Research And Development Of A New Type Of Wear Resistant Roller

Roller is the long axisymmentrical component of supporting conveyor belt or wire rope, which is widely used in coal mines, granaries, mining sand and other delivery eonditions of Powder and Pellet. The structure of roller is comparatively simple. It contains many components, such as roll, axis, bearing block, bearing, sealing arrangement, grease, and so on. The working conditions of roller is usually bad. Because of it’s defects such as high weight, poor corrosion resistance, poor wear resistance and short operating life, etc. The traditional roller made of Q235 steel is unable to meet the rapid development of production. Therefore, developed a new type of roller with high wear resistance, good sealing and long service life is of great practical significance.The microstructure and hardness properties of different material roller steel which is several commonly used were analyzed under different heat treatment level. It was found that the hardness and wear resistance of the roll can be improved by appropriate heat treatment process. The 45# steel has the highest microhardness, 30 Cr steel was followed and 20# steel minimum under hot rolled state. 30 Cr steel has been selected as idler roller material in production, according to the analysis of microstructure and hardness testing, and combine with the processing difficulty and production costs.The dimensions of wear resistance roller was designed as Φ133×4×1305, Φ140×4×417 and Φ194×6×800(Diameter*Thickness*Length, Unit(mm)). The profiles and assembly drawing was given. The new design was improved on the basis of the original ordinary roller, The sealing arrangements were especially optimized by using a double labyrinth seal to substitute the single labyrinth seal and adding two ring groove in the leakage path to prevent the leaking of lubricants. No.2 lithium grease was selected as lubricant of the system.The processing-craft and assembly technology were improved according to the correlation technique requirement of the rollers used in belt conveyors, which not only increase the production efficency, but also ensure that the axiality of roller arbor and bearing chock and the operational roundness was achieved best to decrease the radial displacement of roller.Finally, a batch of new wear resistant steel rollers are produced, and the single roller resistant coefficients of the roller in three different dimensions were measured. They are all conform to the standard of the rotating resistance coefficient of roller in GB10595-89 < General specification for belt conveyors>. Results show that the new roller runs smoothly in production and the service life are effectively improve.