Numerical Simulation of Hardfacing Remanufacturing for Large-Scale Damaged Grinding Roller

Abstract The present study is directed to the temperature and residual stresses fields in the hardfacing remanufacturing for a large-scale grinding roller with damage. For this purpose, a numerical procedure for the hardfacing process based on thermal cycle curve method was established, and the effectiveness of the proposed procedure was verified by the measurements of a multi-pass welding experiment with V-groove butt joint. Considering the characteristics of the hardfacing process, a local model of bead-on-plate welding was used to check the heat source and extract the thermal cycle curve. The resulting thermal cycle curve was applied as a thermal load to the corresponding welding layer one by one. Based on the calculated material properties, the data files of the base metal (Grade:KmTBCr26) and the filling layers (Grade:ARCFCW9024) were re-developed to define the temperature-dependent physical and mechanical properties of the materials used in the hardfacing remanufacturing. The numerical simulation results reveal the changing trend and distribution of the temperature and residual stress fields during the hardfacing remanufacturing for the damaged grinding roller. The distribution of temperature and residual stress is very complicated due to the numerous welding layers in the hardfacing process. It is pointed out that with the increase of surfacing layers, the heat-affected zone of the grinding roller expands gradually, and the maximum tensile stress always appears at the position near the weld toe, which is prone to fatigue failure or interface peeling due to stress concentration.