镜面辊的加工工艺

 

一、组件焊接:

 

组焊内板、轴头、衬套、堵板、内管等，内管做静平衡50g之内，内管划旋向线，焊扁钢流道。

 

二、配车、装、焊接:

 

配车内管、尺寸与外管过盈0.4mm， 两幅板倒焊缝角15X30度，打磨内管，清渣、检验内管尺寸与外管内径尺寸是否相适应，热套到位，待冷却收缩后，整体组焊。(注:45#钢焊前加温，焊后保温)

 

三、退火、粗车、淬火:

 

退火热处理，工艺调质，多重去应力，粗车留余量，做静平衡，大于50g，需要计算借偏量，上车床借车。

 

淬火:表面硬度要求HRC58°-60°，辊面无龟裂纹。

 

四、精车、粗磨:

 

两轴头修顶针孔，两轴头对辊面跳动，<0.05，按图要求加工长度到尺寸，外圆放余量，0.5-0.6。磨支撑圆做托架位，按图要求磨辊面尺寸，Ra0.5两轴头对辊面跳动<0.02。

 

五、动平衡、电镀、精磨:

 

做动平衡G40级，封堵透气孔，做压力实验无泄漏，做水压畅通实验。电镀硬铬，单边0.15铬层均匀无针孔，脱落等缺陷。精磨两轴头，两轴承挡对辊面跳动<0.01粗糙度0.8。其余轴头各挡位磨到公差范围。

 

六、磨砂、精磨镜面:

 

用圆盘磨床磨砂辊面，检验辊面，无水波纹、螺旋纹、针眼、苍蝇租等暇质。上抛光机床，抛辊面至粗糙度Ra0.01-0.005(光洁度达14级)做到超镜面。镀铬抛光后硬度HRC62°。


Processing process of mirror roll
Component welding:
Group welding inner plate, axle head, Bushing, blocking plate, inner Guandeng, inner tube for static balance within 50 g, inner pipe spin line, welding flat steel flow.
Second, the distribution of vehicles, assembly, welding:
The inner pipe, size and outer pipe of the car are 0.4 mm, and the two plates are soldered at an angle of 15X30 degrees. The inner pipe is polished, the slag is cleared, and the inner tube size is matched with the inner diameter size of the outer pipe. The hot sleeve is in place. After cooling and contracting, the whole group is welded. (Note: 45 # Heating before welding, heating after welding)
Third, annealing, rough car, quenching:
Retreat heat treatment, process quality adjustment, multiple stress removal, rough car leaving margin, static balance, greater than 50G, need to calculate the amount of borrowed weight, get on the bed to borrow the car.
Quenching: Surface hardness requires HRC58 ° -60 °, and there is no turtle crack on the roll surface.
Fourth, fine cars, rough grinding:
Two axles to repair the top needle hole, two axles to beat on the roll surface, & lt; 0.05, processing length to size as required, outer circular margin, 0.5-0 .6. The grinding support circle is used as a bracket position. According to the figure, the size of the grinding roller surface is required, and the Ra 0.5 two-axis head beats on the roller surface & lt; 0.02.
Fifth, dynamic balance, electroplating, precision grinding:
Do balance G40, seal the air hole, do pressure experiment without leakage, do water pressure test. Electroplating hard Chromium, unilateral 0.15 Chromium layer uniform without needle holes, fall off and other defects. Grinding two heads, two bearings to block the roll surface beat & lt; 0.01 roughness 0.8. The rest of the shaft heads are grinding to the tolerance range.
Six, grinding, grinding mirror:
Use the disc grinder to grind the roll surface and test the roll surface. There are no water ripples, spiral lines, needle eyes, fly rent, etc.. On the polishing machine tool, the roller surface is thrown to the roughness Ra0.01 -0.005(finish up to 14) to achieve a hypermirror. The hardness of chrome-plated polishing is HRP62 °.