Wisdom Import & Export (Shanghai) Co., Ltd.  

Product Description Corrugated roller made by HVOF process with tungsten carbideCorrugated roller is the most important component of corrugated fiberboard production equipment. The base metal generally uses steel 4145 via Intermediate frequency quenching to achieve hardness above HRC60. As the core component its wear resistance and service life are main technical indicators to measure the quality and cost. It has direct impact on the economic benefits of corrugated board manufacturers. To meet the requirement of increasing higher speed of corrugated cardboard production line, and improve the wear resistance and surface hardness of corrugated roller to improve service life, we use HVOF process to spray tungsten carbide coatings.AdvantagesThere are 3 advantages of tungsten carbide corrugated roller compared to chrome plating process:Higher life expectancyTungsten carbide coating has a hardness of MHV1300 while chrome plating can only reach MHV800. The hardness of its layer is only less than diamond in the world. From a variety of experimental data and production practice, its life is generally 2-5 times of chrome plating corrugated roller, up to 30-50 million meters long.Better qualityBecause of excellent abrasion resistance, tungsten carbide production generally selects flute types with sharper shape and lower height. Through the optimization design of flute shapes, we can increase the strength of the fiberboard, and keep the thickness stable. Meanwhile the consumption of glue is saved. As a result, the quality of the cardboard can maintain stable in a long term scale, so the print quality can be controlled.Lower costAs the tungsten carbide coating is extremely wear-resistant, the flutes can be maximum optimized in the production with the flute-shape optimization software. The paper consumption can be saved 2% - 8% for customers compared to chrome plating roller.The coating is removed by a special method and the roll blank can be reused. Therefore the performance of repaired and new ones are not very different, so that we can reduce downtime rate, glue consumption, and wear of pressure roller and glue roller. Hence the service life can be extended.Comparison of Tungsten Carbide and Chrome PlatingTypeCoating ProcessFlutes per feetHeight (mm)Take-up RatioPage Consumption SavingCTungsten Carbide383.71.4054.3%Chrome Plating393.81.448BTungsten Carbide482.71.394.5%Chrome Plating492.81.435ETungsten Carbide72.51.61.285.4%Chrome Plating741.71.334T.U.R.FLUTE #1FLUTE #2FLUTE #3Flute TypeBBBFlutes per feet484849Flutes163163166Height2.8 mm2.7 mm2.8 mmOuter diameter324.29 mm324.28 mm323.5 mmT.U.R.1.3861.3591.405Page Consumption of Flute Type B - If the speed of corrugated paper machine is 120m/min and it operates 12 hours per dayThe same flutes per feet (48) but different heightsFlute #1 has height of 2.8 mm with T.U.R. 1.386 while Flute #2 has height of 2.7 mm with T.U.R. 1.359.Flute #1 consumes paper 119750 m while Flute #2 consumes 117417 m. Flute #2 saves 2333 m per day.The same height (2.8 mm) but different flutes per feetFlute #1 has 48 flutes per feet with T.U.R. 1.386 while Flute #3 has 49 flutes per feet with T.U.R. 1. 405.Flute #1 consumes paper 119750 m while Flute #3 consumes 121392 m. Flute #1 saves 1642 m per day.Flute TypesTypeFlutes per feetHeight (mm)Take-up RatioA34 ± 34.6 ± 0.21.4 - 1.52C39 ± 33.6 ± 0.31.36 - 1.45B49 ± 32.7 ± 0.251.32 - 1.4E74 ± 31.6 ± 0.251.27 - 1.38F120 ± 30.7 ± 0.21.15 - 1.25