钣金件滚弯工艺成形及其缺陷检测

在社会市场经济不断发展的过程中,加快工业制造的发展速度,针对新型材料和新技术的推广,更是加快了工艺制造的发展速度。在文章的研究过程中,以钣金件的滚弯成形工艺进行分析和研究,并通过缺陷进行技术检测和分析,为我国工业的发展奠定坚实的基础。     

铝型材滚弯机的研制

本文叙述了为适应圆形及弧形铝门窗加工的需要,而研制成功的铝型材滚弯机的机体结构、工作原理和主要技术性能。该机结构紧凑,造价低,有较高的实用价值。     

提高电级壳刚度的有效途径——电极壳滚筋

对电极壳因刚度不足对生产造成的不良影响作了简要叙述,提出采用滚筋来提高电极壳刚度,并设计制做成滚筋机,解决了电极壳滚筋工艺。道过理论计算证明电极壳滚筋后提高了刚度。使用后取得良好效果。     

滚板机加工承载能力鉴定及改进措施

为了解决鞍钢１１号高炉大修工程炉壳钢板的弯卷加工问题，对自制５０ｍｍ滚板机的承载能力进行认真核算鉴定，并提出一定的改进措施，在保证设备安全的前提下，成功地完成了炉壳弯卷加工任务，确保高炉按期投产，并节省外委加工费和运费４６万元。     

中厚板镰刀弯和硬弯控制

针对宽厚板生产过程中出现的镰刀弯和硬弯等板形不良问题进行了理论探讨和研究,提出了相关板形问题的解决方法。采用控制轧制压力差来调整辊缝差,解决了镰刀弯问题;通过控制平整道次轧制速度、轧制压力滑板间隙、轧制线与机架辊道高度差等来提高辊系稳定性,解决高强钢板硬弯的问题。     

气动式小直径精密管材滚切机的研究

用塑性变形的滑移线理论建立了滚切力的数学模型及滚切力与夹紧力间的关系，从而为气动式和液压式管材滚切机的设计及使用提供了理论依据。采用压缩空气为动力及过平衡装置很好地解决了小直径管材在滚切过程中滚切机与被切管材间的同步问题。同时将滚切力的理论结果与实测值进行了比较，两者基本一致。     

滚盘式冷床的设计与应用

介绍了济钢中厚板厂 2 #滚盘式冷床的主要技术参数、原理结构和设计特点。实际使用证明 ,该滚盘式冷床具有钢板下表面无划伤、冷却效率高、面积利用率高、钢板平直度好、故障少、便于操作等优点。     

双边滚切剪结构设计特征浅析

分析、论述双边滚切剪结构设计的优点是滚切、双边剪切、一轴三偏心，用夹送辊控制技术、配备主刀和碎边刀间隙调整等装置、紧凑可靠；缺点是可检修性差、加工和安装难度大。     

高硬齿面滚齿加工探讨

近年来,利用硬质合金滚刀替代粗、精磨齿已广泛应用,此加工技术不仅可以降低成本,还可使效率成倍提高,并且能保证齿轮精度,本文通过对高硬齿面滚齿技术的分析,探讨高硬齿面滚齿加工在冶金机修行业的应用。     

镀锡板生产线中应用的连续拉弯矫正机

本文介绍了连续拉弯矫正反生产线中的发展应用。简要阐述了拉弯矫正要理以及镀锡线用拉弯矫正机的结构。     

Fuzzy Control System of Hydraulic Roll Bending Based on Genetic Neural Network

Withthedevelopmentofendproducts,higher qualityofplateandstripsuppliedbyironandsteel enterprisesarerequestedintermsofsizeandshape tolerance,therebyshapecontrolisalwaysanimpor tantissueforironandsteelenterprises.Becausethe hydraulicrollbendingsystemisabasi…     

六辊冷连轧机弯辊力设定模型

 基于影响函数法建立六辊冷轧机辊系弹性变形计算模型,从理论上深入分析了主要因素如单位宽度轧制力、中间辊横移位置等对最佳弯辊力的影响,从而建立了合理的弯辊力设定模型。根据中间辊弯辊力与工作辊弯辊力之间存在的关系,建立了更为简化的中间辊弯辊力设定模型,降低了模型现场调试和维护的难度。现场应用效果表明,弯辊力设定值与实测值之间偏差在±20%以外的仅占总数的5.25%,这说明模型具有较高的设定精度。     

轧机液压弯辊系统PID控制参数的遗传优化

液压弯辊装置调控板形的效果,取决于PID控制器三个参数的优劣,然而传统PID参数整定方法存在精度低、调试时间长的问题。以某钢铁公司1220冷轧机液压弯辊系统为仿真对象,利用变交叉概率和变异概率的自适应遗传算法优化PID控制器参数,从而提高液压弯辊PID控制器的控制性能和自适应能力。仿真结果表明采用此方法优化PID参数,系统的抗干扰能力较强,同时提高了系统的响应速度和控制精度。     

Deformation Uniformity of Cold-Rolled Q235 Steel Rebar by FEM in Bending and Rolling Processes

 An analytic model based on ANSYS/LS-DYNA has been developed on the cold rolling process for Q235 steel rebar with 12 mm in diameter. The elastic-plastic finite element method (FEM) and the cold deformation resistance model of Q235 steel were adopted in this model. Deformation uniformity of the final product has been analyzed using this model. The results indicate that the uniformity of the final product is obtained only as the centerline of the bending rolls is vertical to the centerline of the driven roll and parallel to the centerline of the drive roll in the whole rolling process. Besides, the number of the bending rolls must even realize the continuous bending and reverse bending process. Also, the number of the bending rolls must match the deformation degree of the workpiece in the cold rolling process. The validity of this finite element model was verified by the size and distribution of grains from the billet to the rebar in a practical cold rolling process.     

改善辊型降低弯辊力提高工作辊轴承及轧辊使用寿命

论述了四辊可逆板带冷轧机较大的弯辊力对昂贵的轧辊及轧辊轴承使用寿命的影响,通过研究辊系的弹性变形曲线,找出合理辊系凸度曲线来降低弯辊力.     

冷轧机弯辊装置的设计改进

本文介绍铝带冷轧机E形凸块液压弯辊装置的结构,分析了存在的问题,提出了相应的改进措施.改进后的E形凸块液压弯辊装置的实际应用效果良好.     

Optimisation of pinch roll load in thin slab continuous casting

Abstract

An analytical model has been developed to investigate the optimum pinch roll load and resulting slab thickness reduction during the continuous casting of a steel, constant thickness, thin slab in a vertical type machine. The pinch roll unit consists of two driven pinch roll sets, which support the solidified hot slab weight and take up the reaction forces owing to slab bending. Optimum conditions prevail when the pinch roll load required to support the slab weight is equally shared by the two pinch roll sets and has the minimum value allowing proper control of the slab speed. The model has been validated by being applied to an existing industrial case of thin slab continuous casting of plain low carbon steel. The effects of pinch roll radius, slab thickness, casting speed, slab temperature and the material carbon percentage on minimum pinch roll load and slab thickness reduction ratio have been investigated. Expressions have been obtained for the optimum pinch roll load and slab thickness reduction ratio related to the prevailing process parameters, which the plant operator can directly apply to determine the optimum pressure setting for the hydraulic cylinders fitted to the movable roll ends. The bending roll load is shown to be small compared with the pinch roll load.     

面向板形控制的辊型窜辊与弯辊技术应用

 根据板形控制理论和现场实际工况,研究了1 580 mm热连轧精轧机组机型配置,基于中值弯辊力,开发了与各机架机型适配的支承辊和工作辊辊型,扩大了弯辊力对辊缝的调节能力,建立起与工作辊辊型匹配的窜辊工艺制度,形成了正弦工作辊VCR支承辊、长行程窜辊和强力弯辊这3项控制的组合技术方案。生产实践表明,长行程WRS技术分散了轧辊热变形,使工作辊磨损曲线平缓、光滑,结合辊型与弯辊技术可以保持承载辊缝形状正常和可控,实现了热轧带钢板形和断面形状的良好控制。     

中厚板辊式矫直过程弯辊作用分析

 为了进一步提高中厚板产品矫直质量,采用弹塑性差分的曲率积分方法,分析了弯辊对矫直效果的影响,研究了弯辊量与压下量的关系,为建立中厚板辊式矫直过程的弯辊设定模型奠定了基础。计算结果表明,为了使板材矫直后的残余曲率和残余应力最小化,施加弯辊时要考虑入口压下量的影响。单从降低残余曲率的角度考虑,小压下量和大压下量下都可以施加负弯辊,但正弯辊只适用于小压下量。从控制宽度方向残余应力的角度考虑,正弯辊施加于小入口压下量时弯辊作用明显,为了消除正弯辊对厚度方向残余应力的不利作用,采用正弯辊时入口压下量不宜过大。施加弯辊会增加矫直力,因此设定弯辊量时要考虑矫直机能力的限制。研究发现了弯辊对塑性变形率的影响规律：负弯辊出现了使塑性变形率随着入口压下量的增加而减少的阶段,正弯辊可消除塑性变形率为零的阶段。     

Modeling and Simulation of Hydraulic Roll Bending System Based on CMAC Neural Network and PID Coupling Control Strategy

The hydraulic roll bending control system usually has the dynamic characteristics of nonlinearity, slow time-variance and strong outside interference in the rolling process, so it is difficult to establish a precise mathematical model for control. So, a new method for establishing a hydraulic roll bending control system is put forward by cerebellar model articulation controller (CMAC) neural network and proportional-integral-derivative (PID) coupling control strategy. The non-linear relationship between input and output can be achieved by the concept mapping and the actual mapping of CMAC. The simulation results show that, compared with the conventional PID control algorithm, the parallel control algorithm can overcome the influence of parameter change of roll bending system on the control performance, thus improve the anti-jamming capability of the system greatly, reduce the dependence of control performance on the accuracy of the analytical model, enhance the tracking performance of hydraulic roll bending loop for the hydraulic and roll bending force and increase system response speed. The results indicate that the CMAC-PID coupling control strategy for hydraulic roll bending system is effective.