In terms of manufacturing process, it generally includes the following steps (taking the stud inlay device and welding repair process on the roller of a mine high-pressure grinding roll as an example):
1. Preparation before welding:
- Prepare gas welding equipment such as welding torches, welding nozzles, oxygen-acetylene cylinders and air hoses;
- Prepare heating devices such as baking guns, welding nozzles, oxygen-acetylene cylinders and air hoses;
- Prepare auxiliary facilities such as angle grinders, files, hammers, flat shovels, colored glasses, copper needles, sheepskin gloves, templates, temperature measuring instruments and magnifying glasses;
- Determine the welding position as the horizontal circumferential peak welding position and rotate for welding;
- Ensure that all welded deposited layers have no welding defects and are metallurgically fused to the base metal;
- Select appropriate welding materials such as bag25cuznsn;
- Prepare gases such as oxygen and acetylene;
- Determine welding process parameters according to welding requirements.
The studs of high-pressure grinding rolls, also known as pins, are important components on high-pressure grinding rolls.
Studs are usually made of highly wear-resistant and high-toughness materials such as cemented carbide. Their main function is that when the high-pressure grinding roll is working, by arranging the studs on the roll surface in a reasonable way, a material lining is automatically generated on the roll surface, thereby enhancing the crushing effect on materials.
In terms of manufacturing process, it generally includes the following steps (taking the stud inlay device and welding repair process on the roller of a mine high-pressure grinding roll as an example):
1. Preparation before welding:
- Prepare gas welding equipment such as welding torches, welding nozzles, oxygen-acetylene cylinders and air hoses;
- Prepare heating devices such as baking guns, welding nozzles, oxygen-acetylene cylinders and air hoses;
- Prepare auxiliary facilities such as angle grinders, files, hammers, flat shovels, colored glasses, copper needles, sheepskin gloves, templates, temperature measuring instruments and magnifying glasses;
- Determine the welding position as the horizontal circumferential peak welding position and rotate for welding;
- Ensure that all welded deposited layers have no welding defects and are metallurgically fused to the base metal;
- Select appropriate welding materials such as bag25cuznsn;
- Prepare gases such as oxygen and acetylene;
- Determine welding process parameters according to welding requirements.
2. Heating and welding:
- Raise the left and right frames on both sides of the extrusion roll of the high-pressure grinding roll symmetrically with the left and right sleepers to ensure sufficient height for the extrusion roll to operate without damaging the mechanical assembly joint surface under the frame;
- Rotate the position on the shaft shoulder on one side of the extrusion roll where the stud needs to be replaced to the horizontal position. Use the magnetic drill fixed on the left frame to drill a stud hole at this position by operating the handle with a drill bit;
- Then aim the fixed long baking gun at the stud hole for heating from the inside to the outside. When the stud hole and the surrounding area are heated to a red-hot surface close to the oxidized state, apply qj102 silver brazing flux and inlay the matching stud into the stud hole so that the surface height of the stud is equal to the height of the existing used stud;
- Use a welding torch to melt the bag25cuznsn welding wire and weld it to the joint between the surface of the extrusion roll and the stud (including the position in the stud hole below the joint on the stud surface);
- After the inlay welding of the stud in the stud hole at this horizontal position is completed, rotate the extrusion roll to the next position where the stud needs to be replaced and repeat the above drilling and welding steps;
- After all the studs are replanted, conduct surface inspection to ensure that the weld seam has no welding defects such as cracks, pores, lack of fusion and incomplete penetration, and pass the acceptance of the original size. After fully meeting the overall rotation requirements of the high-pressure grinding roll, it can be delivered for use.
In the actual manufacturing process, the diameter of the bag25cuznsn welding wire used for welding is usually 2.0mm, and the welding speed is about 10cm/min.
The studs of high-pressure grinding rolls of different manufacturers and models and their manufacturing processes may vary. The specific situation needs to be adjusted and optimized according to the actual equipment and production requirements. The quality and installation process of studs have an important impact on the working efficiency and crushing effect of high-pressure grinding rolls. Therefore, quality needs to be strictly controlled during the manufacturing and installation process. At the same time, in order to extend the service life of studs, attention should also be paid to the operation and maintenance specifications of high-pressure grinding rolls.
