Heavy Machinery Backup Roll Support Roller for Steel Mill Equipment

• Customization: Available
• Casting Method: Sand Casting,Special Casting,as Required
• Casting Form Material: Metal,Sand, Mud,as Required
• Model NO.: Backup Roll 0509
• Casting Metal: Cast Iron, Cast Steel,as Required
• Casting Form Usage Count: as Required
• Surface Treatment: Sand Blast,Polishing,as Required
• Surface Roughness: as Required
• Coating: as Required
• Machining Tolerance: as Required
• Standard: as Required
• Certification: ISO 9001:2000
• Origin: Luoyang
• Production Capacity: 100

Product Description

Backup rolls (support rolls) are critical components in heavy machinery, primarily used in rolling mills to support work rolls and maintain dimensional accuracy during metal forming processes.

Key Specifications:

• Materials:

  • Alloy Types: 3%Cr, 5%Cr, 60CrMo, 9Cr2Mo, and 86CrMoV7 alloys for enhanced wear resistance and tensile strength .
  • Casting Methods: Static monobloc casting for seamless structure (up to 80T weight) or forged steel for high-pressure applications (diameter range: 350-1,500mm) .
  • Hardness: Barrel hardness ranges from 50-80 HSD (Rockwell) depending on alloy composition .

• Applications:

  • Hot Rolling Mills: Withstand temperatures up to 1,200°C, used in roughing stands and tandem mills .
  • Cold Rolling Mills: Precision-ground surfaces for strip thickness control (e.g., 4-Hi and 6-Hi mills) .
  • Specialized Equipment: Tension levelers, vertical mills, and shipbuilding machinery .

• Technical Highlights:

  • Surface Treatments: Induction hardening (40-100mm depth) and micro-polishing for uniform wear .
  • Load Capacity: Supports radial forces exceeding 500kN, with fatigue life optimized via finite element analysis (FEA) .
    

    
    
     

Product Parameters

Category	Parameter	Technical Specifications/Description
Material & Composition	Alloy Grades	3%Cr, 5%Cr, 60CrMo, 9Cr2Mo, 86CrMoV7, 70Cr3Mo, 45Cr4NiMoV, etc. Enhanced wear resistance and tensile strength.
	Chemical Composition (Example)	3%Cr: C 0.3-0.7%, Cr 2.0-4.0%; 5%Cr: C 0.4-0.8%, Cr 4.0-6.0% (with Mo, V trace elements)
Manufacturing Process	Casting Technology	Monobloc static casting (max. single weight: 80T, diameter ≤1800mm) or forged steel (diameter 350-1500mm)
	Heat Treatment Technology	Induction quenching (hardened layer depth 40-100mm), Electroslag Remelting (ESR) to reduce micro-segregation
Mechanical Properties	Barrel Hardness (HSD)	50-80 HSD (adjusted by alloy type, e.g., 5%Cr forged rolls: 55-80 HSD)
	Tensile Strength (MPa)	≥700 MPa (3%Cr), ≥900 MPa (5%Cr)
	Fatigue Life Optimization	Finite Element Analysis (FEA)-designed to withstand radial forces >500kN
Dimensions & Weight	Typical Size Range	Diameter 350-2300mm; Barrel length ≤2800mm; Total length ≤7000mm
	Max. Single Weight	Cast rolls: 80T; Forged rolls: 255T (special applications)
Application Scenarios	Hot Rolling Equipment	Roughing stands, continuous rolling mills (temperature resistance up to 1200°C), e.g., 1780 hot tandem mills
	Cold Rolling Equipment	4/6-high mills (precision-ground surface for strip thickness control, tolerance ±0.001mm)
	Special Equipment	Tension levelers, edger mills, shipbuilding machinery
Surface Treatment & Testing	Surface Treatment	Micro-polishing, wear-resistant overlay welding (restores 92% of original dimensions)
	Concentricity Requirements	Radial runout ≤0.01mm (exceeding causes strip surface defects and vibration marks)
	Testing Standards	Ultrasonic Testing (UT), Magnetic Particle Testing (MT), hardness uniformity deviation ≤4 HSD

Certifications

Our backup rolls comply with international standards to ensure reliability:

• Quality Management: ISO 9001:2015 certification for process control .
  

  
  
   

Packaging & Shipping

• Packaging:
  • Wooden crates with fumigation or steel pallets for corrosion protection .
  • Customized shock-absorbent liners for rolls exceeding 13T .
• Shipping Options:
  • Sea Freight: Cost-effective for bulk orders (lead time: 30-60 days).
  • Air Freight: Expedited delivery for urgent projects (max. weight: 5T) .
  • Land Transport: Secure trucking with GPS tracking (regional coverage) .
    

Installation Instructions

Step-by-Step Guide:

1. Pre-Installation Checks:

   • Verify roll concentricity (≤0.01mm circular runout) to prevent plate surface defects .
   • Clean bearing seats and apply heat-resistant grease (e.g., Molykote HP-870) .

2. Mounting:

   • Use hydraulic press plates (patented CN201529664U) to secure rolls onto mill frames .
   • Align backup rolls with work rolls using laser-guided systems (±0.001mm tolerance) .

3. Post-Installation:

   • Conduct dynamic balancing tests to minimize vibration .
   • Perform trial runs at 20% operational load for 2 hours before full production .

Our Advantages

1. Technical Expertise:

• Advanced Manufacturing:
  • Vacuum casting (VC) and electroslag remelting (ESR) for defect-free ingots .
  • Multi-axis CNC grinding (MK84200 machine) for micron-level precision .

2. Global Experience:

• Supplied to 50+ countries .
• OEM provider 

3. Cost Efficiency:

• Extended service life (20-40% longer than industry average) reduces replacement frequency .
• Bulk-order discounts for rolls exceeding 10T .

After Sales Service

Comprehensive Support:

1. Pre-Sales Consultation:

   • Custom roll design based on mill parameters (e.g., strip width, rolling force) .
   • Remote technical support for emergency troubleshooting .

2. Quality Assurance:

   • Third-party inspection (SGS/BV) available upon request .
   • 12-month warranty against material defects .

3. Post-Sales Maintenance:

   Spare Parts:
   • Priority access to backup bearings, seals, and fasteners .
   • 24/7 Hotline: Multilingual support (English, Russian, Portuguese) .

FAQ

Q1: What material is best for high-speed cold rolling?

• A: 5%Cr forged steel rolls (hardness: 55-80 HSD) offer optimal wear resistance and fracture toughness .

Q2: How to address roll surface scratches?

• A: Schedule immediate regrinding (≤0.05mm depth removal) to prevent strip defects .

Q3: What is the lead time for custom rolls?

• A: 45-60 days for monobloc casting; 30 days for standard forged rolls .

Q4: How to minimize roll vibrations?

• A: Ensure bearing clearance <0.05mm and balance rolls using ISO 1940 G2.5 standards .