WO2020113608A1 - 一种橡胶软管用增强钢丝及其生产工艺 - Google Patents

一种橡胶软管用增强钢丝及其生产工艺 Download PDF

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Publication number
WO2020113608A1
WO2020113608A1 PCT/CN2018/120160 CN2018120160W WO2020113608A1 WO 2020113608 A1 WO2020113608 A1 WO 2020113608A1 CN 2018120160 W CN2018120160 W CN 2018120160W WO 2020113608 A1 WO2020113608 A1 WO 2020113608A1
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Prior art keywords
steel wire
wire
production process
content
rubber hose
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PCT/CN2018/120160
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English (en)
French (fr)
Inventor
刘祥
张正裕
柯增光
陶彦鑫
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江苏兴达钢帘线股份有限公司
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Publication of WO2020113608A1 publication Critical patent/WO2020113608A1/zh

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    • 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
    • B21C37/047—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 of fine wires
    • 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
    • B21C43/00—Devices for cleaning metal products combined with or specially adapted for use with machines or apparatus provided for in this subclass
    • B21C43/02—Devices for cleaning metal products combined with or specially adapted for use with machines or apparatus provided for in this subclass combined with or specially adapted for use in connection with drawing or winding machines or apparatus
    • 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
    • B21C43/00—Devices for cleaning metal products combined with or specially adapted for use with machines or apparatus provided for in this subclass
    • B21C43/02—Devices for cleaning metal products combined with or specially adapted for use with machines or apparatus provided for in this subclass combined with or specially adapted for use in connection with drawing or winding machines or apparatus
    • B21C43/04—Devices for de-scaling wire or like flexible work
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D3/00—Electroplating: Baths therefor
    • C25D3/02—Electroplating: Baths therefor from solutions
    • C25D3/22—Electroplating: Baths therefor from solutions of zinc
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D3/00—Electroplating: Baths therefor
    • C25D3/02—Electroplating: Baths therefor from solutions
    • C25D3/38—Electroplating: Baths therefor from solutions of copper

Definitions

  • the invention relates to the technical field of production of reinforced steel wires for rubber products, in particular to a reinforced steel wire for rubber hoses and its production process.
  • the performance requirements of rubber hoses are relatively high, and structural steel wire is commonly used as the skeleton material for hydraulic hoses and high-pressure hoses.
  • the hose steel wire used for rubber hose is a high-strength steel wire product coated with a uniform layer of brass alloy on the surface. It is used for the reinforcement of rubber hose in the form of braid or winding, mainly used in hydraulic oil pipes.
  • high-pressure rubber hoses need to be able to withstand high temperature, high pressure, and high impact, and can be used in special occasions such as machinery, aviation, automobiles, oceans, and oil drilling.
  • the object of the present invention is to provide a reinforced steel wire for rubber hoses and a production method thereof, which can realize the production of hose steel wire with a diameter> 1.0 mm, and the performance of the steel wire can meet the hoses for construction machinery and petroleum industry demand.
  • the production process of the reinforced steel wire for rubber hose of the present invention includes the following steps:
  • Wire rod pretreatment the surface of the wire rod with a diameter of 5.0-7.0mm is subjected to mechanical shelling, sand belt derusting, electrolytic alkaline cleaning, ultrasonic pickling, hot water washing, boron coating and drying treatment;
  • Coarse wire drawing of wire rod The wire rod after surface pretreatment is drawn on a straight drawing machine using a pressure die to obtain the drawn steel wire.
  • the wire cross section is circular and the diameter is ⁇ 3.0mm;
  • S3 electroplated brass the coarsely drawn process steel wire is subjected to pyrophosphate copper plating, zinc sulfate zinc plating, and then intermediate frequency thermal diffusion to obtain the required copper plated steel wire with brass plating;
  • Fine wire drawing The copper-plated process steel wire is drawn on a straight drawing machine using a pressure die, and the finished die uses a double die;
  • the drawn steel wire is a steel wire with a circular cross-section, a diameter of 1.00 to 2.50 mm, and a tensile strength of the steel wire of 1770-2300 MPa.
  • the cleaning process includes degreasing, three-stage hot water washing, ultrasonic series water washing and drying.
  • the ultrasonic frequency of water washing is 20-30 KHz, and the surface of the steel wire is silver-gray without black marks.
  • the thick wire drawing is produced by using a pressure die.
  • the fine drawing process uses a pressure dual mode with two taper-free working mold cores.
  • composition and weight percentage content of the wire rod in the step 1 are: C content is 0.60-0.95%, Mn content is 0.30-0.60%, Si content is 0.15-0.30%, and P content is not more than 0.030 %, the S content does not exceed 0.030%, and the other components are Fe.
  • the present invention also provides a reinforced steel wire for rubber hoses, the composition and weight percentage content of the steel wire are: C content is 0.60-0.95%, Mn content is 0.30-0.60%, The Si content is 0.15-0.30%, the P content is not more than 0.030%, the S content is not more than 0.030%, and the other component is Fe; the reinforced steel wire is produced by the production process described above.
  • the production process of the reinforced steel wire for the rubber hose of the present invention can realize the production of large specification (diameter>1.0mm) hose steel wire and can meet various performance requirements of the steel wire.
  • the production process of the reinforced steel wire for the rubber hose of the present invention is omitted
  • the intermediate heat treatment and the water tank drawing process have greatly reduced the production cost, and the production efficiency has also been significantly improved; the quality and overall performance of the steel wire have been significantly improved, and can be adapted to the production of steel wires of various strengths.
  • FIG. 1 is a schematic flowchart showing the steps of the production process of the reinforced steel wire for rubber hoses of the present invention
  • FIG. 2 is a schematic diagram of a core structure of a finished double die used in the production of finished steel wire by a straight wire drawing machine in the prior art
  • FIG. 3 is a schematic view showing the structure of the core of the finished dual-mode used in the production of the finished steel wire by the straight wire drawing machine of the present invention
  • FIG. 6 is a photomicrograph of a cross-sectional edge of a steel wire prepared by a prior art production process
  • FIG. 7 is a schematic diagram of a cross-sectional edge photomicrograph of a steel wire prepared by the production process of the present invention.
  • the prepared hose steel wire is mainly used for rubber hose skeleton materials required by engineering machinery and the petroleum industry.
  • the production process of the steel wire includes the following steps:
  • Wire rod pretreatment the surface of the wire rod with a diameter of 5.0-7.0mm is subjected to mechanical shelling, sand belt derusting, electrolytic alkaline cleaning, ultrasonic pickling, hot water washing, boron coating and drying treatment;
  • Coarse wire drawing the wire rod after surface pretreatment is drawn on a straight drawing machine using a pressure die.
  • the drawn wire is a process wire, the wire cross section is round, and the diameter is ⁇ 3.0mm;
  • Electroplated brass the process wire after rough drawing is electrolessly plated with cyanide-free brass, after pyrophosphate copper plating, zinc sulfate zinc plating, and then intermediate frequency thermal diffusion to obtain the required copper-plated steel wire with brass plating ;
  • Fine wire drawing The copper-plated process steel wire is drawn on a straight drawing machine using a pressure die, and the finished die uses a double die;
  • the reinforced steel wire for rubber hose, the composition and weight percentage content of the wire rod in step 1 are: C content is 0.60-0.95%, Mn content is 0.30-0.60%, Si content is 0.15-0.30%, P The content does not exceed 0.030%, the S content does not exceed 0.030%, and the other components are Fe.
  • the drawn steel wire is a circular cross-section steel wire with a diameter of 1.00 to 2.50 mm, and the tensile strength of the steel wire is 1770-2300 MPa .
  • the production process of the reinforced steel wire for rubber hose, wherein the cleaning in step S5 includes degreasing, three-stage hot water washing, ultrasonic tandem water washing and drying.
  • the conventional mechanical shelling-water washing-pickling-water washing-boron coating is improved to mechanical shelling-sand belt derusting-water washing -Electrolytic alkaline washing-water washing-acid washing-water washing-boron coating, the ultrasonic frequency of water washing is set to 20-30KHz, and the surface of the steel wire is silver-gray without black marks; in the continuous drawing process of step S2, the conventional dry The drawing die production is adjusted to the pressure die production to improve the lubricating effect of the steel wire drawing process and ensure that the surface roughness grade of the steel wire reaches level 2.
  • the straight-type wire drawing machine is used to produce the finished steel wire, and the finished product double mold is used.
  • the previous finished double mold 10 adopts a conventional pressure die structure, which includes a pressure die core 12 and a taper working core 14; and the production process of the present invention uses the finished pressure die dual die shown in FIG. 3 20.
  • Figures 4 and 6 are photo illustrations of the surface quality and cross-sectional edge effect of the steel wire prepared by the existing production process
  • Figures 5 and 7 are the surface quality and cross-sectional edge effect of the steel wire prepared by the production process of the present invention. As shown in the photo, it can be clearly seen that the surface quality of the steel wire prepared by the production process of the present invention has been significantly improved.
  • the production process of the reinforced steel wire for the rubber hose of the present invention can be used to produce ordinary, high-strength, ultra-high-strength, and ultra-high-strength structural steel wires with diameters from ⁇ 1.00mm to ⁇ 2.50mm, and they are used in various high-demand Rubber hose.
  • the C content is 0.938%
  • the Mn content is 0.400%
  • the Si content is 0.220%
  • the P content is 0.017%
  • the S content is 0.004%
  • the ⁇ 5.5mm wire rod is directly subjected to mechanical shelling, sand belt rust removal, and high-pressure water.
  • Washing, electrolytic alkaline washing, water washing, ultrasonic acid washing, water washing, boron coating and drying are processed, drawn into ⁇ 4.40mm steel wire on the straight-type wire drawing machine, and then degreasing tank degreasing acid washing, tandem water washing, coke Phosphate copper plating, zinc sulfate zinc plating, and then intermediate frequency thermal diffusion to obtain ⁇ 4.40mm copper-plated steel wire, and then drawn into a ⁇ 2.20mm steel wire on a straight wire drawing machine to obtain a reinforced steel wire for rubber hoses.
  • the test performance comparison between the steel wire made and the steel wire made by the conventional process is as follows:
  • the production process of the reinforced steel wire for the rubber hose of the present invention can realize the production of large specification (diameter>1.0mm) hose steel wire, which can meet various performance requirements of the steel wire.
  • the production process of the reinforced steel wire for the rubber hose of the present invention is omitted
  • the intermediate heat treatment and water tank drawing process greatly reduce the production cost, and the production efficiency is also significantly improved; the quality and overall performance of the steel wire have been significantly improved, and can be adapted to the production of steel wires of various strengths.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
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Abstract

一种橡胶软管用增强钢丝的生产工艺，其包括步骤：盘条预处理；直进式拉丝机压力模粗拉拔；无氰法电镀黄铜；将镀铜后的过程钢丝在直进式拉丝机上采用压力双模细拉拔；将拉拔后钢丝进行清洗，除去表面残余皂粉得到成品钢丝；根据所述的生产工艺制备的增强钢丝。橡胶软管用增强钢丝的生产工艺，能够实现大规格胶管钢丝的生产，能够满足钢丝的各项性能需求，生产工艺省去了中间热处理和水箱拉丝工序，大大降低了生产成本，同时生产效率也明显提高；钢丝的质量和综合性能有了显著的提高，可以适应各种强度的钢丝的生产。

Description

一种橡胶软管用增强钢丝及其生产工艺 技术领域
本发明涉及橡胶制品用增强钢丝生产技术领域，特别涉及一种橡胶软管用增强钢丝及其生产工艺。
背景技术
橡胶软管的性能要求较高，常用结构钢丝作为液压胶管、高压胶管的骨架材料。使用于橡胶软管的胶管钢丝是一种高强度、表面镀有一层均匀一致的黄铜合金的钢丝产品，以编织或缠绕的形式用于橡胶软管的增强，主要用于液压油管中。根据不同的用途和使用环境，高压橡胶软管需要能承受高温、高压力、高冲击，可供机械、航空、汽车、海洋、石油钻探等特殊场合使用。
对于工程机械和石油工业用胶管，由于尺寸较大，且要承受较高的压力，采用传统生产工艺生产的胶管钢丝性能无法满足要求。这种应用场合的胶管一般需要直径＞0.80mm的胶管钢丝，这种钢丝的生产对生产设备和工艺都有较高的要求，通过传统的生产工艺无法实现生产。已公开的申请号为201310112406.4的中国发明专利公布了一种高强度橡胶软管用增强钢丝及生产方法，采用该专利方法生产的胶管钢丝强度能够满足要求，但该钢丝表面没有镀层，与橡胶之间基本没有粘合，对胶管的性能影响太大而且使用寿命很短，无法真正适应实际应用需求。
发明内容
针对现有技术中存在的问题，本发明的目的是提供一种橡胶软管用增强钢丝及其生产方法，能够实现直径＞1.0mm的胶管钢丝生产，钢丝性能能够满足工程机械和石油工业用胶管需求。
为达到本发明的目的，本发明的一种橡胶软管用增强钢丝的生产工艺，其包括如下步骤：
S1、盘条预处理：将直径为5.0-7.0mm的盘条表面进行机械剥壳、砂带除锈、电解碱洗、超声波酸洗、热水洗、涂硼和烘干处理；
S2、盘条粗拉丝：将经表面预处理后的盘条在直进式拉丝机上采用压力模拉拔，得到拉拔后的过程钢丝，钢丝截面为圆形，直径≥3.0mm；
S3、电镀黄铜：将粗拉后的过程钢丝经过焦磷酸盐镀铜、硫酸锌镀锌，再进行中频热扩散获得所需的具有黄铜镀层的镀铜钢丝；
S4、细拉丝：将镀铜后的过程钢丝在直进式拉丝机上采用压力模拉拔，成品模使用双模；
S5、清洗：将拉拔后钢丝进行清洗，除去表面残余皂粉。
优选的，所述的步骤S4中，拉拔后的钢丝为圆形截面钢丝，直径为1.00～ 2.50mm，钢丝抗拉强度为1770-2300MPa。
再优选的，所述的步骤S5中，清洗工艺包括脱脂、三级热水洗、超声波串联水洗以及烘干。
再优选的，所述的步骤S1中，水洗超声波频率为20～30KHz，清洗至钢丝表面呈银灰色无黑色痕迹。
再优选的，所述的步骤S2中，粗拉丝采用压力模生产。
再优选的，所述的步骤S4中，细拉丝过程采用具有两个无锥度工作模芯的压力双模。
再优选的，所述步骤1中的盘条的组分及重量百分比含量为：C含量为0.60-0.95％，Mn含量为0.30-0.60％，Si含量为0.15-0.30％，P含量不超过0.030％，S含量不超过0.030％，其它成分为Fe。
根据本发明的另一目的，本发明还提出一种橡胶软管用增强钢丝，所述的钢丝的组分及重量百分比含量为：C含量为0.60-0.95％，Mn含量为0.30-0.60％，Si含量为0.15-0.30％，P含量不超过0.030％，S含量不超过0.030％，其它成分为Fe；所述的增强钢丝通过如上所述的生产工艺制得。
本发明的橡胶软管用增强钢丝的生产工艺，能够实现大规格(直径＞1.0mm)胶管钢丝的生产，能够满足钢丝的各项性能需求，本发明的橡胶软管用增强钢丝生产工艺省去了中间热处理和水箱拉丝工序，大大降低了生产成本，同时生产效率也明显提高；钢丝的质量和综合性能有了显著的提高，可以适应各种强度的钢丝的生产。
附图说明
通过下面结合附图的详细描述，本发明前述的和其他的目的、特征和优点将变得显而易见。其中：
图1所示为本发明的橡胶软管用增强钢丝的生产工艺的步骤流程示意图；
图2所示为现有技术的直进式拉丝机生产成品钢丝使用的成品双模的模芯结构示意图；
图3所示为本发明的直进式拉丝机生产成品钢丝使用的成品双模的模芯结构示意图；
图4所示为现有技术的生产工艺制备的钢丝的表面状态显微图示；
图5所示为本发明的生产工艺制备的钢丝的表面状态显微图示；
图6所示为现有技术的生产工艺制备的钢丝的截面边缘显微照片图示；
图7所示为本发明的生产工艺制备的钢丝的截面边缘显微照片图示。
具体实施方式
结合附图本发明的一种橡胶软管用增强钢丝及其生产工艺详述如下。
根据本发明的目的，本发明的一种橡胶软管用增强钢丝的生产工艺，制备的胶管钢丝主要用于工程机械和石油工业所需橡胶软管骨架材料。参照图1，所述的钢丝的生产工艺包括如下步骤：
S1、盘条预处理：将直径为5.0-7.0mm的盘条表面进行机械剥壳、砂带除锈、电解碱洗、超声波酸洗、热水洗、涂硼和烘干处理；
S2、盘条粗拉丝：将经表面预处理后的盘条在直进式拉丝机上采用压力模拉拔，所拉拔钢丝为过程钢丝，钢丝截面为圆形，直径≥3.0mm；
S3、电镀黄铜：将粗拉后的过程钢丝采用无氰法电镀黄铜，经过焦磷酸盐镀铜、硫酸锌镀锌，再进行中频热扩散获得所需的具有黄铜镀层的镀铜钢丝；
S4、细拉丝：将镀铜后的过程钢丝在直进式拉丝机上采用压力模拉拔，成品模使用双模；
S5、清洗：将拉拔后钢丝进行清洗，除去表面残余皂粉。
所述的橡胶软管用增强钢丝，步骤1中的盘条的组分及重量百分比含量为：C含量为0.60-0.95％，Mn含量为0.30-0.60％，Si含量为0.15-0.30％，P含量不超过0.030％，S含量不超过0.030％，其它成分为Fe。
在一优选的实施方式中，所述的橡胶软管用增强钢丝生产工艺的步骤S4中，拉拔后的钢丝为圆形截面钢丝，直径为1.00～2.50mm，钢丝抗拉强度为1770-2300MPa。
在另一优选的实施方式中，所述的橡胶软管用增强钢丝的生产工艺，其中步骤S5中的清洗包括脱脂、三级热水洗、超声波串联水洗以及烘干。
本发明的橡胶软管用增强钢丝生产工艺，在钢丝拉拔前预处理工序中，将常规的机械剥壳-水洗-酸洗-水洗-涂硼改进为机械剥壳-砂带除锈-水洗-电解碱洗-水洗-酸洗-水洗-涂硼，水洗超声波频率设定20～30KHz，清洗至钢丝表面呈银灰色无黑色痕迹；在步骤S2的粗拉连续拉拔工艺中，由常规干拉模具生产调整为压力模生产，改善钢丝拉拔过程润滑效果，保证钢丝表面粗糙度等级达到2级。
本发明的橡胶软管用增强钢丝生产工艺，在步骤S4的成品钢丝生产中，采用直进式拉丝机生产成品钢丝，使用成品双模。参照图2所示，以前的成品双模10采用常规压力模结构，其包括压力模芯12以及锥度工作模芯14；而本发明的生产工艺，采用如图3所示的成品压力模双模20，取消压力模芯，变更为两只无锥度工作模芯22和24，如此可以改善结构钢丝表面质量，提高钢丝柔韧性，提高钢丝疲劳性能；在步骤S5的清洗步骤中，采用超声波水洗，改善清洗效果，保证钢丝与橡胶粘合力。
图4和图6所示为采用现有的生产工艺制备的钢丝的表面质量和截面边缘效果照片图示，图5和图7为采用本发明的生产工艺制备的钢丝的表面质量和截面边缘效果照片图示，从图示可以明显看出，采用本发明的生产工艺制备的钢丝的表面质量有了显著的改善。
本发明的橡胶软管用增强钢丝生产工艺，可以用于生产直径φ1.00mm～φ2.50mm的普通强度、高强度、超高强度以及特高强度的结构钢丝，应用于使用要求比较高的各种橡胶软管中。
实施例1：
将C含量为0.938％，Mn含量为0.400％，Si含量为0.220％，P含量为0.017％，S含量为0.004％的直接为Ф5.5mm盘条经过机械剥壳、砂带除锈、高压水冲洗、电解碱洗、水洗、超声波酸洗、水洗、涂硼和烘干等处理，在直进式拉丝机上拉拔成Ф4.40mm的钢丝，然后依次进行脱脂槽脱脂酸洗、串联水洗，焦磷酸盐镀铜、硫酸锌镀锌，再进行中频热扩散，获得Ф4.40mm的镀铜钢丝，然后在直进式拉丝机上拉拔成Ф2.20mm的钢丝，获得橡胶软管用增强钢丝。制得的钢丝与采用常规工艺制得的钢丝的测试性能对比如下表：
项目 常规工艺 本发明工艺
抗拉强度(Mpa) ＞2150 ＞2200
扭转(次/360°L＝100d) ＞20 ＞30
弯曲(次) ＞12 ＞20
镀层重量(g/kg) 2.0～3.0 2.0～3.0
从上表可以看出，利用本发明的工艺制得的钢丝的综合性能明显优于现有的工艺制得的钢丝。
本发明的橡胶软管用增强钢丝的生产工艺能够实现大规格(直径＞1.0mm)胶管钢丝的生产，能够满足钢丝的各项性能需求，本发明的橡胶软管用增强钢丝生产工艺省去了中间热处理和水箱拉丝工序，大大降低了生产成本，同时生产效率也明显提高；钢丝的质量和综合性能有了显著的提高，可以适应各种强度的钢丝的生产。
本发明并不局限于所述的实施例，本领域的技术人员在不脱离本发明的精神即公开范围内，仍可作一些修正或改变，故本发明的权利保护范围以权利要求书限定的范围为准。

Claims (8)

  1. 一种橡胶软管用增强钢丝的生产工艺，其特征在于，所述的生产工艺包括如下步骤：
    S1、盘条预处理：将直径为5.0-7.0mm的盘条表面进行机械剥壳、砂带除锈、电解碱洗、超声波酸洗、热水洗、涂硼和烘干处理；
    S2、盘条粗拉丝：将经表面预处理后的盘条在直进式拉丝机上采用压力模拉拔，得到拉拔后的过程钢丝，钢丝截面为圆形，直径≥3.0mm；
    S3、电镀黄铜：将粗拉后的过程钢丝经过焦磷酸盐镀铜、硫酸锌镀锌，再进行中频热扩散获得所需的具有黄铜镀层的镀铜钢丝；
    S4、细拉丝：将镀铜后的过程钢丝在直进式拉丝机上采用压力模拉拔，成品模使用双模；
    S5、清洗：将拉拔后钢丝进行清洗，除去表面残余皂粉。
  2. 如权利要求1所述的一种橡胶软管用增强钢丝的生产工艺，其特征在于，所述的步骤S4中，拉拔后的钢丝为圆形截面钢丝，直径为1.00～2.50mm，钢丝抗拉强度为1770-2300MPa。
  3. 如权利要求1或2所述的一种橡胶软管用增强钢丝的生产工艺，其特征在于，所述的步骤S5中，清洗工艺包括脱脂、三级热水洗、超声波串联水洗以及烘干。
  4. 如权利要求1所述的一种橡胶软管用增强钢丝的生产工艺，其特征在于，所述的步骤S1中，水洗超声波频率为20～30KHz，清洗至钢丝表面呈银灰色无黑色痕迹。
  5. 如权利要求1所述的一种橡胶软管用增强钢丝的生产工艺，其特征在于，所述的步骤S2中，粗拉丝采用压力模生产。
  6. 如权利要求1所述的一种橡胶软管用增强钢丝的生产工艺，其特征在于，所述的步骤S4中，细拉丝过程采用具有两个无锥度工作模芯的压力双模。
  7. 如权利要求1所述的一种橡胶软管用增强钢丝的生产工艺，其特征在于，所述步骤1中的盘条的组分及重量百分比含量为：C含量为0.60-0.95％，Mn含量为0.30-0.60％，Si含量为0.15-0.30％，P含量不超过0.030％，S含量不超过0.030％，其它成分为Fe。
  8. 一种橡胶软管用增强钢丝，其特征在于，所述的增强钢丝的组分及重量百分比含量为：C含量为0.60-0.95％，Mn含量为0.30-0.60％，Si含量为0.15-0.30％，P含量不超过0.030％，S含量不超过0.030％，其它成分为Fe；所述的增强钢丝通过如权利要求1-6任一项所述的生产工艺制得。
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