EP2064388A1

EP2064388A1 - Method for producing a roller body and roller body

Info

Publication number: EP2064388A1
Application number: EP07818127A
Authority: EP
Inventors: Ulrich Severing; H. Michael Zaoralek; Lutz Krodel-Teuchert
Original assignee: SHW Casting Technologies GmbH
Current assignee: SHW Casting Technologies GmbH
Priority date: 2006-09-12
Filing date: 2007-09-12
Publication date: 2009-06-03
Also published as: WO2008031581A1; JP2010502859A; US20100022371A1; DE102006042752A1

Abstract

Method for producing a roller body (1, 2), in which a) tube portions (1, 2), each made of steel with a carbon equivalent of at least 0.45 and a wall thickness (W) of in each case 130 mm are b) arranged axially next to one another and c) connected to one another by means of electron beam welding.

Description

METHOD FOR THE PRODUCTION OF A ROLLING BODY AND WHALE BODY

The invention relates to a method for producing a roll body for further processing into a roll and a roll body as a component of a roll or for producing a roll for the treatment of a web medium by means of pressure and / or temperature, preferably for the production of paper.

Rolls for the treatment of sheet-like media, in particular for smoothing paper, are increasingly produced with forged steel bodies, which must have a certain minimum surface hardness for certain applications and paper grades. The reason is with the development of the machine speed and the smoothing technique increasing thermal and mechanical loads. A hard surface provides some resistance to wear and resists impression marks when hard particles pass through the nip.

Especially with large paper machines, procurement problems for such forging bodies occur again and again. These can have finished diameters of up to 1.5 m and body lengths over 1 m and weigh massively more than 150 t. Hollow forging over a mandrel is no longer possible at this length. The cast steel body then weighs more than 200 t.

Although the finished hollow body with a wall thickness of approx. 180 mm only has a weight of approx. 50 t, more than 200 t still have to be melted and repeatedly heated for the forging process. In addition to the low net output of about 25%, the energy losses represent a significant cost factor. In addition, the number of forges that can handle such weights is very limited worldwide. These are booked out for years due to the demand from the energy sector for turbine and generator axles because the construction of new power plants is planned for the long term. For a paper machine, it may take less than 18 months from order to commissioning, which is significantly less than the delivery time of large rolls based on the delivery time of large forging bodies.

Depending on the locations of the blacksmiths and the roller manufacturers continue to heavy and special transports, which ultimately make the roller more expensive.

With regard to the prior art, reference may be made to DE 20 2006 005 604 Ul. There, a thermo roll is described, which consists of interconnected parts, in which medium channels are already introduced. Thus, the media channels can be placed close to the surface for high heat outputs. Due to the shortness of the parts, the media channels may be e.g. be introduced by drilling with very low gradients, which makes the achievable surface temperatures very much the same. The so equipped with media channels roll shell parts to be connected by welding.

It is an object of the invention to produce large rolls of steel suitable for roll production, preferably forged steel, more cost-effectively than by means of the previous methods of primary forming or forming and downstream machining processes, and to shorten the delivery times.

The task is solved by first producing shorter pipe or roller sections. The tube or roller sections are formed individually. In particular, they may consist of cast steel, rolled steel or, more preferably, forged steel. The tube or roller sections are accordingly formed separately, for example in a process of primary shaping such as casting (cast steel) or forming such as forging (forgings). In comparison to the casting materials hitherto customary for castors, the steel alloys preferred according to the invention have improved mechanical properties. It has surprisingly been found that according to the invention used higher carbon steels having a carbon equivalent of at least 0.45 at the wall thicknesses of typically at least 130 mm, which are large for web processing rolls, can be joined by electron beam welding in high quality. The joined roll body has an outer diameter of at least 500 mm and an axial length of at least 6 m, the advantages of joining according to the invention increase with larger diameters and longer lengths. Thus, the outer diameter may well be up to 2,000 mm or even more. By means of electron beam welding, it is also possible to connect different materials to each other. Accordingly, the invention is not limited to the joining of pipe sections of respective identical materials.

For example, for the roll of about 1 in length described above by way of example, it is possible to forge three pipe sections. Since these need only be about 3.7 m long, it is possible to forge hollow sections over a mandrel. Each of these roller or pipe sections weighs only about 18 t and can be made from a block with about 25 tons initial weight. Thus, there are many more forges available that are capable of forging such shorter sections of rolls. Their equipment can be much lighter, and thus it is not surprising that the three sections are available at a much lower cost than a corresponding one-piece forging. Also, the delivery times of smaller parts are cheaper than a large one. In 2006, the delivery time ratio was about 20 weeks to 60 weeks for large forging bodies. The numbers given in the example apply correspondingly to differently dimensioned rolls. Forging over a mandrel represents a particularly preferred forming variant for the shaping of the tube or roll sections. The usability of cast steel sections or rolled steel sections increases the availability again, since not only forges but also other suppliers are available.

Forged steels with a so-called carbon equivalent> 0.44, which is needed to increase the hardness of the roll surface to> = 400 HV, are in the discussed dimensions and wall thicknesses of> 130 mm, preferably> 150 mm, as thick-walled tubular body not yet welded, because they are considered even in thinner wall thicknesses as not or only very difficult to weld. According to the invention, the thick-walled pipe sections of heavy or non-weldable steel having a carbon equivalent of at least 0.45, preferably at least 0.6, are metallurgically bonded to one another prior to further processing by means of an electron beam of sufficient power. For this purpose, the pipe sections are positioned relative to one another in a joining position, preferably pressed against one another with their end faces, and welded together in a vacuum chamber. In the welding process, the electron beam device can be arranged stationary, and in the joining position relative to each other fixed pipe sections can be rotated about their common central longitudinal axis. Alternatively, the tube sections can stand still and the electron beam device can be moved in the circumferential direction about the central longitudinal axis of the tube sections. Although less preferred, eventually the tube sections can be rotated about the central longitudinal axis and at the same time the electron beam welding device can be moved in the circumferential direction. The relative movement between the tube sections located in the joining position and the electron beam welding device can in particular be continuous.

Preferably, welding takes place from the outside, i. the electron beam welding device faces an outer peripheral surface of the pipe sections. Basically, but could be welded from the inside instead. In one variant, welding is carried out both from the outside and from the inside. Distributed over the outer circumference or possibly inner circumference of the pipe sections located in the joining position, two or more electron beam welding devices can be distributed and welded at the same time. In principle, however, a single electron beam welding device is sufficient.

After evacuation of the chamber, the areas to be joined together are preheated. This can be done, for example, by resistance heating elements wound on both sides of the intended fusion around the roller sections. In another preferred variant, the electron beam welding device is also used for preheating, for example by operating at a lower power than during the welding process. When preheating by means of the welding device, the relative speed between the pipe sections located in the joining position and the electron beam relative to the welding process can be varied, in particular increased be. For the welding process, an electron beam with a power of, for example, about 8OkV is preferred.

The electron beam directed at the joint, preferably at the butt joint, between the roller sections and in their flight evaporates the steel and drills a capillary. Around it, the steel melts. If the beam reaches the required welding depth, preferably the inner bore or the hollow cross section, the pipe sections are set in rotation about their common central longitudinal axis, preferably at a uniform rotational speed. The preferably stationary jet then melts the material coming towards it during the rotational movement, which material connects to one another after passing through the jet. Because of the small diameter of the jet, which is between 1/10 and 2 millimeters, preferably at least 0.5 mm and at most 1.5 mm, and a rotational speed, which is preferably selected from the range of 0.4 to 1.2 mm per second , measured at the outer circumference of the pipe sections, and in particular may be about 1 mm per second, the so-called heat affected zone of the fusion remains narrowly limited. The above information also applies to inversion of the arrangement, namely, if the welded joint is made at stationary pipe sections and in the circumferential direction of moving electron beam. Even sections of comparatively high carbon steel, e.g. 62CrMoV6.3 (carbon equivalent = 0.69), which due to its good hardenability is preferably used for rolls in paper calenders, can be joined together in this way with wall thicknesses of up to 180 mm and even moreover without cracking. This succeeds u.a. in that unlike the usual welding process, no additional weld metal must be introduced into the melt.

The pipe sections to be joined and subsequent roller portions are preferably pre-heated in the region of the connecting joint prior to welding, preferably to a temperature of at least 150 ⁰ C, more preferably to a temperature of about 400 ⁰ C.

The tube or roller body fused together in this way from two or virtually any number of shots or sections is preferably subjected to an annealing treatment as a whole in an oven and then tempered, so that the Gefugeveränderungen disappear by the local melting at least substantially. Subsequently, the body is further processed like an ordinary forging body and further refined by, for example, tempering and / or inductive surface hardening.

It is advantageous to produce the tube body composed of individual tube sections for tubular bodies from an outer diameter of 800 mm and an axial length of 8 m and more, ie of the order of magnitude typically encountered in roll bodies for the treatment of web-shaped media.

In order to produce a roll body for a roll for the treatment of a sheet-like medium, in preferred embodiments, in the welded roll body, i. formed in the composite of the individual axial sections jacket, axial channels, preferably drilled, which are flowed through during operation of the roller by a thermal fluid. At the two end faces of the roller body fastening means are preferably produced for the attachment of each flange pin. The flange pins serve to pivot the roll and, in the preferred embodiments, as the inlet and outlet for the thermal fluid.

Advantageous features are also described in the subclaims and their combinations.

Hereinafter, an embodiment of the invention will be explained with reference to figures. The features disclosed in the exemplary embodiment advantageously each individually and in each combination of features form the subject matter of the claims and also the embodiments described above. Show it:

Figure 1 shows two in a joining position against each other positioned on impact pipe sections that are joined by means of electron beam welding in the shock, and

Figure 2 shows a cross section through the butt joint of the pipe sections as an end view of one of the two pipe sections. Figure 1 shows an exemplary embodiment of an inventive joining two pipe sections 1 and 2 to a composite roll body, which is to form a roll shell for a roll for the treatment of a web-shaped medium by means of pressure and / or temperature. The pipe sections 1 and 2 are rotationally symmetrical. They are clamped in a vacuum chamber in a joining position in which they each abut one another at one end face. The two abutting end faces form the joining surfaces of the pipe sections 1 and 2. The butt joint formed by the abutting joining surfaces points to a common axis of rotation R of the pipe sections 1 and 2 at right angles. In principle, a different orientation of the joint, for example, a gap to the axis of rotation R, possible.

The vacuum chamber is evacuated for welding. The pipe sections 1 and 2 are heated in the region of the joint to a temperature of at least 150 ° C, preferably to about 400 ° C.

With an electron beam welding device 3, an electron beam 4 is generated. In the welding process, the electron beam 4 is aligned with the joint, i. he lies in the plane of the fugue. The electron beam 4 has a diameter of 0.5 mm and generates in the joining region a melt channel or a melt capillary 5 of about 2 mm diameter. As soon as the melt channel 5 has reached the hollow cross section of the pipe sections 1 and 2, the pipe sections 1 and 2 clamped in the joining position are set into a uniform rotational movement about their common central longitudinal axis, the axis of rotation R, so that the electron beam 4 is continuous about the axis of rotation R. progressively produces the narrow melt channel 5 in the joint area and, with respect to the direction of rotation of the roll sections 1 and 2 behind the electron beam 4, the molten material of the pipe sections 1 and 2 melts continuously with one another.

The electron beam welding is particularly suitable for pipe sections 1 and 2 made of steel, in particular forged steel, with a wall thickness W from the range of 150 to 180 mm and larger wall thicknesses, wherein the ratio of the outer diameter to the inner diameter of the pipe sections to be welded together 1 and 2 should be at least 2: 1, so that the heat input into the joint, ie along the melt channel 5, in the radial direction is still uniform.

Figure 2 shows a cross section through the butt joint, i. an end view of one of the pipe sections, in the example of the pipe section 2. During welding, the pipe sections 1 and 2 located in the joining position are continuously driven in the rotational direction D about the rotation axis R. In the selected view, the direction of rotation D corresponds to the clockwise direction. The electron beam welding device 3 is arranged and aligned such that its beam outlet faces the outer peripheral surface of the pipe sections 1 and 2 approximately at the 3 o'clock position and the electron beam 4 is inclined at an angle α to a straight line extending from the Center of the Strahlauslasses to the rotation axis R extends. Because of the positioning at the 3 o'clock position, said connecting line extends horizontally. The electron beam 4 is directed at the angle α obliquely downward. The enamel capillary 5 runs upward as seen from the inside outward. Due to the non-radial orientation of the electron beam relative to the axis of rotation R, a weld pool fuse is obtained. The angle α is between 15 ° and 25 °, preferably 20 °.

Claims

claims

1. A method for producing a roller body (1, 2), in which a) pipe sections (1, 2) each of steel with a carbon equivalent of at least 0.45 and a wall thickness (W) of at least 130 mm b) arranged axially adjacent to each other and b) are joined together by electron beam welding.

2. The method of claim 1 and at least one of the following features: the pipe sections (1, 2) each have a wall thickness (W) of at least 150 now on; The pipe sections (1, 2) each consist of steel with a carbon equivalent of at least 0.5.

3. The method according to any one of the preceding claims, wherein the pipe sections (1, 2) made of cast steel, rolled steel or preferably forged steel are used.

4. The method according to any one of the preceding claims, wherein the tube sections (1, 2) together welding electron beam (4) in a butt joint of the pipe sections (1, 2) in the welding at an angle α> 0 ° and preferably at most 40 ° to a straight line connecting a central longitudinal axis (R) of the tube sections (1, 2) and a jet outlet of an electron beam welding device (3), the longitudinal axis (R) in the later operation of the roller body (1, 2) Forming axis of rotation.

5. The method according to the preceding claim and at least one of the following features: the electron beam (4) is directed obliquely downwards in the welding; a jet outlet of a welding device (3) generating the electron beam (4) is located in a position between a two o'clock position and a four o'clock position with respect to the tube sections (1, 2) located in a joining position. Position, preferably arranged at least substantially at the three o'clock position.

6. The method according to any one of the preceding claims, wherein for producing a roller for the treatment of a web-shaped medium, peripheral, axial channels in the tubular body (1, 2) formed, preferably drilled, are for the circulation of a liquid or gaseous heat transfer medium.

7. The method according to any one of the preceding claims, wherein at a left end side and a right end side of the tubular body (1, 2) fastening means for roll neck are generated, preferably Schraubbefestigungen.

8. The method according to any one of the preceding claims and one of the following features: the pipe sections (1, 2) are locally heated in the region of a butt joint before welding to a temperature of at least 150 ° C, preferably at least 200 ° C; The pipe sections (1, 2) are locally heated in the region of a butt joint before welding to a temperature of 400 ° C ± 50 ° C.

9. The method according to any one of the preceding claims, wherein the pipe sections (1, 2) for welding locally in the region of a butt joint by means of an external heater, preferably induction coils or an electron beam welding device used for the welding process (3), are preheated.

10. The method according to any one of the preceding claims, wherein the welded roller body (1, 2) is subjected to a remuneration.

11. The method according to any one of the preceding claims, wherein the welded roller body (1, 2) is subjected to a surface hardening.

12. The method according to any one of the preceding claims, wherein the tube sections (1, 2) by means of an electron beam (4) or more electron beams are welded together, and wherein the electron beam (4) or the plurality of electron beams each have a diameter of at least 0, 1 mm and not more than 2 mm or have.

13. The method according to any one of the preceding claims, wherein the pipe sections (1, 2) are clamped relative to each other in a joining position in which they abut against each other at a butt joint, and wherein in the butt joint by means of at least one electron beam (4) a melt channel (5) having a diameter of at least 0.5 mm and at most 5 mm.

14. The method according to any one of the preceding claims, wherein the pipe sections (1, 2) in a butt joint abutting each other clamped in a joining position relative to each other, during welding the pipe sections (1, 2) located in the joining position about a common longitudinal axis (R ) or that an electron beam welding device (3) is moved about the longitudinal axis (R) of the pipe sections (1, 2) in the joining position along the butt joint and wherein the pipe sections (1, 2) and one of the electron beam welding device (3) generated electron beam (4) circumferentially about the longitudinal axis (R) relative to each other have a peripheral speed, based on an outer peripheral surface of the pipe sections (1, 2) a few millimeters per second, preferably at least 0.3 and at most 2 mm per second, is.

15. Roller body of a roller or for a roller for the treatment of a sheet-like medium, a) wherein the roller body has a hollow cylindrical first roller section (1) and a hollow cylindrical second roller section (2), b) the roller sections (1, 2) each made of steel with a carbon equivalent of at least 0.45 c) and have a wall thickness each of at least 130 mm d) and wherein the roller sections (1, 2) by means of Elektronenstrahlsch bevel in a joint around the rotation axis (R) of the roller body (1, 2) circumferentially connected to each other.

16. Roll body according to the preceding claim, characterized in that the welded joint parallel to the axis of rotation (R) measured has a width of at most 10 mm, preferably at most 5 mm.

17. Roller body according to one of the preceding claims, characterized in that the roller body (1, 2) distributed around a rotation axis (R) arranged axially extending tempering channels for the passage of a heat transfer medium.

18. Roller body according to one of the preceding claim, characterized in that at a left and at a right end side of the roller body (1, 2) each fastening means for each one of the rotary bearing about an axis of rotation (R) of the roller body (1, 2) serving roll neck are provided.

19. Roller body according to one of the preceding claims, characterized in that the roller body (1, 2) on a left and on a right end side each have a roll neck for the pivotal mounting about an axis of rotation (R).