Rolling Mill Lubricant Distribution for Wear Reduction
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Solution Overview
Problem
In hot rolling processes, uneven wear and roughness occur in the axial direction of rolling rolls due to inconsistent lubricant distribution, making it difficult to suppress these issues with existing methods like water injection and gas atomization.
Innovation Solution
The method involves adjusting the lubricant supply from spray nozzles, with increased amounts at the ends and decreased amounts at the center of the rolling roll, using internal and external mixing type two-fluid spray nozzles, and controlling the lubricant and gas pressures to optimize lubricant distribution and reduce wear and roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricant is supplied uniformly to the entire rolling roll surface, then the overall lubrication effect is improved, but uneven wear and roughness in the axial direction cannot be suppressed
Solution Approach 1:
The patent applies local quality by differentiating the lubricant supply amount across different axial positions of the rolling roll. Specifically, the lubricant supply amount is set to be larger at the both ends in the axial direction and smaller at the center, creating a non-uniform distribution that addresses the specific wear patterns at different locations. This resolves the contradiction by maintaining overall lubrication while preventing uneven wear through localized supply adjustments.
2Reliability
If the lubricant supply amount is increased at the both ends, then wear at the ends is reduced, but the total lubricant consumption increases
Solution Approach 1:
The patent applies parameter changes by optimizing the lubricant supply distribution pattern to concentrate supply at the both ends in the axial direction where wear occurs, while reducing supply at the center. This parameter optimization ensures that lubricant is delivered where most needed, improving wear resistance at critical locations while minimizing overall lubricant consumption through targeted rather than uniform distribution.
3Reliability
If multiple spray nozzles are used to cover the entire roll surface, then complete lubrication coverage is achieved, but the complexity of the lubrication system increases
Solution Approach 1:
The patent applies local quality by strategically positioning and configuring spray nozzles to achieve differential lubricant distribution. The spray nozzles are arranged and configured to deliver larger amounts of lubricant at the both ends in the axial direction and smaller amounts at the center, achieving complete coverage while optimizing the distribution pattern to prevent uneven wear without requiring excessive numbers of nozzles.
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 effectively suppresses uneven wear and roughness in the axial direction, prolongs roll exchange periods, prevents product defects, and stabilizes the roll profile, improving the precision of metal material control.
Implementation Method 1
the method of rendering, not a semisolid grease, but a liquid lubricant which is used in the water injection method into an atomized or particulate state and spraying and supplying this to a roll together with a noncombustible gas
Implementation Method 2
lubricated rolling is performed for lightening the load on the rolling rolls which are used as working tools, reducing wear or seizing
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Equipment for supplying lubricant for a rolling mill 20 of a rolling mill of a flat shaped metal material M comprises a plurality of spray nozzles 1a and 1b which spray a lubricant toward a rolling roll together with a gas in a particulate or atomized state, a lubricant feed device 2, 3, and 4 which feeds the spray nozzles a lubricant, and a gas feed device 5 and 6 which feeds the spray nozzles a gas. In the present invention, the amount of lubricant supplied from the side spray nozzles among the spray nozzles are made larger than the lubricant feed rate from the center spray nozzle. Further, the amount of lubricant supplied from the spray nozzles between these side spray nozzles and center spray nozzle are made not more than the amount of lubricant supplied from the side spray nozzles and not less than the lubricant feed rate from the center spray nozzle. Due to this, uneven wear and roughness is kept from occurring at the rolling roll in the axial direction of the rolling roll.