Method for manufacturing seamless cathode roller and seamless cathode roller

Abstract

The invention relates to the field of cathode roller manufacturing, and provides a seamless cathode roller manufacturing method and a seamless cathode roller. The seamless cathode roller manufacturing method comprises the steps that a cast ingot and a roller shaft are prepared; forging the cast ingot for multiple times to obtain an annular rolled blank; rolling and heat treatment are conducted on the rolled blank, so that the rolled blank reaches the needed size, and a roller blank is obtained; the inner side and the outer side of the roller blank are machined at the same time through an inner and outer circle machine, and the roller is obtained; and assembling the roller and the roller shaft to obtain the seamless cathode roller. According to the manufacturing method of the seamless cathode roller and the seamless cathode roller, the cast ingot is subjected to the procedures of multiple times of forging, rolling, heat treatment, inner and outer circle machining and the like, the roller meeting the requirement is prepared, the spinning procedure in the conventional roller preparation process is omitted, and the net-shaped grain problem caused by spinning pressure machining is eliminated.

Description

Technical Field

[0001] The present application relates to the field of cathode roller manufacturing, and in particular to a method for manufacturing a seamless cathode roller and a seamless cathode roller. Background Art

[0002] The cathode roller is a key component in the field of electrolytic copper foil production. The conventional cathode roller production method prepares the roller shaft and roller drum separately, and then assembles the roller shaft and roller drum. Among them, the roller drum is processed from raw materials through multiple processes. Among the multiple processes, there is a spinning process. Spinning is a method of rotating the material and applying pressure to further adjust the shape and size of the material, so as to process the material into the desired shape.

[0003] The spinning process is complicated, and the spinning effect is easily affected by the precision of the spinning machine and fluctuates, resulting in the appearance of mesh patterns on the surface of the cathode roller during the spinning process. The mesh patterns will directly affect the performance and life of the cathode roller. Summary of the invention

[0004] In order to solve the problem of mesh patterns on the surface of the cathode roller, the present application provides a method for manufacturing a seamless cathode roller and a seamless cathode roller.

[0005] In a first aspect, the present application provides a method for manufacturing a seamless cathode roller, comprising the following steps: Preparation of ingots and rollers.

[0006] The ingot is forged multiple times to obtain a ring-shaped rolling billet.

[0007] The rolled stock is rolled and heat treated to make the rolled stock reach a desired size, thereby obtaining a roller stock.

[0008] The inner side and the outer side of the roller blank are processed simultaneously by an internal and external circular knitting machine to obtain a roller.

[0009] The roller is assembled with the roller shaft to obtain a seamless cathode roller.

[0010] By adopting the above scheme, the ingot can eliminate internal defects after multiple forgings and initially form an annular structure; then, by rolling and heat treating the annular rolling stock, the mechanical properties of the rolling stock can be improved, and the shape and size of the rolling stock can be further adjusted to obtain a roller stock; then, the inner and outer sides of the roller stock are processed by internal and external circular knitting machines to complete the final size and shape adjustment to obtain a roller; finally, the roller and the roller shaft are assembled to obtain a seamless cathode roller. After multiple forging, rolling, heat treatment, internal and external circular knitting processes, the ingot can be directly processed into a roller without going through a spinning process, avoiding the appearance of mesh patterns.

[0011] Preferably, the step of forging the ingot multiple times comprises: First forging: The ingot is heated to a temperature t1, and then the ingot is forged and deformed to obtain a first blank.

[0012] Second forging: heating the first blank to a temperature t2, t2<t1, and then forging and deforming the first blank to obtain a second blank.

[0013] The third forging: the second blank is heated to a temperature t3, t3<t1, and then the second blank is forged, deformed and punched to obtain a third blank.

[0014] Fourth forging: heating the third blank to a temperature t4, t4<t1, and expanding the hole of the third blank to obtain the rolled blank.

[0015] By adopting the above scheme, the ingot can be forged multiple times, so that its overall performance is gradually improved. The first forging temperature is relatively high, which is convenient for quickly breaking the coarse structure inside the ingot. The subsequent forging temperature is relatively low to avoid overheating or even overburning caused by long-term high temperature, which in turn causes abnormal growth of grains inside the ingot.

[0016] Preferably, t3>t2.

[0017] By adopting the above scheme, the plastic deformation ability of the ingot during the third forging process is stronger than that during the second forging process, thereby making it possible to eliminate the quality defects that were not resolved or occurred during the second forging process during the third forging process.

[0018] Preferably, the forging deformation includes a roughening and lengthening process.

[0019] By adopting the above technical scheme, the microstructure and performance of the ingot can be better controlled during multiple forging processes, and the roughening and stretching process can effectively improve the density and mechanical properties of the material, thereby ensuring that the final rolled billet has excellent mechanical properties and stability.

[0020] Preferably, the step of rolling the rolled stock to make the rolled stock reach a desired size includes: connecting a plurality of ring-shaped rolled stock.

[0021] By adopting the above technical solution, the manufacturing of large-sized rollers can be completed by segmented forging, which reduces the manufacturing difficulty and improves the manufacturing progress. Specifically, multiple ingots are forged multiple times to obtain multiple rolling blanks, and then the multiple rolling blanks are connected, rolled and heat-treated. During the high-temperature rolling and heat treatment process, the size differences between the multiple rolling blanks can be eliminated, the connection strength can be improved, and a large-sized roller blank with excellent performance can be obtained.

[0022] Preferably, the step of rolling the rolled stock to make the rolled stock reach a desired size comprises: First rolling: rolling the rolled stock at a temperature of t5, so that the rolled hot size of the rolled stock gradually increases to a preset size, and the rolling deformation ranges from 35% to 45%.

[0023] Second rolling: rolling the rolled billet again at temperature t6, so that the rolled hot size of the rolled billet gradually increases to a desired size.

[0024] By adopting the above technical solution, the size of the rolled stock can be accurately adjusted. The deformation range of the first rolling is controlled between 35% and 45%, so that a larger deformation can be achieved without damaging the rolled stock, thereby shortening the rolling cycle; the size of the rolled stock is adjusted to the required size in the second rolling.

[0025] Preferably, the internal and external cylindrical machine is an internal and external cylindrical grinder, and the internal and external cylindrical grinder is used to grind the inner and outer sides of the roller blank at the same time.

[0026] By adopting the above technical solution, grinding the roller blank can improve the surface quality, eliminate defects, and complete the final size adjustment. The inside and outside can be ground at the same time, shortening the manufacturing cycle.

[0027] Preferably, the step of assembling the roller with the roller shaft comprises interference fitting the roller with the roller shaft.

[0028] By adopting the above technical solution, the interference fit between the roller and the roller shaft can improve the overall structural strength and stability of the seamless cathode roller, ensuring that it will not loosen or fall off during high-speed operation, thereby extending the service life and improving production efficiency. In a second aspect, the present application further provides a seamless cathode roller, which is manufactured using any of the above-mentioned methods for manufacturing a seamless cathode roller.

[0029] The manufacturing method of the seamless cathode roller and the seamless cathode roller of the present application are prepared into a roller that meets the requirements by subjecting the ingot to multiple forging, rolling, heat treatment and internal and external cylindrical machining processes, thereby eliminating the spinning process in the conventional roller preparation process and the mesh pattern problem caused by the spinning pressure processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a flow chart of the method for manufacturing the seamless cathode roller provided in the present application.

[0031] Figure 2 It is a structural schematic diagram of the internal and external cylindrical grinder provided in this application.

[0032] Figure 3 It is a partial top view of the internal and external cylindrical grinder provided in this application.

[0033] Description of reference numerals: 1. Base; 2. Clamping seat; 3. Mounting seat; 4. First feeding assembly; 41. Cylinder; 42. Connecting plate; 43. Connecting rod; 44. First sliding seat; 5. Second feeding assembly; 51. Bidirectional lead screw; 52. Third motor; 53. Second sliding seat; 6. First motor; 7. Second motor; 8. Inner grinding roller; 9. Outer grinding roller. DETAILED DESCRIPTION

[0034] The following is combined with Figure 1-3 This application is described in further detail.

[0035] like Figure 1 As shown, the embodiment of the present application discloses a method for manufacturing a seamless cathode roller, comprising the following steps: S100: Preparation of ingots and rollers.

[0036] The material of the roller can be alloy steel or titanium. There are many ways to prepare the roller, such as heating and melting the raw materials and pouring them into a mold to cool and shape them. The preparation of the ingot can also adopt the above-mentioned mold forming method to obtain an ingot of suitable size, which is convenient for subsequent ingot processing.

[0037] S200: The ingot is forged multiple times to obtain a ring-shaped rolled billet.

[0038] The forging process can be divided into four steps: First forging: The ingot is heated to temperature t1 along with the furnace temperature by a heating furnace and other equipment. The range of t1 can be 985℃-1020℃, such as 990℃, 1000℃ or 1010℃. Within this range, the ingot can obtain good plastic deformation ability, which is convenient for forging the ingot. At the same time, the temperature will not be too high, and the phenomenon of material performance degradation such as abnormal growth of grains inside the ingot caused by overheating and overburning can be avoided as much as possible.

[0039] After the temperature is raised to t1, it is necessary to keep the temperature for a period of time to ensure that the temperature of the ingot is uniform. The holding time is set according to the specific material, size and other parameters of the ingot. For example, the holding time can be set according to the thickness of 55min / 100mm. While ensuring uniform temperature, avoid heating for too long to cause material performance degradation.

[0040] After ensuring uniform temperature, the ingot is forged and deformed to obtain the first blank. Specifically, the forging deformation method can be: through operations such as roughening and stretching, the coarse structure is broken, the structure becomes finer and more uniform, and the overall performance of the material is improved. In addition, the high temperature and deformation during the forging process can refine the grains of the material, thereby improving the strength and toughness of the material.

[0041] Second forging: the first blank is heated to a temperature t2 along with the furnace temperature, and the range of t2 is: 855°C-875°C, for example, it can be 860°C, 865°C or 870°C.

[0042] Then the heat preservation treatment is carried out, and the heat preservation time can be set according to the setting basis in the first forging process (according to the wall thickness of the material).

[0043] Finally, the first blank is forged and deformed to obtain the second blank. Through forging deformation again (roughening and lengthening), the size can be further adjusted, internal defects can be eliminated, and grains can be refined to prepare for subsequent processing.

[0044] The third forging: the second blank is heated to a temperature t3 along with the furnace temperature, and the range of t3 is: 855°C-875°C, for example, it can be 860°C, 865°C or 870°C.

[0045] Then carry out heat preservation treatment, and the heat preservation time can be set according to the setting basis in the first forging process.

[0046] Afterwards, the second blank with uniform temperature is forged and deformed again to improve the material properties.

[0047] Finally, the second blank is punched to prepare for subsequent processing steps such as hole expansion, thereby obtaining the third blank.

[0048] Fourth forging: the third blank is heated to a temperature t4 along with the furnace temperature, and the range of t4 is 660°C-690°C, for example, 670°C, 680°C, etc.

[0049] Then carry out heat preservation treatment, and the heat preservation time can be set according to the setting basis in the first forging process.

[0050] Finally, the third blank is expanded by the horse frame expansion device, so that the third blank is expanded evenly and steadily to obtain a rolled blank. After the expansion process, the rolled blank is roughly annular, which can provide operating space for subsequent processing equipment.

[0051] In the above four forging processes, at the end of forging, the temperature of the workpiece (the name of the ingot at the end of the corresponding forging process, such as the first blank at the end of the first forging) should not be lower than 600°C to avoid the forging process being carried out at a lower temperature, which will increase the difficulty of forging and deteriorate the forging effect. Furthermore, since the temperature of the workpiece will change during the forging process, it is necessary to reheat it during the next forging to ensure the smooth progress of the process.

[0052] In the above four forging processes, the surface quality of the workpiece needs to be checked after each forging. If there are defects, they need to be repaired by grinding or other methods in order to proceed with subsequent processes.

[0053] Because the ingot has many internal defects and the internal structure of the material is coarse and uneven before forging, in order to improve the material performance as soon as possible and shorten the manufacturing cycle. Therefore, in the first forging process mentioned above, the roughing and drawing process generally needs to be performed multiple times, for example, three roughing and four drawing processes can be performed, and the roughing and drawing processes are performed alternately. In addition, during the forging process, the deformation of the material is generally greater than the deformation in the subsequent forging process, which requires the material to have good plasticity and deformation ability.

[0054] In order to effectively break up the coarse structure inside the ingot, the ingot needs to have good plasticity and deformation ability, so the value of the heating temperature t1 in the first forging process is relatively large. In the subsequent forging process, it is only necessary to further refine the internal structure of the ingot, and the requirements for plasticity and deformation ability can be appropriately reduced. Therefore, t2, t3 and t4 can all be less than t1.

[0055] Under the temperature t1 condition, the ingot will not overheat or overburn, but if the temperature is not well controlled, it may still cause the local temperature to be too high. Long-term high temperature may cause the material to overheat or even overburn. Overheating and overburning will affect the microstructure of the material (such as grain growth and recrystallization, etc.), reducing its mechanical properties and deformation capacity. By lowering the heating temperature, overheating and overburning of the material can be avoided, the growth rate of the grains will slow down, and even grain refinement may occur. Grain refinement can improve the strength and toughness of the material, and it is also beneficial to maintain the deformation ability of the material. In addition, lowering the heating temperature can also reduce the oxidation and decarburization of the material, thereby improving the surface quality and internal quality of the forging.

[0056] Therefore, by setting t2, t3 and t4 to be smaller than t1, it can be ensured that the material will not be overheated or overburned.

[0057] In some embodiments, t4<t3<t2<t1, by gradually reducing the heating temperature, the temperature change during the forging process can be more accurately controlled, thereby ensuring that the temperature of the forging at the end of forging is not lower than a critical value (such as 600°C) to avoid cracks and internal defects. In addition, gradually reducing the heating temperature can also reduce energy consumption and production costs. Among them, under the condition of t4, the material still has sufficient plasticity and deformation ability to perform hole expansion operations.

[0058] In some embodiments, t3>t2. During the second forging and the third forging process, both involve a re-forging deformation process. Since the plasticity and deformation temperature of the material are affected by temperature, when the third forging is performed, if the material is required to have better plasticity and deformation ability than the second forging, the temperature can be adjusted so that during the third forging, the heating temperature t3 is greater than the heating temperature t2 during the second forging.

[0059] For example, after the second forging, when checking the quality of the second blank, if defects such as stress concentration and pores are found, they need to be treated. At this time, there is no need to repair the defects separately, and the third forging can be carried out directly. By setting t3 greater than t2, the plasticity and deformation capacity of the second blank are better, and then the quality defects that are not solved or appear in the second forging are eliminated through the forging deformation in the third forging process.

[0060] In some embodiments, t2=t3. The temperature ranges of t2 and t3 are both in a moderate temperature range. Within this temperature range, the material has good plasticity and deformation ability, and is not prone to overheating and overburning. By setting t2=t3, the number of temperature control can be reduced, the complexity of the manufacturing process can be reduced, and the manufacturing cycle can be shortened.

[0061] S300: rolling and heat treating the rolled blank to make the rolled blank reach a desired size, thereby obtaining a roller blank.

[0062] The rolling process can be divided into two parts: First rolling: The rolled stock is heated to a temperature t5, which ranges from 655°C to 675°C, for example, 665°C. The rolled stock is then rolled by a rolling mill, so that the rolled hot size of the rolled stock gradually increases to a preset size. Through rolling, the internal structure of the material can become denser and the grains finer, thereby improving its mechanical strength, wear resistance, fatigue life and other properties. And the initial rolling can make the rolled stock gradually approach the desired annular shape, preparing for subsequent processing.

[0063] The rolling deformation of the first rolling is generally determined according to various factors such as the material quality. The optional range is 35%-45%, for example, 40%. Within this range, the internal grains of the material can be fully broken and refined, the internal structure is more uniform, and the initial rolling has enough deformation, which helps to shorten the rolling process. In addition, the deformation will not be too large to avoid defects such as cracks.

[0064] Second rolling: The rolled stock is heated to a temperature t6, which ranges from 655°C to 675°C, for example, 665°C. The rolled stock is then rolled again to complete a more refined forming process, and the rolled hot size of the rolled stock gradually increases to the required size. After the second rolling, the mechanical properties of the material become even better.

[0065] In the above two rolling processes, after heating the rolled blank, it is necessary to perform heat preservation treatment to ensure that the rolled blank is heated evenly. The heat preservation time can be set according to the setting basis in the first forging process.

[0066] After each rolling process mentioned above, the surface quality of the material still needs to be checked, and if there are defects, repairs are performed.

[0067] The heat treatment is mainly annealing. Specifically, the rolled stock can be placed in an annealing furnace and heated to a temperature t7, which ranges from 600°C to 630°C, such as 615°C. Then, the rolled stock is subjected to a heat preservation treatment for 2 to 3 hours, and finally, the rolled stock is allowed to cool naturally to room temperature along with the furnace temperature to obtain a roller stock.

[0068] The internal stress of the material can be eliminated through reasonable annealing temperature and annealing time, thus improving the stability and service life of the final roller. In addition, annealing can also refine the internal grains of the material and improve the plasticity and toughness of the roller.

[0069] S400: The inner and outer sides of the roller blank are processed simultaneously by the internal and external circular knitting machines to obtain a roller.

[0070] The internal and external cylindrical knitting machine may include an internal and external cylindrical grinder, which is used to grind the inside and outside of the roller blank at the same time to eliminate surface defects generated or left over from the previous processing process, and further adjust the size of the roller blank to obtain a roller with precise size.

[0071] like Figure 2 and Figure 3 As shown, for example, the internal and external cylindrical grinding machine includes a base 1, a clamping seat 2, a mounting seat 3, a first feeding assembly 4, a second feeding assembly 5, two first motors 6, two second motors 7, two internal grinding rollers 8 and two external grinding rollers 9.

[0072] The clamping seat 2 is rotatably arranged on the base 1. The clamping seat 2 includes a motor and a clamping head. The motor drives the clamping head to rotate, and the clamping head is used to clamp the roller blank.

[0073] The first feeding assembly 4 includes: a cylinder 41, a connecting plate 42, two connecting rods 43 and two first sliding seats 44. The two first sliding seats 44 are both slidably arranged on the mounting seat 3, the two inner grinding rollers 8 are rotationally connected to the two first sliding seats 44 in a one-to-one correspondence, the two first motors 6 are arranged in a one-to-one correspondence on the two first sliding seats 44, and the two first motors 6 are transmission-connected to the two inner grinding rollers 8 in a one-to-one correspondence. One of the first sliding seats 44 is hinged to the connecting plate 42 through a connecting rod 43, and the other first sliding seat 44 is hinged to the connecting plate 42 through another connecting rod 43. The cylinder 41 is connected to the connecting plate 42.

[0074] When it is necessary to grind the inner side of the roller blank, the inner grinding roller 8 is driven to rotate by the first motor 6, and then the connecting plate 42 is driven to move by the cylinder 41, so that the two first sliding seats 44 are moved closer to or farther away from each other, thereby making the inner grinding roller 8 closer to or farther away from the inner wall of the roller blank to complete the inner grinding process.

[0075] The second feeding assembly 5 includes: a bidirectional lead screw 51, a third motor 52 and two second sliding seats 53. The bidirectional lead screw 51 is rotatably connected to the mounting seat 3, and the third motor 52 is connected to the bidirectional lead screw 51. The two second sliding seats 53 are both threadedly connected to the bidirectional lead screw 51, and when the bidirectional lead screw 51 rotates, the two second sliding seats 53 move closer to or farther from each other. The two outer grinding rollers 9 are rotatably connected to the two second sliding seats 53 in a one-to-one correspondence, and the two second motors 7 are arranged on the two second sliding seats 53 in a one-to-one correspondence, and the two second motors 7 are transmission-connected to the two outer grinding rollers 9 in a one-to-one correspondence.

[0076] When it is necessary to grind the outer side of the roller blank, the outer grinding roller 9 is driven to rotate by the second motor 7, and then the bidirectional screw 51 is driven to rotate by the third motor 52, so that the two second sliding seats 53 are moved closer to or away from each other, and then the outer grinding roller 9 is moved closer to or away from the outer wall of the roller blank to complete the outer side grinding process.

[0077] The inner and outer cylindrical grinder provided in the embodiment of the present application grinds the inner side of the roller stock with two inner grinding rollers 8, which helps to improve the inner grinding efficiency. Compared with a single inner grinding roller 8, the double inner grinding rollers 8 have more contact points with the roller stock, which helps to reduce the probability of the roller stock jumping due to the single contact surface during the grinding process. Similarly, the use of double outer grinding rollers 9 for grinding helps to improve the outer grinding efficiency and helps to reduce the probability of the roller stock jumping. Furthermore, the inner and outer sides can be polished at the same time, which helps to shorten the manufacturing cycle.

[0078] S500: Assemble the roller and the roller shaft to obtain a seamless cathode roller.

[0079] The roller and the roller shaft can be assembled by interference fit. For example, the roller shaft is cooled by liquid nitrogen, and the roller shaft shrinks and can be inserted into the center hole of the roller. After the roller shaft returns to room temperature, the roller and the roller shaft are assembled. Of course, in order to improve the connection strength, bolts and nuts can also be used for screw connection.

[0080] In some embodiments, the step of rolling the rolled billet to achieve a desired size also includes: connecting a plurality of ring-shaped rolled billets.

[0081] Specifically, for larger rollers, segmented forging can be used. That is, multiple ingots are forged into multiple rolling blanks, and then the multiple rolling blanks are connected by welding or welding, and then rolled, heat treated, and processed by internal and external cylindrical machining to finally obtain large-sized rollers. Among them, the high-temperature rolling process can eliminate the size differences between multiple rolling blanks, so that the diameters of each part of the roller blank obtained after rolling are basically equal. Even if they are not equal, they can be adjusted in the subsequent internal and external cylindrical machining process to ensure that a qualified roller is obtained.

[0082] The present application also provides a seamless cathode roller, which is manufactured by using the manufacturing method of the seamless cathode roller in any of the above embodiments.

Claims

1. A method for manufacturing a seamless cathode roller, characterized in that: The following steps are involved: Preparation of ingots and rollers; Forging the ingot multiple times to obtain a ring-shaped rolled billet; Rolling and heat treating the rolled stock to make the rolled stock reach a desired size to obtain a roller stock; The inner side and the outer side of the roller blank are processed simultaneously by an internal and external circular knitting machine to obtain a roller; The roller is assembled with the roller shaft to obtain a seamless cathode roller.

2. The method for manufacturing a seamless cathode roller according to claim 1, characterized in that: The step of forging the ingot multiple times comprises: First forging: heating the ingot to a temperature t1, and then forging and deforming the ingot to obtain a first blank; Second forging: heating the first blank to a temperature t2, t2<t1, and then forging and deforming the first blank to obtain a second blank; The third forging: heating the second blank to a temperature t3, t3 < t1, and then forging and punching the second blank to obtain a third blank; Fourth forging: heating the third blank to a temperature t4, t4<t1, and expanding the hole of the third blank to obtain the rolled blank.

3. The method for manufacturing a seamless cathode roller according to claim 2, characterized in that: t3>t2.

4. The method for manufacturing a seamless cathode roller according to claim 2, characterized in that: The forging deformation includes roughening and drawing processes.

5. The method for manufacturing a seamless cathode roller according to claim 1, characterized in that: The step of rolling the rolled stock to make it reach the required size includes: connecting a plurality of ring-shaped rolled stock.

6. The method for manufacturing a seamless cathode roller according to claim 1, characterized in that: The step of rolling the rolled stock to make the rolled stock reach a desired size comprises: First rolling: rolling the rolled stock at a temperature of t5, so that the rolled hot size of the rolled stock gradually increases, and the rolling deformation is in the range of 35%-45%; Second rolling: rolling the rolled billet again at temperature t6, so that the rolled hot size of the rolled billet gradually increases to a desired size.

7. The method for manufacturing a seamless cathode roller according to claim 1, characterized in that: The internal and external cylindrical machine is an internal and external cylindrical grinder, which is used to grind the inner and outer sides of the roller blank at the same time.

8. The method for manufacturing a seamless cathode roller according to claim 1, characterized in that: The step of assembling the roller with the roller shaft comprises interference fitting the roller with the roller shaft.

9. A seamless cathode roller, characterized in that: The seamless cathode roller is manufactured by the manufacturing method of the seamless cathode roller as described in any one of claims 1 to 8 above.

Images