Crush And Grind With Pellet Mill Roller Shells Key Components For Industrial Applications

WHAT'S THE ROLLER SHELLS?

Roller shells, often called roller shells or grinding rollers, are crucial components used in various types of milling and grinding equipment, including pulverizers and roller mills. They are designed to crush and grind materials by applying pressure and shear forces. Roller shells are essential components in grinding and milling equipment, playing a vital role in the efficiency and effectiveness of size reduction processes. Their design, material composition, and maintenance are critical for achieving optimal performance in various industrial applications. Here’s a breakdown of their characteristics and functions:

1. Function

• Crushing and Grinding: Roller shells are used to crush and grind materials into finer particles. They exert pressure on the material, forcing it against a stationary surface.

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• Size Reduction: The design allows for effective size reduction of various materials, including grains, ores, and other bulk solids.

2. Design

• Shape and Surface: Roller shells can vary in shape and surface texture. Some may have smooth surfaces, while others may have grooves or patterns to enhance grinding efficiency.

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• Material: They are typically made from durable materials like hardened steel or alloyed metals to withstand wear and tear during the grinding process.

3. Types

• Vertical Roller Mills: In these systems, roller shells are arranged vertically to grind materials. They are commonly used in the cement and mining industries.

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• Horizontal Roller Mills: These use horizontally arranged rollers and are often employed in grain milling.

4. Wear Resistance

• Durability: Roller shells are designed to be wear-resistant to prolong their lifespan and reduce replacement costs.

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• Maintenance: Regular inspection and maintenance are necessary to ensure optimal performance and efficiency.

5. Applications

• Food Industry: Used in milling grains and other food products.

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• Mining: Employed for grinding ores and minerals.

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• Cement Production: Utilized in the grinding of raw materials and clinker.

Roller shells are essential components in grinding and milling equipment, playing a vital role in the efficiency and effectiveness of size reduction processes. Their design, material composition, and maintenance are critical for achieving optimal performance in various industrial applications.

The Advantage of SHANBAO MACHINERY'S ROLLER SHELLS?

Raw Material: GCr15 Steel

GCr15 is a high carbon chromium bearing steel known for its excellent wear resistance and high hardness. This material is commonly used in the manufacture of bearing components due to its superior mechanical properties.

Key Characteristics of GCr15 Steel:

High Hardness: Achievable hardness levels of 58-61 HRC make GCr15 ideal for applications subjected to heavy loads.

Good Toughness: Despite its hardness, GCr15 maintains a level of toughness that is crucial for resisting cracking and failure under stress.

Wear Resistance: Its composition ensures that it can withstand abrasive conditions, prolonging the lifespan of roller shells.

Depth of Hardening Layer: For roller shells made from GCr15, the depth of the hardening layer is an essential attribute. A hardening layer depth of greater than 5mm ensures that the component can resist wear and deformation even under extreme conditions. This depth provides a balance between surface hardness and core toughness, making the shells suitable for high-performance applications.

Roller Hardness: The hardness of the roller shells is specified to be between 58-61 HRC. This range is crucial for several reasons:

Load Bearing: High hardness allows the rollers to bear significant loads without deforming.

Longevity: Increased hardness contributes to longer service life due to reduced wear.

Performance: Consistent hardness across the roller shell ensures uniform performance in applications requiring precision.

Surface Roughness of Bearing Bore: The surface roughness of the bearing bore is specified to be between Ra 0.8-1.6. This level of surface finish is vital for:

Reduced Friction: A smoother surface reduces friction between moving parts, enhancing efficiency.

Improved Fit: Maintaining a precise surface finish ensures that the rollers fit snugly within the assembly, minimizing play and vibration.

Longevity: A well-finished bore helps in distributing stress evenly, further extending the life of the component.

Coaxiality of Inner and Outer Circles

Coaxiality is a critical parameter in roller shell design, specified to be within 0.05mm. This tight tolerance ensures:

Accurate Rotation: High coaxiality reduces wobble, ensuring smooth and efficient operation.

Less Wear: Proper alignment minimizes uneven wear on both the roller and the mating surfaces, leading to longer service intervals.

Enhanced Performance: Maintaining this precision is crucial in applications requiring high-speed operations.

SHANBAO MACHINERY ROLLER SHELL'S PARAMETER

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Founded in 1989 and with two subsidiaries, Sichuan Meishan Shanbao machine mould co., ltd is one large and professional feed machinery spare parts manufacturer with integration of production, sales and service.The headquarter is located at the new zone of Meishan industrial park Sichuan province ,China.

With the support of strong technical force, excellent equipment, complete testing instruments, and many years of practical experience and scientific research, so we can manufacture a series of parts and accessories for feed machinery use, including ring dies, flat dies,roller assembly, screw-head, screen-mesh,hammer, striking hammer-head, gear ring and so on, which are of application in feed industry, etc.

The key process of production is automated by using international advanced multi-station CNC gun drilling technology and vacuum heat treatment technology in 2001 and the company also expanded another new production line in 2012, which makes all process of production automated from drilling, pressure-reducing, chamfering. The company has 21 sets of four-axis CNC gun-drilling machine tools that equipped with large vertical vacuum furnace for quenching. Our fine products with good features, like good wearing resistance,highdegree of finishing,high cost performance.

The productivity of pellet feed by our ring die is up to 40 million tons per year.

In Dec. 2002, the company was awarded the certificate of ISO 9001:2008 that issued by China quality certification center. In Apr. 2003, the company acquired the licence of import and export qualification .

Our customer contains: Charoen Pokphand Group(CP), CJ Group(Korea), Purina Feed(USA),Tongwei Group,DaChan Food, Uni-President China, New-hope Liuhe Group and Sichuan Tequ Group, Te Qi Li Shi Group, Hunan TRS Group,Hunan Jiuding Group, Da Bei Nong Group, Huan Shan Group,Guangdong evergreen Group, CHIA TAI CONTI GROUP,, Guangdong Chia Tai Conti Group,Guangxi Rui Kang Group , Guangxi Liyuan Group, Fujian Huagang group and etc.

The company established the quality policies of customer satisfaction, integrity operation, first-class quality, technological innovation. and the essence of enterprise culture of "being realistic and dedicated", the concept "working with customers to make granules" was integrated into the production and service.

We also established service network covering the whole country, aim to provide better products and services for the majority of users.

Services outlets: Northeast office, Shandong office, Henan office, East China office, Hunan office, Guangdong office.