Archive for category: Industry News

New progress in the manufacturing and application of large-scale mechanical rollers: Safety production and industry exchanges are equally important. Recently, a series of new progress has been made in the field of large-scale mechanical roller manufacturing, which not only improves production efficiency, but also expands the application field, and also puts forward higher requirements for safety production.
In terms of manufacturing, the application of new materials makes the rollers have higher strength and wear resistance, and increases the service life of the product. At the same time, advanced manufacturing technology also reduces energy consumption and emissions in the production process, reflecting the concept of green environmental protection.
In terms of application fields, large-scale mechanical rollers are not only widely used in traditional textile, food, medicine and other industries, but also gradually expand to emerging fields such as new energy and environmental protection. Its efficient and stable performance provides strong support for the development of these industries.

Safety production has always been the top priority of the roller manufacturing industry. Recently, the industry has strengthened safety production training and improved employees’ safety awareness and operating skills. At the same time, by introducing advanced safety monitoring equipment and technical means, the safety risks in the production process have been effectively reduced.
In addition, exchanges and cooperation within the industry are becoming more and more frequent. By holding seminars, exhibitions and other activities, enterprises and research institutions are able to share the latest technological achievements and market trends, which has promoted the rapid development of the entire industry.
Looking into the future, the large-scale mechanical roller manufacturing industry will continue to adhere to the development concept of innovation, greenness and safety, continuously improve product quality and application level, and make greater contributions to promoting the transformation and upgrading of my country’s manufacturing industry.

In the past, gears were usually made by casting, but now more and more gears are produced by forging.

1. Forging can provide higher strength and toughness. Gears are subjected to huge pressure and load during operation, so their materials must have sufficient strength and durability. In contrast, gears made by casting usually have internal defects and holes, which reduce the strength and toughness of the gears. The forging process can plastically deform the metal raw materials by heating and hammering, eliminate internal defects, and make the gear materials have higher strength and toughness.

2. Forging can provide higher precision and quality. During the casting process, liquid metal is filled through the mold and cooled and solidified, which may cause uneven shrinkage or deformation of the gear surface. These deformations affect the precision and quality of the gear. In the forging process, by heating and hammering the metal, the metal raw materials can be uniformly plastically deformed, thereby ensuring the precision and quality of the gear.

3. Forging can also save materials and costs. During the casting process, due to the free flow of liquid metal, a certain degree of waste will be generated. The forging process, on the other hand, presses the metal raw material into the desired shape without the need for additional material consumption. In addition, the forging process can also reduce production costs by reducing subsequent processing steps, such as reducing milling, grinding and other operations.

Fourth, the forging process also has the advantage of environmental protection. In the casting process, a large amount of fuel is often required to heat the metal, and a large amount of waste gas and waste slag is generated. The forging process can plastically deform the metal raw material by heating and hammering, and does not require a large amount of fuel, thereby reducing pollution to the environment.

Therefore, the forging process provides higher strength and toughness, higher precision and quality, material and cost savings, and environmental advantages. Therefore, the current forging process will play an increasingly important role in gear manufacturing.

As a processing and manufacturing tool, rollers are widely used in factories. Their functions cannot be replaced by other roller products. Of course, the quality requirements for rollers are also very high. After the roller is used for a period of time, various wear problems will occur. In serious cases, the roller may not be able to continue working.
The service life of the roller is generally 8 hours. After that, groove wear and crack fatigue will occur. If the grooves caused by wear are deep, steel sticking and jamming will occur. The plasma aluminum guide roller has obvious resistance to abrasive wear and thermal fatigue. After repairing the roller shaft, the effect is obvious. Plasma cladding technology is used to coat the surface of 45 steel with Al2O3-doped Fe-Ni-based high-temperature anti-wear alloy coating, which can improve the anti-wear and anti-cracking performance of the roller. The application of plasma cladding technology on rollers reduces the labor intensity caused by frequent replacement and reduces the wasted steel rolling work time in disassembly, assembly and transportation of rollers, and can increase the amount of steel rolled, saving a large amount of high-quality steel. At the same time, quality problems caused by roller damage can also be avoided.

From the introduction of the above article, we can know the methods to improve the service life of the rollers, which should be of great help to relevant people. There are many types of rollers on the market. The different materials used to make the rollers will have a great impact on the quality of the rollers and also on the performance of the rollers. For roller manufacturers, roller production needs to be carried out according to formal steps. Improper operation during the production process will greatly affect the quality of the rollers.

1. Rotary kiln kiln body parts wear and overall sinking. The rotary kiln is a large-load continuous operation equipment. After long-term operation, the rolling ring, supporting wheel, backing plate and other parts wear greatly, and the uneven foundation settlement causes the overall kiln body to settle. decreases, causing the tooth tip clearance to become smaller, causing vibration. Sometimes, although the overall kiln line does not drop, the support position close to the large ring gear drops, which also causes the large ring gear to vibrate. This is due to the foundation of the support position sinking or being severely worn, or due to improper kiln adjustment.
2. Caused by wear of connecting parts. The ring gear is connected to the kiln body through a spring plate pin. The ring gear itself is manufactured in sections and is integrated into a whole by using countersunk screws. After the pins, countersunk screws, and these connecting parts are worn, the ring gear components will loosen and the local ring gear will sink, which will also cause the tooth top clearance to become smaller and cause vibration. From a maintenance perspective, the only solution is to replace (or tighten) the corresponding screws. Of course, for countersunk screws, from the perspective of design and manufacturing, it is better to make the ring gear as a whole (or tightly connected) instead of connecting it with countersunk screws, so as to fundamentally eliminate the vibration cause (large tooth factor). The fact that the flaps are made to be turned over is another issue. Practice has proved that the large ring gear has a simple tooth shape and a low rotational speed. It can still operate normally after half of the tooth thickness is worn).

3. The cylinder at or around the ring gear is bent, causing the large ring gear to deflect excessively in the radial direction and cause vibration. This is manifested in the fact that during the meshing operation of the large ring gear and pinion, the top clearance is smaller for half a turn and smaller for half a turn. The vibration is also a periodic half-vibration. Therefore, the real cause of vibration is that the top clearance is too small.
4. Problems with the ring gear itself. The top clearance of the transmission gear is generally 0.2-0.25 times the module. Due to its large outer diameter and radial deflection of the large ring gear of the rotary kiln, the top clearance is 0.28 times the module plus 0.5-1mm. At the same time, it is required that the radial runout and axial deflection of the large ring gear should not be greater than 2mm after installation. Most of the large ring gears are caused by runout or deflection. Since the large ring gear is connected to the kiln body through the spring plate shaft pin, the large ring gear itself is made into two half rings and combined into a whole with countersunk screws.
5. Vibration caused by tooth thickness wear. The vibration caused by this reason appears as continuous and rhythmic vibration, which can be observed through the meshing of the large ring gear and pinion.
6. The pinion gear is not installed in place. In most rotary kilns, the large ring gear and the two pinion gears form an equilateral triangle in the ideal meshing state, but the angle has changed after long-term operation.

Roller shafts, gear shafts and large machinery non-standard parts are indispensable key components in modern industry. They play a vital role in their respective fields of application, ensuring product quality and performance through precise machining processes.

Rollers are widely used in steel, petroleum, chemical industry, machinery manufacturing and other industries, and withstand the test of heavy load and high-speed operation. Its processing technology involves steps such as material selection, heat treatment, cutting and surface treatment to ensure that the roller has sufficient strength and wear resistance.
As an important component in the mechanical transmission system, the gear shaft is responsible for transmitting power and torque. The processing process includes forging, heat treatment, finishing and gear grinding to achieve high-precision gear shape and Surface Quality. The addition of gear shafts requires strict compliance with technical specifications and standards to ensure transmission efficiency and stability.

Non-standard parts of large machinery are customized according to the special needs of customers and have unique structures and sizes. The processing technology is flexible and diverse, and may involve CNC machining, laser cutting, stamping and other technologies. The processing of non-standard parts requires full consideration of material, process and performance requirements to meet the specific needs of customers. These products play an irreplaceable role in their respective fields. Whether it is the load-bearing and transmission functions of rollers, the transmission function of gear shafts, and customized solutions for non-standard parts of large machinery, they all provide for the development of modern industry. strong support.