Ceramic anilox roller is an important equipment in the printing and coating industry, used to evenly distribute ink or coating during the printing process. Its surface textured structure and high-hardness ceramic coating give it superior wear resistance and high precision, and it is an indispensable tool in modern printing technology. Making a ceramic anilox roller is a complex process involving a variety of high-end technologies and strict quality control. This article will analyze the production process of ceramic anilox rollers in detail, and explore its process steps and key technologies.

What are the structures of ceramic anilox rollers?

Ceramic anilox rollers consist of a metal substrate, a ceramic coating and an anilox structure.

● Metal substrate: usually steel or aluminum is used as the skeleton part of the roller to provide the necessary strength and rigidity.

● Ceramic coating: The chromium oxide or aluminum oxide coating formed on the metal surface by thermal spraying technology has extremely high hardness and wear resistance.

● Anilox structure: The fine lines engraved on the surface of the ceramic coating by laser engraving technology are used to control the transfer amount and uniformity of ink or coating.

What is the manufacturing process of ceramic anilox roller?

1. Preparation stage

1.1 Selection and processing of substrate

The substrate of ceramic anilox roller is generally made of high-strength steel or lightweight aluminum. Before manufacturing, the substrate needs to be processed into a cylinder that meets the design specifications to ensure its dimensional accuracy and surface finish. Processing methods include turning, grinding and polishing to ensure that the surface roughness meets the requirements of coating ceramic layer.

1.2 Surface pretreatment

The surface of the substrate must be strictly cleaned and roughened to enhance the adhesion of the ceramic coating. Common methods include sandblasting and chemical cleaning to ensure that the surface of the substrate is free of grease, oxides or other contaminants.

2. Spraying of ceramic coating

2.1 Thermal spraying technology

Ceramic coating is usually prepared by plasma spraying or high velocity flame spraying (HVOF) technology. The spraying process is as follows:

● Material preparation: Add chromium oxide, aluminum oxide or other ceramic powders to the spraying equipment.

● Spraying environment control: Under the action of high temperature and high-speed airflow, the ceramic powder melts and sprays onto the surface of the substrate.

● Coating forming: The molten ceramic particles quickly cool down after hitting the surface of the substrate to form a dense coating.

2.2 Coating thickness control

The thickness of the coating is usually between 100 and 500 microns, depending on the use requirements of the roller. Too thick a coating may cause surface cracking or peeling, while too thin a coating may affect wear resistance.

2.3 Coating post-processing

After spraying, the ceramic layer needs to be processed to improve the surface finish. Common methods include grinding and polishing to ensure that the surface roughness meets the requirements of engraved anilox.

3. Anilox engraving

The anilox structure is the core technology of ceramic anilox rollers, and its quality directly affects the uniformity of ink or coating distribution. Anilox engraving is usually completed by laser engraving technology.

3.1 Laser engraving technology

Laser engraving is a technology that uses a high-energy laser beam to micro-process the surface of the ceramic coating. The steps are as follows:

● Parameter setting: Set the laser power, frequency and scanning speed according to the anilox design requirements.

● Laser etching: The laser beam etches the ceramic surface point by point to form a precise anilox structure.

● Quality inspection: Use a microscope or scanning electron microscope to detect the depth, density and uniformity of the anilox.

3.2 Anilox type

Depending on the application requirements, the anilox can be designed in different shapes and distributions, including:

● Straight anilox: suitable for uniform coating scenarios.

● Oblique anilox: used to improve ink transfer efficiency.

● Dot anilox: suitable for high-precision pattern printing.

4. Coating protection

In order to further improve the corrosion resistance and service life of the ceramic anilox roller, a transparent protective coating can be added to the anilox surface. This coating can reduce the wear of the anilox and improve the ease of cleaning of the roller.

Key technologies in the production of ceramic anilox rollers

1. Coating uniformity

The ceramic coating must have uniform thickness and no cracks or pores on the surface. The uniformity of the coating directly affects the service life of the roller and the printing effect.

2. Engraving accuracy

The accuracy of the anilox engraving needs to reach the micron level to ensure that the depth and shape of each dot are consistent. The focus and energy of the laser beam need to be strictly controlled during the engraving process to prevent over-etching or under-etching.

3. Quality Inspection

The entire production process requires multiple inspections, including coating adhesion test, hardness test and mesh structure inspection to ensure that the finished product meets the technical requirements.

Precautions for making ceramic anilox rolls

1. Temperature control

The temperature of the substrate and the ceramic layer needs to be strictly controlled during the thermal spraying process to avoid cracking caused by thermal stress.

2. Environmental cleanliness

The laser engraving and coating spraying processes need to be carried out in a dust-free environment to prevent impurities from affecting the quality of the mesh.

3. Safe operation

Ceramic spraying and laser engraving involve high temperature, high pressure and laser radiation. Operators need to wear appropriate protective equipment to avoid injury.

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