WO2012060358A1 - 穿孔圧延の不良検知方法、及び継目無管の製造方法 - Google Patents
穿孔圧延の不良検知方法、及び継目無管の製造方法 Download PDFInfo
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- WO2012060358A1 WO2012060358A1 PCT/JP2011/075148 JP2011075148W WO2012060358A1 WO 2012060358 A1 WO2012060358 A1 WO 2012060358A1 JP 2011075148 W JP2011075148 W JP 2011075148W WO 2012060358 A1 WO2012060358 A1 WO 2012060358A1
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- Prior art keywords
- rolling
- piercer
- piercing
- billet
- defect
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- 230000007547 defect Effects 0.000 title claims abstract description 81
- 238000000034 method Methods 0.000 title claims abstract description 14
- 238000004519 manufacturing process Methods 0.000 title description 11
- 238000005096 rolling process Methods 0.000 claims abstract description 165
- 238000001514 detection method Methods 0.000 claims description 28
- 238000005259 measurement Methods 0.000 claims description 5
- 238000010586 diagram Methods 0.000 description 7
- 238000011835 investigation Methods 0.000 description 4
- 239000000314 lubricant Substances 0.000 description 4
- 229910000851 Alloy steel Inorganic materials 0.000 description 3
- 229910000975 Carbon steel Inorganic materials 0.000 description 3
- 230000002093 peripheral effect Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 2
- 239000010962 carbon steel Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
- B21B37/78—Control of tube rolling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B19/00—Tube-rolling by rollers arranged outside the work and having their axes not perpendicular to the axis of the work
- B21B19/02—Tube-rolling by rollers arranged outside the work and having their axes not perpendicular to the axis of the work the axes of the rollers being arranged essentially diagonally to the axis of the work, e.g. "cross" tube-rolling ; Diescher mills, Stiefel disc piercers or Stiefel rotary piercers
- B21B19/04—Rolling basic material of solid, i.e. non-hollow, structure; Piercing, e.g. rotary piercing mills
-
- 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
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B2265/00—Forming parameters
- B21B2265/12—Rolling load or rolling pressure; roll force
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B38/00—Methods or devices for measuring, detecting or monitoring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B38/00—Methods or devices for measuring, detecting or monitoring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product
- B21B38/08—Methods or devices for measuring, detecting or monitoring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product for measuring roll-force
Definitions
- the present invention relates to a piercing and rolling defect detection method when a billet is pierced and rolled with a piercer roll, and a seamless pipe manufacturing method.
- the present invention relates to a piercing and rolling defect detection method capable of easily detecting a piercing and rolling defect, and a seamless pipe manufacturing method including a step of detecting a defect by the defect detection method.
- the billet of the material is first heated to 1200 to 1260 ° C. in a heating furnace, and then pierced and rolled using a piercer plug and a piercer roll of a piercing mill in the piercing and rolling process.
- a mandrel bar is inserted into a skewer shape on the inner surface of the hollow shell, and the outer surface is constrained by a hole-type rolling roll with a mandrel mill usually comprising 5 to 8 stands, thereby reducing the thickness to a predetermined thickness.
- a mandrel bar is extracted from the raw pipe, and the raw pipe is subjected to constant diameter rolling to a predetermined outer diameter with a constant diameter rolling mill to obtain a seamless pipe as a product.
- FIG. 1 is a diagram showing a schematic configuration example of a piercing and rolling mill
- FIG. 1 (a) is a side view
- FIG. 1 (b) is a plan view
- FIG. 2 is a diagram showing a schematic positional relationship among the piercer roll, the piercer plug, and the billet.
- the piercer plug is not shown
- the pair of piercer rolls are shown with an inclination angle and a crossing angle of 0 for simplification.
- the piercing and rolling mill 10 includes a pair of piercer rolls 1 a and 1 b and a bullet-shaped piercer plug 3 whose rear end is supported by a mandrel 2.
- the pair of piercer rolls 1a and 1b are set so that their axial directions are parallel to each other or cross at a predetermined crossing angle in a side view (FIG. 1A shows an example in which they are set parallel to each other). On the other hand, they are arranged at an inclination angle ⁇ in opposite directions in a plan view and are configured to rotate in the same direction.
- the piercer plug 3 is disposed between the pair of piercer rolls 1a and 1b.
- the billet B is fed between a pair of piercer rolls 1a and 1b. After the billet B has been bitten by the pair of piercer rolls 1a and 1b, a force that is rotated and a force that is advanced in the axial direction simultaneously act on the billet B by the frictional force of the piercer rolls 1a and 1b. Then, until reaching the tip of the piercer plug 3, a compressive stress and a tensile stress act alternately and continuously on the center portion of the billet B by the piercer rolls 1a and 1b (rotary forging effect), and a hole is easily opened. It becomes.
- the billet B comes into contact with the piercer plug 3
- a hole is made in the center of the billet B, and thereafter, the hollow shell S is obtained by being subjected to a thickness processing between the piercer rolls 1 a and 1 b and the piercer plug 3.
- Another defect is that the billet B is bitten by the piercer rolls 1a and 1b and comes into contact with the piercer plug 3, but the billet B bites into the piercer rolls 1a and 1b at a low speed or the biting stops. After the billet B comes into contact with the piercer plug 3, the rolling load of the piercer rolls 1a, 1b increases only gently.
- this defect is referred to as a clogged defect.
- a draft rate representing the degree of biting by the piercer rolls 1a and 1b can be increased. If the draft rate is increased too much, a shell inner surface flaw (hollow shell) There is a risk that wrinkles that occur on the inner surface of the ink will occur.
- d is the outer diameter of the billet
- r is the distance between the piercer roll 1 a and the piercer roll 1 b where the billet tip abuts against the piercer plug 3.
- a lubricant is applied to the surfaces of the piercer rolls 1a and 1b to increase the coefficient of friction with the billet B.
- the lubricant is continuously applied, the outer surface of the piercer roll may become rough due to the rough surface of the piercer roll, or the drive unit (not shown) that rotates the piercer rolls 1a and 1b may be damaged. Operation trouble may occur due to the intrusion of the lubricant.
- the billet B is made of a high alloy steel containing 2 mass% or more of Cr
- the appropriate range of the draft rate is very narrow, so it is difficult to eliminate defects in piercing and rolling.
- the rolling condition varies depending on the roughness of the surface of the piercer roll, and therefore it is difficult to eliminate defects in piercing and rolling.
- the present invention has been made to solve the problems of the prior art, and it is an object of the present invention to provide a defect detection method with high accuracy in detecting defects in piercing and rolling.
- the present inventor has studied a method for detecting defects in piercing and rolling with high accuracy using various parameters obtained by piercing and rolling.
- the rolling load parameter corresponding to the rolling load is a parameter having a correlation with the rolling load, for example, a current value of the motor driving the piercer roll or the rolling load itself.
- the thrust load parameter corresponding to the thrust load is a parameter having a correlation with the thrust load, for example, the thrust load itself.
- the present invention has been completed based on the above-mentioned knowledge of the present inventors. That is, in order to solve the above-mentioned problem, the present invention is a method for detecting a piercing-rolling failure when a billet is pierced and rolled with a piercer roll, and includes a rolling load parameter corresponding to the rolling load and a thrust corresponding to the thrust load.
- a defect detection method for piercing and rolling is provided, wherein a load parameter is measured, and a defect in piercing and rolling is detected based on the measurement value of the rolling load parameter and the measurement value of the thrust load parameter.
- the rolling load parameter and the thrust load parameter are measured, and the piercing and rolling defect is detected based on both the measured value of the rolling load parameter and the measured value of the thrust load parameter. High detection accuracy.
- the measured value of the rolling load parameter first exceeds a predetermined rolling first threshold value until a predetermined first predetermined time elapses. If the measured value of the thrust load parameter does not exceed the predetermined first thrust threshold value during this period, it is determined that a piercing-rolling defect (specifically, an idling defect) has occurred.
- the rolling first threshold value here is a first threshold value regarding the rolling load parameter, and is a threshold value for determining whether or not the billet has contacted the piercer roll.
- the thrust first threshold value is a first threshold value regarding the thrust load parameter, and is a threshold value for determining whether or not the tip of the billet is in contact with the piercer plug.
- the measured value of the rolling load parameter exceeds the predetermined first rolling threshold value for the first time, it is determined that the billet has contacted the piercer roll, and the measured value of the thrust load parameter is determined in advance.
- the thrust first threshold value is exceeded, it is determined that the tip of the billet is in contact with the piercer plug. Accordingly, the measured value of the thrust load parameter is determined in advance between the time when the measured value of the rolling load parameter exceeds the predetermined first rolling threshold for the first time until the predetermined first predetermined time elapses. If the thrust first threshold value is not exceeded, it can be determined with high accuracy that an idling failure has occurred.
- the measured value of the thrust load parameter exceeds a predetermined second thrust threshold value for the first time until a predetermined second predetermined time elapses.
- the measured value of the rolling load parameter does not exceed the predetermined second rolling threshold value, it is determined that a piercing and rolling defect (specifically, a clogging defect) has occurred.
- the thrust second threshold value is a second threshold value relating to the thrust load parameter, and it is determined whether or not the tip of the billet is in contact with the piercer plug, similarly to the thrust first threshold value. Therefore, the same value as the thrust first threshold value may be used.
- the second rolling threshold is a second threshold relating to the rolling load parameter, and whether the billet is normally rolled by the piercer roll and the piercer plug after the billet tip abuts against the piercer plug. It is a threshold value for judging whether.
- the measured value of the thrust load parameter exceeds the predetermined second thrust threshold value for the first time, it is determined that the billet is in contact with the piercer plug, and the measured value of the rolling load parameter is When the predetermined second rolling threshold is exceeded, it is determined that the billet is normally rolled by the piercer roll and the piercer plug. Accordingly, the measured value of the rolling load parameter is determined in advance from the time when the measured value of the thrust load parameter exceeds the predetermined second thrust threshold value for the first time until the predetermined second predetermined time elapses. If the rolling second threshold value is not exceeded, it can be determined with high accuracy that a clogging defect has occurred.
- the present invention also includes a step of detecting a defect by any one of the above-described piercing and rolling defect detection methods, and a step of improving the defect when the defect is detected.
- a manufacturing method is provided.
- the defect when a defect in piercing and rolling is detected, the defect is improved, so that a seamless pipe free from defects in piercing and rolling can be manufactured.
- the rolling load parameter and the thrust load parameter are measured, and the piercing and rolling defect is detected based on both the measured value of the rolling load parameter and the measured value of the thrust load parameter. High detection accuracy.
- FIG. 1A and 1B are diagrams showing a schematic configuration example of a conventional piercing and rolling mill, in which FIG. 1A shows a side view and FIG. 1B shows a plan view.
- FIG. 2 is a diagram showing a schematic positional relationship among the piercer roll, the piercer plug, and the billet.
- FIG. 3 is a schematic configuration diagram of a piercing and rolling mill using the piercing and rolling defect detection method according to the present invention.
- FIG. 4 is a diagram showing transition of rolling load and thrust load at the start of piercing rolling.
- FIG. 3 is a schematic configuration diagram of a piercing and rolling mill 10 using the piercing and rolling defect detection method according to the present embodiment.
- the piercing and rolling mill 10 includes a rolling load sensor 4, a thrust load sensor 5, a control unit 6, and a notification unit 7 in addition to the configuration described in FIG. 1.
- the rolling load sensor 4 is, for example, a load cell, measures the rolling load of the piercer rolls 1a and 1b, and transmits an electrical signal corresponding to the measured value of the rolling load to the control unit 6.
- the thrust load sensor 5 is, for example, a load cell, measures the thrust load of the piercer plug 3, and transmits an electrical signal corresponding to the measured value of the thrust load to the control unit 6.
- the control unit 6 detects a piercing and rolling defect based on electrical signals from the rolling load sensor 4 and the thrust load sensor 5.
- the notification unit 7 notifies the occurrence of a piercing and rolling defect by a signal from the control unit 6.
- the notification unit 7 is, for example, a display screen such as a liquid crystal or a buzzer that rings.
- FIG. 4 shows changes in rolling load and thrust load at the start of piercing rolling.
- the rolling load sensor 4 measures the rolling load of the piercer rolls 1 a and 1 b and transmits an electric signal corresponding to the measured value of the rolling load to the control unit 6.
- the control unit 6 is preset with a rolling first threshold value, and the control unit 6 is the first time that the measured value of the rolling load exceeds the first rolling threshold value (the measured value of the rolling load> the first rolling value). Threshold value), it is determined that billet B has been bitten by piercer rolls 1a and 1b.
- the rolling first threshold value is a threshold value for determining whether billet B is caught in piercer rolls 1a and 1b, and bitet B is caught in piercer rolls 1a and 1b. If it is, the control unit 6 is determined by a prior investigation so as not to make an erroneous determination due to noise. When the controller 6 determines that the billet B has been bitten by the piercer rolls 1a and 1b, the controller 6 starts counting the first predetermined time.
- the first thrust threshold value is a threshold value for determining whether or not the tip of the billet B is in contact with the piercer plug 3, and the tip of the billet B is in contact with the piercer plug 3. Then, the control unit 6 is determined by a prior investigation so as not to make an erroneous determination due to noise.
- the first predetermined time is determined in order to determine whether or not an idling failure has occurred.
- the first predetermined time is, for example, from the knowledge based on the preliminary investigation that slipping failure is likely to occur when the billet B does not contact the piercer plug 3 until the billet B rotates three times after the billet B is bitten by the piercer rolls 1a and 1b. It is determined as follows.
- t1 (d ⁇ ⁇ ⁇ 3) / (D ⁇ ⁇ ⁇ N) here, t1: first predetermined time (second), d: outer diameter of billet B (mm), D: outer diameter (mm) of the piercer rolls 1a, 1b at the position where the billet B is bitten, N: the number of revolutions per second of the piercer rolls 1a, 1b, (See FIG. 2).
- the notification unit 7 notifies the occurrence of the idling failure.
- the rolling load parameter and the thrust load parameter are measured, and the piercing and rolling defect is detected based on both the measured value of the rolling load parameter and the measured value of the thrust load parameter.
- High accuracy In the above-described example, it is possible to detect the occurrence of poor slip particularly with high accuracy.
- the billet B is rolled by the piercer rolls 1 a and 1 b and the piercer plug 3 after the tip of the billet B comes into contact with the piercer plug 3. Accordingly, the rolling load of the piercer rolls 1a and 1b increases, and the rolling load becomes maximum when the tip of the hollow shell S reaches the position of the rear end of the piercer plug 3, and is thereafter held in the vicinity of the maximum rolling load. Accordingly, when the rolling load does not exceed a predetermined value within a predetermined time after the billet B contacts the piercer plug 3, it is determined that a head clogging defect has occurred. Specifically, the determination is as follows.
- the thrust load sensor 5 measures the thrust load of the piercer plug 3 and transmits an electric signal corresponding to the measured value of the thrust load to the control unit 6.
- the control unit 6 is set with a second thrust threshold value, and the control unit 6 first exceeds the thrust second threshold value (thrust load measurement value> thrust second threshold value). It is determined that the tip of the billet B is in contact with the piercer plug 3.
- the thrust second threshold value is a threshold value for determining whether or not the tip of the billet B is in contact with the piercer plug 3, and the tip of the billet B is in contact with the piercer plug 3. Then, the control unit 6 is determined by a prior investigation so as not to make an erroneous determination due to noise.
- the thrust second threshold value is a threshold value for determining whether or not the tip of the billet B is in contact with the piercer plug 3, similarly to the thrust first threshold value. The same value as the threshold may be used. However, a value different from the thrust first threshold value may be used as long as the purpose of determining whether or not the tip of the billet is in contact with the piercer plug is fulfilled.
- the second predetermined time is a time for determining whether or not the rolling load is rising normally. After the tip of the billet B comes into contact with the piercer plug 3, the tip of the hollow shell S is positioned at the rear end of the piercer plug 3. It is determined to be equal to or shorter than the time required to reach. When the control unit 6 determines that the billet B is in contact with the piercer plug 3, the control unit 6 starts counting the second predetermined time.
- the measured value of the rolling load transmitted from the rolling load sensor 4 has exceeded the rolling second threshold value until the second predetermined time has elapsed (the measured value of the rolling load> the rolling second threshold value). ), It is determined that the billet B is normally rolled by the piercer rolls 1a and 1b and the piercer plug 3, and if the rolling load does not exceed the rolling second threshold value, a clogging defect has occurred. to decide.
- the second predetermined time and the rolling second threshold value are determined as follows, for example.
- the second predetermined time is a time required for the tip of the hollow shell S to reach the position of the rear end of the piercer plug 3 after the tip of the billet B comes into contact with the piercer plug 3 in a state where normal piercing and rolling is performed.
- the rolling second threshold value is a threshold value for determining whether the billet B is normally rolled by the piercer rolls 1a and 1b and the piercer plug 3 after the tip of the billet B contacts the piercer plug 3. is there.
- the rolling second threshold value is set to 90% of the rolling load when the tip of the hollow shell S reaches the position of the rear end of the piercer plug 3 in a state where normal piercing and rolling is performed, and is determined from a preliminary survey. Therefore, in a normal case, the rolling second threshold value is larger than the rolling first threshold value.
- V Dr ⁇ ⁇ ⁇ N ⁇ sin ⁇ ⁇ 0.5
- Dr maximum diameter (mm) of the piercer rolls 1a and 1b
- N Pierce roll 1a.
- the number of revolutions per second of 1b (See FIG. 1B).
- V calculates the peripheral speed of the piercer rolls 1a and 1b at the place where the outer diameter of the piercer rolls 1a and 1b is maximum, and is set to 50% of the component in the hollow shell axial direction constituting the peripheral speed.
- the ratio of V to the component in the hollow shell axial direction of the peripheral speed of the piercer rolls 1a and 1b may be changed according to the rolling conditions.
- the notification unit 7 notifies the occurrence of the head clogging failure.
- This seamless pipe manufacturing method includes a step of detecting a piercing and rolling defect and a step of improving the defect when the piercing and rolling defect is detected.
- a detection method of a slipping failure detection method and a head clogging failure detection method are executed.
- the step of improving defects in piercing and rolling for example, the following contents are executed.
- the opening of the piercer rolls 1a and 1b is increased with respect to the billet B being pierced and rolled, and the piercer rolls 1a and 1b are opened similarly for the billet B that is pierced and rolled after the billet B. Increase the degree.
- the opening of the piercer rolls 1a and 1b is reduced when the billet B is plain steel and the billet B during piercing and rolling is increased when the billet B is high alloy steel.
- the abrasive is applied to the piercer rolls 1a and 1b. And the same thing is performed also about the billet B which performs piercing-rolling after the said billet B.
- the draft rate may be corrected for the billet B that is pierced and rolled after the billet B.
- the defect is improved, so that a seamless pipe without a defect in piercing and rolling can be manufactured.
- the detection method of the idling failure mentioned above and the detection method of the head clogging failure only one detection method may be performed respectively, or both detection methods may be performed. If the opening of the piercer rolls 1a, 1b is excessively increased when the idling failure is detected, a head clogging failure may occur, and if the opening of the piercer rolls 1a, 1b is excessively decreased when a clogging failure is detected. There is a risk that idling failure may occur. Therefore, if both the slipping failure detection method and the head clogging failure detection method are executed and the opening between the piercer rolls 1a and 1b is adjusted so that both the slipping failure and the head clogging failure do not occur, an appropriate opening is obtained. Can be adjusted.
- the second rolling threshold is 90% of the rolling load when the tip of the hollow shell S reaches the position of the rear end of the piercer plug 3 in a state in which normal piercing rolling is performed.
- the ratio of the rolling second threshold to the rolling load can be arbitrarily determined as long as a clogging defect can be detected.
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Abstract
Description
一つは、送給されたビレットBがピアサロール1a,1bには接触するが、ピアサロール1a,1bに噛み込まれずにピアサプラグ3に当接しない不良である。以下、この不良を空転不良という。
他の不良は、ビレットBが、ピアサロール1a,1bに噛み込まれピアサプラグ3には当接するが、ビレットBのピアサロール1a,1bへの噛み込みの速度が遅い又は噛み込みが停止する不良であり、ビレットBがピアサプラグ3に当接してからピアサロール1a,1bの圧延荷重がなだらかにしか上昇しない。以下、この不良を頭詰まり不良という。
ドラフト率は次のように定義される(図2参照)。
ドラフト率=(d-r)/d×100
ここでdはビレットの外径、rはビレットの先端がピアサプラグ3に当接したところでの、ピアサロール1aとピアサロール1bの間隔である。
しかしながら、これらの穿孔圧延の不良の検知は熟練した作業者の目視によって行われ、作業者の技能の影響を受けるので、検知の精度が低いという問題がある。
しかしながら、この検知方法では、上述したような穿孔圧延開始時の不良を検知することができない。
尚、圧延荷重に対応する圧延荷重パラメータとは、圧延荷重と相関を有するパラメータであり、例えば、ピアサロールを駆動させているモータの電流値や圧延荷重自体である。また、スラスト荷重に対応するスラスト荷重パラメータとは、スラスト荷重と相関を有するパラメータであり、例えば、スラスト荷重自体である。
ここでいう圧延第1しきい値とは、圧延荷重パラメータに関する一つ目のしきい値であり、ビレットがピアサロールに接触したか否かを判断するためのしきい値である。
また、スラスト第1しきい値とは、スラスト荷重パラメータに関する一つ目のしきい値であり、ビレットの先端がピアサプラグに当接したか否かを判断するためのしきい値である。
従って、圧延荷重パラメータの測定値が予め定められた圧延第1しきい値を初めて越えてから予め定められた第1所定時間を経過するまでの間に、スラスト荷重パラメータの測定値が予め定められたスラスト第1しきい値を越えない場合は、空転不良が発生したと高い精度で判断することができる。
ここでいうスラスト第2しきい値とは、スラスト荷重パラメータに関する二つ目のしきい値であり、スラスト第1しきい値と同様に、ビレットの先端がピアサプラグに当接したか否かを判断するためのしきい値であるので、スラスト第1しきい値と同じ値を用いればよい。ただし、ビレットの先端がピアサプラグに当接したか否かを判断する目的を果たす範囲内であれば、スラスト第1しきい値と異なる値を用いても構わない。
また、圧延第2しきい値とは、圧延荷重パラメータに関する二つ目のしきい値であり、ビレットの先端がピアサプラグに当接してから、ビレットがピアサロールとピアサプラグとによって正常に圧延されているか否かを判断するためのしきい値である。
従って、スラスト荷重パラメータの測定値が予め定められたスラスト第2しきい値を初めて越えてから予め定められた第2所定時間を経過するまでの間に、圧延荷重パラメータの測定値が予め定められた圧延第2しきい値を越えない場合は、頭詰まり不良が発生したと高い精度で判断することができる。
穿孔圧延機10は、図1に記載された構成に加えて、圧延荷重センサ4とスラスト荷重センサ5と制御部6と報知部7とを備えている。圧延荷重センサ4は、例えばロードセルであり、ピアサロール1a,1bの圧延荷重を測定し、圧延荷重の測定値に相当する電気信号を制御部6に送信する。スラスト荷重センサ5は、例えばロードセルであり、ピアサプラグ3のスラスト荷重を測定し、スラスト荷重の測定値に相当する電気信号を制御部6に送信する。制御部6は、圧延荷重センサ4及びスラスト荷重センサ5からの電気信号に基づいて穿孔圧延の不良を検知する。報知部7は、制御部6からの信号により穿孔圧延の不良の発生を報知する。報知部7は、例えば、液晶等の表示画面や鳴動するブザーである。
図4は、穿孔圧延開始時の圧延荷重とスラスト荷重の推移を示す。
穿孔圧延が正常に行われている場合には、ビレットBが一対のピアサロール1a,1b間に送給され、ピアサロール1a,1bに噛み込まれてから、所定時間内にビレットBはピアサプラグ3に当接する。そこで、ピアサロール1a,1bに噛み込まれてから所定時間内にビレットBがピアサプラグ3に当接しないときに、空転不良が発生したと判断する。具体的には、次のように判断する。
ビレットBが、搬送機(図示せず)によって一対のピアサロール1a,1b間に送給され、ピアサロール1a,1bに噛み込まれるとピアサロール1a,1bの圧延荷重が大きくなる。圧延荷重センサ4は、ピアサロール1a,1bの圧延荷重を測定しており、圧延荷重の測定値に相当する電気信号を制御部6に送信する。制御部6には、圧延第1しきい値が予め定められており、制御部6は、圧延荷重の測定値が圧延第1しきい値を初めて超えた(圧延荷重の測定値>圧延第1しきい値)ときに、ビレットBがピアサロール1a,1bに噛み込まれたと判断する。圧延第1しきい値は、ビレットBがピアサロール1a,1bに噛み込まれたか否かを判断するためのしきい値であり、ビレットBがピアサロール1a,1bに噛み込まれていないのに噛み込まれたと、制御部6がノイズによって誤判定しないように事前の調査によって定められる。
制御部6は、ビレットBがピアサロール1a,1bに噛み込まれたと判断すると、第1所定時間のカウントを開始する。
スラスト第1しきい値は、ビレットBの先端がピアサプラグ3に当接したか否かを判断するためのしきい値であり、ビレットBの先端がピアサプラグ3に当接していないのに当接したと、制御部6がノイズによって誤判定しないように事前の調査によって定められる。
第1所定時間は、空転不良が発生したか否かを判断するために定められ、空転不良が発生しなかった場合にビレットBがピアサロール1a,1bに噛み込まれてからビレットBの先端がピアサプラグ3に当接するまでに要する時間から定められる。
ビレットBがピアサロール1a,1bに噛み込まれてからビレットBが3回転するまでにピアサプラグ3に当接しない場合に空転不良になり易いという事前調査による知見から、第1所定時間は、例えば、次のように定められる。
t1=(d×π×3)/(D×π×N)
ここで、
t1:第1所定時間(秒)、
d:ビレットBの外径(mm)、
D:ビレットBを噛み込んだ位置でのピアサロール1a,1bの外径(mm)、
N:ピアサロール1a,1bの1秒当たりの回転数、
である(図2参照)。
上述した例では、特に空転不良の発生を高い精度で検知することができる。
穿孔圧延が正常に行われている場合には、ビレットBの先端がピアサプラグ3に当接してから、ビレットBがピアサロール1a,1bとピアサプラグ3とによって圧延される。従って、ピアサロール1a,1bの圧延荷重が上昇し、圧延荷重はホローシェルSの先端がピアサプラグ3の後端の位置に到達したときに最大となり、その後その最大の圧延荷重近傍に保持される。
そこで、ビレットBがピアサプラグ3に当接してから所定時間内に圧延荷重が所定の値を超えないときには、頭詰まり不良が発生したと判断する。具体的には、次のように判断する。
スラスト第2しきい値は、ビレットBの先端がピアサプラグ3に当接したか否かを判断するためのしきい値であり、ビレットBの先端がピアサプラグ3に当接していないのに当接したと、制御部6がノイズによって誤判定しないように事前の調査によって定められる。尚、スラスト第2しきい値は、スラスト第1しきい値と同様に、ビレットBの先端がピアサプラグ3に当接したか否かを判断するためのしきい値であるので、スラスト第1しきい値と同じ値を用いればよい。ただし、ビレットの先端がピアサプラグに当接したか否かを判断する目的を果たす範囲内であれば、スラスト第1しきい値と異なる値を用いても構わない。
第2所定時間は、圧延荷重が正常に上昇しているかを判断するための時間であり、ビレットBの先端がピアサプラグ3に当接してから、ホローシェルSの先端がピアサプラグ3の後端の位置に到達するのに必要な時間と同じ時間、又はそれより短い時間に定められる。
制御部6は、ビレットBがピアサプラグ3に当接したと判断すると、第2所定時間のカウントを開始する。
第2所定時間は、正常な穿孔圧延が行われている状態において、ビレットBの先端がピアサプラグ3に当接してからホローシェルSの先端がピアサプラグ3の後端の位置に達するまでに要する時間とする。圧延第2しきい値は、ビレットBの先端がピアサプラグ3に当接してから、ビレットBがピアサロール1a,1bとピアサプラグ3とによって正常に圧延されているか否かを判断するためのしきい値である。圧延第2しきい値は、正常な穿孔圧延が行われている状態において、ホローシェルSの先端がピアサプラグ3の後端の位置に達したときの圧延荷重の90%とし、事前の調査から定める。したがって、通常の場合、圧延第2しきい値は、圧延第1しきい値よりも大きな値となる。
具体的には、第2所定時間は、例えば、次のように定められる。
t2=L/V
ここで、
t2: 第2所定時間(秒)、
L:ピアサプラグ3の長さ、
V:ホローシェルSの先端における圧延速度、
である(図1、2参照)。
ここで、Vは、
V=Dr×π×N×sinθ×0.5、
Dr:ピアサロール1a,1bの最大径(mm)、
N:ピアサロール1a.1bの秒当たりの回転数、
である(図1(b)参照)。
Vは、ピアサロール1a,1bの外径が最大の箇所でのピアサロール1a,1bの周速を計算し、その周速を構成するホローシェル軸方向の成分の50%としている。尚、上記の式での、ピアサロール1a,1bの周速のホローシェル軸方向の成分に対するVの割合は、圧延条件に応じて変えればよい。
穿孔圧延の不良を検知するステップでは、空転不良の検知方法と、頭詰まり不良の検知方法の内のいずれか一つ以上の検知方法を実行する。
そして、穿孔圧延の不良を改善するステップでは、例えば以下に述べる内容を実行する。
空転不良が発生したときには、穿孔圧延中のビレットBに対してピアサロール1a,1bの開度を大きくし、当該ビレットB以降に穿孔圧延を行うビレットBに対しても同様にピアサロール1a,1bの開度を大きくする。
頭詰まり不良が発生したときには、穿孔圧延中のビレットBに対して、ビレットBが普通鋼の場合にはピアサロール1a,1bの開度を小さくし、ビレットBが高合金鋼の場合には、増摩剤をピアサロール1a,1bに塗布する。そして、当該ビレットB以降に穿孔圧延を行うビレットBに対しても同様のことを行う。
また、空転不良、又は頭詰まり不良が発生すると、当該ビレットB以降に穿孔圧延を行うビレットBについてドラフト率を修正してもよい。
上述したように、穿孔圧延の不良を検知したときに、該不良を改善するので、穿孔圧延の不良の無い継目無管を製造することができる。
3・・・ピアサプラグ
B・・・ビレット
Claims (4)
- ピアサロール及びピアサプラグを用いてビレットを穿孔圧延する際の穿孔圧延の不良を検知する方法であって、
前記ピアサロールの圧延荷重に対応する圧延荷重パラメータと、前記ピアサプラグのスラスト荷重に対応するスラスト荷重パラメータとを測定し、
前記圧延荷重パラメータの測定値と、前記スラスト荷重パラメータの測定値とに基づいて、穿孔圧延の不良を検知することを特徴とする穿孔圧延の不良検知方法。 - 前記ビレットが前記ピアサロールに噛み込まれた後に、前記圧延荷重パラメータの測定値が予め定められた圧延第1しきい値を初めて越えてから予め定められた第1所定時間を経過するまでの間に、前記スラスト荷重パラメータの測定値が予め定められたスラスト第1しきい値を越えない場合は穿孔圧延の不良が発生したと判断することを特徴とする請求項1に記載の穿孔圧延の不良検知方法。
- 前記ビレットが前記ピアサロールに噛み込まれた後に、前記スラスト荷重パラメータの測定値が予め定められたスラスト第2しきい値を初めて越えてから予め定められた第2所定時間を経過するまでの間に、前記圧延荷重パラメータの測定値が予め定められた圧延第2しきい値を越えない場合は穿孔圧延の不良が発生したと判断することを特徴とする請求項1に記載の穿孔圧延の不良検知方法。
- 請求項1乃至請求項3のいずれか一項に記載の穿孔圧延の不良検知方法により不良を検知するステップと、
前記不良を検知したときに、該不良を改善するステップとを含むことを特徴とする継目無管の製造方法。
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US13/882,743 US9333545B2 (en) | 2010-11-02 | 2011-11-01 | Method of detecting fault in piercing-rolling and method of producing seamless pipe or tube |
BR112013010811A BR112013010811A2 (pt) | 2010-11-02 | 2011-11-01 | método de detecção de falha em laminação de perfuração e método de produção de cano ou tubo sem costura. |
EP11838008.8A EP2636462B1 (en) | 2010-11-02 | 2011-11-01 | Method of detecting defects in rotary piercing, seamless pipe manufacturing method |
CN201180063948.6A CN103282135B (zh) | 2010-11-02 | 2011-11-01 | 穿孔轧制的不良检测方法及无缝管的制造方法 |
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