JPH03205269A - Traverse drum - Google Patents

Abstract

PURPOSE:To obtain an integrally formed article which is made of the iron group metal and possesses the superior electric conductivity and abrasion resistance, securing the necessary light weight, by constituting a drum body of a uniform thin structure. CONSTITUTION:A drum 1 consists of a cylindrical drum body 3 having traverse grooves 2, drum edge part 9, etc., and formed integrally from the iron group metal material. The drum body 3 has a nearly constant this thickness in the longitudinal direction, except the drum edge parts 9 on both the sides and the inner surface supporting part. In other words, the thickness (t) of the drum body 3 is set thinner so that the thickness including the groove part 2 is smaller than the opened port width dimension Bx of the groove part 2. In this case, as the iron group metal, gray cast iron (FC), spherical graphite cast iron (FCD), stainless steel, etc., are adopted and the metal is selected from the point of toughness, etc., and the material which is fitted for the condition of the traverse drum, such as electric conductivity, abrasion resistance, and the degree of friction on the surface can be applied. Further, the drum 1 is provided with surface treatment having superior abrasion resistance.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a nuclear vibration drum.

[Prior Art] There are various types of traversing drums with a traverse system used in automatic wine gourds for winding yarn. Traversing drums that traverse at high speed are required to meet various conditions. In other words, first of all, in terms of functionality, a) it must be a conductor to dissipate static electricity generated during winding and prevent static electricity; c) the part that comes into contact with the thread must be wear-resistant; and c) the drum and package diameters must be at a constant ratio. It is required to meet the following requirements: to prevent ribbon winding that occurs when the thread is cut, and to be lightweight in order to stop the drum during thread trimming; and 2) to have a low coefficient of friction on the drum surface.

In terms of manufacturing, e) machining, including complex groove machining, is easy; f)
Stable accuracy and low cost are required.

Various types of drums are produced from this point of view.

Regarding (a), for example, there are drums in which a coating of an antistatic agent or an antistatic agent is coated on the surface of the drum, but there are problems with abrasion of the coating and abrasion of the base body. As for the opening, there are some in which hard metal or ceramic pins are embedded in the thread path to prevent wear, but these are cumbersome to process and have problems in terms of quality and cost. Furthermore, regarding 2) and e), the easiest way to reduce the weight at present is to make the drum body made of aluminum alloy, which can reduce the weight by 1.5 }cg~2
We are planning to reduce the weight to ,0 kg. However, aluminum material lacks wear resistance, and for this reason, hard alumite treatment is applied to the surface, but even in that case, the hardness is only about 500Hv at most, and the alumite coating is non-conductive. , there is a problem of static electricity being charged.

[Problems to be Solved by the Invention] Therefore, in order to improve wear resistance, it is desirable to use iron-based alloy materials, but the specific gravity is high, 2.6 to 3.1 times that of aluminum-based materials. . In addition, drums made of iron-based materials are still rarely used regularly because they have a high melting point and are expensive to manufacture, and are difficult to process because they are harder than aluminum materials.

The present invention aims to solve the above-mentioned various problems all at once, and provides a novel traverse drum having a different design concept from conventional drums.

[Means and effects for solving the problems] The traversing drum of the present invention has a arm portion and other parts made of an integral piece of ferrous metal, and a drum body excluding the end portions and inner support portions as described above. It has an extremely thin wall that is smaller than the width of the opening of the groove, and has a constant wall thickness.With this structure, even though it is a one-piece product made of iron-based material, it is reasonably lightweight, reaching the same weight as an aluminum drum. This is something that could have been made into a reality.

[Example] FIG. 1 shows a cross-sectional structure of a traversing drum 1 according to the present invention. The drum 1 includes a cylindrical drum body 3 having traverse grooves 2.
Other parts, such as the drum end 9, are integrally made of iron-based metal material. The drum main body 3 has an extremely thin wall thickness t that is substantially constant in the longitudinal direction, except for the drum end portions 9 on both sides and the inner surface support portion, as will be described later. That is, the wall thickness t of the drum body 3, including the groove portion 2, is formed to be so thin that it is smaller than the opening width dimension Bx of the groove portion 2. Of course, the opening width Bx of the groove portion 2 changes in the axial direction, but the main body wall thickness t is smaller than its narrowest width, as shown in FIG. Furthermore, in the case of the embodiment, the groove portion 2 is approximately thinner than the bottom width dimension b.

Specifically, the wall thickness t of the drum body 3 is formed with a substantially constant extremely thin wall thickness of about 1.5 to 2.5 mm in the longitudinal direction, and the weight is also comparable to that of an aluminum casting of similar size. The weight is approximately equal, approximately 1.5 kg. That is, the length and average diameter D
Naturally, the weight will be different if the dimensions are different, but if the dimensions of a standard drum are, for example, L=150 mm and D=90 myyn, the drum weight is about 1.5 kg.

As the iron-based metal, for example, gray cast iron (FC)
, spheroidal graphite cast iron (FCD), stainless steel, etc. are used, and appropriate materials are selected from the viewpoint of toughness, etc., and also meet the conditions of traversing drums such as conductivity, abrasion resistance, and degree of surface friction. It is applicable if the material is made of

Furthermore, the drum 1 has been subjected to a surface treatment with excellent wear resistance. That is, in the case of iron-based metals, the surface hardness (Hv) is at most 200 to 400 Hv if it is still in the casting stage.
Therefore, surface treatment is performed to obtain appropriate hardness. For example, ion nitriding treatment with a hardness of 800 to 1000Hv, ion plating, and hardness of 1600 to 1000Hv.
Titanium nitriding treatment with a hardness of 2000 Hv, and surface treatment with titanium carbide having a hardness of 3300 to 5000 Hv are available. By these surface treatments, a hardened layer with a thickness of several microns to several dozen microns is formed on the entire surface of the drum l including the grooves 2.

Further, in the interior 4 of the drum l, a protruding portion 5 having a groove 2 formed therein is formed with different protruding lengths, that is, groove depths, so that the housing 7 for supporting the drive shaft 6 is fitted therein. The inner surface is ground. That is, the support portion 7a of the housing 7
, 7b are precisely ground to have a diameter d1 for the portion 7a and a diameter d2 for the portion 7b, and the housing 7 is inserted and fitted from one end face of the drum l, and the cylindrical body on the fixed side is A drive shaft 6 passing through the drum 8 is inserted, and the cover 10 fixed to the drum end surface 9 and the drive shaft 6 are integrally fixed.

Note that bearings 11 and 12 are provided between the housing 7 and the cylindrical body 8, and a bearing 13 is provided between the drive shaft 6 and the cylindrical body 8.

Reference numeral 14 denotes a screw hole for fixing the cover 10, and a screw hole 15 for attaching the disc-shaped cover is also machined on the drive side end surface after casting. Although the drum wall thickness at the screw hole 14 and the portion 5 is slightly larger than the wall thickness t at other locations, it is also possible to have the same thickness t. Further, it is advantageous to make the wall thickness of the portion supporting the housing 7 thicker than other portions.

In the traversing drum l designed in this way, the drum body 3 has an extremely thin and uniform wall structure, so that although it is an integral piece of iron-based metal, it has the same level of performance as existing aluminum-based drums. It becomes possible to reduce the weight.

Next, a method for manufacturing the above-described traversing drum 1 of the present invention will be explained.

In short, this manufacturing method uses a mold having a limited space, which has the same shape as the traversing drum to be manufactured, and is slightly larger than the wall thickness t, that is, the inner and outer circumferential surfaces of the traversing drum 1 having the groove 2. By instantaneously injecting ferrous molten metal in an unoxidized state into the thin wall space of a directly cast refractory shell mold that has an integral shape inside and outside, the desired extremely thin walled product can be manufactured. Here, the molten metal may be poured in a non-oxidized state where oxygen in the air is blocked with argon, nitrogen gas, etc., or in a non-oxidized state in a vacuum.

Hereinafter, details of the manufacturing process will be explained step by step according to the drawings.

(I) At the beginning of the soluble core manufacturing process, the soluble core 16 shown in FIG. A soluble core 16 having a shape corresponding to the inner space 4 in FIG. 1 is formed.

As shown in Figure 4, the female mold for the core, that is, the fine groove l8.
Set the molding machine 7, which has been completely exposed, on the board 19,
After capping the mold setting cap mold 20, the core 16 is shaped by injecting the first soluble melt into the internal space of the mold l7.

The material for the core 16 can be a material that loses its shape under certain conditions when exposed to water, gas, oil, chemicals, etc., such as water-soluble wax, urea resin, salt, naphthalene, borax, etc. . In this example, a urea resin that dissolves in water at room temperature is used.

Note that the mold 17 is a complicated mold and forms a core having deep grooves, so it is impossible to remove the mold after forming with a conventional half-split mold. Therefore, the mold 17 is
It is vertically divided into three or more pieces (17a to 17n) as shown in the figure, and can be opened and closed radially.

For complex shapes such as traversing drums, the appropriate number of divisions is 10 or more, preferably 16. By doing so, the shape does not collapse during die cutting, and the die can be smoothly cut out.

Each piece of the mold 17 divided in this way (17a to 17
n) as shown by the arrow 24 in Fig. 7, the 9th
As shown in the figure, the protruding stripes 21 that will become grooves and the inner circumferential surface 22 that will become the outer surface of the core are continuous, forming an internal space of the same shape as the core. After injecting the resin solution, wait for it to solidify, remove the cap mold 20, and move the core mold ■7 to the arrow 23 in Fig. 8.
By opening in a radial direction, the groove is cut out without collapsing, and the soluble core 16 is formed into a certain shape.

(II) Manufacturing process of soluble original product Next, a drum 25 made of soluble material as shown in FIG.
Manufacture the original product.

That is, the core manufactured in step (I> After setting the core 16 inside, if the divided mold is closed as shown in FIG. 7, the state shown in FIG. 6, that is, a certain limited space 27 is formed between the core 16 and the mold 26. , a second soluble melt is injected into this space 27. 28 is a cap mold.This second soluble melt is poured into the core 1.
Under the conditions for melting the material No. 6, a solid state can be maintained, and for example, melts of different types that are melted by heating at 60 to 120° C. are used, and for example, ordinary wax is used.

When the second molten liquid injected into the space 27 solidifies, the mold 26 is opened radially in the same way as in step (I), and the original drum product still integrated with the core 16 is taken out. When only the urea resin core 16 is dissolved and disappeared by immersion in water at room temperature, the remaining wax becomes a thin drum close to the actual size, and the soluble original product 25 shown in FIG. 5 is manufactured. The size of the original product 25 is manufactured to be larger than the final drum size by an allowance for shrinkage.

(II [> Manufacturing process of refractory shell mold The above process (n>
The soluble drum prototype 25 obtained in step 1 is bonded to a metal injection cap male mold 29 made of the same material as the original product, and
After thoroughly cleaning the surface of the integrated product with a detergent or the like, the integrated product (FIG. 10) of the original product 25 and the male cap 29 is dipped in a specific liquid mixture A, and the integrated product (25, 29 A refractory is attached to the surface of
0% is appropriate. After dipping in this liquid mixture, the above-mentioned integral parts (25, 29) are taken out from the liquid mixture, and zircon sand is sprinkled on the surface thereof and dried slightly. After further drying, it is dipped in another mixed solution B, for example, a mixed solution of zircon sand and sodium silicate, and the surface to be taken out is sprinkled with a refractory material such as chamotte sand. After further drying, the dipping treatment and refractory adhesion treatment are alternately performed, such as dipping in another mixture C, for example, a mixture of mullite flour and ethyl silicate, and then sprinkling a refractory such as molochite on the surface. Repeat 5 to 10 times,
The thickness of the refractory shell 30 is set to about 6 to 15 mm, that is, an appropriate thickness that does not interfere with the pouring process and the process of taking out the finished product.

As shown in Figure 10, after drying the refractory shell layer 30 on the surface of the dissolvable original 25 for a certain period of time, the drum original 25 and the male cap 29 are dissolved under certain conditions. let

By melting the drum original product 25 and the male cap mold 29 under a certain temperature condition, an integrated inner and outer body having a drum-shaped thin-walled space, that is, the inner and outer circumferential surfaces of the drum including the base are directly cast. A refractory shell mold 30 is formed. This mold has a high temperature (900℃~1100℃)
) to burn out impurities.

(IV) Vacuum pouring process Refractory shell mold 30 manufactured in the above process (III>)
The material for the drum, that is, a molten iron-based metal, is instantaneously injected in a non-oxidized state into the extremely thin limited space of the drum, and the drum is cast.

FIG. 11 shows an example of the device. That is, the refractory shell mold 30 is fixedly installed on a fixed plate 33 in a processing chamber 32 covered with a cover 31, and the molten metal 3 is placed on the lower surface of the fixed plate 33.
A container 35 storing 4 is attached. This fixed plate 33
A hole 36 for passing the melt is formed in the hole 36 . After setting in such a state, the vacuum tank 37 and the pipe 38 are connected to each other by three, and the inside of the processing chamber 32 is brought into a vacuum non-oxidation state at an appropriate pressure. The vacuum tank 37 has a much larger capacity than the processing chamber 32, and by opening the valves 40 and 41, the processing chamber 32 can be instantly brought into a vacuum state. When the inside of the processing chamber 32 reaches a vacuum state of the set pressure, the valves 40 and 41 are closed, the pipe 38 is divided into three parts, and the processing chamber 32 is rotated 180 degrees in the direction of the arrow 42. This rotation is performed for an extremely short period of time (0.
5 seconds>, the molten metal 3 in the container 35
4 is instantaneously injected into the drum-shaped space within the mold 30.

The drum-shaped thin space inside the refractory shell mold 30 has grooves with a complicated shape, so in the normal pouring method performed in the atmosphere, the molten material is poured into every corner of the space. It is impossible to cause an oxidation reaction with oxygen and inject it into the entire thin space, but by instantaneously injecting it in the above-mentioned non-oxidized state, the molten material becomes refractory instantly without causing an oxidation reaction. The material is injected into the entire space of the shell mold 30.

In other words, in precision casting of extremely thin-walled products such as this one, in order to pour the metal to every corner of the narrow mold space, it is necessary to accurately prevent the incorporation and formation of high-melting point oxides that inhibit the flow of the metal. At the same time as preventing this, it is essential to finish the casting instantaneously before the solidified shell that blocks the inside of the mold has developed.

(V) Post-treatment and finishing process The metal drum taken out by breaking the refractory shell mold 30 is subjected to heat treatment to eliminate casting stress, and further processed to correct the roundness and imbalance of the drum. The grooves are polished using a lapping machine or puff polishing to create a surface with a low coefficient of friction.

Additionally, surface treatments are included to increase the hardness of the drum surface and grooves. That is, among the various surface treatment methods described above, a suitable treatment method is performed in view of desired hardness, cost, etc. For example, when ion nitriding, ion plating, etc. are applied, the hardness of the drum surface immediately after casting (200~
400Hv) is increased to 800-2000Hv,
A drum with excellent wear resistance is manufactured.

FIG. 2 schematically shows the above steps.

That is, the process (2) of manufacturing a meltable core 16 and the process (2) of manufacturing a heterogeneous meltable original product 25 using the core 16.
, a step (IV) of manufacturing a refractory shell mold 30 using the original product 25, a step IV of instantaneously injecting a molten metal into the shell mold 30 under non-oxidizing conditions, and ) 43 and step V of performing post-treatment including surface treatment.

The complete drum product 1 obtained by such a manufacturing method is an extremely thin product with the same wall thickness as described above, and satisfies all the requirements for a traverse drum for an automatic winder.

Note that in each of the above steps, the materials, processing liquids, etc. used may be those that meet various conditions, and various materials or combinations are possible. For example, in the embodiment, urea resin and natural wax were used as the materials for the core 16 and the original product 25, but the core is made of materials that are soluble only in certain chemicals, and the materials that are soluble only in other chemicals. It is also possible to manufacture prototypes from the material. Furthermore, although zircon sand, chamotte sand, molochite, etc. are used as the refractory to be attached to the surface of the original product in the examples, it is of course possible to use other easily available refractory materials.

[Effects of the Invention] As described above, in the traversing drum of the present invention, by making the drum body have an extremely thin and uniform wall thickness structure, the necessary weight reduction can be ensured while improving conductivity, wear resistance, etc. We were able to provide Shoya with an integrated product made of iron-based metals with excellent properties.

[Brief explanation of drawings]

FIG. 1 is a sectional front view of a traversing drum showing an embodiment of the present invention. Figures 2 to 1 illustrate the manufacturing method of the traverse drum, Figure 2 is a schematic diagram showing the manufacturing process of the drum, Figure 3 is a perspective view of the core, and Figure 4 is the core. Figure 5 is a perspective view showing the drum in its original form, Figure 6 is a cross-sectional view showing the original item in its form, and Figure 7 is a set of cores and molds for the original item. Fig. 8 is a plan view showing the same mold in the open state, Fig. 9 is a partial perspective view of the same mold in the closed set state, and Fig. l○ is a cross section showing the manufacturing process of the refractory shell mold. The front view and FIG. 11 are schematic elliptical views showing an example of a vacuum injection device. 1... Traverse drum 2... Traverse groove 3... Drum body t... Body wall thickness Bx... Groove opening width dimension

Claims (1)

[Claims] 1. The groove and other parts are made of a single piece of iron-based metal,
A traversing drum characterized in that the drum body excluding the end portions and the inner support portion is formed to have an extremely thin and uniform thickness smaller than the opening width of the groove portion.