Numerical simulation of hardfacing remanufacturing for large-scale damaged grinding roller

Tian, Liang; Xing, Shouhang; Liu, Guojun; Luo, Yan

doi:10.1007/s00170-021-08073-4

Cited by 4 publications

(3 citation statements)

References 33 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, after the backup roll serves under high load for a period of time, the roll surface is prone to spalling, making it unable to work properly. For the backup roll, because of its high technical requirements and difficulties in fabricating, the hardfacing technique is currently used for the roll surface repair [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Hardness Characteristics of Swing-Arc SAW Hardfacing Layers

Zhu,

Ran,

et al. 2024

Materials

View full text Add to dashboard Cite

Hot-rolled backup rolls are widely used in steel rolling and usually need to be repaired by arc hardfacing after becoming worn. However, a corrugated-groove defect commonly occurs on the roll surface due to the uneven hardness distribution in the hardfacing layers, affecting the proper usage of the roll. Accordingly, a new swing-arc submerged arc welding (SA-SAW) process is proposed to attempt to solve this drawback. The microstructure and hardness are then investigated experimentally for both SAW and SA-SAW hardfacing layers. It is revealed that a self-tempering effect occurs in the welding pass bottom and the welding pass side neighboring the former pass for both processes, refining the grain in the two areas. In all the zones, including the self-tempering zone (STZ), heat-affected zone (HAZ), and not-heat-affected zone in the welding pass, both SAW and SA-SAW passes crystallize in a type of columnar grain, where the grains are the finest in STZ and the coarsest in HAZ. In addition, the arc swing improves the microstructure homogeneity of the hardfacing layers by obviously lowering the tempering degree in HAZ while promoting the even distribution of the arc heat. Accordingly, the hardness of the SA-SAW bead overall increases and distributes more uniformly with a maximum difference of < 80 HV0.5 along the horizontal direction of the bead. This hardness difference in SA-SAW is accordingly decreased by ~38.5% compared to that of the SAW bead, further indicating the practicability of the new process.

show abstract

Section: Introductionmentioning

confidence: 99%

Microstructure and Hardness Characteristics of Swing-Arc SAW Hardfacing Layers

Zhu,

Ran,

et al. 2024

Materials

View full text Add to dashboard Cite

show abstract

“…The papers [11,12] present modeling of multi-layer hardfacing with distribution of temperature, deformation and residual stresses of dissimilar welded butt joints with code written in ANSYS APDL and taking into account heat inputs in each element. The papers [13,14] provide modeling of the restoration of hardalloy surfacing parts. The results of numerical simulation revealed the trend of change and distribution of temperature fields and residual stresses during surfacing, taking into account the thermal cycle curve and phase transition effects.…”

Section: Introductionmentioning

confidence: 99%

Simulation of the distribution of temperature, stresses and deformations during splined shafts hardfacing

Nurzhanova,

Zharkevich,

Bessonov

et al. 2023

J Appl Eng Science

View full text Add to dashboard Cite

This article describes the process of modeling the restoration operations of the destroyed segment of the spline and its complete restoration using modern methods, such as hardfacing in a protective gas environment with a consumable electrode. The ANSYS Workbench 19.2 software with an additional Welding Distortion and Moving Heat Source extension was used to simulate the process of hardfacing a damaged surface. The thermomechanical behavior of the deposited layer on the outer surface of the splined shaft is analysed. Dependences of the value of temperature fields on the parameters of the hardfacing mode in one and two passes depending on time are established. Dependences of residual stresses (0.413-239 MPa) and deformations (0.02-0.23 mm) in the process of semi-automatic hardfacing are determined. Experimental studies of samples during hardfacing were carried out for comparison with the geometry of the weld during modeling. The simulation results are in good agreement with the experimental data.

show abstract

“…The Stellite 6 layer had the lowest wear resistance in the dry sand/rubber wheel test, and the Stellite 6 layer had the highest wear resistance in the erosive blasting test. A numerical procedure for the hardfacing process based on a thermal cycle curve method was established by Tian et al [ 11 ] to research the temperature and residual stress fields in the hardfacing remanufacturing for a large-scale grinding roller with damage. The numerical simulation results showed that with an increase in surface layers, the heat-affected zone of the grinding roller gradually expands, and the maximum tensile stress always appears at the position near the weld toe, which is prone to fatigue failure or interface peeling due to stress concentration.…”

Section: Introductionmentioning

confidence: 99%

Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers

et al. 2022

View full text Add to dashboard Cite

To improve the service life and reduce the repair cost of continuous casting rollers, a new welding-hammering hybrid remanufacturing process in which the roller was designed with a gradient structure was proposed, and corresponding equipment was developed. First, the failure modes and their causes for a continuous casting roller were analyzed by numerical simulation. The cyclic tension–compression shear stress, cyclic tension–compression normal stress, thermal cycle, and highly corrosive environment caused fatigue cracking and overall peeling of the roller surface. Second, the gradient structure composed of a base layer, transition layer, and strengthened layer of a continuous casting roller was designed, and materials for each layer were selected according to their different service conditions. Third, novel equipment for continuous welding-hammering composite remanufacturing was developed, and the optimized process parameters were obtained through welding experiments. Finally, an application test was carried out; the microscopic analysis showed that refined grains, fewer welding defects, and better surface toughness were obtained. Compared with traditional remanufacturing processes without hammering, the welding-hammering hybrid process achieved a forged structure instead of as-cast structure, which significantly improved the service life of the continuous casting roller by about 100%.

show abstract

Numerical simulation of hardfacing remanufacturing for large-scale damaged grinding roller

Cited by 4 publications

References 33 publications

Microstructure and Hardness Characteristics of Swing-Arc SAW Hardfacing Layers

Microstructure and Hardness Characteristics of Swing-Arc SAW Hardfacing Layers

Simulation of the distribution of temperature, stresses and deformations during splined shafts hardfacing

Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers

Contact Info

Product

Resources

About