The main causes of roller press shaft wear

Rollers are tools that induce plastic deformation in (rolled) metals, serving as critical large consumable components that determine the efficiency of rolling mills and the quality of rolled products. The most common cause of roller failure is premature wear-induced failure. Currently, when rollers require repair due to wear, methods such as turning or grinding are often employed as "remedial measures" to correct the roller profile. Laser cladding for roller surface repair has emerged as a major development direction and approach to extend roller service life. This technology not only repairs rollers but also enhances their wear resistance, prolongs their operational lifespan, and improves the surface quality of steel products.

The primary causes of roller press shaft wear are as follows:

1. Inadequate control of material particle size in the roller press;

2. Seal failure in the roller press, leading to increased bearing load;

3. Fatigue operation of bearings, resulting in excessive bearing clearance;

4. Insufficient preload force of the pressure plate;

5. Frequent clogging or overly thin design of cooling copper pipes;

6. Failure to regularly clear materials from the steady-flow bin and remove accumulated metal objects, causing frequent equipment overload shutdowns that impact bearing life;

7. Severe long-term deviation in the roll gap due to hydraulic system issues.

Common failure modes for shaft components include shaft deformation, shaft fracture, and surface failure. The destruction of shaft parts, such as generator rotors and various transmission shafts, is primarily dominated by wear. Among these, shaft deformation and fracture are irreparable, whereas surface failures dominated by wear can be repaired. Utilizing high-power laser cladding repair technology, a layer of iron-based alloy material can be applied via laser cladding to the worn surface of shaft components, endowing the clad alloy layer with excellent mechanical properties and enabling the reuse of otherwise scrapped parts.