Back up Rolls for Tension Levelers: The Foundation of Precision

Overview: The Core of Rigidity, Stability, and Accuracy

In the precision world of the tension leveler, if the work rolls are the “spearhead” executing the leveling task, then the backup rolls are the “foundation” that provides steadfast support and safeguards the accuracy of the entire system. Although they never contact the strip directly, their design and condition fundamentally determine whether the work rolls can function stably and precisely. Their core mission is to provide an absolutely solid support for the array of small, densely-packed work rolls, absorb the massive leveling reaction forces, and prevent the work rolls from deflecting under load, thereby ensuring consistent leveling force across the entire length and width of the strip.

A well-designed and properly maintained back up roll system is the prerequisite for achieving exceptional and stable shape quality, as well as high equipment reliability and longevity.


Core Functions & Design

Core Functions: 1. Load-Bearing & Anti-Deflection – Support work rolls under high pressure. 2. Force Transmission – Transfer leveling force to machine frame. 3. Accuracy Guarantee – Create stable foundation for work rolls.

Design Philosophy: Large Diameter, High Rigidity. Fewer in number than work rolls, designed for absolute stability and minimal deflection under extreme loads.

Types & Configurations

TypePrincipleApplication
4-High SystemDirect support. Maximizes rigidity and load capacity.Thick plate, high-strength steel.
6-High SystemIndirect support via intermediate rolls. Isolates vibration.Premium surface materials (auto panel, polished stainless).
Zone ControlSegmented design for active "crown control".Wide strip with complex shape issues.

Material & Manufacturing

Primary Materials:

  • High-Grade Forged Alloy Steel: Best balance of toughness, hardness, and fatigue resistance. (Mainstream choice)
  • Through-Hardened Forged Steel: High hardness and wear resistance. (For heavy loads)
  • High-Strength Ductile Iron: Good damping and castability. (For special damping needs)

Key Processes: Forging & Heat Treatment, Precision Machining, Dynamic Balancing.
Surface Treatment: Fine grinding & chrome plating to reduce friction and resist corrosion.