鋼坯火焰清理機(jī)的設(shè)計(jì)—排屑裝置設(shè)計(jì)

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系統(tǒng)總體方案確定 本課題是以及其經(jīng)濟(jì)性好，人性化設(shè)計(jì)，可靠性高，壽命長(zhǎng)，結(jié)構(gòu)簡(jiǎn)單，易于維修等為設(shè)計(jì)思路 初選電機(jī)減速器系統(tǒng)反感 （a）為帶轉(zhuǎn)動(dòng)渦輪-渦桿減速器系統(tǒng) （b）為帶傳動(dòng)-二級(jí)圓柱圓錐減速器系統(tǒng) （c）為聯(lián)軸器-二級(jí)圓柱斜齒輪減速器系統(tǒng) （d）為帶傳動(dòng)-二級(jí)圓柱斜齒輪減速器系 圖2.1 電機(jī)減速器系統(tǒng)方案 方案評(píng)價(jià)： （a） 方案為整體布局最小，傳動(dòng)平穩(wěn)，而且可以實(shí)現(xiàn)較大的傳動(dòng)比，但是由于渦輪渦桿效率低，功率損失大，很不經(jīng)濟(jì)。（b）方案布局比較小，但是圓錐齒輪加工較困難，特別是大直徑，大模數(shù)的錐輪，所以一般不采用。（c）方案中減速器選擇合理，但本設(shè)計(jì)是用于自動(dòng)排屑系統(tǒng)裝置，工作速度很低，使用聯(lián)軸器不利于減速，會(huì)增加減速器的成本，不夠經(jīng)濟(jì)。 最終確定方案為（d）方案。 該方案的優(yōu)缺點(diǎn)： 該工作機(jī)有輕微震動(dòng) ，由于V帶有緩沖吸震能力，采用V帶傳動(dòng)能減小震動(dòng)帶來(lái)的影響，而且利于減速，還能起過(guò)載保護(hù)的作用，并且該工作機(jī)屬于小功率，載荷變化不大，可以采用V帶這種簡(jiǎn)單的結(jié)構(gòu)，并且價(jià)格便宜，標(biāo)準(zhǔn)化程度高，大幅度降低成本。減速器部分兩級(jí)展開式圓柱齒輪減速，這是兩級(jí)減速器中應(yīng)用最廣泛的一種，齒輪相對(duì)于軸承不對(duì)稱，要求軸具有較大的剛度，高速及齒輪常布置在遠(yuǎn)離扭矩輸入端的一邊，以減小因彎曲變形所引起的載荷沿齒寬分布不均勻現(xiàn)象。電動(dòng)機(jī)部分為Y系列三相交流，異步電動(dòng)機(jī)。 總體來(lái)講，該傳動(dòng)方案滿足工作機(jī)的性能要求，使用工作條件，工作可靠，此外還結(jié)構(gòu)簡(jiǎn)單，成本低，傳動(dòng)效率高。 2.3輸送外傳動(dòng)系統(tǒng)的確定 （a）帶傳動(dòng) （b）履帶傳動(dòng) （c）鏈傳動(dòng) 方案評(píng)價(jià)： （a）方案成本較低，但是防腐蝕性不強(qiáng)。（b）履帶主要用在坦克等觸地設(shè)備，在此處用履帶傳動(dòng)很不經(jīng)濟(jì)。（c）方案中鏈傳動(dòng)選擇合理。 最終確定方案為（c）方案 該方案的優(yōu)缺點(diǎn)： 鏈傳動(dòng)的傳動(dòng)比精確，傳動(dòng)效率高，鏈傳動(dòng)對(duì)軸的作用力較小，鏈傳動(dòng)尺寸較緊湊，鏈傳動(dòng)對(duì)環(huán)境的使用能力較強(qiáng)，鏈條的磨損伸長(zhǎng)比較緩慢，張緊調(diào)節(jié)量較小。 2.4總體方案的確定 方案為：電動(dòng)機(jī)——帶傳動(dòng)——減速器——鏈傳動(dòng) 如下圖： 圖2.2 系統(tǒng)總體方案 電動(dòng)機(jī)型號(hào)的選擇 電動(dòng)機(jī)功率的選擇 根據(jù)鏈傳輸機(jī)結(jié)構(gòu)的布置由已知條件鏈傳動(dòng)機(jī)構(gòu)承受的鐵屑質(zhì)量為為此排屑的質(zhì)量，即為2.28（最大板寬度）*4（最大版長(zhǎng)度）*0.01（平均每次清理厚度）*7.85*1000（普通剛的的密度）=716KG的鐵屑，即7016N（取G=9.8），取3000， 鏈的傳動(dòng)速度為（燒嘴速度為V=8M/MIN,每次清理寬度為100mm，所以清理一面的時(shí)間為（2.28*10*4）/8=11.4min，取12MIN，搜所以每12分鐘便有2806.72N鐵屑排出，假設(shè)一次清理的鐵屑分連詞排出，算的6min/次，總行程為3.6M，3.6/6=0.6M/MIN，由于傳動(dòng)機(jī)構(gòu)還受鏈條摩擦力f和刮板的重力分量F1。由上述可知總的載荷為F=f+F1+3000 設(shè)所選鏈型號(hào)為48A，P=76.2MM,單排質(zhì)量Q=22.6KG/M，總長(zhǎng)度為10M，刮板尺寸為500mm*300mm*10,選用普通碳素鋼密度為7.85，相鄰刮板之間的距離為五個(gè)節(jié)距88.9*6=533.4MM，F(xiàn)1約為2193N，f約為5880N F=5880+2193+7016=15089 則工作機(jī)有效功率為P=F*V=15089*0.01=0.151KW 由已知條件得電動(dòng)機(jī)有效功率為Pd=P/η，式中η為系統(tǒng)總的傳動(dòng)效率 電動(dòng)機(jī)到鏈傳動(dòng)總的傳動(dòng)效率為η=η1*η2（平方）*η3（六次方）*η4*η5 式中：η1為V帶傳動(dòng)效率，η2為閉式齒輪的傳動(dòng)效率，η3為圓錐滾子軸承的傳動(dòng)效率，，η4為聯(lián)軸器的傳動(dòng)效率，η5為鏈傳動(dòng)效率 查表：η1=0.95 η2=0.97 η3=0.98 η4=0.99 η5=0.96 代入上式：η=0.723 所以電動(dòng)機(jī)的有效功率Pd=p/η=0.209KW 所選電動(dòng)機(jī)的額定功率必須滿足Pe>Pd 確認(rèn)電動(dòng)機(jī)型號(hào) 根據(jù)已知條件本排屑裝置的輸送速度為： Nw=V*60*1000/Z1*P=11.04 選取電動(dòng)機(jī)型號(hào)為Y2-90S-8,同步轉(zhuǎn)速為750r/min,對(duì)應(yīng)額定功率為0.37KW，外伸軸直徑24mm 方案 電機(jī)機(jī)型號(hào) 額定功率(KW) 同步轉(zhuǎn)速（r/min） 滿載轉(zhuǎn)速（r/min） 總傳動(dòng)比i 1 Y2-90S-8 0.37 750 700 65 4，V帶的設(shè)計(jì)計(jì)算 4.1 傳動(dòng)比的分配 計(jì)算總的傳動(dòng)比：i=Nm/Nw=715/11=65 傳動(dòng)比的分配：i1=3,i2*i3=i/i1=21.66 雙極斜齒圓柱齒輪減速器高速級(jí)的傳動(dòng)比為5 低速級(jí)傳動(dòng)比：i3=4.33 4.2 各軸的轉(zhuǎn)速，功率和轉(zhuǎn)矩 轉(zhuǎn)速：N1=715/3=238.33R/MIN 功率：P1=Pd*η4=0.209*0.95=0.199KW 扭矩：T1=9550P1/N1=9550*0.199/238.33=7.97N。M 轉(zhuǎn)速：N2=238.33/5=47.67R/MIN 功率：P2=P1*η2*η3=0.199*0.97*0.98=0.189KW 扭矩：T2=9550P2/N2=9550*0.189/47.67=37.86N。M 轉(zhuǎn)速：N3=47.67/4.33=11.01R/MIN 功率：P3=P2*η2*η3=0.189*0.97*0.98=0.180KW 扭矩：T3=9550P3/N3=9550*0.180/11.01=156.13N。M 轉(zhuǎn)速：N4=N3=11.01R/MIN 功率：P4=P3*η1*η5=0.180*0.99*0.96=0.17KW 扭矩：T4=9550P4/N4=9550*0.17/11.01=147.46N。M 表1.1各軸的運(yùn)動(dòng)與動(dòng)力參數(shù) 軸號(hào) 轉(zhuǎn)速（r/min） 功率（KW） 扭矩（N.M） 1 238.33 0.199 7.97 2 47.67 0.189 37.86 3 11.01 0.180 156.13 4 11.01 0.17 147.46 帶傳動(dòng)方案的確定 外傳動(dòng)帶選為普通V帶傳動(dòng) 1. 確定計(jì)算功率：Pc a (1)查文獻(xiàn)得工作情況系數(shù)KA=1.2 （2）Pca=KA*P=1.2*0.151=0.1812 2.選擇V帶型號(hào) 選A形V帶 4.4帶傳動(dòng)設(shè)計(jì)計(jì)算 1，確定帶輪尺寸d1,d2 根據(jù)帶輪要求去小帶輪尺寸為d1=160mm d 1/2120 確定V帶根數(shù)Z Z>Pca/(P0+ΔP)KαKl P0為單根V帶的基本額定功率，Δp0為I≠1是單根V帶額定功率增量，Kl為帶長(zhǎng)修正系數(shù)，Ka為小帶輪包角系數(shù) P0=1.51 Δp0=0.09 Ka=0.93 KL=1.13 代入得Z=2 確定單跟初拉力F0 F0=500*Pca/VZ(2.5/Ka-1)+qv2=16.37N 查表的q=0.1kg/m 計(jì)算對(duì)軸的壓力Fp Fp=2ZF0sin(α1/2)=2*2*16.37*sin(159.86/2)=64.47 帶輪的結(jié)構(gòu)設(shè)計(jì) 1. 小帶輪的設(shè)計(jì) 因?yàn)樾л喕鶞?zhǔn)直徑d1=160<300,故可采用實(shí)心式結(jié)構(gòu) 帶輪寬：B=（Z-1）e+2f=35 式中：e為槽間距，取e=15，f為第一槽對(duì)稱面值斷面的距離，f=10 輪轂寬：L=（1.5-2）d=43.2 輪轂外直徑：d1=1.9d=45.6 帶輪外徑：da=dd+2Ha=160+2*2.75=165.5 查得Ha=2.75 輪緣寬：δ=8mm 基準(zhǔn)線下深槽：10mm 簡(jiǎn)圖如下： 大帶輪設(shè)計(jì) 因?yàn)榛鶞?zhǔn)直徑d2=480>300故可采用輪輻式 帶輪寬：B=（Z-1）e+2f=(2-1)*15+2*10=35mm 輪轂寬：L=（1.5-2）d=1.8*60=108 輪轂外直徑：d1=1.9d=114mm 帶輪外徑：da=dd+2ha=480+2*2.75=485.5 輪緣寬：δ=8mm 基準(zhǔn)線下深槽：10mm 由以上數(shù)據(jù)，大帶輪結(jié)構(gòu)簡(jiǎn)圖如下： 鏈傳動(dòng)的計(jì)算 1， 選擇從動(dòng)鏈輪齒數(shù) 取傳動(dòng)比為i=1 取Z2=29 2， 選擇主動(dòng)鏈輪齒數(shù) Z1=iZ2=1*29=29＜120 故合理 3，確定計(jì)算功率 已知鏈傳動(dòng)工作平穩(wěn)，設(shè)計(jì)功率為 Pd=KaP/KzKm=1*0.151/1.579*1=0.096kw 式中：P-傳遞功率KV Ka-工礦系數(shù)，取Ka=1.0 Kz-小鏈輪齒數(shù)系數(shù)，取Kz=1.579 Km-多排鏈排數(shù)系數(shù)，去Km=1 3， 鏈條節(jié)距選用 根據(jù)設(shè)計(jì)功率Pd(取Pd=P0)和小鏈輪轉(zhuǎn)速n1,選用56B號(hào)鏈條，查表節(jié)距P=88.9,設(shè)鏈長(zhǎng)10M 計(jì)算鏈輪尺寸 D1=P/（sin180/Z1）=88.9/sin(180/29)=822.4mm D2= P/（sin180/Z2）=88.9/sin(180/29)=822.4mm 初定中心距 中心距暫取3540（根據(jù)漏斗長(zhǎng)決定） 9，鏈條長(zhǎng)度及鏈長(zhǎng)節(jié)速 鏈長(zhǎng)：L=10M 鏈條節(jié)數(shù)：Lp=L/P=10000/88.9=112.49 元整偶數(shù)節(jié)，取Lp=114 鏈速：V=Z1N1P/60*1000=29*11.04*88.9/（60*1000=0.47<0.6m/s 屬于低速運(yùn)動(dòng) 2鏈輪的結(jié)構(gòu)和尺寸 1，鏈輪材料： 鏈輪材料為45鋼，硬度為40-50HBS。 工藝為： 鏈輪的結(jié)構(gòu)和尺寸 由前面設(shè)計(jì)可知D1=D2=822.4 P=88.9 Z1=Z2=29 鏈輪結(jié)構(gòu)如下 鏈輪結(jié)構(gòu)簡(jiǎn)圖 輪轂厚度：h=K+Dk/6+0.01d=9.5+220/6+0.01*822.4=54.4mm 由于d=822.4 K取9.5 輪轂長(zhǎng)度：L=3.3h=3.3*54.4=179.5mm 輪轂直徑：Dh=Dk+2h=220+2*54.4=328.8mm 齒寬Bf1=0.93*b1=49.6mm B1為內(nèi)鏈節(jié)寬度 齒側(cè)倒角： Ba=0.13p=0.13*88.9=11.56mm 齒側(cè)半徑：Rx=P=88.9mm 齒全寬：Bfn=(n-1)Pt+Bf1=49.6mm 4， 基本參數(shù)和主要尺寸 分度圓直徑：D1=D2=822.4mm 齒頂圓直徑：Da max=d+1.25p-d1=822.4+1.25*88.9-53.98=879.545 式中：d1-滾子直徑 查表得d1=53.98 Da min=d+p(1-1.6/Z)-d1=822.4+88.9*（1-1.6/29）-53.98=852.42mm 取Da=866.0mm 齒根圓直徑： Df=D-D1=822.4-53.98=768.42mm 分度圓弦齒高：Ha max=(0.652+0.8/Z)p-0.5d1=31.02mm Ha min=0.5（p-d1）=17.46 取Ha=24.24mm 最大齒跟距高： Lx=dcos90/Z-d1=822.4*cos(90/29)-53.98=767.21mm 齒輪凹緣直徑：dg=Pcot180/Z-1.04h2-0.76= 查表得 齒表面粗糙度：Ra=6.3um 齒根圓極限偏差 量柱測(cè)量距極限偏差： 由于:Df=768.42mm查表得：上偏差0，下偏差h11 量柱測(cè)量距： Mr=dcos90/Z+dr=822.4*cos(90/29)+53.98=875.17mm dr=d1 式中：dr-量柱直徑，DR=D1,量柱技術(shù)要求為：極限偏差為：上片車+0.01，下偏差：0；表面粗糙度Ra=1.6um；表面硬度為：55-60HRC。 鏈輪孔和根圓直徑之間的跳動(dòng)量： 不能超過(guò)max(0.008df+0.08,0.15)=0.15 軸孔到鏈輪齒側(cè)平直部分的斷面跳動(dòng)量： 不能超過(guò)max(0.009df+0.08,0.14)=0.14 孔徑：H8 齒寬：H14 聯(lián)軸器的選定 根據(jù)聯(lián)軸器的特征，結(jié)構(gòu)，經(jīng)濟(jì)等考慮，采用凸緣聯(lián)軸器。 電機(jī)軸徑D=24， 選用聯(lián)軸器的型號(hào)為GYS2。 9 南昌航空大學(xué)科技學(xué)院學(xué)士學(xué)位論文 外文翻譯譯文 用拋丸清理機(jī)對(duì)板材軋輥進(jìn)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(guān)注，特別是板料。這從相當(dāng)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(zhǔn)備。這篇文章的作者來(lái)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(xué)院，來(lái)研究這個(gè)現(xiàn)實(shí)的問(wèn)題。 微表面質(zhì)量，或粗糙施工的冷軋板，對(duì)金屬的機(jī)械性能和生產(chǎn)性能，也對(duì)來(lái)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(guò)對(duì)已用金屬球粗加工過(guò)的表面進(jìn)行工作輾壓得到的。 通常情況下，對(duì)不合標(biāo)準(zhǔn)表面的工作輾壓粗加工是由氣動(dòng)力學(xué)和電動(dòng)拋丸清理機(jī)完成。在使用中的經(jīng)驗(yàn)表明國(guó)家鋼鐵廠使用的氣動(dòng)機(jī)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(hào)冷的混亂的磨房研究了SM-2型拋丸清理機(jī)，發(fā)現(xiàn)了一些它結(jié)構(gòu)上的缺點(diǎn)。 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(jī)設(shè)計(jì)的基本要求是確定的。機(jī)器必須滿足： 1. 在操作時(shí)一個(gè)持續(xù)的噴丸尺寸，換句話說(shuō)，有效去除已磨損彈丸的既定尺寸； 2. 平穩(wěn)操作時(shí)，控制拋丸機(jī)收集的空氣氣壓的可能性； 3. 在機(jī)器沒有特別的設(shè)備時(shí)，對(duì)不同直徑（400-500mm）的工作輥的處理； 4. 控制簡(jiǎn)單，維修方便。 圖一 SM-2拋丸機(jī)（如圖1）是由一個(gè)裝有輪子的固定的封閉室1，一個(gè)可移動(dòng)噴管2（2在壓縮空氣的行動(dòng)下，對(duì)軋輥表面發(fā)射彈丸），一個(gè)蠕蟲輸送機(jī)3，有分隔的傳送機(jī)4，拋丸裝置5，和排氣系統(tǒng)6組成。該設(shè)備安裝在一個(gè)低于地面水平1905毫米的特殊地基上。有小車的機(jī)器的長(zhǎng)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(zhǎng)度2000-4000毫米。整臺(tái)設(shè)備的總重量是15噸。 研究表現(xiàn)了操作中一個(gè)工作中混合磨料磨損的動(dòng)力和彈丸變化的原始情況。在拋丸時(shí)，彈丸在一個(gè)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(huì)破壞拋丸過(guò)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(wèn)題，有必要既定期地檢查彈丸構(gòu)成，在拋丸過(guò)程中做適當(dāng)調(diào)整（在實(shí)際中很難做到），又要在機(jī)器運(yùn)行過(guò)程中篩選彈丸以提供特定大小的微粒。 拋丸過(guò)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(shí)驗(yàn)表明，在氣壓2.5 -4.0atm下,提供0.3-0.4kg/sec的彈丸到運(yùn)行的兩個(gè)噴管中可以使操作穩(wěn)定。給機(jī)器裝配一個(gè)篩選裝置是一個(gè)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(jī)的實(shí)際操作經(jīng)驗(yàn)都證實(shí)了這一點(diǎn)。 彈丸通過(guò)拋丸裝置傳送到輥表面，機(jī)器的封閉室被分為兩個(gè)隔膜間，每間分為三格，并配備一個(gè)電子氣動(dòng)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(jī)器時(shí)，排氣口被關(guān)閉（打開）。彈丸要么在電子氣動(dòng)控制裝置關(guān)閉閥門后送入，要么在操作者關(guān)閉拋丸機(jī)以后送入。當(dāng)機(jī)器關(guān)閉時(shí)，出氣孔下降，并且在它和膜片之間形成了一個(gè)圓空5毫米寬的圓孔。排氣口是一個(gè)大約有30度的錐體，彈丸慢慢通過(guò)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(jī)時(shí)，發(fā)現(xiàn)由于零件的腐蝕，控制系統(tǒng)經(jīng)常不運(yùn)行。正常磨料（根據(jù)銘牌三百七十五千克），在交替通過(guò)每個(gè)噴管后必須停止拋丸，因?yàn)橹罅硪粋€(gè)通過(guò)彈丸的低射艙室是不夠的。在拋丸時(shí)由于控制裝置不運(yùn)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(shè)備從空氣系統(tǒng)中分離后，下一部分的彈丸才能被送過(guò)來(lái)。在這種情況下，兩個(gè)掌管的通風(fēng)口都必須被打開，磨料要被送到較低的艙室。機(jī)器的連續(xù)工作使磨料通過(guò)沒有控制裝置的三至四個(gè)噴管，在磨料增加到標(biāo)準(zhǔn)要求650kg后，上述彈丸的運(yùn)輸才變?yōu)榭赡堋Ｈ欢?，解決這個(gè)問(wèn)題的基本方案還是控制裝置的穩(wěn)定運(yùn)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(jī)的接受槽。平行于蠕蟲傳送機(jī)的板材處在一個(gè)更大的角度，而那些垂線正處于一個(gè)角度，傾向于收集朝它們射來(lái)的彈丸。因此，在對(duì)一個(gè)輥板進(jìn)行拋丸后有必要關(guān)閉機(jī)器將累積的彈丸推到螺旋傳送器上。為了消除這個(gè)缺點(diǎn)，將螺旋傳送器加長(zhǎng)到工作室長(zhǎng)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(zhǎng)以符合蠕蟲輸送機(jī)的長(zhǎng)度。 提供給拋丸設(shè)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(shè)備內(nèi)，結(jié)果彈丸在低艙室內(nèi)都粘到一起，形成了堅(jiān)實(shí)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(dá)收集室的過(guò)程，也打亂了拋丸過(guò)程中彈丸拋向空中的最佳比例。這對(duì)拋丸過(guò)程及軋輥表面質(zhì)量有不良影響。空氣中存在的水分導(dǎo)致機(jī)器的腐蝕，也導(dǎo)致機(jī)器氣動(dòng)設(shè)備的操作性能更差。因此，在設(shè)計(jì)拋丸清理機(jī)時(shí)，有必要指定干燥空氣的設(shè)備。例如，外國(guó)企業(yè)使用特殊的干燥設(shè)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(dòng)噴管的機(jī)制存在一些缺陷。磨料射到軋輥表面是通過(guò)一個(gè)安裝在肘形槍管（圖2）上的噴管完成的。槍管的一個(gè)缺點(diǎn)是對(duì)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(gè)直角，這導(dǎo)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(shí)，改變了彈丸射向空中的比例。然而，這個(gè)比例必須保持穩(wěn)定。因?yàn)樵趻佂柽^(guò)程中很難糾正這個(gè)問(wèn)題，因此有必要改善設(shè)計(jì)，增加零件的抗磨損度。 為了這個(gè)目的設(shè)計(jì)了一款新型噴槍，它的管道直徑增大了（圖2b），從管道過(guò)渡到管道和噴嘴的形狀也改變了。提出并經(jīng)過(guò)測(cè)試，新的噴嘴設(shè)計(jì)更為有效。五個(gè)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(gè)月后就損壞了。 噴槍通過(guò)傳送帶沿著輥移動(dòng)。在臺(tái)車重量和它沿著導(dǎo)軌運(yùn)動(dòng)導(dǎo)致的振蕩的作用下，傳送帶離開對(duì)準(zhǔn)線。從輥表面落下的彈丸在導(dǎo)軌上積累。結(jié)果，彈丸流對(duì)其表面的作用不是一個(gè)直角，而是掃過(guò)，導(dǎo)致表面質(zhì)量更差。安置小條在肘槍之下解決了這個(gè)問(wèn)題，而且使輥表面質(zhì)量變得更令人滿意。 運(yùn)行初期，SM-2拋丸機(jī)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(cè)壓器讀數(shù)，其間的氣壓不超過(guò)4.0atm 。在這個(gè)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(lái)控制壓力的，但它對(duì)空氣壓力的變化非常敏感，而且拋丸機(jī)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(shè)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 ?？諝忾y的運(yùn)用使拋丸裝置能夠穩(wěn)定的運(yùn)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(jī)的設(shè)計(jì)沒有提供這個(gè)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(guān)閉拋丸機(jī)做調(diào)整。在設(shè)計(jì)新拋丸機(jī)時(shí)，應(yīng)該考慮改變槍的高度的可能。 為了觀察拋丸過(guò)程，燈火通明的工作艙長(zhǎng)壁上開了一個(gè)特別的觀察窗。然而，觀察輥表面的拋丸過(guò)程是很困難的。因此，三個(gè)額外的500瓦燈泡在百葉窗的保護(hù)下，安裝在工作艙的天花板上。 圖三 機(jī)器（圖3）的控制是通過(guò)控制面板2，在空中路線的閥5，用來(lái)控制輥的轉(zhuǎn)速和噴管移動(dòng)的變阻器，可以起動(dòng)排氣風(fēng)扇機(jī)、在機(jī)器后的起動(dòng)按鈕來(lái)完成的。 SM-2拋丸裝置這樣的布置控制起來(lái)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(shí)上，為確定每個(gè)控制手柄的新位置，有必要決定速度。這些缺點(diǎn)在設(shè)計(jì)新機(jī)器的時(shí)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(dá)到地面水平4米以上的位置。 為了給拋丸機(jī)的獨(dú)立單元提供更多方便和簡(jiǎn)化它的維護(hù)，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(jī)器使用，而且將研究設(shè)計(jì)類似的新機(jī)型。 SM-2氣動(dòng)拋丸機(jī)的改進(jìn)使得控制和維持指定順序拋丸冷軋工作輥和表面通過(guò)板料站更加可能。因此，Zaporozhstal廠正大量生產(chǎn)被冷軋的建設(shè)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)。 6 7 南昌航空大學(xué)科技學(xué)院學(xué)士學(xué)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. 7