Forged Steel Rolls Production Process

Casting molding → Electroslag remelting → Forging → Spheroidizing annealing → Rough machining → Quenching and tempering → Semi precision machining → Non-destructive testing → Preheating treatment → Dual frequency quenching → Cryogenic treatment → Low-temperature tempering → Precision machining → Hardness testing → Metallographic testing → Ultrasonic testing → Anti rust oil coating → Packaging.

Electroslag remelting

Forging

Quenching and tempering

Ultrasonic testing

Inclined Centrifugal Double Pouring Rolls Production Process

Material reserve

Outer material: High chromium cast iron, high-speed steel and other high hardness and high wear resistant materials are usually selected.
Core material: Usually ductile iron or low-alloy steel is selected to ensure toughness and strength.
Smelting: Smelt the outer and core materials separately to ensure that the chemical composition and temperature meet the requirements.

Centrifugal casting

Preheat mold: Preheat the mold to a certain temperature to reduce casting defects.
Tilt rotation: Install the mold at a certain angle (usually 10 ° -30 °) on the centrifuge and start rotating.
First pouring (outer layer): Inject the melted outer layer material into the rotating mold, and use centrifugal force to evenly distribute the material on the inner wall of the mold, forming the outer layer of the rolling mill.
Cooling: After the outer material has preliminarily solidified, stop rotating and cool down.

Double pouring

Second casting (core): Inject the melted core material into the solidified outer layer to form the core of the rolling mill.
Cooling: Gradually solidify the core material to ensure a tight bond between the outer layer and the core.

Heat treatment

Normalization: Heat the cast rolling mill to an appropriate temperature and then air cool it to achieve uniform organization and eliminate internal stress.
Quenching: Heating the rolling mill above the critical temperature and then rapidly cooling it (such as water quenching or oil quenching) to improve hardness and strength.
Tempering: Heat the quenched rolling mill to a lower temperature and then cool it to reduce brittleness and improve toughness.

Machining

Rough machining: Use lathes, milling machines, and other equipment to perform rough machining on rolling rolls, remove excess materials, and initially form precise dimensions.
Precision machining: Performing precision machining to ensure that the size, shape, and surface finish of the rolling mill meet the requirements.
Grinding: Use a grinder to finely grind the surface of the rolling mill, further improving the surface quality and accuracy.

Surface treatment

Hardening treatment: By surface quenching, carburizing, nitriding and other processes, the hardness and wear resistance of the rolling mill surface are improved.
Coating treatment: Apply wear-resistant and corrosion-resistant coatings on the surface of the rolling mill as needed to extend its service life.

Quality inspection

Dimensional inspection: Use measuring tools to check the dimensional accuracy of the rolling mill to ensure compliance with design requirements.
Hardness testing: Use a hardness tester to test the surface and core hardness of the rolling mill to ensure compliance with standards.
Non destructive testing: Inspect the interior and surface of the rolling mill for defects through ultrasonic, magnetic particle, or penetrant testing.
Performance testing: Conduct mechanical performance testing, such as tensile strength, impact toughness, etc., to ensure the comprehensive performance of the rolling mill.

Balance and Dynamic Balance

Static balance: Check the static balance of the rolling mill to ensure that it is not eccentric in a stationary state.
Dynamic balance: Detecting the balance of the rolling mill in high-speed rotation to avoid vibration during operation.

ICDP production process

Cast Steel Rolls Production Process

Material reserve

Outer material: High chromium cast iron, high-speed steel and other high hardness and high wear resistant materials are usually selected.
Core material: Usually ductile iron or low-alloy steel is selected to ensure toughness and strength.
Smelting: Smelt the outer and core materials separately to ensure that the chemical composition and temperature meet the requirements.

Casting

Preheat mold: Preheat the mold to a certain temperature to reduce casting defects.
Pouring: Inject molten steel into the mold to ensure that the steel fills the entire cavity.
Cooling: gradually solidifying the molten steel in the mold to form the blank of the rolling mill.

Heat treatment

Normalization: Heat the cast rolling mill to an appropriate temperature and then air cool it to achieve uniform organization and eliminate internal stress.
Quenching: Heating the rolling mill above the critical temperature and then rapidly cooling it (such as water quenching or oil quenching) to improve hardness and strength.
Tempering: Heat the quenched rolling mill to a lower temperature and then cool it to reduce brittleness and improve toughness.

Machining

Rough machining: Use lathes, milling machines, and other equipment to perform rough machining on rolling rolls, remove excess materials, and initially form precise dimensions.
Precision machining: Performing precision machining to ensure that the size, shape, and surface finish of the rolling mill meet the requirements.
Grinding: Use a grinder to finely grind the surface of the rolling mill, further improving the surface quality and accuracy.

Surface treatment

Hardening treatment: By surface quenching, carburizing, nitriding and other processes, the hardness and wear resistance of the rolling mill surface are improved.
Coating treatment: Apply wear-resistant and corrosion-resistant coatings on the surface of the rolling mill as needed to extend its service life.

Balance and Dynamic Balance

Static balance: Check the static balance of the rolling mill to ensure that it is not eccentric in a stationary state.
Dynamic balance: Detecting the balance of the rolling mill in high-speed rotation to avoid vibration during operation.

Quality inspection

Dimensional inspection: Use measuring tools to check the dimensional accuracy of the rolling mill to ensure compliance with design requirements.
Hardness testing: Use a hardness tester to test the surface and core hardness of the rolling mill to ensure compliance with standards.
Non destructive testing: Inspect the interior and surface of the rolling mill for defects through ultrasonic, magnetic particle, or penetrant testing.
Performance testing: Conduct mechanical performance testing, such as tensile strength, impact toughness, etc., to ensure the comprehensive performance of the rolling mill.

Heat Treatment

Machining Workshop