The Research Of Complexing Roller Based On Dual Electro-Slag Technology

This subject was brought up during the carrying out of "National 863 Program" The application and development of integral shaping the bent axle by one step in electro-slag melting casting (ESC) ".And the subject has already supported by the Key Technology Research and Development project in NanChang.The ESC technology belongs to the net shaping technology, It centralizes the metal refinement pure and the crystallization solidification shaping on one step, and makes the formed part not only have good metallurgical quality and solidification quality, but also has the size of form close to or even equal to the final products. Along with the ESC technology's using and popularizing, people have discovered many problems and shortages in this technology. So, it need us to study the ESC technology's mechanism deeply, direct the ESC practical using by theory. In the steel rolling and foundry producing process, The roller suffered tough working strength, and worked under extremely adverse conditions, so it was always badly abraded, so the rough surfaces must be rubbed off, or need to be replaced. The short using life and the problem of invalidation have greatly restricted the producing efficiency and economic benefits.This paper put forward the "Heating by electro-slag technology actively" technology under the experiment of ESC process. Based on this, this paper introduced a new method-"Composite Roller Based On Dual Electro-Slag Technology". This method has many advantages against other methods of roller casting and complex technology, it can completely actualize the high speed, simplify and economy.Based on the studying intention and purport , the phenomena of thermoelectricity transmission boundary conditions of the system are deposed reasonably by dint of electrode, slag hull, mould and slag pool etc. ANSYS, a finite element method (FEM) analysis software is applied to couple the thermal field and electric field. The distributing laws of temperature, heat source, electric field, voltage, current density and axial, radial, circumferential Temperature direction are analyzed. It is found that a high temperature region exists between the electrode tip and the roller. The heat transfer between high temperature region and the roller made the surface layer of the roller heated up quickly and actively.It is also found that the craft parameters influence the high electric field of heating system remarkably, such as : Yolt,slag pool's depth,insert depth and the distance between electrode and roller. And the shape of the electrode tip can't be omitted when analyzing. Based on the simulation of all the above, this paper estimates the pull-out velocity,pull-out time and other key parameters etc., and this paper also introduces the method for automatic controlling ordered by computer.In order to validate the reliability of simulation results, plans and a lot of experiments are carried out on the HeXing metallurgy mechanism plant in NanChang.The results measured by several of equipments are close to the simulation results.Both the simulation and experiment results prove that the using foreground of "heating technology by electro-slag actively" is optimistic. It can not only used in the composite roller, but also in other areas such as ESHT technology, metal heat-treatment etc. So it can inaugurate a new method on metal surface heating field when complexing metals or taking heat-treatment. This paper has great theory meaning and real value to the following experiment and manufacturing.