In recent developments, the Zhengzhou Machinery Research Institute has conducted in-depth research on enhancing wear-resistant surfacing technology and improving the efficiency of grinding systems. The focus has been on addressing issues such as roll surface wear, surfacing materials, wear patterns, repair methods, and high-quality wear-resistant welding wires. The study also evaluated how the choice of welding materials and processes impacts the performance of the grinding system.
**First, Analysis of Roll Surface Wear**
1. **Causes of Wear**
To improve the wear-resistant surfacing process and enhance the grinding system's efficiency, the institute analyzed the causes of roll surface wear. Based on the working principle of roller presses, material is compressed between two rollers, leading to inevitable wear on the roll surface. The primary causes include:
- Improper selection of hardfacing materials with poor wear resistance.
- An inefficient surfacing process that results in low-quality coatings and potential peeling.
- Material hardness that is too high, reducing the roll’s wear resistance.
2. **Impact of Different Materials on Wear**
The type of material used in the roller press significantly affects the rate of wear. For example, raw material roller presses tend to wear faster than cement roller presses. Even within the same category, regional differences in raw materials can lead to varying levels of wear.
3. **Material Selection for Surfacing**
Because no single welding wire can address all problems, the institute developed specialized welding wires for different materials. These include:
- ZD1, ZD2, ZD3, and ZD310 for general cement grinding rolls.
- ZD330 for raw material roller presses.
**Second, Roll Surface Surfacing Materials**
1. **Cement Roller Press Surfacing Materials**
- **ZD1**: Offers excellent toughness and crack resistance, preventing cracks from spreading into the roll body.
- **ZD2**: Provides high compressive strength, acting as a bridge between the roll body and the wear layer.
- **ZD3**: Combines high toughness with good wear resistance, making it ideal for continuous use.
- **ZD310**: A highly wear-resistant layer directly in contact with the material, offering superior performance over traditional high-chromium cast iron.
2. **Raw Material Roller Press Welding Materials**
Raw material roller presses typically use ZD330, but it must be preceded by a ZD1 base layer. This ensures better adhesion and durability, especially under harsh conditions.
**Third, Types of Roll Surface Wear**
1. **Wear Forms**
Roll surface wear can be categorized into:
- Normal wear: Uniform wear during initial operation.
- Partial peeling: Caused by metal debris or improper maintenance.
- Fatigue failure: Occurs after multiple repairs, leading to stress accumulation.
- Severe damage: Requires offline repair to prevent further degradation.
2. **Reasons for Different Wear Patterns**
Each wear form has distinct causes, such as material quality, maintenance practices, and repair frequency. Proper maintenance is essential to avoid costly failures.
3. **Characteristics of Composite Roller Sleeves**
Composite sleeves are centrifugally cast and difficult to repair due to poor weldability. In many cases, replacing the sleeve is the most effective solution.
**Fourth, Roll Surface Repair Methods**
1. **Repair Procedures for Different Wear Conditions**
Depending on the level of wear, specific repair steps are followed, including cleaning, preheating, and applying appropriate welding layers. Online and offline repairs differ in complexity and cost.
2. **Importance of Timely Maintenance**
Delayed maintenance can lead to severe damage, increasing repair costs and downtime. Timely surfacing not only extends the life of the roller but also reduces operational expenses.
**Fifth, Impact of High-Quality Surfacing Materials**
High-quality wear-resistant materials and advanced surfacing techniques play a crucial role in optimizing the grinding system. They ensure stable performance, reduce downtime, and improve overall efficiency. While premium materials may have higher initial costs, they offer long-term value through durability and reliability. Choosing the right surfacing solution is key to maintaining productivity and minimizing operational disruptions.
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