CERATIZIT - the parent companies

Transcription

1 Carbide rolls

2 CERATIZIT - the parent companies Headquarters and parent company in MAMER / Luxembourg Parent company in REUTTE / Austria Hard material matters - it is the core of our business. Through profound knowledge and highly flexible production facilities we strive to provide our business partners with direct competitive advantages in the field of hard materials for tooling solutions and wear parts. Our dedication to hard material matters creates intelligent solutions for tomorrow and time to come. Production plants in the three main economic areas and a worldwide sales network of subsidiaries and distribution partners ensure a quick response to customer needs. In-house trainings and seminars guarantee that both business partners and employees share the latest information on our product range. We promote intensive dialogue with our customers and strive for long-term business relations on a partnership basis. The CERATIZIT corporate value 'The focus and point of view of our business partners matters' is a guiding principle for all CERATIZIT employees worldwide. Europe Austria Bulgaria Czech Republic France Germany Hungary Italy Luxembourg Netherlands Poland Switzerland Spain United Kingdom North America USA Mexico South America Brazil Asia China India Japan Direct sales and distribution partners 2

3 Competence and know-how 3

4 Carbide grades for hot rolls Composition and properties Grades Binder Density Hardness rupture strength modulus of conductivity ot thermal Transverse Compressive Young's Thermal Coefficient Current Future strength elasticity expansion designation % g/cm 3 HV10 N/mm 2 N/mm 2 N/mm 2 W/mK K/1000 COARSE GRADES CE3 CTC12A CE51 CTC20A CE65 CTC25A CE79 CTC30A CE103 CTC35A CE107 CTC40A CE CE CE CE220 CTC20M CE230 CTC30M CE CE CE CERMETS TCN SILICON NITRIDE SNC1 SNC Carbide (coarse grain) Cermets Silicon nitride 4

5 Competence in development & production 5

6 Carbide rolls for No-Twist mills We supply the following roll types: 1. As sintered, with sintering tolerances that are common in the sector, external diameter max. 450 mm 2. Semi-finished, with external diameter as sintered (bore and sides fi nish-ground) 3. External diameter machined, bore and sides fi nish-ground, without groove 4. Completely finished with grooves Upon request types 1, 2, 3 can be delivered with a sintered groove Carbide guide rolls Ready for use Types: same as carbide rolls Grades: carbides, cermets, silicon nitride Minimum external diameter: D = 30 mm 6

7 Composite rolls for conventional hot rolling lines 7

8 Wire rolling mill Table of grades with Co - Ni - Cr - binders Schematic view of a No-Twist wire rolling mill Stand # Stand # Stand # Reducing-Sizing (RSM) Finishing Sizing Pre-finishing (PFM / RSM) Finishing Finishing Sizing Grade/stand (recommended values) Stand # 1 Product Ø Binder % (Co-Ni-Cr) B = carbon steel Material: A = low carbon steel Rolling temperature T [ C]: see diagram on top of right-hand page 8 CTC30M CTC30M C = alloyed steel

9 Wire rolling mill Temperatures in the wire rolling mill Rolling temperature T [ C] Stand # Material Rolling temperaturet [ C] A CTC20M CTC20M CTC20M CTC20M CTC30M CTC30M B C CTC30M CTC30M CTC30M CTC30M D 1 CTC30M CTC30M CTC20M CTC20M CTC20M CTC20M A CTC30M CTC30M B CTC30M CTC30M C D 2 CTC30M CTC30M CTC30M CTC30M A CTC30M CTC30M B C D 3 D = special steel 9

10 Wire rolling mill Table of grades with pure Co binder Schematic view of a No-Twist wire rolling mill Stand # Stand # Stand # Reducing-Sizing (RSM) Finishing Sizing Pre-finishing (PFM / RSM) Finishing Finishing Sizing Grade/stand (recommended values) Stand # 1 Product Ø CTC40A CTC40A CTC30A CTC30A CTC40A CTC40A CTC40A CTC40A Binder % (Co) Material: A = low carbon steel B = carbon steel Rolling temperature T [ C]: see diagram on top of right-hand page 10 CTC40A CTC40A C = alloyed steel

11 Wire rolling mill Temperatures in the wire rolling mill Rolling temperature T [ C] Stand # Material Rolling temperaturet [ C] CTC25A CTC25A CTC20A CTC20A CTC12A CTC12A A CTC30A CTC30A CTC25A CTC25A CTC20A CTC20A B CTC35A CTC35A CTC30A CTC30A CTC25A CTC25A C CTC40A CTC40A CTC35A CTC35A CTC30A CTC30A D CTC30A CTC30A CTC25A CTC25A CTC20A CTC20A A CTC35A CTC35A CTC30A CTC30A CTC25A CTC25A B CTC40A CTC40A CTC35A CTC35A CTC30A CTC30A C CTC40A CTC40A CTC35A CTC35A D CTC35A CTC35A CTC30A CTC30A CTC25A CTC25A A CTC35A CTC35A CTC30A CTC30A B CTC40A CTC40A CTC35A CTC35A C CTC40A CTC40A CTC40A CTC40A D D = special steel 11

12 Mill roll diameters of various manufacturers Ashlow 216 Danieli 166 Danieli 212 Demag 210 Morgan Morgan Morgan Morgan Morgan Morgårdshammar 170 Morgårdshammar 223 SIMAG 180 SIMAG 215 VAI Pomini 210 Ashlow 325 Morgan 340 Morgan

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14 Application advice Cooling The extremely high temperature, especially in the contact zone between the roll and the wire, causes a series of effects which reduce roll life. These negative factors, such as corrosion, wear, reduced dimensional accuracy and cracks can be decreased by applying sufficient cooling. In fact, a roll which is cooled enough can be used up to 100 % longer compared to rolls which are not provided with an appropriate amount of cooling. Optimum cooling is determined by the water volume supplied, adequate pressure and correct positioning of the exit nozzles for the coolant. Approx. 30 % of the coolant quantity should be focused on the exit side of the rolled product, close to the rolling line. Mill roll Corrosion In hot rolling operations, corrosion represents an electro-chemical process which causes anticipated wear and leads to a rougher surface of the groove. The degree of corrosion increases with the rolling temperature, therefore the groove shows more corrosion than the rest of the roll. Corrosion causes the cobalt matrix to detach from the tungsten carbide structure. In the case of regular surface corrosion this leads to considerably higher wear and, with irregular corrosion it can result in mechanical or thermal cracks. Apart from the rolling temperature, both the temperature and ph-value of the coolant are decisive with regard to corrosion. The highest acceptable temperature of the water with a ph-value ranging between 7.5. and 8.5 is 35 C. If the water temperature is 25 C, the phvalue lies between 6.5 and 9. Acid water attacks the cobalt binder, while extremely alcaline water will attack the tungsten carbide. Special binders such as nickel-cobalt-chromium alloys show notably higher corrosion resistance, i.e. they may be used up to ph 5.5. Corrosion test according to DIN50905/ASTM G54 Material removal [g/(m 2 *h)] ph-value Binder: Co High degree of cobalt detachment Binder: Co/Ni Low degree of cobalt detachment CTC40A ph4 Duration of test: 168 hours 14

15 Finishing Thermal cracks The alternating cooling and heating phases of the roll during the process lead to a considerable thermal gradient. The tension arising from these temperature changes mainly concerns the profile of the roll and produces a whole network of surface cracks, their type depending primarily on the carbide grade chosen. Carbide grades with a major binder content have a higher thermal expansion coeffi cient and are characterized by low thermal conductivity. In such grades cracks occur more often but are basically limited to the surface. Obviously, for carbide grades with a low binder content the opposite is true. With optimum cooling, a rolling speed of more than 10 m/sec. and a reduction of the section by a maximum of 20 % the depth of the cracks is limited to 0.2 mm. For lower rolling speeds and thus longer contact time between the roll and the rolled product, the crack depth can go up to 0.8 mm. It is important that cracks caused by tension are eliminated completely when redressing the roll. Network of cracks Finishing of carbide rolls Hard materials such as carbides, cermets and silicon nitride are mainly ground by applying a diamond wheel. For turning with a binder content of >15 % the use of a geometrically defi ned cutting edge is recommended. Suitable cutting materials are cubic boron nitride (CBN) and polycrystalline diamond (PCD). The insert shape should be as robust as possible depending on the roll profi le that is to be produced. For classic longitudinal and face turning operations button inserts have proven to be best. When fi nish-turning the groove, it is the shape of the groove itself which is decisive for the choice of the insert type. The cutting edge should be sharp, a negative protective edge chamfer is, however, not necessary. When using CBN, dry machining is possible, whereas the application of polycrystalline diamond requires abundant quantities of cooling emulsion. The CERATIZIT engineers will gladly help you choose the suitable tool and cutting parameters. Carbide roll Cutting data for CBN and PCD Binder content [%] v c [m/min] a p [mm] f [mm/rev] >

16 Maximum pressure, heat, rolling speed, work overload! CERATIZIT carbide rolls are used to provide top performance even with extreme rolling conditions. CERATIZIT, because reliability counts. 16

17 Notes 17

18 18 Notes

19 Headquarters: CERATIZIT S.A. Main site Luxembourg CERATIZIT Luxembourg Sàrl Route de Holzem 101, B.P. 51 L-8201 Mamer Tel.: Fax: Main site Austria CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) Sales Companies Austria CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) Brazil CERATIZIT AMERICA LATINA Ltda. Praça das Orquídeas, 52 Térreo Centro Comercial de Alphaville CEP Barueri Estado de São Paulo Tel.: Fax: Bulgaria CERATIZIT Bulgaria AG Boulevard Stoletov 157 BG-5301 Gabrovo Tel: +359 (66) Fax: +359 (66) China CERATIZIT China Ltd. Room Hollywood Centre 233 Hollywood Rd., Sheung Wan Hong Kong Tel.: +852 (2542)-1838 Fax: +852 (2854) CERATIZIT Langfang Ltd. Guang Ming Xi Dao Sheng Tian Bridge Langfang Tel.: +86 (316) Fax: +86 (316) France CERATIZIT France Sàrl 20, Rue Lavoisier F Pontoise Tel.: +33 (1) Fax: +33 (1) Germany CERATIZIT Deutschland GmbH Office Langenfeld Hans-Böckler-Straße 10 D Langenfeld Tel.: +49 (2173) Fax: +49 (2173) CERATIZIT Deutschland GmbH Office Dettingen Karlstraße 80 D Dettingen Tel.: +49 (7123) Fax: +49 (7123) CERATIZIT Horb GmbH Stadionstraße 10 D Horb Tel.: +49 (7451) Fax: +49 (7451) info.horb@ceratizit.com CERATIZIT Logistik GmbH Daimlerstraße 70 D Kempten Tel.: +49 (831) Fax: +49 (831) info.logistik@ceratizit.com Great Britain CERATIZIT UK Ltd. Cliff Lane Grappenhall Warrington WA4 3JX Tel.: +44 (1925) Fax: +44 (1925) info.uk@ceratizit.com India CERATIZIT India Pvt. Ltd. 58, Motilal Gupta Road Barisha IN Kolkata Tel.: +91 (33) Fax: +91 (33) Telex: ihm in info.india@ceratizit.com Italy CERATIZIT Italia SpA Piazza Franco Martelli, 7 I Milano Tel.: +39 (02) Fax: +39 (02) info.italia@ceratizit.com CERATIZIT Alserio SpA Via Milanese, 6 I Alserio (CO) Tel.: +39 (031) Fax: +39 (031) info.italia@ceratizit.com Japan CERATIZIT Japan Ltd , Mizuho Shizuoka Tel.: +81 (54) Fax: +81 (54) info.japan@ceratizit.com Luxembourg CERATIZIT Luxembourg Sàrl Route de Holzem 101, B.P. 51 L-8201 Mamer Tel.: Fax: info@ceratizit.com Netherlands CERATIZIT Nederland B.V. Bergrand 224 NL-4707 AT Roosendaal Tel.: +31 (165) Fax: +31 (165) info.nederland@ceratizit.com Spain CERATIZIT Ibérica S.L. Office Pozuelo Vía de las Dos Castillas, 9c Portal 2, Bajo B E Pozuelo de Alarcón Tel.: +34 (91) Fax: +34 (91) info.iberica@ceratizit.com CERATIZIT Ibérica S.L. Office Bilbao Alameda de Mazarredo 41-1-IZ E Bilbao Tel.: +34 (944) Fax: +34 (944) info.bilbao@ceratizit.com Switzerland CERATIZIT Schweiz AG Solothurnstrasse 68 CH-2504 Biel Tel.: +41 (32) Fax: +41 (32) info.schweiz@ceratizit.com USA CERATIZIT South Carolina, lnc. 777 Old Clemson Road Columbia, South Carolina Toll free: +1 (800) Tel.: +1 (803) Fax: +1 (803) info.usa@ceratizit.com

20 - just a click EN We reserve the right to make technical changes for improvement of the product.