Investigation of Roller Press Surface and Stud Based on FEM Simulation

Abstract

As an emerging grinding equipment, roller presses are widely used in Cement industry. The current problem with roller press is that the rolls surface is prone to wear and needs to be replaced regularly. This greatly reduces the service life of the roller press and affects the development of the roller press. Therefore, how to reduce the wear on the surface of the roller press and increase the service life of the roller press is an urgent problem that needs to be solved for the current roller press. Current research mainly focuses on the mechanism research of roller press wear and the optimization of rolls surface structure. In this paper, the extrusion force between the stud-lining and the material is calculated by analyzing the stress of the studded rolls under actual working conditions and the compression and rebound characteristics of material layer. The failure modes of studded rolls are mainly divided into two parts. On the one hand, it is fatigue cracking of the roller shaft and stud-lining. On the other hand, it is cracking at the contact between the stud-lining and the stud, and the fracture of the stud. Because the failure modes of the studded rolls are divided into two parts, the studded rolls are divided into two parts for simulation by using ANSYS 18.0. Firstly, the static analysis is carried out on the roller shaft and the stud-lining, and the distribution cloud diagram of the stress and contact pressure of the roller shaft and the stud-lining is obtained, and the stress concentration area is optimized. After optimization, the contact pressure between the roller shaft and the stud-lining is reduced by about 50%. The maximum equivalent stress of the roller shaft and stud-lining has also been reduced. Secondly, a static analysis was conducted on the stud-lining and studs. Since the stud-lining of the studded rolls are composed of stud holes arranged in a certain order. Therefore, stress concentration is prone to occur around the stud hole. The simulation experiment was carried out by changing the optimization schemes such as the assembly method of the stud and the stud-lining, the distance between the studs, and the length of the stud. To reduce the stress concentration of stud and stud-lining. After optimizing the model of the stud and stud-lining, the maximum equivalent stress of the stud-lining and stud decreased by about 10% and 25% respectively. Through the optimized design of roller shafts, stud-lining and studs. The service life of the studded rolls can be effectively improved and the production cost can be reduced. This can provide a reference for the design of the studded rolls.