连续挤压铜包钢线材工程化关键问题实验研究
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摘要
铜包钢线在性能上兼备了钢的机械性能和铜的电学性能,因而具有传导效率高、材料成本低、抗拉断力大、耐磨损等特点,广泛应用于电力、通讯、电子、化工等领域。目前铜包钢线材的生产方法主要有机械包覆法、熔铜浸渍法、电镀法。机械包覆法修整处置量较大,铜带利用率较低,界面结合为机械结合。熔铜浸渍法设备复杂,操作较难控制。电镀成形法主要存在环境污染问题、产量小、包覆厚度薄、界面结合弱等问题。连续挤压包覆技术设备投资少、生产率高、铜包覆层厚度均匀、界面结合质量好、成本低,是理想的生产工艺。
本文以径向连续挤压铜和连续挤压包覆铝包钢为技术基础,通过建立连续挤压包覆模型用上限法计算了中性点位置和最佳包覆角,并在自制JL350型切向式连续挤压机上进行了单轮双槽和单轮单槽连续挤压包覆的实验研究,实验过程中自制了单轮双槽U型轮槽挤压轮、单轮单槽带凸台U型轮槽挤压轮及对应模腔及附属配套设施,并解决了如下工程化关键问题：
(1)模腔的可拆换问题；(2)闷车问题及挤压轮槽结构设计；(3)堵头结构及材料选择；(4)模具结构设计；(5)钢芯与铜杆的预热及其与挤压轮转速的匹配问题；(6)该实验条件下的工艺参数整体控制。实验条件下初步实现了连续挤压包覆法生产铜包钢线材的连续化。
本文对连续挤压包覆铜包钢线材工程化生产还需要解决的问题进行了分析,并对下一步实验方向、实验内容及需要改进的地方做了阐述。
Copper-clad steel wire combines the mechanical properties of steel and the electrical properties of copper, Thus it has the conduction of high efficiency, low cost of materials, resisting tensile force, light weight, low wear resistance etc. It was widely used in electric power, communication, electronics, chemical engineering etc. The methods of produce copper-clad steel wire includes clad drawing method, Hot-dip coating, electroplating. Clad dressing disposal a large amount of copper, The utilization ratio of copper is low, interface with the mechanical bond, The device of hot-dip coating is complexity, the operation is difficult to control. Electroplating forming method brings the pollution of the environment, production of small, thin coating, bonding and weak issues. Continuous extrusion coating technology need less equipment investment, high productivity, uniform thickness of copper coating, bonding quality, low cost, So it is an ideal production process.
This paper was based on the radial continuous extrusion copper and aluminum continuous extrusion coated technology, Through the establishment of continuous extrusion coated model,using upper-bound method and calculated the neutral position、best coated Angle. And to do continuous extrusion coated experimental research in JL350 type continuous extrusion machine which was homemade, The experiment process contains the manufacture of u-shaped trough with convex platform extrusion wheel, and the corresponding wheel cavity and affiliated facilities. This paper to solve the following main problems of industrialization:
(1) The cavity of the removable problem;(2) Wheel trough structural design; (3) seal structure and material choice;(4) mould structure design;(5) Steel and copper preheated and speed matching problem with extrusion wheel;(6) The process parameters of overall control. experimentation primarily achieved continuous production.
This paper also analyzed the problems of continuous extrusion coated copper clad steel wire industrialized production need to resolved, And made an exposition for the next experimental direction, experimental contents and the part which in need of improvement.
本文以径向连续挤压铜和连续挤压包覆铝包钢为技术基础,通过建立连续挤压包覆模型用上限法计算了中性点位置和最佳包覆角,并在自制JL350型切向式连续挤压机上进行了单轮双槽和单轮单槽连续挤压包覆的实验研究,实验过程中自制了单轮双槽U型轮槽挤压轮、单轮单槽带凸台U型轮槽挤压轮及对应模腔及附属配套设施,并解决了如下工程化关键问题：
(1)模腔的可拆换问题；(2)闷车问题及挤压轮槽结构设计；(3)堵头结构及材料选择；(4)模具结构设计；(5)钢芯与铜杆的预热及其与挤压轮转速的匹配问题；(6)该实验条件下的工艺参数整体控制。实验条件下初步实现了连续挤压包覆法生产铜包钢线材的连续化。
本文对连续挤压包覆铜包钢线材工程化生产还需要解决的问题进行了分析,并对下一步实验方向、实验内容及需要改进的地方做了阐述。
Copper-clad steel wire combines the mechanical properties of steel and the electrical properties of copper, Thus it has the conduction of high efficiency, low cost of materials, resisting tensile force, light weight, low wear resistance etc. It was widely used in electric power, communication, electronics, chemical engineering etc. The methods of produce copper-clad steel wire includes clad drawing method, Hot-dip coating, electroplating. Clad dressing disposal a large amount of copper, The utilization ratio of copper is low, interface with the mechanical bond, The device of hot-dip coating is complexity, the operation is difficult to control. Electroplating forming method brings the pollution of the environment, production of small, thin coating, bonding and weak issues. Continuous extrusion coating technology need less equipment investment, high productivity, uniform thickness of copper coating, bonding quality, low cost, So it is an ideal production process.
This paper was based on the radial continuous extrusion copper and aluminum continuous extrusion coated technology, Through the establishment of continuous extrusion coated model,using upper-bound method and calculated the neutral position、best coated Angle. And to do continuous extrusion coated experimental research in JL350 type continuous extrusion machine which was homemade, The experiment process contains the manufacture of u-shaped trough with convex platform extrusion wheel, and the corresponding wheel cavity and affiliated facilities. This paper to solve the following main problems of industrialization:
(1) The cavity of the removable problem;(2) Wheel trough structural design; (3) seal structure and material choice;(4) mould structure design;(5) Steel and copper preheated and speed matching problem with extrusion wheel;(6) The process parameters of overall control. experimentation primarily achieved continuous production.
This paper also analyzed the problems of continuous extrusion coated copper clad steel wire industrialized production need to resolved, And made an exposition for the next experimental direction, experimental contents and the part which in need of improvement.
引文
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[34]Avitzur Bet al, Criterion for Prevention of Core Fracture during Extrusion of Bi-mental Rods. Journal of Engineering for Industry,1982,104 (2):293-304
[35]B. S Yilbas, Friction welding of St—AI and AI—Cu materials, Journal of Materials Processin2, Technology,1995 49(5):431-443
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[41]运新兵,铜包钢接触线坯连续包覆工艺优化设计,塑性工程学报,2008,15(3)：204-208
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[43]刘彬彬.连续挤压包覆(CONCLAD)过程的数值模拟：[硕士学位论文].昆明：昆明理工大学,2003
[44]张志豪.高强度轻型导线成形工艺及机理研究：[硕士学位论文].昆明：昆明理工大学,2001
[45]刘明月,宋宝韫,运新兵,李冰,基于有限元法的铜母线连续挤压扩展成形过程的数值模拟,金属铸锻焊技术,2008,37(17)：52-55
[46]赵颖,运新兵,宋宝韫,轮槽形状对铜母线连续挤压影响的有限元分析,锻压技术,2008,33(2)：139-142
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[2]汪秉庸,张北斗,王森林等,铜包钢承力索和吊弦的研制,电气化铁道,2001,1(1)：30-33
[3]黄崇祺,论中国电缆工业的以铝节铜,电线电缆,2008,6(6)：1-3
[4]http://cn.sonhoo.com/info/352165.html
[5]张国光,铜包钢线和铜包铝线的新用途,应用技术,2009.3(3)：36-37
[6]http://blog.sina.com.cn/s/blog_4dcb39bc0100ecir.html
[7]张国春,夏建华,刘礼华,铜包钢丝——一种用途广泛的复合材料,金属制品,1996,22(5)：40-42
[8]张建富,铜包铝、铜包钢型同轴电缆的应用思考,现代传输,2006,4：24-25
[9]黄崇祺,轮轨高速电气化铁路接触网用接触线的研究,中国铁道科学,2001,22(1)：1-5
[10]朱小超,‘张北斗,铜包钢承力索与铝包钢承力索、铜承力索的比较,铁道勘测与设计,2002,121(1)：24-25
[11]何慧兰,铜包钢线的研制与应用,电镀与环保2002,22(6)：32-33
[12]吴运忠戴雅康,刘世程,用于用户同轴电缆的包覆焊接法铜包钢线,有线电视技术,2002,11：46-48
[13]贺飞,刘利梅,钟云,何永福,苏永庆,铜包钢线材及其生产工艺表面技术,2007,36(5)：24-28
[14]刘于雄,国外钢丝镀铝工艺综述,金属制品,1984,23(5),20-22
[15]段天鹏,卑多慧,铜包钢线的生产工艺及其应用,电镀与涂饰,1998,17(3)：26-29
[16]运新兵,宋宝韫,刘元文,高飞,电气化铁路用铜包钢接触线制造技术,有色金属,2002,54(3)：22-23,35
[17]王庆娟,杜忠泽,王海波,铜包钢线生产工艺的特点及现状,电线电缆,2008,4(4)：15-17,27
[18]李明茂,金属复合线材的生产使用现状与发展趋势,塑性工程学报,2005,12(3)：93-95
[19]Yoshihisa. Ohashi, Process for manufacturing clad metal tubing, US Patent 2000,209:50-56
[20]高山辉等[日],采用热浸涂法制造的铜包钢线及其特性和应用,藤仓技报,1987,7：9-12
[21]Teruyuki Takayama,热浸法钢包锻线通用性与应用,电线电缆,1993,1：23-29.
[22]J.GSzota, Steel wire galvanizing by the VERT-DOWN method, Journal of materials, Processing Technology,1995,55:134-139
[23]李伯林.覆铜导线生产工艺研究：[硕士学位论文].大连：大连理工大学,2007
[24]刘桂林.宽铜带连续挤压轮槽变形区的理论研究：[硕士学位论文].大连：大连交通大学,2008
[25]R.Hardwick, Method of fabricating a bi-metal tube,United States Patent, US, 518 (4),111
[26]何康生,曹雄夫,异类金属焊接,北京：机械工业出版社,1986,56=61
[27]吴云忠.包覆拉拔法铜包铝、铜包钢双金属导线的研究：[博士学位论文].大连：大连海事大学博士学位论文,2007
[28]N. Bay., Cold Welding Influence of surface preparation on bond strength,Metal Construction,1986,8:486-490
[29]H.Φ.卡扎柯夫,材料的扩散焊接.北京：国防工业出版社,1982,14-24
[30]张桂木,王景龙,不同金属材料的扩散接合,沈阳航空工业学院学报,1997,14(4)：64-70
[31]史志远,温景林,铝包钢丝的加工工艺,轻金属,1996,12：50-52
[32]彭大署.英国CONFORM连续挤压技术近期的发展,轻合金加工技术,1990,23(1)：33-39
[33]H. Tokuno, Analysis of deformation in extrusion of composite rods, Journal of Materials Processing technology,1991(26):323-325
[34]Avitzur Bet al, Criterion for Prevention of Core Fracture during Extrusion of Bi-mental Rods. Journal of Engineering for Industry,1982,104 (2):293-304
[35]B. S Yilbas, Friction welding of St—AI and AI—Cu materials, Journal of Materials Processin2, Technology,1995 49(5):431-443
[36]口高山辉久,包覆导线的制造方法及其特性,铜加工,1993,23(1)：92-98
[37]井形直弘,关于高强度铜包覆不锈钢,铜加工,1992,25(2)：11-14
[38]刘文元,电缆铝护套连续挤压包覆型腔设计的均压判定准则,铁道学报,1997,19(2)：91-95
[39]宋宝韫,连续包覆型腔塑变区速度场分析与几何参数确定,中国机械工程,1999,10(3)：314-317
[40]张新宇,铝包钢连续挤压包覆挤压力的上限计算,塑性工程学报,1999,6(1)：46-51
[41]运新兵,铜包钢接触线坯连续包覆工艺优化设计,塑性工程学报,2008,15(3)：204-208
[42]闫琳.双金属连续挤压包覆机理研究：[硕士学位论文].昆明：昆明理工大学,2001
[43]刘彬彬.连续挤压包覆(CONCLAD)过程的数值模拟：[硕士学位论文].昆明：昆明理工大学,2003
[44]张志豪.高强度轻型导线成形工艺及机理研究：[硕士学位论文].昆明：昆明理工大学,2001
[45]刘明月,宋宝韫,运新兵,李冰,基于有限元法的铜母线连续挤压扩展成形过程的数值模拟,金属铸锻焊技术,2008,37(17)：52-55
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