Grinding Roller Reconditioning via Segmented Turning and Welding
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Solution Overview
Problem
The reconditioning of used grinding rollers with hard surface materials is labor-intensive due to their high hardness, requiring significant effort to restore the cylindrical shape and accommodate new profile bodies.
Innovation Solution
A method involving partial surface turning and welding of material layers to create bores for new profile bodies, allowing for customized diameter adjustments and anchorage depths based on wear conditions, reducing material and work expenditure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the complete surface of the roller body is turned to restore cylindrical shape, then the roller can be reused, but the reconditioning process requires considerable effort and time due to high hardness of the surface material
Solution Approach 1:
The roller surface is divided into different sub-areas based on wear severity. Instead of uniformly turning the entire surface, only the most heavily worn sub-area is turned, or less severely worn sub-areas are turned to match the diameter of the most heavily worn area. This segmentation approach significantly reduces the turning effort while still achieving the required cylindrical shape restoration.
Solution Approach 2:
Different sub-areas of the roller surface receive different treatments based on their local wear conditions. Heavily worn areas undergo turning, while less worn areas may be left as-is or receive lighter treatment. Material layers are welded onto specific sub-areas rather than the entire surface, creating a locally optimized reconditioning process that reduces overall effort.
2Productivity
If material layers are welded onto the turned surface, then the diameter is increased and new profile bodies can be accommodated, but the process complexity increases
Solution Approach 1:
Material layers are welded onto only the turned sub-areas rather than the entire roller surface. This partial action approach increases productivity by reducing the welding scope while still achieving the necessary diameter increase and profile body accommodation in the critical worn areas.
Solution Approach 2:
The welding process is segmented to apply material layers only to specific sub-areas that require diameter restoration. This segmentation simplifies the overall process by avoiding unnecessary welding on already adequate areas, thereby reducing process complexity while maintaining productivity.
3Reliability
If new bores are made and profile bodies are inserted, then the roller functionality is restored, but the material and work expenditure increases
Solution Approach 1:
New bores are created and profile bodies are inserted only in the sub-areas where wear has occurred, rather than replacing all profile bodies across the entire roller. This local quality approach restores roller functionality in the critical areas while minimizing material expenditure by avoiding unnecessary replacement in less worn areas.
Solution Approach 2:
Instead of discarding the entire roller or replacing all profile bodies, the method selectively replaces only the worn profile bodies in specific sub-areas. The remaining functional profile bodies are retained and reused, thereby reducing material expenditure while maintaining roller reliability.
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
This approach enables a cost-effective and time-saving reprocessing of used grinding rollers by evenly out the worn surface with minimal material and work, accommodating varying wear levels across the roller body.
Implementation Method 1
A layer of material to increase the diameter is then applied at least to the machined surface in a welding process
Data Source
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AI summary
The invention relates to a method for reconditioning a used grinding roller of a bed grinding mill having profiled members which are mounted in bores of the roller element by a part of their length, the other part of their length projecting beyond the surface of the roller element. For the reconditioning, the worn surface of the roller element is turned following removal of the worn profiled members and a material layer is applied in a welding process. The material layer is then provided with bores for receiving new profiled members. Such a method enables a particularly cost-effective reconditioning.