Abstract
The present study is directed to the temperature and residual stress fields in the hardfacing remanufacturing for a large-scale grinding roller with damage. For this purpose, a numerical procedure for the hardfacing process based on the thermal cycle curve method was established, and the effectiveness of the proposed procedure was verified by the measurements of a multi-pass welding experiment with V-groove butt joint. A local model of bead-on-plate welding was used to check the heat source and extract the thermal cycle curve. The resulting thermal cycle curve was applied as a thermal load to the corresponding welding layer one by one. Based on the calculated material properties, the data files of the base metal (Grade:KmTBCr26) and the filling layers (Grade:ARCFCW9024) were re-developed to define the temperature-dependent physical and mechanical properties of the materials used in the hardfacing remanufacturing. The numerical simulation results reveal the changing trend and distribution of the temperature and residual stress fields during the hardfacing remanufacturing for the damaged grinding roller. The distribution of temperature and residual stress is very complicated due to the numerous welding layers in the hardfacing process. It is pointed out that with the increase of welding layers, the heat-affected zone of the grinding roller expands gradually, and the maximum tensile stress always appears at the position near the weld toe, which is prone to fatigue failure or interface peeling due to stress concentration.
Highlights
With the rapid development of the power and building materials industry, various types of milling facilities are commonly used to pulverize coal gangues and cement aggregates in large-scale power and cement plants, respectively
Based on the calculated material properties, the data files of the base metal (Grade:KmTBCr26) and the filling layers (Grade:ARCFCW9024) were re-developed to define the temperature-dependent physical and mechanical properties of the materials used in the hardfacing remanufacturing
In order to verify the effectiveness of the above methods applied to hardfacing process, the multi-pass welding of V-groove butt joint in the literature [51] was taken as an example, the thermal cycle curve method was used to implement the numerical simulation of this case, and the numerical results were compared with the experimental measurements
Summary
With the rapid development of the power and building materials industry, various types of milling facilities are commonly used to pulverize coal gangues and cement aggregates in large-scale power and cement plants, respectively. Hardfacing remanufacturing usually involves multi-pass welding for wear resistant materials such as high chromium cast iron (HCCI), which is a very complicated thermo-mechanical process due to the large wear-resistant parts to be repaired and the difficult to accurately measure the thermo-physical properties for ironchromium based alloys [12, 13]. This brings a great obstacle to the numerical simulation of hardfacing remanufacturing for large-scale grinding rollers with damage. The proposed numerical scheme may serve as a tool for prediction the temperature and residual stresses fields to be used as an evaluation standard for the hardfacing remanufacturing of the worn grinding roller
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