钢丝帘布压延整经辊与压力辊的设计与检测

介绍钢丝帘布压延整经辊和压力辊的工作原理、设计与检测方法。整经辊和压力辊采用38CrMoAl制造，表面硬度为FIRC60～65。对新加工和使用一段时间后的整经辊和压力辊进行检测时建议使用投影仪检测，通过对沟槽制作环氧树脂模型，打磨后使用投影仪投影并测量，可较容易地测量沟槽的密度、深度及表面状况，从而保证压延钢丝帘布的品质。     

钢丝帘布压延生产线改进

对原使用B40锭子的钢丝帘布压延生产线进行改进,将B40锭子形式改进为B80锭子形式并增设了张力辊装置,使每一批次锭子可减少一次钢丝帘线浪费,在自制张力辊的作用下还可生产至最短钢丝帘线离开张力辊,大大节省了钢丝帘线浪费;通过对原整经器改进,使钢丝帘线在梭形板上相互交叉排列,可防止钢丝帘线移位和跳动,杜绝了生产中钢丝帘线的交叉问题。     

钢丝帘布压延质量与压延机压力辊位置的关系

通过对不同规格钢丝帘线、相同钢丝帘线不同压延厚度及不同胶料进行压延并测试帘布性能，指出不同规格钢丝帘线对压力辊位置的敏感程度不同；相同钢丝帘线不同压延厚度时，压延厚度越大，对压力辊的位置越敏感，因此需要调整压力辊位置及压力设定值；不同胶料压延时，胶料硬度和门尼粘度增大，压力辊与3^#辊间隙应小一些，而且压延压力应大一些。     

钢丝帘布压延线上辅机的设计与应用

介绍了钢丝帘布压延线上辅机锭子张力装置、电磁吸盘及整经压力辊的设计与应用情况。张力控制装置采用重锤式结构，重锤重量按公式Ｐ＝Ｆ１Ｄ２ｄｆ计算。电磁吸盘装置主要由机架、导辊、轴承、电磁吸盘和电控箱组成，左右两个靠近电磁吸盘的导辊调整的最佳高度是：在运行过程中大部分帘线与磁盘表面平行，只有个别张力值小于电磁吸力的帘线被磁盘吸附在其表面或处于若即若离的状态。整经压力辊装置主要由交叉板、整经辊、压力辊等组成。整经辊的沟槽深度等于帘线直径，压力辊的沟槽深度为帘线直径的一半。一般调整压力辊与３＃辊筒的间隙略小于所给的胶片厚度     

全钢子午线轮胎压延钢丝帘布幅宽收缩对帘布的影响及相关对策

对全钢子午线轮胎压延钢丝帘布幅宽收缩率进行统计分析,寻找帘布收缩的影响因素,分析帘布收缩对钢丝帘布物料清单质量结构及钢丝帘线密度的影响,给出整经辊和压力辊沟槽间距的修正方法。结果表明,通过对整经辊和压力辊沟槽间距的修正及对生产过程的严格控制,可尽可能稳定和减小帘布幅宽收缩率,进而精确计算轮胎安全倍数和控制轮胎质量,避免材料浪费。     

使用校直辊工艺简易模拟方法的单层钢丝帘线质量评估

用作汽车轮胎增强材料的钢丝帘线是由盘条拉成细丝捻制而成。为满足轮胎的刚度需求,人们开发了不同类型的钢丝帘线。钢丝帘线的结构稳定性是其质量评估的重要因素之一。一般在钢丝帘线捻制工序后评估钢丝帘线的平直性和残余扭转。校直辊是利用周期弯曲变形来改善钢丝帘线的平直性和残余应力的一种装置。校直辊装置的工艺设计大多数情况下是基于工程师经验的反复试验,需要大量的时间和成本。因此需要一个有效工具来节省校直辊工艺设计的时间和成本。有限元分析模拟方法是校直辊工艺设计的一种有效选择。本工作提出通过有限元分析校直辊工艺数值模拟单层钢丝帘线质量的评估方法,以3×0.30单层钢丝帘线作为试验样品。简易模拟方法如     

全钢载重子午线轮胎钢丝帘线压延质量问题及解决措施

分析全钢载重子午线轮胎钢丝帘线压延工艺中钢丝帘线重叠交叉、跳线、覆胶喷霜、露钢丝等质量问题。通过调整整经辊和压力辊,降低供胶温度和压延速度、减小供胶机胶容量、确保适合的钢丝张力值等措施,钢丝帘线的压延质量大幅提高,压延质量缺陷率小于0.2%。     

巨型工程机械子午线轮胎钢丝帘布压延机组裁刀支架改造和压力辊间隙调节

采用SolidWorks的CosmosXpress软件对钢丝帘布压延机组的直刀支架进行受力分析,根据分析结果重新设计了直刀支架,提高了支架的刚度,使裁断过程中支架最大变形点的位移减小到原来的25.8%,满足了压延机组裁断钢丝帘线直径3.0mm以上帘布的需求;通过分析压力辊与主机3#辊之间的间隙不一致的原因,并采取相应措施后使间隙一致,大大提高了钢丝帘布的压延质量。     

4+3×0.33ST钢丝帘线在全钢载重子午线轮胎带束层中的应用及压延工艺探讨

研究4+3×0.33ST钢丝帘线替代3×0.20+6×0.35HT钢丝帘线在全钢载重子午线轮胎带束层中的应用,重点探讨4+3×0.33ST钢丝帘线的压延工艺。结果表明:与3×0.20+6×0.35HT钢丝帘线相比,4+3×0.33ST钢丝帘线具有线密度低、渗胶性能好、覆胶弯曲刚度高等优点,可以实现等强度、等密度替代,在保证轮胎各项性能的同时,满足轮胎轻量化和降低制造成本的需求;由于4+3×0.33ST钢丝帘线为不规则结构,在压延时需要匹配合适的压力辊和整经辊槽径,避免压延时跳线的发生。     

压下量对单层钢丝帘线校直辊工艺的影响

钢丝帘线一般用作提升轮胎性能的增强材料.平直度和残余扭转是评估单层钢丝帘线质量的重要项目.钢丝帘线通常是由拉拔单丝采用不同的捻制方法制成,捻制过程中钢丝帘线通过捻制和校直装置达到各种捻合和弯曲条件.捻制过程通常会引起钢丝帘线内部残余应力的不均衡,这是造成钢丝帘线质量下降的主要原因.为了缓解残余应力的不均衡,在钢丝帘线捻制过程中通常使用过捻和校直辊装置.     

滚压成型机滚头轴控制系统的研制

采用变频调速器实现滚压成型机滚头轴的速度控制,实现滚压成型机的柔性化设计,使之能适应多品种产品生产的需要,而且生产效率得到提高。     

Effect of thickness and viscoelastic properties of roll cover on deformable roll coating flows

Roll coating is distinguished by the use of one or more gaps between rotating cylinders to meter a continuous liquid layer and to apply it to a flexible substrate. Of the two rolls that make a forward-roll coating gap, one is often covered by a layer of deformable elastomer. Liquid carried into the gap develops high enough pressure to deform the resilient roll cover. The complete understanding of the coupling between the liquid flow and roll cover deformation is vital to the optimization of this widely used and simple coating method. Most of the earlier works on deformable roll coating analyzed the action with both the lubrication approximation and the full Navier-Stokes solution of the liquid flow, and one-dimensional elastic models of the roll cover deformation. The effect of the roll cover thickness was not explored and can explain some of the discrepancy observed from the available theoretical predictions and experimental measurements from different researchers. Moreover, rubber and rubber-like materials used as roll covers do not behave purely elastically. Their responses depend to a great extent on the stress history and the temperature of the roll cover. In this work, the flow between a rigid and a deformable rotating roll was examined by solving the complete Navier-Stokes system coupled with a plane-strain elastic and viscoelastic model of the roll cover deformation. The stress at each location of the roll cover was evaluated by an integral of the deformation along the material path of the point being analyzed. The equation system was solved by the Galerkin/finite element method. Results show how thickness of the roll cover and its viscoelastic properties affect the performance of deformable roll nips.     

Tri-helical gravure roll coating

A mathematical model is presented and solved for the fluid flow within the coating bead of a tri-helical gravure roll coater, operating in reverse mode. A variety of rolls etched circumferentially with grooves of different cross-sectional shape and aligned at non-zero angles of pitch are investigated. Predictions of fluid pick-out from the grooves are compared with complementary experimental data. Quantitative agreement between the two is found to be very good, showing a linear increase in pickout as a function of web-to-roll speed ratio and groove depths up to the point at which streaking, as observed experimentally, occurs and beyond which the model is no longer valid. In regions of parameter space for which there is no experimental data available for comparison purposes the model predicts that: (i) fluid pick-out decreases with increasing groove depth while the film thickness tends to increase and (ii) an increase in groove aspect ratio leads to a reduction in both pick-out and film thickness for a given land width and groove cross-sectional shape.     

塑料在滚动轴承中的应用

介绍了塑料在滚动轴承中的应用和发展,提出为扩大产品用途,改善材料摩擦磨耗性能的必要性.论述了如何楸据PV值和使用工况条件合理选择轴承用塑料,改善润滑条件,搞好节能减排,并建议根据技术性和经济性进一步推广塑料在轴承中的应用.     

Blotching in roll coating

After thermoforming, plastic parts are stacked for shipping, and these parts tend to stick together. Called nesting, sheet stock is often first coated with a silicone compound before thermoforming to prevent this. The coating usually consists of a small amount of lubricant dispersed in a majority of carrier fluid, and this fluid must then dry before reaching the sheet winder or else the coating blotches. This coupling of coating and drying to determine when to expect blotching is examined. Roll coating involves a dimensionless group called the elasticity number that governs the thickness of the coating to be dried. The drying section involves the evaporation of the coating carrier fluid, and then diffusion into the dry surrounding atmosphere. When analyzing the drying, a new dimensionless group that governs blotching is discovered, called blotchability. The result of this analysis allows practitioners to determine which operating conditions cause blotching, and how to eliminate it. Roll coating uses a deflecting rubber roll to apply vanishingly thin coatings (≤1 μm), an interesting elastohydrodynamic problem.     

小三辊压延机的技术改造

介绍了小三辊压延机控制部分的提速变频改造及其配套的油路系统和管道的维修改造情况。在小三辊压延机主电机和输送带电机的控制电路上分别增设一台变频器,可提高生产效率25％,并可任意调节输送带与主机的速度,从而可提高覆胶质量并延长机械寿命。     

辊式破碎机辊轴轴端改造

篦冷机的辊式破碎机在使用中，发现辊轴内部的冷却水在轴两端螺栓连接密封处滴漏。针对这种情况进行了分析改造，认为辊轴和端轴的连接强度不足和密封简单是冷却水滴漏的主要原因，因此对辊轴和端轴的连接以及密封进行了改造，效果显著，完全解决了冷却水泄漏问题。     

玻纤布卷长度计算

卷在轴上的一卷布,展开后有多长呢?要求出这个长度,可以先量出卷轴的直径d,布卷外径D,布的厚度t.那么这卷布的长度就可以用下式计算出: