Apparatus and method for grinding work rollers

Abstract

A grinding wheel comprising a cylindrical hub of a desired material having a first band of yieldable material on its outer circumferential surface, and a second band of abrasive material on the outer circumferential surface of the first band. The first band of yieldable material can be flexible or semi-flexible and provides support for the second band. An adhesive can be used to avoid relative motion between the hub and the first belt, and between the first and second belts.

1 . A work roll grinder comprising:
 a single circular hub having an outer surface and a bore therethrough a rotational centerline of the hub;   a resilient layer connected to the hub outer surface, wherein the resilient layer includes an outer surface having a convex shape being capable of compliance with a mating surface of a work roll when the resilient outer surface contacts the mating surface to form a contact area; and   abrasive material being disposed on the resilient layer outer surface, wherein the abrasive material contacts the mating surface in the contact area and extends outside the contact area as the grinder longitudinally traverses along an entire length of the work roll,   
     whereby the conforming nature of the compliant resilient layer allows for minimal removing of material from the surface of the work roll. 
   
   
       2 . The work roll grinder according to  claim 1  wherein the resilient layer is inflatable. 
   
   
       3 . The work roll grinder according to  claim 1  wherein the resilient layer is not inflatable. 
   
   
       4 . The work roll grinder according to  claim 3  wherein the resilient layer is solid. 
   
   
       5 . The work roll grinder according to  claim 3  wherein the resilient layer is hollow. 
   
   
       6 . The work roll grinder according to  claim 1  wherein one or more additional resilient layers are disposed between the hub and the resilient layer. 
   
   
       7 . The work roll grinder according to  claim 1  further comprising a filler disposed over the hub outer surface and an edge of the resilient layer, wherein the filler being of sufficient properties not to score or mark the grinding surface to further facilitate a smooth or seamless transition. 
   
   
       8 . The work roll grinder according to  claim 1  wherein the resilient layer being made of a material having about 50 to 95 Durometer. 
   
   
       9 . The work roll grinder according to  claim 1  wherein a width of the abrasive material is greater than a width of the resilient layer to form at least one overlap. 
   
   
       10 . The work roll grinder according to  claim 2  wherein the inflatable resilient layer has a concave outer surface when deflated. 
   
   
       11 . The work roll grinder according to  claim 1  wherein the contact area is less than a width of the outer surface of the resilient layer. 
   
   
       12 . The work roll grinder according to  claim 1  wherein the convex shape includes a substantially flat portion. 
   
   
       13 . A work roll grinder comprising:
 a single circular hub having an outer surface and a bore therethrough a rotational centerline of the hub;   an inflatable resilient layer connected to the hub outer surface, wherein the inflatable resilient layer includes an outer surface having a convex contour when inflated being capable of compliance with a mating surface of a work roll when the grinder contacts the mating surface to form a contact area; and   a resilient abrasive band connected to the inflatable resilient layer outer surface, wherein the abrasive band contacts the mating surface in the contact area and extends outside the contact area as the grinder longitudinally traverses along an entire length of the work roll,   
     whereby the work roll surface irregularities coating removal are substantially reduced and the life of the work roll is significantly increased. 
   
   
       14 . The work roll grinder according to  claim 13  wherein a width of the resilient abrasive band is greater than a width of the inflatable resilient layer hub to form at least one overlap. 
   
   
       15 . The work roll grinder according to  claim 13  wherein the inflatable resilient layer has a concave outer surface when deflated. 
   
   
       16 . A method of grinding a work roll having a work roll surface comprising the steps of:
 providing a grinding wheel with a substantially convex pliable ring and an abrasive material;   rotating the grinding wheel at a predetermined plurality of revolutions per minute;   rotating the work roll at a predetermined plurality of revolutions per minute;   contacting the rotating work roll with the grinding wheel to form a contact area;   traversing the abrasive belt laterally across the work roll surface;   whereby, the work roll surface will be substantially free of scoring and marking due to the edges or other anomalies of the abrasive material.   
   
   
       17 . The method according to  claim 16  wherein providing a grinding wheel with a substantially convex pliable ring and an abrasive belt comprises the steps of:
 providing a pliable ring having a concave outer surface when in deflated condition;   assembling the concave pliable ring onto a hub;   assembling the abrasive material into the concave pliable ring;   inflating the concave pliable ring to a predetermined pressure to form the substantially convex pliable ring when in inflated condition;   rotating the work roll and the grinding wheel;   contacting the work roll surface with the abrasive material to form a contact area on to the work roll surface;   withdrawing the grinding wheel;   measuring the contact area for compliance with a predetermined standard; and   inflating or deflating the concave pliable ring to adjust the contact area.   
   
   
       18 . The method according to  claim 17  wherein providing the pliable ring having a concave outer surface when in deflated condition comprises the steps of:
 installing the grinding wheel with a hub and a pliable ring on to a rotation device;   measuring run-out of the hub while the rotation device is rotating;   inflating the pliable ring to a predetermined pressure or until an outer surface of the pliable ring bulges radially outward;   adhering an abrasive pad to a work roll surface of the work roll to be ground or a shop work roll;   rotating the work roll at the predetermined plurality of revolutions per minute;   rotating the rotation device at a predetermined plurality of revolutions per minute;   contacting the outer surface of the pliable ring with the abrasive pad;   measuring the outer surface of the pliable ring for flatness and roundness using conventional measurement equipment to form a concave outer surface of the pliable ring when deflated; and deflating the pliable ring once the flatness and roundness is acceptable at the predetermined pressure.   
   
   
       19 . The method according to  claim 17  wherein the step of measuring the contact area comprises measuring one or more of a length, a depth, a width, a corner radii, a edges or sides, and a general geometric shape. 
   
   
       20 . The method according to  claim 17  wherein the step of measuring the contact area comprises the step of comparing the contact area to a standard or desired shape.