Corrugated roller similar to the following 2.5 module pinion, common frequency quenching frequency is generally between 2500 ~ 8000Hz. The corrugating roll with a large diameter is between 2500 and 4000 Hz. Therefore, there is a clear temperature difference between the tooth top and the tooth groove when quenching, which often results in hardened tooth tops and soft tooth grooves after quenching, and concentrates a large tensile stress near the tooth grooves, which can easily cause axial cracking.
The new process took targeted breakthroughs in heat treatment equipment, induction coil, water spray ring, distance between induction coil and water spray ring, clearance between two rings and workpiece, spray angle, heating method, and speed and method of induction coil movement. Improvements have been made to obtain a hardened layer with a depth of more than HRC58 and a depth of 6 to 7 mm, uniform hardness, and a soft groove with a grooved roller, thus ensuring the stability of heat treatment quality.
Third, the quality of the chrome-plated layer Hardened and fine-ground corrugated roller surface plating more than 0.1 mm hard chrome plating, can reduce the friction surface friction coefficient, enhance the wear resistance of enamel teeth, extend the life of corrugating roller. At present, the traditional hard chrome plating process is applied in the country. Since the cathode current efficiency is low, it is generally 12% to 14%. The plating solution concentration and the plating temperature are controlled to be rough, and most of them are judged by the operator based on experience, so the coating quality is unstable. The performance is:
1. Coating thickness is not easy to control. If a pair of corrugating rollers are not plated in pairs, the upper and lower corrugating roller plating thickness errors may even reach 50%.
2. Poor plating ability, especially grooved corrugating roller, flank teeth are often not coated with chromium or plating is very small, resulting in corrugated roller wear and tear during use.
3. The hardness is low and non-uniform. Since the corrugated roll plating is a deep well plating tank, if there is no agitation, the temperature difference between the upper and lower sides is large, resulting in the upper temperature high chromium layer is soft, and the lower temperature lower chromium layer is brittle, which seriously affects the quality of use.
The new process adopts the most advanced HBEF25 high-efficiency hard chrome plating process in the world currently in the functional chrome plating process. Its advantages are:
1. The current density is higher than that of the traditional electroplating hard chrome process, the cathode current efficiency is 22-26%, twice as high as the conventional chrome plating process, and the deposition speed is 2 to 3 times that of the conventional chrome plating. Therefore, the plating ability is greatly improved.
2. The microhardness of the coating reaches HV900-1050, and the traditional process is HV700-800.
3. The wear of the hard chrome coating obtained by this process is approximately 25% less than that of the conventional coating.
4. The thickness of the coating is uniform due to the reduction of excessively high current and excessively thick deposits.
5. The coating is smooth and delicate.
6. Another major advantage of the HEEF-25 coating is the number of micro-cracks as many as 400 per cm.
Microcracks represent a situation that is more susceptible to corrosion. Corrosion occurs along these microcracks. The smaller the number of microcracks, the deeper and longer the cracks, and the easier it is to corrode. The process generates many shallow and short micro-cracks, and the anti-corrosion capability is increased, so that the defects are less corroded.
Strict process management during electroplating, each roller set process parameters according to diameter, length and plating area, strict operation records, continuous circulating filtration of bath, strict control of plating temperature according to process requirements, strict detection and control of bath Concentration and various indicators. Ensure that hard chrome plating above 0.10mm is evenly plated on the top of the tooth most susceptible to wear and that a certain percentage of chromium plating is applied to the root and grate to obtain a harder, smoother, brighter, more wear-resistant than traditional hard chrome processes. Hard chrome plating.
Practice has proved that although the process cost is 3 times that of traditional process, it greatly improves the quality of the product, improves the wear resistance by 40%, prolongs the service life, and reduces maintenance costs.
Fourth, the scientific design of corrugated roller roll paper consumption for corrugated board manufacturing industry, is an important factor affecting the cost of production technology companies. Some foreign countries with relatively advanced packaging industry have attached great importance to the economic indicators of corrugated roller paper consumption. For example, Mitsubishi Japan has designed the same type of corrugated roller type as standard type and economic type separately. Therefore, although the height is the same, but the number of turns per 300 mm is different, the paper consumption rate (also known as buckling, shrinkage and corrugation, etc.) is completely different. Taking a three-layer corrugated paperboard production line with an annual output of 10 million square meters as an example, if the paper consumption rate is reduced by 1%, then more than 100,000 square meters of corrugated base paper can be saved, and the larger the output, the thicker the paperboard (such as five floors). Seventh floor), the more potential savings are. The paper consumption rate is the ratio of the length of a single tooth profile curve to the length of a single tooth. That is, the ratio of the length of the corrugated fiber to the length of the corrugated base paper after forming. Its rationality is an important economic indicator for directly measuring the quality of corrugating rollers.
The new process is computer-aided and scientifically designed. Users can directly participate in the design when repairing and making new corrugating rollers. The software can be used to evaluate and select the economy, rationality and quickness of various types of stencils.
With the rapid development of the carton industry, corrugating rollers tend to have wide widths, large diameters, and high speeds, and the equipment tends to be versatile. Some production lines will increase E-cardboard, F-type, G-type, etc. It is determined by the forming mechanism of the corrugation that the corrugating must be single-tooth meshing. When designing the corrugated type, it must be controlled within a certain range of wrapping angles (where the wrapping angle is the sum of the wrapping angles of the running paper on the tops of the contacting teeth). ) If the system is reformed blindly, the angle of the corrugated paper is too large, and the corrugating base paper cannot slide between the tooth profiles to supplement the amount of paper needed for corrugation molding. This will impede the forming of the cardboard and cause the corrugated paper to break. The design software calculates the roll angle of the roll while designing the roll shape, and can adjust it through calculation to design a scientific, economical, reasonable, and reliable micro cardboard.
Fifth, the old roller repair process The above process is also used to repair a variety of corrugated roller, pressure roller, greatly improving the durability of the repair roller, while repairing its diameter, length, corrugated roller height, high, Bounce, hardness, surface appearance and other comprehensive cleaning inspections, all damage areas and data are recorded in the incoming report to the factory, in order to promptly contact the customer in detail repair content. Computer-aided design of enamel type and preparation of relative special precision diamond rollers. In addition to the repair of the roller surface and the repair and repair of bearing positions and other axial positions, it is also possible to modify and replace the entire shaft head. The repaired rollers leave the factory with detailed inspection reports of various technical indicators for users' reference and filing. At the same time, the old roller will be mapped for calculation and preparation so that new rollers can be made for customers at any time.
The manufacturing and repairing process of alloy steel corrugating rollers has prolonged the service life of corrugating rollers, improved economic performance, ensured various precision indexes of corrugating rollers, guaranteed the quality of cardboard, and at the same time also satisfied the import of high-speed production lines of 25CM/min or more. Upper corrugated roller repair and manufacturing needs. (Wujin Haili Roller Co., Ltd. Du Jianchun)
The new process took targeted breakthroughs in heat treatment equipment, induction coil, water spray ring, distance between induction coil and water spray ring, clearance between two rings and workpiece, spray angle, heating method, and speed and method of induction coil movement. Improvements have been made to obtain a hardened layer with a depth of more than HRC58 and a depth of 6 to 7 mm, uniform hardness, and a soft groove with a grooved roller, thus ensuring the stability of heat treatment quality.
Third, the quality of the chrome-plated layer Hardened and fine-ground corrugated roller surface plating more than 0.1 mm hard chrome plating, can reduce the friction surface friction coefficient, enhance the wear resistance of enamel teeth, extend the life of corrugating roller. At present, the traditional hard chrome plating process is applied in the country. Since the cathode current efficiency is low, it is generally 12% to 14%. The plating solution concentration and the plating temperature are controlled to be rough, and most of them are judged by the operator based on experience, so the coating quality is unstable. The performance is:
1. Coating thickness is not easy to control. If a pair of corrugating rollers are not plated in pairs, the upper and lower corrugating roller plating thickness errors may even reach 50%.
2. Poor plating ability, especially grooved corrugating roller, flank teeth are often not coated with chromium or plating is very small, resulting in corrugated roller wear and tear during use.
3. The hardness is low and non-uniform. Since the corrugated roll plating is a deep well plating tank, if there is no agitation, the temperature difference between the upper and lower sides is large, resulting in the upper temperature high chromium layer is soft, and the lower temperature lower chromium layer is brittle, which seriously affects the quality of use.
The new process adopts the most advanced HBEF25 high-efficiency hard chrome plating process in the world currently in the functional chrome plating process. Its advantages are:
1. The current density is higher than that of the traditional electroplating hard chrome process, the cathode current efficiency is 22-26%, twice as high as the conventional chrome plating process, and the deposition speed is 2 to 3 times that of the conventional chrome plating. Therefore, the plating ability is greatly improved.
2. The microhardness of the coating reaches HV900-1050, and the traditional process is HV700-800.
3. The wear of the hard chrome coating obtained by this process is approximately 25% less than that of the conventional coating.
4. The thickness of the coating is uniform due to the reduction of excessively high current and excessively thick deposits.
5. The coating is smooth and delicate.
6. Another major advantage of the HEEF-25 coating is the number of micro-cracks as many as 400 per cm.
Microcracks represent a situation that is more susceptible to corrosion. Corrosion occurs along these microcracks. The smaller the number of microcracks, the deeper and longer the cracks, and the easier it is to corrode. The process generates many shallow and short micro-cracks, and the anti-corrosion capability is increased, so that the defects are less corroded.
Strict process management during electroplating, each roller set process parameters according to diameter, length and plating area, strict operation records, continuous circulating filtration of bath, strict control of plating temperature according to process requirements, strict detection and control of bath Concentration and various indicators. Ensure that hard chrome plating above 0.10mm is evenly plated on the top of the tooth most susceptible to wear and that a certain percentage of chromium plating is applied to the root and grate to obtain a harder, smoother, brighter, more wear-resistant than traditional hard chrome processes. Hard chrome plating.
Practice has proved that although the process cost is 3 times that of traditional process, it greatly improves the quality of the product, improves the wear resistance by 40%, prolongs the service life, and reduces maintenance costs.
Fourth, the scientific design of corrugated roller roll paper consumption for corrugated board manufacturing industry, is an important factor affecting the cost of production technology companies. Some foreign countries with relatively advanced packaging industry have attached great importance to the economic indicators of corrugated roller paper consumption. For example, Mitsubishi Japan has designed the same type of corrugated roller type as standard type and economic type separately. Therefore, although the height is the same, but the number of turns per 300 mm is different, the paper consumption rate (also known as buckling, shrinkage and corrugation, etc.) is completely different. Taking a three-layer corrugated paperboard production line with an annual output of 10 million square meters as an example, if the paper consumption rate is reduced by 1%, then more than 100,000 square meters of corrugated base paper can be saved, and the larger the output, the thicker the paperboard (such as five floors). Seventh floor), the more potential savings are. The paper consumption rate is the ratio of the length of a single tooth profile curve to the length of a single tooth. That is, the ratio of the length of the corrugated fiber to the length of the corrugated base paper after forming. Its rationality is an important economic indicator for directly measuring the quality of corrugating rollers.
The new process is computer-aided and scientifically designed. Users can directly participate in the design when repairing and making new corrugating rollers. The software can be used to evaluate and select the economy, rationality and quickness of various types of stencils.
With the rapid development of the carton industry, corrugating rollers tend to have wide widths, large diameters, and high speeds, and the equipment tends to be versatile. Some production lines will increase E-cardboard, F-type, G-type, etc. It is determined by the forming mechanism of the corrugation that the corrugating must be single-tooth meshing. When designing the corrugated type, it must be controlled within a certain range of wrapping angles (where the wrapping angle is the sum of the wrapping angles of the running paper on the tops of the contacting teeth). ) If the system is reformed blindly, the angle of the corrugated paper is too large, and the corrugating base paper cannot slide between the tooth profiles to supplement the amount of paper needed for corrugation molding. This will impede the forming of the cardboard and cause the corrugated paper to break. The design software calculates the roll angle of the roll while designing the roll shape, and can adjust it through calculation to design a scientific, economical, reasonable, and reliable micro cardboard.
Fifth, the old roller repair process The above process is also used to repair a variety of corrugated roller, pressure roller, greatly improving the durability of the repair roller, while repairing its diameter, length, corrugated roller height, high, Bounce, hardness, surface appearance and other comprehensive cleaning inspections, all damage areas and data are recorded in the incoming report to the factory, in order to promptly contact the customer in detail repair content. Computer-aided design of enamel type and preparation of relative special precision diamond rollers. In addition to the repair of the roller surface and the repair and repair of bearing positions and other axial positions, it is also possible to modify and replace the entire shaft head. The repaired rollers leave the factory with detailed inspection reports of various technical indicators for users' reference and filing. At the same time, the old roller will be mapped for calculation and preparation so that new rollers can be made for customers at any time.
The manufacturing and repairing process of alloy steel corrugating rollers has prolonged the service life of corrugating rollers, improved economic performance, ensured various precision indexes of corrugating rollers, guaranteed the quality of cardboard, and at the same time also satisfied the import of high-speed production lines of 25CM/min or more. Upper corrugated roller repair and manufacturing needs. (Wujin Haili Roller Co., Ltd. Du Jianchun)
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