The following are the basic process and precautions for casting rolling rings in our company:
1. Design and process preparation
Material selection: The rolling ring is usually made of high-strength alloy steel (such as ZG35CrMo, ZG42CrMo, etc.), which has good wear resistance and fatigue resistance.
Mold design: Design casting molds based on the size and shape of the rolling ring to ensure dimensional accuracy and surface quality.
Process design: Develop casting processes, including pouring systems, cooling methods, heat treatment processes, etc.
2. Melting and pouring
Smelting: Smelting alloy steel raw materials in an electric arc furnace or induction furnace, strictly controlling the chemical composition and temperature.
Pouring: Pour molten metal into a pre prepared sand or metal mold to ensure a smooth pouring process and avoid defects such as porosity and slag inclusion.
3. Cooling and Cleaning
Cooling: After pouring, the casting is naturally cooled in the mold or the cooling rate is controlled to avoid cracking caused by rapid cooling.
Cleaning: After cooling, remove the sand mold, sprue, riser, etc. on the surface of the casting and perform surface cleaning.
4. Heat treatment
Annealing or normalizing: Eliminating casting stress and improving internal structure.
Quenching and tempering: Improve the hardness and wear resistance of the rolling ring, ensuring that it has sufficient strength and toughness during use.
5. Mechanical processing
Rough machining: perform preliminary machining on the rolling ring to ensure that the size is close to the design requirements.
Precision machining: ensuring the dimensional accuracy and surface smoothness of the rolling ring through processes such as turning and grinding.
6. Testing and Acceptance
Non destructive testing: detecting internal defects through methods such as ultrasonic and magnetic particle inspection.
Dimensional inspection: Use equipment such as coordinate measuring instruments to measure dimensional accuracy.
Hardness testing: Ensure that the hardness of the rolling ring meets the design requirements.
7. Surface treatment
Spray coating or plating: According to the usage environment, rust proof and wear-resistant treatment should be carried out on the surface of the rolling ring to extend its service life.
8. Installation and use
Installation: When installing the rolling ring, it is necessary to ensure the accuracy of the fit with the equipment to avoid stress concentration or uneven wear caused by improper installation.
Maintenance: Regularly check the wear of the rolling ring and perform maintenance or replacement in a timely manner.
9. Precautions
Material uniformity: Ensure uniform alloy composition and avoid segregation.
Casting defect control: Strictly control defects such as porosity, shrinkage, and slag inclusion.
Heat treatment process: Reasonably select the heat treatment process to ensure the comprehensive performance of the rolling ring.
The quality of the cast rolling ring directly affects the service life and operational efficiency of the equipment. Therefore, strict control of each link is required during the casting process to ensure that the final product meets the design requirements.
