🔥 Breaking Through Pain Points in Large-Size Special Steel Wire Rod Rolling!

I. Roller Ring Fracture: The “Cracking Curse” of High-Alloy Steels

✅ Core Pain Point

Frequent cracking of cemented carbide roller rings in the RSM mill for large-size products (≥Φ21mm) such as spring steel and bearing steel. Root causes: “black head” formation due to head temperature drop, insufficient locking contact surface (<80%), and sharp stress increase when pass filling degree exceeds 95%.

🛠️ Targeted Solutions

1. Head temperature control: Waterproof equipment + optimize cooling water tank parameters, reserve heat recovery time;
2. Locking reinforcement: Ensure roller ring-taper sleeve-roller shaft contact surface ≥80%;
3. Filling degree management: Strictly limit to 90%-95% range。

📊 Implementation Results

Significant reduction in roller ring fracture frequency, minimized production interruptions, lowered spare part costs, and improved rolling continuity!

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II. Surface Scratches: The “Appearance Killer” of Large-Size Products

✅ Core Pain Point

High self-weight and deformation resistance of products lead to increased friction with tooling during laying, air cooling, and coiling. Scratches are prone to occur due to guide wear, poor laying pipe adaptability, and rough roller table surfaces.

🛠️ Targeted Solutions

1. Laying head optimization: Adopt multi-guide wheel downward bending device + component alignment + regular wear inspection;
2. Laying pipe adaptation: Customize by specification (16-22mm matched with 34mm inner diameter / 23-28mm matched with 38mm inner diameter), and produce in “large→small” specification order;
3. Guide/roller table upgrade: Shorten forming guides + regular polishing, optimize laying speed.

📊 Implementation Results

Dramatic drop in surface scratch defect rate, qualified finished product smoothness, and significantly reduced scrap/rework rates!

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III. Tail Coil Shape Loss: The “Regularity Dilemma” in Coiling

✅ Core Pain Point

Tail coil issues such as small coils (insufficient inertia/speed asynchrony), loose coils (unable to integrate after shaping), and coil tilting (large drop during falling) often occur, affecting packaging and heat treatment.

🛠️ Targeted Solutions

1. Speed synchronization: Synchronize speed of laying head + pinch roll + RSM mill, optimize acceleration slope;
2. Coil laying/cooling adjustment: Optimize oscillation/acceleration parameters, and adopt tail pause mode for air cooling roller table;
3. Coiling optimization: High-position coiling in the reel to reduce falling drop.

📊 Implementation Results

Regular tail coil shape, complete elimination of loose/small coil problems, compact and uniform coil shape, meeting subsequent packaging and heat treatment requirements!

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IV. Process Root Cause: The “Chain Reaction” of Skipping Pre-Finishing Rolling

✅ Core Pain Point

Direct entry into the RSM mill (skipping pre-finishing/finishing mills) leads to: continuous temperature drop of rolled pieces, increased rolling force/biting impact, and higher coil forming resistance due to low-temperature laying, resulting in various quality issues.

🛠️ Systematic Solutions

1. Precise temperature control: Match heating/RSM temperatures by steel grade;
2. Parameter synergy: Integrate optimization measures for pass design, locking, speed, etc.;
3. Tooling upgrade: Customize laying pipes and optimize guides to adapt to large-size products.

📊 Implementation Results

Comprehensive control of full-process defects, stable qualification of product performance, precision, surface quality, and coil shape, achieving efficient and high-quality production!

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💡 The core of large-size special steel wire rod rolling: Identify process root causes + adopt precisely adapted solutions!

If you are facing similar rolling challenges or need in-depth discussion on solutions, feel free to contact us:

📱 Whats App: 0086 13613814286

📧 Email: hengyuan6@hotmail.com

Looking forward to collaborating with industry peers to overcome technical difficulties and create a new paradigm of efficient production!