In recent years, the development of rolling technology has been rapid. Rolling production has made significant progress in automation, high precision, and continuity. Rolling production is an important production link and the main method of rolling steel ingots or billets into steel materials. Because the steel produced using the rolling method has advantages such as high productivity, strong continuity in the production process, diverse varieties, and ease of mechanization and automation, and because the performance is higher and the cost is lower compared to forging, extrusion, and drawing processes, approximately 93% of steel is currently manufactured through rolling. The rolling method is also extensively used in non-ferrous metal production.
Straightening is a rear-end process in metal material processing, which can greatly improve product quality levels and significantly rectify various shape defects occurring during rolling, cooling, and transportation, such as the arcuate bends of rails, transverse and longitudinal bends of strip plates, edge waves, and sickle bends. A leveler machine is a metal strip shape correction device that stretches and bends the strips to eliminate wavy, buckled, and bent three-dimensional defects, thus improving the quality of the strip shape. Under the cooperation of tension and bending stress, the leveler machine allows the strip to extend under minimal tension. The leveler machine has become an indispensable piece of equipment in rolling workshops and is widely used in various workshops with slab materials, such as automobile factories and shipyards.
The basic principle of strip shape correction: The strip should be appropriately elongated. When the external force disappears, the elastic deformation recovers and the plastic deformation remains, causing the deformation of metal fibers to ultimately become consistent, thereby correcting the three-dimensional defects of the strip. This elongation is measured by the elongation rate. Operating a leveler machine is essentially managing the elongation rate.
A leveler machine consists of two inseparable parts: the tension roll group and the main machine (which we usually refer to as the leveler machine). To correct the shape to an ideal state, the tension roll must provide enough tension, and the leveler machine must supply adequate bending stress. The tension roll needs an appropriate diameter, friction coefficient, power system, and initial tension, provided by the equipment in front and behind the leveler machine group. To provide adequate bending stress, the machine frame and roller box must have sufficient rigidity and strength, the quick opening cylinder must have enough diameter, and the lifting device should have sufficient tonnage capacity.
The elongation rate is the goal of the leveler machine group. The elongation rate derives from the difference in speed between the tension rolls before and after the leveler machine, which is electronically controlled, directly related to the tension provided by the tension rolls, and also affected by the wrap angle of the work roll to the strip.
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