CN114619045A - Roll shaft manufacturing device and composite roll manufacturing method - Google Patents

Abstract

The present application relates to a roller shaft manufacturing apparatus and a composite roller manufacturing method, the roller shaft manufacturing apparatus of the present application includes: the device comprises a spraying module, a crystallization module and a traction module, wherein the spraying module comprises a crucible and a crucible fixing support, the crucible fixing support is fixedly connected with the crucible, and the crucible is provided with at least one nozzle; the crystallization module comprises a fixed pipe die and a pipe die fixing support, and the pipe die fixing support is connected with the fixed pipe die; the traction module comprises a forming platform, a platform lifting mechanism and a platform rotating mechanism, wherein the forming platform is configured to move in the fixed pipe die; wherein, the injection direction of nozzle is towards the shaping platform, and fixed pipe die and shaping platform form and are used for fashioned shaping space. This application can adopt the mode of 3D printing to make the roller cool off solidification on rotatory shaping platform, has changed casting mode and casting equipment that the metal liquid bulky solidified, has improved the roller quality of making for the roller crystalline grain that makes is tiny, and the tissue is even, does not have the composition segregation.

Description

Roll shaft manufacturing device and composite roll manufacturing method

Technical Field

The application relates to the technical field of roller shaft manufacturing, in particular to a roller shaft manufacturing device and a composite roller manufacturing method.

Background

The roll shaft is a cylindrical machine member capable of rolling on the machine. The composite roller is applied to a rolling mill, the composite roller comprises a roller body outer layer and a roller core part which are made of different materials, and the roller neck and the shaft head are arranged on the roller core part.

The manufacturing method of the composite roller mainly comprises a centrifugal casting method, spray forming, continuous casting outer layer forming, hot isostatic pressing and rotary electroslag casting method. However, the composite roller manufactured by the centrifugal casting method has serious segregation of the structure of the roller layer, has thick eutectic carbide, short service life and long-term performance which is not improved or broken through; the spray forming is easy to cause the over-spraying of the sprayed liquid drops, the yield is low, the tissue is loose, and obvious pores exist; the continuous casting outer layer forming process is complex, difficult and high in equipment requirement, and industrialization cannot be realized; the hot isostatic pressing process is limited by equipment, only can produce small-diameter rollers and is not suitable for producing large and medium-sized rollers; rotary electroslag casting is also expensive and difficult to produce larger diameter rolls.

Therefore, how to improve the roller shaft manufacturing device and the manufacturing method becomes a problem to be solved.

Disclosure of Invention

An object of the present application is to provide a roll shaft manufacturing apparatus capable of improving the quality of a manufactured roll shaft.

It is also an object of the present application to provide a composite roll manufacturing method that can improve the quality of the manufactured composite roll.

In order to achieve the above-mentioned objects,

in a first aspect, the present invention provides a roll manufacturing apparatus comprising: the device comprises a spraying module, a crystallization module and a traction module, wherein the spraying module comprises a crucible and a crucible fixing support, the crucible fixing support is fixedly connected with the crucible and used for fixing the crucible, and at least one nozzle is arranged on the crucible; the crystallization module comprises a fixed pipe die and a pipe die fixing support, and the pipe die fixing support is connected with the fixed pipe die and used for fixing the fixed pipe die; the traction module comprises a forming platform, a platform lifting mechanism and a platform rotating mechanism, the platform lifting mechanism is in transmission connection with the forming platform and used for driving the forming platform to lift, the platform rotating mechanism is in transmission connection with the forming platform and used for driving the forming platform to rotate, and the forming platform is configured to be capable of moving in the fixed pipe mould; wherein, the injection direction orientation of nozzle the shaping platform, fixed pipe die with the shaping platform forms and is used for fashioned shaping space.

In one embodiment, the crucible is a ring-shaped structure, and the crucible is provided with a storage cavity for storing materials and a first through hole for the roller core to pass through; wherein the axis of the first through hole and the axis of the fixed pipe die are overlapped.

In one embodiment, the plurality of nozzles are distributed in a circumferential array around the axis of the first through hole.

In one embodiment, the roller manufacturing apparatus further includes: the preheating module comprises a first heating element, the first heating element is arranged on one side of the crucible along the axis direction of the first through hole and is used for heating the roller core.

In one embodiment, the injection module further comprises: and the continuous liquid supply mechanism is connected with the storage cavity and is used for supplying liquid.

In one embodiment, the injection module further comprises: a second heating member disposed on an outer surface of the crucible.

In one embodiment, the injection module further comprises: the crucible temperature measuring element is arranged in the storage cavity.

In one embodiment, the injection module further comprises: the crucible is arranged in the outer cavity; an air inlet and an air outlet are arranged on the outer cavity; the vacuumizing element is connected with the exhaust hole; the pressure regulating element is connected with the air inlet.

In one embodiment, the injection module further comprises: an air pressure detecting element. The air pressure detection element is arranged in the outer chamber and used for detecting the air pressure of the outer chamber.

In one embodiment, the crystallization module further includes: and the pipe die temperature measuring element is arranged in the forming space.

In one embodiment, the roller manufacturing apparatus further includes: and the cooling module comprises a first cooler and a second cooler, the first cooler is arranged on the fixed pipe die, and the second cooler is arranged on the forming platform.

In one embodiment, the roller manufacturing apparatus further includes: the main control module is electrically connected with the injection module, the crystallization module and the traction module and used for controlling.

In a second aspect, the present invention provides a method for manufacturing a composite roll, comprising:

fixing the roller core and a forming platform, and enabling the roller core, the forming platform and a fixed pipe die to form a forming space;

introducing an initial material into a crucible, and enabling the crucible to be in a preset environment;

continuously injecting the starting material into the forming space through a nozzle on the crucible, the starting material accumulating in the forming space to form a melt pool;

rotating the forming platform, and solidifying part or all of the molten pool on the forming platform to form a solid phase;

moving the forming platform towards a preset direction to obtain a roller body outer layer fixed on the roller core;

and separating the roller core from the forming platform to obtain the composite roller comprising the outer layer of the roller body and the roller core.

Compared with the prior art, the beneficial effect of this application is:

this application can adopt the mode of 3D printing to make the roller cool off solidification on rotatory shaping platform, has changed casting mode and casting equipment that the metal liquid bulky solidified, has improved the roller quality of making for the roller crystalline grain that makes is tiny, and the tissue is even, does not have the composition segregation.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are required to be used 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 for those skilled in the art, other related drawings can be obtained from the drawings without inventive effort.

Fig. 1 is a schematic structural view of a roller shaft manufacturing apparatus according to an embodiment of the present application.

Fig. 2 is a schematic structural view of a roller shaft manufacturing apparatus according to an embodiment of the present application.

Fig. 3 is a schematic structural view of a roller shaft manufacturing apparatus according to an embodiment of the present application.

Fig. 4 is a schematic structural view of a roller shaft manufacturing apparatus according to an embodiment of the present application.

FIG. 5 is a bottom view of a crucible according to an embodiment of the present application.

Fig. 6 is a schematic structural view of a roller shaft manufacturing apparatus according to an embodiment of the present application.

Fig. 7 is a schematic flow chart illustrating a method for manufacturing a composite roll according to an embodiment of the present application.

Fig. 8 is a schematic structural diagram of a composite roll according to an embodiment of the present application.

Fig. 9 is a metallographic structure diagram of a composite roll according to an embodiment of the present disclosure.

Fig. 10 is a metallographic structure diagram of a composite roll according to an embodiment of the present disclosure.

Icon: 100-a spray module; 110-a crucible; 111-a first through-going hole; 112-a storage cavity; 120-crucible fixing support; 130-a nozzle; 140-nozzle valve; 150-a continuous liquid supply mechanism; 160-a second heating element; 170-crucible temperature measurement element; 180-an outer chamber; 181-air inlet hole; 182-air outlet holes; 191-a vacuum-pumping element; 192-a voltage regulating element; 193-air pressure detecting element; 200-a crystallization module; 210-fixing a pipe die; 220-pipe die fixing support; 230-tube die temperature element; 300-a traction module; 310-a forming platform; 320-a platform lifting mechanism; 330-a platform rotation mechanism; 340-a guide tube; 350-roller core temperature measuring element; 400-a molding space; 500-preheating module; 510-a first heating element; 530-a porcelain tube; 540-electrolytic cotton cloth layer; 600-a cooling module; 610-a first cooler; 620-a second cooler; 700-a master control module; 810-roll core; 820-outer layer of the roll body; 830-solid phase; 831-upper surface of the solid phase; 840-a molten pool; 850-compound roll; 9-roll shaft manufacturing means; 550-a porcelain tube fixing support; 183-outer chamber fixed support.

Detailed Description

The terms "first," "second," "third," and the like are used for descriptive purposes only and not for purposes of indicating or implying relative importance, and do not denote any order or order.

Furthermore, the terms "horizontal", "vertical", "overhang" and the like do not imply that the components are required to be absolutely horizontal or overhang, but may be slightly inclined. For example, "horizontal" merely means that the direction is more horizontal than "vertical" and does not mean that the structure must be perfectly horizontal, but may be slightly inclined.

In the description of the present application, it should be noted that the terms "inside", "outside", "left", "right", "upper", "lower", and the like indicate orientations or positional relationships based on orientations or positional relationships shown in the drawings or orientations or positional relationships that are conventionally arranged when products of the application are used, and are used only for convenience in describing the application and simplifying the description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the application.

In the description of the present application, unless expressly stated or limited otherwise, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements.

The technical solution of the present application will be clearly and completely described below with reference to the accompanying drawings.

Fig. 1 is a schematic structural diagram of a roller shaft manufacturing apparatus 9 according to an embodiment of the present application. A roll shaft manufacturing apparatus 9 comprising: a spray module 100, a crystallization module 200, and a drag module 300.

The spray module 100 comprises a crucible 110 and a crucible fixing bracket 120, the crucible fixing bracket 120 is fixedly connected with the crucible 110 for fixing the crucible 110, and at least one nozzle 130 is arranged on the crucible 110. The nozzle 130 is used to spray the liquid starting material.

The crystallization module 200 includes a fixed pipe mold 210 and a pipe mold fixing bracket 220, and the pipe mold fixing bracket 220 is connected with the fixed pipe mold 210 for fixing the fixed pipe mold 210. The fixed tube die 210 is used to control the cross-sectional shape and size of the roll shaft being made.

The traction module 300 comprises a forming platform 310, a platform lifting mechanism 320 and a platform rotating mechanism 330, wherein the platform lifting mechanism 320 is in transmission connection with the forming platform 310 and used for driving the forming platform 310 to lift, the platform rotating mechanism 330 is in transmission connection with the forming platform 310 and used for driving the forming platform 310 to rotate, the forming platform 310 is configured to be capable of moving in the fixed pipe die 210 and used for manufacturing a roller shaft with a large length, and in order to prevent liquid leakage, the outer diameter of the forming platform 310 is matched with the inner diameter of the fixed pipe die 210, that is, the outer diameter of the forming platform 310 is equal to the inner diameter of the fixed pipe die 210. The platform lift mechanism 320 may include a rail, a hydraulic cylinder, an air cylinder, or a motor. The platform rotation mechanism 330 may include motors, gears, and the like.

Wherein the injection direction of the nozzle 130 is toward the molding stage 310, the fixed pipe mold 210 and the molding stage 310 form a molding space 400 for molding.

In one operation, the nozzle 130 is first closed and the position of the forming platform 310 is adjusted such that the forming platform 310 is located within the fixed pipe mold 210. Introducing the melted starting material into the crucible 110; controlling the injection module 100, feeding the initial material into the molding space 400 through the nozzle 130, maintaining the molten initial material on the molding platform 310 by the platform rotating mechanism 330 to accumulate on the molding platform 310 to form a melt pool, cooling and solidifying the initial material in the melt pool on the rotating molding platform 310, controlling the molding platform 310 to lift by the platform lifting mechanism 320, continuously pulling out the casting blank which is initially solidified in the molding space 400, taking out the casting blank by the molding platform 310 after the casting blank reaches the required size for preparation and the initial material in the molding space 400 is completely solidified, obtaining a roll shaft after demolding the casting blank, closing the roll shaft manufacturing device 9, and finishing the whole preparation process.

The embodiment can adopt a 3D printing mode to cool and solidify the roller on the rotating forming platform 310, changes the casting mode and the casting equipment of large-volume solidification of molten metal, and improves the quality of the manufactured roller, so that the manufactured roller has fine grains, uniform tissues and no component segregation.

In this embodiment, the spraying direction of the nozzle 130 is downward, and the spraying module 100 is located above the crystallization module 200. The roll shaft manufacturing apparatus 9 can be used to manufacture square rolls, flat rolls, and round casting rolls of various sizes by changing the shape of the fixed pipe mold 210. The roll shaft manufacturing apparatus 9 of the present embodiment may be used to manufacture a solid roll shaft, or may be used to manufacture a hollow roll shaft or a composite roll 850 by adding a roll core 810. The roller shaft manufacturing device 9 of the embodiment has a low requirement on raw materials, and can be used for a wide range of materials, for example, the roller shaft manufacturing device 9 can be used for metal casting, i.e., casting of pure metals and casting of alloy materials, and the metal materials can be steel materials, pure aluminum and aluminum alloys, pure copper and copper alloys, pure zinc and zinc alloys, magnesium alloys, pure titanium and titanium alloys; it can also be used for 3D printing using bondable materials such as powdered metals or plastics.

Fig. 2 is a schematic structural diagram of a roller shaft manufacturing apparatus 9 according to an embodiment of the present application. In order to manufacture the hollow roll shaft or the composite roll 850, a prepared roll core 810 is fixed on the forming platform 310, and the roll core 810 can move along with the movement of the forming platform 310 and rotate along with the rotation of the forming platform 310. The roller core 810 is inserted into the fixed pipe mold 210, and the molding space 400 is defined by the upper surface of the molding platform 310, the inner surface of the fixed pipe mold 210, and the outer surface of the roller core 810. The shape and size of the roll core 810 and the shape and size of the fixed pipe die 210 are determined by the final desired prepared roll shaft.

The injection module 100 further includes: the crucible comprises an outer chamber 180, a pressure regulating element 192 and a vacuumizing element 191, wherein the crucible 110 is arranged in the outer chamber 180; an air inlet hole 181 and an air outlet hole 182 are arranged on the outer chamber 180; the vacuum pumping unit 191 is connected to the exhaust hole 182 for pumping vacuum of the outer chamber 180; the pressure regulating element 192 is connected with the air inlet 181, the pressure regulating element 192 can be an air inflation assembly such as an air storage box and an air pump, the pressure regulating element 192 regulates and controls the air pressure of the outer cavity 180 by filling a proper amount of inert gas such as nitrogen or argon into the outer cavity 180, a certain pressure difference is formed between the outer cavity 180 and the forming space 400, so that the nozzle 130 is facilitated to spray, and the initial material can be deposited in the forming space 400. The intake holes 181 and the exhaust holes 182 may be provided with valves for controlling the opening and closing of the intake holes 181 and the exhaust holes 182. The outer chamber 180 may be fixed by an outer chamber fixing bracket 183.

The injection module 100 further includes: and a second heating member 160, the second heating member 160 being provided on an outer surface of the crucible 110, for heating or maintaining the material in the crucible 110 to maintain the material in the crucible 110 in a liquid state and at a certain degree of superheat. The second heating member 160 may include a plurality of heating elements, heating pipes, or electromagnetic induction coils, which are uniformly and directly fixed on the outer surface of the crucible 110.

In this embodiment, the crucible 110 is a ring structure, the crucible 110 has a storage cavity 112 for storing material and a first through hole 111 for the roller core 810 to pass through (see fig. 1); the axis of the roller core 810, the axis of the first through hole 111, and the axis of the fixed pipe die 210 are arranged to overlap. Accordingly, the outer chamber 180 is also a ring structure having a cavity for storing the crucible 110 and the gas, a nozzle hole through which the nozzle 130 passes, and a through hole through which the roll core 810 passes. The nozzles 130 are provided in plurality and are distributed in a circumferential array around the axis of the first through-hole 111. With such an arrangement, the structure is compact, the space is saved, and the liquid flow sprayed by the nozzle 130 surrounds the roller core 810, so that the sprayed initial material can be well metallurgically combined with the roller core 810.

The diameter of the first through hole 111 is larger than or equal to that of the roller core 810, and the diameter of the through hole is larger than or equal to that of the roller core 810, so that the crucible 110 and the outer chamber 180 are prevented from interfering with the movement of the roller core 810.

The injection module 100 further includes: a crucible temperature measuring element 170, the crucible temperature measuring element 170 is arranged in the storage cavity 112. The crucible temperature measuring element 170 may be a temperature sensor or a thermocouple or other temperature measuring element for detecting the temperature of the material in the crucible 110 or detecting the ambient temperature of the crucible 110. One or more crucible temperature sensing elements 170 can be provided.

In this embodiment, the injection module 100 further includes: and the continuous liquid supply mechanism 150, wherein the continuous liquid supply mechanism 150 is connected with the storage cavity 112 and is used for supplying liquid. The starting material may be melted in a melting apparatus such as an intermediate frequency furnace, and after reaching the tapping temperature, the molten alloy steel is poured into the crucible 110, which is kept warm by the second heating member 160, through the continuous liquid supply mechanism 150. The continuous feed mechanism 150 may include components such as a storage cartridge and a pump, and may be located within the outer chamber 180 or outside the outer chamber 180.

In another embodiment, the starting material may be in a solid state, and the starting material is melted by heating in the crucible 110 by the second heating member 160 and transformed into a liquid state.

The roller shaft manufacturing apparatus 9 further includes: the preheating module 500, the preheating module 500 includes a first heating member 510 for heating the roller core 810, the first heating member 510 is disposed on one side of the crucible 110 along the axial direction of the first through hole 111, that is, the first heating member 510 may be disposed above or below the crucible 110 as long as it is above the forming platform 310. The first heating member 510 may include a plurality of elements such as an electric heating sheet, a heating pipe, or an electromagnetic induction coil. In this embodiment, the preheating module 500 is disposed above the crucible 110.

Please refer to fig. 3, which is a schematic structural diagram of a roller shaft manufacturing apparatus 9 according to an embodiment of the present application, and also refer to fig. 2. In one operation, the roll core 810 is secured to the forming table 310 and the forming table 310 is positioned within the region of the fixed tube mold 210; introducing molten metal into the crucible 110 through the continuous liquid supply mechanism 150, and generating a pressure difference between the crucible 110 and the forming space 400; molten metal is continuously injected into the molding space 400 through the nozzle 130, and the molten metal accumulates in the molding space 400 to form a molten pool 840.

Rotating the forming platform 310 before or after the molten pool 840 is formed, and rapidly solidifying part or all of the molten pool 840 on the rotating forming platform 310 under the action of a cooling mechanism to form a solid phase 830; the forming platform 310 is moved downwards at a certain speed while keeping the rotating state, the partially solidified solid phase 830 and the roller core 810 move along with the movement of the forming platform 310, and simultaneously, the molten metal is continuously injected into the forming space 400 through the nozzle 130, the upper surface 831 of the solid phase can continuously form or keep a part of the molten pool 840, and the molten pool 840 is gradually solidified on the roller core 810 to form the roller body outer layer 820; and finally, after the casting blank reaches the required size for preparation, the crucible 110 is not filled with molten metal, after the molten metal in the crucible 110 is completely consumed and the molten metal in the forming space 400 is completely solidified, the roller core 810 and the outer layer 820 of the roller body arranged on the roller core 810 are taken out through the forming platform 310, a finished product can be obtained after demolding, the roller shaft manufacturing device 9 is closed, and the whole preparation process is finished.

During demolding, the roller core 810 can be communicated with the roller body outer layer 820 to be separated from the forming platform 310, and the roller core 810 does not need to be separated from the roller body outer layer 820, so that a solid composite roller can be obtained. This embodiment thus forms a composite roll comprising a roll body outer layer 820 and a roll core 810 by directly plating a layer of dissimilar material onto the roll core 810.

In the forming process of the composite roll 850, the liquid flow ejected by the nozzle 130 impacts the molten pool 840 under the action of pressure difference, so that the formation of the reticular eutectic carbide can be avoided, the liquid flow ejected by the nozzle 130 continuously impacts the molten pool 840 in the forming process of the composite roll 850, the temperature gradient is constant all the time, the solidification rate is stable, the generation of final finished product pores can be reduced, and the liquid initial materials of the materials can be uniformly mixed because the partially solidified solid phase 830 and the roll core 810 rotate along with the rotation of the forming platform 310, so that the prepared composite roll 850 has no component segregation, fine grains, uniform tissues and strong toughness.

In addition, in the embodiment, the moving distance of the forming platform 310 can be controlled, and the height of the roller shaft can be controlled, so that a large-size roller shaft can be manufactured, and the roller shaft has a simple structure and low cost, and is easy to realize industrialization. The spray module 100, the crystallization module 200, the traction module 300 and the preheating module 500 of the present embodiment are all independently detachable, which facilitates replacement and prolongs the service life of the roller shaft manufacturing apparatus 9.

In another embodiment, the molten metal may be injected into the molding space 400 through the nozzle 130 at intervals by controlling the interval opening and closing of the nozzle 130. Compared with the continuous liquid supply of the embodiment, the continuous liquid supply can adjust the liquid flow speed by controlling the air pressure difference between the crucible 110 and the forming space 400, ensure the flow rate of the injected molten pool, and adjust the liquid flow cooling speed by adjusting the liquid flow speed, so that the molten metal on the surface of the molten pool is not completely solidified, and the liquid flow sprayed by the nozzle 130 can continuously impact the surface of the unsolidified molten pool 840 in the forming process of the composite roll 850, thereby ensuring that the temperature gradient is always constant, the solidification rate is stable, and the generation of final finished product pores can be reduced; the intermittent injection may cause solidification delamination, so the continuous liquid supply of the present embodiment has better uniformity of the final product than the intermittent liquid supply.

Fig. 4 is a schematic structural diagram of a roller shaft manufacturing apparatus 9 according to an embodiment of the present application. The roller shaft manufacturing apparatus 9 further includes: the cooling module 600, the cooling module 600 includes a first cooler 610 and a second cooler 620, the first cooler 610 is disposed on the fixed pipe mold 210, and the second cooler 620 is disposed on the forming platform 310. The first cooler 610 and the second cooler 620 may be a water cooling mechanism or an air cooling mechanism for cooling the material in the molding space 400 so that the solidification process thereof may be accelerated.

The traction module 300 further comprises: and the guide pipe 340, wherein the guide pipe 340 is arranged above the preheating module 500, and the inner diameter of the guide pipe 340 is larger than or equal to the outer diameter of the roller core 810. The guide tube 340 is stationary, and the roller core 810 may be inserted into the guide tube 340 to limit the moving range of the roller core 810.

The preheating module 500 further comprises a porcelain tube 530, and the porcelain tube 530 is sleeved outside the roller core 810; the first heating member 510 is disposed on the outer surface of the porcelain tube 530, and the porcelain tube 530 may be made of ceramic, which may not only insulate, but also easily conduct heat. An electrolytic cotton cloth layer 540 for heat preservation may be further disposed on the inner surface of the porcelain tube 530. The porcelain tube 530 may be fixed by a porcelain tube fixing bracket 550.

The injection module 100 may further include an air pressure detecting element 193 such as an air pressure gauge or an air pressure sensor disposed in the outer chamber 180 for detecting the air pressure in the outer chamber 180.

The crystallization module 200 may further include a pipe mold temperature measuring element 230 disposed in the molding space 400 for detecting the temperature of the casting slab or the molten metal in the molding space 400. The tube die temperature element 230 may be a temperature sensor or a thermocouple.

The traction module 300 may further include a roll core temperature measuring element 350 disposed below the preheating module 500 for detecting the temperature of the roll core 810 preheated by the preheating module 500. The roll core temperature sensing element 350 can be an infrared thermometer.

Referring to fig. 5, a bottom view of the crucible 110 is shown according to an embodiment of the present application. A nozzle valve 140 is disposed on one nozzle 130, and the nozzle valve 140 is disposed to facilitate opening and closing of the nozzle. The valve may be an electrically operated valve or a manually operated valve.

When the nozzle valves 140 are electrically operated valves, the nozzle valves 140 of all the nozzles 130 can be controlled in a linkage manner, and automation is easy to realize. In this embodiment, six nozzles 130 are provided.

The inner hole of the nozzle 130 may be a circular truncated cone hole, the aperture is sequentially reduced from top to bottom, and the inner hole of the nozzle 130 may also be a cylindrical hole.

Fig. 6 is a schematic structural diagram of a roller shaft manufacturing apparatus 9 according to an embodiment of the present application. The roll shaft manufacturing apparatus 9 may be controlled automatically in addition to manual control. The roll shaft manufacturing apparatus 9 further includes a main control module 700, and the main control module 700 includes electronic devices such as a human-computer interface, a processor, a transceiver, and a controller. The man-machine interaction interface can be computer input and output equipment such as a display screen, a touch screen, a key, a knob, a switch, a rocker and the like.

The main control module 700 is electrically connected to the injection module 100, the crystallization module 200 and the traction module 300, and is configured to implement automation control, information reception and information processing. The main control module 700 integrates data collection and control of each module in the roll shaft manufacturing device 9, and realizes functions of opening and closing control of the nozzle valve 140, temperature measurement of the crucible 110, heating control of the crucible 110, pressure measurement of the outer chamber 180, pressure control of the outer chamber 180, temperature measurement of the fixed pipe die 210, control of the traction module 300 and the like.

In this embodiment, the main control module 700 is further electrically connected to the cooling module 600 and the preheating module 500, and is used for controlling the cooling module 600 and the preheating module 500.

Referring to fig. 7, a flow chart of a method for manufacturing a composite roll 850 according to an embodiment of the present application is shown. The method can be used in the roll shaft manufacturing apparatus 9 shown in fig. 1 to 6 for manufacturing the composite roll 850 shown in fig. 8. The method of manufacturing the composite roll 850 may include the steps of:

step S101: the roll core 810 is fixed to the forming platform 310, so that the roll core 810, the forming platform 310 and the fixed pipe mold 210 form a forming space 400.

As a result of manufacturing the composite roll 850, a core 810 needs to be secured to the forming table 310. In this step, the fixing manner of the roller core 810 and the forming platform 310 may be a snap connection, a clamping fixation, or a bolt connection.

Step S102: the starting material is introduced into the crucible 110, and the crucible 110 is placed in a predetermined environment.

The starting material in this step may be a completely molten liquid metal. This step may be performed by introducing the starting material into the crucible 110 through the continuous liquid supply mechanism 150, and the nozzle 130 may be in a closed state or an open state.

The preset environment in this step may be a preset temperature T1 and a preset pressure P1, and the preset pressure P1 may be controlled by the vacuum pumping element 191, the pressure regulating element 192, and the pressure detecting element 193, for example, vacuum pumping is performed first, and then inert gas is filled. The preset temperature T1 can be controlled by the second heating member 160 and the crucible temperature measuring element 170.

Wherein T1 is 150-250 ℃ higher than the melting point of the initial material, P1 is 0.5-2MPa higher than 1 atmosphere (normal pressure), namely T1 is Tm + (150-250) DEG C, and P1 is 1atm + (0.5-2) MPa. So set up, can realize good metallurgical bonding, the tissue is even tiny, and too high low can all influence metallurgical quality.

For example: if T1 is less than Tm + (150-250) DEG C, the liquid metal has high viscosity and poor fluidity, and is not easy to print in liquid state. If the P1 is less than 1atm + (0.5-2) MPa, the impact force is insufficient, and the eutectic phase can not be broken, and if the P1 is more than 1atm + (0.5-2) MPa, the control of the pressure capacity and the deposition speed of the whole equipment is not facilitated.

And because the deposition forming speed of the composite roll 850 can be controlled by the temperature difference between the crucible 110 and the roll core 810 and the air pressure difference between the crucible 110 and the forming space 400, the air pressure of the forming space 400 is 1 atmosphere, and the temperature of the roll core 810 is related to the preheating module 500, the deposition forming speed of the composite roll 850 can be regulated and controlled by accurately adjusting the temperature of the crucible 110, the temperature of the roll core 810 and the air pressure of the crucible 110.

After this step, the crucible 110 can be continuously controlled to be in the environment of the preset temperature T1 and the preset pressure P1 by the injection module 100.

Step S103: the starting material is continuously injected into the forming space 400 through the nozzle 130 on the crucible 110, and the starting material accumulates in the forming space 400 to form a melt pool 840.

The roll core 810 may be preheated by the preheating module 500 before this step, and the preheating temperature of the roll core 810 may be controlled by the first heating member 510 and the roll core temperature measuring element 350. The preheating temperature of the roller core 810 is the key of metallurgical bonding, the metallurgical quality can be influenced when the preheating temperature is too high or too low, if the preheating temperature of the roller core 810 is too low, the roller core 810 and high-temperature melt are contacted with each other to easily generate heat cracks, and the preheating temperature of the roller core 810 is too high, so that the roller core 810 is easily softened, and the structure of a final finished product is not stable enough. The temperature to preheat the core 810 needs to be lower than the melting point of the starting material, and in one embodiment, when the starting material is 45 steel, the temperature to preheat the core 810 is 950-.

In this step, the starting material accumulates on the forming table 310 in the forming space 400 to form a melt pool 840, ready to solidify. In this step, the forming table 310 may be in a rotated state or a non-rotated state.

Step S104: the forming table 310 is rotated and some or all of the melt pool 840 solidifies to form a solid phase 830 on the forming table 310.

In this step, the forming platform 310 can be rotated by the platform rotating mechanism 330, and a certain stirring effect can be exerted on the molten pool 840, so that the produced roll shaft has fine grains, uniform tissue and no component segregation.

Step S105: the forming table 310 is moved in a predetermined direction to form the outer roll shell 820 secured to the roll core 810.

The preset direction of this step is downward, the forming platform 310 is passed through the fixed pipe die 210, and in this step, the nozzle 130 is kept in an open state all the time to perform continuous liquid supply. In the liquid supply process, the liquid flow speed can be adjusted by controlling the air pressure difference between the crucible 110 and the forming space 400, the flow rate of the injected molten pool is ensured, the liquid flow cooling speed can be adjusted by adjusting the liquid flow speed, so that the molten metal on the surface of the molten pool is not completely solidified, the liquid flow sprayed by the nozzle 130 can continuously impact the surface of the unsolidified molten pool 840 in the forming process of the composite roll 850, the temperature gradient is always constant, the solidification rate is stable, and the generation of final product pores can be reduced.

In this step, the temperature of the molten pool 840 in the upper surface 831 of the solid phase can be measured by the tube die temperature measuring element 230, and the speed of the forming platform 310 can be controlled according to the temperature measured by the tube die temperature measuring element 230. For example, when the surface temperature of the unsolidified molten pool 840 of one layer is reduced to 0.5 to 0.7 times the melting point of the starting material, (0.5-0.7) Tm, the forming platform 310 is controlled to be lowered a certain distance for the next layer of liquid printing.

Wherein the rotating speed of the forming platform 310 is 60-200r/min, and the descending speed of the forming platform 310 is 5-10 cm/min. The rotation speed of the forming platform 310 and the descending speed of the forming platform 310 complement each other, and if one of the rotation speed and the descending speed of the forming platform 310 is not in the above range, the cooling effect of the melt is easily poor, and the mutual combination between two adjacent liquid printing layers is easily caused, so that the metallurgical quality of the final finished product and the like cannot achieve the ideal effect.

In another embodiment, the nozzle 130 may be controlled to be opened or closed, so that the starting material may be intermittently discharged. For example: firstly opening the nozzle 130, outputting initial materials to the upper surface 831 of the solid phase to form a new molten pool 840, closing the nozzle 130, solidifying part or all of the new molten pool 840 under the action of the fixed pipe die 210 to form a liquid printing layer, then opening the nozzle 130, outputting the initial materials to form a next new molten pool 840, closing the nozzle 130 to form a new liquid printing layer, and repeatedly circulating to obtain the outer layer 820 of the roller body with the preset size.

Step S106: the roll core 810 is separated from the forming table 310 to provide a composite roll 850 comprising a roll body outer layer 820 and a roll core 810.

Prior to this step, the product of step S105 is annealed to prevent cracking of the roll body outer layer 820 and the roll core 810. The annealing temperature of the annealing treatment is 580-700 ℃, the heat preservation time is 2-4 hours, and the annealing treatment is cooled along with the furnace.

After this step, the composite roll 850 may be rough machined to meet the required dimensional requirements, followed by a quenching and tempering heat treatment to improve the hardness and wear resistance of the composite roll 850.

In one embodiment, the composite roll 850 is rough machined, the rough machined composite roll 850 is heated to 1050-.

The composite roll 850 may be a composite high speed steel roll, a high chromium cast iron roll, a semi-steel roll, or a high alloy chilled iron roll, wherein the composite roll 850 has excellent high hardness, high wear resistance, and good hardenability.

Please refer to fig. 9 and 10, which are metallographic structure diagrams of a composite roll 850 according to an embodiment of the present disclosure. In one embodiment, the applicant has conducted tests on the roll shaft manufacturing apparatus 9 shown in fig. 1 to 6 and the manufacturing method of the composite roll 850 shown in fig. 7.

Test objectives: the cast composite high-speed steel roll is made of No. 45 steel.

The test parameters include:

the preheating temperature of the roller core 810 is about 1050 ℃, the air pressure difference between the crucible 110 and the forming space 400 is less than 2MPa, and the heat preservation temperature of the crucible 110 is about 1695 ℃, which is the sum of the melting point of No. 45 steel and 200 ℃. The rotation speed of the forming platform 310 is 120r/min, and the descending speed of the forming platform 310 is 8 cm/min.

The prepared composite high-speed steel roller has fine and uniform crystal grains, the average size of the crystal grains is less than 10 microns, no component segregation and coarse carbide exist, the structure is uniform, and a metallographic structure diagram is shown in figures 9 and 10.

It should be noted that the features of the embodiments in the present application may be combined with each other without conflict.

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, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims (10)

1. A roll manufacturing apparatus, comprising:

the spraying module comprises a crucible and a crucible fixing support, the crucible fixing support is fixedly connected with the crucible and used for fixing the crucible, and at least one nozzle is arranged on the crucible;

the crystallization module comprises a fixed pipe die and a pipe die fixing support, and the pipe die fixing support is connected with the fixed pipe die and used for fixing the fixed pipe die; and

the traction module comprises a forming platform, a platform lifting mechanism and a platform rotating mechanism, wherein the platform lifting mechanism is in transmission connection with the forming platform and used for driving the forming platform to lift, the platform rotating mechanism is in transmission connection with the forming platform and used for driving the forming platform to rotate, and the forming platform is configured to be capable of moving in the fixed pipe mould;

wherein, the injection direction orientation of nozzle the shaping platform, fixed pipe die with the shaping platform forms and is used for fashioned shaping space.

2. The roller manufacturing apparatus of claim 1, wherein the crucible has a ring-shaped structure having a storage chamber for storing a material and a first through-hole through which the roller core passes;

the axis of the first through hole and the axis of the fixed pipe die are overlapped, and the plurality of nozzles are distributed in a circumferential array around the axis of the first through hole.

3. The roller shaft producing apparatus of claim 2, further comprising:

the preheating module comprises a first heating element, is arranged on one side of the crucible along the axis direction of the first through hole and is used for heating the roller core.

4. The roller manufacturing apparatus of claim 2, wherein the injection module further comprises:

and the continuous liquid supply mechanism is connected with the storage cavity and used for supplying liquid.

5. The roller manufacturing apparatus of claim 2, wherein the injection module further comprises:

the second heating element is arranged on the outer surface of the crucible; and

and the crucible temperature measuring element is arranged in the storage cavity.

6. The roller manufacturing apparatus of claim 1, wherein the injection module further comprises:

the crucible is arranged in the outer cavity; an air inlet and an air outlet are arranged on the outer cavity;

the vacuumizing element is connected with the exhaust hole; and

the pressure regulating element is connected with the air inlet;

and the air pressure detection element is arranged in the outer chamber and used for detecting the air pressure of the outer chamber.

7. The roller shaft manufacturing apparatus of claim 1, wherein the crystallization module further comprises:

and the pipe die temperature measuring element is arranged in the forming space.

8. The roller shaft producing apparatus according to any one of claims 1 to 7, further comprising:

and the cooling module comprises a first cooler and a second cooler, the first cooler is arranged on the fixed pipe die, and the second cooler is arranged on the forming platform.

9. The roller shaft producing apparatus of claim 1, further comprising:

and the main control module is electrically connected with the injection module, the crystallization module and the traction module and is used for controlling.

10. A method of manufacturing a composite roll, comprising:

fixing the roller core and a forming platform, and enabling the roller core, the forming platform and a fixed pipe die to form a forming space;

introducing an initial material into a crucible, and enabling the crucible to be in a preset environment;

continuously injecting the starting material into the forming space through a nozzle on the crucible, the starting material accumulating in the forming space to form a melt pool;

rotating the forming platform, and solidifying part or all of the molten pool on the forming platform to form a solid phase;

moving the forming platform to a preset direction to obtain a roller body outer layer fixed on the roller core;

and separating the roller core from the forming platform to obtain the composite roller comprising the outer layer of the roller body and the roller core.

Images