In modern steel industry, high-speed wire rod rolling mill (referred to as "high-speed wire rolling mill") is the core equipment for achieving precision rolling of steel, and bearings, as the "joints" of its transmission system, carry the dual pressure of high-speed rotation of the rolling mill and huge impact loads. However, due to the complex working environment and high-frequency operation, the failure rate of bearings remains high, directly affecting production efficiency and equipment life. How to scientifically diagnose the root cause of faults and take targeted measures has become a key issue in ensuring the stable operation of rolling mills.

1、 Causes and hazards of typical faults

The common faults of high-speed rolling mill bearings mainly include oil film burning, axial displacement, lubrication failure, etc. For example, if the oil film of an oil film bearing ruptures due to the infiltration of cooling water or lubricant emulsification, the instantaneous high temperature can cause metal adhesion between the rolling mill shaft and the inner ring of the bearing, and in severe cases, it can lead to the scrapping of the roller box. Axial movement is often caused by wear of thrust bearings or insufficient interference fit during assembly, resulting in abnormal displacement of the rolling mill shaft, exacerbating seal wear and even causing shaft breakage accidents. In addition, poor lubrication can directly damage the integrity of the oil film on the surface of the bearing, causing dry friction between the rolling elements and the raceway, which can lead to deformation of the raceway due to bluing, and in severe cases, cause the bearing to jam and stop. These failures not only cause a sharp increase in equipment maintenance costs, but also may lead to the paralysis of the entire production line due to unplanned shutdowns, resulting in economic losses of hundreds of thousands of yuan per hour.

2、 Practice of Systematic Solutions

To address the above issues, a prevention and control system needs to be constructed from three aspects: design optimization, process improvement, and intelligent monitoring. Firstly, in the equipment design phase, anti emulsion lubricants (such as Mobil 525) are used and the sealing structure is optimized. For example, a waterproof baffle is added on the outside of the bearing seat to control the sealing gap within 0.1mm, which can effectively block the invasion of iron oxide scale and cooling water. Secondly, the assembly process requires strict control of process parameters: using a laser alignment instrument to ensure that the coaxiality error between the bearing seat and the roll shaft is ≤ 0.02mm, replacing traditional thrust bearings with four point contact ball bearings, and dynamically adjusting the axial clearance to the range of 0.05-0.08mm. A certain steel plant has extended the average life of bearings from 3 months to 8 months by improving the assembly process. In addition, it is crucial to establish an IoT monitoring system. By installing vibration sensors and infrared temperature probes on the bearing seat, abnormal frequency signals can be captured in real time, and 2-3 weeks in advance warning of lubrication failure or clearance abnormalities. After the introduction of this technology in a certain branch of Baosteel, the bearing failure rate decreased by 47%.

3、 The Prospective Significance of Whole Life Cycle Management

Currently, the maintenance of high-speed rolling mill bearings is transitioning from "post fault repair" to "preventive maintenance". By establishing a bearing life prediction model and combining parameters such as rolling tonnage and cumulative speed, the replacement cycle of spare parts can be accurately planned. At the same time, promoting ultrasonic cleaning technology and oil spectral analysis can effectively remove micrometer sized abrasive particles in the lubrication system, avoiding chain wear caused by metal debris. These innovative practices not only reduce equipment operation and maintenance costs, but also provide a new paradigm for the health management of rolling mills in the era of intelligent manufacturing.

As the "precision gear" of the steel industry, the stable operation of high-speed rolling mill bearings affects the nerves of the entire production chain. Only through interdisciplinary technological innovation and full process control can we break through the limitations of traditional maintenance models and inject lasting momentum into the high-quality development of the industry. This is not only a progress in the field of equipment management, but also an important epitome of China's manufacturing moving towards high-end.