Development of a new type of weld rolling machine

**Development of a New Type of Weld Rolling Machine** **Sun Lihua, Zhang Baoqing** **Abstract:** In industries such as packaging, chemical, pharmaceutical, and food, stainless steel welds often produce significant residual stress and an uneven appearance. To address these issues, a new type of roller compactor was developed using a double-roller single-active transmission method. This machine is designed to handle flat plates and cylindrical workpieces with wall thicknesses ranging from 3 to 8 mm, suitable for both straight and ring welds. After rolling, the appearance of the weld joint is corrected, internal structure and defects are adjusted, and residual stress is significantly reduced—by approximately 50%, which is much more effective than traditional grinding methods. **Keywords:** weld, stainless steel, roller, residual stress **Introduction:** Stainless steel welds are widely used across various industries, but improper treatment can lead to unsightly appearances, high residual stress, and increased susceptibility to corrosion and contamination. These problems negatively impact the quality of manufacturing equipment and affect product prices and market competitiveness. Traditional methods like polishing, grinding, and chemical cleaning have limitations. Polishing is labor-intensive and ineffective at reducing internal stress, while chemical cleaning only removes surface discoloration without addressing structural issues. In contrast, the weld rolling technique offers a faster, more efficient solution with no consumables and a smoother finish, making it ideal for stainless steel and aluminum alloy products requiring high-quality surfaces. **Challenges in Weld Treatment:** Straight-line welds often cause warping or excessive height, while ring welds tend to develop large tensile stresses during cooling, leading to deformation and structural weakness. Common methods to eliminate residual stress include mechanical stretching, temperature differential stretching, and weld rolling. However, the first two are time-consuming and inefficient. Weld rolling has become a standard process in pressure vessel manufacturing due to its effectiveness. Compared to traditional techniques, rolling not only improves surface roughness and hardness but also introduces beneficial compressive residual stress, enhancing fatigue resistance and corrosion protection. It also refines the metal structure, improving overall performance. **Current Market Limitations:** Most existing weld processing machines are either expensive cleaning devices or specialized tools with limited flexibility. Many weld rolling machines cannot handle long welds (typically under 2600 mm) or thick materials (less than 6 mm). As a result, many companies still rely on grinding or costly special-purpose equipment, which leads to suboptimal results. Therefore, there is a pressing need for a simple, practical, and cost-effective stainless steel weld rolling machine that can handle a wide range of applications. **Machine Working Principle and Implementation:** The roller compactor applies controlled rolling pressure to the weld area, causing plastic deformation of the metal. This process rearranges the crystal lattice, increases density, and reduces residual stress. The machine’s design ensures stable operation and precise control over the rolling force. The single active transmission system is chosen for its simplicity, compactness, and versatility, allowing for both longitudinal and circular rolling. Key components include the motor, gears, and rollers, all designed to provide sufficient strength and precision. **Key Component Design:** The roller is made from Cr12MoV alloy steel, heat-treated to achieve a hardness exceeding 57HRC. This allows it to apply high compressive stress, effectively flattening the weld and minimizing deformation. The frame and base are constructed from H-shaped steel, ensuring stability and rigidity. A 3kW motor provides enough power for consistent rolling, with adjustable speed and direction for different applications. **Performance Evaluation After Rolling:** After rolling, the weld appearance becomes smoother, with reduced ridges and better flow of metal. Residual stress measurements using the small hole method showed a significant reduction in both longitudinal and lateral stresses. This confirms the effectiveness of the rolling process in improving weld quality and structural integrity. **Conclusion:** The development of this new weld rolling machine took nearly a year and has proven to be highly effective in industrial settings. It reduces material waste, lowers labor costs, and supports environmental sustainability. By replacing traditional grinding methods, it addresses key challenges in weld quality, offering a reliable and efficient solution. With its simple design, advanced performance, and low investment, this machine represents a significant advancement in the stainless steel welding industry, with great potential for commercial success.

Household Cleaning Supplies

oilet Cleaner,Toilet Tools,Rainwater Collection System,Rain Barrel Diverter

ZHEJIANG HAOCHUAN RUBBER &PLASTIC CO.,LTD , https://www.zjhaochuan.com