How does the wear resistance of carbide rollers perform in actual applications?
Publish Time: 2025-04-05
The wear resistance of carbide rollers is extremely outstanding in actual applications, which is specifically reflected in the following aspects:1. Excellent performance under extreme working conditionsHigh temperature wear resistance: carbide rollers can still maintain high hardness at high temperatures of 900~1000℃ (the hardness is still higher than that of ordinary high-speed steel), and are suitable for high-temperature environments such as dry cutting. For example, actual measurements on a hot rolling production line of Baosteel show that the wear of carbide rollers is only 0.15mm after 1200 hours of continuous work, while traditional steel rollers need to be replaced after 400 hours under the same working conditions.Processing of high-hardness materials: When processing high-hardness gears above HRC50 (such as aircraft engine turbine disc gears), the cutting speed can reach 200~300m/min, and the tool life is increased by 3~5 times.2. Long life and low maintenance costImproved wear resistance: The wear resistance of carbide rollers is 8 to 10 times that of high-speed steel and more than 15 times that of ordinary alloy steel rollers. For example, laboratory tests show that its hardness can reach HRA90 to 93, while ordinary alloy steel rollers are only HRC60 to 65.Reduce downtime frequency: In metal wire processing, the life of carbide rollers is 5 to 8 times that of traditional rollers, reducing the frequency of downtime and replacement and improving production efficiency.3. Micro-strengthening effectReinforcement of tungsten carbide particles: The core material of carbide rollers is a composite structure of tungsten carbide (WC) and cobalt (Co). The micro-strengthening effect of WC particles enables its hardness to remain above 85% of the normal temperature state at a high temperature of 800°C, completely solving the problem of thermal softening of steel rollers.High hardness and low friction coefficient: The hardness of carbide rollers can reach HRA86~93, and the wear resistance is improved by 5~8 times. At the same time, the friction coefficient is low, which reduces vibration and noise during processing.4. Typical application casesTextile machinery: In high-speed textile machinery, the wear resistance of carbide rollers extends the roller life to 5~8 times that of traditional materials, reduces the frequency of downtime and replacement, and improves production efficiency.3C electronic precision machining: When used for CNC machining of mobile phone middle frames, the roundness error is ≤0.002mm and the surface roughness Ra≤0.1μm, which meets the micro-groove processing requirements of 5G antennas.New energy battery pole piece rolling: Its wear resistance increases the consistency of pole piece thickness by 20%, reduces the risk of belt breakage, and is suitable for high-speed rolling of copper foil and aluminum foil (line speed ≥80m/min).5. Economic and environmental protectionFull life cycle cost advantage: Although the initial purchase cost is higher than that of ordinary rollers, the full life cycle cost of carbide rollers is reduced by more than 40%.Resource recovery value: The recovery rate of cobalt, tungsten and other metals in carbide rollers exceeds 90%, which meets the green manufacturing standards.Carbide rollers have shown significant advantages in metal processing, textile machinery, 3C electronics, new energy and other fields due to their excellent wear resistance, high temperature stability and long life, becoming a key tool to improve production efficiency and reduce maintenance costs.
