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Induction heating and quenching process for rollers without iron core
Published Time:
2026-01-21
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Summary
By adopting the coreless inductor heating and quenching process, the depth of the hardened layer of the rollers can be increased, significantly improving the stress state of the rollers during use. This increases the number of grinding cycles when the rollers wear out, extending their lifespan by 50% to 80%. The specific process is as follows:
1. Roller material
It is essential to use roll steel with good hardenability. The selection includes 8CrMoV, 9Cr, 9Cr2, 9CrV, or steel grades such as DZ801 and DZ811, which have better hardenability than 86CrMoV7.
2. Preheating and heating
Induction heating without an iron core has a lower specific power, and it is usually best to use high-induction heaters without an iron core for heating and quenching of rollers. It is recommended to preheat the entire roller in a furnace, with the preheating temperature determined based on the desired depth of the hardened layer. The preheating temperature should also be determined based on the size of the roller, the power of the inductor, whether internal and external cooling is used, and whether cold treatment is performed after quenching. A preheating temperature of ≥500~560℃ is generally recommended. Increasing the heating temperature of the roller by 30-45℃ and the austenitizing time by 8-15min can enhance the depth of the hardened layer in the roller quenching process.
3. Water spray quenching
The coreless high-induction sensor is used for induction heating and quenching of the roll. Due to the deep heating depth, a large amount of water must be used for spray quenching. If necessary, the central hole can be used for internal and external cooling with a large amount of water to obtain high-quality rolls with high hardness, ultra-deep depth, and optimal stress state. A new type of sprayer with large spray holes, large water volume, low water pressure, and multi-level steady state is adopted, and a cooling device using adiabatic expansion and air cooling is added.
4. Auxiliary devices for heating and quenching, as well as temperature measuring instruments
To use a coreless high-induction sensor for roll heating and quenching, corresponding auxiliary devices are necessary, including 1) a voltage regulation and stabilization device to ensure voltage power adjustment and voltage stability. 2) A spray quenching system with sufficient water volume and low water pressure, as well as a sprayer with a large water volume. Additionally, like all induction heating, accurate temperature measurement instruments should be used for roll induction heating and quenching. Optical pyrometers have too large a temperature measurement error, so infrared thermometers from the American IRCON company or high-precision induction heating infrared thermometers from domestic companies, as well as SMT furnace temperature tracking instruments, can be selected.
5. Cold treatment
To obtain high-hardness and ultra-deep high-quality rollers, they must undergo cold treatment after being heated and quenched by a high-induction device without an iron core. It is necessary to be able to perform -120℃ cold treatment to adjust the amount of residual austenite in the roller after quenching, ensuring that the roller has a high-hardness, deeper quenched hardened layer and optimal stress state.
Keywords:
Metallurgical Equipment
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Induction heating and quenching process for rollers without iron core
2026-01-21
2018-06-14
Innovation, Progress, Satisfactory Solutions, Quality Products is what the company pursues always.
2018-06-14
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