CN114425620A - Device and method for manufacturing roller - Google Patents
Device and method for manufacturing roller Download PDFInfo
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- CN114425620A CN114425620A CN202210116746.3A CN202210116746A CN114425620A CN 114425620 A CN114425620 A CN 114425620A CN 202210116746 A CN202210116746 A CN 202210116746A CN 114425620 A CN114425620 A CN 114425620A
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- Prior art keywords
- mandrel
- metal melt
- roller
- spraying
- roll
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
Abstract
The application provides equipment and a method for preparing a roller, and relates to the technical field of roller preparation. The equipment for preparing the roller comprises a mandrel, a rotating mechanism, a translation mechanism, a spraying mechanism and a cooling mechanism; the mandrel is transversely arranged, and the rotating mechanism is configured to drive the mandrel to rotate around the rotating axis; the translation mechanism is configured to drive the rotation mechanism and the mandrel to synchronously reciprocate linearly along the extension direction of the rotation axis; the injection mechanism is provided with an injection port for injecting the metal melt to the surface of the mandrel in a planar flow mode, wherein the injection direction of the metal melt points to the roll surface of the mandrel, the distance from the injection port to the roll surface of the mandrel along the injection direction is 5-10 mm, the included angle between the injection direction and the vertical direction is 0-30 degrees, and the diameter of the mandrel is 80-140 mm; the cooling mechanism is configured to cool and solidify the metal melt sprayed onto the surface of the mandrel. The technical problems of thick structure and obvious pores in the prior art can be solved.
Description
Technical Field
The application relates to the technical field of roller preparation, in particular to equipment and a method for preparing a roller.
Background
At present, the manufacturing method of the roller mainly comprises the following steps: centrifugal casting, spray forming, continuous casting skin forming, hot isostatic pressing and rotary electroslag casting, which are widely used in mass industrial production, however, the rolling layer structure formed by the centrifugal casting is severely segregated and has coarse eutectic carbides. Spray forming is a rapid solidification technology, which utilizes refined liquid metal to form liquid drop jet flow through atomization, so that semi-solidified particles are deposited on a roller core, and rapid solidification realizes the structure refinement and uniform components of the metal and eliminates macrosegregation, but the method easily causes loose structures and has obvious pores. The continuous casting outer layer forming process is more complicated, and the basic principle is that molten steel used as the material of the working layer of the roller is cast into a gap between a vertically vertical core rod and a water-cooling casting mold, the molten steel is solidified in sequence while being gradually deposited with the core rod, and the molten steel is continuously drawn downwards to form the composite roller. The method has higher difficulty and high requirement on equipment, and only Japanese New Japanese iron and Hitachi realize industrialization at present abroad.
Disclosure of Invention
The embodiment of the application provides equipment and a method for preparing a roller, which can solve the technical problems of thick structure and obvious pores in the prior art.
The embodiment of the application is realized as follows:
in a first aspect, an embodiment of the present application provides an apparatus for manufacturing a roll, including:
the mandrel is transversely arranged;
a rotation mechanism configured to drive the mandrel to rotate about a rotation axis;
the translation mechanism is configured to drive the rotation mechanism and the mandrel to synchronously reciprocate linearly along the extension direction of the rotation axis;
the injection mechanism is used for containing the metal melt and is provided with an injection port for injecting the metal melt to the surface of the mandrel in a planar flow mode, wherein the injection direction of the metal melt points to the roller surface of the mandrel, the distance from the injection port to the roller surface of the mandrel along the injection direction is 5-10 mm, the included angle between the injection direction and the vertical direction is 0-30 degrees, and the diameter of the mandrel is 80-140 mm; and
and the cooling mechanism is configured to cool and solidify the metal melt sprayed to the surface of the mandrel.
In the technical scheme, the mandrel is driven to rotate around the rotating axis through the rotating mechanism, the rotating mechanism and the mandrel are driven to synchronously and linearly move along the extending direction of the rotating axis through the translation mechanism, meanwhile, the metal melt is sprayed out from the spraying opening to the surface of the mandrel through the spraying mechanism, the metal melt can be uniformly distributed on the surface of the mandrel in the rotating and translating processes of the mandrel, and the metal sprayed on the surface of the mandrel is cooled and solidified through the cooling mechanism, so that the roller can be formed. Because the distance of jet orifice to the roll surface of dabber is 5 ~ 10mm along the injection direction for metal melt sprays the surface to the dabber with the mode of plane flow, and can inject the molten bath in narrow and small space, forms than the little small molten bath of spray forming, is favorable to the rapid solidification of metal melt, forms tiny crystalline grain, and is difficult to cause the waste of metal melt. In addition, the contained angle between injection direction and the vertical direction is 0 ~ 30, the diameter of dabber is 80 ~ 140mm, can make the metal melt of plane flow contact better with the surface of dabber, because carry out the injection of metal melt when the dabber is rotatory, at the in-process of dabber autogyration, utilize centrifugal inertia to distribute the metal melt at the roll surface uniformly, can not cause the waste of metal melt because of the overspray of plane flow, and the solidification structure on dabber surface can be more even, greatly reduced hole's production. Therefore, the equipment for preparing the roller can solve the technical problems of thick structure and obvious pores in the prior art.
In a second aspect, embodiments of the present application provide a method for preparing a roll, which uses the apparatus for preparing a roll of the embodiments of the first aspect to prepare a roll, and includes the following steps:
the mandrel is driven to rotate around the rotation axis at the speed of 60-180 r/min through the rotating mechanism, and meanwhile, the rotating mechanism and the mandrel are driven to synchronously and linearly move along the extending direction of the rotation axis by the translation mechanism;
jetting the metal melt from the jetting port through a jetting mechanism, and jetting the metal melt to the surface of the mandrel in a plane flow manner along the jetting direction;
and cooling the metal melt on the surface of the mandrel by a cooling mechanism.
In the technical scheme, the method for preparing the roller is carried out by using the device for preparing the roller, so that a smaller molten pool can be formed, the rapid solidification of the metal melt is facilitated, and fine grains are formed. In addition, the mandrel rotates at a speed of 60-180 r/min and simultaneously sprays the metal melt, and the rotating speed is matched with the control condition of the equipment for preparing the roller, so that the solidification structure on the surface of the mandrel is more uniform, the generation of pores is greatly reduced, and the metal melt cannot be oversprayed. Therefore, the method for preparing the roller can solve the technical problems of thick structure and obvious pores in the prior art.
Drawings
To more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and those skilled in the art can also obtain other related drawings based on the drawings without inventive efforts.
FIG. 1 is a schematic structural view of an apparatus for manufacturing a roll according to an embodiment of the present application;
FIG. 2 is a schematic view of a nozzle and a mandrel according to an embodiment of the present disclosure;
FIG. 3 is an SEM image of a roll outer layer prepared in example 1 of the present application;
fig. 4 is an SEM image of the roll outer layer prepared in example 2 of the present application.
Icon: 10-equipment for preparing the roller; 11-a mandrel; 111-a second induction coil; 12-a rotation mechanism; 121-a first motor; 122-a support; 13-a translation mechanism; 131-a translation stage; 132-a translation drive; 14-a spraying mechanism; 141-crucible; 142-a nozzle; 1421-jet orifice; 143-a first induction coil; 15-a cooling mechanism; 16-the direction of ejection; 17-a lifting mechanism; 18-a vacuum chamber; 191-a support frame.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. The components of the embodiments of the present application, generally described and illustrated in the figures herein, can be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the present application, presented in the accompanying drawings, is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. 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 application.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.
In the description of the present application, it should be noted that the terms "upper", "lower", "inner", "outer", and the like indicate orientations or positional relationships based on orientations or positional relationships shown in the drawings or orientations or positional relationships conventionally found in use of products of the application, and are used only for convenience in describing the present application and for simplification of description, but do not indicate or imply that the referred devices or elements must have a specific orientation, be constructed in a specific orientation, and be operated, and thus should not be construed as limiting the present application. Furthermore, the terms "first," "second," and the like are used merely to distinguish one description from another, and are not to be construed as indicating or implying relative importance.
In the description of the present application, it is further noted that, unless expressly stated or limited otherwise, the terms "disposed," "mounted," and "connected" are to be construed broadly, e.g., as meaning fixedly connected, detachably connected, or integrally connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in this application will be understood to be a specific case for those of ordinary skill in the art.
In a first aspect, an embodiment of the present application provides an apparatus 10 for preparing a roll, please refer to fig. 1, which includes a mandrel 11, a rotating mechanism 12, a translating mechanism 13, a spraying mechanism 14, and a cooling mechanism 15.
Wherein the mandrel 11 is arranged laterally and the rotation mechanism 12 is configured for driving the mandrel 11 in rotation around the rotation axis. Illustratively, the rotating mechanism 12 includes a first motor 121 and a support 122, a power output shaft of the first motor 121 is coaxially connected with the spindle 11 in a transmission manner, the spindle 11 is rotatably supported on the support 122, and the first motor 121 is operated to drive the spindle 11 to rotate. The motor may be replaced with a speed reducer or the like as long as it can drive the spindle 11 to rotate around the rotation axis.
The translation mechanism 13 is configured to drive the rotation mechanism 12, the mandrel 11, to reciprocate linearly in synchronization along the extension direction of the rotation axis. Alternatively, the translation mechanism 13 includes a translation stage 131 and a translation driving member 132, the first motor 121 and the support 122 are both fixed on the translation stage 131, and the translation stage 131 is driven by the translation driving member 132 to move linearly along the extending direction of the rotation axis, so that the rotation mechanism 12 and the mandrel 11 can be driven to move linearly and synchronously. Illustratively, the translation driving member 132 is a hydraulic cylinder or an air cylinder, and a power output end of the hydraulic cylinder or the air cylinder is connected with the translation stage 131.
The injection mechanism 14 is disposed above the mandrel 11 for containing the metal melt, and the injection mechanism 14 has an injection port 1421 for injecting the metal melt to the surface of the mandrel 11 in a planar flow. The cooling mechanism 15 is configured to cool and solidify the metal melt sprayed onto the surface of the mandrel 11. Wherein, cooling water smoke can be erupted to cooling mechanism 15 and metal melt cools off the cooling to make metal melt cooling solidify.
In some embodiments, the injection mechanism 14 includes a crucible 141, a support frame 191 for supporting the crucible 141, and a nozzle 142 installed at the bottom of the crucible 141, the nozzle 142 having an injection port 1421. In the specific operation, the melted metal is poured into a tundish, the tundish controls the metal to be at a better heat, the metal is supplied into the crucible 141 through a continuous liquid supply device, and the metal is finally sprayed out from the spray opening 1421 of the nozzle 142 to the surface of the mandrel 11. Wherein the temperature of the metal melt in the crucible 141 can be measured by a thermocouple.
Illustratively, the outer wall of the nozzle 142 is annularly provided with a first induction coil 143, alternating current flowing through the first induction coil 143 generates an alternating magnetic field by applying high-frequency alternating current to the first induction coil 143, and the metal melt flowing through the nozzle 142 is heated by the magnetic field, so that the metal melt can maintain temperature.
When the device 10 for preparing the roller is used, the mandrel 11 is driven to rotate around the rotating axis through the rotating mechanism 12, the translating mechanism 13 drives the rotating mechanism 12 and the mandrel 11 to synchronously and linearly move along the extending direction of the rotating axis, meanwhile, the spraying mechanism 14 sprays the metal melt from the spraying port 1421 to the surface of the mandrel 11, the metal melt can be uniformly distributed on the surface of the mandrel 11 in the rotating and translating processes of the mandrel 11, and the metal on the surface of the spraying mandrel 11 is cooled and solidified through the cooling mechanism 15, so that the roller can be formed. When the equipment 10 for manufacturing the roller is used, a molten pool is limited between the bottom surface of the nozzle 142 and the mandrel 11, and the bottom surface of the nozzle 142 plays a role in restraining the molten pool, so that disturbance of factors such as a gas boundary layer and the surface roughness of the mandrel 11 to the molten pool is greatly reduced, and the stability of the molten pool is high.
Generally, the spray forming method in the prior art needs to atomize the liquid droplets, i.e. blow off and solidify the liquid stream by blowing inert gas, and finally form semi-solid and liquid mixed liquid droplets, and from the forming effect, the spray forming method inevitably forms pores due to the accumulation of the mixed liquid droplets. Moreover, since the spray forming method requires atomization, it is necessary to ensure that the spray distance is large, usually 40-50 cm, i.e. the distance between the nozzle 142 and the deposition surface is large, which results in a large molten pool, and the formed microstructure contains inherent pores, which are unavoidable, and easily causes over-spraying of the molten metal, which results in waste.
In the embodiment of the application, the distance between the roll surface of jet 1421 along jet direction 16 and dabber 11 is 5 ~ 10mm, wherein, jet direction 16 points to the roll surface of dabber 11, and then metal melt can strike dabber 11 with the mode of plane flow, can inject the molten bath in narrower and small space, forms the little molten bath that forms than spray forming, is favorable to the rapid solidification of metal melt, forms tiny crystalline grain, and be difficult to cause the waste of metal melt. Alternatively, the distance between the ejection port 1421 and the roll surface of the mandrel 11 in the ejection direction 16 is 5mm, 6mm, 7mm, 8mm, 9mm, or 10 mm.
The included angle alpha between the spraying direction 16 and the vertical direction is 0-30 degrees (refer to fig. 2), the diameter of the mandrel 11 is 80-140 mm, the metal melt of the plane flow can be better contacted with the surface of the mandrel 11, the metal melt is sprayed while the mandrel 11 rotates, in the self-rotating process of the mandrel 11, the metal melt can be uniformly distributed on the roller surface by utilizing centrifugal inertia, the waste of the metal melt caused by the over-spraying of the plane flow can be avoided, the solidification structure on the surface of the mandrel can be more uniform, and the generation of pores is greatly reduced. Therefore, the equipment for preparing the roller can solve the technical problems of thick structure and obvious pores in the prior art. Optionally, the angle between the injection direction 16 and the vertical is 0 °, 5 °, 10 °, 15 °, 20 °, 25 °, or 30 °. Illustratively, the direction of the spray may pass through the axis of rotation of the spindle 11. Optionally, the diameter of the mandrel 11 is 80mm, 100mm, 120mm or 140mm
Because the roller manufactured by the device 10 for manufacturing the roller has excellent surface quality, the conventional roller rough machining link can be omitted, and only the finish turning and grinding treatment is needed to achieve the required roller size. Before finish turning and grinding treatment, in order to prevent cracks from being generated on the outer layer and the mandrel 11, annealing treatment can be selectively carried out on a roller sample, wherein the annealing temperature is 600-620 ℃, the temperature is kept for 4-6 hours, furnace cooling is carried out, and then quenching and tempering heat treatment is carried out, so that the hardness and the wear resistance of the roller are improved. Specifically, the roller is heated to 1000-1180 ℃ for heat preservation and air cooling, then tempered for three times at 520-560 ℃, the heat preservation time is 2 hours each time, and after the heat preservation is finished, the roller is taken out of the furnace and cooled to the room temperature.
Further, in order to improve the bonding of the metal melt to the mandrel 11, the mandrel 11 is provided with a second induction coil 111, an alternating magnetic field is generated by passing a high-frequency alternating current to the second induction coil 111, the alternating current passing through the second induction coil 111, and the mandrel 11 is heated by the magnetic field, so that the mandrel 11 is preheated before the melt is sprayed, thereby improving the metallurgical bonding of the metal melt to the mandrel 11. It should be noted that the mandrel 11 may be solid or hollow, and when the mandrel 11 is a hollow structure, a heating element may be disposed inside the hollow mandrel 11 to preheat the mandrel 11. The equipment 10 for preparing the roller in the embodiment of the application has the advantages that the requirement on the material of the mandrel 11 is reduced, the material of the mandrel 11 with high toughness can be selected in a wider range, and the toughness of the composite roller is improved.
In addition, the metal melt is continuously sprayed on the surface of the mandrel 11, and the distance between the surface of the bonding layer and the nozzle 142 is gradually reduced due to the formation of the bonding layer after the metal melt is cooled and solidified, and the subsequent molten pool forming effect is influenced due to the distance between the surface of the bonding layer and the nozzle 142, so that the lifting mechanism 17 of the lifting mechanism 17 can be further arranged and configured to drive the translation mechanism 13, the rotating mechanism 12 and the mandrel 11 to synchronously lift. When the mandrel 11 is used, the mandrel 11 is driven to descend through the lifting mechanism 17 while rotating and translating, and when the bonding layer on the surface of the mandrel 11 is thickened, the distance between the bonding layer and the nozzle 142 can be kept within a reasonable range.
Illustratively, the lifting mechanism 17 includes a lifting table and a lifting driving member for driving the lifting table to lift, the translation mechanism 13 is fixed on the lifting table, and the lifting table is driven to descend by the lifting driving member, so that the mandrel 11 descends while rotating and translating. Alternatively, two lifting mechanisms 17 may be provided, with the translation drive 132 provided on one of the lifting tables and the translation table 131 provided on the other lifting table.
Further, when the vacuum melting furnace is used specifically, the mandrel 11, the rotating mechanism 12, the translation mechanism 13, the lifting mechanism 17, the spraying mechanism 14 and the cooling mechanism 15 can be arranged in the vacuum chamber 18, the vacuum chamber 18 is in a closed state when the metal melt enters the crucible 141, inert gas is filled into the vacuum chamber 18 after the vacuum chamber 18 is vacuumized, the whole vacuum chamber 18 is in an inert atmosphere protection state, and the metal melt is not easy to be oxidized.
Inert gas is also filled in the injection mechanism 14, the pressure difference between the inside of the injection mechanism 14 and the inside of the vacuum chamber 18 is 0.1-0.3 MPa, and the pressure inside the injection mechanism 14 is greater than that inside the vacuum chamber 18, so that the metal melt is favorably sprayed out of the injection mechanism 14. The continuous liquid supply device, the rotating mechanism 12, the translation mechanism 13, the lifting mechanism 17 and a power supply for supplying power to the first induction coil 143 and the second induction coil 111 are all in communication connection with a controller, the operation of the components is controlled by the controller, and a control switch of the controller is arranged outside the vacuum chamber 18.
In a second aspect, the present embodiment provides a method for preparing a roll, which uses the above roll preparing apparatus 10 to prepare the roll, including the following steps:
the mandrel 11 is driven to rotate around the rotating axis at the speed of 60-180 r/min through the rotating mechanism 12, and meanwhile the translation mechanism 13 drives the rotating mechanism 12 and the mandrel 11 to synchronously and linearly move along the extending direction of the rotating axis;
the metal melt is ejected from the ejection port 1421 by the ejection mechanism 14 and ejected to the surface of the mandrel 11 in the ejection direction 16;
the metal melt on the surface of the mandrel 11 is cooled by a cooling mechanism 15.
The rotating speed of the mandrel 11 is a main factor for ensuring the centrifugal force of the metal melt, and the rotating speed of the mandrel 11 around the rotating axis is 60-180 r/min. If the rotation speed of the mandrel 11 is lower than this speed, the metal melt may be caused to be deposited and overflow on the upper surface of the mandrel 11 seriously, and if the rotation speed of the mandrel 11 is higher than this speed, the solidification speed of the metal melt on the surface of the mandrel 11 is affected, and the uniformity of the texture composition is affected. Illustratively, the speed of rotation of the mandrel 11 about the axis of rotation is 60r/min, 80r/min, 100r/min, 120r/min, 150r/min or 180 r/min.
Because the method for preparing the roller is carried out by using the device 10 for preparing the roller, a smaller molten pool can be formed, and the rapid solidification of the metal melt is facilitated, and fine grains are formed. Because the mandrel 11 rotates at a speed of 60-180 r/min and simultaneously sprays the metal melt, and the rotating speed is matched with the control condition of the roller manufacturing equipment 10, the structure of the surface of the mandrel 11 is more uniform, and the generation of pores is greatly reduced, so that the technical problems of thick structure and obvious pores in the prior art can be solved by the roller manufacturing method.
In addition, the size of the injection port 1421 of the injection mechanism 14 also has an influence on whether or not the molten metal is deposited and overflowed on the mandrel 11, and in order to reduce the influence, the size of the injection port 1421 is, for example, W (width) ═ L (length 1/100 to 1/50); the flow rate of the single nozzle was (50g-150 g)/s.
In order to ensure that the metal melt has good fluidity to facilitate injection, the temperature of the metal melt is, for example, 30 to 80 ℃ higher than the melting point, for example, 30 ℃, 40 ℃, 50 ℃, 60 ℃, 70 ℃ or 80 ℃ higher than the melting point, and if the temperature of the metal melt is too high, the crystal grains of the metal melt after solidification are easily coarse.
In addition, the linear reciprocating speed of the mandrel 11 along the extension direction of the rotating axis is related to the number of the nozzles 142 and the length of the mandrel 11, and optionally, the linear movement speed of the mandrel 11 along the extension direction of the rotating axis is 4-12 cm/min, so that the distribution uniformity of the metal melt on the surface of the mandrel 11 can be further improved. Illustratively, the speed of the linear movement of the mandrel 11 in the direction of extension of the axis of rotation is 4cm/min, 6cm/min, 8cm/min, 10cm/min or 12 cm/min.
Further, when the second induction coil 111 is disposed around the mandrel 11, the mandrel 11 is preheated by the second induction coil 111 before being sprayed with the metal melt, and the preheating temperature is 1080-. If the preset temperature of the mandrel 11 is too low, preheating cannot be performed, and after the metal melt contacts the mandrel 11, heat cracks are easily generated, so that the bonding with the surface of the mandrel 11 is reduced. If the preheating temperature of the mandrel 11 is too high, the mandrel 11 is easily softened, and the mandrel 11 is easily deformed when rotating, so that the preheating temperature is controlled to be 1080-.
Further, when the apparatus 10 for manufacturing a roll further includes the lifting mechanism 17, the mandrel 11 is driven to descend by the lifting mechanism 17 at a speed of 5-20mm/min while the mandrel 11 rotates and moves linearly, the descending speed can ensure that the distance between the bonding layer on the surface of the mandrel 11 and the nozzle 142 is in a relatively suitable range, and optionally, the descending speed of the mandrel 11 is 5mm/min, 10mm/min, 15mm/min, or 20mm/min, or a value between any two of them.
The method for manufacturing the roll of the present application will be described in further detail with reference to examples.
The metal melt used in the following examples had the following chemical composition:
example 1
The embodiment provides a method for preparing a roller, which utilizes the roller preparing device 10 of the embodiment of the application to prepare the roller, and comprises the following steps:
vacuumizing the vacuum chamber 18 and introducing inert gas, introducing inert gas into a crucible 141 with metal melt, and enabling the pressure in the crucible 141 to be 0.15MPa higher than the pressure in the vacuum chamber 18; wherein the holding temperature of the metal melt is 1530 ℃.
Preheating the mandrel to a temperature of 1080 ℃, driving the mandrel 11 to rotate around a rotating axis at a speed of 120r/min through the rotating mechanism 12, simultaneously driving the rotating mechanism 12 and the mandrel 11 to linearly move at a speed of 12cm/min along the extending direction of the rotating axis by the translation mechanism 13, and driving the translation mechanism 13, the rotating mechanism 12 and the mandrel 11 to descend at a speed of 10mm/min by the lifting mechanism 17; wherein the diameter of the mandrel 11 is 100 mm.
The metal melt is ejected from the ejection port 1421 by the ejection mechanism 14 and ejected to the surface of the mandrel 11 in the ejection direction 16; wherein, the included angle between the spraying direction 16 and the vertical direction is 15 °, and the distance from the spraying port 1421 of the nozzle 142 to the roller surface of the mandrel 11 along the spraying direction 16 is 5 mm; the composition of the metal melt is high-speed steel-1.
And spraying cooling water mist through a cooling mechanism 15 to cool the metal melt on the surface of the mandrel 11.
The carbide on the outer layer of the roller prepared by the embodiment is uniformly distributed, no obvious net-shaped carbide is seen, the structure is compact, and no macroscopic pores are found. Wherein the average grain size of the carbide is 10 μm, the hardness change fluctuation of the outer layer of the roller is small along the radial direction of the roller, the trend of gradual increase is shown from inside to outside, and the microhardness is maintained at 660-690 HV. The outer layer of the roll refers to a metal layer formed by a metal melt, and does not include a mandrel.
Example 2
This example provides a method for manufacturing a roll, which is different from example 1 only in that the composition of the molten metal of this example is high speed steel-2, the rotation speed of the mandrel 11 is 100r/min, and the linear movement speed of the mandrel 11 in the extending direction of the rotation axis is 10 cm/min. The holding temperature of the metal melt was 1510 ℃.
The carbide on the outer layer of the roller prepared by the embodiment is uniformly distributed, and no obvious network carbide is seen. The tissue was dense and no macroscopic pores were found. Wherein the average grain size of the carbide is 8 μm, the hardness variation fluctuation of the outer layer of the roll along the radial direction of the roll is small, the variation trend is the same as that of the example 1, and the microhardness is maintained at 800-850 HV.
Example 3
This example provides a method for manufacturing a roll, which is different from example 1 only in that the composition of the molten metal of this example is high speed steel-3, the rotation speed of the mandrel 11 is 60r/min, and the linear movement speed of the mandrel 11 in the extending direction of the rotation axis is 6 cm/min. The holding temperature of the metal melt is 1490 ℃.
The carbide on the outer layer of the roller prepared by the embodiment is uniformly distributed, and no obvious network carbide is seen. The tissue was dense and no macroscopic pores were found. Wherein, along the radial direction of the roller, the variation fluctuation of the hardness of the outer layer of the roller is smaller, the variation trend is the same as that of the embodiment 1, and the microhardness is maintained at 880-920 HV.
Example 4
The present embodiment provides a method for manufacturing a roll, which is different from embodiment 1 only in that the spindle 11 of the present embodiment rotates at a speed of 100r/min, the angle between the spraying direction 16 and the vertical direction is 0 °, and the distance of the nozzle 142 from the roll surface of the spindle 11 in the spraying direction 16 is 10 mm.
The carbide on the outer layer of the roller prepared by the embodiment is uniformly distributed, and no obvious network carbide is seen. The tissue was dense and no macroscopic pores were found. Wherein, along the radial direction of the roller, the hardness change fluctuation of the outer layer of the roller is smaller, the change trend is the same as that of the embodiment 1, and the microhardness is maintained at 680-720 HV.
Example 5
The present embodiment provides a method for manufacturing a roll, which is different from embodiment 1 only in that the spindle 11 of the present embodiment is rotated at a speed of 150r/min and the angle between the spraying direction 16 and the vertical direction is 30 °.
The carbide on the outer layer of the roller prepared by the embodiment is uniformly distributed, and no obvious network carbide is seen. The tissue was dense and no macroscopic pores were found. Wherein, along the radial direction of the roller, the variation fluctuation of the hardness of the outer layer of the roller is smaller, the variation trend is the same as that of the embodiment 1, and the microhardness is maintained at 670-710 HV.
Comparative example 1
The present comparative example provides a method for manufacturing a roll, which is different from example 1 only in that the rotation speed of the mandrel 11 in the present comparative example is 60r/min, the distance of the injection port 1421 of the nozzle 142 from the roll surface of the mandrel 11 in the injection direction 16 is 10mm, the linear movement speed of the mandrel 11 in the extension direction of the rotation axis is 2cm/min, and the angle between the injection direction 16 and the vertical direction is 45 °.
In the process of preparing the roller, partial metal melt overflows out of the roller surface of the mandrel 11, and the prepared roller has coarse reticular carbide on the outer layer, extremely uneven distribution and irregular carbide shape. The average grain size of carbide cannot be measured, and the hardness fluctuation of the outer layer of the roller is large along the radial direction of the roller and is maintained at 820-900 HV.
Comparative example 2
This comparative example provides a method of manufacturing a roll, which is different from example 1 only in that the angle between the spraying direction 16 and the vertical direction is 45 ° and the diameter of the mandrel is 180mm in this comparative example.
In the process of preparing the roller, the comparative example shows that the direction of the jet flow is easy to be tangent with the contact point of the roller surface of the mandrel, part of the metal melt overflows out of the roller surface of the mandrel 11, the carbide is uniformly distributed, and the structure is compact. But the weight of the melt with the same quality left on the surface of the mandrel after solidification is obviously reduced, the waste of the melt is caused, and the yield is low.
Comparative example 3
This comparative example provides a method of manufacturing a roll, which is different from example 1 only in that the rotation speed of the mandrel 11 is 240 r/min.
The carbide on the outer layer of the roller prepared by the comparative example is distributed more uniformly, no obvious net-shaped carbide is seen, the structure is compact, and no macroscopic pores are found. The tendency of gradual reduction is shown from inside to outside along the radial direction of the roller, which shows that the excessive rotating speed reduces the cooling efficiency along with the accumulation of the melt, the carbide of the microstructure at the outermost layer is gradually coarsened, and the hardness is maintained at 620-650 HV.
Comparative example 4
The present comparative example provides a method of manufacturing a roll, which is different from example 1 only in that the distance of the ejection port 1421 of the nozzle 142 from the roll surface of the mandrel 11 in the ejection direction 16 in the present comparative example is 2 mm.
The comparative example shows that the nozzle is easy to block in the process of preparing the roller, the melt is blocked at the outlet of the nozzle, and the preparation of the roller composite layer is difficult to realize.
Comparative example 5
The present comparative example provides a method of manufacturing a roll, which is different from example 1 only in that the distance of the ejection port 1421 of the nozzle 142 from the roll surface of the mandrel 11 in the ejection direction 16 in the present comparative example is 15 mm.
The carbide of the outer layer of the roller prepared by the comparative example is distributed more uniformly, no obvious net-shaped carbide is seen, the structure is more compact, the solidified outermost layer has individual macroscopic pores, and a small amount of melt sputtering occurs. Along the radial direction of the roller, the variation fluctuation of the hardness of the outer layer of the roller is small, and the hardness is maintained at 640-660 HV.
It should be noted that the average grain size of the carbides in the examples is calculated from the microstructure of the corresponding roll outer layer. The average size of carbides is analyzed by Image-Pro Plus statistics based on SEM (scanning electron microscope) images, and the SEM Image of example 1 is shown in FIG. 3, and the SEM Image of example 2 is shown in FIG. 4.
As a result of comparing the experimental results of example 1 and comparative example 1, it was found that when the rotation speed of the mandrel, the distance from the spray port to the roll surface of the mandrel in the spray direction, the linear movement speed of the mandrel in the extension direction of the rotation axis, and the included angle between the spray direction and the vertical direction were out of the proper ranges, carbide was coarse and was unevenly distributed on the roll surface of the mandrel.
The experimental results of comparative example 1 and comparative example 5 revealed that the roll outer layer of comparative example 5 had macroscopic voids and had melt sputtering, indicating that the distance between the ejection opening of comparative example 5 and the roll surface of the mandrel in the ejection direction was greater than that of example 1, which resulted in the generation of voids and in the melt sputtering.
As can be seen from the experimental results of comparative example 1 and comparative example 2, when the included angle between the spraying direction and the vertical direction is greater than 30 ° and the diameter of the mandrel is greater than 140mm, the waste of the melt is easily caused.
The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims (10)
1. An apparatus for manufacturing a roll, comprising:
the mandrel is transversely arranged;
a rotation mechanism configured to drive the mandrel to rotate about a rotation axis;
a translation mechanism configured to drive the rotation mechanism, the mandrel, and the linear motion to reciprocate synchronously along the extension direction of the rotation axis;
a spraying mechanism for containing the metal melt, the spraying mechanism having a spraying port for spraying the metal melt to the surface of the mandrel in a planar flow; the spraying direction of the metal melt points to the roll surface of the mandrel, the distance from the spraying opening to the roll surface of the mandrel along the spraying direction is 5-10 mm, the included angle between the spraying direction and the vertical direction is 0-30 degrees, and the diameter of the mandrel is 80-140 mm; and
a cooling mechanism configured to cool and solidify the metal melt sprayed to the mandrel surface.
2. The apparatus for preparing a roll according to claim 1, further comprising an elevating mechanism configured to drive the translation mechanism, the rotation mechanism, and the mandrel to be synchronously elevated.
3. The apparatus for manufacturing a roll according to claim 1 or 2, wherein the injection mechanism includes a crucible, a support frame for supporting the crucible, and a nozzle installed at a bottom of the crucible, the nozzle having an injection port, and an outer ring of the nozzle being provided with a first induction coil.
4. The apparatus for manufacturing a roll according to claim 1 or 2, further comprising a second induction coil wound around the mandrel for heating the mandrel.
5. The apparatus for manufacturing a roll according to claim 1 or 2, further comprising a vacuum chamber, wherein the mandrel, the rotating mechanism, the translating mechanism, the spraying mechanism, and the cooling mechanism are all provided in the vacuum chamber.
6. A method for manufacturing a roll, which is performed by using the apparatus for manufacturing a roll according to any one of claims 1 to 5, comprising the steps of:
the mandrel is driven to rotate around the rotating axis at the speed of 60-180 r/min by the rotating mechanism, and meanwhile, the rotating mechanism and the mandrel are driven to synchronously linearly move along the extending direction of the rotating axis by the translation mechanism;
ejecting the metal melt from the ejection port by the ejection mechanism and ejecting the metal melt to the surface of the mandrel in a planar flow manner in the ejection direction;
cooling the metal melt of the mandrel surface by the cooling mechanism.
7. The method for manufacturing a roll according to claim 6, wherein the speed of the linear movement of the mandrel in the extending direction of the rotation axis is 4 to 12 cm/min.
8. The method for manufacturing the roller according to claim 6, wherein the temperature of the metal melt is 30 to 80 ℃ higher than the melting point temperature;
and/or preheating the mandrel before spraying the metal melt, wherein the preheating temperature is 1080-1180 ℃.
9. The method for preparing the roller according to any one of claims 6 to 8, wherein the apparatus for preparing the roller further comprises a lifting mechanism, and the translation mechanism, the rotation mechanism and the mandrel are driven to synchronously descend by the lifting mechanism; optionally, the speed of the mandrel descent is 5-20 mm/min.
10. The method for manufacturing a roller according to any one of claims 6 to 8, wherein the mandrel, the rotating mechanism, the translating mechanism, the spraying mechanism and the cooling mechanism are all arranged in a vacuum chamber, and inert gas is filled in the vacuum chamber;
optionally, inert gas is filled in the injection mechanism, the pressure difference between the inside of the injection mechanism and the inside of the vacuum chamber is 0.1-0.3 MPa, and the pressure inside the injection mechanism is greater than the pressure inside the vacuum chamber.
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