阅读说明：本技术 一种穿孔轧辊堆焊方法 (Perforated roller surfacing method ) 是由 强茂俊 贾焕祥 于 2020-12-16 设计创作，主要内容包括：本发明公开了一种穿孔轧辊堆焊方法,该穿孔轧辊堆焊方法包括以下步骤：对轧辊的待堆焊面进行清理,将检测合格的轧辊固定,在变位机上,待堆焊面朝上；使用焊带与焊剂,用带极埋弧堆焊方法将过渡层堆焊在轧辊的待堆焊面上,将检测合格的试件进行消应热处理。该穿孔轧辊堆焊方法,采取自动焊堆焊的方法来保证轧辊的使用周期,穿孔轧辊因反复车加工直径较小时,就在原轧辊表面用自动焊堆焊至原始尺寸再车加工轧制带后装机使用,和整体更换的轧辊相比较使用周期和穿孔质量是一样的,经测算每堆焊一套轧辊的费用是13000元,每年使用两套轧辊计算,在穿孔这一项每年可节约生产车本32000元,可产生良好的经济效益。(The invention discloses a perforated roller surfacing method, which comprises the following steps: cleaning the surface to be subjected to surfacing of the roller, fixing the roller which is qualified in detection, and enabling the surface to be subjected to surfacing to be upward on a positioner; and (3) overlaying the transition layer on the surface to be overlaid of the roller by using a welding strip and a welding flux by using a strip submerged arc overlaying method, and performing stress relief heat treatment on the test piece qualified in detection. The method for overlaying the perforated roller adopts an automatic overlaying method to ensure the service cycle of the roller, when the diameter of the perforated roller is repeatedly lathed, the perforated roller is automatically overlaid to the original size on the surface of the original roller and then lathed into a rolled strip to be used by a loading machine, compared with the integrally replaced roller, the service cycle and the perforation quality are the same, the cost of one set of roller per overlaying is 13000 yuan by calculation, two sets of rollers are used for calculation every year, the production cost can be saved 32000 yuan per year in perforation, and good economic benefit can be generated.)

1. A perforated roller surfacing method is characterized in that: the perforating roller process comprises the following steps:

firstly, detecting a zero horizontal reference on a reference pad and a sliding block, adjusting the thickness of the sliding block to a proper value according to requirements, and ensuring that the center of an operation trolley is on a rolling line;

step two, the blank heated to 1100-;

step three, after the hollow billet is pulled out of the rolling line, putting the hollow billet into the through hole again for extending rolling;

and step four, when the diameter of the roller to be rolled is small to a certain degree, an automatic surfacing welding method is adopted to ensure the service cycle of the roller.

2. A piercing roll overlay welding method according to claim 1, characterized in that: the diameter of the roller is 800 mm.

3. A piercing roll overlay welding method according to claim 1, characterized in that: the through-hole roller surfacing method comprises the following steps:

cleaning the surface to be subjected to surfacing of the roller, fixing the roller which is qualified in detection on a positioner, wherein the surface to be subjected to surfacing is upward;

secondly, using a welding strip and a welding flux, overlaying a transition layer on the surface to be overlaid of the roller by a strip submerged arc overlaying method, and performing stress relief heat treatment on the qualified test piece;

and thirdly, overlaying the corrosion-resistant layer on the surface of the transition layer of the roller by using a strip submerged arc overlaying method, staggering the welding seam of the transition layer and the corrosion-resistant layer, and performing 100% penetration detection on the corrosion-resistant layer after overlaying.

4. The method according to claim 3, wherein the surface to be built-up welded is subjected to 100% magnetic powder inspection.

5. A piercing roll overlay welding method according to claim 3, characterized in that: and performing 100% penetration detection on the transition layer after surfacing.

6. A piercing roll overlay welding method according to claim 1, characterized in that: the elongation rolling time in step three was 30-60s and the pressure was 5 MPA.

7. A piercing roll overlay welding method according to claim 3, characterized in that: the strip electrode submerged arc surfacing method is formed by multi-wire (parallel) submerged arc welding and expansion.

8. A piercing roll overlay welding method according to claim 3, characterized in that: the strip electrode submerged arc surfacing adopts a metal strip with the thickness of 0.4-0.9mm and the width of 25-110 mm.

9. A piercing roll overlay welding method according to claim 3, characterized in that: the deposition coefficient of the low-carbon steel band electrode in the band electrode submerged arc surfacing is 15g/Ah, the deposition rate of the stainless steel band electrode is 20g/Ah, and the deposition rate can reach 22-68kg/h when double-band electrode surfacing is adopted.

10. A piercing roll overlay welding method according to claim 1, characterized in that: the flux can be any one of molten salt, organic matter, active gas and metal steam, and is preferably active gas.

Technical Field

The invention relates to the technical field of perforated roller surfacing, in particular to a perforated roller surfacing method.

Background

Hot rolling refers to rolling performed at a temperature above the metal recrystallization temperature.

Recrystallization is that when the annealing temperature is high enough and the annealing time is long enough, new grains (recrystallization core) without strain are generated in the fiber structure of the deformed metal or alloy, the new grains grow continuously until the original deformed structure disappears completely, the performance of the metal or alloy also changes obviously, the process is called recrystallization, wherein the temperature for starting to generate the new grains is called recrystallization starting temperature, the temperature for the microstructure to be occupied by the new grains is called final recrystallization temperature, the recrystallization temperature is generally called the arithmetic mean value of the recrystallization starting temperature and the final recrystallization temperature, and the recrystallization temperature is mainly influenced by the factors such as alloy components, deformation degree, original grain size, annealing temperature and the like.

The principle is that when the ingot is heated to a certain temperature in a heating furnace, namely above the recrystallization temperature, the ingot is rolled, the temperature is determined mainly according to a phase diagram of the aluminum alloy, namely under the most ideal condition, the heating temperature is determined according to the temperature of 80% of a solidus line of the alloy in a multiple phase diagram, so that the problem of the multiple phase diagram of different alloys is involved, the heating temperature is determined according to 80% of the solidus line of the alloy, and in the execution of a system, the obtained temperature suitable for the production of the alloy is additionally modified according to the actual production condition and the operation condition of equipment.

When hot rolling is carried out in a hot rolling and piercing workshop, a heated stainless steel round steel tube blank is pierced into a 'blank pipe' required for producing a seamless steel tube, the tube blank is repeatedly rolled by a roller during piercing through a piercing machine, the rolling belt generates 'grooves' due to repeated rolling and abrasion after the roller is used for a period of time, if the worn roller is not finished in time, serious influence is brought to piercing production quality, and at the moment, the rolling belt on the surface of the piercing roller needs to be lathed by a lathe to remove a layer (about 5mm to 8 mm) again, so that the machine can be installed for continuous use.

The diameter of the perforating roller is smaller and smaller due to the fact that the roller needs to be frequently refitted and machined, the roller must be scrapped and cannot be reused when the diameter of the roller is small to a certain degree, a whole set of roller is purchased for standby after the roller is scrapped, the purchase price of each set of new roller is 29000 yuan, and at least 2 sets of rollers are purchased every year;

in order to improve the utilization rate of the roller and save the cost, a perforated roller surfacing method is provided.

Disclosure of Invention

Aiming at the defects of the prior art, the invention provides a perforated roller surfacing method, which comprises the following technical scheme: a method for overlaying a perforated roller, the perforated roller process comprising the steps of:

firstly, detecting a zero horizontal reference on a reference pad and a sliding block, adjusting the thickness of the sliding block to a proper value according to requirements, and ensuring that the center of an operation trolley is on a rolling line;

step two, the blank heated to 1100-;

step three, after the hollow billet is pulled out of the rolling line, putting the hollow billet into the through hole again for extending rolling;

and step four, when the diameter of the roller to be rolled is small to a certain degree, an automatic surfacing welding method is adopted to ensure the service cycle of the roller.

Preferably, the diameter of the roller is 800 mm.

A perforated roller surfacing method is characterized in that: the through-hole roller surfacing method comprises the following steps:

cleaning the surface to be subjected to surfacing of the roller, fixing the roller which is qualified in detection on a positioner, wherein the surface to be subjected to surfacing is upward;

secondly, using a welding strip and a welding flux, overlaying a transition layer on the surface to be overlaid of the roller by a strip submerged arc overlaying method, and performing stress relief heat treatment on the qualified test piece;

and thirdly, overlaying the corrosion-resistant layer on the surface of the transition layer of the roller by using a strip submerged arc overlaying method, staggering the welding seam of the transition layer and the corrosion-resistant layer, and performing 100% penetration detection on the corrosion-resistant layer after overlaying.

Preferably, 100% magnetic powder detection is carried out on the surface to be subjected to surfacing.

Preferably, after surfacing, 100% penetration detection is carried out on the transition layer.

Preferably, the elongation rolling time in step three is 30-60s, and the pressure is 5 MPA.

Preferably, the strip submerged arc surfacing method is formed by multi-wire (parallel) submerged arc welding and expansion.

Preferably, the strip electrode submerged arc surfacing adopts a metal strip with the thickness of 0.4-0.9mm and the width of 25-110 mm.

Preferably, the deposition coefficient of the low-carbon steel strip electrode in the strip electrode submerged arc surfacing is 15g/Ah, the deposition coefficient of the stainless steel strip electrode is 20g/Ah, and the deposition speed can reach 22-68kg/h when double-strip electrode surfacing is adopted.

Preferably, the flux can be selected from any one of molten salt, organic matter, active gas and metal steam, and is preferably active gas.

Compared with the prior art, the invention has the following beneficial effects: the method for overlaying the perforated roller adopts an automatic overlaying method to ensure the service cycle of the roller, when the diameter of the perforated roller is repeatedly lathed, the perforated roller is automatically overlaid on the surface of the original roller to the original size and then lathed into a rolled strip to be used by a loading machine, compared with the integrally replaced roller, the service cycle and the perforation quality are the same, the cost of one set of roller per overlaying is 13000 yuan by calculation, two sets of rollers are used for calculation every year, the production cost can be saved 32000 yuan per year in the process of perforation, and good economic benefit can be generated.

Detailed Description

The technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

The invention discloses a through-hole roller surfacing method, which comprises the following steps:

firstly, detecting a zero horizontal reference on a reference pad and a sliding block, adjusting the thickness of the sliding block to a proper value according to requirements, and ensuring that the center of an operation trolley is on a rolling line;

step two, the blank heated to 1100-;

step three, after the hollow billet is pulled out of the rolling line, putting the hollow billet into the through hole again for extending rolling;

and step four, when the diameter of the roller to be rolled is small to a certain degree, an automatic surfacing welding method is adopted to ensure the service cycle of the roller.

The diameter of the roller is 800 mm.

A perforated roller surfacing method includes the following steps:

cleaning the surface to be subjected to surfacing of the roller, fixing the roller which is qualified in detection on a positioner, wherein the surface to be subjected to surfacing is upward;

secondly, using a welding strip and a welding flux, overlaying a transition layer on the surface to be overlaid of the roller by a strip submerged arc overlaying method, and performing stress relief heat treatment on the qualified test piece;

and thirdly, overlaying the corrosion-resistant layer on the surface of the transition layer of the roller by using a strip submerged arc overlaying method, staggering the welding seam of the transition layer and the corrosion-resistant layer, and performing 100% penetration detection on the corrosion-resistant layer after overlaying.

And performing 100% magnetic powder detection on the surface to be subjected to overlaying welding.

And performing 100% penetration detection on the transition layer after surfacing.

The elongation rolling time in step three was 30-60s and the pressure was 5 MPA.

The submerged arc bead welding method with electrode is formed by multiple wires (parallel) submerged arc welding and expansion.

The band electrode submerged arc surfacing adopts a metal band with the thickness of 0.4-0.9mm and the width of 25-110 mm.

The deposition coefficient of the low-carbon steel band electrode in the band electrode submerged arc surfacing is 15g/Ah, the deposition rate of the stainless steel band electrode is 20g/Ah, and the deposition rate can reach 22-68kg/h when double-band electrode surfacing is adopted.

The flux can be selected from any one of molten salt, organic matter, active gas and metal steam, and is preferably active gas.

Example 1

When the roller is perforated, firstly detecting a zero horizontal reference on a reference pad and a slide block, adjusting the thickness of the slide block to a proper value according to requirements, and ensuring that the center of an operation trolley is on a rolling line; the blank heated to 1100 ℃ is brought into a perforating machine by an active roller, a capillary is perforated by the upper top of the perforating machine and is gradually opened by three-roller centering rollers, when the capillary passes through a second centering roller, a hydraulic power device starts to drive a mandril and a top head to slowly retreat according to set parameters until the capillary is perforated, the hydraulic power device returns to the original position, the inner cavity of the capillary is drawn out, all the centering rollers are opened, the capillary is pulled out of a rolling line, and an extension rolling process is carried out; after the hollow billet is pulled out of the rolling line, putting the hollow billet into the through hole again for extending rolling; when the diameter of the roller to be welded is small to a certain degree, the service cycle of the roller is ensured by adopting an automatic surfacing welding method.

The diameter of the roller is 800 mm;

the cost of one set of roller for each surfacing welding is calculated to be 13000 yuan, and the two sets of rollers are used by the company every year, so that 32000 yuan of production vehicle cost can be saved in the process of perforating every year, and good economic benefit is generated.

Example 2

When the roller is perforated, firstly detecting a zero horizontal reference on a reference pad and a slide block, adjusting the thickness of the slide block to a proper value according to requirements, and ensuring that the center of an operation trolley is on a rolling line; the blank heated to 1300 ℃ is brought into a perforating machine by an active roller, a capillary is perforated by the upper top of the perforating machine and is gradually opened by three-roller centering rollers, when the capillary passes through a second centering roller, a hydraulic power device starts to drive a mandril and a top head to slowly retreat according to set parameters until the capillary is perforated, the hydraulic power device returns to the original position, the inner cavity of the capillary is drawn out, all the centering rollers are opened, the capillary is pulled out of a rolling line, and an extension rolling process is carried out; after the hollow billet is pulled out of the rolling line, putting the hollow billet into the through hole again for extending rolling; when the diameter of the roller to be welded is small to a certain degree, the service cycle of the roller is ensured by adopting an automatic surfacing welding method.

The diameter of the roller is 800 mm;

the cost of one set of roller for each surfacing welding is calculated to be 13000 yuan, and the two sets of rollers are used by the company every year, so that 32000 yuan of production vehicle cost can be saved in the process of perforating every year, and good economic benefit is generated.

Example 3

When the perforated roller is used for surfacing, cleaning the surface of the roller to be surfaced, fixing the roller which is qualified in detection, and enabling the surface to be surfaced to be upward on a positioner; overlaying a transition layer on a to-be-overlaid welding surface of the roller by using a welding strip and a welding flux by using a strip submerged arc overlaying method, and performing stress relief heat treatment on a test piece qualified by detection; and overlaying the corrosion-resistant layer on the surface of the transition layer of the roller by using a strip submerged arc overlaying method, staggering the welding seam of the transition layer and the corrosion-resistant layer, and performing 100% penetration detection on the corrosion-resistant layer after overlaying.

Performing 100% magnetic powder detection on a surface to be subjected to surfacing, performing 100% penetration detection on a transition layer after surfacing, wherein the extension rolling time is 30s, and the pressure is 5 MPA;

the submerged arc bead welding method with electrode is formed by multiple wires (parallel) submerged arc welding and expansion.

The strip submerged arc surfacing adopts a metal strip with the thickness of 0.4mm and the width of 50 mm.

The deposition coefficient of the low-carbon steel band electrode in the band electrode submerged arc surfacing is 15g/Ah, the deposition rate of the stainless steel band electrode is 20g/Ah, and the deposition rate can reach 30kg/h when double-band electrode surfacing is adopted.

The flux can be selected from fused salt;

the precision perforation process of the high-precision hollow billet rolling equipment of the perforating machine is stable, the tolerance precision of the wall thickness of the hollow billet is higher, the precision of the wall thickness of the tail part of the hollow billet is at least improved by 5 percent compared with that of the tail part of the hollow billet, the tail cutting length of the hollow billet is greatly reduced, the yield is at least improved by 0.6 percent, a percentage point is improved in the actual income of a factory, 75 yuan of benefit is realized, and then the annual benefit of the factory is at least improved: 25 ten thousand tons, 75 yuan, 0.5 yuan 937.5 yuan.

Example 4

When the perforated roller is used for surfacing, cleaning the surface of the roller to be surfaced, fixing the roller which is qualified in detection, and enabling the surface to be surfaced to be upward on a positioner; overlaying a transition layer on a to-be-overlaid welding surface of the roller by using a welding strip and a welding flux by using a strip submerged arc overlaying method, and performing stress relief heat treatment on a test piece qualified by detection; and overlaying the corrosion-resistant layer on the surface of the transition layer of the roller by using a strip submerged arc overlaying method, staggering the welding seam of the transition layer and the corrosion-resistant layer, and performing 100% penetration detection on the corrosion-resistant layer after overlaying.

Performing 100% magnetic powder detection on a surface to be subjected to surfacing, performing 100% penetration detection on a transition layer after surfacing, wherein the extension rolling time is 60s, and the pressure is 5 MPA;

the strip submerged arc surfacing method is formed by multi-wire (parallel) submerged arc welding expansion, the strip submerged arc surfacing adopts a metal strip with the thickness of 0.5mm and the width of 80mm, the deposition coefficient of a low-carbon steel strip in the strip submerged arc surfacing is 15g/Ah, the deposition rate of a stainless steel strip is 20g/Ah, the deposition rate can reach 110kg/h when double-strip surfacing is adopted, and active gas can be selected as a welding flux;

the precise perforation process of the high-precision capillary tube rolling equipment of the perforating machine is stable, the tolerance precision of the wall thickness of the capillary tube is high, particularly, the precision of the wall thickness of the tail part of the capillary tube is at least improved by 5 percent compared with the prior art, the tail cutting length of the capillary tube is greatly reduced, and the yield is at least improved by 0.5 percent. There is 80 yuan benefit to increase one percentage point in the actual profit of the plant, then the annual benefit of the plant is at least increased: 25 ten thousand tons, 80 yuan, 0.5 yuan 1000 yuan.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.