WO2019041828A1 - 用于钢板表面形貌轧制的轧辊及其制造方法 - Google Patents

用于钢板表面形貌轧制的轧辊及其制造方法 Download PDF

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Publication number
WO2019041828A1
WO2019041828A1 PCT/CN2018/083469 CN2018083469W WO2019041828A1 WO 2019041828 A1 WO2019041828 A1 WO 2019041828A1 CN 2018083469 W CN2018083469 W CN 2018083469W WO 2019041828 A1 WO2019041828 A1 WO 2019041828A1
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Prior art keywords
roll
texturing
steel sheet
points
less
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PCT/CN2018/083469
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English (en)
French (fr)
Inventor
陈孝明
李山青
杨凯夫
全基哲
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宝山钢铁股份有限公司
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Application filed by 宝山钢铁股份有限公司 filed Critical 宝山钢铁股份有限公司
Priority to US16/474,320 priority Critical patent/US20190337032A1/en
Priority to JP2019530781A priority patent/JP7041679B2/ja
Priority to KR1020197019370A priority patent/KR20190092496A/ko
Priority to EP18849942.0A priority patent/EP3677355B1/en
Publication of WO2019041828A1 publication Critical patent/WO2019041828A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
    • B21B27/005—Rolls with a roughened or textured surface; Methods for making same
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B23K26/0624—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses using ultrashort pulses, i.e. pulses of 1ns or less
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/3568—Modifying rugosity
    • B23K26/3584—Increasing rugosity, e.g. roughening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/362—Laser etching
    • B23K26/364—Laser etching for making a groove or trench, e.g. for scribing a break initiation groove
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F4/00—Processes for removing metallic material from surfaces, not provided for in group C23F1/00 or C23F3/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
    • B21B27/02—Shape or construction of rolls
    • B21B27/021—Rolls for sheets or strips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles

Definitions

  • the present invention relates to a roll for steel sheet rolling and a method of manufacturing the same, and more particularly to a roll having a special surface topography and a method of manufacturing the same.
  • the last rolling pass of the cold rolling mill and the cold rolling mill working rolls require the use of a texturing roll, that is, a roll having a certain roughness on the surface, so that the surface of the steel plate has a certain surface topography.
  • the existing roll texturing technologies mainly include shot blasting, electric spark texturing technology, laser texturing technology, electron beam texturing technology, and chrome texturing technology.
  • the surface topography formed by shot blasting, electric sparking, laser texturing and electron beam texturing is mainly based on the shape of the pit.
  • the surface topography of this structure has this morphology during the rolling process.
  • the replication rate is low and the pits are easily filled with metal powder to rapidly attenuate the roughness.
  • the chrome texturing technology can grow a hemispherical convex hull on the surface of the roll by reasonably controlling the electrochemical process parameters in the electroplating process.
  • the surface morphology of this structure has a high surface replication rate and its rolling. There are a large number of small pits distributed on the steel plate, which is beneficial to improve the oil storage effect of the steel plate.
  • the biggest disadvantage of this technology is the use of the electroplating chromium process, which has a very large environmental risk.
  • the above roll texturing technology can properly adjust the surface roughness, peak number, and waviness of the roll surface after appropriate adjustment of the process parameters, the adjustment range is very limited, and the surface morphology formed by the texturing is also It still has some inherent characteristics, and it is impossible to specifically control each texturing point, so that the surface topography cannot be refined and designed.
  • the main problems existing in the existing texturing technology include the surface topography as a pit structure or the existence of environmental risks, and it is impossible to finely design and control the surface topography.
  • the publication number is CN104884180A, and the publication date is September 2, 2015.
  • the Chinese patent entitled “Plate products made of metal materials, especially steel materials, use of the flat products, rolls, and methods for producing the flat products” The literature relates to flat products made of metallic materials, in particular steel, to advantageous uses and to rolls which are particularly suitable for the manufacture of such flat products, and to methods for producing such flat products.
  • the technical scheme can realize the fine design and processing of the surface microstructure and appropriately reduce the waviness, the surface morphology is still mainly concave, which does not improve the roll topography replication rate, and because of the roll surface thereof Morphology is a texture with a specific rule. Steel sheets produced using such rolls are prone to "moire" defects during coating.
  • the Chinese Patent Publication No. CN103889642B published on Apr. 13, 2016, entitled “Method and Apparatus for Producing a Structured Surface on an Embossed Steel Roll”, relates to the production of a pulverized steel roll by a short pulse laser.
  • the technical solution involves the fine design and processing of the surface microstructure, but the surface topography is mainly based on pits, which does not effectively improve the surface topography of the roll.
  • the technical problem to be solved by the present invention is to provide a roll having a special surface topography which has a good topography replication rate and a low waviness when the surface topography of the steel sheet is rolled.
  • a roll for surface topography rolling of a steel sheet wherein a plurality of raised texturing points are arranged on the roll surface, and a shape formed by a single intersection of the texturing points and the roll surface is circular or substantially circular
  • the diameter of the circle is 50-150 ⁇ m; the height of the protrusion of a single of the texturing points is 2-12 ⁇ m, the overlap between adjacent texturing points is less than 10%; the number of texturing points within the square millimeter of the roll surface The difference is less than 20%, and the area covered by the textured points per square millimeter is 30 to 90%.
  • the texturing point is circular or approximately circular.
  • the directional difference of surface topography parameters can be avoided, and on the other hand, it is convenient to construct mutually independent texturing points to avoid mutual interference between the texturing points.
  • the diameter of a single texturing point is limited to 50-150 ⁇ m because when the diameter of the texturing point is ⁇ 50 ⁇ m, the surface microstructure of the roll is slightly fine, and the wear resistance is significantly reduced when used, and the diameter of the texturing point is decreased. >150 ⁇ m, the microstructure of the roll surface is coarse, and the microstructure of the rolled or flat steel plate is not easily covered by the paint film when it is coated.
  • the texturing point is designed as a convex structure in order to increase the replication rate of the surface topography; the height of the raised point of the texturing point is designed to be 2 to 12 ⁇ m in order to have a suitable roughness range of the roll surface.
  • controlling the overlap between adjacent texturing points is less than 10% because when the overlap between the texturing points is too large, the independence and integrity of the texturing points are destroyed, and the microscopic shape of the local area is easily caused. Uneven appearance.
  • the difference in the number of texturing points per square millimeter is less than 20% because the larger the difference in the number of texturing points per unit area, the worse the macroscopic uniformity of the surface morphology of the rolls.
  • the coverage area of the texturing point per square millimeter is between 30% and 90% because too little the number of texturing points will cause the average spacing of the texturing points to be too large, resulting in an increase in waviness, and the effect of rolling or leveling the steel plate. Deterioration, and too many texturing points will make the spacing of the texturing points too close, affecting the shape flow of the material and reducing the replication rate of the roughness.
  • the bottom diameter of the raised texturing point is not less than the top diameter; for example, a frustum-shaped structure.
  • the amount of overlap between adjacent texturing points is less than 5%.
  • the amount of overlap between adjacent texturing points is preferably zero.
  • the difference in the number of texturing points per square millimeter of the roll surface is less than 10%, preferably less than 5%.
  • the coverage area of the rolling point per square millimeter of the roll surface is 50-80%.
  • the steel sheet may be a cold rolled steel sheet.
  • Another technical problem to be solved by the present invention is to provide a method for manufacturing the above-mentioned roll for surface topography rolling of a steel sheet, comprising the following steps:
  • the surface material of the roll is subjected to layer-by-layer ablation using an ultrashort pulse laser; during the ablation, the ultrashort pulse laser performs lateral translational motion along the incoming roll bus, and at the same time, the incoming material
  • the rolls are in a rotatable state after being driven.
  • the surface design can be refined and designed, and the surface morphology of the roll can be effectively improved, so that the roll has good shape replication rate and low ripple. degree.
  • Figure 1 illustrates the surface topography of the roll of Example 1
  • Figure 2 illustrates the surface topography of the roll of Example 2
  • Figure 3 illustrates the surface topography of the roll of Example 3
  • Figure 4 is a view showing the structure of the device corresponding to the manufacturing method of the present invention.
  • Figure 5 illustrates the surface fabrication process corresponding to Example 1, including 1)-8) a total of 8 states/stages;
  • 1 in Fig. 4 is a numerical control machine tool
  • 2 is a roll
  • 3 is an ultrashort pulse laser.
  • the invention proposes a roll having a special surface topography, the surface topography of which has the following characteristics:
  • the shape of the texturing point is approximately circular or substantially circular, and the diameter is between 50 and 150 ⁇ m;
  • the texturing point is a convex structure, and the height of the protrusion is between 2 and 12 ⁇ m;
  • the amount of overlap between adjacent texturing points is less than 10%
  • the difference in the number of texturing points per square millimeter is less than 20%;
  • the area of the textured area per square millimeter is between 30% and 90%.
  • the inventors have found through a large number of experimental studies that the surface morphology of the obtained roll has a good topography replication rate and low waviness.
  • Another object of the present invention is to provide a method of manufacturing a roll having a special surface topography by which a roll having the above-described technical features can be obtained.
  • the ultrashort pulse laser is controlled to selectively ablate the surface material of the roll.
  • a roll having a special surface topography and a method for manufacturing the same according to the present invention will be further explained and explained in conjunction with the drawings and specific embodiments of the present specification. However, the explanation and description do not constitute an improper design of the technical solution of the present invention. limited.
  • Example 1-3 the surface morphology of the roll was refined and processed, so that the roll surface has a large number of texturing points, the shape of the texturing point is approximately circular, the diameter is between 50 and 150 ⁇ m, and the texturing point is The convex structure has a convex height difference of 2 to 12 ⁇ m, and the overlap between each texturing point is less than 10%, and the area covered by the texturing point in the unit area is between 30% and 90%.
  • Figures 1 to 3 illustrate the surface topography of the designed roll.
  • Examples 1-3 and Comparative Examples 1-3 were tested in accordance with the measurement standard ISO 4287:1997.
  • the filter was Gaussian filtered, the sampling length of the roughness was 12.5 mm, and the sampling length of the waviness was 40 mm. 0.8 to 8 mm.
  • the roll is loaded into a hot-dip galvanizing leveling machine, and materials of the same specification material are flattened under substantially the same working conditions using substantially the same process parameters, and the surface roughness and roll roughness of the steel sheet after the flattening are measured.
  • the ratio is used as the topographical replication rate indicator.
  • the surface morphology of the roll is designed in Examples 1-3, and the manufacturing method described in the present invention is employed.
  • the roll is processed so that the surface of the roll has a large number of texturing points, the shape of the texturing point is approximately circular, the diameter is between 50 and 150 ⁇ m, the texturing point is a convex structure, and the difference in protrusion height is between 2 and 12 ⁇ m.
  • the amount of overlap between each texturing point is less than 10%, and the area covered by the texturing point in the unit area is between 30% and 90%.
  • Comparative Example 1-3 adopts the conventional electric spark texturing process, so that the surface of the ordinary roll obtained by the same does not have the above characteristics, and the replicativity of the topography is also low, and the waviness is high.
  • the CNC machine 1 is used to drive the rotation of the roll 2 and the ultrashort pulse laser 3 is laterally translated along the roll 2 bus;
  • the ultrashort pulse laser is controlled to selectively ablate the surface material of the roll.
  • Example 1 a picosecond pulse laser having an average power of 100 W was used. After the laser was focused, each pulse ablated a material having a diameter of about 5 ⁇ m and a depth of about 1 ⁇ m on the surface of the roll. Therefore, according to the maximum protrusion height of the microscopic topography of Embodiment 1, it is required to process in 8 layers, and FIG. 5 shows a material processing process of a microscopic region on the surface of the roll, which removes the material layer by layer by ultrashort pulse laser to obtain the final place. The surface topography required.

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  • Optics & Photonics (AREA)
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Abstract

一种用于钢板表面形貌轧制的轧辊，在辊面布设有多个凸起的毛化点，单个所述毛化点与辊面相接处形成的形状为圆形或大致为圆形，该圆形的直径为50～150μm；单个所述毛化点的凸起高度为2～12μm，相邻毛化点之间重叠量小于10％；辊面单位平方毫米内的毛化点数量差异小于20％，每平方毫米内的毛化点覆盖面积占比在30～90％。还公开了一种轧辊的制造方法，包括对来料轧辊（2）进行表面处理的步骤，使轧辊表面粗糙度控制在Ra<0.5μm；以及对轧辊表面材料进行逐层烧蚀以形成所述毛化点的步骤。该轧辊具有较好的形貌复制率、低的波纹度。

Description

用于钢板表面形貌轧制的轧辊及其制造方法 技术领域
本发明涉及一种用于钢板轧制的轧辊及其制造方法，尤其涉及一种具有特殊表面形貌的轧辊及其制造方法。
背景技术
通常，冷轧机的最后一个轧制道次和冷轧平整机工作辊都需要使用毛化辊，即表面具有一定粗糙度的轧辊，从而使得钢板表面具有一定的表面形貌。
现有的轧辊毛化技术主要有抛丸毛化、电火花毛化技术、激光毛化技术、电子束毛化技术、镀铬毛化技术。其中抛丸毛化、电火花毛化、激光毛化、电子束毛化所形成的表面形貌结构都以凹坑形状为主，这种结构的表面形貌在轧制过程中存在这形貌复制率偏低且凹坑容易被金属粉末填充从而使粗糙度快速衰减。镀铬毛化技术通过合理控制电镀过程中的电化学工艺参数，可以在轧辊表面生长出一个个半球型的凸包，这种结构的表面形貌具有较高的形貌复制率，且其轧制的钢板上分布有大量的小凹坑，有利于改善钢板的储油效果，但该技术的最大缺点是采用了电镀铬工艺，具有非常大的环保风险。
此外，以上轧辊毛化技术虽然可以通过适当调整工艺参数实现对毛化后轧辊表面的粗糙度、峰值数、波纹度等进行适当调整，但其调节范围非常有限，毛化形成的表面形貌也仍然是具有一些的固有特征，无法对每个毛化点进行具体控制，从而无法对表面形貌进行精细化的设计和控制。
另一方面，越来越多的用户对钢板涂装效果提出了更高的要求，研究表明降低钢板表面波纹度可以有效改善钢板涂装效果，对钢厂来说，即需要对轧辊的波纹度进行控制，而传统的毛化技术由于难以对表面形貌进行精细化的设计和加工，因此在波纹度控制方面也存在着局限。
综上所述，现有毛化技术存在的主要问题包括表面形貌为凹坑结构 或存在环保风险，无法对表面形貌进行精细化设计和控制。
公开号为CN104884180A，公开日为2015年9月2日，名称为“由金属材料特别是钢材制成的平板产品、该平板产品的用途、辊以及用于生产该平板产品的方法”的中国专利文献涉及由金属材料特别是钢材制成的平板产品，涉及有利的用途并且涉及特别适用于制造该种平板产品的辊，以及涉及用于生产该种平板产品的方法。在该专利文献所公开的技术方案中，其公开了一种具有双I形、H形、十字形、C形或X形确定性纹理的轧辊。该技术方案虽然可以实现表面微观结构的精细化设计和加工，并适当降低了波纹度，但其表面形貌仍然是以凹坑为主，并未改善轧辊形貌复制率，且由于其轧辊表面形貌是一种具有特定规则的纹理形貌，使用这种轧辊生产的钢板在涂装时容易产生“莫尔纹”缺陷。
公开号为CN103889642B，公开日为2016年4月13日，名称为“在压花钢辊上产生具有结构的表面的方法和设备”的中国专利文献涉及通过短脉冲激光在压花钢辊上产生具有结构的表面的方法和设备，该结构为宏观结构，该宏观结构的维度超过20μm而深度达200μm和更多，其公开了一种短脉冲加工具有特殊图案结构的压花轧辊。该技术方案涉及表面微观结构的精细化设计和加工，但其表面形貌也是以凹坑为主，并未有效改善轧辊表面形貌结构。
综上所述，虽有部分专家学者在表面形貌的精细化设计及加工方面做了一些工作，但在改善轧辊表面微观结构、提高形貌复制率、降低轧辊表面波纹度等方面仍未提出有效的技术方案。
发明内容
本发明所要解决的技术问题在于提供一种具有特殊表面形貌的轧辊，其用于钢板表面形貌轧制时具有好的形貌复制率和低的波纹度。
其所要解决的技术问题可以通过以下技术方案来实施。
一种用于钢板表面形貌轧制的轧辊，在辊面布设有多个凸起的毛化点，单个所述毛化点与辊面相接处形成的形状为圆形或大致为圆形，该圆形的直径为50～150μm；单个所述毛化点的凸起高度为2～12μm，相邻毛化点之间重叠量小于10％；辊面单位平方毫米内的毛化点数量差异小于20％，每平方毫米内的毛化点覆盖面积占比在30～90％。
毛化点为圆形或近似为圆形，一方面是可以避免表面形貌参数出现方向性差异，另一方面能方便的构建彼此独立的毛化点，避免毛化点之间的相互干扰。
并且，单个毛化点的直径限定为50～150μm是因为当毛化点直径<50μm时，会导致轧辊在使用时表面微观结构由于较细微，耐磨损性显著下降，而当毛化点直径>150μm时，会导致轧辊表面微观结构偏粗大，所轧制或平整钢板在涂装时其微观结构不易被漆膜完全遮盖。
另一方面，将毛化点设计为凸起结构是为了提高表面形貌的复制率；将毛化点凸起高度设计为2～12μm是为了使得轧辊表面具有合适的粗糙度范围。而控制相邻毛化点之间相互重叠量小于10％，是因为当毛化点之间的重叠量过大时，会破坏毛化点的独立性和完整性，容易造成局部区域的微观形貌不均匀。
单位平方毫米内的毛化点数量差异小于20％是因为单位面积的毛化点数量差异越大，轧辊表面形貌的宏观均匀性越差。每平方毫米内的毛化点覆盖面积占比在30～90％之间是因为毛化点太少会使得毛化点平均间距过大，导致波纹度增加，所轧制或平整钢板涂装效果变差，而毛化点太多又会使得毛化点间距过近，影响材料塑形流动，降低了粗糙度的复制率。
作为本技术方案的进一步改进，所述凸起的毛化点的底部直径不小于顶部直径；例如为锥台形结构。
也作为本技术方案的进一步改进，相邻毛化点之间重叠量小于5％。其中，相邻毛化点之间重叠量优选为0。
还作为本技术方案的进一步改进，辊面单位平方毫米内的毛化点数量差异小于10％，优选小于5％。
另外，也作为本技术方案的进一步改进，辊面每平方毫米内的毛化点覆盖面积占比在50～80％。
此外，所述钢板可以为冷轧钢板。
本发明所要解决的另一技术问题在于提供一种上述用于钢板表面形貌轧制的轧辊的制造方法，包括如下步骤：
(1)、对来料轧辊进行表面处理的步骤，使轧辊表面粗糙度控制在Ra<0.5μm；
(2)、对轧辊表面材料进行逐层烧蚀以形成所述毛化点的步骤。
作为该制造方法的进一步改进，采用超短脉冲激光器对所述轧辊表面材料进行逐层烧蚀；烧蚀时所述超短脉冲激光器沿来料轧辊母线做横向平移运动，同时，所述来料轧辊经驱动后处于可旋转状态。
通过采用上述具有特殊表面形貌的轧辊及相应的制造技术，可以实现对表面形貌进行精细化的设计和加工，有效改善轧辊表面形貌，使轧辊具有好的形貌复制率、低的波纹度。
附图说明
图1示意了实施例1的轧辊表面微观形貌；
图2示意了实施例2的轧辊表面微观形貌；
图3示意了实施例3的轧辊表面微观形貌；
图4示意了本发明制造方法对应的装置结构；
图5示意了实施例1对应的表面制造加工过程，包括了1)-8)共8个状态/阶段；
其中，图4中的1为数控机床，2为轧辊，3为超短脉冲激光器。
具体实施方式
下面结合附图对本发明的具体实施方式进行进一步的详细说明。
本发明提出了一种具有特殊表面形貌的轧辊，所述轧辊的表面形貌具有以下特征：
表面上散布大量的毛化点；
毛化点的形状近似为圆形或大致为圆形，直径在50～150μm之间；
毛化点为凸起结构，凸起高度在2～12μm之间；
相邻毛化点之间重叠量小于10％；
单位平方毫米内的毛化点数量差异小于20％；
每平方毫米内的毛化点覆盖面积占比在30～90％之间。
发明人通过大量实验研究发现，具备上述特点的毛化点，所获得轧辊表面形貌具有较好的形貌复制率和低的波纹度。
相应地，本发明的另一目的在于制造上述的具有特殊表面形貌的轧 辊的方法，通过该制造方法可获得具有上述技术特征的轧辊。
包括如下步骤：
(1)、对轧辊进行磨削抛光加工，并对辊面进行清洁，使轧辊表面粗糙度Ra<0.5μm，表面无油污；
(2)、设计具有上述技术特征的轧辊表面形貌；
(3)、使用数控机床驱动轧辊旋转并使超短脉冲激光器沿轧辊母线做横向平移运动；
(4)、根据所设计的表面形貌，控制超短脉冲激光器选择性的对轧辊表面材料进行逐层烧蚀。
下面将结合说明书附图和具体的实施例对本发明所述的一种具有特殊表面形貌的轧辊及其制造方法做进一步的解释和说明，然而该解释和说明并不对本发明的技术方案构成不当限定。
实施例1-3及对比例1-3：
实施例1-3对轧辊的表面形貌进行了精细化设计与加工，使得轧辊表面具有大量毛化点，毛化点的形状近似为圆形，直径在50～150μm之间，毛化点为凸起结构，且凸起高度差在2～12μm之间，各毛化点之间重叠量小于10％，单位面积范围内毛化点所覆盖面积占比在30～90％之间。图1至图3示意了所设计的轧辊表面微观形貌。
并将实施例1-3和对比例1-3的轧辊依照测量标准ISO 4287:1997进行测试，滤波器采用高斯滤波，粗糙度的取样长度为12.5mm，波纹度的取样长度为40mm，滤波区间0.8～8mm。随后将轧辊装入热镀锌平整机，在基本相同的工况条件下，使用基本相同的工艺参数对相同规格材质的材料进行平整，测量平整完成后的钢板表面粗糙度与轧辊粗糙度的比值，将该比值作为形貌复制率指标。
具体的设计参数和测量对比结果如下表1所示。
表1：
Figure PCTCN2018083469-appb-000001
Figure PCTCN2018083469-appb-000002
由于轧辊表面形貌的微观结构会影响到轧辊表面形貌的复制率和波纹度，因而在实施例1-3中通过对轧辊表面形貌进行设计，并采用本发明中所述的制造方法对轧辊进行加工，使得轧辊表面具有大量毛化点，毛化点的形状近似为圆形，直径在50～150μm之间，毛化点为凸起结构，且凸起高度差在2～12μm之间，各毛化点之间重叠量小于10％，单位面积范围内毛化点所覆盖面积占比在30～90％之间的特征。而对比例1-3采用常规的电火花毛化工艺，因而其所获得的普通轧辊表面并不具有上述特征，其形貌复制率也偏低，波纹度偏高。
下面再以实施例1为例，并结合图1、图4与图5，对本发明中所涉及的轧辊制造方法的具体实施过程进行描述：
(1)对轧辊进行磨削抛光加工，并对辊面进行清洁，使轧辊表面粗糙度Ra<0.5μm，表面无油污；
(2)设计轧辊表面微观形貌，具体如图1所示；
(3)如图4所示，使用数控机床1驱动轧辊2旋转并使超短脉冲激光器3沿轧辊2母线做横向平移运动；
(4)根据所设计的表面形貌，控制超短脉冲激光器选择性的对轧辊表面材料进行逐层烧蚀。
在实施例1中，使用了平均功率为100W的皮秒脉冲激光器，该激光经过聚焦后，每个脉冲会在轧辊表面烧蚀掉直径约为5μm，深度约为1μm体积的材料。因此根据实施例1的微观形貌的最大凸起高度，需要 分8层进行加工，图5展示了轧辊表面一个微观区域的材料加工过程，其通过超短脉冲激光逐层去除材料从而获得最终所需的表面形貌。
需要注意的是，以上列举的仅为本发明的具体实施例，显然本发明不限于以上实施例，随之有着许多的类似变化。本领域的技术人员如果从本发明公开的内容直接导出或联想到的所有变形，均应属于本发明的保护范围。

Claims (10)

  1. 一种用于钢板表面形貌轧制的轧辊，其特征在于，在辊面布设有多个凸起的毛化点，单个所述毛化点与辊面相接处形成的形状为圆形或大致为圆形，该圆形的直径为50～150μm；单个所述毛化点的凸起高度为2～12μm，相邻毛化点之间重叠量小于10％；辊面单位平方毫米内的毛化点数量差异小于20％，每平方毫米内的毛化点覆盖面积占比在30～90％。
  2. 根据权利要求1所述用于钢板表面形貌轧制的轧辊，其特征在于，所述凸起的毛化点的底部直径不小于顶部直径。
  3. 根据权利要求1所述用于钢板表面形貌轧制的轧辊，其特征在于，相邻毛化点之间重叠量小于5％。
  4. 根据权利要求3所述用于钢板表面形貌轧制的轧辊，其特征在于，相邻毛化点之间重叠量为0。
  5. 根据权利要求1所述用于钢板表面形貌轧制的轧辊，其特征在于，辊面单位平方毫米内的毛化点数量差异小于10％。
  6. 根据权利要求5所述用于钢板表面形貌轧制的轧辊，其特征在于，辊面单位平方毫米内的毛化点数量差异小于5％。
  7. 根据权利要求1所述用于钢板表面形貌轧制的轧辊，其特征在于，辊面每平方毫米内的毛化点覆盖面积占比在50～80％。
  8. 根据权利要求1所述用于钢板表面形貌轧制的轧辊，其特征在于，所述钢板为冷轧钢板。
  9. 一种权利要求1-8中任一权利要求所述用于钢板表面形貌轧制 的轧辊的制造方法，其特征在于，包括如下步骤：
    (1)、对来料轧辊进行表面处理的步骤，使轧辊表面粗糙度控制在Ra<0.5μm；
    (2)、对轧辊表面材料进行逐层烧蚀以形成所述毛化点的步骤。
  10. 根据权利要求9所述的制造方法，其特征在于，采用超短脉冲激光器对所述轧辊表面材料进行逐层烧蚀；烧蚀时所述超短脉冲激光器沿来料轧辊母线做横向平移运动，同时，所述来料轧辊经驱动后处于可旋转状态。
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