Carbide rolls - Sanimex · • India • Japan ... Finishing of carbide rolls ... For classic longitudinal and face turning operations button inserts have proven to be best

Carbide rolls

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CERATIZIT - the parent companies

South America• Brazil

Direct sales and distribution partners

North America• USA• Mexico

Europe• Austria• Bulgaria• Czech Republic• France• Germany• Hungary• Italy• Luxembourg• Netherlands• Poland• Switzerland• Spain• United Kingdom

Asia• China• India• Japan

Headquarters and parent company in MAMER / Luxembourg

Parent company in REUTTE / Austria

Hard material matters - it is the core of our business. Through profound knowledge and highly flexible production facilities we strive to provide our business partners with direct competitive advantages in the field of hard materials for tooling solutions and wear parts. Our dedication to hard material matters creates intelligent solutions for tomorrow and time to come.

Production plants in the three main economic areas and a worldwide sales network of subsidiaries and distribution partners ensure a quick response to customer needs. In-house trainings and seminars guarantee that both business partners and employees share the latest information on our product range.

We promote intensive dialogue with our customers and strive for long-term business relations on a partnership basis. The CERATIZIT corporate value 'The focus and point of view of our business partners matters' is a guiding principle for all CERATIZIT employees worldwide.

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Competence and know-how

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% g/cm3 HV10 N/mm2 N/mm2 N/mm2 W/mK K/1000

CE3 CTC12A 6.0 15.00 1330 2800 5400 630.000 110 4700CE51 CTC20A 10.0 14.55 1170 3000 4200 580.000 105 5000CE65 CTC25A 12.5 14.30 1080 3100 3900 550.000 100 5600CE79 CTC30A 15.0 14.05 1020 3150 3900 530.000 100 5600CE103 CTC35A 17.5 13.80 950 3200 3500 505.000 95 5900CE107 CTC40A 20.0 13.55 900 3200 3300 485.000 95 6300CE112 CTE44A 22.0 13.40 810 2900 3100 470.000 95 6500CE114 CTC50A 25.0 13.15 810 3200 3000 455.000 95 7000CE115 CTC60A 30.0 12.70 730 3200 2500 440.000 95 7300

CE220 CTC20M 10.0 14.50 1100 2600 4400 560.000 110 5100CE230 CTC30M 15.0 14.15 970 2700 4000 530.000 105 5800CE240 CTC40M 20.0 13.60 850 2800 3500 495.000 100 6300CE250 CTC50M 25.0 13.15 760 2700 3100 460.000 100 7000CE260 CTC60M 30.0 12.70 650 2700 3000 420.000 100 7500

TCN541 14.1 6.40 1550 2400 4700 400.000 15 6300

SNC1 SNC1 9.0 3.20 1550 1000 3000 300.000 30 3300

Carbide gradesfor hot rolls

Composition and properties

Grades Binder Density Hard-ness

Transverserupturestrength

Compressivestrength

Young'smodulus ofelasticity

Thermalconductivity

Coeffi cientot thermalexpansionCurrent Future

designation

COARSE GRADES

CERMETS

SILICON NITRIDE

Carbide (coarse grain) Cermets Silicon nitride

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Competence in development & production

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Carbide rollsfor No-Twist mills

We supply the following roll types:

1. As sintered, with sintering tolerances that are common in the sector, external diameter max. 450 mm

2. Semi-fi nished, with external diameter as sintered (bore and sides fi nish-ground)

3. External diameter machined, bore and sides fi nish-ground, without groove

4. Completely fi nished with grooves

Upon request types 1, 2, 3 can be delivered with a sintered groove

Carbide guide rollsReady for use

Types: same as carbide rolls

Grades: carbides, cermets, silicon nitride

Minimum external diameter: D = 30 mm

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Composite rollsfor conventional hot rolling lines

8

1 2 3 4 5 6 7 8

21 – 24 18 – 20 15 – 17 12 – 14

CTC50M CTC50MCTC50M CTC50M CTC40M CTC40M

CTC30M CTC30M

CTC60M CTC60M CTC40M CTC40MCTC60M CTC60M CTC50M CTC50M

CTC60M CTC60MCTC50M CTC50M

CTC40M CTC40M


CTC60M CTC60M



CTC60M CTC60M CTC50M CTC50M

Wire rolling mill

Reducing-Sizing(RSM)

Finishing Sizing

Pre-fi nishing(PFM / RSM)

Finishing

Finishing Sizing

Stand # Stand # Stand #

Grade/stand (recommended values)

Stand #

Product Ø

Binder % (Co-Ni-Cr)

Material: A = low carbon steel B = carbon steel C = alloyed steel Rolling temperature T [°C]: see diagram on top of right-hand page

Schematic view of a No-Twist wire rolling mill

Table of grades with Co - Ni - Cr - binders

9

9 10 11 12 13 14

9 – 11 7 – 8 5.5 – 6

CTC30M CTC30MCTC20M CTC20M CTC20M CTC20M

A

1B

CTC30M CTC30M CTC30M CTC30MC

CTC40M CTC40M D

CTC30M CTC30MCTC20M CTC20M CTC20M CTC20M A

2CTC30M CTC30MCTC30M CTC30M

B

CTC40M CTC40MC

CTC40M CTC40M D


CTC30M CTC30MA

3CTC40M CTC40M

B

CTC40M CTC40MC

CTC40M CTC40M D

Rolling temperature T [°C]

Stand #

Material Rolling temperatureT [°C]

D = special steel

Wire rolling mill

Temperatures in the wire rolling mill

10

1 2 3 4 5 6 7 8

21 – 24 18 – 20 15 – 17 12 – 14

CTC50A CTC50ACTC50A

CTE44A CTC40A CTC40A CTC30A CTC30A

CTC60A CTC60ACTC50A CTE44A CTE44A CTC40A CTC40A

CTC60A CTC60A CTC50A CTC50A CTE44A CTE44A

CTC60A CTC60ACTC50A CTC50A CTE44A CTE44A CTC40A CTC40A

CTC60A CTC60A CTC50A CTC50A CTE44A CTE44A

CTC60A CTC60ACTC50A CTC50A CTE44A CTE44A

CTC40ACTC40A

CTE44ACTC60A CTC60A CTC50A CTC50A CTE44A

Wire rolling mill

Reducing-Sizing(RSM)

Finishing Sizing

Pre-fi nishing(PFM / RSM)

Finishing

Finishing Sizing

Stand # Stand # Stand #

Grade/stand (recommended values)

Stand #

Product Ø

Binder % (Co)

Material: A = low carbon steel B = carbon steel C = alloyed steel Rolling temperature T [°C]: see diagram on top of right-hand page

Schematic view of a No-Twist wire rolling mill

Table of grades with pure Co binder

11

9 10 11 12 13 14

9 – 11 7 – 8 5.5 – 6

CTC25A CTC25A CTC20A CTC20A CTC12A CTC12A A

1CTC30A CTC30A CTC25A CTC25A CTC20A CTC20A BCTC35A CTC35A CTC30A CTC30A CTC25A CTC25A CCTC40A CTC40A CTC35A CTC35A CTC30A CTC30A D


2CTC35A CTC35A CTC30A CTC30A CTC25A CTC25A B

CTC40A CTC40ACTC35A CTC35A CTC30A CTC30A CCTC40A CTC40A CTC35A CTC35A D


3CTC40A CTC40A

CTC35A CTC35A CTC30A CTC30A B

CTC40A CTC40ACTC35A CTC35A CCTC40A CTC40A D

Material Rolling temperatureT [°C]

D = special steel

Rolling temperature T [°C]

Stand #

Wire rolling mill

Temperatures in the wire rolling mill

12

Dem

ag 2

10

Mor

gan

155.

6

Mor

gan

158.

75

Mor

gan

170.

66

Mor

gan

210.

5

Mor

gan

228.

34

Mor

gård

s-ha

mm

ar 1

70

Mor

gård

s-ha

mm

ar 2

23

SIM

AG

180

SIM

AG

215

VAI P

omin

i 210

Ash

low

325

Mor

gan

340

Mor

gan

390

Ash

low

216

Mill roll diametersof various manufacturers

Dan

ieli

166

Dan

ieli

212

13

14

CTC40A CTC40M

Mat

eria

l rem

oval

[g/(m

2 *h)]

Corrosion test according to DIN50905/ASTM G54

Binder: CoHigh degree of cobalt detachment

Binder: Co/NiLow degree of cobalt detachment

pH4Duration of test: 168 hours

pH-value

Mill roll

Application advice

Cooling

Corrosion

The extremely high temperature, especially in the contact zone between the roll and the wire, causes a series of effects which reduce roll life. These negative factors, such as corrosion, wear, reduced dimensional accuracy and cracks can be decreased by applying suffi cient cooling. In fact, a roll which is cooled enough can be used up to 100 % longer compared to rolls which are not provided with an appropriate amount of cooling. Optimum cooling is determined by the water volume supplied, adequate pressure and correct positioning of the exit nozzles for the coolant. Approx. 30 % of the coolant quantity should be focused on the exit side of the rolled product, close to the rolling line.

In hot rolling operations, corrosion represents an electro-chemical process which causes anticipated wear and leads to a rougher surface of the groove. The degree of corrosion increases with the rolling temperature, therefore the groove shows more corrosion than the rest of the roll. Corrosion causes the cobalt matrix to detach from the tungsten carbide structure. In the case of regular surface corrosion this leads to considerably higher wear and, with irregular corrosion it can result in mechanical or thermal cracks. Apart from the rolling temperature, both the temperature and pH-value of the coolant are decisive with regard to corrosion. The highest acceptable temperature of the water with a pH-value ranging between 7.5. and 8.5 is 35 °C. If the water temperature is 25 °C, the pH-value lies between 6.5 and 9. Acid water attacks the cobalt binder, while extremely alcaline water will attack the tungsten carbide. Special binders such as nickel-cobalt-chromium alloys show notably higher corrosion resistance, i.e. they may be used up to pH 5.5.

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Carbideroll

Cutting datafor CBN and PCD

Binder content[%]

vc[m/min]

ap[mm]

f[mm/rev]

15 - 20 10 - 200.1-2.5 0.15-0.320 - 25 20 - 30

>25 30 - 50

Network of cracks

Finishing

Thermal cracks

The alternating cooling and heating phases of the roll during the process lead to a considerable thermal gradient. The tension arising from these temperature changes mainly concerns the profi le of the roll and produces a whole network of surface cracks, their type depending primarily on the carbide grade chosen. Carbide grades with a major binder content have a higher thermal expansion coeffi cient and are characterized by low thermal conductivity. In such grades cracks occur more often but are basically limited to the surface. Obviously, for carbide grades with a low binder content the opposite is true. With optimum cooling, a rolling speed of more than 10 m/sec. and a reduction of the section by a maximum of 20 % the depth of the cracks is limited to 0.2 mm. For lower rolling speeds and thus longer contact time between the roll and the rolled product, the crack depth can go up to 0.8 mm. It is important that cracks caused by tension are eliminated completely when redressing the roll.

Finishing of carbide rolls

Hard materials such as carbides, cermets and silicon nitride are mainly ground by applying a diamond wheel. For turning with a binder content of >15 % the use of a geometrically defi ned cutting edge is recommended. Suitable cutting materials are cubic boron nitride (CBN) and polycrystalline diamond (PCD). The insert shape should be as robust as possible depending on the roll profi le that is to be produced. For classic longitudinal and face turning operations button inserts have proven to be best. When fi nish-turning the groove, it is the shape of the groove itself which is decisive for the choice of the insert type. The cutting edge should be sharp, a negative protective edge chamfer is, however, not necessary. When using CBN, dry machining is possible, whereas the application of polycrystalline diamond requires abundant quantities of cooling emulsion.

The CERATIZIT engineers will gladly help you choose the suitable tool and cutting parameters.

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CERATIZIT carbide rolls are used to provide top performance even with extreme rolling conditions.CERATIZIT, because reliability counts.

Maximum pressure, heat, rolling speed, work overload!

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Notes

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Notes

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Headquarters: CERATIZIT S.A.Main site LuxembourgCERATIZIT Luxembourg SàrlRoute de Holzem 101, B.P. 51L-8201 MamerTel.: +352 312 085-1Fax: +352 311 911E-Mail: [email protected]

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Documents

Carbide rolls - Sanimex · • India • Japan ... Finishing of carbide rolls ... For classic longitudinal and face turning operations button inserts have proven to be best