纺纱钢丝圈热处理清洁生产技术及工艺研究
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摘要
热处理是强化金属材料性能的重要工艺措施,是保证和提高产品质量和寿命的关键因素,也是形成环境污染不可忽视的重要方面。目前国内钢丝圈大部分的淬火回火介质都采用油,存在很大的安全隐患,对环境污染严重,因此迫切需要一种较清洁的淬火回火介质取而代之。本文以清洁热处理技术为基本出发点,以纺纱钢丝圈为研究对象,对水基淬火回火介质进行了一系列系统而深入的研究。
实验结果表明:(1) 0.25%聚乙烯醇(PVA)淬火液能适用于钢丝圈淬火,但生产中浓度不易测定,PVA易附着工件表面,实际生产操作难度大。并在试验的基础上得出,加热温度和保温时间是得到均匀组织和达到要求性能的重要因素,通过正交实验法确定了最佳热处理工艺。(2) 3%-7%聚醚(PAG)淬火剂满足钢丝圈淬火性能要求。随着浓度的上升,硬度值下降。经反复实验,5%-5.75%PAG得到的效果最好。(3)研制的水玻璃淬火液在浓度为8%~13%时满足钢丝圈淬火性能要求;改变浓度可调节冷却性能,浓度测定方便,易现场监测;有良好的防锈效果;所需原料来源广泛,价格便宜。(4)碱浴具有优良的温度分布优越性,用于钢丝圈的低温回火能达到油浴的效果。碱浴的配比很重要,其中碱和脱氧剂的用量对回火硬度影响显著。通过实验设计和分析,得出了较优配比。
为了观察温度变化对钢丝圈淬火冷却过程的影响,进行了计算机模拟。利用ANSYS软件进行了温度场和应力场的分析,得出了各阶段温度分布图及不同节点的冷却曲线和应力分布图,进一步从理论上探讨了冷却介质的冷却机理,其结果对指导工程实际具有重要意义,同时探讨了先进计算机模拟技术在清洁热处理中的应用。
Heat treatment is most important in mechanical industry, but it is easy to cause environment pollution. Currently, the most common used quenching and tempering medium for steel ring travelers is oil. However, oil is expensive, easy to start fire and cause heavy pollution. Especially, it is time consuming to remove the oil stain on work pieces, which severely affect the product efficiency. Besides, the waste oil is not easy to recover. Therefore, there is an urgent need to look for clean medium to replace oil. The investigation into clean quenching and tempering medium is carried out based on clean heat treatment technology for steel ring travelers.
The results show that:(1) in the heat treatment process, the heating temperature and holding time are vital factors to obtain uniform microstructure and good performance. The optimal heat treatment process is obtained by orthogonal experiments. (2) Based on experiments, it is found that 0.25% PVA solution can suit the quenching of 80steel. The cooling velocity can be adjusted by different concentration. But it is difficult to determine the concentration in practice and PVA easily attaches to the work piece’s surface, which will increase a lot of difficulties in practical operation. (3) 3%~7% PAG solution could attain the quenching requirement of steel ring traveler. The hardness decreases with the concentration increase. The best effect can obtain with the concentration of 5%~5.75%PAG through many repeat experiments. (4) The new sodium metasilicate solution with 8%~13% could attain the demand requirement. Its cool performance could be adjusted by different concentration which can be easily tested in practice. Besides, it has good antirust performance and its raw material is much cheaper. (5) The alkaline bath with the good temperature uniformity can satisfy the required hardness after temper as well as oil bath. Further more, the ratio of the main compositions of the alkaline bath is very important for its tempering effect. The results strongly indicate that the contents of alkali and the anti-oxidation reagent can significantly affect the hardness. Its optimal composition is derived based on orthogonal experiments and data analysis.
The quenching process of steel ring traveler is simulated with ANSYS. The temperature distribution and stress distribution during every period and deferent nodes’cool curves are derived. The working mechanism of cooling is also discussed and the results and analysis reveal some insight into the computer simulation applied on the clean heat treatment.
实验结果表明:(1) 0.25%聚乙烯醇(PVA)淬火液能适用于钢丝圈淬火,但生产中浓度不易测定,PVA易附着工件表面,实际生产操作难度大。并在试验的基础上得出,加热温度和保温时间是得到均匀组织和达到要求性能的重要因素,通过正交实验法确定了最佳热处理工艺。(2) 3%-7%聚醚(PAG)淬火剂满足钢丝圈淬火性能要求。随着浓度的上升,硬度值下降。经反复实验,5%-5.75%PAG得到的效果最好。(3)研制的水玻璃淬火液在浓度为8%~13%时满足钢丝圈淬火性能要求;改变浓度可调节冷却性能,浓度测定方便,易现场监测;有良好的防锈效果;所需原料来源广泛,价格便宜。(4)碱浴具有优良的温度分布优越性,用于钢丝圈的低温回火能达到油浴的效果。碱浴的配比很重要,其中碱和脱氧剂的用量对回火硬度影响显著。通过实验设计和分析,得出了较优配比。
为了观察温度变化对钢丝圈淬火冷却过程的影响,进行了计算机模拟。利用ANSYS软件进行了温度场和应力场的分析,得出了各阶段温度分布图及不同节点的冷却曲线和应力分布图,进一步从理论上探讨了冷却介质的冷却机理,其结果对指导工程实际具有重要意义,同时探讨了先进计算机模拟技术在清洁热处理中的应用。
Heat treatment is most important in mechanical industry, but it is easy to cause environment pollution. Currently, the most common used quenching and tempering medium for steel ring travelers is oil. However, oil is expensive, easy to start fire and cause heavy pollution. Especially, it is time consuming to remove the oil stain on work pieces, which severely affect the product efficiency. Besides, the waste oil is not easy to recover. Therefore, there is an urgent need to look for clean medium to replace oil. The investigation into clean quenching and tempering medium is carried out based on clean heat treatment technology for steel ring travelers.
The results show that:(1) in the heat treatment process, the heating temperature and holding time are vital factors to obtain uniform microstructure and good performance. The optimal heat treatment process is obtained by orthogonal experiments. (2) Based on experiments, it is found that 0.25% PVA solution can suit the quenching of 80steel. The cooling velocity can be adjusted by different concentration. But it is difficult to determine the concentration in practice and PVA easily attaches to the work piece’s surface, which will increase a lot of difficulties in practical operation. (3) 3%~7% PAG solution could attain the quenching requirement of steel ring traveler. The hardness decreases with the concentration increase. The best effect can obtain with the concentration of 5%~5.75%PAG through many repeat experiments. (4) The new sodium metasilicate solution with 8%~13% could attain the demand requirement. Its cool performance could be adjusted by different concentration which can be easily tested in practice. Besides, it has good antirust performance and its raw material is much cheaper. (5) The alkaline bath with the good temperature uniformity can satisfy the required hardness after temper as well as oil bath. Further more, the ratio of the main compositions of the alkaline bath is very important for its tempering effect. The results strongly indicate that the contents of alkali and the anti-oxidation reagent can significantly affect the hardness. Its optimal composition is derived based on orthogonal experiments and data analysis.
The quenching process of steel ring traveler is simulated with ANSYS. The temperature distribution and stress distribution during every period and deferent nodes’cool curves are derived. The working mechanism of cooling is also discussed and the results and analysis reveal some insight into the computer simulation applied on the clean heat treatment.
引文
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