Manufacturing process for weldless total-prefabricated rollers

Abstract

The invention provides a manufacturing process for weldless total-prefabricated rollers, and relates to the technical field of processing and manufacturing of rollers. The manufacturing process for weldless total-prefabricated rollers is technically characterized in that a position where a shaft head is connected with a roller does not have weld, and requirements of stress of the roller and / or airtightness and processing precision of the roller are met and ensured by bonding strength generated by reliable interference fit between the shaft head and the roller completely. After the shaft headand the roller are assembled, welding, stress-relieving heat treatment, heat treatment such as medium-frequency hardening, processing such as finish turning of the shaft head and dynamic balance emendation of the roller are not required, a technological process can be greatly shortened, processing procedures can be greatly reduced, processing time can be greatly shortened, processing difficulty can be greatly relieved, manufacturing costs can be greatly reduced, and perfect dynamic balance grade and manufacturing precision are realized. Therefore, a series of configuration and matching of machine tool equipment, change and innovation of technical requirements, change and innovation of fixtures, workshop planning and layout and change and innovation of a technology of the manufacturing process for rollers can be further initiated.

Description

technical field [0001] The invention relates to the technical field of roller processing and manufacturing. Among them, corrugated rollers are typical products, involving and including pressure rollers, rubber rollers, anilox rollers, calender rollers, embossing rollers, rubber rollers, etc., which are characterized by the three-part structure of the shaft head and the roller body. The technical field of roller processing and manufacturing required for airtightness. technical background [0002] 1. The main features of the roller are: it consists of three parts: the shaft head (1) at both ends, the shaft head (2) and the roller body (3). The traditional manufacturing process of the roller is that after the shaft head and the roller body are assembled by interference, it is necessary to weld the reserved weld seam at the joint between the shaft head and the roller body to meet and ensure the force and or airtightness of the roller. [0003] 2. The important reason why the t...

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Problems solved by technology

[0003] 2. The important reason why the traditional manufacturing process of the roller needs to weld the joint between the shaft head and the roller body is because the interference fit of the shaft head and the roller body such as H / u and H / t of the traditional roller cannot be satisfied and guaranteed Due to the complex force and / or airtightness requirements of the roller, necessary welding has to be carried out at the junction of the shaft head and the roller body

[0004] 3. The material of the shaft head and the roll body of the roller is mostly medium carbon steel, and the weldability is not very good. Because of the different functions of the shaft head and the roll body, there is a certain difference in the carbon content of the selected materials, and thus Increased difficulty of welding

Taking the corrugated roller as an example, the material of the shaft head is usually 35CrMo, and the roller body is required to have a high surface hardness (HRC55-60), and the special material with 50CrMo or higher carbon content is usually used, which has poor weldability and dissimilar metals. Welding also increases the difficulty of welding, and cracks are prone to occur. If the cracks cannot be found and treated effectively in time, when the cracks are transferred to the subsequent intermediate frequency quenching process, the cracks are easy to expand. If they expand to the surface of the roll body, the roll can only be scrapped. Treatment, even if it does not extend to the surface of the roll body, rework treatment is quite difficult, both of which directly lead to high costs

[0005] 4. In the traditional manufacturing process of the roller, welding is required after the shaft head and the roller body are assembled, and welding will inevitably result in man-hours and costs

[0006] 5. In the traditional manufacturing process of the roller, the shaft head and the roller body need to be stress-relieved and tempered after assembly and welding. The heat treatment will inevitably lead to man-hours and costs.

[0007] 6. In the traditional manufacturing process of the roller, the shaft head and the roller body need to be welded after assembly, so there is bending deformation caused by welding thermal stress, and effective stress relief heat treatment is required after welding. The shaft head and the roller body must leave a large gap. The machining allowance is the overall processing after assembly and welding. The milling keyway of the roller, the steam inner hole of the boring shaft head, the pipe thread and the external thread, the threaded hole of the end flange connection, copper knife groove, embossing, etc. can only be completed after assembly and welding. overall processing

[0008] 7. The traditional manufacturing process of the roller, due to welding and intermediate frequency quenching, will cause the roller to bend and deform to varying degrees, and the inner cavity of the roller cannot be processed after welding and assembly. The uneven thickness of the roller wall is inevitable, and dynamic balance correction is required , and the dynamic balance is only corrected at the normal temperature of the roller, which cannot eliminate the problem of uneven thickness of the roller wall

For rollers like corrugated rollers that need to work under high temperature conditions, high temperature will inevitably lead to slight bending of the rollers during operation, resulting in high noise during operation and rapid wear of the rollers.

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