\u0627\u0644\u0645\u062a\u062f\u0627\u0648\u0644<\/a>, the stock passes through #2 flying shear for cropping before entering pre-finishing mill, where pneumatic vertical loopers enable twist-free, tensionless rolling for precise dimensional control.<\/p>\n3.Pre-finished stock undergoes water cooling and #3 flying shear cropping before entering finishing mill. Emergency shutoff shears activate to prevent further stock entry during malfunctions.<\/p>\n
4.The 45\u00b0 top-cross finishing mill employs gang-driven tungsten carbide roll rings for twist-free micro-tension rolling, achieving final dimensions at speeds up to 95m\/s for \u03c65.5\uff5e7mm products.<\/p>\n
<\/p>\n
Root Cause Analysis of Roll Ring Failures<\/h1>\n
The cost-optimized tungsten carbide roll rings exhibited these failure mechanisms:<\/p>\n
Ambient humidity caused rust corrosion at roll ring\/taper sleeve interfaces<\/p>\n
Thermal fatigue from cyclic temperature variations (Fig.1) accelerated crack propagation<\/p>\n
Insufficient cooling exacerbated thermal stresses (increased \u0394T)<\/p>\n
Improper assembly caused taper sleeve seizure<\/p>\n
Brittle material properties increased handling damage risks<\/p>\n
<\/p>\n
Technical Improvements & Process Controls<\/h1>\nMaterial Selection Optimization<\/h2>\n
The YGR-series roll rings were selected for their Ni\/Cr-enhanced properties:<\/p>\n
1.Superior oxidation resistance (700-1000\u2103)<\/p>\n
2.Improved acid corrosion resistance (pH\u22647.2)<\/p>\n
3.Enhanced thermal crack resistance<\/p>\n
4.Optimal hardness-toughness balance across mill stands<\/p>\n
<\/p>\n
Cooling System Enhancements<\/h2>\n
Implemented strict water management protocols:<\/p>\n
1.Flow rates: 18-25m\u00b3\/h per stand (slot-width dependent)<\/p>\n
2.Pressure maintenance: 3-7bar at nozzles<\/p>\n
3.Monthly water quality testing for particulate control<\/p>\n
Dedicated pipe alignment inspections during maintenance<\/p>\n
<\/p>\n
Optimum Rolling Tonnage<\/h2>\n
Established safe grinding thresholds at 0.2-0.4mm crack depth:<\/p>\n
Stands 1-4: 1,800-2,500 tons<\/p>\n
Stands 5-8: 1,500-2,000 tons<\/p>\n
Stands 9-10: 600-1,000 tons<\/p>\n
<\/p>\n
Precision Assembly Standards<\/h2>\n
Mandatory surface cleaning before assembly<\/p>\n
Prohibited impact mounting methods<\/p>\n
Individual roll storage in partitioned containers<\/p>\n
Strict taper sleeve inspection\/rejection criteria<\/p>\n
<\/p>\n
\u0627\u0633\u062a\u0646\u062a\u0627\u062c<\/h1>\n
The comprehensive improvement program addressing material selection, cooling optimization, production control, and precision maintenance successfully resolved roll ring failures, achieving sustained operational stability. This methodology provides valuable reference for similar applications.<\/p>\n
Key Recommendations<\/h2>\n
1.Select roll ring grades considering environmental factors<\/p>\n
2.Maintain rigorous cooling water quality standards<\/p>\n
3.Adhere to prescribed rolling tonnage limits<\/p>\n
4.Implement precision handling and maintenance protocols<\/p><\/div>\n
<\/p>","protected":false},"excerpt":{"rendered":"
Tungsten carbide roll rings (WC rolls) are high-performance rolling mill components made from tungsten carbide (WC) particles bonded with cobalt (Co) or nickel (Ni) through powder metallurgy. They are widely used in high-speed wire rod mills, bar mills, and section mills due to their exceptional wear resistance, thermal stability, and strength. They can be usefully…<\/p>","protected":false},"author":2,"featured_media":23436,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[107],"tags":[],"class_list":["post-23433","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-industrial-products-weekly"],"jetpack_featured_media_url":"https:\/\/www.meetyoucarbide.com\/wp-content\/uploads\/2025\/03\/2.webp","jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/posts\/23433","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/comments?post=23433"}],"version-history":[{"count":3,"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/posts\/23433\/revisions"}],"predecessor-version":[{"id":23439,"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/posts\/23433\/revisions\/23439"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/media\/23436"}],"wp:attachment":[{"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/media?parent=23433"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/categories?post=23433"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.meetyoucarbide.com\/ar\/wp-json\/wp\/v2\/tags?post=23433"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}