Tungsten Carbide Coating Alloy Steel Corrugating Rolls For BW Papersystems
1. Strict Selection of Corrugated Rollers Material
Good raw material is an important factor in high quality of corrugating roll. We select the best raw material manufacturer in China. With high strength and toughness, good hardenability, no obvious temper brittleness, 50CrMo alloy steel is specialized material for manufacturing corrugating rolls. Our raw material shell thickness is more than 70mm, the thicker shell can reduce deformation and keep stability during production.
2.Precision Welding Make Inseparable
Both ends of the roller body should be heated to release the size of the inner bored hole. After the spindle heads are put in, the roller body and the spindle heads should be held tightly after natural cooling. When everything is ready, a driving fit interface has been formed between the roller body and the spindle heads by means of preheating, welding or bolting. Special care should be taken when welding, because finished corrugated roller body’s temperature will rise constantly when the roller is running, and the roller body also bears pressure of the steam from the inside of the roller body, which will form the so-called “pressure vessel”. In view of this, the roller body and the spindle heads joint must pass the pressure test. When the welding process finished, the work piece shall be put into the furnace for high temperature tempering to reduce stress.
3. High Hardness from Vertical Quenching Process
Intermediate frequency quenching can guarantee both the hardness and harden depth we need. Our harden layer depth can reach to 8-12mm. With harder base material as foundation, the lifetime of our corrugating rolls are greatly extended. After different heat treatment process, the corrugated roller surface becomes more wear-resistant and durable.
Intermediate frequency quenching machine.
4. Rigorous for Precise Grinding
After heat treatment and the cutting slots, the roller shall be put on high precision automatic CNC grinding machine to do finish grinding.By grinding wheel grind each flute several times until the accuracy is within our technical permitted requirement. The Siemens control system play a key role in guarantee the accuracy.
High precison grinding machine with Siemens CNC system.
5. Durable from Supersonic Tungsten Carbide Spraying
Spraying technology is the key, which can ensure the hardness and binding force of tungsten carbide.Most advanced Praxair JP 8000 HVOF tungsten carbide spraying equipment and technology is adopted and Praxair 1342 super hard tungsten carbide powder is used for our corrugating roll. Before tungsten carbide spraying, we do sand blasting treatment on the surface which make rough surface to increase adhesion of tungsten carbide powder.
Sand blasting machine
American Praxair Tungsten Carbide Plating equipment.
Praxair 1342 super hard tungsten carbide powder
6. Repeatedly Polished, Smooth As a Mirror
Meijia adopts special polishing crafts, such as the corrugated rollers use America Praxair 1342VM series super hard tungsten carbide roller, special customized polishing wheel. With our company’s fully automatic CNC corrugated roller producing process’s special polishing machine and our independent grinding polishing technology R&D, the tungsten carbide roller’ s surface finish degree can reach Ra<0.6μm, which will improve the accuracy of the flute profile, and make sure the quality of the corrugated roller.
7. Strict Test to Keep Improving
Before and after the surface treatment including tungsten carbide plating or hard chrome coating of corrugating rolls, it is needed to check the size, hardness, precision, flute profile, and simulation feeding paper. Special projector is used to check the flute profile and feeding different GSM paper to ensure the performance of corrugating rolls.
Test flute profile with computer and projector.
8. Flute Profile
| Flute | Profile | Height(mm) | Pitch(mm) | Flutes/300mm | T.U.R |
| A | UV | 4.5-5.0 | 8.0-9.5 | 34±3 | 1.45-1.52 |
| C | UV | 3.5-4.0 | 6.8-7.9 | 41±3 | 1.37-1.47 |
| B | UV | 2.5-3.0 | 5.5-6.5 | 50±4 | 1.33-1.41 |
| E | UV | 1.1-2.0 | 3.0-3.5 | 93±6 | 1.24-1.36 |
| F | UV | 0.8-1.0 | 2.2-3.2 | 115±20 | 1.19-1.25 |
| G | UV | 0.6-0.8 | 1.8-2.8 | 136±20 | 1.15-1.20 |
| N | UV | 0.4-0.6 | 1.2-2.2 | 193±55 | 1.10-1.15 |
| Others | UV | Customized | Design | Design | Design |
9. Precision index of corrugating rolls
| Item | Index |
| Gear teeth height limits of deviation | ≤ 0.01mm |
| Addendum circle run out tolerance | ≤ 0.02mm |
| Gear teeth width limits of deviations | ≤ 0.015mm |
| Tooth profile limits of deviations | ≤ 0.01mm |
| Gear lateral face counter shaft parallelism | ≤ 0.01mm |
| Tip cylinder element linear | ≤ 0.01mm |
| Gear teeth division limits of deviations | ±10" |
| Smooth finish | Ra<0.6µm |
10. About us
Qingdao Meijia Corrugated Roller Co.,Ltd., founded on May7, 2010, is a professional manufacturer specialized in corrugated roller design, producing and renovation, which is one of the rare professional manufacturer in China with whole-process capacity for corrugated roller. Meijia company with registered capital of 36 million RMB, is located in Jiaozhou, Qingdao City, Shandong Province, China (mainland), covering over 30,000 square meter, and has first phase of 15000 square meter. All equipment of our industry adopts high standard configuration, and the overall scale ranks at the top among domestic similar enterprises. Meijia company has been established in the North of China, with “Fulfill you and me to create win-win situation” business philosophy, high and strict standards, providing customers with excellent quality and services. With mature and stable processing technology, a group of featured, efficient, scrupulous stuff, to ensure that every design and production to maximize the profit of our customers and create new competitive advantage.
Main products:Tungsten carbide corrugated rollers, hard chrome corrugated rollers, pressure roller, glue roll and doctor rolls. The products are mainly sold in China, India, South Korea, Russia ,Thailand, Myanmar, Iran, Egypt and other countries.Therefore, our products are widely recognized by the global customers, which make us gaining sound reputation all over the world.
Contact me:
Bonnie Li
