Comparison of roller materials for Rolling Mill

Comparison of roller materials for Rolling Mill

In the field of metal processing, the choice of roller material for the Rolling Mill directly affects the durability, processing accuracy and applicable scenarios of the equipment. The following is an comparison of roller materials for Rolling Mill and their differences and advantages:

1. Common Roller Material Types

(1) Alloy Tool Steel (such as DC53, Cr12MoV)

– Features: High carbon and high chromium steel, hardness can reach HRC 58-62 after heat treatment.

– Advantages:

– Low cost, high cost performance, suitable for small and medium batch production.

– Good wear resistance, can process medium and low hardness metals (such as copper, aluminum, low carbon steel).

– Shortages:

– Poor high temperature resistance, long-term work may cause micro cracks due to thermal fatigue.

– Faster wear on high hardness materials (such as stainless steel, titanium alloy).

(2) Tungsten steel (hard alloy, such as YG series)

– Features: Sintered from tungsten-cobalt alloy, with a hardness of HRA 90 or above (about HRC 75+).

– Advantages:

– Extremely wear-resistant, with a service life of 5-10 times that of tool steel, suitable for large-scale high-precision processing.

– High temperature resistance, suitable for high-speed rolling or high-hardness materials (such as stainless steel, titanium alloy).

– shortages:

– High cost (the price may be 3-5 times that of tool steel).

– Brittle, poor impact resistance, not suitable for working conditions with severe vibration.

(3) Ceramic rollers (such as zirconium oxide, aluminum oxide)

– Features: super-hard ceramic coating or integral ceramic rollers.

– Advantages:

– Highest hardness (Hv 1500+), excellent wear resistance, suitable for mirror processing.

– Corrosion and oxidation resistance, suitable for special environments (such as chemical and food industries).

– Shortages:

– Extremely brittle, only suitable for light-load precision rolling (such as thin sheets and foils).

– Difficult to process and extremely expensive.

(4) High-speed steel (such as M2, M42)

– Features: Contains elements such as molybdenum and cobalt, hardness HRC 63-67.

-Advantages:

– It has both wear resistance and toughness, and is suitable for medium-load rolling.

– It can process harder metals (such as spring steel and alloy steel).

–Shortages:

– Its high-temperature performance is not as good as tungsten steel, and it needs cooling and lubrication for long-term use.

2. Material comparison summary

3. Selection suggestions

– Pursuit of cost-effectiveness: Choose DC53/Cr12MoV tool steel, suitable for conventional metal processing. (Detailed description below)

– High precision and long life: Choose tungsten steel rollers, suitable for high value-added products (such as electronic copper foil, medical device plates).

– Special needs:

– Corrosion resistance/no pollution → ceramic rollers (food, chemical industry).

– Impact resistance → high-speed steel (such as rolling recycled metal with impurities).

4. Additional considerations

– Cooling and lubrication: Tungsten steel and high-speed steel need to be used with coolant to avoid thermal damage.

– Maintenance cost: Once the ceramic roller is damaged, it needs to be replaced as a whole, and the tool steel can be repaired and then quenched again.

CDOCAST can make material selection recommendations based on your specific processing materials (such as copper, stainless steel) and budget.

Comparison of common roller materials DC53 and Cr12MoV for Rolling Mill

In the selection of roller materials for Rolling Mill, **DC53** and **Cr12MoV** are both commonly used alloy tool steels, but their composition, performance and application scenarios are significantly different. The following is a detailed comparison and selection recommendations between the two:

1. Material basis comparison

2. Core performance differences

(1) Wear resistance

– DC53:

– Higher content of molybdenum (Mo) and vanadium (V), more uniform distribution of carbides, better wear resistance than Cr12MoV (life increased by about 20-30%).

– Suitable for long-term continuous rolling of medium-to-high hardness materials (such as stainless steel and alloy steel).

– Cr12MoV:

– High chromium carbides provide basic wear resistance, but carbide segregation is more obvious, and wear resistance is slightly inferior to DC53.

(2) Toughness

– DC53:

– Through optimized composition and cryogenic treatment, the toughness is significantly higher than Cr12MoV (impact resistance increased by about 30%).

– Suitable for rolling materials that are prone to cracks or impurities (such as recycled metals, plates with oxide scale).

– Cr12MoV:

– High carbon and high chromium lead to greater brittleness, and it is easy to break or crack under severe impact.

(3) Processing and heat treatment

– DC53:

– The heat treatment process is more complicated (requires deep cryogenic treatment), but **the deformation is small**, suitable for high-precision rollers.

– Cr12MoV:

– The heat treatment is simple and the cost is low, but the quenching deformation is relatively large and requires subsequent fine grinding.

2. Comparison of applicable scenarios

4. Selection Recommendations

– Choose DC53:

– Long life, high precision or processing of high hardness/high impurity materials (such as stainless steel, titanium alloy, recycled metal).

– Typical applications: precision electronic copper foil, medical device plates, high-speed continuous rolling mills.

– Choose Cr12MoV:

– Limited budget, processing ordinary metals (such as pure copper, aluminum, low carbon steel) and moderate load.

– Typical applications: small tablet presses, intermittent production, low value-added products.

5. Cost and maintenance

– DC53: The unit price is about 20-30% higher than Cr12MoV, but the overall life is longer, and the long-term use cost may be lower.

– Cr12MoV: Suitable for short-term or small-batch production, simple maintenance, but more frequent roller replacement is required.

Summary: If you are looking for performance and life, DC53 is the first choice; if you want to control costs and the working conditions are mild, Cr12MoV is more economical.

CDOCAST can make material selection recommendations based on your specific processing materials (such as copper, stainless steel) and budget.

🛠 Ready to Supercharge Your Output? 🛠

👇Click the link below now to get exclusive quotes and technical solutions!

WA:‪+86 158 6960 2281‬

Email: [email protected]

Website: www.cdocast.com

(You can click the picture for more details)