CN113684704A - 一种耐疲劳钢丝绳的生产工艺 - Google Patents
一种耐疲劳钢丝绳的生产工艺 Download PDFInfo
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 78
- 239000010959 steel Substances 0.000 title claims abstract description 78
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 239000011248 coating agent Substances 0.000 claims abstract description 46
- 238000000576 coating method Methods 0.000 claims abstract description 46
- 238000010438 heat treatment Methods 0.000 claims abstract description 35
- 238000002791 soaking Methods 0.000 claims abstract description 11
- 238000005260 corrosion Methods 0.000 claims abstract description 10
- 238000004381 surface treatment Methods 0.000 claims abstract description 6
- 238000001035 drying Methods 0.000 claims description 20
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 10
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- 239000003795 chemical substances by application Substances 0.000 claims description 10
- 238000004140 cleaning Methods 0.000 claims description 10
- 238000001816 cooling Methods 0.000 claims description 10
- 238000002347 injection Methods 0.000 claims description 10
- 239000007924 injection Substances 0.000 claims description 10
- 238000005246 galvanizing Methods 0.000 claims description 6
- 239000002994 raw material Substances 0.000 claims description 6
- 229910000838 Al alloy Inorganic materials 0.000 claims description 5
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 5
- 238000005098 hot rolling Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 235000015112 vegetable and seed oil Nutrition 0.000 claims description 5
- 239000008158 vegetable oil Substances 0.000 claims description 5
- 239000011701 zinc Substances 0.000 claims description 5
- 229910052725 zinc Inorganic materials 0.000 claims description 5
- 238000000034 method Methods 0.000 claims 3
- 230000007797 corrosion Effects 0.000 abstract description 5
- 230000002035 prolonged effect Effects 0.000 abstract description 3
- 239000000243 solution Substances 0.000 description 4
- 238000010276 construction Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
- B21C1/02—Drawing metal wire or like flexible metallic material by drawing machines or apparatus in which the drawing action is effected by drums
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
- B21C37/042—Manufacture of coated wire or bars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21F—WORKING OR PROCESSING OF METAL WIRE
- B21F1/00—Bending wire other than coiling; Straightening wire
- B21F1/02—Straightening
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
- D07B1/0606—Reinforcing cords for rubber or plastic articles
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/14—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable
- D07B1/141—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable comprising liquid, pasty or powder agents, e.g. lubricants or anti-corrosive oils or greases
- D07B1/144—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable comprising liquid, pasty or powder agents, e.g. lubricants or anti-corrosive oils or greases for cables or cable components built-up from metal wires
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/16—Ropes or cables with an enveloping sheathing or inlays of rubber or plastics
- D07B1/162—Ropes or cables with an enveloping sheathing or inlays of rubber or plastics characterised by a plastic or rubber enveloping sheathing
Abstract
本发明公开了一种耐疲劳钢丝绳的生产工艺,依次包括以下步骤:表面处理、首次拉拔、磷化、再次拉拔、捻股成绳、浸泡、热处理、校直和涂层处理得到耐疲劳钢丝绳。本发明的技术方案制备所得的钢丝绳,钢丝绳的应力消除良好,提高了钢丝绳的耐疲劳、耐腐蚀、耐磨损及低松驰性能,有效消除了钢丝绳的残余结构伸长,提高了使用寿命,能够承受长时间的矿下作业。
Description
技术领域
本发明涉及钢丝绳技术领域,具体涉及一种耐疲劳钢丝绳的生产工艺。
背景技术
空间结构用钢丝绳主要为单股绳,由于具有较大的破断拉力、较高的耐腐蚀性,较高的弹性模量及良好的不旋转性能已广泛应用于空间桁架悬索结构建设、赛车场伞状顶棚、空间拉索式体育场钢结构罩棚、船舶锚固等大型建筑中,但现有钢丝绳生产技术仍存在不足,主要是钢丝绳生产中采用高含碳量82B盘条为原料生产,钢丝的应力大,抗变形能力强,钢丝绳捻制时采用多层次(分层次)捻制技术,钢丝存在弯曲应力,导致钢丝绳应力消除不好,钢丝绳耐疲劳和耐腐蚀性能低,低松驰性能差,不能满足工程建设需要。
发明内容
本发明的目的在于针对现有技术的缺陷和不足,提供一种耐疲劳钢丝绳的生产工艺。
为实现上述目的,本发明采用的技术方案是:一种耐疲劳钢丝绳的生产工艺,其创新点在于,包括以下步骤:
S1、表面处理:将原料线材置于放线架上,经机械除鳞设备去除热轧氧化皮,清洗,然后进入涂硼设备进行涂硼处理,最后进入烘干设备烘干,得预处理线材;
S2、首次拉拔:将步骤一得预处理线材置于拉拔机上进行多道次拉拔,拉拔成型后采用热镀锌铝合金镀层处理;
S3、磷化:将步骤2得半成品线材进行磷化处理,在钢丝表面形成磷化膜;
S4、再次拉拔:将磷化处理后线材置于拉拔机上进行多道次拉拔,得成品线材,收线;
S5、捻股成绳:将步骤4得成品线材置于捻股机上捻股合绳,得成品钢丝绳;
S6、浸泡:成品钢丝绳浸入植物油中浸泡1-2h后,在0-80℃的真空环境中干燥;
S7、热处理:将钢丝绳经过热处理炉加热,加热温度780-880℃,冷却,清洗,进入助涂剂槽涂覆助涂剂,烘干,进入锌锅镀锌,锌锅温度为420-480℃,冷却,得半成品线材,收线;
S8、校直:将热处理的钢丝绳通过变形校直器消除钢丝绳中的预应力并进行校直;
S9、涂层处理:最后对钢丝绳外层进行注塑涂层处理,注塑材料采用具有较好延展性的高耐腐蚀塑胶,涂层厚度2-3mm。
进一步的,所述步骤2中多道次拉拔的道次为5.5-4.85-3.75-3.3-2.90-2.60-2.30或5.5-4.85-3.75-3.3-2.90-2.60-2.30-2.00。
进一步的,所述步骤4中的拉拔的道次为2.3-2.00-1.75-1.55-1.35-1.2或2.00-1.75-1.55-1.35-1.2-1.1-1.0。
进一步的,所述步骤7中的热处理炉加热为三段式,各段加热温度为 780℃、830℃、880℃。
本发明有益效果为:
本发明的技术方案制备所得的钢丝绳,钢丝绳的应力消除良好,提高了钢丝绳的耐疲劳、耐腐蚀、耐磨损及低松驰性能,有效消除了钢丝绳的残余结构伸长,提高了使用寿命,能够承受长时间的矿下作业。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合具体实施方式,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施方式仅用以解释本发明,并不用于限定本发明。
实施例1
一种耐疲劳钢丝绳的生产工艺,包括以下步骤:
S1、表面处理:将原料线材置于放线架上,经机械除鳞设备去除热轧氧化皮,清洗,然后进入涂硼设备进行涂硼处理,最后进入烘干设备烘干,得预处理线材;
S2、首次拉拔:将步骤一得预处理线材置于拉拔机上进行5.5-4.85-3.75-3.3-2.90-2.60-2.30拉拔,拉拔成型后采用热镀锌铝合金镀层处理;
S3、磷化:将步骤2得半成品线材进行磷化处理,在钢丝表面形成磷化膜;
S4、再次拉拔:将磷化处理后线材置于拉拔机上进行2.3-2.00-1.75-1.55-1.35-1.2拉拔,得成品线材,收线;
S5、捻股成绳:将步骤4得成品线材置于捻股机上捻股合绳,得成品钢丝绳;
S6、浸泡:成品钢丝绳浸入植物油中浸泡1-2h后,在0-80℃的真空环境中干燥;
S7、热处理:将钢丝绳经过热处理炉加热,热处理炉加热为三段式,各段加热温度为780℃、830℃、880℃,然后再进冷却,清洗,进入助涂剂槽涂覆助涂剂,烘干,进入锌锅镀锌,锌锅温度为420℃,冷却,得半成品线材,收线;
S8、校直:将热处理的钢丝绳通过变形校直器消除钢丝绳中的预应力并进行校直;
S9、涂层处理:最后对钢丝绳外层进行注塑涂层处理,注塑材料采用具有较好延展性的高耐腐蚀塑胶,涂层厚度2-3mm。
实施例2
一种耐疲劳钢丝绳的生产工艺,包括以下步骤:
S1、表面处理:将原料线材置于放线架上,经机械除鳞设备去除热轧氧化皮,清洗,然后进入涂硼设备进行涂硼处理,最后进入烘干设备烘干,得预处理线材;
S2、首次拉拔:将步骤一得预处理线材置于拉拔机上进行5.5-4.85-3.75-3.3-2.90-2.60-2.30-2.00拉拔,拉拔成型后采用热镀锌铝合金镀层处理;
S3、磷化:将步骤2得半成品线材进行磷化处理,在钢丝表面形成磷化膜;
S4、再次拉拔:将磷化处理后线材置于拉拔机上进行2.3-2.00-1.75-1.55-1.35-1.2拉拔,得成品线材,收线;
S5、捻股成绳:将步骤4得成品线材置于捻股机上捻股合绳,得成品钢丝绳;
S6、浸泡:成品钢丝绳浸入植物油中浸泡1-2h后,在0-80℃的真空环境中干燥;
S7、热处理:将钢丝绳经过热处理炉加热,热处理炉加热为三段式,各段加热温度为780℃、830℃、880℃,然后再进冷却,清洗,进入助涂剂槽涂覆助涂剂,烘干,进入锌锅镀锌,锌锅温度为480℃,冷却,得半成品线材,收线;
S8、校直:将热处理的钢丝绳通过变形校直器消除钢丝绳中的预应力并进行校直;
S9、涂层处理:最后对钢丝绳外层进行注塑涂层处理,注塑材料采用具有较好延展性的高耐腐蚀塑胶,涂层厚度2-3mm。
实施例3
一种耐疲劳钢丝绳的生产工艺,包括以下步骤:
S1、表面处理:将原料线材置于放线架上,经机械除鳞设备去除热轧氧化皮,清洗,然后进入涂硼设备进行涂硼处理,最后进入烘干设备烘干,得预处理线材;
S2、首次拉拔:将步骤一得预处理线材置于拉拔机上进行5.5-4.85-3.75-3.3-2.90-2.60-2.30-2.00拉拔,拉拔成型后采用热镀锌铝合金镀层处理;
S3、磷化:将步骤2得半成品线材进行磷化处理,在钢丝表面形成磷化膜;
S4、再次拉拔:将磷化处理后线材置于拉拔机上进行2.00-1.75-1.55-1.35-1.2-1.1-1.0拉拔,得成品线材,收线;
S5、捻股成绳:将步骤4得成品线材置于捻股机上捻股合绳,得成品钢丝绳;
S6、浸泡:成品钢丝绳浸入植物油中浸泡1-2h后,在0-80℃的真空环境中干燥;
S7、热处理:将钢丝绳经过热处理炉加热,热处理炉加热为三段式,各段加热温度为780℃、830℃、880℃,然后再进冷却,清洗,进入助涂剂槽涂覆助涂剂,烘干,进入锌锅镀锌,锌锅温度为450℃,冷却,得半成品线材,收线;
S8、校直:将热处理的钢丝绳通过变形校直器消除钢丝绳中的预应力并进行校直;
S9、涂层处理:最后对钢丝绳外层进行注塑涂层处理,注塑材料采用具有较好延展性的高耐腐蚀塑胶,涂层厚度2-3mm。
综上所述,本发明极大程度地提高了钢丝绳的耐疲劳、耐腐蚀、耐磨损及低松驰性能,有效消除了钢丝绳的残余结构伸长,提高了使用寿命,能够承受长时间的矿下作业。
以上所述,仅用以说明本发明的技术方案而非限制,本领域普通技术人员对本发明的技术方案所做的其它修改或者等同替换,只要不脱离本发明技术方案的精神和范围,均应涵盖在本发明的权利要求范围当中。
Claims (4)
1.一种耐疲劳钢丝绳的生产工艺,其特征在于,包括以下步骤:
S1、表面处理:将原料线材置于放线架上,经机械除鳞设备去除热轧氧化皮,清洗,然后进入涂硼设备进行涂硼处理,最后进入烘干设备烘干,得预处理线材;
S2、首次拉拔:将步骤一得预处理线材置于拉拔机上进行多道次拉拔,拉拔成型后采用热镀锌铝合金镀层处理;
S3、磷化:将步骤2得半成品线材进行磷化处理,在钢丝表面形成磷化膜;
S4、再次拉拔:将磷化处理后线材置于拉拔机上进行多道次拉拔,得成品线材,收线;
S5、捻股成绳:将步骤4得成品线材置于捻股机上捻股合绳,得成品钢丝绳;
S6、浸泡:成品钢丝绳浸入植物油中浸泡1-2h后,在0-80℃的真空环境中干燥;
S7、热处理:将钢丝绳经过热处理炉加热,加热温度780-880℃,冷却,清洗,进入助涂剂槽涂覆助涂剂,烘干,进入锌锅镀锌,锌锅温度为420-480℃,冷却,得半成品线材,收线;
S8、校直:将热处理的钢丝绳通过变形校直器消除钢丝绳中的预应力并进行校直;
S9、涂层处理:最后对钢丝绳外层进行注塑涂层处理,注塑材料采用具有较好延展性的高耐腐蚀塑胶,涂层厚度2-3mm。
2.根据权利要求1所述的一种耐疲劳钢丝绳的生产工艺,其特征在于:所述步骤2中多道次拉拔的道次为5.5-4.85-3.75-3.3-2.90-2.60-2.30 或 5.5-4.85-3.75-3.3-2.90-2.60-2.30-2.00。
3.根据权利要求1所述的一种耐疲劳钢丝绳的生产工艺,其特征在于:所述步骤4中的多道次拉拔的道次为2.3-2.00-1.75-1.55-1.35-1.2 或 2.00-1.75-1.55-1.35-1.2-1.1-1.0。
4.根据权利要求1所述的一种耐疲劳钢丝绳的生产工艺,其特征在于:所述步骤7中的热处理炉加热为三段式,各段加热温度为 780℃、830℃、880℃。
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