Research on Spiral Intermediate Roller

2025-09-05 11:53:27

In industrial production, the Spiral intermediate roller is an important component widely used in fields such as sheet metal processing, material mixing, and metal surface treatment, which is of great significance for improving product quality and production efficiency. It is necessary to conduct in-depth research on spiral intermediate rollers to optimize industrial production processes and enhance product competitiveness.

The spiral Intermediate roller is mainly composed of a roller body, a spiral groove, and an end support mechanism. The material of the roller body is selected according to the working conditions. For example, in plate straightening machines, high-strength alloy steel is often selected, which has been specially treated to obtain good comprehensive performance. Spiral groove parameters (pitch, helix angle, groove depth, groove width) affect its working effect. Pitch determines the axial movement speed of materials or sheets, helix angle affects their motion trajectory on the roller surface, and groove depth and width consider material characteristics and equipment operating conditions. The end support mechanism includes a bearing seat, bearings, and a sealing device to ensure stable rotation of the roller body. The bearings are selected according to the load, speed, and working environment, and the sealing device prevents impurities from entering.

Plate straightening:

In the plate straightening machine, the spiral intermediate roller works in conjunction with the working roller and the supporting roller. The sheet metal is first subjected to plastic deformation caused by the bending of the work roll. The spiral intermediate roll uses a spiral groove to guide the movement of the sheet metal, adjust the internal stress distribution of the sheet metal, eliminate residual stress and deformation, and make the sheet metal smoother. At the same time, the spiral groove can store lubricating fluid, reduce friction between the plate and the roller surface, reduce surface damage, and improve surface quality.

Material mixing:

In the material mixing equipment, when the spiral intermediate roller rotates, the spiral groove pushes the material to move in the axial and circumferential directions. Different materials collide and mix with each other in complex motion, accelerating the mixing process and improving mixing uniformity. Reasonable design of spiral groove parameters can adapt to different material characteristics and mixing requirements, such as special groove types and parameters required for viscous materials.

Metal surface treatment:

When used for metal surface treatment, the spiral line processing blade of the spiral intermediate roller performs spiral processing on the metal surface. Remove the oxide scale and decarburization layer on the metal surface, causing plastic deformation on the metal surface, forming a hardened layer, and improving surface hardness, wear resistance, and fatigue life. During processing, grooves allow coolant to enter and discharge machining debris, ensuring smooth machining.

Application Cases

Sheet metal processing industry

A certain sheet metal production enterprise uses a straightening machine with a spiral intermediate roller to process aluminum alloy sheets with a thickness of 0.5-3mm. After testing, the flatness error of the straightened board is ≤ 0.5mm/m, and the surface roughness Ra is ≤ 0.8 μ m. The product quality has significantly improved, and the scrap rate has decreased from 10% to within 3%.

Material mixing field

In the mixing of chemical raw materials, the use of a spiral intermediate roller mixing device has shortened the mixing time from 30 minutes to 15 minutes, increased the mixing uniformity from 85% to over 95%, improved production efficiency, and ensured product quality stability.

In terms of metal surface treatment

After surface treatment of high-strength steel components, the surface hardness is increased by 20% -30% and the fatigue life is extended by 1-2 times through spiral intermediate roller processing, effectively improving the service performance and service life of metal components.

optimization strategy

structural optimization

Using new materials such as high-strength and wear-resistant composite materials to manufacture the roller body reduces weight while improving strength and wear resistance. Optimize the spiral groove structure, use computer simulation technology to accurately design parameters according to different working conditions, and improve work efficiency and effectiveness. Improve the end support mechanism, adopt advanced bearing and sealing technology, reduce frictional resistance, and enhance equipment stability and reliability.

Manufacturing process improvement

Using precision machining technology to improve the accuracy of roller body and spiral groove processing, reduce manufacturing errors, and ensure the stability and uniformity of roller operation. Using surface treatment techniques such as chrome plating and nitriding to improve the surface hardness and corrosion resistance of the roller body, and extend its service life.

Intelligent control and monitoring

Introduce an intelligent control system to monitor the working status of the spiral intermediate roller in real time (speed, load, temperature, etc.), automatically adjust the working parameters according to the working conditions, and achieve equipment operation. Install fault warning devices to promptly detect potential problems, maintain in advance, reduce downtime, and improve production continuity.