Composite Steel Screen Bar for Wear Resistance and Impact Absorption
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Solution Overview
Problem
Existing screen bars used in bar screens are prone to abrasive wear and breakage due to high dynamic loads and stress, requiring frequent replacement and complex manufacturing processes, which increases costs and reduces service life.
Innovation Solution
A screen bar made from a multi-layer steel composite material with a deformable core layer and harder outer cover layers, connected by roll cladding, providing enhanced wear resistance and deformability to absorb impacts without fracturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screen bars are made of hard steel material to resist abrasive wear, then wear resistance is improved, but the risk of material breakage increases due to reduced deformability
Solution Approach 1:
The screen bar is constructed with different steel grades in different regions: harder steel (e.g., 1.8933 or 1.8942) for the outer surfaces that contact abrasive material, and more deformable steel (e.g., 1.5510 or 1.5520) for the core regions that experience dynamic loads. This spatial differentiation of material properties resolves the contradiction between wear resistance and deformability.
Solution Approach 2:
The screen bar uses a composite structure combining multiple steel materials with different properties within a single component. The composite design integrates hard, wear-resistant steel layers with softer, more ductile steel layers, allowing the component to simultaneously exhibit high wear resistance at the surface and high deformability in the core to absorb impacts without fracturing.
2Strength
If screen bars are made of spring steel with good elastic deformation properties, then impact absorption is improved, but wear resistance deteriorates under abrasive conditions
Solution Approach 1:
The screen bar is constructed with different steel grades in different regions: harder steel (e.g., 1.8933 or 1.8942) for the outer surfaces that contact abrasive material, and more deformable steel (e.g., 1.5510 or 1.5520) for the core regions that experience dynamic loads. This spatial differentiation of material properties resolves the contradiction between wear resistance and deformability.
Solution Approach 2:
The screen bar uses a composite structure combining multiple steel materials with different properties within a single component. The composite design integrates hard, wear-resistant steel layers with softer, more ductile steel layers, allowing the component to simultaneously exhibit high wear resistance at the surface and high deformability in the core to absorb impacts without fracturing.
3Reliability
If a wear-resistant coating is applied to screen bars, then wear resistance is improved, but manufacturing complexity increases and thermal distortion may occur
Solution Approach 1:
The screen bar uses a composite structure combining multiple steel materials with different properties within a single component. The composite design integrates hard, wear-resistant steel layers with softer, more ductile steel layers, allowing the component to simultaneously exhibit high wear resistance at the surface and high deformability in the core to absorb impacts without fracturing.
Solution Approach 2:
Instead of applying a separate coating layer, the wear-resistant property is achieved by changing the material composition parameter of the screen bar itself, using hard steel grades (e.g., 1.8933, 1.8942) for the outer layers. This eliminates the need for additional coating processes and associated thermal distortion risks while maintaining wear resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite steel sheet structure offers a fivefold increase in service life and reduced production costs by combining high wear resistance with improved deformability, effectively handling dynamic loads and abrasive wear.
Implementation Method 1
the core layer consisting of a steel which is more deformable than the respective steel of the cover layers and as such is able to absorb elastic and, if necessary, plastic or partially plastic deformations without the risk of fracture
Implementation Method 2
the core layer consisting of a steel which is more deformable than the respective steel of the cover layers and as such is able to absorb elastic and, if necessary, plastic or partially plastic deformations without the risk of fracture
Implementation Method 3
the cover layers, which are made of a harder steel but have less deformability, offer the required wear resistance, in particular with regard to abrasive wear
Implementation Method 4
connected inseparably to one another by roll cladding
Data Source
Figure 1~2
AI summary
The present invention relates to a screen bar (1) for a bar screen, a bar screen and a method for producing a screen bar (1). The screen bar (1) according to the invention and the bar screen equipped with such a screen bar not only are more cost-effective to produce and have a long service life, but also have improved use properties. The method according to the invention furthermore makes it possible to produce such bar screens in a cost-effective manner. This is achieved according to the invention in that the screen bar (1) is produced from a composite steel sheet which is composed of at least three steel layers that are located one above the other and are connected non-detachably together by roll cladding, wherein the steel layer located in each case on the outside is in each case an outer layer (D1, D2) and the steel layer located between the outer layers is a core layer (K), and in that the core layer (K) has greater deformability than the outer layers (D1, D2) and the outer layers (D1, D2) exhibit greater hardness than the core layer (K).