METHOD FOR MANUFACTURING EQUAL-HARDNESS CR5 BACK UP ROLL

Abstract

The present disclosure discloses a method for manufacturing an equal-hardness Cr5 back up roll. The method comprises the following steps: 1) preparing a steel raw material according to chemical components and weight percentage contents in a Cr5 back up roll material, and preparing a steel ingot according to a smelting procedure production process; 2) preparing a roller blank from the steel ingot according to a forging procedure production process; 3) performing thermal treatment on the roller blank; and 4) processing and detecting the roller blank to obtain an equal-hardness forged steel back up roll. The present disclosure solves problems that a hardness, an abrasion resistance, and a contact fatigue of a conventional forged steel back up roll are rapidly reduced in a middle and later use period, and prolongs a comprehensive use period and a service life of the back up roll.

Claims

1. A method for manufacturing an equal-hardness Cr5 back up roll, comprising the following steps: 1) preparing steel raw materials according to chemical components in weight percentages for a Cr5 back up roll, and obtaining a steel ingot according to a smelting procedure production process; 2) preparing a roller blank from the steel ingot according to a forging procedure production process; 3) performing thermal treatment on the roller blank; and 4) processing and detecting the roller blank to obtain the equal-hardness Cr5 back up roll.

2. The method according to claim 1, wherein the chemical components in weight percentages for the Cr5 back up roll are: 0.40%~0.70% of C, 0.20%~0.80% of Si, 0.20%~0.80% of Mn, 4.00%~5.00% of Cr, 0.20%~0.60% of Ni, 0.10%~0.80% of Mo, 0.10%~0.50% of V, P ≤ 0.015%, S ≤ 0.015%, and the balance Fe and an inevitable impurity.

3. The method according to claim 1, wherein the chemical components in weight percentages for the Cr5 back up roll material are: 0.55%~0.60% of C, 0.40%~0.45% of Si, 0.35%~0.38% of Mn, 4.50%~5.00% of Cr, 0.20%~0.60% of Ni, 0.60%~0.70% of Mo, 0.20%~0.30% of V, P ≤ 0.015%, S ≤ 0.010%, and the balance Fe and an inevitable impurity.

4. The method according to claim 1, wherein the smelting procedure for the steel ingot in step 1) comprises the following specific steps: A smelting the steel raw materials by using an electric arc furnace and a ladle furnace, testing chemical components and weight percentages of molten steel in the ladle furnace, and performing degassing in vacuum after the molten steel is tested to be qualified; and B injecting molten iron into a steel ingot mold in a vacuum environment to form the steel ingot, wherein the steel ingot mold has a small height-diameter ratio and a large taper, a section is in a multi-edge design, and a high-efficiency exothermic compound is used in a riser.

5. The method according to claim 1, wherein the steel ingot is heated and preserved for a period of time before the forging procedure in step 2), then transferred to an 80MN oil press for forging, and prepared into a forging blank through upsetting and drawing-out forging; during the forging process, methods of high-temperature slow forging, medium-temperature fast forging, and low-temperature slow forging are used; and the forging blank is turned after being subjected to a post-forging thermal treatment to obtain a fine-grain roller blank.

6. The method according to claim 5, wherein the steel ingot is heated at a temperature in a range of 1,200~1,300° C. before the forging for 20~30 h; and during the forging process, the high-temperature slow forging is performed at a temperature in a range of 1,100~1,300° C.; the medium-temperature fast forging is performed at a temperature in a range of 900~1,100° C.; and the low-temperature slow forging is performed at a temperature in range of 750~900° C.

7. The method according to claim 5, wherein the post-forging thermal treatment comprises the following specific processes: the forging blank is heated to 750~850° C., preserved for 10~20 h, then slowly cooled to 680~720° C., preserved for 30~40 h, and then annealed.

8. The method according to claim 1, wherein the thermal treatment of the roller blank in step 3) comprises the following specific steps: (1) preheating: preheating the processed roller blank in a trolley furnace at a preheating temperature in a range of 400~500° C., and heat-preserving the roller blank for 10~20 h; (2) transferring the preheated roller blank into an induction-type differential-temperature quenching device, wherein the induction-type differential-temperature quenching device has a surface temperature measurement precision of 0.1° C. and a surface temperature uniformity of ≤ 2° C., rapidly heating a steel blank to 950~1,050° C. in the induction-type differential-temperature quenching device at a speed of 15~20° C./min, and heat-preserving the steel blank for 100~150 min; (3) transferring the heated roller blank into a quenching device with a continuously controllable cooling speed for quenching, opening a pipeline by adjusting an electromagnetic valve, simultaneously detecting a flow rate and a pressure of the pipeline according to a flowmeter and a pressure gauge respectively, wherein the roller blank is rapidly cooled within an initial 20~30 min, water cooling is used in the rapid cooling stage, the flow rate is controlled to be 300~600 cubic meters/hour, then the flow rate is reduced, and the flow rate is controlled to be 150~250 cubic meters/hour, such that a working layer is a fully quenched martensite structure; and (4) tempering the quenched roller blank at a tempering temperature in a range of 300~500° C.

9. The method according to claim 1, wherein a surface hardness and a hardness drop of a roller body are detected by using a D-type mechanical Shore hardness tester in step 4), a hardness within 80 mm of a surface of the roller body is in a range of 60~75 HS, a hardness uniformity is ≤ 2 HS, a working layer is detected according to a metallographic detection method, and a metallographic structure within 80 mm of the surface of the roller body is a quenched tempered martensite structure.

Description

DESCRIPTION OF THE EMBODIMENTS

[0033] The present disclosure is further described in detail below with reference to the following examples.

[0034] A method for manufacturing an equal-hardness Cr5 back up roll comprises the following steps:

[0035] 1) Steel raw materials according to chemical components in weight percentages for a Cr5 back up roll is prepared, and a steel ingot is obtained according to a smelting procedure production process, wherein the chemical components and the weight percentage contents in the Cr5 back up roll material are: 0.40%~0.70% of C, 0.20%~0.80% of Si, 0.20%~0.80% of Mn, 4.00%~5.00% of Cr, 0.20%~0.60% of Ni, 0.10%~0.80% of Mo, 0.10%~0.50% of V, P ≤ 0.015%, S ≤ 0.015%, and the balance Fe and an inevitable impurity.

[0036] The chemical components and the weight percentage contents in the Cr5 back up roll material are preferably: 0.55%~0.60% of C, 0.40%~0.45% of Si, 0.35%~0.38% of Mn, 4.50%~5.00% of Cr, 0.20%~0.60% of Ni, 0.60%~0.70% of Mo, 0.20%~0.30% of V, P ≤ 0.015%, S ≤ 0.010%, and the balance Fe and an inevitable impurity.

[0037] The smelting procedure for the steel ingot comprises the following specific steps: [0038] A. smelting the steel raw materials by using an electric arc furnace and refining ladle furnace, testing the chemical components and the weight percentages of molten steel in the refining ladle furnace, and performing degassing in vacuum after the molten steel is tested to be qualified; and [0039] B. injecting molten iron into a steel ingot mold in a vacuum environment to form the steel ingot, wherein since Cr, Mo and other alloy elements have a high content and the steel ingot has a large specification, a shape of a steel ingot mold is optimized for the material, the steel ingot mold has a small height-diameter ratio and a large taper, a section is in a multi-edge design, a heat-dissipation area is increased, a solidification speed is improved, a solidification segregation is reduced, at the same time, a high-efficiency exothermic compound is used in a riser, and solidification quality of the riser is improved.

[0040] 2) A roller blank is prepared from the steel ingot according to a forging procedure production process; the forging procedure comprises the following specific processes: the steel ingot is heated to 1,200~1,300° C. in a trolley furnace before forging for 20~30 h, then transferred to an 80 MN oil press for forging, and prepared into a forging blank through upsetting and drawing-out forging, wherein during the forging process, methods of high-temperature slow forging, medium-temperature fast forging, and low-temperature slow forging are used, the high-temperature slow forging is performed at a temperature in a range of 1,100~1,300° C., the medium-temperature fast forging is performed at a temperature in a range of 900~1,100° C., the low-temperature slow forging is performed at a temperature in a range of 750~900° C., the steel ingot is gently pressed in a high-temperature area, starts a large-pressure control until a middle-temperature section, actual operation time is based on a specific product design forging process, and the forging blank is turned after being subjected to a post-forging thermal treatment to obtain a fine-grain roller blank; and the post-forging thermal treatment comprises the following specific processes: the forging blank is heated to 750~850° C., preserved for 10~20 h, then slowly cooled to 680~720° C., preserved for 30~40 h, and then annealed.

[0041] 3) The roller blank is thermally treated; and the thermal treatment comprises the following specific steps: [0042] (1) preheating: preheating the processed roller blank in a trolley furnace at a preheating temperature in a range of 400~500° C., and heat-preserving the roller blank for 10~20 h; [0043] (2) transferring the preheated roller blank into an induction-type differential-temperature quenching device, wherein the induction-type differential-temperature quenching device has a surface temperature measurement precision of 0.1° C. and a surface temperature uniformity of ≤ 2° C., rapidly heating a steel blank to 950~1,050° C. in the induction-type differential-temperature quenching device at a speed of 15~20° C./min, and heat-preserving the steel blank for 100~150 min; [0044] (3) transferring the heated roller blank into a quenching device with a continuously controllable cooling speed for quenching, opening a pipeline by adjusting an electromagnetic valve, simultaneously detecting a flow rate and a pressure of the pipeline according to a flowmeter and a pressure gauge respectively, wherein the roller blank is rapidly cooled within an initial 20~30 min, water cooling is used in the rapid cooling stage, the flow rate is controlled to be 300~600 cubic meters/hour, then the flow rate is reduced, and the flow rate is controlled to be 150~250 cubic meters/hour, such that a working layer is a fully quenched martensite structure; and [0045] (4) tempering the quenched roller blank at a tempering temperature in a range of 300~500° C.

[0046] 4) The roller blank is processed and detected to obtain an equal-hardness forged steel back up roll: a surface hardness and a hardness drop of a roller body are detected by using a D-type mechanical Shore hardness tester, a hardness within 80 mm of a surface of the roller body is in range of 60~75 HS, a hardness uniformity is ≤ 2 HS, a working layer is detected according to a metallographic detection method, and a metallographic structure within 80 mm of the surface of the roller body is a quenched tempered martensite structure.

[0047] The present disclosure is further described in detail below with reference to the following examples.

Example 1 to Example 4

[0048] TABLE-US-00001 Comparisons of main chemical components and weight percentage contents of back up roll of examples 1-4 Example 1 2 3 4 Chemical component C (%) 0.55 0.59 0.58 0.60 Si (%) 0.45 0.42 0.40 0.42 Mn (%) 0.35 0.35 0.38 0.36 Cr (%) 4.00 4.50 5.00 4.75 Ni (%) 0.40 0.38 0.34 0.49 Mo (%) 0.65 0.60 0.62 0.70 V (%) 0.20 0.21 0.25 0.30 P (%) 0.010 0.010 0.011 0.010 S (%) 0.004 0.005 0.005 0.007

TABLE-US-00002 Comparisons of process parameters of examples 1-4 Example 1 2 3 4 Process parameter Forging procedure Heating temperature of steel ingot (°C.) 1300 1250 1200 1280 Heat-preserving time (h) 20 25 30 25 Post-forging heating temperature (°C.) 830 800 750 850 Heat-preserving time (h) 15 10 20 16 Post-slow cooling temperature (°C.) 680 720 680 700 Heat-preserving time (h) 40 40 40 30 Thermal treatment Preheating temperature (°C.) 450 400 500 400 Heat-preserving time (h) 20 15 20 10 Differential-temperature heating speed (°C./min) 20 15 18 15 Differential-temperature heating temperature (°C.) 980 950 1050 980 Differential-temperature heating preserving time (min) 100 150 150 125 Rapid cooling time (min) 30 30 20 25

TABLE-US-00003 Comparisons of hardness detection results of examples 1-4 Example 1 2 3 4 Depth from surface (mm) 0 65 75 70 69 20 65 75 71 70 40 66 75 71 70 50 66 75 70 70 60 65 74 70 70 70 64 74 69 69 80 64 74 69 68 90 61 73 67 66 100 60 71 65 65 110 56 69 63 62 120 47 64 60 60

TABLE-US-00004 Comparisons of metallographic structure detection results of examples 1-4 Example 1 2 3 4 Depth from surface (mm) I 0 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 20 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 40 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 50 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 60 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 70 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 80 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 90 Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 100 Tempered sorbite +pearlite +carbide Tempered sorbite +carbide Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide 110 Tempered sorbite +pearlite+carbide Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +pearlite +carbide Tempered sorbite +pearlite +carbide 120 Tempered sorbite +pearlite +carbide Tempered sorbite +pearlite +carbide Tempered sorbite +pearlite +carbide Tempered sorbite +pearlite +carbide

Comparative Examples 5-8

[0049] Compared with example 1, comparative example 5 had the following distinguishing technical characteristic: a heating mode of flame differential temperature was used in the thermal treatment process.

[0050] Compared with example 2, comparative example 6 had the following distinguishing technical characteristic: a conventional water cooling process was used for cooling in the thermal treatment process.

[0051] Compared with example 3, comparative example 7 had the following distinguishing technical characteristic: relatively short rapid cooling time of 15 min was used in the thermal treatment process.

[0052] Compared with example 4, comparative example 8 had the following distinguishing technical characteristic: differential-temperature heating preserving time of 160 min was used in the thermal treatment process.

TABLE-US-00005 Process parameters of thermal treatment of examples 5-8 Example 5 6 7 8 Process parameter Thermal treatment Preheating temperature (°C.) 450 400 500 400 Heat-preserving time (h) 20 15 20 10 Differential-temperature heating speed (°C./min) 20 15 18 15 Differential-temperature heating temperature (°C.) 980 950 1050 980 Differential-temperature 100 150 150 160 Rapid cooling time (min) 30 30 15 25

TABLE-US-00006 Comparisons of hardness detection results of comparative examples 5-8 Example 5 6 7 8 Depth from surface (mm) 0 65 73 70 69 20 65 72 71 70 40 64 68 69 67 50 63 67 65 63 60 60 59 60 60 70 58 55 57 56 80 53 52 52 50 90 48 50 44 45 100 38 48 38 40 110 42 48 37 37 120 43 44 40 36

TABLE-US-00007 Comparisons of metallographic structure detection results of comparative examples 5-8 Example 5 6 7 8 Dept from surface (mm) 0 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 20 Tempered Tempered sorbite Tempered sorbite Tempered sorbite sorbite +carbide +carbide +carbide +carbide 40 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 50 Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide Tempered sorbite +carbide 60 Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide 70 Tempered sorbite +pearlite +carbide Tempered sorbite +pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide 80 Tempered sorbite +pearlite +carbide Tempered sorbite +pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide Tempered sorbite +a small amount of pearlite +carbide 90 Tempered sorbite +pearlite +carbide Tempered sorbite +pearlite +carbide Pearlite +carbide Pearlite +carbide 100 Pearlite +carbide Pearlite +carbide Pearlite +carbide Pearlite +carbide 110 Pearlite +carbide Pearlite +carbide Pearlite +carbide Pearlite +carbide 120 Pearlite +carbide Pearlite +carbide Pearlite +carbide Pearlite +carbide

[0053] In conclusion: aiming at serious component segregation and poor solidification quality existing in steel ingot smelting and casting, the present disclosure optimally designs a shape of a steel ingot mold, the used steel ingot mold has a small height-diameter ratio and a large taper, a section is in a multi-edge design, a heat-dissipation area is increased, a solidification speed is improved, a solidification segregation is reduced, at the same time, a high-efficiency exothermic compound is used in a riser, and solidification quality of the riser is improved. The present disclosure obtains a fine-grain roller blank, improves strength and toughness of the roller blank, and at the same time avoids generation of forging cracks by studying stress, strain conditions, and internal microstructure changes of the steel ingot in the forging process under different anvil shapes and deformation modes, and using high-temperature slow forging, medium-temperature fast forging, and low-temperature slow forging methods. A roller blank thermal treatment uses a process of preheating+induction-type differential-temperature heating+controllable cooling speed quenching, a heating speed is high, a surface temperature uniformity may be controlled within 2° C., a surface temperature measurement precision is 0.1° C., an austenitizing depth of a roller body is 100~120 mm, and an austenite grain is fine and uniform, and has a grain size about 10~11 grades. A pipeline is opened by adjusting an electromagnetic valve, a flow rate and a pressure of the pipeline are simultaneously detected according to a flowmeter and a pressure gauge respectively, the roller blank is rapidly cooled within an initial 20~30 min, water cooling is used in the rapid cooling stage, the flow rate is controlled to be 300~600 cubic meters/hour, then the flow rate is reduced, and the flow rate is controlled to be 150~250 cubic meters/hour, such that a fully quenched martensite structure is obtained within 80 mm of a surface of the roller body, a hardness of a working layer is improved, a hardness range within 80 mm of the surface of the roller body is 60~75 HS, and a hardness uniformity is ≤ 2 HS. An abrasion resistance of the Cr5 back up roll in the present disclosure is improved by 20% compared with the conventional Cr5 forged steel back up roll. The contact fatigue strength of the Cr5 back up roll is over 2 million of revolutions in a fatigue period under an experimental condition, and a comprehensive service period in a whole service period is improved by 20% compared with the conventional Cr5 forged steel back up roll.