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FORGE-Roll
ETERNAL
The working roll of the roller press is a typical component that is "hard on the outside and tough on the inside".
The internal components are made of high-quality forged steel that has undergone quenching and tempering heat treatment, providing strong support and impact resistance;
The surface relies on wear-resistant surfacing materials containing high-hardness carbides, providing excellent wear resistance.
Material
Roll core (body) material:
Forged steel: commonly used high-strength alloy structural steelssuch as 42CrMo, 35CrMo, or 50CrMo. The internal structure of the forged piece is dense, without porosity or shrinkage, and has good impact toughness, capable of withstanding substantial torque and compressive forces.
Roller surface (wear-resistant layer) material:
Wear-resistant surfacing alloy: the most advanced technology at present. Self-shielded flux-cored wire or solid wire containing high-hardness carbides (such as tungsten carbide WC, chromium carbide Cr7C3) is usually used.
Common alloy systems include:
High chromium alloy (Cr-Mo-V): high hardness, resistant to abrasive wear.
High-Vanadium alloy: forms VC carbides, boasts extremely high hardness (HRC > 60), and exhibits excellent wear resistance.
Feature
High load-bearing capacity: During operation, it withstands substantial compressive forces (typically ranging from 50 to 300 MPa), necessitating the roller body to possess exceptional compressive strength and rigidity to prevent deformation or fracture.
Strong wear resistance: It comes into direct contact with materials (such as clinker and ore) and withstands severe high-stress abrasive wear.
Impact resistance: When non-fracturable foreign objects (such as iron pieces) are mixed into the material, the roller surface needs to possess a certain degree of toughness to resist impact and prevent cracking.
Occlusal ability: The roller surface design (such as the shape of the grooves) needs to have good "engagement" ability to ensure that the material can enter stably between the two rollers and prevent slipping.
Structural form:
Integrated type: The roller shaft and roller sleeve are forged as a single unit, providing high strength and suitable for small machines or special working conditions.
Assembled (sleeve-type): The roller shaft and wear-resistant roller sleeve are connected through hot assembly or hydraulic expansion sleeve. The advantage is that the roller sleeve can be replaced separately after wear, reducing maintenance costs. It is currently the mainstream form adopted by large-scale rollers.
Application
The working roller is primarily utilized in industrial sectors where material layer crushing of high-hardness and high-brittleness materials is required:
Cement industry: the primary application field. It is used in the final grinding or pre-grinding system of cement clinker, significantly reducing power consumption.
Mining and metallurgy: used for fine crushing of metal ores such as iron ore, bauxite, and copper concentrate.
Power industry: used for the preparation of limestone for desulfurization in power plants.
Non-metallic minerals: used for processing materials such as coal, calcite, and quartz sand.
Quenching and tempering treatment: Martensite structure is obtained through quenching, followed by high-temperature tempering.
Objective: To achieve excellent comprehensive mechanical properties, specifically high strength (tensile strength > 1000 MPa) and high toughness, to prevent fracture under high pressure.
Stress relief annealing: It is carried out after rough machining to eliminate residual stress caused by forging and machining.
Surface Treatment
Surface treatment is the most crucial aspect determining the performance of work rolls, and there are primarily two methods:
A. Surfacing / Welding Technology
Create a build-up welding groove: Machining a grid-like or spiral groove on the surface of the roller body.
Backing weld: Use a material with good toughness (such as high nickel-based alloy) for backing to relieve thermal stress and prevent cracking of the wear-resistant layer.
Wear-resistant layer build-up welding: Build up high-hardness alloy in the groove.
B. Roller surface hardening and repair
Laser cladding: Using a laser beam to melt wear-resistant powder onto the roller surface, it has high bonding strength, small heat-affected zone, and is suitable for local repair.
Plasma cladding: Its principle is similar to that of laser cladding, with higher efficiency and relatively lower cost.
The working roll of the roller press is a typical component that is "hard on the outside and tough on the inside".
The internal components are made of high-quality forged steel that has undergone quenching and tempering heat treatment, providing strong support and impact resistance;
The surface relies on wear-resistant surfacing materials containing high-hardness carbides, providing excellent wear resistance.
Material
Roll core (body) material:
Forged steel: commonly used high-strength alloy structural steelssuch as 42CrMo, 35CrMo, or 50CrMo. The internal structure of the forged piece is dense, without porosity or shrinkage, and has good impact toughness, capable of withstanding substantial torque and compressive forces.
Roller surface (wear-resistant layer) material:
Wear-resistant surfacing alloy: the most advanced technology at present. Self-shielded flux-cored wire or solid wire containing high-hardness carbides (such as tungsten carbide WC, chromium carbide Cr7C3) is usually used.
Common alloy systems include:
High chromium alloy (Cr-Mo-V): high hardness, resistant to abrasive wear.
High-Vanadium alloy: forms VC carbides, boasts extremely high hardness (HRC > 60), and exhibits excellent wear resistance.
Feature
High load-bearing capacity: During operation, it withstands substantial compressive forces (typically ranging from 50 to 300 MPa), necessitating the roller body to possess exceptional compressive strength and rigidity to prevent deformation or fracture.
Strong wear resistance: It comes into direct contact with materials (such as clinker and ore) and withstands severe high-stress abrasive wear.
Impact resistance: When non-fracturable foreign objects (such as iron pieces) are mixed into the material, the roller surface needs to possess a certain degree of toughness to resist impact and prevent cracking.
Occlusal ability: The roller surface design (such as the shape of the grooves) needs to have good "engagement" ability to ensure that the material can enter stably between the two rollers and prevent slipping.
Structural form:
Integrated type: The roller shaft and roller sleeve are forged as a single unit, providing high strength and suitable for small machines or special working conditions.
Assembled (sleeve-type): The roller shaft and wear-resistant roller sleeve are connected through hot assembly or hydraulic expansion sleeve. The advantage is that the roller sleeve can be replaced separately after wear, reducing maintenance costs. It is currently the mainstream form adopted by large-scale rollers.
Application
The working roller is primarily utilized in industrial sectors where material layer crushing of high-hardness and high-brittleness materials is required:
Cement industry: the primary application field. It is used in the final grinding or pre-grinding system of cement clinker, significantly reducing power consumption.
Mining and metallurgy: used for fine crushing of metal ores such as iron ore, bauxite, and copper concentrate.
Power industry: used for the preparation of limestone for desulfurization in power plants.
Non-metallic minerals: used for processing materials such as coal, calcite, and quartz sand.
Quenching and tempering treatment: Martensite structure is obtained through quenching, followed by high-temperature tempering.
Objective: To achieve excellent comprehensive mechanical properties, specifically high strength (tensile strength > 1000 MPa) and high toughness, to prevent fracture under high pressure.
Stress relief annealing: It is carried out after rough machining to eliminate residual stress caused by forging and machining.
Surface Treatment
Surface treatment is the most crucial aspect determining the performance of work rolls, and there are primarily two methods:
A. Surfacing / Welding Technology
Create a build-up welding groove: Machining a grid-like or spiral groove on the surface of the roller body.
Backing weld: Use a material with good toughness (such as high nickel-based alloy) for backing to relieve thermal stress and prevent cracking of the wear-resistant layer.
Wear-resistant layer build-up welding: Build up high-hardness alloy in the groove.
B. Roller surface hardening and repair
Laser cladding: Using a laser beam to melt wear-resistant powder onto the roller surface, it has high bonding strength, small heat-affected zone, and is suitable for local repair.
Plasma cladding: Its principle is similar to that of laser cladding, with higher efficiency and relatively lower cost.
