Rubber Roller Covering Techniques - Strip extrusion vs. Three Roll Constructing
ลูกกลิ้งยาง by บริษัท บีอาร์เอ็ม อินเตอร์เนชั่นแนล จำกัด รับหล่อลูกกลิ้งยาง ลูกกลิ้งยางอุตสาหกรรมทุกชนิด ลูกกลิ้งยาง ลูกกลิ้งยางอุตสาหกรรม ลูกกลิ้งยางชนิดต่าง ๆ โดยใช้ยาง NR, NBR, EPDM, PU, SILICONE, HYPALON, CR -สร้างแกนลูกกลิ้งใหม่ตามแบบหรือตัวอย่าง -บริการงานซ่อม-เปลี่ยน เพลา, หน้าแปลน, ลูกปืน, อะไหล่ลูกกลิ้ง -เจียรผิวลูกกลิ้งยาง -ขึ้นลาย-ตัดร่องลูกกลิ้งยาง -ถ่วงสมดุลลูกกลิ้ง -ชุบฮาร์ดโครมลูกกลิ้ง เคลือบเทฟล่อนลูกกลิ้ง -ผลิตชิ้นส่วนอะไหล่ยาง และ อุปกรณ์เครื่องจักรต่าง ๆ
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There are actually various methods of applying rubber to a metal core to be able to manufacture a roller.
The most common strategies are:
Wrapping a prepared calendared sheet of rubber around the core, that is definitely held amongst two points within a lathe.
Extruding an endless rubber strip and applying it to a gradually rotating core that is certainly fixed in between two points in a spin station.
Sending the core through a cross head extruder, where the rubber is flowing round the core, therefore covering it.
Putting the core amongst the rolls of a Three-roll-builder and covering it with an endless calendared sheet of rubber - a roll of which can be placed inside the Three-roll building machine.
There are positive aspects and disadvantages to every single of those procedures and certain situations where one may very well be preferable to one more.
1. ‘Traditional’ wrapping
The ‘traditional’ wrapping starts with cutting the rubber sheet based on the demands with the roller (width and diameter) and putting the ready core in to the lathe. The core is turned gradually as the rubber sheet wraps about it.
According to the diameter needed along with the geometry of your calendared sheets this wrapping must be repeated several instances. Just after reaching the final diameter (plus overbuild) a bandage could be wrapped around the roller within the same machine for curing purposes.
This method is low cost and valid for rollers of a medium size both in length and diameter. It's flexible and, offered a roller of 1500 x 500 mm, takes roughly 15 minutes covering time which includes all setup and handling work.
In the case of series production this method will not supply any possibilities of expense reduction. It also requires calendared rubber sheets, which are extra expensive than rubber batches.
Care should be taken as the connecting line among two rubber sheets as well as the lack of pressure that sticks the rubber to the core and itself, often causes air bubbles. On account of the relatively low investment required, this wrapping method is used in practically each commence up company.
2. Extrusion method
Compared to regular wrapping, the strip extrusion method offers several positive aspects. Firstly there is absolutely no need to make use of the far more high-priced calendared rubber; batches which can be fed towards the extruder are adequate.
Secondly there is no limitation in the roller size. This approach could be used for any roller width and diameter and it is the only productive method to cover huge paper mill rollers.
Thirdly there isn't any set up time for distinct rollers as long as identical compounds are used; changing width and diameter don't influence the process at all.
What’s much more the compound remaining inside the machine or reduce away in the ends with the roller right after wrapping is often used again with no additional treatment.
It’s also probable to cut down the wrapping time per roller by 10 to 20%, with staff preparing the subsequent core whilst the process continues. And ultimately, the reject rate is usually reduce down to about 50%.
You'll find, nonetheless, some disadvantages. On account of the fact that the compound applied for the roller tends to flow towards the ends, overbuilds of up to 16 mm (around the diameter) is needed.
Important investment - up to ten occasions greater than for regular wrapping - and extremely skilled personnel are also needed. On typical it requires a worker six to twelve months’ training to develop into an expert in extrusion.
Regardless of the improvement in rejects, you can find nevertheless two percent or a lot more of rejects caused by air bubbles. Undoubtedly there is certainly a gain in flexibility and cost reduction, but strip extrusion will not be the final solution in rubber roller covering.
3. Cross head extrusion
For series production - starting with a great deal of 15 - 20 identical rollers and quantities in excess of one hundred rollers with identical compound - cross head extrusion is actually a wonderful alternative.
It also uses low-cost rubber batches and may lower the covering time per roller (1000 mm wide) to about 2 minutes. Even if at least two, commonly three, workers help the process, the personnel time per roller is often reduce down to 5 - 6 minutes, one third from the time needed for the methods pointed out above.
Though the positive aspects are apparent, crosshead extrusion is just not a common decision for roller makers. The key purpose is definitely the wide array of diverse rollers manufactured by the average roller covering company in mixture together with the little quantity of identical rollers. There are actually also diameter limitations with all the crosshead extruder.
In addition these machines expense additional than £200.000 GBP and smaller or start-up companies can hardly ever afford such an investment. The expertise required are also far beyond the average know-how of roller covering. Even seasoned companies meet new challenges with this approach from time for you to time.
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Datum: 04.10.2020 - 10:54 Uhr
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