电磁场作用下球形磁极辅助研磨弯管内表面研究

弯管弯曲成形后,在弯折处易产生微裂纹、褶皱等表面质量缺陷问题。本文通过采用六自由度机械手拖动电磁场发生装置沿加工轨迹往复运动,电磁场发生装置驱动球形辅助磁极绕管件内壁转动,实现了对弯管内表面的光整加工。在此基础上,通过对弯管轮廓采集及曲线拟合,重新构建了弯管中心线并转换为新的研磨加工轨迹。采用超景深3D电子显微镜和触针式表面粗糙度测量仪对研磨试验前后弯管内表面的形貌和粗糙度进行了对比分析。结果表明,通过重新构建研磨加工轨迹,试验装置有效解决了研磨弯折处的干涉与研磨不均匀等问题。研磨55 min后,表面粗糙度由原始的0.713μm降低到0.194μm,铜合金弯管内表面原始质量缺陷基本去除,表面纹理较为致密均匀。该方法有效避免了未规划研磨轨迹时出现的犁耕等纹理缺陷,提高了弯管的服役可靠性。     

锡石多金属硫化矿微波助磨试验研究

本文以广西某选矿厂锡石多金属硫化矿矿石为原料,研究了微波预处理对矿石磨矿产物粒度组成、磨矿动力学、破碎速率及磨机生产能力的影响。结果表明,微波预处理后,矿石在不同磨矿时间下的磨矿产物粒度均变细,-0.074mm粒级含量提高了4.41%~12.90%；微波预处理前后该矿石磨矿均符合一级磨矿动力学模型；微波预处理使矿石的破碎速率(S₁)值提高近57%,且磨机的生产能力得到了明显提升。因此,微波预处理可以降低矿石的强度,强化矿石的磨矿过程,是一种有效的降低磨矿能耗、提高磨矿效率的方法。     

Energy aspects and workpiece surface characteristics in ultrasonic-assisted cylindrical grinding of alumina–zirconia ceramics

Ultrasonic assisted grinding is a novel method for improving the grinding process of difficult-to-cut materials. In the present research a novel setup has been designed and manufactured for utilizing ultrasonic vibrations in external cylindrical grinding. The designed ultrasonic head vibrates a rotating workpiece in axial direction. An alumina–zirconia ceramic (AZ90) has been selected as the workpiece material. Energy aspects and workpiece surface characteristics of ultrasonic assisted cylindrical grinding (UACG) and conventional cylindrical grinding (CG) processes have been analytically modeled and corresponding grinding experiments have been performed. The combined kinematics of the cylindrical plunge grinding process and axial ultrasonic vibrations provide a unique surface treatment conditions, which leads to reduced peak heights and increased valley depths of the surface topography. The main axial vibration mode provides the overlap of the adjacent cutting traces and consequently smoothens the surface topography in cylindrical plunge grinding. It has been analytically and experimentally shown that, applying ultrasonic vibrations, grinding energy can be reduced up to more than 35% depending on the process parameters. The surface characteristics of the ground workpieces have been investigated in terms of four surface roughness parameters and the roundness error.     

Investigating multicomponent breakage in cement grinding

The production of blended cements involves grinding raw materials such as cement clinker, pozzolan, blast furnace slag, limestone and gypsum, within the same mill. This is known as intergrinding. However, it is not possible to control the product fineness of each component separately in the multicomponent system and this results in overgrinding of relatively softer components. Since each component exhibits different breakage characteristics, the fineness of the components around the closed grinding circuit will vary depending on relative grindabilities and the overall fineness of the cement will then depend on the ratio of the components in the blend with different grindabilities. This paper aims to examine the size by mass distribution of each component around a closed circuit ball mill during cement production by intergrinding. For this purpose, a ball mill with an air classifier in a cement plant was sampled and size by assay analyses of the samples was carried out to calculate the particle size distribution of each component around the circuit. The results indicated that the size distributions of the components in each stream vary depending on their grindabilities and the final product comprises components with different fineness. The breakage rates of the components were calculated and it was seen that the breakage rates of the relatively softer components are higher than that of harder ones.     

多孔金属结合剂CBN砂轮孔隙结构对磨料层胎体力学性能的影响

为解决多孔金属结合剂CBN砂轮在高孔隙率下的强度下降问题，采用球形尿素颗粒为造孔剂，制作孔径、孔形和孔隙可控的多孔金属结合剂砂轮磨料层胎体，研究不同载荷情况下的孔隙率和孔隙排布等孔隙结构因素，对多孔金属结合剂磨料层胎体力学性能的影响规律。结果表明:孔隙有序排布时的胎体弹性模量要小于孔隙无序排布的；胎体材料的屈服强度随孔隙率增大而下降；在相同孔隙率下，孔隙有序排布的胎体，在纵向受压、孔隙正向排布的情况下屈服强度更高。      

水泥联合（半终）粉磨系统管磨机一仓仓长的探讨

在水泥管磨机前应用高效率料床粉磨设备辊压机或外循环立磨预处理工艺的前提下,根据配置不同分级机分级后的入磨物料颗粒粒径、易磨性、综合水分及熟料温度等工艺参数,后续管磨机必须选择相对科学合理的仓位比例,以实现磨内磨细与水泥颗粒的整形。磨内各仓有效长度参数能否合理选取,对管磨机段产量、质量与系统粉磨电耗影响较大,这个具有普遍性的问题,在生产过程中往往容易被忽视。由于一仓粗粉碎(磨)能力是决定管磨机系统产量的重要因素之一,而系统产量与粉磨电耗关系密切,故一仓有效长度L1的选择极其重要。在被磨材料特性、磨前预处理工艺及磨内配置与研磨体级配、水泥成品细度相对稳定的条件下,若管磨机一仓选用的有效仓长L1比例参数不合理,在系统运行过程中,一般都会出现共性问题:磨头进料端"冒灰"、"溢料"及磨内一仓"饱磨"现象,主电机运行电流明显下降,不得不采取减料或止料或调整运行参数,使系统长期处于低产量状态运行,粉磨电耗居高不下。实践中,应根据系统不同分级设备、不同工艺等因素科学确定管磨机一仓有效长度。     

某高硫难处理金精矿超细磨提金试验研究

针对某高硫难处理金精矿中金大部分被黄铁矿包裹、直接氰化浸出金浸出率低的问题,采用超细磨-碱预处理-氰化浸出工艺处理金精矿,通过条件优化可获得金浸出率84.50%,氰化钠耗量控制在3 kg/t以内,该工艺简单、流程短、安全环保。     

从磨矿性能角度解决大鳞片石墨的保护问题

针对国外某大鳞片石墨矿, 结合磨矿细度与浮选精矿筛析数据, 在保护矿石中大鳞片石墨的同时, 简化了工艺流程, 最终采取阶段磨矿、一粗两精一扫-筛分分级的浮选工艺流程, 获得了产率4.37%、品位92.81%、回收率79.59%的大鳞片石墨精矿, 以及产率0.80%、品位91.23%、回收率14.29%的细鳞片石墨精矿。     

双磁极式磁粒研磨机理分析及试验研究

目的解决平面磁粒研磨中压力不均匀和需要反复调整研磨间隙的问题,设计双磁极式研磨方法。方法首先对双磁极式研磨方法机理进行分析,并对研磨区域单颗磨粒进行受力分析,寻找影响研磨压力的主要因素;其次利用Ansoft Maxwell软件对两种研磨方法进行磁场仿真,分析两种研磨方法的研磨区域磁场梯度变化,通过面积积分法对比磁感应强度的影响程度;最后设计试验装置,通过试验对理论分析及有限元分析的结果进行验证,对比研磨前后工件表面粗糙度及微观形貌变化。结果双磁极式研磨方法中磨粒的研磨压力完全由磁场力提供,与研磨区域磁感应强度成正比,研磨区域磁感应强度比"铣削式"研磨方法提高约34.56%。两种方法在相同试验条件下对SUS304不锈钢板研磨40 min,双磁极式研磨方法研磨后,工件表面原始纹理基本被去除,表面粗糙度值由原始的0.25μm下降至0.16μm,下降率为36%,比"铣削式"研磨方法提高约80%,粗糙度曲线波动平缓,波峰波谷高度差变化均匀且表面形貌光滑平整。结论双磁极式研磨方法研磨区域磁场梯度变化明显,利于磨粒流动更新,研磨压力相对稳定,表面粗糙度下降率高,研磨后工件表面形貌光整,与"铣削式"研磨方法相比具有较明显的优势。     

水泥辊压机终粉磨系统的工业化应用

介绍了水泥辊压机终粉磨系统及运行情况,与辊压机联合粉磨系统生产的水泥以及所配制的混凝土进行了对比,水泥辊压机终粉磨系统电耗大幅降低,两种水泥所配制的混凝土性能相当。