In the metal rolling process, rolls play a crucial role, and strictly adhering to their usage specifications is essential for ensuring production quality and operational safety. This guide is based on industry standards, covering the key steps in the roll usage process and providing comprehensive references for relevant operations.

Preparation Before Use

1. Roll Selection and Installation

Different rolling processes have distinct requirements for rolls, so rational selection is necessary. High-chromium cast iron rolls, with excellent heat resistance and wear resistance, are ideal for hot rolling processes and can withstand temperatures up to 1000°C. Alloy forged steel rolls, featuring high strength and good precision, are suitable for cold rolling processes and can ensure that product tolerances are controlled within strict ranges. Meanwhile, cemented carbide rolls perform optimally in profile rolling, especially for profiles with complex shapes.

During the roll installation process, it is necessary to ensure that the roll axis is at an accurate 90° perpendicular angle to the rolling line, with the parallelism tolerance controlled within 0.05mm/m. Laser alignment tools can effectively help achieve this high-precision requirement. At the same time, the bearing housing bolts should be tightened firmly to avoid adverse effects on roll performance due to vibration, or even the triggering of safety hazards.

2. Rolling Mill Parameter Setting

The rolling speed and reduction amount should be set according to the allowable load of the rolls. In accordance with engineering specifications, limiting the bending stress of the work rolls to within 300MPa can effectively prevent the rolls from spalling and breaking. Improper parameter setting will not only lead to premature wear of the rolls but also may cause high downtime losses.

Operation Key Points

1. Temperature Control and Cooling Lubrication

During the hot rolling process, the surface temperature of the rolls needs to be maintained between 600-800°C. At this time, a high-pressure water system with a pressure of no less than 2MPa should be used for uniform cooling to prevent thermal cracks from forming on the rolls. In the cold rolling process, the concentration of the emulsion needs to be maintained at 3%-5%. Through good lubrication, scratches on the rolled products and metal adhesion to the roll surface can be avoided.

2. Load Control

When adjusting the rolling force, the principle of gradual increase should be followed to avoid the generation of impact loads. For profile rolling, when the wear amount of the pass exceeds 0.5mm, the rolls should be replaced in a timely manner to ensure that the product quality meets the requirements.

3. Real-Time Monitoring

An online monitoring system equipped with sensors can conduct real-time tracking of key parameters such as roll temperature, vibration (with the vibration frequency controlled within 50Hz), and rolling force. Once abnormal conditions such as a sudden temperature rise are detected, the shutdown procedure can be activated immediately, thereby avoiding major equipment damage and reducing maintenance costs and downtime.

Strict compliance with the above specifications can not only give full play to the performance advantages of the rolls, extend their service life but also significantly improve the overall efficiency of the metal rolling process, creating higher economic benefits for enterprises.