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南昌航空大學科技學院學士學位論文
外文翻譯譯文
用拋丸清理機對板材軋輥進行拋丸處理
V. I. Meleshko, A. P. Kachailov, V. G. Boikov,
V. L. Mazur, T. P, Kobka, 和 I. I. Krivolapov
目前，軋制品的質(zhì)量受到許多關注，特別是板料。這從相當大的程度上取決于軋輥表面處理。許多公司著手提高軋輥表面處理的質(zhì)量，為輾壓作準備。這篇文章的作者來自Zaporozhstal公司，Magnetogorsk冶金聯(lián)合企業(yè)的人員，有色冶金研究所, Dnepropetrovsk和Magnetogorsk采礦和冶金學院，來研究這個現(xiàn)實的問題。
微表面質(zhì)量，或粗糙施工的冷軋板，對金屬的機械性能和生產(chǎn)性能，也對來自于這塊板料部分的最終質(zhì)量有影響。薄鋼板最終微表面的形成是通過對已用金屬球粗加工過的表面進行工作輾壓得到的。
通常情況下，對不合標準表面的工作輾壓粗加工是由氣動力學和電動拋丸清理機完成。在使用中的經(jīng)驗表明國家鋼鐵廠使用的氣動機不能滿足輥板表面拋丸處理的高質(zhì)量要求。
1969年，Dnepropetrovsk冶金研究所在Zaprozhstal廠1號冷的混亂的磨房研究了SM-2型拋丸清理機，發(fā)現(xiàn)了一些它結(jié)構(gòu)上的缺點。
為了提供符合伏爾加汽車廠表面粗糙度要求的板料（粗糙度為0.8-1.6u）,用于拋丸機設計的基本要求是確定的。機器必須滿足：
1. 在操作時一個持續(xù)的噴丸尺寸，換句話說，有效去除已磨損彈丸的既定尺寸；
2. 平穩(wěn)操作時，控制拋丸機收集的空氣氣壓的可能性；
3. 在機器沒有特別的設備時，對不同直徑（400-500mm）的工作輥的處理；
4. 控制簡單，維修方便。
圖一
SM-2拋丸機（如圖1）是由一個裝有輪子的固定的封閉室1，一個可移動噴管2（2在壓縮空氣的行動下，對軋輥表面發(fā)射彈丸），一個蠕蟲輸送機3，有分隔的傳送機4，拋丸裝置5，和排氣系統(tǒng)6組成。該設備安裝在一個低于地面水平1905毫米的特殊地基上。有小車的機器的長度是15，200拉姆 ，高度是4070毫米，寬度4600毫米。操作的輥的尺寸是直徑400-500毫米，長度2000-4000毫米。整臺設備的總重量是15噸。
研究表現(xiàn)了操作中一個工作中混合磨料磨損的動力和彈丸變化的原始情況。在拋丸時，彈丸在一個更大的尺寸范圍內(nèi)變化，磨損，形成許多微粒。在這種情況下，零件的拋丸取決于所用彈丸的尺寸。特定大小的微粒污染會破壞拋丸過程，使輥表面以及最后板料上的表面粗糙度降低。為了解決這些問題，有必要既定期地檢查彈丸構(gòu)成，在拋丸過程中做適當調(diào)整（在實際中很難做到），又要在機器運行過程中篩選彈丸以提供特定大小的微粒。
拋丸過程中的穩(wěn)定性也是由送入噴管的彈丸的數(shù)量所決定的。實驗表明，在氣壓2.5 -4.0atm下,提供0.3-0.4kg/sec的彈丸到運行的兩個噴管中可以使操作穩(wěn)定。給機器裝配一個篩選裝置是一個保持彈丸尺寸的有效方法。理論上的數(shù)據(jù)和Zaporozhstal公司在SM-1 和TsKb_P-1拋丸清理機的實際操作經(jīng)驗都證實了這一點。
彈丸通過拋丸裝置傳送到輥表面，機器的封閉室被分為兩個隔膜間，每間分為三格，并配備一個電子氣動控制裝置。工作混合物從上格式下降到較低的，然后收集。在操作機器時，排氣口被關閉（打開）。彈丸要么在電子氣動控制裝置關閉閥門后送入，要么在操作者關閉拋丸機以后送入。當機器關閉時，出氣孔下降，并且在它和膜片之間形成了一個圓空5毫米寬的圓孔。排氣口是一個大約有30度的錐體，彈丸慢慢通過這一缺口，但不完全，然后彈丸直徑減少到10毫米。裝載噴口由控制裝置輪流打開。首次維修SM-2拋丸機時，發(fā)現(xiàn)由于零件的腐蝕，控制系統(tǒng)經(jīng)常不運行。正常磨料（根據(jù)銘牌三百七十五千克），在交替通過每個噴管后必須停止拋丸，因為之后另一個通過彈丸的低射艙室是不夠的。在拋丸時由于控制裝置不運轉(zhuǎn)，它不能從較高的艙室下降到較低的。僅僅在操作者將拋丸設備從空氣系統(tǒng)中分離后，下一部分的彈丸才能被送過來。在這種情況下，兩個掌管的通風口都必須被打開，磨料要被送到較低的艙室。機器的連續(xù)工作使磨料通過沒有控制裝置的三至四個噴管，在磨料增加到標準要求650kg后，上述彈丸的運輸才變?yōu)榭赡堋Ｈ欢?，解決這個問題的基本方案還是控制裝置的穩(wěn)定運行。
可用的彈丸是由工作室的收集艙收集的，然后落入蠕蟲傳送機的接受槽。平行于蠕蟲傳送機的板材處在一個更大的角度，而那些垂線正處于一個角度，傾向于收集朝它們射來的彈丸。因此，在對一個輥板進行拋丸后有必要關閉機器將累積的彈丸推到螺旋傳送器上。為了消除這個缺點，將螺旋傳送器加長到工作室長度的一半是可行的。此外，更小的板料已經(jīng)完全消除，平行板被拉長以符合蠕蟲輸送機的長度。
提供給拋丸設備收集室的壓縮空氣被油水分離裝置烘干。然而，這種干燥方法是不夠的。水蒸氣凝結(jié)在主線和拋丸設備內(nèi)，結(jié)果彈丸在低艙室內(nèi)都粘到一起，形成了堅實的一堆。這一堆彈丸阻塞在垂直管內(nèi)，阻礙了磨料沿著垂直管到達收集室的過程，也打亂了拋丸過程中彈丸拋向空中的最佳比例。這對拋丸過程及軋輥表面質(zhì)量有不良影響?？諝庵写嬖诘乃謱е聶C器的腐蝕，也導致機器氣動設備的操作性能更差。因此，在設計拋丸清理機時，有必要指定干燥空氣的設備。例如，外國企業(yè)使用特殊的干燥設備利用吸水物質(zhì)，如硅膠和活性氧化鋁干燥壓縮空氣。
圖二
移動噴管的機制存在一些缺陷。磨料射到軋輥表面是通過一個安裝在肘形槍管（圖2）上的噴管完成的。槍管的一個缺點是對壓縮空氣的混合物和彈丸的節(jié)流作用，節(jié)流處橫向和縱向的管道也在。交匯處是一個直角，這導致了肘形槍的快速磨損，管道和噴管的交界區(qū)域增加。然而，隨著噴管直徑從10毫米增加到12毫米（允許的最大值），空氣的消耗從13增加到19立方米每小時，改變了彈丸射向空中的比例。然而，這個比例必須保持穩(wěn)定。因為在拋丸過程中很難糾正這個問題，因此有必要改善設計，增加零件的抗磨損度。
為了這個目的設計了一款新型噴槍，它的管道直徑增大了（圖2b），從管道過渡到管道和噴嘴的形狀也改變了。提出并經(jīng)過測試，新的噴嘴設計更為有效。五個月的操作后，改良后肘槍和噴管沒有發(fā)現(xiàn)顯著的磨損跡象，而舊的肘槍一個月后就損壞了。
噴槍通過傳送帶沿著輥移動。在臺車重量和它沿著導軌運動導致的振蕩的作用下，傳送帶離開對準線。從輥表面落下的彈丸在導軌上積累。結(jié)果，彈丸流對其表面的作用不是一個直角，而是掃過，導致表面質(zhì)量更差。安置小條在肘槍之下解決了這個問題，而且使輥表面質(zhì)量變得更令人滿意。
運行初期，SM-2拋丸機的壓縮空氣是從主要線路間得到的，其間有6atm的壓力。根據(jù)在拋丸單位的收集室前安置的測壓器讀數(shù)，其間的氣壓不超過4.0atm 。在這個氣壓下，即使用尺寸最合適的彈丸，輥的粗糙度也在上限（粗糙度為2.7u）。
因此，有必要降低空氣的工作壓力?？諝忾y是用來控制壓力的，但它對空氣壓力的變化非常敏感，而且拋丸機的操作也不穩(wěn)定。因此，減壓閥被放置在油水分離器和拋丸設備間。這使我們能在精確度0.1atm下把在收集室的氣壓從4.0控制到2.0atm 。空氣閥的運用使拋丸裝置能夠穩(wěn)定的運行。
為了把輥加工到不同直徑，有必要每次都改變拋丸槍的位置，而SM-2拋丸機的設計沒有提供這個功能。例如，現(xiàn)在要把直徑為400毫米的輥加工到500毫米，必須關閉拋丸機做調(diào)整。在設計新拋丸機時，應該考慮改變槍的高度的可能。
為了觀察拋丸過程，燈火通明的工作艙長壁上開了一個特別的觀察窗。然而，觀察輥表面的拋丸過程是很困難的。因此，三個額外的500瓦燈泡在百葉窗的保護下，安裝在工作艙的天花板上。
圖三
機器（圖3）的控制是通過控制面板2，在空中路線的閥5，用來控制輥的轉(zhuǎn)速和噴管移動的變阻器，可以起動排氣風扇機、在機器后的起動按鈕來完成的。
SM-2拋丸裝置這樣的布置控制起來不方便，控制速度的變阻器沒有精確的范圍，這使決定正確的速度變的困難。事實上，為確定每個控制手柄的新位置，有必要決定速度。這些缺點在設計新機器的時候必須消除。排氣線的水平部分累積的金屬垃圾的清除也有必要改善。排氣線難以達到地面水平4米以上的位置。
為了給拋丸機的獨立單元提供更多方便和簡化它的維護，鋼鐵冶金研究所開發(fā)并交給Zaporozhstal廠的建議已部分投入在現(xiàn)有的機器使用，而且將研究設計類似的新機型。
SM-2氣動拋丸機的改進使得控制和維持指定順序拋丸冷軋工作輥和表面通過板料站更加可能。因此，Zaporozhstal廠正大量生產(chǎn)被冷軋的建設板料，這些板料以符合有色冶金技術(shù)規(guī)格1-683-69 和 1-686-69的表面粗糙度生產(chǎn)。
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南昌航空大學科技學院學士學位論文
外文翻譯原文
SHOT BLASTING MACHINES FOR THE BLASTING OF SHEET MILL ROLLS
V. I. Meleshko, A. P. Kachailov, V. G. Boikov,
V. L. Mazur, T. P, Kobka and I. I. Krivolapov
At the present time~ much attention is being devoted to increasing the quality of rolled products, partieularly sheet. To a significant degree this depends upon the preparation of the roll surface. Many plants are engaged in improving the quality of working the roll surface in preparing them for rolling.This article was written by personnel from Zaporozhstal Plant, Magnetogorsk Metallurgical Combine, the Institute for Ferrous Metallurgy, Dnepropetrovsk, and Magnetogorsk Mining and Metallurgical Institute on this very real problem..
The surface microrelief, or roughness, of cold rolled constructional sheet has an influence on the mechanical and production properties of metal, and also on the finish quality of parts made from this sheet. The final surface microrelief of thin sheet steel is formed in a skin pass on work roils which have been given a rough finish with metal shot.
Normally the rough surface finish on the work rolls of skin pass stands is produced in pneumatic and rotor shot blasting machines. Experience in their use has shownthat the pneumatic machines used in the country's steel plants do not fill the need for high quality blasting of roll surfaces.
In 1969 the Institute for Ferrous Metallurgy, Dnepropetrovsk, did work on the SM-2 shot blasting machine in No. 1 Cold Roiling Mill of Zaprozhstal Plant, which revealed a number of shortcomings in its construction.
To provide sheet with the surface roughness required by the specifications of Volga Automobile Plant (R a =0.8-1.6 g),the basic requirements for the design of shot blasting machines were determined, The machine must provide:
1. a constant shot size during operation, in other words, effective removal of shot of the specified size from
worn shot;
2. the possibility of controlling air pressure in the collector of the shot blast machine during stable operations;
3. the handling of work rolls of different diameters (400-500 mm) without special equipment on the machine;;
4. simplicity in control and convenience in maintenance.
Fig.1
The SM-2 machine (Fig. 1) consists of a stationary closed chamber ! with a trolley on wheels aad movab!enozzles 2~ which under the action of compressed air discharge shot on to the roll surface, a worm conveyor 8, an elevator with a separator 4, the shot blast equipment 5, and an exhaust system 6. The equipment is mounted on a special foundation 1905 mm below the floor level The length of the machine withthe trolley out is 15fl00 ram, the height 4070 ram, and the width 4600 mr~ The dimensions of the rolls handled are 400-500 mm in diameter and 2000-4000 mm in length. The total weight of the equipment is 15 tons.
As research has shown, the dynamics of the wear of a working mixture of abrasive and the original condition of the shot changes during operation. During blasting, the shot takes on a wider size range and is worn down, forming many fine particles. The conditions under which the parts are blasted depend upon the size of the shot used. The contamination of the specified size by fine particles disrupts the process, producing a poor quality surface on the rolls and consequently on the sheet. To eliminate these problems it is necessary to either regularly measure the composition of the shot and make appropriate changes in the blasting sequence, which is difficult to do in practice, or to screen the shot during operation of the machine to provide the specified particle size.
Stability in the blasting process is also determined by the quantity of shot delivered to the nozzles. It was experimentally established that supplying 0.3-0.4 kg/sec of shot to the two nozzles in operating with an air pressure of 2.5-4.0 atm provided stable operation. Equipping the machine with screening devices is an effective method for maintaining a constant shot size mix. This is confirmed both by data in the literature and by experience in the operation of SM-1 and TsKb_P-1 shot blast machines at Zaporozhstal Plant.
The shot is delivered to the surface of the roll by the shot blast equipment, the chamber of which is divided by two diaphragms with charging vents into three compartments and is equipped with an electropneumatic control device. The working mixture from the upper compartment of the chamber drops to the lower and then to the collector. During operation of the machine,the vents are closed (turned on). The shot is poured in either after turning off the valves by the electropneumatic control device, or after shutting down the machine by the operator. When it is turned off, the vent descends, and between it and the diaphragm a circular gap 5 mm wide is formed. The vent is a cone with a slope of about 30% The shot drops slowly through this gap but not completely, and therefore it increases to t0 ram. The loading vents are alternately turned on by the control device. The first time the SM-2 machine was repaired, it was discovered that the control device frequently did not operate because of corrosion of the parts. With normal charging of abrasive (375 kg according to the nameplate), blasting must be stopped after each alternate pass of the nozzles, since after another pass the shot in the lower compartment is insufficient, and during blasting, With nonoperation of the control device, it does not drop from the upper compartment to the lower. Delivery of the nextportion of shot must be done only after the operator disconnects the shot blast equipment from the air system. In this case both charging vents are opened, and the abrasive is fed to the lower compartment. Continuous operation of the machine for three or four passes of the nozzles with nonoperation of the control device and the delivery of shot described above became possible after increasing the standard charge to 650 kg. However, the basic solution of this problem is stable operation of the control device.
The used shot is collected by the collecting bunker of the working chamber and drops into the receiving chute of the worm conveyor. The plates parallel to the worm conveyor are at a greater angle, and those perpendicular are at less of an angle, which tends to collect shot on them. Therefore, after blasting one roll it is necessary to shut the machine down to push the accumulated shot on to the screw conveyor. To eliminate this shortcoming, it is possible to lengthen the screw conveyor, which is half the length of the working chamber. In addition, the smaller plate is removed completely,and the parallel plates are elongated to correspond with the length of the worm conveyor.
The compressed air supplied to the collector of the shot blast equipment is dried by an oil moisture separator. However, this method of drying is inadequate. Water vapor condenses in the main line and in the shot blast equipment, and as a result shot sticks together in the lower compartment and forms a solid mass. The solid mass clogs the vertical channels along which the abrasive is transported to the collector and disrupts the optimum ratio of shot to air in the blast. This has a detrimental effect on the blasting process and the quality of the roll surface. The presence of moisture in the air causes corrosion of the equipment and causes operation of the pneumatic equipment of the machine to be poorer. Therefore, in designing shot blast equipment,it is necessary to specify equipment for drying the air. Foreign firms, for example, use special drying equipment utilizing water absorbing substances such as silica gel and activated alumina for drying compressed air.
The mechanism for moving the nozzle has a number of shortcomings. Application of the jet of abrasive material on to the roll is through a nozzle mounted in an elbow shaped gun (Fig. 2). A shortcoming of the gun is the throttling of the mixture of compressed air and shot where the vertical and horizontal channels join. The junction is a right angle, which causes quick wearing away of the elbow. The cross sections of the channels and nozzle was increased. However, with an increase in the nozzle diameter from 10 to 12 mm (the allowable maximum) the consumption
of air increased from 13 to 19 mS/h, which changed the ratio of shot to air in the blast. However, thisratio must be kept constant. Since during blasting it is difficult to make corrections, it was necessary ~o improve the design and increase the wear resistance of the parts.
Fig.2
For this purpose a new design of blast guns, in which the diameter of the channels was increased (Fig. 2 b) and the shape of the transition from the channel to the channel and nozzle was changed, was proposed and tested, The new nozzle design is much more effective. After five months of operation,noticeable signs of wear in the elbowand nozzle have not been found, while the old design elbows wore out in a month.
The blast guns are moved along the roll by a conveyor belt. Under the action of the weight of the troJ.ley and oscillations caused by its movement along the guides on which shot falling from the surface of the rolls accumulates, the belt gets out of alignment. As a result, the impact of the stream of shot on the surface is not at a right angle, but glancing, which produces a poorer surface quality. Placing a strip under the gun eliminated this problem, and the roll surface quality became satisfactory.
In the first period of operation the compressed air tn the SM-2 machine was obtained from the shop main i',ine, which has a pressure of 6 atm. According to readings on a manometer placed before the collector of the shot btaat unit, the air pressure in it did not exceed 4.0 aim. With this pressure, even with the use of the finest shot (DChK-0.8), the roughness of the rolls is at the upper limit (R a = 2.7 #).
Therefore, it was necessary to reduce the working pressure of the air. An air valve was used to control the pressure, but it was very sensitive to changes in air pressure, and operation of the shot blast machine was unstaSle. As a result, a reducing valve was placed between the oil moisture separator and the shot blast equipment. This made it possible to control the air pressure in the collector from 4.0 to 2.0 atm with an accuracy of 0.1 atrr. The use of this valve provides stable operation of the shot blast equipment.
To blast rolls of different diameters it is necessary each time to change the position of the blast gun, which is not provided for in the design of the SM-2 machine. For example, at the present time to blast a 400 mm diameter roll after a 500 mm roll the machine must be shut down for adjustment. In designing new shot blast machines the possibility of changing the height of the gun must be specified.
To observe the blasting process, special observation windows were cut in the long wal! of the lighted working chamber. Nonetheless, observation of the surface of the roll being blasted was difficult. Therefore, three additional 500 W lights, protected by louvers, were placed on the ceiling of the working chamber.
Fig .3
Control of the machine (Fig. 3) is from the control panel 2, the valve 5 at the air line, the rheostats for con. trolling the speed of rotation of the roll and the movement of the nozzles, and the push bu~on for starting up the exhaust fan motor, which is behind the machine.
Such an arrangement of the SM-2 shot blast machine equipment is not convenient for control The rheostats for controlling the speeds do not have graduated scales, which makes choice of the correct speed difficuR. Actual: 15 for each new position of the control handle it is necessary to determine the speed. These disadvantages must be eliminated in the design of new machines, It is also necessary to improve removal of accumulated metal dust from the horizontal portion of the exhaust line, which is in a difficult to reach location about 4 m above the floor tevel.
To provide more convenient placement of the individual units of the shot blast machine and simplify i~maintenance, the Institute of Ferrous Metallurgy has developed and turned over to Zaporozhstal Plant recommendations which have been partially put into use on the existing machine and will be studied in designing similar new machines.
The improvement in the SM-2 pneumatic shot blasting machine has made it easily possible to controt and maintain the specified sequence for blasting work rolls for cold rolling and skin pass sheet stands. As a result, Zaporozhstal Plant is mass producing cold roiled constructional sheet with a surface roughness meeting Ferrous Metallurgy Technical Specifications 1-683-69 and 1-686-69.
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