Tungsten Carbide Coated Corrugating Roller

• After-sales Service: Online and Onsite Overseas
• Warranty: 2 Years
• Certification: UL, ISO9001, TUV, GMP, ISO, CE
• Material Capabilities: Tungsten Carbide Coated
• Type: Corrugating Roller
• Transport Package: Plywood Case
• Specification: Customized
• Trademark: Wisdom
• Origin: China

Product Description

Corrugating roller made by HVOF process with tungsten carbide

Corrugating 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 corrugating roller to improve service life, we use HVOF process to spray tungsten carbide coatings.

Advantages

There are 3 advantages of tungsten carbide corrugating roller compared to chrome plating process:

1. Higher life expectancy

   Tungsten 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 corrugating roller, up to 30-50 million meters long.

2. Better quality

   Because 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.

3. Lower cost

   As 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 Plating

 

Type	Coating Process	Flutes per feet	Height (mm)	Take-up Ratio	Page Consumption Saving
C	Tungsten Carbide	38	3.7	1.405	4.3%
	Chrome Plating	39	3.8	1.448
B	Tungsten Carbide	48	2.7	1.39	4.5%
	Chrome Plating	49	2.8	1.435
E	Tungsten Carbide	72.5	1.6	1.28	5.4%
	Chrome Plating	74	1.7	1.334

T.U.R.

 

	FLUTE #1	FLUTE #2	FLUTE #3
Flute Type	B	B	B
Flutes per feet	48	48	49
Flutes	163	163	166
Height	2.8 mm	2.7 mm	2.8 mm
Outer diameter	324.29 mm	324.28 mm	323.5 mm
T.U.R.	1.386	1.359	1.405

 

 

Page Consumption of Flute Type B - If the speed of corrugated paper machine is 120m/min and it operates 12 hours per day

1. The same flutes per feet (48) but different heights

   Flute #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.

2. The same height (2.8 mm) but different flutes per feet

   Flute #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 Types

 

Type	Flutes per feet	Height (mm)	Take-up Ratio
A	34 ± 3	4.6 ± 0.2	1.4 - 1.52
C	39 ± 3	3.6 ± 0.3	1.36 - 1.45
B	49 ± 3	2.7 ± 0.25	1.32 - 1.4
E	74 ± 3	1.6 ± 0.25	1.27 - 1.38
F	120 ± 3	0.7 ± 0.2	1.15 - 1.25