After the episode, Xu Zhenming, with the assistance of a group of workers, began surveying and mapping the rough roll of Nippon Steel.
The rough roll manufactured by Nippon Steel maintains the consistent style of the RB people, saves materials, and has high machining accuracy. The mechanical calculation of the roll working surface is very accurate.If during the production process, the roll reduction is too large, the roll will definitely be deformed and scrapped.
The same is true for trucks produced by RB people. If you overload them too much, the steel beams and compartment panels of the truck will be deformed, and sometimes they may be scrapped.
In this regard, our domestically produced trucks are more powerful. A 10-ton truck can pull 30 tons, and a 30-ton truck can pull 60 to 100 tons.Some trucks are overloaded, can they collapse the viaduct just built?
"Naruko! Look at the tapered surface of this roll, it seems that two tapered surfaces are connected!"
When Xu Zhenming was thinking about it, Ma Jimin pointed to the tapered surface at both ends of the roughing roller and shouted in surprise.
When the voice fell, Xu Zhenming hadn't spoken yet, Gao Jianjun shouted in surprise, "Oh! What's the matter?" He personally participated in the surveying and mapping of this kind of rough roll, and actually ignored this small difference.
When Ma Jimin reminded him, he quickly put on his reading glasses, leaned on the cone-shaped transition surface under the working surface of the roughing roller, and observed it carefully.
Sure enough, as Ma Jimin said, the tapered surface with very small difference is actually two angles.Only the original design can explain why this is done.
For domestic roughing mills, the tapered surface of the roughing roll does not have any technical requirements, so it can be processed by an ordinary lathe.Gao Jianjun mapped out the map based on his old experience and ignored this place.
Xu Zhenming did not understand metallurgical equipment.
He draws a sketch based on the one-to-one measurement data of the sample.He will design what the sample looks like.The current surveying and mapping tools are relatively poor. If you have a holographic laser surveying and mapping instrument, you can directly restore the overall dimensions of this rough roll in the software one by one.
Seeing Gao Jianjun's somewhat surprised appearance, Xu Zhenming also reacted.
"This old man Gao must have made a mistake in the surveying and mapping, and he did not restore the sample size drawings one by one!" He secretly guessed, but did not show it.
At this time, Gao Jianjun blushed and smiled awkwardly: "Xiao Xu, old man, I made an empirical mistake! Your request for re-surveying the rough roll data is correct!"
This old man is a little cute, keeping the simplicity and honesty of the mechanical man.If there is a mistake, admit it in person, and if there is a truth, you will argue with others to the end!
Xu Zhenming certainly wouldn't embarrass Gao Jianjun, and smiled slightly: "Old man, the same workpiece, the same set of surveying and mapping instruments, the drawings drawn by two people are still different! You are an expert, and you can definitely understand this. We are now surveying and mapping. The products produced may not be suitable for the 2200 roughing mill!"
"Haha...Xiao Xu, you are right!"
Seeing Xu Zhenming stepping down the stairs, Gao Jianjun laughed.
Not long after, Xu Zhenming completed the survey and mapping of this rough roll with the help of Ma Jimin and a group of veteran technicians.He asked the workers to restore it immediately and put the rough roller back in the wooden box.
Gao Jianjun was relieved to go to the staff canteen for lunch with Xu Zhenming when the truck was watching the loading.
"Xiao Xu, how are you going to repair the scrapped rough roller?" Gao Jianjun asked while eating.Seeing Xu Zhenming's calmness, he felt very curious and couldn't help but consult.
Upon hearing this, Xu Zhenming replied unhurriedly: "We still have to survey and map, we have to use data to speak!"
What he meant by words and deeds was that he was going to scrap this rough roll. He had to carefully survey and map, and after obtaining the real data, he would come up with a practical plan.
Gao Jianjun was impatient, and he wanted to immediately put down his job, went to the workshop to participate in surveying and mapping again, and took out the data of the scrapped rough roller.
Fortunately, Yiming Company implements a four-shift three-operation model. Workers on day shifts go to work at 8 in the morning and leave at 4 in the afternoon. They do not have the habit of taking a lunch break.In order to be over-productive, they work as soon as they have lunch.When Xu Zhenming and Gao Jianjun came to the heavy-duty factory, the roughing roll was already installed on the heavy-duty lathe by the workers.
Xu Zhenming required the method of installing the rough roll on the heavy-duty sleeping car to survey and map data.In this way, it can be detected whether the rough roll is deformed or bent, the amount of deformation is not large, and the value is not worth repairing... etc.
After some inspection, the rough roll that was judged to be scrapped has not been bent or deformed, that is, the dimensions of the work roll surface and the mounting shaft head have become smaller.
After obtaining these data, Xu Zhenming led Ma Jimin, Gao Jianjun and several old technicians to the company's third-floor office for a meeting.
He turned on the laptop and connected the projector to the computer.While drawing the drawing of the rough roll with CAD software, it introduces the data of the two rough rolls after comparison.
"The outer diameter of the mounting shaft heads at both ends of this roughing roll is 0.05 mm smaller, mainly because of rust and corrosion. How can this place be repaired?"
Xu Zhenming clicked the position of the two shaft ends of the rough roll with the mouse, and asked the colleagues who attended the meeting.
"It's impossible to repair this place with surfacing!"
"Surfacing welding is definitely not possible. The outer diameter of the shaft head is relatively small, and it will bend when heated!"
After seeing this situation, Ma Jimin and others all started talking.
For a time, everyone has no good solutions.
Seeing this scene, Gao Jianjun couldn't help but feel a little upset.
"These bastards are too irresponsible, and the scrapped rough rolls are not well protected!"
He muttered with a green face, complaining about the workers in the No. 1 Machine Repair Factory of Nan'an Iron and Steel Group Company.Because of these workers' mistakes, a problem was added to the repair of this rough roll.
Looking at the expressions of everyone, Xu Zhenming lit a cigarette and started to think.Immediately, his eyes lit up and he smiled and said, "How about we use chrome plating?"
The chromium plating process is generally used on ornamental workpieces. Electroplating a layer of metal chromium on the workpiece increases the beauty and wear resistance of the workpiece.Used in this place, the veteran technicians present have never encountered it.
Xu Zhenming encountered this situation in his career.
At that time, in the factory he managed, the shaft products manufactured were similar to this rough roll.This batch of products is to be installed on mechanical equipment for export, and it is too late to make temporary production.He chose to apply chromium-containing chemical reagents to those shafts, and increased the outer diameter of shaft workpieces through electroplating.
The current situation is similar to that at the time, and it seems that this is the best way.
Thinking of this, Xu Zhenming emphasized his tone and said: "It should be feasible to increase the outer diameter of the shaft by the chrome plating process. If the outer diameter exceeds the tolerance range, we can put the rough roll on the machine tool again!"
He said this method is more scientific!
Chromium plating is a chemical reaction. The chromium layer and the metal surface of the rough roll are tightly bonded, and the chromium molecules and iron molecules are closely connected, which is much better than surfacing welding.
"This method is better, I think it's the most scientific! Xiao Xu, you dare to experiment! Anyway, we are tackling the localization project of rough rolls, and we are allowed to make mistakes!"
At this time, Gao Jianjun was also persuaded by Xu Zhenming.He made a final decision and finalized the repair process of the shaft ends at both ends of the rough roll.
Solve the shaft head problem, the following is the most important work roll surface repair work for roughing rolls.
The working roll surface of the roughing roll of the 2200 roughing mill has been used in a high temperature and sudden cooling environment for a long time, and it is constantly worn out, which is much different from the original data.
This kind of working surface needs to repair the size data of the rough roll surface through surfacing, tempering, rough turning, fine turning, and fine grinding.After the repaired rough roll, the work roll surface part must be quenched and tempered before delivery.
With these procedures and processes, the No. 1 Machine Repair Plant of Nan'an Iron and Steel Group Corporation has tested several rough rolls, but they have failed.In this case, if Yiming Company uses ordinary technology for surfacing, it will definitely be the same as the situation in the first machine repair shop, and it will still fail!
According to Gao Jianjun's introduction, everyone knows that the No. 1 Mechanic Repair Factory has used various forms of surfacing welding process tests, such as submerged arc welding, gas shielded welding, and manual welding with alloy electrodes, but they have not succeeded.
With these data as a reference, Yiming's surfacing process has to avoid many detours.Once this difficulty is overcome, the roll repair business will also be a major business of Yiming Company.
After introducing all of these conditions, Xu Zhenming glanced around, looked at several old technicians, and smiled and said: "Masters, everyone talk about it, how will our company arrange the surfacing process?"
Welding is not Xu Zhenming's strong point, but the few old technicians he invited are experts.They all frowned and thought, sorting out the information Xu Zhenming and Gao Jianjun had said.
"Since the first machine repair shop has tried so many surfacing processes without success, I think the surfacing layer may be too thin. It is more appropriate to turn the rough roll a few more times before surfacing!"
"Before surfacing welding, the heating of the workpiece is very important. Our company will build a constant temperature welding room!"
"Those are common sense problems! I think that the weld meat part of the surfacing welding and the roller material are not fused enough, and then there will be problems after the surfacing of the first machine repair shop!"
These old technicians all expressed their opinions one after another, and no one could convince anyone.
Seeing this situation, Gao Jianjun had no good solutions.
Although these masters all made sense, no one proposed a good solution to the problem.
Ma Jimin is an old fitter technician and is not an expert in welding.He frowned, scratching his head from time to time.The thin hair was wiped to the left by him for a while, then to the right again.In short, he was very anxious, but helpless.
At this moment, Xu Zhenming was a little embarrassed.
After thinking about it for a long time, he suddenly became cruel and decided to combine the opinions of these veteran technicians and come up with a plan to test it before talking.The big deal, if you lose some material costs and labor costs, Yiming can still afford it!
After making up his mind, Xu Zhenming looked at the veteran technicians, Gao Jianjun and Ma Jimin who participated in the meeting, and said slowly: "Master! I am not good at welding technology. Based on everyone's opinions, I came up with a surfacing welding process plan. Please advise and see if it works!"
Immediately, he told everyone: First, turn the working surface of the roughing roll by two more cuts, and cut 10 millimeters more.Then, use a stainless steel electrode to build up the first layer as an adhesive layer.Finally, the alloy electrode is used for surfacing welding as the working layer of the roller working surface.
This scheme is somewhat similar to the surfacing process of the No. 1 Mechanic Repair Factory, which is to add an adhesive layer.This kind of adhesive layer is inferred based on the rough roll material data provided by Gao Jianjun. I don't know how effective it is. The result can only be known after testing.
After hearing Xu Zhenming's introduction, everyone's eyes lit up.
They all know the characteristics of stainless steel, the higher the temperature, the greater the hardness.This material has good adhesion properties and may have unexpected results.
"Just do it! Xiao Xu's mind is still bright!"
At this time, Gao Jianjun, who presided over the localization project of Roller, laughed and patted the conference table.
He also supported Xu Zhenming's plan and decided to use two different materials of electrodes for surfacing.
This is a new way of thinking. If it is unsuccessful, new data of a process can be obtained; if it succeeds, this project can be regarded as a breakthrough progress.
After the episode, Xu Zhenming, with the assistance of a group of workers, began surveying and mapping the rough roll of Nippon Steel.
The rough roll manufactured by Nippon Steel maintains the consistent style of the RB people, saves materials, and has high machining accuracy. The mechanical calculation of the roll working surface is very accurate.If during the production process, the roll reduction is too large, the roll will definitely be deformed and scrapped.
The same is true for trucks produced by RB people. If you overload them too much, the steel beams and compartment panels of the truck will be deformed, and sometimes they may be scrapped.
In this regard, our domestically produced trucks are more powerful. A 10-ton truck can pull 30 tons, and a 30-ton truck can pull 60 to 100 tons.Some trucks are overloaded, can they collapse the viaduct just built?
"Naruko! Look at the tapered surface of this roll, it seems that two tapered surfaces are connected!"
When Xu Zhenming was thinking about it, Ma Jimin pointed to the tapered surface at both ends of the roughing roller and shouted in surprise.
When the voice fell, Xu Zhenming hadn't spoken yet, Gao Jianjun shouted in surprise, "Oh! What's the matter?" He personally participated in the surveying and mapping of this kind of rough roll, and actually ignored this small difference.
When Ma Jimin reminded him, he quickly put on his reading glasses, leaned on the cone-shaped transition surface under the working surface of the roughing roller, and observed it carefully.
Sure enough, as Ma Jimin said, the tapered surface with very small difference is actually two angles.Only the original design can explain why this is done.
For domestic roughing mills, the tapered surface of the roughing roll does not have any technical requirements, so it can be processed by an ordinary lathe.Gao Jianjun mapped out the map based on his old experience and ignored this place.
Xu Zhenming did not understand metallurgical equipment.
He draws a sketch based on the one-to-one measurement data of the sample.He will design what the sample looks like.The current surveying and mapping tools are relatively poor. If you have a holographic laser surveying and mapping instrument, you can directly restore the overall dimensions of this rough roll in the software one by one.
Seeing Gao Jianjun's somewhat surprised appearance, Xu Zhenming also reacted.
"This old man Gao must have made a mistake in the surveying and mapping, and he did not restore the sample size drawings one by one!" He secretly guessed, but did not show it.
At this time, Gao Jianjun blushed and smiled awkwardly: "Xiao Xu, old man, I made an empirical mistake! Your request for re-surveying the rough roll data is correct!"
This old man is a little cute, keeping the simplicity and honesty of the mechanical man.If there is a mistake, admit it in person, and if there is a truth, you will argue with others to the end!
Xu Zhenming certainly wouldn't embarrass Gao Jianjun, and smiled slightly: "Old man, the same workpiece, the same set of surveying and mapping instruments, the drawings drawn by two people are still different! You are an expert, and you can definitely understand this. We are now surveying and mapping. The products produced may not be suitable for the 2200 roughing mill!"
"Haha...Xiao Xu, you are right!"
Seeing Xu Zhenming stepping down the stairs, Gao Jianjun laughed.
Not long after, Xu Zhenming completed the survey and mapping of this rough roll with the help of Ma Jimin and a group of veteran technicians.He asked the workers to restore it immediately and put the rough roller back in the wooden box.
Gao Jianjun was relieved to go to the staff canteen for lunch with Xu Zhenming when the truck was watching the loading.
"Xiao Xu, how are you going to repair the scrapped rough roller?" Gao Jianjun asked while eating.Seeing Xu Zhenming's calmness, he felt very curious and couldn't help but consult.
Upon hearing this, Xu Zhenming replied unhurriedly: "We still have to survey and map, we have to use data to speak!"
What he meant by words and deeds was that he was going to scrap this rough roll. He had to carefully survey and map, and after obtaining the real data, he would come up with a practical plan.
Gao Jianjun was impatient, and he wanted to immediately put down his job, went to the workshop to participate in surveying and mapping again, and took out the data of the scrapped rough roller.
Fortunately, Yiming Company implements a four-shift three-operation model. Workers on day shifts go to work at 8 in the morning and leave at 4 in the afternoon. They do not have the habit of taking a lunch break.In order to be over-productive, they work as soon as they have lunch.When Xu Zhenming and Gao Jianjun came to the heavy-duty factory, the roughing roll was already installed on the heavy-duty lathe by the workers.
Xu Zhenming required the method of installing the rough roll on the heavy-duty sleeping car to survey and map data.In this way, it can be detected whether the rough roll is deformed or bent, the amount of deformation is not large, and the value is not worth repairing... etc.
After some inspection, the rough roll that was judged to be scrapped has not been bent or deformed, that is, the dimensions of the work roll surface and the mounting shaft head have become smaller.
After obtaining these data, Xu Zhenming led Ma Jimin, Gao Jianjun and several old technicians to the company's third-floor office for a meeting.
He turned on the laptop and connected the projector to the computer.While drawing the drawing of the rough roll with CAD software, it introduces the data of the two rough rolls after comparison.
"The outer diameter of the mounting shaft heads at both ends of this roughing roll is 0.05 mm smaller, mainly because of rust and corrosion. How can this place be repaired?"
Xu Zhenming clicked the position of the two shaft ends of the rough roll with the mouse, and asked the colleagues who attended the meeting.
"It's impossible to repair this place with surfacing!"
"Surfacing welding is definitely not possible. The outer diameter of the shaft head is relatively small, and it will bend when heated!"
After seeing this situation, Ma Jimin and others all started talking.
For a time, everyone has no good solutions.
Seeing this scene, Gao Jianjun couldn't help but feel a little upset.
"These bastards are too irresponsible, and the scrapped rough rolls are not well protected!"
He muttered with a green face, complaining about the workers in the No. 1 Machine Repair Factory of Nan'an Iron and Steel Group Company.Because of these workers' mistakes, a problem was added to the repair of this rough roll.
Looking at the expressions of everyone, Xu Zhenming lit a cigarette and started to think.Immediately, his eyes lit up and he smiled and said, "How about we use chrome plating?"
The chromium plating process is generally used on ornamental workpieces. Electroplating a layer of metal chromium on the workpiece increases the beauty and wear resistance of the workpiece.Used in this place, the veteran technicians present have never encountered it.
Xu Zhenming encountered this situation in his career.
At that time, in the factory he managed, the shaft products manufactured were similar to this rough roll.This batch of products is to be installed on mechanical equipment for export, and it is too late to make temporary production.He chose to apply chromium-containing chemical reagents to those shafts, and increased the outer diameter of shaft workpieces through electroplating.
The current situation is similar to that at the time, and it seems that this is the best way.
Thinking of this, Xu Zhenming emphasized his tone and said: "It should be feasible to increase the outer diameter of the shaft by the chrome plating process. If the outer diameter exceeds the tolerance range, we can put the rough roll on the machine tool again!"
He said this method is more scientific!
Chromium plating is a chemical reaction. The chromium layer and the metal surface of the rough roll are tightly bonded, and the chromium molecules and iron molecules are closely connected, which is much better than surfacing welding.
"This method is better, I think it's the most scientific! Xiao Xu, you dare to experiment! Anyway, we are tackling the localization project of rough rolls, and we are allowed to make mistakes!"
At this time, Gao Jianjun was also persuaded by Xu Zhenming.He made a final decision and finalized the repair process of the shaft ends at both ends of the rough roll.
Solve the shaft head problem, the following is the most important work roll surface repair work for roughing rolls.
The working roll surface of the roughing roll of the 2200 roughing mill has been used in a high temperature and sudden cooling environment for a long time, and it is constantly worn out, which is much different from the original data.
This kind of working surface needs to repair the size data of the rough roll surface through surfacing, tempering, rough turning, fine turning, and fine grinding.After the repaired rough roll, the work roll surface part must be quenched and tempered before delivery.
With these procedures and processes, the No. 1 Machine Repair Plant of Nan'an Iron and Steel Group Corporation has tested several rough rolls, but they have failed.In this case, if Yiming Company uses ordinary technology for surfacing, it will definitely be the same as the situation in the first machine repair shop, and it will still fail!
According to Gao Jianjun's introduction, everyone knows that the No. 1 Mechanic Repair Factory has used various forms of surfacing welding process tests, such as submerged arc welding, gas shielded welding, and manual welding with alloy electrodes, but they have not succeeded.
With these data as a reference, Yiming's surfacing process has to avoid many detours.Once this difficulty is overcome, the roll repair business will also be a major business of Yiming Company.
After introducing all of these conditions, Xu Zhenming glanced around, looked at several old technicians, and smiled and said: "Masters, everyone talk about it, how will our company arrange the surfacing process?"
Welding is not Xu Zhenming's strong point, but the few old technicians he invited are experts.They all frowned and thought, sorting out the information Xu Zhenming and Gao Jianjun had said.
"Since the first machine repair shop has tried so many surfacing processes without success, I think the surfacing layer may be too thin. It is more appropriate to turn the rough roll a few more times before surfacing!"
"Before surfacing welding, the heating of the workpiece is very important. Our company will build a constant temperature welding room!"
"Those are common sense problems! I think that the weld meat part of the surfacing welding and the roller material are not fused enough, and then there will be problems after the surfacing of the first machine repair shop!"
These old technicians all expressed their opinions one after another, and no one could convince anyone.
Seeing this situation, Gao Jianjun had no good solutions.
Although these masters all made sense, no one proposed a good solution to the problem.
Ma Jimin is an old fitter technician and is not an expert in welding.He frowned, scratching his head from time to time.The thin hair was wiped to the left by him for a while, then to the right again.In short, he was very anxious, but helpless.
At this moment, Xu Zhenming was a little embarrassed.
After thinking about it for a long time, he suddenly became cruel and decided to combine the opinions of these veteran technicians and come up with a plan to test it before talking.The big deal, if you lose some material costs and labor costs, Yiming can still afford it!
After making up his mind, Xu Zhenming looked at the veteran technicians, Gao Jianjun and Ma Jimin who participated in the meeting, and said slowly: "Master! I am not good at welding technology. Based on everyone's opinions, I came up with a surfacing welding process plan. Please advise and see if it works!"
Immediately, he told everyone: First, turn the working surface of the roughing roll by two more cuts, and cut 10 millimeters more.Then, use a stainless steel electrode to build up the first layer as an adhesive layer.Finally, the alloy electrode is used for surfacing welding as the working layer of the roller working surface.
This scheme is somewhat similar to the surfacing process of the No. 1 Mechanic Repair Factory, which is to add an adhesive layer.This kind of adhesive layer is inferred based on the rough roll material data provided by Gao Jianjun. I don't know how effective it is. The result can only be known after testing.
After hearing Xu Zhenming's introduction, everyone's eyes lit up.
They all know the characteristics of stainless steel, the higher the temperature, the greater the hardness.This material has good adhesion properties and may have unexpected results.
"Just do it! Xiao Xu's mind is still bright!"
At this time, Gao Jianjun, who presided over the localization project of Roller, laughed and patted the conference table.
He also supported Xu Zhenming's plan and decided to use two different materials of electrodes for surfacing.
This is a new way of thinking. If it is unsuccessful, new data of a process can be obtained; if it succeeds, this project can be regarded as a breakthrough progress.
