Faults and Causes of the Guide Roll of the High Wire Roll Forming Machine
I. Introduction
Roll forming machinery is an important machinery used in a variety of industrial productions. High-wire roll forming machines are used in the process of manufacturing a wide range of products, such as metal sheet and reinforced metal products, and are essential in the development of most metal producing industries. The guide roll of the high-wire roll forming machine plays an important role in ensuring its smooth operation, as it directs the rolling metal strip and supports its weight to prevent unnecessary deformations and damages. However, the guide roll is one of the most common components of the machine to fail. This article will discuss the main failure forms of the guide roll of the high wire-roll forming machine, and the likely causes of such failures.
II. Major Faults and Causes of the Guide Roll
A. Spalling
Spalling is a common fault of the guide roll, which refers to the separation of a portion of the material on the surface of the roll caused by fatigue. It is typically caused by excessive loading, poor lubrication, high running speed, or other forms of excessive wear and tear. Another cause of spalling is the lack of roll hardness, which reduces the roll’s capacity to withstand the pressure of heavy loads and the impact of high speeds. Some common spalling conditions include ridges, grooves, and cracks on the surface of the roll.
B. Cracking
Cracking is another common fault and failure form of the guide roll. It is usually caused by either excessive impact or overload, and is manifested by a break or separation along the line of the crack. It is usually caused by defects in the material of the roll, including brittle materials, wrong type of material, or corrosion due to incorrect lubrication.
C. Uneven Wear
Uneven wear is another common fault of the guide roll. It is caused by a lack of uniform rolling speed, excessive axial load, or long time of running without maintenance. Uneven wear is manifested by fatigue gouges and uneven surface, which increase the friction resistance and cause further damage.
D. Poor Bearing
Poor bearing can also cause fault and failure of the guide roll. The improper fitting of the roll bearing, or a defect in the roller bearing, can lead to vibration, misalignment, and other functional dysfunctions.
III. Conclusion
The guide roll of the high wire roll forming machine is essential in ensuring the operational quality and efficiency of the machine, and its malfunction can lead to serious damages, excessive wear, and major production losses. This analysis has discussed the major failure forms and likely causes of the guide roll. It is important for operators to be aware of the faults and causes of the guide roll in order to prevent or minimize damages and malfunctions of the machine.
