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CASTING & ROLLING ROLL FOR ALUMINIUM CASTER

 

Roller Shell

Roller shell for aluminium casting & rolling machine works under serious circumstances. The temperature on the surface layer of shell changes periodically from 30?C to 650?C, which results in periodical thermal stress. Thermal stress causes fatigue crack on the suface. During production, thermal fatigue crack occurrs in a certain depth later, service life of the shell will be longer accordingly.

Sun-Glare roller shell adopts material of Cr-Mo-V alloy steel, which is specially melted, forged and heat treated, and has good property of fatigue resistance. The peroid before thermal fatigue crack occurrs in a certain depth is one time longer than normal material. Better mechanical properties of the material also improve the quality of aluminium products. Meawhile, with continuous study of heat treatment process by Sun-Glare technicians, axial hardness differential of roller shell reduces to less than 10HB. Complete quality control system and after sales service enable us to meet the most demanding requirements of our customers. For example, for our Ф960XФ800X1950 roller shell, service life reaches over 15000T per pair rolls.

 

Main Technical Data of Roller Shell Material

Material: 32Cr3Mo1V

-- Chemical Composition

C

Si

Mn

P

S

Ni

Cr

Cu

Mo

V

0.27
-0.37

0.20
-0.40

0.20
-0.50

<0.025

<0.025

<0.25

2.70
-3.20

<0.25

0.9-1.1

0.15
-0.20

-- Mechanical Properties

Temperature
oC

Tensile Strength
MPa

Yield Strength
MPa

Elongation
%

Surface Reduction
%

Impact Toughness
J/cm3

surrounding

1358

1258

16.1

57.3

83.5

500

1064

905

17.8

78.4

 

600

835

752

19.7

84

 

630

721

592

22.6

92.1

 

680

442

375

29.3

95.6

 

-- Physical Properties

--- Elastic coefficient: E=1.97X105 N/mm2

--- Thermal Conductivity

Temperature oC

Thermal Conductivity W/m oC

300

35.8

400

35.8

500

33.9

600

28.0

700

20.5

--- Heat Expansion Coefficient

Temperature oC

Heat Expansion Coefficient 10-6/oC

0-100

11.87

-200

12.71

-300

13.22

-400

13.77

-500

14.15

-600

14.40

-700

14.68

 

Roller Core

 Material

42CrMo, ladle refining melting

Structure:

Reversible-type, water-cooled casting & rolling core structure, which is with high cooling capacity, makes even temperature on the roll surface, and ensures product in good shape.

Manufacturing Process of Sun-Glare Roller Core

  1. Forging: 12000T hydraulic presser with forging ration not less than 3

  2. Heat treatment after forging: normalizing + tempering, relieving forging stress

  3. Rough machining: machining subject to dimension reqirement of hardening and tempering treatment

  4. Detection: according to GB/T6402-91 with accuracy of Class 2

  5. Hardening and tempering treatment: hardness 300-340, furnace cooling for stress relieving

  6. Sample cutting: mechanical property inspection

  7. Full body welded with stainless steel by machine

  8. Surface rough turning after welding

  9. Surface heat treatment hardness: HRC40

  10. Detection to inspect no defects on the surface, such as cracks etc.

  11. Semi-finish machining: drilling axial and radial water holes and making radial water groove

  12. Stability treatment

  13. Finish machining: finish machining each dimensions to meet the dimension requirements in the drawing except for outer diameter and roll neck

  14. Final finish machining: finish grinding outer diameter and roll neck to meet the dimension requirements in the drawing