多绳金刚石串珠锯关键功能部件研究
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摘要
随着我国石材行业的快速发展,迫切需要革新开采工艺技术和开采装备水平。作为花岗石锯解领域的最先进成果,多绳金刚石串珠锯(多绳锯)是世界上前沿的石材加工设备,具有灵活、安全、高效、环保、成荒率高等优点。国内多绳锯的发展还处在起步阶段,因此对多绳锯相关部件的研究有重要的意义。本文旨在研究拥有自主知识产权的多绳金刚石串珠锯荒料车系统和整机制动系统。
通过应用机械产品现代设计方法,拟定了多绳金刚石串珠锯荒料车的方案创新设计流程。深入分析了国外多绳金刚石串珠锯荒料车的结构特点,确定了荒料车的技术参数及性能要求,并给出了荒料车的总体设计要求。对多绳金刚石串珠锯荒料车进行了功能分解,建立了功能-结构关系图,对结构进行了模块划分,然后将TRIZ应用到方案设计过程中,完成了荒料车的创新设计,并对各模块应用Solidworks软件进行建模、装配,最后完成荒料车的三维设计。
基于ANSYS Workbench(AWE)协同开发平台,就如何将三维软件建立的荒料车模型直接导入平台进行了探究,实现Solidworks三维设计、CAE分析的协同和管理。介绍了有限元分析前期的材料、网格划分、边界条件的施加、载荷等处理方法,对多绳金刚石串珠锯荒料车进行有限元分析,同时应用优化设计思想,利用基于实验技术的DOE模块对荒料车进行轻量化设计,最后得到综合指标趋于最好的多绳金刚石串珠锯荒料车设备。
利用ANSYS Workbench中的模态分析模块分析了多绳金刚石串珠锯荒料车的固有频率、振型,提取了前六阶模态,找出了变形的最大区域。拟定了动态性能的优劣性评价方法,然后依据评价方法对多绳金刚石串珠锯荒料车车架的模态分析结果进行了评估,从而进一步验证了荒料车的设计合理性。
通过多绳金刚石串珠锯各个轮系的深入研究分析,确定了选用能耗制动为主动轮的制动方式,经过计算可知制动功率、制动电阻以及制动单元的电流都与制动时间t有关。张紧轮、定位轮通过串珠绳与张紧轮绳槽的摩擦力来制动,以带传动的分析方法来分析串珠绳与张紧轮绳槽之间的传动情况,计算出了最大静摩擦力所能提供的最大制动转矩及最短制动时间。最后对整机制动单元进行了计算和分析。
本课题得到了山东省科技发展计划项目(2010GGX10405)和山东省自然科学基金(ZR2012EEM032)资助。
With the rapid development of China's stone industry, there is an urgent need of innovation for mining technology and mining equipment level. Multi-wire diamond saw is as the latest achievements in the granite sawing field. With the advantages of flexibility, security, universities, environmental protection and high produced rate, it is commonly recognized the world's frontal stone mining equipment. It's domestic development is still in its infancy, so the research of multi-wire diamond saw related components have important significance. The purpose of this Paper is to develop a new blocks car and whole brake components of multi-wire diamond saw with independent intellectual property rights.
Combined with modern design methods of mechanical products, a program of innovative design process of multi-wire diamond saw blocks car is formulated. With the depth analysis of the structural characteristics of foreign multi-wire diamond saw blocks car, the technical Parameters and performance requirements of the blocks car is determine, and the blocks car's overall design requirements is given. Then the functional decomposition of multi-wire diamond saw blocks car is done and function-structure relationship is established, a list of structure is modular divided, then apply the TRIZ method to the blocks car innovative design process, this innovative design is completed. Finally, each module structure is established and then all modules is integrated to establish the whole three-dimensional design in Solidworks software.
Based on the ANSYS Workbench (Hereinafter referred to AWE) collaborative development platform, how to directly import three-dimensional design built by Solidworks software is researched and the coordination and management of the three-dimensional design and CAE analysis is achieved. Material definition, meshing, contact set, load and boundary conditions in pre-treatment are expounded, finite element analysis of the multi-wire diamond saw blocks car is carried, and use optimization design ideas and DOE module based on the experimental to lightweight design, finally the composite indicator of multi-wire diamond saw blocks car equipment which tends to be best was obtained.
Use the modal analysis module of the ANSYS Workbench to analysis the natural frequency and vibration of the blocks car, extract previous Sixth-order modes, identify the largest area of deformation. Develop the performance evaluation method about the pros and cons of the dynamic and perform the evaluation of the multi-wire diamond saw blocks car, finally provided a theoretical basis for the design of the blocks car.
Through the depth research and analysis of each gear of multi-wire diamond saw, determine that the driving wheel brake way is dynamic braking. According to calculations, the braking power, the resistor and the current of the brake unit and are all related to the braking time. The tensioner pulley and the positioning wheel are braked by the friction between the bead-rope and rope groove. Use belt drive analysis methods to analyze the transmission situation between the bead-rope and rope groove. The maximum braking torque and the shortest braking time under the maximum static friction force is figured out. Finally, the whole brake unit is calculated and analyzed.
The study is funded by Shandong Province Science and Technology Development Program (item numbers:201OGGX10405) and Natural Science Foundation of Shandong Province (item numbers:ZR2012EEM032).
通过应用机械产品现代设计方法,拟定了多绳金刚石串珠锯荒料车的方案创新设计流程。深入分析了国外多绳金刚石串珠锯荒料车的结构特点,确定了荒料车的技术参数及性能要求,并给出了荒料车的总体设计要求。对多绳金刚石串珠锯荒料车进行了功能分解,建立了功能-结构关系图,对结构进行了模块划分,然后将TRIZ应用到方案设计过程中,完成了荒料车的创新设计,并对各模块应用Solidworks软件进行建模、装配,最后完成荒料车的三维设计。
基于ANSYS Workbench(AWE)协同开发平台,就如何将三维软件建立的荒料车模型直接导入平台进行了探究,实现Solidworks三维设计、CAE分析的协同和管理。介绍了有限元分析前期的材料、网格划分、边界条件的施加、载荷等处理方法,对多绳金刚石串珠锯荒料车进行有限元分析,同时应用优化设计思想,利用基于实验技术的DOE模块对荒料车进行轻量化设计,最后得到综合指标趋于最好的多绳金刚石串珠锯荒料车设备。
利用ANSYS Workbench中的模态分析模块分析了多绳金刚石串珠锯荒料车的固有频率、振型,提取了前六阶模态,找出了变形的最大区域。拟定了动态性能的优劣性评价方法,然后依据评价方法对多绳金刚石串珠锯荒料车车架的模态分析结果进行了评估,从而进一步验证了荒料车的设计合理性。
通过多绳金刚石串珠锯各个轮系的深入研究分析,确定了选用能耗制动为主动轮的制动方式,经过计算可知制动功率、制动电阻以及制动单元的电流都与制动时间t有关。张紧轮、定位轮通过串珠绳与张紧轮绳槽的摩擦力来制动,以带传动的分析方法来分析串珠绳与张紧轮绳槽之间的传动情况,计算出了最大静摩擦力所能提供的最大制动转矩及最短制动时间。最后对整机制动单元进行了计算和分析。
本课题得到了山东省科技发展计划项目(2010GGX10405)和山东省自然科学基金(ZR2012EEM032)资助。
With the rapid development of China's stone industry, there is an urgent need of innovation for mining technology and mining equipment level. Multi-wire diamond saw is as the latest achievements in the granite sawing field. With the advantages of flexibility, security, universities, environmental protection and high produced rate, it is commonly recognized the world's frontal stone mining equipment. It's domestic development is still in its infancy, so the research of multi-wire diamond saw related components have important significance. The purpose of this Paper is to develop a new blocks car and whole brake components of multi-wire diamond saw with independent intellectual property rights.
Combined with modern design methods of mechanical products, a program of innovative design process of multi-wire diamond saw blocks car is formulated. With the depth analysis of the structural characteristics of foreign multi-wire diamond saw blocks car, the technical Parameters and performance requirements of the blocks car is determine, and the blocks car's overall design requirements is given. Then the functional decomposition of multi-wire diamond saw blocks car is done and function-structure relationship is established, a list of structure is modular divided, then apply the TRIZ method to the blocks car innovative design process, this innovative design is completed. Finally, each module structure is established and then all modules is integrated to establish the whole three-dimensional design in Solidworks software.
Based on the ANSYS Workbench (Hereinafter referred to AWE) collaborative development platform, how to directly import three-dimensional design built by Solidworks software is researched and the coordination and management of the three-dimensional design and CAE analysis is achieved. Material definition, meshing, contact set, load and boundary conditions in pre-treatment are expounded, finite element analysis of the multi-wire diamond saw blocks car is carried, and use optimization design ideas and DOE module based on the experimental to lightweight design, finally the composite indicator of multi-wire diamond saw blocks car equipment which tends to be best was obtained.
Use the modal analysis module of the ANSYS Workbench to analysis the natural frequency and vibration of the blocks car, extract previous Sixth-order modes, identify the largest area of deformation. Develop the performance evaluation method about the pros and cons of the dynamic and perform the evaluation of the multi-wire diamond saw blocks car, finally provided a theoretical basis for the design of the blocks car.
Through the depth research and analysis of each gear of multi-wire diamond saw, determine that the driving wheel brake way is dynamic braking. According to calculations, the braking power, the resistor and the current of the brake unit and are all related to the braking time. The tensioner pulley and the positioning wheel are braked by the friction between the bead-rope and rope groove. Use belt drive analysis methods to analyze the transmission situation between the bead-rope and rope groove. The maximum braking torque and the shortest braking time under the maximum static friction force is figured out. Finally, the whole brake unit is calculated and analyzed.
The study is funded by Shandong Province Science and Technology Development Program (item numbers:201OGGX10405) and Natural Science Foundation of Shandong Province (item numbers:ZR2012EEM032).
引文
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[3]Ozcelik, Y.Kanbir, E.S. Determination of Optimum Working Condition and Development of Cuttability Abacus for a Limestone and Real Marble Sample in Diamond Wire Cutting[J]. Geomechanics Symposium.2011,45(6):12-16.
[4]滕忠良.意大利金刚石串珠多绳锯综述(一)[J].石材.2011(12)：11-16.
[5]滕忠良.意大利金刚石串珠多绳锯综述(二)[J].石材.2012(1)：11-18.
[6]Martin Jennings. Diamond Wire Sawing Provides the Power[J]. IDR.2008,13(1):14-15.
[7]廖原时.多绳金刚石串珠锯的技术特点和加工成本分析(一)[J].石材.2008(5)：28-31.
[8]廖原时.多绳金刚石串珠锯的技术特点和加工成本分析(二)[J].石材.2008(6)：20-24.
[9]L Fratini,V Liguori,B Oriti. On the Slabbing of Stones Through Diamond Wire Cutting Operations[J]. Mechanical Engineering Science.2010,224(1):143-148.
[10]Mohammad Ataei, Reza Mikaiel. Predicting the Production Rate of Diamond Wire Saw Using Statistical Analysis [J]. Arab J Geosci.2012,5(6):69-71.
[11]Zhang JS, Huang B, Wang Z. The Experiment Research of Diamond Wire Saw in Quarrying Granite with High Efficiency [J]. Materials Science Forum.2004,471(1):117-121.
[12]张进生,张政梅,王志.新型石材回采金刚石串珠锯的研究及创新设计[J].金刚石与磨料磨具工程.2006,20(4)：17-20.
[13]黄国钦,徐西鹏.金刚石串珠绳锯技术的研究[J].工具技术.2005,39(8)：7-11.
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