Introduction:

Shanbao Machinery, founded in 1989, is a large-scale professional feed machinery fittings manufacturer integrating production, sales, and service. The headquarter is located at the new zone of Meishan Industrial Park, Sichuan, China. We cover an area of 40000 sq.m with 3 plants for forging, casting, drilling, and fine turning. We’re the only dies manufacturer who has its own forging and casting factory in China, it means we can control the quality from the beginning.

We’re a professional feed spare designer and have 15 professional technicians, all of whom have more than 30 years of experience in production.

We have produced different roller shells for many famous machines, such as Buhler, CPM, Andritz, and some others. The Roller shell is another important accessory of the pellet mill. The roller and die work together to extrude the feed.

Parameter:

Roller shells are critical components in various machinery, particularly in applications that require high durability and precision. This article delves into the specifications and properties of roller shells made from GCr15 high carbon chromium bearing steel, highlighting their importance in industrial applications.

Raw Material:

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.

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.

Roller shells made from GCr15 high carbon chromium bearing steel offer a combination of outstanding mechanical properties and precision engineering. With a hardening layer depth greater than 5mm, a roller hardness of 58-61 HRC, controlled surface roughness, and tight coaxiality tolerances, these components are well-suited for demanding industrial applications. Investing in high-quality roller shells not only improves operational efficiency but also enhances the durability and reliability of machinery.

How to select the roller shells:

From the surface consider

Straight teeth: have a strong rolling capacity but the materials will be dropped from the two sides.

Closed-end teeth: have a strong rolling capacity and the materials will not be dropped from the two sides. Because the material is easy to slip lead uneven wear, and is widely used in livestock and poultry feed production

Full Dimples: Poor rolling capacity, but the materials won’t be dropped from the sides with even wear.

Suggest to choose hole+teeth for stronger roller capacity and even wear.

From the modulus to consider

Modulus:1.5, 1.75, 2, 2.25, 2.5, 2.75, 3, 3.5, 4, 4.5, 5

Under the same depth of the teeth, coarse tooth (2.5modulus, depth 4) with lower volume and lower rolling capacity. It’s good to extend the grinding time and enhance the hardness of the pellets.

Smaller teeth ( 2modulus, depth 4) with higher volume and higher rolling capacity than the bigger ones.

The output is higher since the material comes out of the holes quickly, but the wear resistance is lower since the width of the teeth is too narrow.

Medium teeth ( 2.5modulus, depth 5) with the biggest volume, rolling capacity medium wear resistance. The material discharge speed is very fast. However, the high volume performance can not be fully utilized under certain conditions, as: lower opening rate and smaller holes.

Focus on the low yield and the hole’s opening rate can not be high for other reasons, you can select the medium teeth.

The fine teeth can be selected from the press roller to shorten the grinding time if the pellets are hard.

If the particle is too soft and the secondary compression is easy to produce large particles, and the coarse teeth can be selected to extend the grinding time of the material in the dies.

Packing:

Enough Workblanks:

Production:

Exhibition: