Sheet Metal Cone Rolling Machine

We are a professional cone rolling machine manufacturer with over 10 years of industry experience. Today, we would like to introduce to you the anti-scratch roll surface structure design of not cone rolling machine:

The cone rolling machine is a critical piece of equipment for metal sheet forming, where the roller surface structure directly impacts workpiece surface quality. To address surface scratching issues in high-demand materials such as stainless steel and aluminum plates, modern cone rolling machines employ multi-layered structural designs for anti-scratch functionality. The following explanation covers three key aspects: Design principles, structural solutions, and implementation considerations.

1, Anti-scratch design core principles

The design of anti-scratch roll surface needs to balance three requirements: The rigidity of the roll body must be ensured to meet the molding pressure. Secondly, the friction coefficient between the roll surface and the plate must be reduced, and at the same time, the retention of hard particles must be avoided to cause secondary damage. These three requirements dictate that the anti-scratch structure cannot simply be a soft cover, but requires a composite solution.

2, Typical anti-scratch roll surface structure

Composite roll cover layered design

Modern anti-scratch rollers mostly use three-layer composite structure. The base layer is a high-strength alloy steel forging, to ensure the load-bearing capacity. The middle layer is a hardness of HRC45-50 tempered steel, to provide impact resistance. The working surface is coated with a special alloy or replaceable engineering plastic bushings. This structure maintains rigidity while keeping the roll surface hardness below the level of common stainless steel plates.

Integrated dynamic lubrication system

Axial oil channels are designed inside the roll body to continuously seep out the specialized lubricant through the micropores on the surface. The spacing of the oil channels varies from 50-100mm according to the width of the sheet to ensure full width coverage. The matching intelligent lubrication control module can automatically adjust the oil supply volume according to the processed material, and the oil volume increases by 30% compared with carbon steel when stainless steel is processed.

Clean shoulder structure

The traditional right-angle design of the roll shoulder is easy to accumulate metal chips, the improved program adopts 15° slope transition with compressed air blowing channel. Removable scraper rings at both ends of the roll body prevent particles from entering the work area. Tests have shown that this structure reduces press-in scratches by 85%.

3, Key Implementation Details

Surface treatment process selection

Chrome-plated roll faces are suitable for normal carbon steel processing, but for processing stainless steel a WC-Co based thermal spray coating is recommended. For aluminum plate processing, anodized aluminum bushings perform better. All coated surfaces should be mirror polished to Ra ≤ 0.2μm.

Gap compensation mechanism

A dynamic floating gap of 0.05-0.1mm is set to eliminate the instantaneous no-load caused by equipment vibration through the hydraulic compensation system. This design is particularly suitable for thin plate thicknesses <2mm and prevents vibration ripples from occurring.

Online monitoring configuration

Laser distance sensors are installed on both sides of the roll surface to monitor the parallelism of the roll seam in real time. Automatic adjustment program is triggered when deviation exceeds 0.03mm. The matching industrial camera can perform initial surface quality inspection to identify potential scratch risks.

4, Maintenance points

A special maintenance system should be established for the anti-scratch roll surface. The coating condition should be inspected every 40 hours of processing, and a special thickness gauge should be used to evaluate the amount of wear. The lubrication system filter element should be replaced every 200 working hours, and the oil selection should be in accordance with ISO VG68 standard. The roll surface should be coated with corrosion inhibiting grease and wrapped with moisture-proof paper when it is out of service for a long period of time.

5, Adaptation adjustment for different materials

When processing 304 stainless steel, it is recommended to control the roll surface temperature in the range of 40-60 ℃, too high will accelerate the coating wear. Aluminum processing needs to reduce the roll speed by 20%, and switch to alcohol-based lubricants. For titanium alloy and other special materials, should be replaced with special bushings made of polyether ether ketone.

5, Adaptation adjustment for different materials

When processing 304 stainless steel, it is recommended to control the roll surface temperature in the range of 40-60 ℃, too high will accelerate the coating wear. Aluminum processing needs to reduce the roll speed by 20%, and switch to alcohol-based lubricants. For titanium alloy and other special materials, should be replaced with special bushings made of polyether ether ketone.

Excellent anti-scratch roll surface design requires the synergy of mechanical structure, material science and control system. In practice, it is recommended that a roll surface condition file be established to record wear data for different materials after processing. Operators need to be specifically trained in the proper use and limitations of anti-scratch structures. With the development of new composite materials, more durable and maintenance-free roll face solutions may be available in the future.

If you are interested in a cone rolling machine, please contact us.