US2155610A - Composite roll - Google Patents

Description

April 25, 1939.

w. H. MELANEY COMPOSITE ROLL Filed July 19, 1938 Big. 1

2 Sheets-Sheet 1 D INVENTOR. m W

ATTORNEY.

April 25, 1939.

Filed July 19, 1938 W. H. MELANEY COMPOSITE ROLL 2 Sheets-Sheet 2 W I INVENTOR.

ATTORNEY.

Patented Apr. 25, 1939 UNITED STATES PATENT OFFICE 2 Claims.

This invention relates to new and useful improvements in chilled or alloy rolls for metal rolling mills, more particularly to the method of making same, and it is among the objects thereof to provide a method of making rolls for metal rolling mills of a composite metal to provide a chilled body surface for the face of the roll of a dense hard or tough metal and neck or journal portions of an easily machinable metal, whereby the costly machining and grinding operations incident to the manufacture of such rolls by methods heretofore practiced are substantially reduced.

A further object of the invention is to provide a composite metal roll in which the outer portions of the necks or bearings are constitutedpf prefabricated metal sleeves which are cast integrally with the main body of the rolls and which may be prepared in a manner to produce a fusion of substantial portions of the neck or hearing portions with the metal forming the main body of the rolls.

Still a further object of the invention is the provision of a metal roll in which the working body of the roll is cast of a tough or hard metal and in which the necks, bearings or driving portions are partially constituted by preformed sleeve castings and partially of poured metal of different characteristics than the preformed sleeve pori'ill tions, the main body, the sleeve portions, and

the metal joining the sleeve and main body portions being integrally formed by casting.

These and other objects of the invention will become more apparent'from a consideration of 35 the accompanying drawings constituting a part hereof in which like reference characters designate like parts and in which:

Fig. 1 is .a vertical cross-sectional view of a mold for casting rolls for metal rolling mills em- 40 bodying the principles of this invention;

Fig. 2 a view partially in section and partially in side elevation of a preformed sleeve which is adapted to be joined integrally with the neck portion of the roll;

45 Fig. 3 a vertgal cross-sectional view of a preformed sleeve having the inner wall surface thereofv provided with annular serrations;

Fig. 4 a transverse section taken along the lines 4-4, Fig. 1; e

50 Fig. 5 a similar section showing a different form of serrations;

Fig. 6 a vertical cross-sectional view of a mold for casting rolls embodying a modified form of the invention;

Fig. 7 a side elevational view of a neck of varying insert for use in the method of making rolls by the apparatus shown in Fig. 6; and

Fig. 8 a vertical cross-sectional view of the mold shown in Fig. '7.

With reference to Fig. 1 of the drawings, the numeral I designates a metal mold having an interior matrix surface 2 corresponding to the contour of the main body portion of the roll to be cast, the metal mold quickly chilling the casting to a substantial depth to constitute a very hard rolling surface, which is finished by a grinding or machining operation. The numeral 3 and numerals 4 and 5 designate mold sections or flasks for receiving sand 6, the top portion being molded to form a sink-head l and the bottom portion of the sand mold is gated to a downrunner 8 through whichthe metal is poured, the gate Q'being disposed to produce a tangential flow of metal which sets up a swirling motion to the molten metal as it enters the mold. 2o

Numerals Ill and II constitute the neck or bearing portions of the roll and the numerals l2 and I3 the Wobbler ends. The neck portions II and I2 are formed of prefabricated sleeves I4, Figs. 2 and 3, the sleeve in Fig. 2 being provided with serrations or flutes Ha as shown in Fig. 5, which are axially .disposed and the serrations or flutes l5, Fig. 3, are of annular form. These neck portions may be pickled, machined, or sandblasted or otherwise prepared to clean the inner surfaces and may be coated with a non-oxidizing or rust-preventing substance such as by galvanizing or zinc coating before placing them in the sand portions, as shown in Fig. 1.

In casting the roll, the metal forming the main body portion of the roll designated by the numeral i6 is first poured into the down-runner 8 andenters the base of the mold, filling the matrix portion thereof to just above the top of Wobbler l2, the sink-head portion l remaining empty of metal. The metal thus initially poured into the mold is of a character suitable for the severe rolling operations to which the roll is subjected in rolling mill practice, and is chilled for a substantial depth along the metallic matrix portion 2 as heretofore explained.

A softer or more readily machinable metal is then poured through the'runner 8 to displace only the molten metal of the down gate and sprue. The same metal isthen poured into the 6G sink-head I to feed downwardly into the upper neck portion as the metal contracts in the main body portion of the roll for sinking purpose only.

When the metal is poured as described, it will fuse or melt the serrated portions Ma and I5,

as the case may be, to eflect an intimate welding of the preformed neck pieces with the adjacent cast or supporting body portion of the roll, it being obvious that the faces of the neck portions l3 may be otherwiseprepared to promote the welding action of the molten metal with the preformed sleeve portions.

As shown in Fig. 2, the bottom' neck portion I3 is provided with a gate l1 and by employing metal of the same or similar properties as that of which the neck pieces l3 are formed for the displacement of the metal from down gate and sprue only, initially poured to form the main body of the rolls, the gate I! will be of the same material as the sleeve I3, so that the finished roll will have no hard spot on the fin ished surface of the neck or bearings.

In Fig. 6 of the drawings, neck or hearing sleeves I8 are provided with flanges l9 which extend into the matrix portion 2 of the mold in which the roll body is cast. Because of the swirling motion of the metal entering the bottom of the mold through the offset gate II, it will form a meniscus as shown at 20 and 2|, Fig. 6, all impurities of the metal accumulating in the depressed portion at 22 and 23. As the metal rises, the metal at'the outer edge is free from impurities and when it reaches the level above the flange I9 of the insert that forms the neck or bearing of the roll, it will flow in the annular space 24. As it rises further, as shown near the top of the roll body matrix 2, the same meniscus effect is maintained so that pure metal will reach the annular space 24a between the flange I9 and the roll body matrix. Otherwise, the pouring of the metal through the down-gate is the same as described in connection with Fig. 1, the metal being filled to the top of the Wobbler l2. It is then displaced by softer metal of the character of the neck sleeves 18 to an amount just sufficient to displace the metal in the gate ll of the sleeve portion so that upon subsequent machining there will be no hard spots. in the neck or hearing portion. The same grade of metal is poured into the sink-head 1 to feed into the top of the casting when shrinkage takes place.

In Figs. Sand 8 I have shown the sleeve portions lined at 25 with sheet, copper, or other.

metal which may be coated with a flux so that when the molten metal is poured into the mold it will be welded or brazed with the metal of the sleeves l8 through the fusing action of the lining 25. This is an alternative method ofbonding the cast metal with the preformed sleeve members to that employing the serrations or flutes of the sleeves shown in Figs. 2 and 3 of the drawings.

-By employing the flanged sleeves as shown in Fig. 6, the clear line of demarkation will result between the outer periphery of the flanges I9 and the metal in the annular grooves 24 which will be immediately apparent when the neck and roll portions are machined and/or ground after the casting operation.

Rolls cast as hereinbefore described have a main body portion 16 of a very hard or tough metal which may be finished by machining or grinding, whereas the neck portions l and II are of a softer material which may be readily machined to size without requiring the long tedious grinding or other slow machining operations to reduce said parts to their approximate finished dimensions as in the manner of conventional practice, the elimination of which results in a very substantial reduction in the cost of machining these rolls.

Although several embodiments of the invention have been herein illustrated and described, 20

it will be evident to those skilled in the art that various modifications may be made in the details of construction without departing from the principles herein set forth.

I claim:

1. The method of making rolls for metal rolling mills and the like which comprises providing a mold consisting of a metallic matrix portion for casting the main body of the roll, sand portions adjacent tothe metal body portion for casting the necks and Wobblers of the roll and a down gate and sprue for one of the sand portions, placing sleeve portions of preformed metal in the sand portions of the molds to form the outer portions of the necks thereof, pouring molten metal in the bottom of the mold to form the main body of the roll, displacing said cast fluid metal from the down-gate and sprue of the mold by fluid metal of the character of the preformed sleeve portions, and pouringmetal similar to the metal of the sleeve portions in the sink-head at the top of the mold to flll the void caused by shrinkage in the main body portion Y of the mold.

2. The method of making rolls for metal rolling mills and the like which comprises the steps of inserting prefabricated sleeve portions in a mold adjacent the main body chill, the sleeve portions having fluted inner surfaces constituting passages for the molten metal poured in the mold, pouring the metal for the main body portion into the mold to completely flll the mold in contact with the fluted surfaces of the prefabricated sleeve portions to thereby melt the fluted surfaces of the sleeve portions to produce a fusing of the molten metal with the metal of the prefabricated sleeve portions.

WILLIAM H. MELANEY.

GERTIFiGATE 0F .CORRECTION.

ia'ten t No. 2,155,610. April 25; 19 9.

HILLIAM H. mum.

' It is hereby certified, that error appears in the -fminted specification of the'above numbered pa'tent requiring correctionas follows: Page 1, second column, lines 32 and 35, strike out the words "such as by galvanizing or zinc coating"; and that the and Letters Patent should be read with this correction therein that the same may conferm'to the record of the case in the Patent Office.

Signed and sealed this 1st day of August, A. D. 1939,,

- Henry Wm Arrmdale (Seal) Acting Gomissiener ex" Patents,

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