanical properties that: impact toughness (no notch in the test specimen): 12j/cm2Hardness: HRC 66.5.
The fifth step of carriage and packing
And packaging and warehousing the grinding roller finished products meeting the drawing requirements.
Example 2
Preparing an insert A
First, a raw material is prepared
Weighing materials such as scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, ferrotungsten, rare earth ferrosilicon, silicon barium, silicon calcium, aluminum wire, ferrozirconium and the like.
The second step of modeling
Utilizing the metal mold to carry out modeling, preheating the metal mold in advance, wherein the preheating temperature is as follows: 236 ℃.
Thirdly, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, carrying out pre-deoxidation treatment when the temperature of molten iron reaches 1548 ℃, adding 0.52% ferromanganese firstly, adding 0.23% ferrosilicon after 10 minutes, testing the chemical composition of molten iron, and adjusting the chemical composition of the molten iron. When the temperature of the molten iron in the furnace reaches 1626 ℃, a 0.025 percent aluminum wire is inserted, and then the molten iron is discharged.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.151 percent of silicon calcium, 0.127 percent of silicon barium, 0.311 percent of rare earth ferrosilicon and 0.035 percent of ferrozirconium, before tapping, the inoculant is placed into the casting ladle and is poured into a metal mold, and the insert A is obtained after cooling to room temperature.
The size of the insert A is a cylinder with the diameter of 25.1mm, the height of the insert A is 55.8mm, the insert A is in a rod-shaped structure, the diameter of one end of the insert A is 1.92mm larger than that of the other end of the insert A, the end with the larger diameter of the insert A is arranged in the grinding roller base body, and the end with the smaller diameter of the insert A is exposed on the surface of the grinding roller.
The insert A comprises the following chemical components in percentage by weight: 0.748% of C, 1.17% of Si, 1.15% of Mn, 7.27% of Cr, 0.004% of B, 2.48% of V, 2.39% of Mo, 0.88% of Ni, 1.08% of Cu, 0.39% of Nb, 0.12% of N, 0.64% of W, 0.04% of Re, 0.0025% of Ca, 0.0041% of Ba, 0.00018% of Zr, 0.021% of Al, 0.02% of S, 0.02% of P and the balance of Fe and impurities.
(II) preparing an insert B
First, a raw material is prepared
Weighing raw iron, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, ferrochromium nitride, ferrotungsten, rare earth ferrosilicon, aluminum wire and other materials.
The second step of modeling
Utilizing the metal mold to carry out modeling, preheating the metal mold in advance, wherein the preheating temperature is as follows: 185 ℃ C.
The third step, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of pig iron, scrap steel, alloy and precious metal, pre-deoxidation treatment is carried out when molten iron reaches 1506 ℃, 0.61% ferromanganese is added, 0.03% ferrosilicon and 0.041% ferrochromium nitride are added after 6 minutes, then chemical components are adjusted, smelting is continued, heat preservation is carried out for 8 minutes when the molten iron reaches 1566 ℃, the molten iron is fully kept stand, at the moment, slag floats upwards and is timely slagged, after 8 minutes, when the temperature of the molten iron is 1546 ℃, 0.018% aluminum wires are inserted, then discharging is carried out, and the molten iron is timely discharged.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.148% of ferroboron, 0.21% of ferrovanadium, 0.33% of rare earth ferrosilicon and 0.035% of ferrochromium nitride, before tapping, the inoculant is placed into the casting ladle and poured into a metal mold, and the insert B is obtained after cooling to room temperature.
The insert B is a cylinder with the diameter of 6.28mm, the height of the insert B is 49.8mm, the insert B is of a rod-shaped structure, the diameter of one end of the insert B is 0.88mm larger than that of the other end of the insert B, the end with the larger diameter of the insert B is arranged in the grinding roller base body, and the end with the smaller diameter of the insert B is exposed on the surface of the grinding roller.
The insert B comprises 4.348 wt% of C, 1.05 wt% of Si, 1.04 wt% of Mn, 37.56 wt% of Cr, 0.23 wt% of B, 2.16 wt% of V, 2.09 wt% of Mo, 0.85 wt% of Ni, 0.78 wt% of Cu, 0.31 wt% of Nb, 0.15 wt% of N, 1.14 wt% of W, 0.04 wt% of Re, 0.032 wt% of Al, 0.03 wt% of S, 0.032 wt% of P, and the balance Fe and impurities.
(III) preparing the composite grinding roller
First, a raw material is prepared
Weighing materials such as scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, rare earth ferrosilicon, silicon barium, aluminum wire, ferrozirconium and the like.
The second step of modeling
The method comprises the following steps of respectively welding the thin ends of the diameter of the insert A and the diameter of the insert B by using nails, then inserting the nails into a casting mold, and enabling the insert A and the insert B to be respectively distributed on the working surface of a grinding roller in a crossed manner, wherein the distance between the insert A and the insert A is 1.53 times of the diameter of the insert A, the distance between the insert B and the insert B is 1.21 times of the diameter of the insert B, the insert A and the insert B are uniformly distributed on the working surface, and before casting, the insert A and the insert B are preheated to 245 ℃.
The third step, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, carrying out pre-deoxidation treatment when the temperature of molten iron reaches 1565 ℃, adding 0.43% ferromanganese, adding 0.013% ferrosilicon after 10 minutes, testing the chemical components of molten iron, adjusting the weight percentage of the chemical components of the molten iron, inserting 0.023% aluminum wires when the temperature of the molten iron in the furnace reaches 1635 ℃, and then discharging.
Fourth step of inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.13% of silicon-barium, 0.23% of ferrovanadium, 0.35% of rare earth ferrosilicon and 0.185% of ferrozirconium, before tapping, the inoculant is placed into the casting ladle, poured into a casting mold, cooled to room temperature, and opened.
The grinding roller substrate comprises the following chemical components in percentage by mass: 0.48 percent of C, 1.37 percent of Si, 2.15 percent of Mn, 4.17 percent of Cr, 0.003 percent of B, 0.48 percent of V, 1.99 percent of Mo, 0.78 percent of Ni, 1.06 percent of Cu, 0.39 percent of Nb, 0.12 percent of N, 0.04 percent of Re, 0.0031 percent of Ba, 0.00076 percent of Zr, 0.026 percent of Al, 0.03 percent of S, 0.032 percent of P, and the balance of Fe and impurities. Fifthly, cleaning and polishing
And cleaning and polishing the casting obtained in the fourth step to obtain the composite casting grinding roller blank.
(IV) Heat treatment of grinding rolls
First step, annealing
And (4) charging the obtained grinding roller blank and carrying out annealing treatment. The annealing treatment process comprises the following steps: the temperature of the casting entering the furnace is controlled below 185 ℃ and below 300 ℃, the heating rate is controlled at 36 ℃/h, the temperature is kept at 300 ℃ for 1 h and 300-650 ℃, the heating rate is controlled at 55 ℃/h, the temperature is kept at 650 ℃ for 1.5 h and 650-1000 ℃, the heating rate is controlled at 65 ℃/h, the temperature of the casting is kept at 1000 ℃ for 5.5 h, and the temperature is properly adjusted according to the wall thickness of the casting. After the temperature is kept at 1000 ℃, the furnace is cooled in the furnace.
Secondly, rough machining
The grinding roller obtained after annealing is subjected to rough machining.
A third step of quenching
And (4) charging the grinding roller blank obtained by rough machining and quenching. The quenching treatment process comprises the following steps: the temperature of the casting entering the furnace is controlled below 178 ℃ and below 300 ℃, the heating rate is controlled at 45 ℃/h, the temperature is kept at 300 ℃ for 1 h and 300-650 ℃, the heating rate is controlled at 56 ℃/h, the temperature is kept at 650 ℃ for 1.5 h and 650-1020 ℃, the heating rate is controlled at 71 ℃/h, the temperature of the casting is kept at 1020 ℃ for 4.5 h, and the temperature is properly adjusted according to the wall thickness of the casting. And after heat preservation, discharging, quenching, wherein the quenching adopts a mode of air cooling and spraying (water mist), the air cooling and spraying are started after the casting is discharged, the spraying is stopped when the temperature of the casting is reduced to below 698 ℃, the air cooling is continued until the temperature is reduced to below 396 ℃, the blowing is stopped, and the casting is naturally cooled in the air.
Fourthly, tempering
And (3) re-charging the quenched casting, tempering, and tempering: the temperature of the cast entering the furnace is controlled below 168 ℃ and below 280 ℃, the temperature rising speed is controlled at 45 ℃/h, and the temperature is kept for 8 h at 280 ℃. And after the heat preservation time is up, discharging the furnace, and naturally cooling the furnace in the air.
Fifthly, finishing
And (4) carrying out finish machining on the tempered grinding roller according to the requirements of a drawing.
Sixthly, detecting quality
And (4) carrying out hardness, impact toughness and ultrasonic flaw detection on the finished grinding roller.
Performance indexes are as follows: the mechanical properties of the grinding roller substrate are as follows: impact properties (no specimen notch): 171j/cm2HRC 52.5. The insert A has the following mechanical properties: impact toughness (unnotched sample) 29.5j/cm2: hardness: HRC 61.5. The insert B has the mechanical properties that: impact toughness (no notch in the test specimen): 12j/cm2Hardness: HRC 65.5.
The fifth step, packing and warehousing
And packaging and warehousing the grinding roller finished products meeting the drawing requirements.
Example 3
Preparing an insert A
First, a raw material is prepared
Weighing scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, ferrotungsten, rare earth ferrosilicon, silicon barium, silicon calcium, aluminum wire and ferrozirconium material.
The second step of modeling
Utilizing the metal mold to mold, preheating the metal mold in advance, wherein the preheating temperature is as follows: 236 deg.c.
The third step, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, when the temperature of molten iron reaches 1556 ℃, carrying out pre-deoxidation treatment, adding 0.52% ferromanganese firstly, adding 0.23% ferrosilicon after 10 minutes, testing the chemical components of the molten iron, and adjusting the chemical components of the molten iron. When the temperature of the molten iron in the furnace reaches 1636 ℃, a 0.025 percent aluminum wire is inserted, and then the furnace is taken out.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.151 percent of silicon calcium, 0.127 percent of silicon barium, 0.311 percent of rare earth ferrosilicon and 0.035 percent of ferrozirconium, before tapping, the inoculant is placed into the casting ladle and is poured into a metal mold, and the insert A is obtained after cooling to room temperature.
The size of the insert A is a cylinder with the diameter of 15.1mm, the height of the insert A is 41.3mm, the insert A is of a rod-shaped structure, the diameter of one end of the insert A is 1.82mm larger than that of the other end of the insert A, the thick end of the insert A is positioned in the grinding roller base body, and the thin end of the insert A is exposed on the surface of the grinding roller.
The weight percentage of the insert A is as follows: 0.638% of C, 0.93% of Si, 0.87% of Mn, 6.89% of Cr, 0.003% of B, 2.31% of V, 1.97% of Mo, 0.81% of Ni, 0.88% of Cu, 0.38% of Nb, 0.06% of N, 0.53% of W, 0.03% of Re, 0.0025% of Ca, 0.0035% of Ba, 0.00018% of Zr, 0.019% of Al, 0.024% of S, 0.021% of P and the balance of Fe and impurities.
(II) preparing the insert B
First, a raw material is prepared
Weighing raw iron, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, ferrochromium nitride, ferrotungsten, rare earth ferrosilicon, aluminum wire and other materials.
Second step of modeling
Utilizing the metal mold to carry out modeling, preheating the metal mold in advance, wherein the preheating temperature is as follows: 138 ℃.
The third step, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of pig iron, scrap steel, alloy and precious metal, pre-deoxidation treatment is carried out when the temperature of molten iron reaches 1468 ℃, 0.61% ferromanganese is added, 0.03% ferrosilicon and 0.041% ferrochromium nitride are added after 6 minutes, chemical components are adjusted, smelting is continued, when the temperature of the molten iron reaches 1556 ℃, heat preservation is carried out for 8 minutes, the molten iron is fully kept stand, at the moment, slag floats upwards and is timely slagged, after 8 minutes, when the temperature of the molten iron is 1539 ℃, 0.018% aluminum wires are inserted, then discharging is carried out, and the molten iron is timely discharged.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.148% of ferroboron, 0.21% of ferrovanadium, 0.33% of rare earth ferrosilicon and 0.035% of ferrochromium nitride, before tapping, the inoculant is placed into the casting ladle and poured into a metal mold, and the insert B is obtained after cooling to room temperature.
The size of the insert B is a cylinder with the diameter of 3.61mm, the height of the insert B is 41.3mm, the insert B is of a rod-shaped structure, the diameter of one end of the insert B is 0.58mm larger than that of the other end of the insert B, the end with the larger diameter of the insert B is positioned in the grinding roller base body, and the end with the smaller diameter of the insert B is exposed on the surface of the grinding roller.
The insert B comprises 3.838% of C, 0.83% of Si, 0.89% of Mn, 34.89% of Cr, 0.13% of B, 2.01% of V, 1.91% of Mo, 0.81% of Ni, 0.68% of Cu, 0.26% of Nb, 0.09% of N, 0.93% of W, 0.03% of Re, 0.035% of Al, 0.024% of S, 0.021% of P and the balance of Fe and impurities.
(III) preparing the composite grinding roller
First, a raw material is prepared
Weighing materials such as scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, rare earth ferrosilicon, silicon barium, aluminum wire, ferrozirconium and the like.
The second step of modeling
The method comprises the following steps of respectively welding the thin ends of the diameter of the insert A and the diameter of the insert B by using nails, then inserting the nails into a casting mold, and enabling the insert A and the insert B to be respectively distributed on the working surface of a grinding roller in a crossed manner, wherein the distance between the insert A and the insert A is 1.53 times of the diameter of the insert A, the distance between the insert B and the insert B is 1.21 times of the diameter of the insert B, the insert A and the insert B are uniformly distributed on the working surface, and before casting, the insert A and the insert B are preheated to 245 ℃.
The third step, smelting raw materials
Smelting the raw materials in the first step, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, when the temperature of molten iron reaches 1548-1565 ℃, carrying out pre-deoxidation treatment, firstly adding 0.43% ferromanganese, adding 0.013% ferrosilicon after 10 minutes, testing the chemical components of the molten iron, adjusting the weight percentage of the chemical components of the molten iron, when the temperature of the molten iron in the furnace reaches 1628-1635 ℃, inserting 0.023% aluminum wires, and then discharging.
Fourthly, inoculation and pouring
Pouring the iron liquid obtained in the third step into a casting ladle for inoculation, wherein the inoculant consists of 0.13% of silicon-barium, 0.23% of ferrovanadium, 0.35% of rare earth ferrosilicon and 0.185% of ferrozirconium, before tapping, the inoculant is placed into the casting ladle, poured into a casting mold, cooled to room temperature, and opened.
The chemical components of the grinding roller matrix comprise 0.38 percent of C, 1.10 percent of Si, 1.97 percent of Mn, 3.89 percent of Cr, 0.002 percent of B, 0.31 percent of V, 1.87 percent of Mo, 0.61 percent of Ni, 0.78 percent of Cu, 0.28 percent of Nb, 0.05 percent of N, 0.03 percent of Re, 0.0039 percent of Ba, 0.00086 percent of Zr, 0.031 percent of Al, 0.03 percent of S, 0.03 percent of P and the balance of Fe and impurities.
Fifthly, cleaning and polishing.
And cleaning and polishing the casting obtained in the fourth step to obtain a composite casting grinding roller blank.
(IV) Heat treatment of grinding rolls
First step, annealing
And (4) charging the obtained grinding roller blank and carrying out annealing treatment. The annealing treatment process comprises the following steps: the temperature of the casting in the furnace is controlled below 185 ℃ and below 300 ℃, the heating rate is controlled between 28 ℃/h and 36 ℃/h, the temperature is kept for 1 hour and between 300 ℃ and 650 ℃ at 300 ℃, the heating rate is controlled between 38 ℃/h and 55 ℃/h, the temperature is kept for 1.5 hours at 650 ℃, the temperature is kept between 650 ℃ and 1000 ℃, the heating rate is controlled between 58 ℃/h and 65 ℃/h, the temperature of the casting is kept for 3.5 hours at 1000 ℃, and the temperature is properly adjusted according to the wall thickness of the casting. After the temperature is kept at 1000 ℃, the furnace is cooled in the furnace.
Secondly, rough machining
The grinding roller obtained after annealing is subjected to rough machining.
A third step of quenching
And (4) charging the grinding roller blank obtained by rough machining and quenching. The quenching treatment process comprises the following steps: the temperature of the casting entering the furnace is controlled below 178 ℃ and below 300 ℃, the heating rate is controlled at 38 ℃ per hour, the temperature is kept at 300 ℃ for 1 hour and 300-650 ℃, the heating rate is controlled at 48 ℃/hour, the temperature is kept at 650 ℃ for 1.5 hours and 650-1020 ℃, the heating rate is controlled at 65 ℃/hour, the temperature of the casting is kept at 1018-1020 ℃ for 3.5 hours, and the temperature is properly adjusted according to the wall thickness of the casting. And after heat preservation, discharging from the furnace, quenching, wherein the quenching adopts a mode of air cooling and spraying (water mist), the air cooling and spraying are started after the casting is discharged from the furnace, the spraying is stopped when the temperature of the casting is reduced to be below 698 ℃, the air cooling is continued until the temperature is reduced to be below 396 ℃, the air blowing is stopped, and the casting is naturally cooled in the air.
Fourthly, tempering
And (3) re-charging the quenched casting, and carrying out tempering and tempering processes: the temperature of the cast entering the furnace is controlled below 168 ℃ and below 280 ℃, the temperature rising speed is controlled at 38 ℃/h, and the temperature is kept for 5 h at 280 ℃. And after the heat preservation time is up, discharging the furnace, and naturally cooling the furnace in the air.
Fifthly, finely machining
And (4) carrying out finish machining on the tempered grinding roller according to the requirements of a drawing.
Sixthly, detecting quality
And (4) carrying out hardness, impact toughness and ultrasonic flaw detection on the finished grinding roller.
Performance indexes are as follows: the mechanical properties of the grinding roller substrate are as follows: impact properties (no specimen notch): 238j/cm2HRC 48.5. The insert A has the following mechanical properties: impact toughness (unnotched sample) 23.5j/cm2: hardness: HRC 61.5. The insert B has the mechanical properties that: impact toughness (no notch in the test specimen): 9.5j/cm2Hardness: HRC 66.5.
The fifth step of carriage and packing
And packaging and warehousing grinding roller finished products meeting the drawing requirements.
Example 4:
the other steps are the same as in example 3, except for the chemical composition of the grinding roller substrate.
The grinding roller comprises the following chemical components in percentage by weight: 0.45% of C, 1.11% of Si, 1.97% of Mn, 3.99% of Cr, 0.002% of B, 0.46% of V, 1.87% of Mo, 0.61% of Ni, 1.06% of Cu, 0.39% of Nb, 0.05% of N, 0.03% of Re, 0.0041% of Ba, 0.00076% of Zr, 0.031% of Al, 0.03% of S, 0.03% of P and the balance of Fe and impurities.
The insert A and B have the same chemical composition and mechanical properties as those of example 3.
The mechanical property indexes of the grinding roller substrate after heat treatment are as follows: impact properties (no specimen notch): 208j/cm2，HRC49.5。
Example 5
The other steps are the same as in example 3, except for the chemical composition of the grinding roller substrate.
The grinding roller comprises the following chemical components in percentage by weight: 0.48% of C, 1.10% of Si, 2.15% of Mn, 3.89% of Cr, 0.003% of B, 0.37% of V, 1.97% of Mo, 0.65% of Ni, 1.06% of Cu, 0.28% of Nb, 0.06% of N, 0.03% of Re, 0.0051% of Ba, 0.00096% of Zr, 0.031% of Al, 0.03% of S, 0.03% of P and the balance of Fe and impurities.
The insert A and the insert B have the same chemical composition and mechanical property as those of the embodiment 3.
The mechanical property indexes of the grinding roller substrate after heat treatment are as follows: impact properties (no specimen notch): 198j/cm2，HRC51.5。
Example 6
The other steps are the same as in example 3, except for the chemical composition of the grinding roller substrate.
The grinding roller comprises the following chemical components in percentage by weight: 0.38% of C, 1.11% of Si, 1.97% of Mn, 3.99% of Cr, 0.002% of B, 0.31% of V, 1.87% of Mo, 0.61% of Ni, 0.88% of Cu, 0.29% of Nb, 0.06% of N, 0.03% of Re, 0.0042% of Ba, 0.00066% of Zr, 0.031% of Al, 0.03% of S, 0.03% of P and the balance of Fe and impurities.
The insert A and the insert B have the same chemical composition and mechanical property as those of the embodiment 3.
The mechanical property indexes of the grinding roller substrate after heat treatment are as follows: impact properties (no specimen notch): 228j/cm2，HRC48.5。
Although the present invention has been described with reference to the specific embodiments, it should be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.

Claims (7)

1. A high-wear-resistance grinding roller is characterized by comprising an insert A, an insert B and a base body, wherein the insert A and the insert B are respectively of a rod-shaped structure with one thick end and one thin end, the rod-shaped structure is embedded in the base body, the thin end surface of the rod-shaped structure is exposed on the surface of the base body and the surface of the base body to form a working surface of the grinding roller, and the thin end surfaces of the insert A and the insert B are uniformly distributed on the surface of the base body in a staggered mode at intervals; the insert A is made of medium and high alloy steel, the insert B is made of ultrahigh alloy cast iron, and the matrix is made of medium alloy steel;
the matrix is made of the following materials in percentage by weight: 0.38-0.48% of C, 1.10-1.37% of Si, 1.97-2.15% of Mn, 3.89-4.17% of Cr, 0.002-0.003% of B, 0.31-0.48% of V, 1.87-1.99% of Mo, 0.61-0.78% of Ni, 0.78-1.06% of Cu, 0.28-0.39% of Nb, 0.05-0.12% of N, 0.03-0.04% of Re, 0.0031-0.0066% of Ba, 0.00056-0.00151% of Zr, 0.021-0.043% of Al, S, P not more than 0.031% of Re, and the balance of Fe and impurities, wherein the total amount of the impurities is not more than 0.053%.
The insert A is made of the following materials in percentage by weight: 0.638 to 0.748 percent of C, 0.93 to 1.17 percent of Si, 0.87 to 1.15 percent of Mn, 6.89 to 7.27 percent of Cr, 0.003 to 0.004 percent of B, 2.31 to 2.48 percent of V, 1.97 to 2.39 percent of Mo, 0.81 to 0.88 percent of Ni, 0.88 to 1.08 percent of Cu, 0.38 to 0.39 percent of Nb, 0.06 to 0.12 percent of N, 0.53 to 0.64 percent of W, 0.03 to 0.04 percent of Re, 0.0023 to 0.2 percent of Ca, 0.0031 to 0.0066 percent of Ba, 0.00016 to 0.00035 percent of Zr, 0.011 to 0.033 percent of Al, S, P not more than 0.025 percent of impurities and the balance of Fe and impurities, wherein the total amount of Fe and impurities is not more than 0.049 percent.
The insert B is made of the following materials in percentage by weight: 3.838-4.348% of C, 0.83-1.05% of Si, 0.89-1.04% of Mn, 34.89-37.56% of Cr, B:0.13 to 0.23 percent of V, 2.01 to 2.16 percent of V, 1.91 to 2.09 percent of Mo, 0.81 to 0.85 percent of Ni, 0.68 to 0.78 percent of Cu, 0.26 to 0.31 percent of Nb, 0.09 to 0.15 percent of N, 0.93 to 1.14 percent of W, 0.03 to 0.04 percent of Re, 0.022 to 0.045 percent of Al, S, P not more than 0.032 percent, and the balance of Fe and impurities, wherein the total amount of the impurities is not more than 0.036 percent.
2. The high abrasion resistant grinding roller according to claim 1, wherein the size of the insert A is 15.1-35.8 mm in diameter and 41.3-59.8 mm in length, the diameter of one end of the insert A is 1.82-2.71 mm larger than that of the other end, the thick end of the insert A is positioned in the grinding roller base body, and the thin end of the insert A is exposed on the surface of the grinding roller base body.
3. A high wear resistant grinding roll according to claim 1, wherein the insert B has a diameter of 3.61 to 8.28mm and a length of 41.3 to 59.8mm, one end of the insert B has a diameter 0.58 to 1.62mm larger than the other end, the larger end of the insert B is located within the grinding roll base, and the smaller end of the insert B is exposed on the surface of the grinding roll base, and forms the working surface of the grinding roll together with the end surface of the tip of the insert A and the surface of the grinding roll.
4. A method for manufacturing a grinding roller with high wear resistance as claimed in any one of claims 1 to 3, wherein the insert a and the insert B are cast, the insert a and the insert B are pre-embedded in a casting mold of the grinding roller, and then the base iron liquid of the grinding roller is poured, the base iron liquid is metallurgically combined with the insert a and the insert B to obtain a grinding roller blank, and the grinding roller blank is annealed, quenched and tempered to obtain a finished grinding roller.
5. A method for manufacturing a grinding roller with high wear resistance as claimed in claim 4, characterized by comprising the steps of:
preparing an insert A
Preparing raw materials:
weighing scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, ferrotungsten, rare earth ferrosilicon, silicon barium, silicon calcium, aluminum wire and ferrozirconium material;
the modeling is as follows:
utilizing the metal mold to carry out modeling, preheating the metal mold in advance, wherein the preheating temperature is as follows: 158-236 ℃;
smelting raw materials:
smelting raw materials, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, when the temperature of molten iron reaches 1518-1556 ℃, carrying out pre-deoxidation treatment, firstly adding 0.52% ferromanganese, adding 0.23% ferrosilicon after 8-10 minutes, testing the chemical components of the molten iron, adjusting the chemical components of the molten iron to meet the requirements of the medium-high alloy steel, when the temperature of the molten iron in the furnace reaches 1625-1636 ℃, inserting 0.025% aluminum wires, and then discharging;
fourth inoculation pouring:
pouring the obtained molten iron into a casting ladle for inoculation, putting an inoculant into the casting ladle before tapping, pouring the inoculant into a metal mold, and cooling to room temperature to obtain an insert A;
(II) preparing an insert B
Preparing raw materials:
weighing pig iron, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, ferrochromium nitride, ferrotungsten, rare earth ferrosilicon and aluminum wires;
the modeling is as follows:
utilizing the metal mold to mold, preheating the metal mold in advance, wherein the preheating temperature is as follows: 138-196 ℃;
smelting raw materials:
smelting raw materials, wherein the smelting sequence is carried out according to the sequence of pig iron, scrap steel, alloy and precious metal, when the temperature of molten iron reaches 1468-1506 ℃, carrying out pre-deoxidation treatment, adding 0.61% ferromanganese, adding 0.03% ferrosilicon and 0.041% ferrochromium nitride after 6 minutes, then adjusting chemical components to ensure that the weight percentage of the chemical components meets the requirements of the ultrahigh alloy cast iron, continuing smelting, when the temperature of the molten iron reaches 1556-1566 ℃, preserving heat for 8-10 minutes, fully standing the molten iron, floating slag, and timely slagging, when the temperature of the molten iron is 1539-1546 ℃, inserting 0.018% aluminum wires, then discharging, and timely discharging the molten iron;
fourth, inoculation pouring:
pouring the obtained molten iron into a casting ladle for inoculation, putting an inoculant into the casting ladle before tapping, pouring the inoculant into a metal mold, and cooling to room temperature to obtain an insert B;
(III) preparing the composite grinding roller
Preparing raw materials:
weighing scrap steel, ferrosilicon, ferromanganese, electrolytic chromium, ferroboron, electrolytic vanadium, ferromolybdenum, ferronickel, copper, ferroniobium, chromium nitride, rare earth ferrosilicon, silicon barium, aluminum wire and ferrozirconium material;
the modeling is as follows:
welding the thin ends of the insert A and the insert B with nails respectively, then inserting the nails into the casting mold, and enabling the insert A and the insert B to be distributed on the working surface of the grinding roller in a staggered manner respectively, wherein the distance between the insert A and the insert A is kept to be 1.47-1.53 times of the diameter of the thin end of the insert A, the distance between the insert B and the insert B is kept to be 1.15-1.21 times of the diameter of the thin end of the insert B, the insert A and the insert B are uniformly distributed on the working surface, and before casting, the insert A and the insert B are preheated to 186-245 ℃;
smelting of base raw materials
Smelting raw materials, wherein the smelting sequence is carried out according to the sequence of scrap steel, alloy and scrap steel, when the temperature of molten iron reaches 1548-1565 ℃, carrying out pre-deoxidation treatment, firstly adding 0.43% ferromanganese, adding 0.013% ferrosilicon after 10 minutes, testing the chemical components of the molten iron, adjusting the chemical components of the molten iron to meet the requirements of the medium alloy steel, when the temperature of the molten iron in the furnace reaches 1628-1635 ℃, inserting 0.023% of aluminum wires, and then discharging the molten iron;
fourth, inoculation pouring:
pouring the obtained molten iron into a casting ladle for inoculation, putting an inoculant into the casting ladle before tapping, pouring the inoculant into a grinding roller casting mold, cooling to room temperature, and opening the mold;
fifthly, cleaning and polishing to obtain a composite casting grinding roller blank;
(IV) Heat treatment of grinding rolls
Annealing: charging the obtained grinding roller blank and carrying out annealing treatment;
and (2) roughing: carrying out rough machining on the grinding roller obtained after annealing;
quenching: charging the grinding roller blank obtained by rough machining, and quenching;
fourth tempering: re-charging the quenched casting, and carrying out tempering treatment;
and fifthly, carrying out finish machining on the grinding roller after tempering.
6. A method for manufacturing a grinding roller with high wear resistance as claimed in claim 5, wherein the annealing process comprises: controlling the temperature of the casting entering the furnace to be below 185 ℃, controlling the heating rate to be 28-36 ℃/h below 300 ℃, keeping the temperature for 1 h at 300 ℃, controlling the heating rate to be 38-55 ℃/h between 300 ℃ and 650 ℃, keeping the temperature for 1.5 h at 650 ℃, controlling the heating rate to be 58-65 ℃/h between 650 ℃ and 1000 ℃, keeping the temperature for 3.5-5.5 h at 1000 ℃, properly adjusting the wall thickness of the casting, keeping the temperature at 1000 ℃, and cooling the casting in the furnace along with the furnace;
the quenching treatment process comprises the following steps: controlling the temperature of a cast to be below 178 ℃, controlling the heating rate to be 38-45 ℃/h below 300 ℃, keeping the temperature for 1 h at 300 ℃, controlling the heating rate to be 48-56 ℃/h between 300 ℃ and 650 ℃, keeping the temperature for 1.5 h at 650 ℃, controlling the heating rate to be 65-71 ℃/h between 650 ℃ and 1020 ℃, keeping the temperature for 3.5-4.5 h at 1018 ℃ -1020 ℃, properly adjusting the wall thickness of the cast according to the wall thickness of the cast, discharging the cast, quenching in an air cooling and spraying manner, starting air cooling and spraying after the cast is discharged, stopping spraying when the temperature of the cast is reduced to be below 698 ℃, continuing air cooling, stopping air blowing when the temperature of the cast is reduced to be below 396 ℃, and naturally cooling in the air;
the tempering process comprises the following steps: controlling the charging temperature of the casting below 168 ℃, controlling the heating rate below 280 ℃ to be 38-45 ℃/h, preserving the heat at 280 ℃ for 5-8 h, discharging the casting after the heat preservation time is up, and naturally cooling the casting in the air.
7. The method for preparing a high abrasion-resistant grinding roller according to claim 5, wherein the insert A adopts the following inoculants: 0.151 percent of silicon calcium, 0.127 percent of silicon barium, 0.311 percent of rare earth ferrosilicon and 0.035 percent of ferrozirconium are processed by a punching and packing method; the inoculant adopted by the insert B is as follows: 0.148 percent of ferroboron, 0.21 percent of ferrovanadium, 0.33 percent of rare earth ferrosilicon and 0.035 percent of ferrochromium nitride are processed by a punching and packing method; the inoculant adopted by the matrix is as follows: 0.13 percent of silicon-barium, 0.23 percent of ferrovanadium, 0.35 percent of rare earth ferrosilicon and 0.185 percent of ferrozirconium, and the processing is carried out by a punching and packing method.
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