Common Faults of Strip Roller and Their Solutions

Strip Roller surface wear

Causes

During the rolling process, there is continuous friction between the strip and the roller surface, which will cause roller surface wear under long-term action.
Too fast rolling speed and excessive rolling force will increase friction and accelerate roller surface wear.
High surface roughness and foreign matter on the strip will also increase the wear on the roller surface.

Solutions

Reasonably adjust the rolling process parameters, such as reducing the rolling speed, optimizing the rolling force, and reducing unnecessary friction.
Pre-treat the strip to remove foreign matter and sharp edges on the surface and reduce surface roughness.
Select a strip roller material with better wear resistance, or perform surface hardening treatment on the roller surface, such as quenching, hard chrome plating, etc.

Strip Roller surface cracks

Cause

During the manufacturing process of the plate and strip roller, if the heat treatment process is improper, residual stress will exist inside, and the stress will be released during the rolling process, which is easy to cause cracks.
During rolling, the temperature changes dramatically, and the thermal stress acts repeatedly, resulting in thermal fatigue cracks on the roller surface.
Overload operation causes the stress on the roller surface to exceed the material strength limit, thus causing cracks.

Solution

Optimize the manufacturing process of the plate and strip roller, strictly control the heat treatment process, and eliminate residual stress.
Improve the cooling system to make the temperature of the plate and strip roller change smoothly during the rolling process to avoid thermal shock.
Install an overload protection device to prevent the plate and strip roller from overloading. For minor cracks that have appeared, grinding and other methods can be used to remove them; if the cracks are serious, the plate and strip roller needs to be replaced.

Strip Roller deformation

Cause

Long-term uneven rolling force causes excessive local force on the roller, resulting in deformation.
During transportation and storage, the plate and strip rollers are improperly placed and deformed under the influence of gravity.
The roller material is uneven, and under the action of rolling force, the deformation of different parts is different.

Solution

Adjust the rolling process to ensure uniform distribution of rolling force, such as reasonably designing the rolling pass and optimizing the width and thickness distribution of the plate and strip.
Improve the transportation and storage methods of the plate and strip rollers, use special brackets to ensure that the rollers are placed horizontally to avoid gravity deformation.
For slightly deformed rollers, straightening technology can be used for repair; severely deformed rollers need to be reprocessed or replaced.

Bearing failure

Causes

Poor bearing lubrication leads to increased friction, overheating and wear.
The vibration and impact during rolling cause the bearing to bear additional dynamic loads, accelerating bearing fatigue damage.
Insufficient bearing installation accuracy, such as too large or too small installation clearance, will affect the normal operation of the bearing.

Solutions

Regularly check and replace lubricating oil to ensure the normal operation of the lubrication system. You can choose the appropriate lubricant and lubrication method according to the working conditions.
Remove vibration and noise on the rolling equipment, such as installing shock pads and optimizing the transmission system to reduce the impact of vibration and impact on the bearing.
Install the bearing strictly in accordance with the installation specifications to ensure installation accuracy, regularly check the installation status of the bearing, and adjust the clearance in time.

Seal failure

Causes

After long-term use, seals age, wear and lose their sealing performance.
The harsh environment such as high temperature and oil pollution during the rolling process accelerates the aging and damage of seals.
Improper seal installation, such as too tight or too loose seal installation, leads to poor sealing effect.

Solution

Regularly check the status of seals, replace aging and damaged seals in time, and choose reliable, high temperature and oil resistant sealing materials.
Improve the working environment of the sealing part, such as adding protective devices to prevent oil pollution, dust, etc. from entering the sealing area.
Install seals strictly in accordance with the installation requirements to ensure the correct installation size and installation method.