Roller: Structure of Roll Grinder

The Roller grinder is a special grinder developed on the basis of the cylindrical grinder. According to the weight of the roller, it can be divided into two categories:

1. Movable workpiece bed. It is mainly used for roller grinder with the roller weight ≤ 6 tons.

2. Move the wheel frame. It is mainly used for roll grinder with a weight of more than 6 tons. Regardless of the type of roll grinder, their structure is roughly the same. It mainly consists of the following parts: bed, bedside table, tailstock, bracket, grinding wheel rack, convex (concave) forming mechanism, electrical control equipment, coolant supply and filtering equipment. The main components of the roll grinder are briefly described below.

1. Roll grinder bed. This is the basis of ensuring grinding accuracy. 

(1). the main machine of the workpiece mobile grinder is used to support the fixation of roll, tailstock, bracket and headstock, as well as the guiding function of mobile worktable. The auxiliary bed is used to support the wheel frame, and the longitudinal direction of the wheel frame is fixed. 

(2). The main bed of the mobile grinder with the grinding wheel frame is used to support the grinding wheel frame, and the longitudinal direction of the grinding wheel frame moves back and forth on the grinding wheel frame. His machining accuracy and installation accuracy are very high. The auxiliary bed is used to support the fixation of the roller, tailstock, bracket and headframe. The bed is made of cast iron. In order to keep the high precision of the bed, aging treatment and scraping treatment were carried out after machining. The whole bed is placed on the correct angle which is fixed on the cement foundation. Most of the bed rails are in the form of V-P rails (except hydrostatic rails), which have high guiding accuracy and good rigidity. Bed movement is divided into hydraulic cylinder type (short stroke), gear carrier type, and roller screw type.

2. The headstock is used to drive the rolls, most of which use the multi-stage belt drive to ensure stable driving. A special starting motor is also installed on the heavy roller mill. For small roller mills, there are also gearing with reduction mechanisms, such as turbines or gears. The headstock is driven by the electric motor and can be adjusted steplessly. In order to ensure the smooth rotation of the roll, a floating driving device is set on the dial, and the pressure on the two dial must be evenly applied during the rotation.

3. Tailstock. The function of the tailstock is to position the roll axially during grinding to avoid the mill roll moving axially during grinding. Most tailstock consists of upper and lower parts. The lateral direction can be slightly adjusted from the upper part so that the two shafts of the main axle box are parallel to the main axis. Usually, the diamond finishing pen is mounted on the tailstock to finish the grinding wheel. The tailstock of CNC grinding machine is also equipped with a reference plate, which is used to correct the diameter measured by CNC.

4. Bracket. The carriage is used to support the roll during grinding. It is usually supported on the neck of the roller. It is divided into left and right brackets. The position of the left and right supports and the upper and lower support shoes of each support cannot be reversed. Each support shoe also has a different support diameter to choose from. When adjusting the support seat each time, the upper shoe and lower shoe should be adjusted after the reel is positioned together with the headstock and tailstock by means of lifting equipment.

5. Grinding wheel rack. It is the core of the roll grinder. The formation mechanism of roll shape and spindle which affect grinding accuracy is concentrated on the grinding wheel frame. The grinding wheel rack usually consists of the following parts: the main body of the rack, the spindle, the dynamic balance device of the grinding wheel, the horizontal feed mechanism, the convex (concave) forming mechanism, the power-off protection mechanism, etc.

If you are looking for rolls of rolling mills, please contact me.
Email: marketing2@hanrm.com.

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Disadvantages of the Heating furnace

Heating Defect of the Heating Furnace

1. Cracking of alloy steel.

At the beginning stage of heating (below 700 ℃), for high carbon tool steel, high manganese steel, bearing steel, high-speed steel and other steel with low thermal conductivity, if the heating rate is too fast, the surface temperature of the heating furnace rises suddenly and the temperature difference of cross-section is too large, thermal stress will be produced, leading to cracks.

2. Overheating and overburning.

If the heating temperature of the heating furnace is too high or the residence time at a high temperature is too long, the grain of the steel will grow excessively, the connection between grains will be weakened, and the steel will become brittle, which is called overheating. Even if there is no cracking in rolling, the mechanical properties of the finished product can not meet the requirements. It can be saved by normalizing the overheated billet. With the further development of overheating, the grains continue to grow up, and the grain boundaries are oxidized or melted, which is often broken or cracked during rolling, which is called overburning. The over burned blank is an irreparable waste. When the rolling operation breaks down suddenly, it is easy to cause overheating or overburning; if the temperature of high carbon steel is not controlled properly, it is also easy to cause overheating or overburning.

3. Oxidation and decarburization of billet.

During the process of billet heating in the heating furnace, metal elements in steel react with oxidizing atmosphere in the heating furnace and produce scale (the inner layer of scale is iron oxide, the middle layer is iron oxide, and the outermost layer is iron oxide). Decarburization is caused by the diffusion of carbon in steel to the surface and reaction with the atmosphere in the furnace. Decarburization of bearing steel, tool steel, spring steel and some other steels is harmful. The surface of decarburized steel can not reach the required hardness during quenching. In addition, the compressive performance, wear resistance and elasticity are reduced.

Oxidation and decarburization are carried out simultaneously, which are related to heating conditions (temperature, furnace time, furnace atmosphere and chemical composition of billet). Generally speaking, oxidation and decarbonization are not obvious when the temperature is less than 750 ℃. But when the temperature is higher than 800 ℃, it increases very fast.

In particular, the heating temperature of carbon steel should not be higher than 1300 ℃. Firstly, the oxide scale on the surface of steel billet will melt (the melting point of pure oxide scale is 1377 ~ 1565 ℃, and it will drop to 1300 ~ 1350 ℃ when it contains impurities), which will fall off the steel surface and expose a new surface, and the burning loss will increase rapidly. Secondly, when the heating temperature of the heating furnaces is higher than 1300 ℃, the billet is likely to overheat or overburnt. The maximum heating temperature should be paid more attention to when producing other kinds of steel.

After the billet is oxidized and burned, it will inevitably affect the yield; the thermal conductivity of the scale is very poor, which has an impact on the heating time of the billet; the scale falls off and accumulates in the heating furnace, which makes manual cleaning very difficult and hard work.

Inquiry about heating furnaces, please mail at marketing2@hanrm.com.

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Heating Furnace What You Need to Know

1. Heating furnace's purpose

The heating furnace is to heat the billet to a uniform temperature (austenite structure) suitable for rolling. After the temperature increases, the first thing is to improve the plasticity of the steel and reduce the deformation resistance, so that the steel is easy to deform. For example, the deformation resistance of T12 steel is about 600 MPa at room temperature, and it decreases to about 30 MPa when heated to 1200 ℃, which is only one twentieth of that at room temperature.

For the steel with proper heating temperature, a larger reduction can be used during rolling, which can reduce the equipment accidents caused by wear and impact, improve the productivity and operation rate of the rolling mill, and reduce the rolling energy consumption. Secondly, heating can improve the internal structure and properties of the billet. The inhomogeneous structure and non-metallic inclusions are homogenized by the diffusion of high-temperature heating. The heating temperature and uniformity are the marks of heating quality. The steel with good heating quality is easy to obtain the finished product with the correct section shape and accurate geometric size.

2. Heating furnace's heating process

The heating temperature of the billet includes surface temperature, temperature difference along with section and temperature difference along billet length. The final heating temperature of the billet in the furnace is determined after considering the actual situation of the rolling process, structural characteristics of the rolling mill and heating furnace. The time required for heating to the specified temperature depends on the billet size, steel grade, temperature system adopted and some other conditions.

The billet gets heat by convection and radiation in the heating furnaces. The former is that the furnace gas washes the billet surface, while the latter is that the furnace gas and hot lining radiate heat. Along the length direction, our furnace is divided into three sections: preheating section, heating section and soaking section. When the billet enters the preheating section of the heating furnace, the heat flux increases gradually. When the billet reaches the second heating section, the heat flux basically remains unchanged. When the billet reaches the soaking section, the heat flux decreases gradually.

In the soaking zone, the surface temperature of the billet remains basically unchanged, while the temperature difference of the cross-section decreases gradually, and the heat from the billet surface diffuses to the interior in the way of heat conduction. The smaller the heat flux to the billet surface, the larger the heating area, the smaller the section size of the billet and the greater the thermal conductivity of steel, the smaller the section temperature difference. Generally, the heating time of billets with large section is longer than that of billets with small section, and that of alloy steel is longer than that of carbon steel.

3. Heating furnace pressure system

The size and distribution of the heating furnace pressure are an important means to adjust the temperature field, control the flame and atmosphere in the furnace. It affects the heating speed and quality, and also affects the utilization of fuel. In particular, the furnace pressure at the discharge section of the furnace is particularly important.

The heating furnace pressure should be set at 0 ~ 30Pa higher than atmospheric pressure. If the furnace pressure is too high, the charging port, discharging port, observation hole and other opening parts will be exposed to fire. The results are as follows: (1) the furnace gas loss increases, which increases the heat loss; (2) SO 2 and other harmful gases enter the workshop, which pollutes the working environment; (3) the furnace wall, nearby steel structure or mechanical equipment at the burning part are damaged or deformed. On the contrary, if the furnace pressure is too low, the absorption of cold air in the workshop will make (1) the furnace temperature decrease and the fuel consumption increase; (2) the cooling of billet by low-temperature air will lead to uneven temperature; (3) the increase of oxygen content in the furnace gas will lead to the increase of burning loss.

4. Heating furnace combustion system:

The basic requirement is to ensure that the fuel is completely burned in the heating furnaces and the air coefficient α is small. Excess air leads to a large amount of flue gas and more heat carried away; insufficient air leads to incomplete combustion in the furnace, which also increases heat loss.

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What Is Continuous Casting Machine?

Continuous steel casting refers to the production process of continuously pouring high-temperature molten steel onto cast slabs with a certain cross-sectional shape and size specifications. To complete this process, the equipment required is called a complete set of continuous casting equipment. Mechatronics casting equipment, continuous casting fuselage equipment, cutting area equipment, and ingot bar receiving equipment, etc. constitute the continuous casting steel core equipment, which is often referred to as a continuous casting machine.

The continuous casting process of the continuous casting machine. When high-temperature molten steel is continuously poured into one or a group of cold copper molds, the molten steel gradually solidifies into a blank shell around the mold. When the steel liquid level rises to a certain height and the blank shell solidifies to a certain thickness, pull out the orthopedic machine and pull it out. The billet shell is cooled by spraying water in the secondary cooling zone to completely solidify the billet shell. Then, according to the needs of steel rolling, the cutting equipment cuts the billet into size. This process of pouring high-temperature molten steel directly onto the billet is called continuous casting.

Continuous casting machine can be divided into many different types. According to its structure and shape, the continuous casting machine can be divided into vertical curve, arc straight section, arc section, multi-radius ellipse, horizontal continuous casting machine and other types. With the development of continuous casting technology, wheeled continuous casting machine, especially thin slab continuous casting machines have been developed again.

If distinguished by the size and shape of its casting section, the continuous casting machine can be divided into slab continuous casting machine, billet continuous casting machine, bloom continuous casting machine, round billet continuous casting machine, special-shaped section continuous casting machine, and slab caster. The rectangular billet continuous casting machine also includes the rectangular billet on the rectangular billet continuous casting machine. The cast slab whose casting cross-section or equivalent sectional area is greater than 200×200mm is called bloom, and the cast slab with the cross-section or equivalent sectional area less than 160×160mm is called a small billet. Square billets, rectangular billets with a width ratio greater than 3 are called slabs.

According to how many slabs can be poured by the continuous casting machine in the same ladle, it can be divided into three types: single-strand, double-strand, and multi-strand.

 

The emergence of the continuous casting machine has fundamentally changed the one-time rolling and serving method of steel ingots for a century. The use of a continuous casting machine has the advantages of simplifying production procedures, improving production efficiency and metal yield, saving energy, greatly reducing production costs, and ensuring the quality of billets. It has developed rapidly at home and abroad. In today's steelmaking enterprises, it is almost inevitable to equip continuous casters, no matter if it is a long process or a short process.

If you are interested in purchasing the continuous casting machine, please mail at marketing2@hanrm.com.

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What are the Advantages of Medium Frequency Furnace in Metal Smelting?

In recent years, with the development of science and technology and the improvement of product quality requirements, many manufacturers choose to use intermediate frequency furnaces for non-ferrous metal smelting and obtain remarkable results. So, what are the advantages of a medium frequency furnace in metal smelting?

First of all, the intermediate frequency furnace is easy to operate, fast heating, and low energy consumption, which can ensure the optimal and stable melting process and reduce the complicated work of furnace workers. With the adoption of new technology, new material, and new processes, the performance and application effect of medium frequency furnaces are becoming more and more perfect, showing more and more vitality, and obtaining remarkable social and economic benefits.

Secondly, in terms of frequency conversion equipment, the original thyristor intermediate frequency equipment gives full play to its advantages of a lightweight, high efficiency, fast start-up, power saving, fast melting speed, simple manufacturing process, etc., and adopts the frequency automatic tracking system, which can automatically adjust the frequency with load change without switching capacitors. In recent years, the intermediate frequency furnace adopts an advanced IGBT frequency conversion induction heating device, with high element density, outstanding performance, better start-up, more reliable use, simple and convenient maintenance, less floor space and more advanced manufacturing process.

Third, the furnace body and lining of the intermediate frequency furnace are made of a new structure and new materials, and the part close to the inductor coil is isolated with high insulation and high strength materials, which greatly prolongs the service life of the crucible and furnace village and makes it easier to replace the crucible. The heating efficiency of graphite crucible and quartz crucible is much higher than that of the refractory crucible, which shortens the melting time and greatly reduces the heat loss. The maximum temperature of the intermediate frequency furnace is 2600 ℃, which is especially suitable for smelting platinum, gold, K-gold, silver, copper, aluminum, and other metals. The electric efficiency reaches 90-95, and ideal economic benefits can be obtained.

Finally, compared with other types of the smelting furnace, the specific power of the intermediate frequency furnace is higher, and the metal is heated by electromagnetic induction, so the temperature rises and melts quickly. There is no need for starter and residual metal liquid, and it can be melted only by adding scrap or small material. It is very suitable for intermittent operation and frequent change of metal grade, and has great adaptability and flexibility.

So many advantages make intermediate frequency furnaces popular in the industry. Nowadays, the medium frequency furnace is gradually exploring into large, medium, and small factories, the scope of application is expanding, the variety of equipment is increasing, and the degree of automation is also improving. It is believed that medium frequency furnaces will play a more and more important role in high-tech, high-quality product manufacturing and jewelry processing.

If you are interested in purchasing medium frequency furnace, please mail at marketing2@hanrm.com directly.

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Solution to Environmental Protection Problems of Intermediate Frequency Furnace

1. Dust removal of intermediate frequency electric furnace

Since the charge of induction heating furnace usually contains dust and oil, soot will rise from the furnace mouth when the charge is added to the furnace. If the charge contains zinc-plated materials and waste materials, the dust produced will also contain zinc or tin oxides. The smoke and dust generated in the operation of the intermediate frequency heating furnace is harmful to the human body and the production environment, so a dust removal system must be used to discharge the harmful smoke and dust outdoors. The amount of soot produced is related to the size of the intermediate frequency equipment and the cleanliness of the charge. The air volume of the dust removal system should be large enough to generate a large amount of negative pressure at the furnace mouth.

The dust removal system consists of an induced draft fan, a dust collector, a cyclone separator, a flue gas temperature adjustment device, and pipelines. In order to ensure that the temperature of the flue gas entering the precipitator does not exceed the value that the precipitator can withstand, the flue gas temperature adjustment device can adjust the amount of cold air mixed to control the temperature of the flue gas entering the precipitator. The flue gas of the intermediate frequency furnace through the dust removal system should meet the national standard GB9078-1996 "Industrial Kiln Air Pollutant Emission Standard". In order to capture the smoke and dust, the intermediate frequency electric furnace is generally equipped with a furnace mouth dust removal ring or a full cover type dust removal furnace cover. The dust removal ring at the furnace mouth is not as good as the full cover dust removal furnace cover, but it is suitable for electromagnetic chuck or manual feeding, so it is more used on furnaces less than 5t. The full hood dust removal furnace cover has a better ability to capture smoke and dust, and needs to be used in conjunction with a charging car, usually used for furnaces with larger specifications.

For the dust removal of the intermediate frequency electric furnace, it is very important to select a dust removal system with good performance. However, the maintenance of the dust removal system is also very important. The dust collector and pipes should be cleaned regularly to maintain the system with a good dust removal effect.

2. Noise of intermediate frequency furnace

During the operation of the intermediate frequency electric furnace, noise is mainly generated from the intermediate frequency power supply, furnace body and hydraulic pump. Secondly, the noise level generated by transformers and water pumps is relatively small. Generally, it is required that the noise at the furnace working platform 1m away from the furnace body and the height of 1m should be ≤85dB (excluding background noise).

At present, most of the equipment layout of intermediate frequency electric furnaces place the intermediate frequency power supply, furnace body, hydraulic pump station and water pump station under the working platform (in a semi-underground pit), which is helpful to reduce the noise at the operating station on the working platform. Improving the operating environment of workers plays a big role.

When the furnace with high power density is in operation, the noise is relatively large due to the vibration of the induction coil, yoke and other components. If necessary, the furnace body structure can take some measures to reduce noise, such as lining the inner wall of the furnace shell with sound insulation material, repair hole cover plate with rubber pad, and filling in the cavity of the furnace body structure. The hydraulic pump is noisy when it is working, so it should be shut down in time when it is not in use. For this reason, there is a stop button on the hydraulic operation console, so that the operator can stop the hydraulic pump in time, or configure a timer to shut down the hydraulic pump on time.



3. Harmonic problem of intermediate frequency furnace

Solid-state intermediate frequency power supplies use electronic devices such as thyristors, diodes, and IGBTs for rectification and inversion, which will cause harmonic interference to the power supply grid. With the widespread application of electronic devices such as electronic computers and numerical control machine tools, the requirements for power quality of the power grid are getting higher and higher. In modern industrial production, the use of various converter equipment is increasing, and the capacity is also increasing. The harmonics generated by it are injected into the power grid, distorting the voltage waveform of the public power grid, affecting the quality of power, and threatening the safe and economic operation of various electrical equipment. To this end, the country formulated the national standard GB/T14549-1993 "power quality, harmonics of the public grid". This standard specifies the allowable value of harmonics injected into the grid.

The harmonic interference produced by the solid-state intermediate frequency power supply mainly depends on the form of its rectifier circuit.

The rectification of the voltage feedback series resonant intermediate frequency power supply adopts a bridge-type uncontrollable rectifier circuit, which generates fewer harmonics than the current feedback parallel resonant intermediate frequency power supply.

In addition, the use of multi-phase rectification methods, such as 6-phase 12-pulse rectification, 12-phase 24-pulse rectification, and the rectifier transformer windings are equalized, can greatly reduce the harmonic interference of the intermediate frequency electric furnace.

4. Magnetic field of intermediate frequency electric furnace

Alternating current passing through the coil of the induction heating furnace will generate an alternating magnetic field. The strength of the magnetic field depends on the power of the electric furnace. At present, the working frequency of the intermediate frequency electric furnace is 100-3000 Hz. This frequency is not a radio wave transmission frequency, and generally does not cause interference to radio communications. However, if technical measures are not taken to limit the alternating magnetic field generated by the induction coil, the alternating magnetic field will heat the metal parts near the furnace, causing harm to workers operating on the furnace (especially for metal dentures). , Metal artificial joints, etc.), so the intermediate frequency electric furnace needs to use a yoke to restrict the magnetic field from radiating outward. Modern coreless induction furnaces are surrounded by multiple yokes around the induction coil. The length enclosed by the yoke in the circumferential direction of the coil reaches 60% to 65% of the circumference of the coil.

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Factors Affecting Energy Consumption of Intermediate Frequency Furnace

The intermediate frequency furnace has the advantages of high electrical and thermal efficiency, short melting time, power saving, less floor space, lower investment, easy process automation, and production flexibility. Compared with other melting furnaces, such as industrial frequency furnaces, intermediate frequency furnace has lower energy consumption and higher production efficiency. However, the low energy consumption is relative to other equipment. For enterprise production, it is of course to achieve the maximum benefit as the goal and minimize energy consumption. Therefore, it is necessary to increase the production base and reduce the total energy consumption.

To reduce the energy consumption of the intermediate frequency furnace, it is necessary to understand the factors that affect the energy consumption of the intermediate frequency furnace. The main factors affecting the energy consumption of the intermediate frequency furnace are as follows:

1. Power

The power density configuration of the induction furnace. High configuration, fast melting speed and good energy-saving effect. Whether the electric furnace can maintain high power and continuously send power to the furnace will affect the level of energy consumption; the messy arrangement of the power cord of the intermediate frequency furnace will affect the processing capacity of the power supply, resulting in unstable power, low power conversion efficiency, and energy consumption.

2. Melt

The cleanliness of the surface of the charge, if there are 5% impurities, it will consume 5% of the electrical energy to melt these impurities, which will also affect the life of the furnace lining; whether the length of the charge block is appropriate will affect the electric efficiency and melting quality of the electric furnace, generally 200～ 300mm block size is appropriate.

3. Refractory materials

Using a suitable crucible can increase the melting rate. Quartz crucibles are resistant to high temperatures, and when used with intermediate frequency furnaces, the metal materials in the crucible can generate heat by induction heating, which can reduce the consumption of heat transfer.

4. The improper operation causes high energy consumption

The molten metal is overheated, and the furnace is discharged continuously. Not only is it unsafe, but it is also wrong in terms of energy consumption and the melting process. Generally, electric furnace sensors are divided into upper and lower parts. When the molten metal level in the furnace is lower than half of the upper sensor, due to the change of resistance, the upper sensor no longer has induced current to pass, and all are concentrated in the lower sensor, making the lower molten metal overheating, scouring the furnace wall, the life of the furnace lining drops sharply.

Understanding these four major factors that affect the energy consumption of intermediate frequency furnaces and improving them in production can avoid unnecessary consumption, reduce production costs, and improve production efficiency.

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