Industrial grade high-precision frosted roller product introduction
1、 Product Overview
Matte roller is a functional roller product applied in multiple industries, mainly used for material surface treatment. It achieves matte texture, matte effect, microstructure embossing and other process treatments through precision frosted structure, and is widely used in plastic film, sheet metal production, printing and packaging, textile printing and dyeing, metal processing, paper processing and other fields. The product relies on precision machining technology and strict material selection, and can adapt to the high-precision surface treatment needs of different production scenarios, helping downstream customers improve the surface texture and functional characteristics of the product.
2、 Product Structure and Material Description
Core material selection
Application scenario characteristics of roller body substrate material: Q345 carbon steel has excellent cost-effectiveness in conventional low and medium load scenarios, with rigidity meeting the general production requirements. S45C medium carbon steel standard industrial production has a dense structure after quenching and tempering treatment, and comprehensive mechanical properties are balanced. 42CrMo/60CrMnMo alloy steel has excellent strength and toughness in heavy-duty high-precision scenarios, strong deformation resistance, suitable for wide and large diameter rollers. SUS304 stainless steel corrosion working conditions and food grade requirements have excellent corrosion resistance, meeting the hygiene production standards. Imported special alloy steel has extremely high precision requirements, low thermal expansion coefficient, strong stability, and is suitable for optical grade product production
Surface treatment process
After the processing of the roller substrate is completed, the outer surface is first subjected to deep quenching treatment, and then uniform frosted texture is formed through processes such as sandblasting and etching. Finally, electrolytic hard chromium plating or special ceramic coating treatment is carried out to balance texture retention and wear and corrosion resistance.
3、 Key technical parameters
- Material hardness index
Matrix quenching hardness: After deep quenching treatment, the matrix hardness reaches HRC50~55, ensuring the overall deformation resistance of the roller body;
Surface coating hardness: After electroplating hard chromium, the surface hardness can reach HRC58~65 (corresponding to HV800~1000). If ceramic coating (CrN/DLC) is used, the hardness can be further increased to HV1200 or above, greatly extending the wear-resistant service life;
Cold hard cast iron grinding roller: For special scenarios such as three roll grinding, centrifugal casting of cold hard alloy cast iron is selected, with a surface hardness of HS70 ° or above, to meet the grinding needs of high viscosity materials.
- Surface accuracy parameters
Dimensional tolerance: The outer diameter tolerance of the roller is controlled within * * ± 0.02mm * *, and the coaxiality error of the wide roller is ≤ 0.01mm, ensuring uniform force distribution on the roller surface;
Surface roughness: According to different process requirements, the roughness can be customized
Conventional sanding: Ra0.8~Ra3.2 μ m;
Fine matte surface: Ra0.2~Ra0.8 μ m;
Micro textured frosted: Ra0.16~Ra0.2 μ m;
Surface quality: The roller surface has no air holes, grooves, or scratches, and the frosted texture is uniform and consistent, with a texture deviation of ≤ 5%;
Temperature uniformity: The temperature fluctuation of the temperature controlled sanding roller (heating/cooling) surface is controlled within * * ± 1 ℃ * * to avoid thermal deformation affecting product quality.
- Range of specifications and parameters
Diameter: 200~1600mm, customizable according to requirements;
Roller surface width: 600~8000mm, suitable for wide width production line requirements;
Weight: Depending on the specifications, it ranges from several hundred kilograms to 15000kg.
4、 Core advantages of the product
Excellent wear and corrosion resistance: High hardness chrome plated layer/ceramic coating, can withstand continuous friction and medium corrosion. The chrome plated layer has passed the 72 hour ASTM B117 salt spray test without rust spots, and the service life under continuous operation conditions can reach more than 5 years, far superior to ordinary roller products;
Customized texture scheme: Different thicknesses of frosted texture, matte extinction texture, and leather texture effects can be processed according to customer needs, supporting sample customization to meet the surface texture requirements of different products;
High rigidity and stable structure: adopting hot fit interference fit technology, double-layer spiral flow channels can be designed internally, which combines high strength and excellent temperature control performance. It can compensate for medium to high bending of large width rollers and reduce thickness errors of finished products;
Strong process adaptability: It can design non powered/driven structures, heating/cooling structures according to different application scenarios, and adapt to the production needs of multiple processes such as extrusion, rolling, traction, and winding.
5、 Application Fields
Plastic industry: matte extinction treatment in the production of cast film and sheet metal, surface texture embossing of PP, PC, ABS, HDPE and other sheet materials;
Printing and packaging: printing rollers, sanding rollers for laminating machines, used for surface extinction and texture treatment of packaging materials;
Chemical grinding: The three roll grinding machine uses grinding rollers to achieve the grinding and dispersion of high viscosity materials such as paint, ink, pigments, etc;
Textile and papermaking: textile sanding treatment, paper extinction finishing;
Metal processing: Surface sanding and wire drawing treatment of aluminum sheet and stainless steel strip.
6、 Service and Support
We can provide customized design solutions based on customer production line parameters and process requirements;
Provide repair and refurbishment services for old rollers, restoring roller surface accuracy and sanding performance;
Before leaving the factory, the product undergoes full testing for dynamic balance, hardness, and roughness to ensure quality;
