The world No. 1 in crude steel production steel plant, over 70% of the HSS for bar and wire are from us.

One Stop Solution For Tungsten Carbide Rolls​

WE can provide characteristic service and differentiated products according to the different conditions of rolling mill.

Tungsten Carbide Rolls

The tungsten carbide rolls is mainly used on the finishing mill for bar, deformed steel bar and common wire. In this way, we can greatly reduce the frequency of changing groove and roll, thus to reduce the labor intensity and improve the work efficiency. The surface quality and yield shall be improved to a maximrurn degree, which leads to a rernarkable ecornmoic benlefit.

According to the different working conditions of different stands and rolls, a variety of different grades of cemented carbide rolls have been developed.

Product design→ Roll blank design→ Roll blank manufacturing→ Roll blank acceptance→ Annealing→ Rough turning→ Ultrasonic flaw detection→ High temperature quenching→ Low temperature tempering→ Ultrasonic flaw detection→ Finishing→ Ultrasonic flaw detection→ Roll body grinding→ Roll numbering→ Inspection→ Cleaning → Packing → Shipping → Warehousing → Inspection → Use and Maintenance → On-site Communication → Design Improvement.

As can be seen from the flow chart, roll manufacturing forms a closed-loop system from product design, production and manufacturing, use and maintenance, and improved design, and the quality of rolls is constantly improving.

How to find a trustworthy Tungsten Carbide Rolls manufacturer
If you want to find a trustworthy Tungsten Carbide Rolls supplier with long-term cooperation, maybe you need to concern about as the following

Previous slide
Next slide

Production Process and Production Facilities

composite rolls

Raw material:

The main raw material is tungsten carbide powder. LMM funded 20,000,000.00 USD, and imported the carbide powder manufacture equipment in 2010.
Tungsten carbide powder is produced by APT, and burning in electric heating rotary calcination furnace, and then come into being blue tungsten oxide, then through burning and producing the tungsten powder.

Screened & Classified:

The tungsten powder is screened by a vibrating screen. And then through the air classification equipment, it is classified into different granularity.

Ball Milling & Mixxing:

Tungsten powder in a certain proportion, adding carbon black and other additives after ball milling and mixing.

High Quality TC Powder:

The tungsten powder with good carbon black is added to the intermediate frequency carbonization furnace. In the end, the WC the powder was milled by the ball milling machine, and the high quality tungsten carbide powder was produced.

Forming Powder:

The WC powder, cobalt powder, and other rare elements are formulated in good proportion. Join the ball mill through the 24 hours of wet grinding, and mixed into the forming powder, then put them into the spray drying tower.

Press & Burning:

Compression molding will be prepared and put the powder into the mold, press molding with a hydraulic press; Put the roughcast into the furnace and burn it into the roll roughcast.

Finish Machine:

Through flat grinding, internal hole grinding, and cylindrical grinding comes into being the product of the ring. Also according to different rolling, different rolling mills, processed into wire grooved roll rings, wire thread roll rings, bar combination rolls, and roll steel.

Recommended applications of grades for carbide roll rings

GradeRecommended applications
LMM08RMaximum hardness, excellent wear resistance in the series. Used in the last 1~2 stands of good high-speed rolling mills for rolling common and hard steel bars.
LMM10RHigher wear resistance. Mode rate impact resistance in the series. Used in the last 1~2 stands of good high-speed finishing rolling mills for rolling common and hard steel bars.
LMM12RHigh wear resistance and corrosion resistance. Used in the last 1~4 stands of finishing mills.
LMM15RModerate wear resistance and impact resistance, good for general purpose. Used in the last 1~4 stands or all stands of finishing mills.
LMM18RGood toughness and thermal crack resistance, good for general purpose. Used in most stands of the finishing mills and the rear stands of common mills.
LMM20RBest for general purposes. Used in the front stands of good rolling mills and in the rear stands of common rolling mills.
LMM25RUsed in the first and second stands of finishing rolling mills and in the stands of pre-finishing rolling mills. For every stand of rolling lines for tow speed rolling low precision and unstable operations.
LMM30RMaximum binder content in LMMR series, good toughness and thermal crack resistance. Used in the stands of pre-finishing rolling mills and for rolling rings for hot rolling of ribbed steel.
LMM32RWith good toughness and impact resistance, used for bar, deformed bar finish stand rolling.
GradeRecommended applications
LMM06HIt possesses the highest hardness and the best wear-resistance among all the varieties of cemented carbide roll rings, thus used for the rolling of common wire and hard wire on the last 1~2 stands of high- speed wire rod finishing mill.
LMM08HIt possesses better wear-resistance and moderate impact-resistance with the hardness second to LMM06H among all the varieties, thus used at the last two stands of high-speed wire rod finishing mill.
LMM10HIt possesses the moderate wear-resistance and impact resistance, thus used at the last 3~4 stands of high-speed wire rod finishing mills.
LMM15HModerate wear resistance and impact resistance, good for general purpose. Used in the last 1~4 stands or all stands of finishing mills
LMM20HBest for general purpose. Used in the front stands of good rolling mills and in the rear stands of common rolling mills.
LMM25HMaximum binder content in LMMH series, good toughness and thermal crack resistance. Used in the stands of pre-finishing rolling mills and for roll rings for hot rolling of ribbed steel.
LMM30HMaximum binder content in LMMH series, good toughness and thermal crack resistance. Used for roll rings for hot rolling of ribbed steel and in the stands of pre-finishing rolling mills.
LMM32HWith good toughness and impact resistance, used for bar, deformed bar finish standing rolling.
GradeRecommended applications
YGR20High wear resistance and corrosion resistance. Used in the last 1~2 stands of finishing mills.
YGR25High wear resistance and corrosion resistance. Used in the last 1~3 stands of finishing mills.
YGR30Good toughness, wear resistance, corrosion resistance and thermal crack resistance. Used in the middle and rear stands of finishing mills.
YGR40Good roughness and thermal crack resistance, good for general purpose. Used in the most stands of the finishing mills and in the rear stands of common mills.
YGR45Good toughness and thermal crack resistance. Used in the front stands of finishing mills.
YGR55Good impact resistance. Used in the stands of pre-finishing rolling mills for hot rolling ribbed steel bars and they can be machined with turning and milling.
YGR60Good impact resistance. Used for hot rolling ribbed steel bars and in the first and second stands of pre-finishing rolling mills.
YGH40TWith good toughness and shock resistance, used for preferably high speed wire rolling machine, rolling small size deformed bar finish stand.
YGH45TWith good toughness and shock resistance, used for general high speed wire or common rolling machine, rolling small size deformed bar finish stand

Advantages of Tungsten Carbide Rolls

HBW05 is a new type of material specially developed by our company for KOCKS rolling mill bar production line. The hardness of the roll surface is HSD84-89, the uniformity of the roll surface hardness: ≤3HSD, the hardness drop/mm: ≤2HSD. The hardness difference of 3 roller rings of the same hole type is less than or equal to 3HSD. Single grinding amount (reduction): ≤1 mm. The material has high wear resistance and impact toughness under thermal load, so the product has high wear resistance and impact toughness, no ring burst phenomenon, and low processing difficulty. Its steel passing capacity can reach 60-80% of the cemented carbide roller ring, the price is less than 50% of the alloy roller ring, and the frequency of slot changing can reach 2 shifts.

It can be seen from the metallographic photos that the metallographic structure of the Cementer carbide roll is much better than other materials in terms of the shape, quantity, size and distribution of carbides, as well as the matrix structure and grain size.

During the use of Cementer carbide roll , under good cooling conditions, a thin and dense oxide film is formed on the surface of the roll body. This uniform, thin and dense oxide film can exist for a long time without falling off, so that the wear resistance of the Cementer carbide roll is significantly improved.

  • Cementer carbide roll have good thermal stability, and the roll surface has high hardness and good wear resistance at rolling temperature.
  • Cementer carbide roll has good hardenability, and the hardness from the surface of the roll body to the inside of the working layer hardly decreases, thus ensuring that the roll has the same good wear resistance from the outside to the inside.

Main chemical composition of the material

composition

C

Si

Mn

P

S

Cr

Proportion(%)

1.3-1.6

0.3-1.0

0.4-1.2

≤0.03

≤0.03

3.75-4.4

composition

Ni

Mo

V

W

Nb

Co

Proportion(%)

0.5-1.5

3.0-6.0

3.0-6.0

4.0-6.5

0.5-1.5

≤1.0

Testing standards

Design specifications and standards for manufacturing, quality control and inspection

The relevant standards of the roller ring are as follows:

  • Anti-rust packaging implements GB/T1504 and GB/T1503-2008 standards.
  • Sampling method of samples for chemical analysis of GB222 steel and allowable deviation of chemical composition of finished products
  • GB223 Chemical Analysis Methods of Steel and Alloy
  • GB/T13313 Roller Shore Hardness Test Method
  • GB/T1804 General Tolerances Tolerances of linear and angular dimensions without tolerances
  • GB/T1503-2008 National Standard for Cast Steel Rolls

    Testing regulations:

  1. Check the size and surface quality of each part one by one;
  2. Carry out ultrasonic flaw detection three times one by one;
  3. Carry out hardness test piece by piece;
  4. The depth of the hardened layer of the roll body is affected by the manufacturing process.
Precautions for use

Before determining the grade of cemented carbide for every stand, we shall have a thorough understand about theirproperties so as to make the correct choice (Please refer to the Product manual).

The sleeve insertion and assmbly of cemented carbide roll rings shall be carried out in accordance with the requirementsof precision. There shall be appropriate space between the roll rings and axle or between the roll rings and sleeve. The fit is neither tight nor loose. You should check whether the roll rings contorms to the technological requirement and cleanthe mounting surface of roll rings, sleeve and axle before the installation. it is prohibited to beat the roll rings with hammeror other hard things while assemblying.

For YGH series medium or weak alkali water of PH>7.2
YGRFor YGR series or PH<7.2 weak acid water of PH>7.2
The content of solid particles in the water<15 milligram/L

lt is inevitable to find the microcrack on the rolling groove. The microcrack will gradually extend, stretch and deepen. The groove shall be repaired immediately while the depth of crack reaching 0.2-0.4mm. Otherwise, the crack will deepen quickly, which leads to a risk of broken roller. The range of normal yield is reguated as follows:

Stands of pre-finishing rolling mill: (3500-4000)tons

1-2 Stands of finishing rolling mill: (1800-2500)tons

3-4 Stands of finishing rolling mith(1800-2500)tons

5-6 Stands of finishing rolling mill: (1500-2000)tons

7-8 Stands of finishing rolling mill: (1500-2000)tons

9-10Stands of finishing rolling mill: (1200-1500)tons减

Stands for reducing diameters: (800-1200)tons

lt is normal to find the microcrack on the rolling groove. The groove shall be repaired immediately while the depth of crack reaching 0.2 mm. lt is necessary to prevent the roller from being broken. While repairing, we must ensure to remove the crack thoroughly. Otherwise, it will bring a potential risk to next rolling.It is difficult and inconvenient to check if the surface is polishing. To ensure the complete remove of microcrack, we can increase the grinding quantity. Under thenormal condition, the repair is controlled in the range of:

Roll rings for stands 9-10 of finishing rolling mill(0.4-0.6)mm
Roll rings for stands 1-8 of finishing roiling mill(0.7-1.2)mm
Roll rings for s~nds of pre-finishing rolling mill(1.2——2.0)mm

FAQs about tungsten carbide rolls

Carbide rolls can be used in the intermediate finishing section of the rolling mill.

LMM produces carbide rolls with outer diameters up to 550 mm.

To convert from cast iron or steel rolls to carbide rolls, LMM carbide roll product experts will work with the rolling mill to improve roll cooling, machining and handling capabilities. Most rolling mills can be easily changed from cast iron to tungsten carbide.

Due to their higher wear resistance, LMM tungsten carbide rolls last up to 20 times longer than cast iron rolls. This reduces mill downtime while increasing productivity and lowering operating costs

The minimum rolling speed that can be used with tungsten carbide rolls is one meter per second (1 m/s).

Proper cooling is essential to ensure optimal performance of carbide rolls. The recommended minimum pressure is 4 to 6 bar and 250 to 300 liters per minute per molding.

The Products Are Used In More Than 200 Rolling Production Lines

Our Clients Give The Best Feedback For Our Services

What do I need for offering a quote ?

Please offer us 2D or 3D drawings (with material, dimension, tolerance, surface treatment and other technical requirement etc.) ,quantity, application or samples. Then we will quote the best price within 24h.

Contact US Now !

We would be happy to help and advise if you have any questions or inquiries.