CN105522126B - The compound roll shaft manufacturing process of high-performance and equipment - Google Patents
The compound roll shaft manufacturing process of high-performance and equipment Download PDFInfo
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- CN105522126B CN105522126B CN201510763882.1A CN201510763882A CN105522126B CN 105522126 B CN105522126 B CN 105522126B CN 201510763882 A CN201510763882 A CN 201510763882A CN 105522126 B CN105522126 B CN 105522126B
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Abstract
The invention discloses a kind of compound roll shaft manufacturing process of high-performance and equipment, when being heated to 840~1100 DEG C using sensing heater is overall to the plug progress in Combined water cooling crystallizer, pour into roll shaft working lining liquation, continue heating 10~50 minutes, start lowering or hoisting gear to be lifted up heater with certain speed, being raised to insulation ring through 5~15 minutes stops, and continues heating 10~50 minutes, feeding is carried out to rising head, stops water flowing after heating and cools down 30 minutes~24 hours.When the present invention manufactures compound roll shaft, controllable process parameters are few, and compound bed boundary is easily controllable, and technique is simple, and efficiency high, power consumption is small, and cost is low, and composite bed is without component segregation, roll shaft service life length.Overcome centrifugal process and be also easy to produce microstructure segregation defect, solve the high deficiency of CPC methods, ESR methods complex manufacturing, cost.
Description
Technical field
The invention belongs to metal-pressed machine technical field, the compound roll shaft manufacturing process of more particularly to a kind of high-performance and set
It is standby, the manufacture of composite roll suitable for Steel-rolling Industry.
Background technology
Roller parts are widely used in the fields such as metallurgy, mine, electric power, petrochemical industry, building materials, be calendering deformation, broken, grinding and
Large easily consumption critical component of the equipments such as supporting, conveying, guiding, consumes more than 500 ten thousand tons, be worth more than 1,000 hundred million yuan in year.Axle class zero
Part is the critical component of equipment, consumes several hundred billion yuan in year.There is cost height in existing manufacturing process, efficiency is low, of poor quality, the life-span is low
Etc. problem, huge waste and pollution are caused.
Roll is described as " mothers of steel ", is metal material is produced plastic deformation in the production of the rolling metals such as steel, aluminium, copper
Instrument, be to determine milling train production efficiency and mill bar quality and the important large component of economy, be mill milling can not or
Scarce critical piece and most important large consumable part, its consuming cost are about the 5%~15% of Rolling production cost.If
The ratio for the factors, then its shared production cost such as the production for considering to bring by roll consumption is shut down, drop is produced and plant maintenance increases
Again can be higher.
Milling train is the visual plant in metal-pressed machine production, is the aobvious of one national Iron ＆ Steel Development technical merit of measurement
Principal coordinates will.It is the critical component largely consumed in Rolling production and roll is the chief component of milling train, is to determine one
The basic guarantee of national rolling technique development level, be a national metal material design, material forming technique, processing and manufacturing and
The embodiment directly perceived of the basic industries comprehensive technical levels such as heat treatment.Rolling industry production in, each stocking none be not according to
Shaped by the rolling of roll, in other words " no roller is good-for-nothing ", so, the quality of roll and effect are most important.
Roll quality is not only related to Rolling production cost and milling train production operational availability, also largely influences stocking
Quality.With the development of steel rolling technology, rolling mill speed and automaticity improve constantly, to the resistance to of roll quality particularly roll
Mill property, intensity and toughness etc. propose higher requirement.Roller performance is further improved to adapt to the needs of milling train, realizes steel
The energy-saving production of section bar, it is the fresh target that roll development person faces.
China's roll manufacturing industry passes through the development and growth of decades, turns into roll yield big country of the world, roll at present
There is very big development in terms of manufacturing technology and material kind.In terms of roll material, from spheroidal graphite cast-iron, alloy infinitely chilled ductile cast iron
Acicular constituent spheroidal graphite cast-iron till now, high alloy infinitely chilled ductile cast iron, rich chromium cast iron, hard alloy, semi-high speed steel and
High-speed steel etc..It is multiple also to develop into centrifugation from conventional cast single material and press over system casting composite in terms of casting technique
Close casting process.Current domestic roll deliverability has reached more than 1,000,000 tons, and design and manufacture ability can reach 120~
1500000 tons.With China's rolling equipment transformation and constantly introduce advanced milling train from foreign countries, milling train is to automation, continuous
Change, heavy-duty direction are developed, and the tissue and performance to roll propose higher requirement.
However, the metallurgical roller rolled steel mean consumption that China voluntarily develops still has larger difference compared with developed countries
Away from.Recent statistics from China Steel association, China's steel yield has reached 1,125,570,000 tons within 2014, accounts for global steel production
Amount more than 40%, calculated according to the kg/t steel of loss per ton steel roll 1.0~1.2, more than 110~130 ten thousand tons of roll of year consumption, year disappears
Consume more than 20,000,000,000 yuan of roll fund.In order to meet being actually needed for Rolling production, China is required for spending a large amount of foreign exchanges every year
Import roll, the only high-quality roll of import in 2010 be about more than 3.0 ten thousand ton, and consumption foreign exchange is about more than 200,000,000 dollar.China's roll it is big
Amount consumption, causes resource and the huge waste of the energy.In addition, external roll Year's consumption is also above million tons, the market demand
Amount is big.No matter so big learies are from the rolling cost of steel rolling mill, or in terms of the energy and resource consumption in China
All it is a huge waste, environment and resource is exerted heavy pressures on.Therefore, roll quality is improved, extends roll campaign, no
It is only capable of saving a large amount of foreign exchanges, but also substantial amounts of roll material can be saved, develops high-quality long-life roll material and its shaping
It technology, can not only meet domestic demand, but also foreign exchange earning can be realized.
To meet requirement of the modern rolling industry to high-performance roll, in recent years, the high property of various new is have developed both at home and abroad
Energy roll making technology, wherein the technique developed in terms of casting manufactures combination process mainly has：Centrifugally cast composite roll,
Continuously casting (CPC) compound car is shallow, electroslag remelting (ESR) composite roll, combined roll etc..
Centrifugally cast composite roll technique（CF）, it is the method production bimetallic composite roll using centrifugal casting.Mainly
It is to produce centrifugal force using rotation, molten metal is poured into the casting mold rotated, using centrifugal force the gold poured into a mould
Category liquid gets rid of the outer rim to casting mold from pivot, carries out the solidification ecto-entad order of molten metal, it is tissue to be frozen into outer layer
The high abrasion resisting material of densification, the composite roll that internal layer is common material.The flowing of molten metal contribute to the broken of dendritic crystal and
Refinement, while the resistance for overcoming intercrystalline " tunnel " carries out feeding, is improved the consistency of casting.In outer sphere molten metal
After solidification, casting mold is sling and assembled with bottom and top and rising head sand mold, core and upper lower impressions are filled with gravity-assist pouring, it is real
Existing two kinds of materials it is compound.Centrifugal roller casting manufacture composite roll has the advantages of other casting technique does not possess, specifically
It is as follows:(1) some parts do not need dead head, effectively improve the service efficiency of molten metal;(2) core need not be used just
The casting of annular and empty tubular can be cast out, while the length cast tube different with diameter can also be produced, is had well
Production efficiency, production cost be not also high;(3) under the influence of centrifugal force, after molten metal solidification, quality is fine and smooth;(4) with this
The skin of the roll of method production has higher wearability, and the toughness material and can of internal layer ensures that roll has higher toughness,
With than integral material roll broader practice prospect and higher cost performance.
Although the technique has, equipment is simple, and equipment investment is small, and production efficiency is high, and cost is low, suitable for producing it in enormous quantities
Feature.But there is following several deficiencies in the technique：
1）When the roll for manufacturing high alloy material, due to often containing the high alloy of big metric density in material, such as
Tungsten, molybdenum, vanadium etc., during centrifugal casting, due to the effect of centrifugal force, the high alloy of these density can be segregated in roller surface, make to roll
Roller inner alloy constituent content reduces, and makes tissue and composition uneven so as to deteriorate roller surface layer toughness, reduces skin of the roll
Wearability, influence the quality of roll.
2）When the fusing point of core material is higher than the fusing point of cladding material, in the inner surface of the cladding material solidified during cast
Produce fused layers.Therefore when core material selects cast steel, it is impossible to obtain good compound interface.
3）The composite roll of the forged steel core with high intensity, high tenacity can not be produced.
Continuous cast outer layer forming process (CPC methods), the technique are that the Nippon Steel Corp of Japan grinds with late 1980s
Study carefully exploitation to put into production.CPC methods are to integrate material, technique, equipment, the new and high technology automatically controlled[10], at present in the world
Only Nippon Steel and Hitachi, Ltd is used successfully to industrialized production.Its operation principle is to make roller with forged steel, cast steel or waste or old roll
Core, last layer silicon systems glass protection film is applied on its surface, prevents roller core surface oxidation.Compound outer sphere molten metal will be needed to pour into
To between vertically arranged roller core and water mold, to make the outer layer high-speed steel of casting be fused completely with roller core, using two sets
Electromagnetic induction heater carries out concurrent heating and preheating to molten steel and roller core respectively.The outer sphere molten metal of melting is fusing with roller core
Order solidification upwards simultaneously, makes the interface of two kinds of materials reach metallurgical binding.It is by stripping equipment, compound good roll is continuous
Ground is extracted out from water mold, until composite roll casting complete.In cohesive process, the appearance of roller core surface is micro- molten, makes roller
Core and outer layer high speed steel metal realize firm metallurgical binding, improve bond strength.The high-speed steel roller stock of this method production
Tissue and grain size are much thinner than centre spinning method, and carbide even dispersion is distributed, and the life-span is than centrifugal casting roll
It is high by 30%.
The formation of binder course affects the decrease speed of roll, also just determines the production efficiency of CPC methods.This method has
Following features:1. the outer layer material of roll can select a variety of high alloy materials, core material can use obdurability and rigidity high
Steel based material, avoid primary carbie segregation and tissue, composition segregation shortcoming that Centrifugal Cast High Speed Steel Roll occurs；②
Molten steel solidifies in water cooling knot product device, and cooling velocity is fast, can obtain tiny, fine and close solidified structure, hot-cracking resistance is good, roll
Can be good the features such as;3. consecutive solidification from bottom to top, keep away and exerted oneself shrinkage cavity and the generation of the casting flaw such as loose；4. it can both manufacture
New roll, also old roll can be carried out to remanufacture reparation.
The shortcomings that CPC is mainly：1. due to using two sets of induction heating systems, equipment is more complicated, and technical difficulty is big；2. by
In using stripping mode, production efficiency is relatively low, and the pure brilliant degree of the steel produced is poor；3. need to carry out molten steel in production process
Prolonged insulation, power consumption is big, requires high to tundish refractory material, production cost is high；4. factory building and operator are required
It is high.Based on above reason, scope very little is promoted the use of at present, and China has not been put to industrialization production so far.
Liquid pouring of electroslag method（ESSLM）, ESSLM is in E.O. bars electric welding research institute invention of the beginning of the nineties in last century
's.Its production technology is put among a copper water mold by compound forging, casting or used waste and old roller
Core, then the slag melted in advance is poured into the gap between roller core and crystallizer, it is powered, leads between crystallizer and roller core
Cross molten slag and form electrical circuit, caused heat is by the surface melting of roller core in slag, by melted liquid metal with one
Fixed technique is poured into the gap between roller core and crystallizer, and liquid metal floats slag, when passing through slag bath by electroslag essence
Refining, at the same by roller core cladding get up and the roller core surface preheated with oneself fuse, solidified under the cooling of crystallizer, formed it is compound
Layer.In the process, constantly extracted out by stripping device roller core from crystallizer, while constantly pour into liquid metal, until
Untill predetermined length.The material for covering layer can be cast iron, high-speed steel and other metals, and made composite roll both may be used
To be used as cold roll, hot roll or Continuous Casting Rolls, casting clad can be carried out to waste or old roll again and is remanufactured.But strictly to control
The time of melt cinder temperature and roller core in melt cinder, the fusing that core is excessive is prevented, pollute working lining.
ESSLM technologies allow composite diameter from 100 mm to 1800 mm, even more major diameter billet outer surface.Composite bed
The mm of thickness 15~20 to 100 mm, even more greatly.The technique is compared with electroslag remelting process, its efficiency high, and poring rate is
200~800 kg/h, power consumption is close to 800 kWh/t steel[10]。
When the shortcomings that technique is mainly that molten steel injects crystallizer in batches or continuously in recombination process, because poring rate is non-
Often slow, molten steel needs to be incubated, and molten steel storage facility is extremely complex and expensive, and the refractory material of holding furnace and steel ladle is by high temperature gold
Category liquid washes away for a long time to be caused largely to be lost, and causes nonmetal inclusion to pollute, long under molten metal overheat and high temperature strongly
Time, which preserves, can all cause alloying element and deoxidier to aoxidize and accelerate.The energy expenditure of the process is bigger, and is taken out due to using
Ingot technique, matching and metal liquid level control technology of the slag temperature with stripping speed are complicated, roller core surface fusion penetration layer control technology difficulty
Greatly, low production efficiency.
Although CPC techniques and ESSLM techniques can manufacture the composite bed of big thickness, due to present in technique and equipment
Above mentioned problem, it is currently only used for the high-end composite rolls such as high-speed steel of the manufacture less than 10 tons.
Combined roll is that roll is made into several parts, is mechanically combined.Roll internal layer uses tough
Property material, outer layer mostly make carbide ring.This roll can save valuable hard alloy, and cost performance is higher.Outer layer
Carbide ring can ensure that roll has very high wearability.But due to carbide ring and internal layer roller core be difficult accomplish it is seamless
Engagement, can cause roll unbalance stress in the operation of rolling and chipping.
Although having been developed that numerous composite roller manufacturing process both at home and abroad, up to the present, do not have also still
The composite roll manufacturing process that one technique is simple, production cost is low, performance is good.Therefore, composite roller system is researched and developed
Technique and equipment are made, it is current urgent need solution to carry out low cost, high efficiency, high-performance to various material rolls and large-scale roller to manufacture
Problem certainly.It is the new direction of composite roll Manufacturing Technology Development.
The content of the invention
It is an object of the invention to there is the deficiency of technology for oneself, propose that a kind of simple production process, equipment investment are small, raw
Efficiency high, the compound roll shaft manufacturing process of novel high-performance and equipment that cost is low, performance is good are produced, simplifies compound roll shaft manufacture work
Skill, compound roll shaft performance and production efficiency are improved, reduce production cost and equipment investment, solved centre spinning and composition easily occurs
Segregation, CPC methods, ESR methods complex manufacturing, the deficiency that power consumption is big, cost is high, efficiency is low.
The equipment scheme for solving its technical problem is:The equipment has a planer-type region directional solidification jacking equipment 16,
Lifting platform 17 is installed on planer-type region directional solidification jacking equipment 6, being provided with electromagnetic induction above lifting platform 17 adds
Hot device 8, lifting screw 15 is rotated by lifting motor 14 or hydraulic test drives lifting platform 17 to be moved down in set speed
It is dynamic, the side installation electromagnetic induction electrical power control cabinet 19 of directional solidification jacking equipment 16, electromagnetic induction power supply in planer-type region
Two output ends of switch board 19 are connected by water-cooled cable 20 with the both ends of electromagnetic induction heating device 8, are determined in planer-type region
There is a base support to the bottom of solidification jacking equipment 16, support plinth 12 is installed on base support 13, in support plinth
Water-cooled bottom water tank 11 is installed, the center of bottom water tank 11 is manhole, in being provided with above bottom water tank 11 above 12
The heart is the bottom board 10 of manhole, and Combined water cooling crystallizer 7 is provided with above bottom board 10, is crystallized in water cooling
The top of device 7 is provided with insulation ring 6, the center hole that roll shaft plug 5 passes through support plinth 12, bottom water tank 11 and bottom board 12
The center of crystallizer 7 is fixed on, connection has casting runner 3 in the side of bottom board 10, and casting runner 3 is arranged on base support
On 13 and sit brick 4 with cast to be connected, cast sits that brick 4 is installed above feed trumpet 2, and casting leakage is provided with the top of feed trumpet
Bucket 1, there is pouring ladle 18 above depositing funnel 1.
There are water inlet pipe 23 and outlet pipe 24 respectively in the side of Water-cooled bottom water tank 11；Water mold 7 in crystallizer by justifying
The fourplatemold arc water cooling box assembly 7 of equally distributed 2 or 3 integral multiples forms on week, in each arc water cooling box
The bottom connection of body component 7 has water inlet pipe 21, and on the top of each arc water cooling box assembly 7, connection has outlet pipe 22, passes through
Arc water cooling box assembly 7 is connected into drum-shaped entirety by attachment bolt 9；Insulation ring 6 is resistance to by refractory material or fiber reinforcement
Fiery material manufacture；Electromagnetic induction power supply be line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, frequency be 500Hz~
3000Hz。
Solving the process technology scheme that its technical problem uses is:First by the roll shaft plug table of the required size manufactured
After face carries out oil removing, processing of rust removing, one layer of antioxidizing paint is uniformly coated on its surface, is put into heating furnace and is preheating to
After 500 DEG C~700 DEG C, the center of crystallizer is fixed on by the center hole of support plinth, bottom water tank and bottom board, is started
Region directional solidification lowering or hoisting gear, electromagnetic induction heater is dropped to the bottom of crystallizer, open water mold and bottom water
The water inlet pipe and water outlet pipe of case, start electromagnetic induction heating power supply, by the sensing heater outside water mold to plug
Surface heating is carried out, after to be heated to 820 DEG C~1100 DEG C, the roll shaft outer sphere molten metal for the required composite parts smelted is fallen
Enter in pouring ladle, the molten metal in pouring ladle is passed through into depositing funnel, feed trumpet, casting runner according to predetermined cast program
Pour into the space in crystallizer between roll shaft plug, in casting process, electromagnetic induction heater does not stop heating, metal
After liquid is poured, sensing heater continues heating 10~50 minutes, makes poured into a mould molten metal within the regular hour
Liquid is kept, to increase the liquid solid time, interface is formed metallurgical binding, starting region directional solidification lowering or hoisting gear is by electromagnetic induction
Heater is lifted up with certain speed, and the roll shaft composite bed for gradually disengaging electromagnetic induction heating is successively sequentially solidifying from bottom to top
Gu and the different rates of climb, forming region directional solidification, through 5~15 points are controlled in different regions according to quality requirement
Clock, which is raised at insulation ring, to be stopped, and continues to carry out heating 10~50 minutes to insulation ring, to postpone insulated feeder setting time, to emitting
Mouth carries out feeding, the gas in composite-layer metal liquid and field trash is fully floated, and eliminates composite-layer metal casting flaw, reaches
Stop heating after the scheduled time, continue water flowing and cool down 30 minutes~24 hours, the compound roll shaft cast is taken out of crystallizer
Go out.
Described roll shaft mandrel material for forging or cast low alloy steel, medium carbon steel or spheroidal graphite cast-iron, alloy cast iron, roller
Axle composite material is spheroidal graphite cast-iron, graphitic steel, nickel-chrome-molybdenum alloy cast iron, rich chromium cast iron, cast steel, high boron steel, high-speed steel, mould
Steel material.
When being iteratively repeated above-mentioned combination process, large-scale composite roll, composite support with MULTILAYER COMPOSITE layer can have both been manufactured
Roller is supportted, large-scale composite roll, composite support roller are manufactured using small-sized smelting equipment so as to reach, when every layer of composite material of change
During composition, it can both realize and manufacture the Gradient Composite Layer roll being made up of different materials composition, support roller.
When doing plug using waste or old roll, support roller, both can to spheroidal graphite cast-iron, graphitic steel, nickel-chrome-molybdenum alloy cast iron,
Rich chromium cast iron, cast steel with high chromium, alloy cast steel, high boron steel, high-speed steel, the waste or old roll of die steel material and support roller are made again
Produce and repair multiple.
Described fourplatemold can both have been realized by adding or reducing various sizes of arc water cooling box assembly
The adjustment of fourplatemold inner diameter size within the specific limits, meet the manufacture of the different compound roll shafts of different-diameter size,
So as to reduce mould expense.
The composition of the mandrel surface antioxidizing paint is Na2B407, Si02, Na20, K20, A1203, CaO therein one
Kind or Multiple components composition.
Beneficial effect
The roll that the methods of the inventive method and centre spinning, CPC methods, ESLLM methods produces is very different, and it is led
Wanting feature is:
1st, compound roll shaft is manufactured using the invented technology, because special casting method makes the metal of melting coagulate from bottom to top
Gu being advantageous to the feeding of liquid metals, the defects of centre spinning is also easy to produce microstructure segregation, manufactured compound roll shaft are overcome
Material does not have gravity segregation, and crystalline structure is excellent, even tissue, and the tiny consistency of crystal grain is high, and centrifugal casting can not be used before making
The production of the material of method production is possibly realized.The range of choice of plug and composite material is wide, can be wanted according to different uses
The forging or the composite material of rod cast thereby material and different performance, skin of the roll for asking free selection varying strength requirement can
To use high alloy material, good red hardness and high temperature abrasion resistance are made it have.
2nd, roll mandrel is directly preheated in crystallizer before cast using electromagnetic induction heater, it is right after cast
Roll mandrel and the molten metal poured into a mould are incubated, and reduce the temperature difference between roller core and outer sphere molten metal, are advantageous to double
Metal material it is good compound, there is good mechanical performance.On the other hand in order to reduce casting flaw, metallic composite is allowed
Realize to lower and upper consecutive solidification, the flowing of molten metal automatically from top to bottom, be advantageous to molten metal feeding from top to bottom, so as to contract
The short length in feeding area, reduce casting flaw, form the fine and close composite roll without shrinkage cavity；Continue in casting process to multiple
Condensation material carries out electromagnetic induction heating, can reduce the oxidation for by the preheating temperature of composite, reducing composite, Ke Yizeng
The liquid feeding solid time, promote the diffusion of two phase material more abundant, while function composite by electromagnetic stirring can be utilized, increase liquid metals pair
By washing away for mandrel material surface, promote the matter and energy exchange between two phase material, make compound bed boundary easily controllable, from
And greatly improve the bond strength at interface, it is possible to achieve good metallurgical bonding interface, product quality are easily controllable.
3rd, the present invention is using water mold substitution sand mold and metal mold shaping, in roll forming process, due to roll
Outer sphere molten metal is the cooled and solidified in water mold, and cooling velocity is high, and nucleation ability is strong, can obtain tiny solidifying of crystal grain
Gu tissue, dense structure degree is high, and hardness is uniform, and mechanical property is good, improves the obdurability and thermal fatigue resistance of roll, have compared with
The properties possessed needed for high wearability and cold-resistant, thermal fatigue and modern roll working layer, and with excellent
Machinability, casting and forging can be achieved, the service life of roll is improved, so as to meet modern rolling steel industry to high-performance
The requirement of roll.Sand mold and metal mold shaping are substituted using water mold, the technique recovery rate of casting is high, liquid metals consumption
Reduce, 15~30% are saved than sand casting；Rate of metal is high.Product size precision, surface light Zhi Dugao, machinery add remaining
At least, while cast(ing) surface is without viscosity sand layer.And quality and dimensionally stable.Meanwhile reduced by very little allowance, it is corresponding to improve
Rate of metal, has saved material.
4th, the present invention is cast using water mold, can be completely without molding sand, so reducing the work of molding sand processing
Sequence.Casting can be poured into a mould again after going out type simultaneously, thus be easy to do mechanization and automated production, and production efficiency is high.
5th, due to being molded using water mold, the mold use life-span is up to thousands of times or even tens of thousands of times, great section
Modeling Material has been saved, has reduced die cost, due to without sand molding, when having saved a large amount of molding sand and moulder, improving
Efficiency.Substantial amounts of manufacturing expense has been saved, has reduced manufacturing cost, has reduced the waste of resource and the energy and the dirt of environment
Dye.
6th, it is domestic at present usually using centrifugal compound technique manufacture roll, this roll exist during long-term use with
Lower deficiency：1. hardness drop is big, roll use for the first time and the last time of centrifugal process manufacture use, and material structure changes
Greatly, hardness wearability declines very fast, and rolling tonnage can decline 50-70 tons；2. thermal fatigue resistance is poor, roll long-term work exists
Under the condition of high temperature, low thermal fatigue resistance causes roll in use for some time, and it is existing to be also easy to produce crackle and top layer chip off-falling etc.
As having a strong impact on rolled piece quality；3. the toughness for centrifuging bainite roll is low, fragility is big, roll breakage phenomenon happens occasionally.The present invention adopts
Compound roll shaft is manufactured with imbedding process, in casting process, although mandrel has carried out the preheating of certain temperature, but relative to being poured
For the high temperature fluent metal of note, mandrel material acts on equivalent to chill in casting process, cold inside roll so as to improve
But effect, increase roll cast when inside cooling velocity, improve and enhance roll dense internal organization, make interface by
Fused layers, diffusion layer and Quench solidification layer composition, reduce the hardness drop of composite material radial direction, and whole composite material is hard
It is minimum to spend drop, further increases compound roll shaft performance, manufactured composite roll is repaiied every time in whole service life
It is small that service life after multiple reduces amplitude.Meanwhile the present invention is molded using water mold, composite-layer metal liquid is by crystallizer
Quick cooling, change composite bed crystalline structure, improve composite material performance, answered through what the technique was manufactured/remanufactured
Close roll and the life-span is intended for single use more than the new roll more than 20~30% of material used in original.Comprehensive life improves more than 50%.
7th, using the technique and device fabrication/manufacture compound roll shaft again, due to using integrally being preheated in type, Quick pouring into
Type, region directional solidification control crystalline structure, solve CPC methods, ESLLM methods using stripping technique productions low production efficiency, consumption
Can be big, high to factory building and operator's requirement；CPC methods use two sets of induction heating systems, equipment compared with it is complicated, technical difficulty is big,
The pure brilliant degree of steel is poor；Matching and metal liquid level control technology of the ESLLM method slag temperature with stripping speed are complicated, roller core surface fusion penetration layer
The drawbacks such as control technology difficulty is big, have the production efficiency higher than centrifuging process, and overcome Centrifugal compound foundry process institute
Existing component segregation and the drawbacks of can not manufacturing forged steel roll neck roll, controllable process parameters are few, and simple production process is easy to grasp
Make, production efficiency is high, and power consumption is small, and production cost lower than electroslag remelting process 1/2, lower than submerged arc bead welding method 2/3, equipment is simply thrown
Provide small, suitable batch production.It can not be limited by equipment and technique, realization manufactures large-sized multilayer laminar with mini-plant
Joint product or Gradient Composite Layer product, it is applied widely.
Brief description of the drawings
Fig. 1 is present device installation diagram, wherein 1 is depositing funnel, 2 be feed trumpet, and 3 be a cast runner, and 4 sit for cast
Brick, 5 be roll shaft plug, and 6 be insulation ring, and 7 be fourplatemold, and 8 be electromagnetic induction heater, and 9 be attachment bolt, and 10 be to pour
Bottom plate is noted, 11 be bottom water tank, and 12 be support plinth, and 13 be base support, and 14 be lifting motor, and 15 be lifting screw, and 16 be dragon
Gate-type region directional solidification jacking equipment, 17 be lifting platform, and 18 be pouring ladle, and 19 electromagnetic induction electrical power control cabinets, 20 be water cooling
Cable, 23 be bottom tank inlet pipe, and 24 be bottom radiator drain.
Fig. 2 is fourplatemold structure chart of the present invention, wherein 7 be fourplatemold.
Fig. 3 is fourplatemold arc water cooling casing modular construction top view of the present invention, wherein 21 be that combined type crystallizes
Device water inlet pipe, 22 be fourplatemold outlet pipe, and 7 be crystallizer arc water cooling box assembly.
Fig. 4 is cisten mechanism figure in bottom of the present invention, wherein 11 be bottom water tank, be water inlet pipe, be outlet pipe.
Fig. 5 is cisten mechanism top view in bottom of the present invention, wherein 11 be bottom water tank, 23 be bottom tank inlet pipe, and 24 be bottom water
Case outlet pipe.
Embodiment
With reference to accompanying drawing, it is as follows to provide embodiments of the invention:
Embodiment 1:In Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, the equipment has a planer-type region directional solidification jacking equipment
16, lifting platform 17 is installed on planer-type region directional solidification jacking equipment 6, electromagnetism sense is installed above lifting platform 17
Heater 8 is answered, lifting screw 15 is rotated by lifting motor 14 or hydraulic test drives lifting platform 17 with set speed
Lower movement, the side installation electromagnetic induction electrical power control cabinet 19 of directional solidification jacking equipment 16, electromagnetic induction in planer-type region
Two output ends of electrical power control cabinet 19 are connected by water-cooled cable 20 with the both ends of electromagnetic induction heating device 8, in planer-type area
There is a base support bottom of domain directional solidification jacking equipment 16, support plinth 12 is provided with base support 13, is supporting
Water-cooled bottom water tank 11 is installed, the center of bottom water tank 11 is manhole, is installed above bottom water tank 11 above base 12
The bottom board 10 for having center to be manhole, is provided with Combined water cooling crystallizer 7, in water cooling above bottom board 10
The top of crystallizer 7 is provided with insulation ring 6, the center that roll shaft plug 5 passes through support plinth 12, bottom water tank 11 and bottom board 12
Circular hole is fixed on the center of crystallizer 7, and in the side of bottom board 10, connection has casting runner 3, and casting runner 3 is arranged on base
On support 13 and sit brick 4 with cast to be connected, cast sits that brick 4 is installed above feed trumpet 2, is provided with and pours at the top of feed trumpet
Funnel 1 is cast, there is pouring ladle 18 above depositing funnel 1.
There are water inlet pipe 23 and outlet pipe 24 respectively in the side of Water-cooled bottom water tank 11；Water mold 7 in crystallizer by justifying
Equally distributed 2 fourplatemolds arc water cooling box assembly 7 forms on week, in each arc water cooling box assembly 7
Bottom connection has water inlet pipe 21, and on the top of each arc water cooling box assembly 7, connection has outlet pipe 22, passes through attachment bolt 9
Arc water cooling box assembly 7 is connected into drum-shaped entirety；Insulation ring 6 is by refractory material or fiber reinforcement refractory material system
Make；Electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, frequency 1000Hz.
When work starts, the forging low-alloy steel roll mandrel surface of the required size manufactured is subjected to oil removing, derusting
After processing, one layer of antioxidizing paint is uniformly coated on its surface, is put into heating furnace after carrying out being preheating to 600 DEG C, passes through supporting
The center hole of base, bottom water tank and bottom board is fixed on the center of crystallizer, and starting region directional solidification lowering or hoisting gear will
Electromagnetic induction heater drops to the bottom of crystallizer, opens the water inlet pipe and water outlet pipe of water mold and bottom water tank, starts electromagnetism sense
Heating power supply is answered, surface heating is carried out to plug by the sensing heater outside water mold, it is to be heated to 880
DEG C when, the nickel-chrome-molybdenum alloy cast iron skin of the roll molten metal smelted is poured into pouring ladle, the molten metal in pouring ladle is pressed
Sky in crystallizer between roll plug is poured into by depositing funnel, feed trumpet, casting runner according to predetermined cast program
In gap, in casting process, electromagnetic induction heater does not stop heating, after pouring metal melt, sensing heater continue into
Row heating 10 minutes, makes poured into a mould molten metal keep liquid within the regular hour, to increase the liquid solid time, forms interface
Electromagnetic induction heater is lifted up, progressively taken off by metallurgical binding, starting region directional solidification lowering or hoisting gear with certain speed
From the Roll Cladding successively consecutive solidification from bottom to top of electromagnetic induction heating, it was raised at insulation ring and stops through 5 minutes, continues pair
Insulation ring carries out heating 10 minutes, to postpone insulated feeder setting time, carries out feeding to rising head, makes in composite-layer metal liquid
Gas and field trash fully float, and eliminate composite-layer metal casting flaw, stop heating after reaching the scheduled time, it is cold to continue water flowing
But 12 hours, the composite roll cast is taken out out of crystallizer.
Embodiment 2：In Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, the equipment has a planer-type region directional solidification jacking equipment
16, lifting platform 17 is installed on planer-type region directional solidification jacking equipment 6, electromagnetism sense is installed above lifting platform 17
Heater 8 is answered, lifting screw 15 is rotated by lifting motor 14 or hydraulic test drives lifting platform 17 with set speed
Lower movement, the side installation electromagnetic induction electrical power control cabinet 19 of directional solidification jacking equipment 16, electromagnetic induction in planer-type region
Two output ends of electrical power control cabinet 19 are connected by water-cooled cable 20 with the both ends of electromagnetic induction heating device 8, in planer-type area
There is a base support bottom of domain directional solidification jacking equipment 16, support plinth 12 is provided with base support 13, is supporting
Water-cooled bottom water tank 11 is installed, the center of bottom water tank 11 is manhole, is installed above bottom water tank 11 above base 12
The bottom board 10 for having center to be manhole, is provided with Combined water cooling crystallizer 7, in water cooling above bottom board 10
The top of crystallizer 7 is provided with insulation ring 6, the center that roll shaft plug 5 passes through support plinth 12, bottom water tank 11 and bottom board 12
Circular hole is fixed on the center of crystallizer 7, and in the side of bottom board 10, connection has casting runner 3, and casting runner 3 is arranged on base
On support 13 and sit brick 4 with cast to be connected, cast sits that brick 4 is installed above feed trumpet 2, is provided with and pours at the top of feed trumpet
Funnel 1 is cast, there is pouring ladle 18 above depositing funnel 1.
There are water inlet pipe 23 and outlet pipe 24 respectively in the side of Water-cooled bottom water tank 11；Water mold 7 in crystallizer by justifying
Equally distributed 3 fourplatemolds arc water cooling box assembly 7 forms on week, in each arc water cooling box assembly 7
Bottom connection has water inlet pipe 21, and on the top of each arc water cooling box assembly 7, connection has outlet pipe 22, passes through attachment bolt 9
Arc water cooling box assembly 7 is connected into drum-shaped entirety；Insulation ring 6 is by refractory material or fiber reinforcement refractory material system
Make；Electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, frequency 500Hz.
When work starts, after the medium carbon steel roll mandrel surface of the required size manufactured is carried out into oil removing, processing of rust removing,
One layer of antioxidizing paint is uniformly coated on its surface, is put into heating furnace after carrying out being preheating to 650 DEG C, passes through support plinth, bottom
The center hole of water tank and bottom board is fixed on the center of crystallizer, starting region directional solidification lowering or hoisting gear, by electromagnetism sense
Answer heater to drop to the bottom of crystallizer, open the water inlet pipe and water outlet pipe of water mold and bottom water tank, start electromagnetic induction heating
Power supply, surface heating is carried out to plug by the sensing heater outside water mold, after to be heated to 900 DEG C,
The high-chromium iron-cast roller outer sphere molten metal smelted is poured into pouring ladle, the molten metal in pouring ladle is poured according to predetermined
Note program is poured into the space in crystallizer between roll plug by depositing funnel, feed trumpet, casting runner, is being poured into a mould
Cheng Zhong, electromagnetic induction heater does not stop heating, and after pouring metal melt, sensing heater continues heating 20 minutes,
Poured into a mould molten metal is kept liquid within the regular hour, to increase the liquid solid time, interface is formed metallurgical binding, start
Electromagnetic induction heater is lifted up by region directional solidification lowering or hoisting gear with certain speed, gradually disengages electromagnetic induction heating
Roll Cladding successively consecutive solidification from bottom to top, be raised at insulation ring and stop through 7 minutes, continue to heat insulation ring
20 minutes, to postpone insulated feeder setting time, feeding is carried out to rising head, fills the gas in composite-layer metal liquid and field trash
Divide and float, eliminate composite-layer metal casting flaw, stop heating after reaching the scheduled time, will when continuation water flowing cools down 60 minutes
The composite roll cast takes out out of crystallizer and carries out insulation cooling.
Embodiment 3：In Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, the equipment has a planer-type region directional solidification jacking equipment
16, lifting platform 17 is installed on planer-type region directional solidification jacking equipment 6, electromagnetism sense is installed above lifting platform 17
Heater 8 is answered, lifting screw 15 is rotated by lifting motor 14 or hydraulic test drives lifting platform 17 with set speed
Lower movement, the side installation electromagnetic induction electrical power control cabinet 19 of directional solidification jacking equipment 16, electromagnetic induction in planer-type region
Two output ends of electrical power control cabinet 19 are connected by water-cooled cable 20 with the both ends of electromagnetic induction heating device 8, in planer-type area
There is a base support bottom of domain directional solidification jacking equipment 16, support plinth 12 is provided with base support 13, is supporting
Water-cooled bottom water tank 11 is installed, the center of bottom water tank 11 is manhole, is installed above bottom water tank 11 above base 12
The bottom board 10 for having center to be manhole, is provided with Combined water cooling crystallizer 7, in water cooling above bottom board 10
The top of crystallizer 7 is provided with insulation ring 6, the center that roll shaft plug 5 passes through support plinth 12, bottom water tank 11 and bottom board 12
Circular hole is fixed on the center of crystallizer 7, and in the side of bottom board 10, connection has casting runner 3, and casting runner 3 is arranged on base
On support 13 and sit brick 4 with cast to be connected, cast sits that brick 4 is installed above feed trumpet 2, is provided with and pours at the top of feed trumpet
Funnel 1 is cast, there is pouring ladle 18 above depositing funnel 1.
There are water inlet pipe 23 and outlet pipe 24 respectively in the side of Water-cooled bottom water tank 11；Water mold 7 in crystallizer by justifying
Equally distributed 6 fourplatemolds arc water cooling box assembly 7 forms on week, in each arc water cooling box assembly 7
Bottom connection has water inlet pipe 21, and on the top of each arc water cooling box assembly 7, connection has outlet pipe 22, passes through attachment bolt 9
Arc water cooling box assembly 7 is connected into drum-shaped entirety；Insulation ring 6 is by refractory material or fiber reinforcement refractory material system
Make；Electromagnetic induction power supply is line-frequency induction power supply, medium frequency induction power supply, high frequency induction power supply, frequency 2000Hz.
When work starts, the low-alloy steel roll mandrel surface of the required size manufactured is subjected to oil removing, processing of rust removing
Afterwards, its surface uniformly coating one layer of antioxidizing paint, be put into heating furnace after carrying out being preheating to 700 DEG C, by support plinth,
The center hole of bottom water tank and bottom board is fixed on the center of crystallizer, starting region directional solidification lowering or hoisting gear, by electromagnetism
Sensing heater drops to the bottom of crystallizer, opens the water inlet pipe and water outlet pipe of water mold and bottom water tank, starts electromagnetic induction and adds
Thermoelectric generator, surface heating is carried out to plug by the sensing heater outside water mold, it is to be heated to 980 DEG C
Afterwards, the skin of the roll molten metal for the high speed composition of steel smelted is poured into pouring ladle, by the molten metal in pouring ladle according to institute
Predetermined cast program is poured into the space in crystallizer between roll plug by depositing funnel, feed trumpet, casting runner,
In casting process, electromagnetic induction heater does not stop heating, and after pouring metal melt, sensing heater continues to heat
30 minutes, poured into a mould molten metal is kept liquid within the regular hour, to increase the liquid solid time, interface is formed metallurgical junction
Close, electromagnetic induction heater is lifted up by starting region directional solidification lowering or hoisting gear with certain speed, gradually disengages electromagnetism
The Roll Cladding of sensing heating successively consecutive solidification, and control difference in different regions according to quality requirement from bottom to top
The rate of climb, forming region directional solidification, stop through being raised within 5~15 minutes at insulation ring, continue to heat insulation ring
35 minutes, to postpone insulated feeder setting time, feeding is carried out to rising head, fills the gas in composite-layer metal liquid and field trash
Divide and float, eliminate composite-layer metal casting flaw, stop heating after reaching the scheduled time, will when continuation water flowing cools down 50 minutes
The composite roll cast takes out out of crystallizer and carries out insulation cooling.
General principle, principal character and the advantages of the present invention of the present invention has been shown and described above.The technology of the industry
For personnel it should be appreciated that the present invention is not limited by step embodiment, that described in step embodiment and specification is the present invention
Principle, without departing from the spirit and scope of the present invention, design of the invention can by other various forms implement transport
With also having various changes and modifications, these changes and improvements equally all fall within the protetion scope of the claimed invention.The present invention
Claimed scope is by appended claims and its equivalent thereof.
Claims (3)
- A kind of 1. compound roll shaft manufacturing process of high-performance, it is characterised in that：First by the roll shaft plug of the required size manufactured After surface carries out oil removing, processing of rust removing, one layer of antioxidizing paint is uniformly coated on its surface, is put into heating furnace and is preheating to After 500 DEG C~700 DEG C, the center of crystallizer is fixed on by the center hole of support plinth, bottom water tank and bottom board, is started Region directional solidification lowering or hoisting gear, electromagnetic induction heater is dropped to the bottom of crystallizer, open water mold and bottom water The water inlet pipe and water outlet pipe of case, start electromagnetic induction heating power supply, by the sensing heater outside water mold to plug Surface heating is carried out, after to be heated to 820 DEG C~1100 DEG C, the roll shaft outer sphere molten metal for the required composite parts smelted is fallen Enter in pouring ladle, the molten metal in pouring ladle is passed through into depositing funnel, feed trumpet, casting runner according to predetermined cast program Pour into the space in crystallizer between roll shaft plug, in casting process, electromagnetic induction heater does not stop heating, metal After liquid is poured, sensing heater continues heating 10~50 minutes, makes poured into a mould molten metal within the regular hour Liquid is kept, interface is formed metallurgical binding, starting region directional solidification lowering or hoisting gear is by electromagnetic induction heater with certain Speed is lifted up, and gradually disengages the roll shaft composite bed of electromagnetic induction heating successively consecutive solidification from bottom to top, and according to quality It is required that controlling the different rates of climb in different regions, forming region directional solidification, it was raised to through 5~15 minutes at insulation ring Stop, continuing to carry out heating 10~50 minutes to insulation ring, feeding is carried out to rising head, stop heating after reaching the scheduled time, after Continuous water flowing is cooled down 30 minutes~24 hours, and the compound roll shaft cast is taken out out of crystallizer；Described roll shaft mandrel material is multiple for forging or cast low alloy steel, medium carbon steel or spheroidal graphite cast-iron, alloy cast iron, roll shaft Conjunction layer material is spheroidal graphite cast-iron, graphitic steel, nickel-chrome-molybdenum alloy cast iron, rich chromium cast iron, cast steel with high chromium, alloy cast steel, high boron steel, height Fast steel, die steel material；When being iteratively repeated above-mentioned combination process, you can to manufacture large-scale composite roll, composite support roller with MULTILAYER COMPOSITE layer, Large-scale composite roll, support roller are manufactured using small-sized smelting equipment so as to reach, when changing every layer of composite material composition, i.e., It can realize and manufacture the Gradient Composite Layer roll being made up of different materials composition, support roller.
- 2. the compound roll shaft manufacturing process of a kind of high-performance according to claim 1, it is characterized in that：Core is made when using waste or old roll During rod, you can with to spheroidal graphite cast-iron, graphitic steel, nickel-chrome-molybdenum alloy cast iron, rich chromium cast iron, cast steel, high boron steel, high-speed steel, mould Steel material waste or old roll or support roller carry out remanufacturing reparation.
- 3. the compound roll shaft manufacturing process of a kind of high-performance according to claim 1, it is characterized in that：The mandrel surface is anti-oxidation The composition of coating is Na2B4O7, SiO2, Na2O, K2O, A12O3, CaO one or more composition compositions therein.
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| CN105441937B (en) * | 2015-11-12 | 2018-10-30 | 丹阳恒庆复合材料科技有限公司 | A kind of waste or old roll founding clad renovation technique and equipment |
| CN106825513A (en) * | 2016-12-30 | 2017-06-13 | 丹阳恒庆复合材料科技有限公司 | A kind of cladded type double metallic composite material preparation technology and equipment |
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| CN106825516A (en) * | 2017-02-19 | 2017-06-13 | 丹阳恒庆复合材料科技有限公司 | A kind of composite roll roller covers manufacturing process and equipment |
| CN107262696B (en) * | 2017-02-28 | 2019-05-07 | 孙劲腾 | A kind of interface fusion process prepares the method and device of metal composite pipe |
| CN109834239A (en) * | 2019-03-25 | 2019-06-04 | 河南中原吉凯恩气缸套有限公司 | A kind of high-phosphorous iron Cylinder Sleeve by Centrifugal Casting mold |
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Application publication date: 20160427 Assignee: Taizhou Haitian Machinery Parts Co., Ltd Assignor: DANYANG HENGQING COMPOSITE MATERIAL TECHNOLOGY Co.,Ltd. Contract record no.: X2020320000006 Denomination of invention: Manufacturing technique and equipment for high-performance composite roller shaft Granted publication date: 20180406 License type: Exclusive License Record date: 20200325 |
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Address after: Taizhou Haitian Machinery Accessories Co., Ltd., No.6 bianzhuang Industrial Park, Yuxi Town, Jiangyan District, Taizhou City, Jiangsu Province, 225513 Patentee after: DANYANG HENGQING COMPOSITE MATERIAL TECHNOLOGY Co.,Ltd. Address before: 212300 Danyang Hengqing composite material technology Co., Ltd., Gaoqiao village, Xinqiao Town, danbei Town, Danyang City, Zhenjiang City, Jiangsu Province Patentee before: DANYANG HENGQING COMPOSITE MATERIAL TECHNOLOGY Co.,Ltd. |
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