In the rolling industry, the Work rolls is one of the main components of the rolling mill. Its surface quality and rolling force will gradually decrease with the increase of use time, thus affecting the quality and output of rolled products. Therefore, the work rolls need to be replaced regularly.
The following are the main reasons for replacing work rolls:
Maintain product quality: As the work rolls are used over time, their surfaces will be subject to wear and oxidation, which will lead to a decrease in the surface quality of the rolled products. In order to maintain the high quality standards of the product, the work rolls need to be replaced regularly.
Improve production efficiency: Wear and oxides will affect the rolling force and rolling accuracy of the work rolls, resulting in reduced rolling efficiency. Replacing new work rolls can restore their initial performance and improve rolling efficiency.
Avoid equipment damage: If the work roll is severely worn or faulty, failure to replace it in time may cause equipment failure or damage, and may even affect the stable operation of the production line. Regular replacement of work rolls can prevent equipment failure and damage.
Maintain safe production: During the rolling process, damage to the work rolls may lead to equipment failure, product quality issues, and even personal safety issues. Regular replacement of work rolls can ensure the safe operation of equipment and the safety of employees.
Preparations before changing rollers
1. Confirm the rolling mill that requires roll replacement, and determine the roll diameter and roll width required for roll replacement.
2. Confirm whether the new roller is in place, and check whether the appearance and size of the roller meet the requirements.
3. Check the transmission system of the rolling mill to ensure that the rolling mill is in a stopped state.
4. Turn off the hydraulic system of the rolling mill and drain the hydraulic oil.
5. Prepare the necessary tools and equipment, such as cranes and trucks, and provide sufficient space and safety equipment.
6. Provide training to operators to ensure that they can perform roll changing operations correctly.
Roll changing procedure
1.Remove the old roller
a. Use a crane to remove the old rollers from the rolling mill.
b. Move the old rollers to the designated storage area and mark them clearly.
2.Install new roller
a. Use a crane to install the new roll onto the rolling mill.
b. According to the size and weight of the roller, select the corresponding support equipment for installation.
3. Calibrate the rolling mill
a. Calibrate the new roller and adjust the horizontal and vertical differences between rollers to ensure normal operation of the rolling mill.
b. Adjust the transmission system of the rolling mill, confirm that the transmission system of the rolling mill meets the requirements, and make necessary repairs and replacement parts.
4. Test the rolling mill
a. Carry out tests to check whether the rolling mill is operating normally.
b. Carry out trial rolling to confirm whether the quality and effect of the new roll meet the requirements.
5. Restart the rolling mill
a. Re-inject hydraulic oil, start the hydraulic system, and perform necessary inspections.
b. Restart the rolling mill and carry out rolling production.
Precautions
1. A safety inspection must be carried out before changing the roller to confirm that there is enough space for the roller change and to provide sufficient safety equipment.
2. When using a crane to remove and install rollers, you must pay attention to safety and the operation must be standardized and correct.
3. When calibrating the rollers, they must be carefully aligned to avoid excessive differences between the rollers.
4. When testing the rolling mill and trial rolling, a no-load test must be performed first to ensure that the rolling mill is operating normally before trial rolling can be carried out.
5. Pay attention to the injection and venting of the rolling mill hydraulic system, and confirm that the air pressure and oil pressure are safe and meet the requirements.
In short, every link must be carefully checked when performing roll changing operations in a rolling mill to ensure operating specifications and safety. Through effective roll replacement procedures and correct operating techniques, the quality and effect of the rolls can be ensured, and production efficiency and safety can be improved.
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