Roll Reconstruction
Roll reconstruction is an important part of surface engineering. Heating and grinding of rolls takes place over a long period of time and involves quite a few steps. This process often involves the removal of superficial stresses, reconditioning and welding of components, and reshaping and re-dressing of the final roll to ensure uniformity of profile. During this process, stringent checks are done to ensure that all components are in the right condition before they are re-assembled and placed into service.
Roll reconstruction is mainly done in steel mills, where new rolls are checked and ground to a specific profile. The quality of rolling depends on the shape and size of the roll, together with appropriate grinding parameters. In order to reduce the cost of roll reconstruction, reliable and optimal grinding strategies must be adopted. The quality of the rolls thus produced must also comply with the requirements of the steel mills.
The roll reconstruction process is usually divided into three stages: pre-treatment, roll grinding and post-treatment. During the pre-treatment process, the rolls are scanned to determine the surface quality of each roll by using non-contact measurement techniques. This helps to identify any areas that are causing problems or are in need of repair. After this, the rolls are cleaned and pre-ground before they are put back into service.
In the second stage of the process, the rolls are then reshaped by grinding. During this stage, the rolls are ground up to a very tight tolerance so as to create a uniformed profile that is required by the steel mills. The grinding is done in multiple passes until the required shape and size of the grind profile is achieved.
In the third stage of the process, the rolls are then cleaned, brushed and tested. Once the rolls are put back into service, they are tested again to ensure that any surface contaminants are removed, as well as to check for any possible roll deflection. Following that, any areas requiring repair, such as welding and reconditioning, are done to restore the roll to its original condition.
Roll reconstruction is a complex process that requires significant experience within the industry as there are a large number of parameters, including surface finish, that need to be taken into account during the process. It is also very important to ensure that all components are in the right condition before the roll is put back into service. Finally, when all components are re-assembled and ready, the roll is tested again to confirm the uniformity of profile and quality. Roll reconstruction is an important process in maintaining the quality and production of steel mills, and it is essential that it is done incorporating the best industry practices.
