基于CNC技术的辊形曲线

针对轧辊曲线如何生成的问题,介绍了正弦函数在数控轧辊磨床中的应用,主要阐述了半角参数在正弦函数中所起的作用,以及如何用正弦曲线拟合抛物线,为正确选择曲线参数提供了依据.结果表明,以选择合适的半角参数来适应广泛的轧辊磨削工艺要求,不失为一种灵活可靠的方法.     

热轧工作辊磨削质量的改进

针对不同的轧辊材质及磨削要求进行磨削实验,选择合适的砂轮,在保证磨削效率的前提下通过砂轮的选材、磨削工艺的优化以及设备基础精度的保证,结合现场实际情况对提高热轧工作辊磨削质量进行分析,并制定对策具体实施.     

数控轧辊磨床的磨削工艺改进

数控轧辊磨床是板材轧制生产的重要配套设备,保证轧辊磨床精度是轧辊数控磨削加工的关键,而影响轧辊磨削精度和表面质量的因素很多。分析了影响轧辊数控磨床的影响因素,通过研究设计改进了磨削工艺和磨削用量,通过合理选择砂轮并进行修整,从而有效保证磨削精度和表面质量。     

提高轧辊磨削质量的措施

随着制造技术的迅猛发展,现代轧辊磨床获得的轧辊磨削精度和表面质量也越来越高,以满足终端用户的要求,如辊面圆度误筹为0．001～0．003mm;表面粗糙度Ra0．025～0．1um;辊面在白炽灯光下不能有明显缺陷,色差一致。轧辊磨削精度和表面质量除了依靠精良的轧辊磨床工作精度之外,主要还取决于对特定的加工轧辊选用相匹配的砂轮和磨削工艺参数,以及操作者应有的丰富的现场经验。     

精密轧辊磨削中存在的问题及处理办法

在实验中,针对精密轧辊磨削中存在的问题及产生的原因进行研究。通过对轧辊磨床结构细节的分析调整,同时在磨削过程中改变磨削工艺参数等方法,分析研究各因素对精度的影响程度,从而达到精密轧辊磨削的要求。     

高温合金材料磨削砂轮参数的选择

如何正确对高温合金等难加工材料磨削砂轮特性参数进行选择,一直是从事磨削加工研究者长期研究探讨的问题之一.本文以钛合金为主要研究对象,利用模糊多目标评价方法,结合专家经验,构建了"基于模糊理论高温合金材料磨削砂轮特性参数的选择"数学模型,并通过试验研究,证实了该方法的先进性、可靠性与实用性.     

轧辊磨削精度提高的方法及其应用

传统提高磨削加工精度的方法主要包括以下三类：从工件轴向刚度最弱处考虑;采用中心架来提高工件的刚度以及采取误差补偿措施,该三种方法均有不足之处。在分析变速磨削的机理、变速磨削与磨削颤振抑制之间的关系的基础上,提出了根据轧辊的材质、结构,合理确定所用砂轮的特性及磨削工艺参数的变速磨削工艺条件适配策略。并在充分考虑轧辊磨床-轧辊系统沿轧辊轴向刚度的变化,控制磨削中轧辊变形的基础上提出了变速优化自适应控制的新策略,为轧辊磨削的精度提高提出了一种新的有效解决方法,并在实际应用中获得了较好的效果。     

基于开放式数控平台的轧辊辊型研究

轧辊磨床用于磨削轧制机中的各种具有中凸或中凹的轧辊,不同辊型的生成和磨削是其关键所在.目前基于CNC装置的轧辊磨床辊型加工还不能最大的满足用户的要求.提出基于西门子最新的840D开放式数控平台的轧辊磨床辊型曲线智能生成.详细分析了圆弧、正弦轧辊辊型曲线在数控系统上的形成算法,并在对西门子OEM开发包的二次开发中得到了应用,最终实现了参数化辊型曲线的智能生成.同时,加工过程的人机交互变得更加动态与直观.     

陶瓷结合剂CBN砂轮高速磨削凸轮轴的表面粗糙度研究

本文通过一系列的试验,分析了磨削工艺参数对工件表面粗糙度的影响,建立了磨削表面粗糙度的经验公式,研究了陶瓷结合剂CBN砂轮磨削表面粗糙度的变化规律及其特点,这些规律为凸轮轴的CBN高速磨削提供了一系列实用的工艺参数.     

轧辊磨床的优化与应用

介绍了镜面铜箔轧辊磨削时产生的辊面斜纹现象,并对轧辊磨床特性及磨削过程工艺进行优化以达到对磨削精度和表面质量的提升,对磨削工艺进行优化并精细操作,避免轧辊磨削缺陷。     

Fuzzy algorithm for calculating roll speed variation based on roll separating force in hot rolling

Thickness control of hot-rolled strips has become an important issue in recent years because of the need for improving the quality of the hot-rolled strip. For this purpose, various thickness control systems such as finishing mill set-up (FSU), automatic gauge control (AGC), and looper control system, have been developed at steel works. Although these systems have greatly improved the quality of the strip thickness, there still exists a small amount of thickness deviation. It is difficult to adequately control by applying conventional thickness control techniques since hot rolling process is a highly nonlinear system in which many process parameters are coupled. In this study, a fuzzy algorithm to calculate the roll speed variations was developed in order to improve the thickness uniformity of hot-rolled strips. Since the strip thickness is mostly affected by the magnitude of roll separating force depending on the roll speed, the strip thickness deviation between the desired and actual thicknesses can be reduced by controlling roll speed. In order to carry out this investigation, slab analysis was carried out to determine the relation between roll separating force and roll speed for various process parameters such as roll speed, reduction ratio, strip entry thickness, and front and back tensions. From the production data, the effective stress-strain rate relations of the materials used in slab analyses were acquired. Based on the analytical results, the relation between roll separating force and roll speed was approximated by a log function. A fuzzy algorithm was developed to determine variations in roll speed according to variations of roll separating force, depending on various ranges of rolling temperature, reduction ratio, front and back tensions, and strip thickness. In addition, simulations to predict roll speed variations for a small amount of thickness deviation were carried out at continuous finishing mills consisting of seven stands and the calculated roll speed variations were found to be reasonable. Thus, the developed fuzzy algorithm might be useful in reducing the thickness deviation in the actual hot rolling mills.     

Simplified theories of flat rolling-I. The calculation of roll pressure, roll force and roll torque

The classical theories of rolling continue to be widely used in practice although finite element methods can provide a more detailed analysis of the deformation during rolling. Both a homogeneous deformation solution and an inhomogeneous method for calculating the roll pressure are reformulated as a development of the classical theories of flat rolling. The new solutions do not require the gradient of the stress-strain curve d(2k)/dφ. This simplifies the computations, leads to consistent estimates of the main rolling parameters including the calculation of the roll torque and allows more general yield stress functions to be readily included in solutions for hot or cold rolling. Data for the rolling of annealed copper is used to establish the consistency and accuracy of the new solutions.     

助卷辊液压伺服系统分析改进

介绍热轧厂卷取机助卷辊伺服系统在使用过程中所存在的系列问题,分析故障成因,阐述采取的措施及取得的效果.     

Precision evaluation of surface form error of a large-scale roll workpiece on a drum roll lathe

This paper presents on-machine evaluation of surface form error components of a large-scale roll workpiece, including the out-of-roundness, the out-of-straightness, the taper angle and the diameter deviation, on a drum roll lathe. A pair of capacitive-type displacement probes is mounted on the carriage slide to target the two sides of the roll workpiece mounted on the spindle, which has a length of 2000 mm, a diameter of 320 mm and a mass of 350 kg. The outputs of the probes are employed to accurately evaluate the surface form error components through separating the influences of the motion errors of the spindle and the carriage slide of the lathe. It has been difficult to apply the reversal error-separation method for measurement of the out-of-roundness component of such a large workpiece because it is difficult to reverse the workpiece with respect to the spindle on the lathe due to its large size and heavy mass. An improved reversal operation technique, in which the spindle is rotated with respect to the stationary roll workpiece being held by a crane, is therefore proposed to solve this problem. Measurement uncertainty analysis is carried out to verify the reliability of the new technique for on-machine evaluation of the out-of-roundness component. The out-of-straightness component and the taper angle component of the roll workpiece are then evaluated by using a previously developed method. A simple and effective algorithm for evaluation of the diameter deviation component is also presented.     

Quality control with matching technology in roll to roll printed electronics

R2R (Roll to roll) printed electronics has been an attractive technology for the mass production. Therefore, many research works have been focused on an optimal flexible substrate, ink formulation, printing process, curing method for a conductive ink in printed electronics applications. However, they did not relate their analysis with the system parameters of R2R continuous printing systems. In this paper, it is found that a printed pattern geometric quality which affects functional quality of printed electronic device could be changed with respect to operating tension of bare substrate even if local optimized ink, substrate, and printing process were applied. Additionally, ink transfer mechanism for R2R printed electronics is analyzed regarding a dynamic surface energy of a bare substrate under a tension in R2R printing systems. With the aim of an efficient prediction of the thickness of R2R printed patterns for given operating conditions, a simple meta-model is developed by using the design of experiment (DOE) method. Also, the proposed meta-model has been verified by several experiments. Through the results, it is presented that how to find an optimal operating tension in R2R printed electronics for guaranteeing a required thickness of R2R printed patterns.     

二辊矫直机辊形参数设计

从研究矫直原理入手，借鉴国内外先进的技术经验，设计了二辊矫直机。该机为当前比较先进矫直机，同时对金属变形理论、矫直工艺及矫直机械的设计制造进行了深入研究，给出了二辊矫直机辊形参数的确定方法。     

电动旋转卷料夹钳

电动旋转卷料夹钳用于起重机起吊卷料,可以自动挂、摘钩,可动力旋转,并已经经过1年的使用,其性能良好,安全可靠,自重轻、结构简单。与目前其他吊运卷料的吊具相比,有其独到之处。     

离心浇铸轧辊生产工艺系统研究

介绍了离心浇铸轧辊计算机辅助生产系统。该系统以轧辊专家长期积累的经验为基础 ,对轧辊生产能起到辅助指导作用 ,提高了离心轧辊的成材率。     

Thermal reliability research on entire roller-embedded shapemeter roll

The reversible cold-strip flatness was detected by an entire roller-embedded shapemeter roll. During detection, the contact condition of the interference fit surface (between the top surface of the framework and the inner hole surface of the roll body) changes with increasing thermal deformation. This, in turn, affects the thermal reliability of the roll. Temperature field and thermal deformation models of the shapemeter roll were established based on heat transfer and thermal elasticity theory; the temperature difference, thermal displacement difference, and the interference fit value associated with the interference fit surfaces were derived from these models. A seven-pass cold reversible rolling process in a 1050 cold rolling mill was experimentally and theoretically analyzed. These analyses revealed that the temperature difference between the interference fit surfaces is largest (maximum value 20 °C) during the third rolling pass and normal functioning of the shapemeter roll is prevented. This occurred only in the third rolling pass. An optimal design model of the initial interference fit value was developed to ensure contact between the interference fit surfaces. The optimum results showed that an initial interference fit value of 0.06 mm yields a maximum temperature difference of only 5 °C in the third rolling pass. More importantly, the shapemeter roll functions normally and its thermal reliability is improved.