Nosov Magnitogorsk State Technical University, Magnitogorsk, Russia
K. V. Fochina, Assistant, Dept. of Mechanics
A. S. Savinov, Dr. Eng., Prof., Head of the Dept. of Mechanics, Director of the Institute of Metallurgy, Mechanical Engineering, and Materials Processing
I. V. Mikhalkina, Cand. Eng., Associate Prof., Dept. of Casting Processes and Materials Science, e-mail: miv.mgtu@mail.ru
S. M. Andreev, Dr. Eng., Head of the Dept. of Automated Control Systems
V. P. Chernov, Dr. Eng., Prof., Dept. of Casting Processes and Materials Science

Abstract: The paper presents the technological features of manufacturing a support roll using the washing method. When designing the technological equipment for manufacturing the back-up roll, existing materials that have proven themselves positively in the practice of rolling production were considered. Their physical (liquidus temperature, solidus temperature) and thermophysical (thermal conductivity, heat capacity and density) characteristics, taken as boundary conditions for solving the thermal conductivity problem using a numerical method with subsequent implementation of the obtained solutions in a software product that provides prediction of the thermal state of the “casting - combined mold” system. Analyzing the internal structure of existing support roll, templates were prepared, during the study of which it was established that the working layer of the support roll is 100 mm, and the existing transition layer is 18-20 mm. Based on the solutions obtained, the growth of the working layer of the support roll was calculated, which is one of the determining factors in obtaining a cast product with the specified performance characteristics when manufactured by the washing method. A mathematical prediction of the thermal state of the boundary of the “casting - metal mold” system was carried out at different thicknesses of the die wall, which makes it possible to avoid weldability defects, as well as to carry out a qualitative assessment of the durability of the casting die during the manufacture of the support roll. This will make it possible to predict the technological parameters of washing during the production of rolls. The solutions proposed in the work can be used by technologists of metallurgical industry enterprises as recommendations when designing technological processes for the production of import-substituting products - support rolls.
The study was carried out by grant of the Russian Science Foundation No. 25-79-31018, https://rscf.ru/project/25-79-31018/.

1. Drobyshev A. N., Starchenko V. G. Production of rolling rolls in the EVRAZ ZSMK`s foundry shop. Chernaya metallurgiya. Byulleten nauchno-tekhnicheskoy i ekonomicheskoy informatsii. 2014. No. 6. pp. 55–59.
2. Kuryaev D. V., Avdienko A. V., Ivanov D. M. et al. Production of rolling rolls at MZPV. Teoriya i tekhnologiya metallurgicheskogo proizvodstva. 2017. No. 1 (20). pp. 32–33.
3. Heisterkamp P., Schneider Z., Ji W. Expanding the limits of back-up rolls. Proceedings of the XII Congress of Rollers. Moscow: Izdatelstvo “Grin Print“, 2020. pp. 215–225.
4. Martini A. Two-layer cast back-up rolls with a working layer of AST 70X steel. Metallurg. 1999. No. 9. pp. 44–47.
5. Feoktistov N. A., Vdovin K. N., Savinov A. S., Skripkin E. V. Study of the process of the cast structure formation of roll steel. Izvestiya Volgogradskogo gosudarstvennogo tekhnicheskogo universiteta. 2020. No. 7 (242). pp. 36–40.
6. Vdovin K. N., Kuryaev D. V., Feoktistov N. A., et al. Rolling rolls: monograph. Magnitogorsk : Nosov Magnitogorsk State Technical University, 2018. 335 p.
7. Gulakov A. A., Tukhvatulin I. Kh., Potapov M. G. Production of centrifugally cast sheet rolling rolls from advanced materials for hot rolling mills. Tekhnologii metallurgii, mashinostroeniya i materialoobrabotki. 2017. No. 6. pp. 150–160.
8. Gulakov A. A., Tukhvatulin I. Kh., Potapov M. G. et al. Experience in the production of centrifugally cast sheet rolling rolls for hot rolling mills at Kushva Roll Manufacturing Factory. Chernaya metallurgiya. Byulleten nauchno-tekhnicheskoy i ekonomicheskoy informatsii. 2018. No. 5. pp. 75–80.
9. Gulakov A. A., Tukhvatulin I. Kh., Khrapov E. V. Production of centrifugally cast extra-large sheet rolling rolls for thick-plate mills. Proceedings of the IX Congress of Rollers. Cherepovets : Izdatelstvo “Cherepovetskiy gosudarstvenny universitet“, 2013. pp. 255–257.
10. Utochkin Yu. I., Smirnov N. A., Eroshkin S. B. Production of large-sized back-up rolls up to 250 tons abroad and the possibility of their production in Russia. Elektrometallurgiya. 2012. No. 12. pp. 2–7.
11. Efimov S. V., Popkov A. G., Pavlova A. G. New technologies in the production of large-sized forgings at OMZ-Spetsstal: back-up rolls. Chernaya metallurgiya. Byulleten nauchno-tekhnicheskoy i ekonomicheskoy informatsii. 2016. No. 7. pp. 94–98.
12. Pokrovsky A. M. Comparative analysis of the durability of solid-forged and bimetallic back-up rolling rolls. Metallurg. 2013. No. 10. pp. 71–75.