The wear of the sinking roller surface is usually caused by a combination of multiple factors, which can be mainly summarized into the following aspects:

1. Material characteristic factors

*Hardness and particle size: The material in the feed has a high hardness or contains a large amount of metal impurities and hard particles. These foreign objects will generate a huge reaction force in an instant when squeezed by the roller press, directly impacting and wearing down the roller surface. Meanwhile, if the material particles are too large and unevenly distributed, it will make it difficult to adjust the roller gap, causing local stress concentration and accelerating the wear of the roller surface.

*Moisture content and viscosity of materials: If the moisture content of materials is too high or they have viscosity, it is easy to form a material accumulation layer on the roller surface. This layer of material will intensify the abrasive wear on the roller surface during the extrusion process and may cause the roller gap to be blocked, affecting the extrusion effect.

2. Equipment operation and process parameter factors

*Work pressure: Roller presses are high-pressure equipment, and excessive work pressure can significantly increase the contact stress on the roller surface. Although appropriate pressure can improve crushing efficiency, excessive pressure can accelerate plastic deformation and fatigue wear of the roller surface, shortening its service life.

*Roller gap adjustment and alignment: Improper adjustment of the roller gap, or offset (misalignment) between two rollers, can lead to uneven force on the roller surface, resulting in unilateral wear or local point wear, which is a common cause of abnormal roller surface wear.

*Overload operation: The tight production tasks lead to long-term operation of the equipment beyond the design load, which can cause the roller press to bear forces far beyond the rated value, leading to plastic flow and accelerated wear of the roller surface material.

3. Equipment maintenance and structural factors

*Lubrication and cooling system: Insufficient lubrication or poor cooling of key parts such as bearings can lead to high operating temperatures, grease failure, and increased dry friction between metals. This high temperature and friction can indirectly affect the working conditions of the roller surface, and even cause a decrease in the performance of the roller surface material.

*Sealing system failure: After the sealing components wear or fail, dust and other foreign objects will enter the bearing and roller end seals. These hard particles will become abrasives, exacerbating the wear of the roller surface and bearing position.

*Roller surface material and processing accuracy: Insufficient hardness and wear resistance of the roller surface itself, or inadequate surface processing accuracy (such as roughness and roundness), can pose a high risk of wear in the early stages of use.

4. The vicious cycle of wear and tear

The above factors are often interrelated, forming a vicious cycle. For example, seal failure leads to dust intrusion → bearing wear → roller gap deviation → uneven force distribution on the roller surface → accelerated roller surface wear → further exacerbating equipment vibration and sealing load → more severe dust intrusion.

Therefore, in order to effectively control the wear of the sinking roller surface, it is necessary to comprehensively control it from multiple aspects, such as optimizing material management, setting process parameters reasonably, strengthening daily maintenance (especially lubrication and sealing inspections), and selecting high-quality roller surface materials.