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Introduction: Corrugated rolls are critical components of single-facer machines in carton production. Cracks in these rolls can lead to tooth loss or breakage, posing safety risks. This section analyzes the causes and offers preventive measures.
1. Improper Heat Treatment
Improper heat treatment can cause longitudinal or transverse cracks. Using 35CrM or 42CrM materials with a surface hardness of HRC55–60 ensures durability. Inadequate tempering or delayed tempering can lead to residual stress and aging cracks.
Solution: Ensure proper heat treatment and maintain the tooth surface hardness within the recommended range.
2. Incorrect Installation
Misalignment or uneven pressure between the corrugating and pressure rollers can cause localized stress concentration, leading to cracks and tooth loss.
Solution: Ensure proper alignment and uniform pressure distribution during installation.
3. Incorrect Grinding Process
Grinding burns caused by high temperatures during grinding can lead to surface cracks. These cracks are usually shallow and perpendicular to the grinding direction.
Solutions:
(a) Improve cooling with high-pressure coolant and air baffles.
(b) Optimize grinding parameters such as speed and depth.
(c) Use rubber-bonded grinding wheels and ensure proper wheel dressing.
In conclusion, most corrugated roll cracks are due to heat treatment issues. Incorrect installation and grinding can also contribute but typically result in less severe damage.