高功率连续CO_2激光轧辊表面多头毛化技术及工艺实验研究
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摘要
在了解目前激光毛化加工技术的研究与发展的基础上,针对当前激光毛化无法突破提高生产效率这一问题,采用直流开关电源激励轴快流CO2激光器进行多头激光轧辊毛化的技术方案。多头激光毛化系统结构简单、成本低,使用寿命长,生产维护容易、生产效率高,有助于推广多头激光毛化这种高新技术的应用。
结合工程实际分析了当前对轧辊毛化加工系统所提出的新要求,制定了高功率激光多头毛化方案,介绍了多头激光毛化系统的结构与各组成部分功能,对激光器系统、毛化机床系统和西门子数控系统分别做了介绍。
分析了多头分光技术原理及多头毛化加工方法,设计了多头毛化的各个加工装置,并以具体实践中的双头激光毛化为例设计了双头激光毛化的外光路分光系统和聚焦系统。
采用直流开关电源激励轴快流CO2激光器对轧辊进行了快速毛化的工艺实验,通过实验研究了各种不同工艺参数下激光毛化的表面形貌,以及双头毛化的加工参数。研究了激光功率对粗糙度的影响,也分析了脉冲频率对峰值数Pc值的影响。同时还通过实验分析了扫描速度、离焦量、侧吹气的角度和流量以及侧吹气的种类对毛化点形貌形成的影响。
具体分析了激光毛化表面的特征及其表面特征的参数的描述,分析了激光毛化轧辊使用寿命提高的具体途径和原因,特别强调了激光毛化工艺可以在多个方面改善冷轧生产工艺,还分析了激光毛化表面对冷轧板产品使用性能的影响,包括改善深冲性能、提高涂镀性和鲜映度、改善抗摩擦性能等,全面论述了激光毛化板的各种工艺性能优势。
Multi-head roll surface texturing with high power CO2 laser has been adopted to enhance production efficiency based on research of laser texture technology .The equipment for mtlti-head roll texturing with high power CO2 laser, which has a lot of advantages as easy modulation of laser pulse, compacted configuration, low-cost for implement, operation and maintaining. Therefore, it is conduced to extend application of muti-head roll surface texturing with high power CO2 laser.
More new request for the system components of roll surface texturing is analyzed with project practice. The system componentsof high power CO2 laser texture are described, including the function and performance of high power CO2 laser, beam delivery system, controlling system and machine.
The technology of multi-head beam is studied, about each maching equipment of multi-head roll surface texturing. The system of focus and outside beam route is designed by double-head laser texture which practiced in project.
High power CO2 laser is adopted in the experiment of laser texture, effects of the technology parameters to laser texture are studied in experiments. With appropriate assist gas pressure and reasonable defocus, results show that the remarkable effects to the size and shape of textured spots are the frequency, width of laser pulse and the velocity of process. The microstructure of textured spots is studied with microscope.
The charater and diagnostic parameter of laser texture surface is analyzed. The results show dense microstructure in the textured spot, which brings about the improvement of the hardness, wear and corrosion resistance. It is especially emphasized that cold roll production craftwork would be improved by laser texture, and the capability of cold roll steel also would be influenced by laser texture.
结合工程实际分析了当前对轧辊毛化加工系统所提出的新要求,制定了高功率激光多头毛化方案,介绍了多头激光毛化系统的结构与各组成部分功能,对激光器系统、毛化机床系统和西门子数控系统分别做了介绍。
分析了多头分光技术原理及多头毛化加工方法,设计了多头毛化的各个加工装置,并以具体实践中的双头激光毛化为例设计了双头激光毛化的外光路分光系统和聚焦系统。
采用直流开关电源激励轴快流CO2激光器对轧辊进行了快速毛化的工艺实验,通过实验研究了各种不同工艺参数下激光毛化的表面形貌,以及双头毛化的加工参数。研究了激光功率对粗糙度的影响,也分析了脉冲频率对峰值数Pc值的影响。同时还通过实验分析了扫描速度、离焦量、侧吹气的角度和流量以及侧吹气的种类对毛化点形貌形成的影响。
具体分析了激光毛化表面的特征及其表面特征的参数的描述,分析了激光毛化轧辊使用寿命提高的具体途径和原因,特别强调了激光毛化工艺可以在多个方面改善冷轧生产工艺,还分析了激光毛化表面对冷轧板产品使用性能的影响,包括改善深冲性能、提高涂镀性和鲜映度、改善抗摩擦性能等,全面论述了激光毛化板的各种工艺性能优势。
Multi-head roll surface texturing with high power CO2 laser has been adopted to enhance production efficiency based on research of laser texture technology .The equipment for mtlti-head roll texturing with high power CO2 laser, which has a lot of advantages as easy modulation of laser pulse, compacted configuration, low-cost for implement, operation and maintaining. Therefore, it is conduced to extend application of muti-head roll surface texturing with high power CO2 laser.
More new request for the system components of roll surface texturing is analyzed with project practice. The system componentsof high power CO2 laser texture are described, including the function and performance of high power CO2 laser, beam delivery system, controlling system and machine.
The technology of multi-head beam is studied, about each maching equipment of multi-head roll surface texturing. The system of focus and outside beam route is designed by double-head laser texture which practiced in project.
High power CO2 laser is adopted in the experiment of laser texture, effects of the technology parameters to laser texture are studied in experiments. With appropriate assist gas pressure and reasonable defocus, results show that the remarkable effects to the size and shape of textured spots are the frequency, width of laser pulse and the velocity of process. The microstructure of textured spots is studied with microscope.
The charater and diagnostic parameter of laser texture surface is analyzed. The results show dense microstructure in the textured spot, which brings about the improvement of the hardness, wear and corrosion resistance. It is especially emphasized that cold roll production craftwork would be improved by laser texture, and the capability of cold roll steel also would be influenced by laser texture.
引文
[1]张光钧.激光表面工程的发展趋势.机械制造, 2005, 485(43): 1～2
[2]曹国辉,赵万生,王振龙等.冷轧辊毛化技术的对比研究.电加工与模具, 2002, (4): 1～3
[3]颜永根.冷轧辊毛化技术现状与进展.宝钢技术, 1995, (6): 2～4
[4]谢琼,许振鄂,周新军.高功率轴快流CO2激光器气体压力控制.应用激光, 2001, 21(2): 100～102
[5]陈培锋,王英,朱明珠.高功率激光辊类表面多头毛化加工方法及其装置.中国专利,专利号: 200610018261.1, 2006. 1～11
[6]姚贵升.钢板表面形貌对冲压成型性能和油漆后外观质量的影响.宝钢技术, 2001, (12): 16～17
[7]林子光.激光毛化与摩擦学设计.机械设计, 2000, (4): 26～27
[8]陈光南,沈还,朱怀清.激光毛面钢板的使用性能.轧钢, 1996, (5): 13～15
[9]周家碂.冷轧轧辊毛化技术.钢铁钒鈦, 1996, (5):13～15
[10]高宏,陈光南.利用激光毛化技术在普通冷带轧机上实现异步轧制.钢铁, 1998, 33(3): 63～64
[11]陈光南.毛化轧辊的新方法及其应用.应用激光, 1995, 16(4): 156～157
[12]王旭,赵冰,柳春芳.汽车冷轧深冲激光毛化钢板的试验研究.汽车工艺与材料, 1996, (8): 19～20
[13]朱大庆.快速激光该花的理论与实验研究: [博士学位论文].武汉:华中科技大学图书馆, 2000
[14]徐安定.新型大功率CO2激光毛化成套设备及工艺.冶金设备, 2004, 12(6): 35～37
[15]朱大庆,李适民,左都罗等.高功率CO2激光快速刻花实验研究.红外与激光, 1996, 26(3): 172～174
[16]刘莹,陈大融,杨文言等.轧辊表面微凸体形貌激光毛化技术的试验研究.机械工程学报, 2003, 39(7): 107～110
[17]丘军林,程祖海.工业激光技术.武汉:华中科技大学出版社, 2002. 39～40
[18]林子光,郭炎.表面形貌对抗擦伤能力影响的实验研究.机械设计, 1999, (11) : 1～3
[19]何云峰,都东,岁波等.轧辊表面冠状微凸形貌的激光加工.应用激光, 2002, 22(3): 327～330
[20]林子光.网纹状激光毛化轧辊.中国, 99257952. X1, 1999. 5～11
[21]郑启光,辜建辉.激光与物质相互作用.武汉:华中理工大学出版社, 1996. 13～20
[22]姚远.激光加工技术在汽车工业中的应用.汽车工艺与材料, 2004, (2): 19～21
[23]杨森,黄卫东,刘文今等.激光表面快速熔凝过程中熔区组织重构.应用激光, 2001, 21(4): 224～228
[24] Ravinder B. Siripuram, Lyndon S. Stephens. Effect of Deterministic Asperity Geometry on Hydrodynamic Lubrication. Journal of Tribology, 2004, 126: 527～528
[25] Da-ping Wana, Hong-bin Liua, Yu-ming Wangb, et al. CO2 laser beam modulating for surface texturing machining. Otipics&laser technology, 2007, 27: 572～573
[26] Sameera Chilamakuri, Bharat Bhushan. Effect of peak radius on design of W-type donut shaped laser textured surfaces. Wear, 1999, 43: 119～120
[27] Davi Neves, Anselmo Eduardo Diniz b, Milton Sergio Fernandes de Limac. Efficiency of the laser texturing on the adhesion of the coated twist drills. Journal of Materials Processing Technology, 2006, 179: 139～145
[28] Y. Kligerman, I. Etsion, A. Shinkarenko. Improving Tribological Performance of Piston Rings by Partial Surface Texturing. Transactions of the ASME, 2005,127: 632～633
[29] Hiroshi Ike, Kunio Tsuji, Makoto Takase. In situ observation of a rolling interface and modeling of the surface texturing of rolled sheets. Wear, 2002, 43:49～50
[30] Zhengyang Lia, Yang Mingjiang, Wenjin Liu, et al. Investigation on crater morphology by high repetitive rate laser-induced discharge texturing. Surface & Coatings Technology, 2006, 200: 4493～4499
[31] A.A. Voevodin, J.S. Zabinski. Laser surface texturing for adaptive solid lubrication. Wear, 2006, 261: 1285～1292
[32] D. Du, Y.F. He, B. Sui, et al. Laser texturing of rollers by pulsed Nd:YAG laser.Journal of Materials Processing Technology, 2005, 161:456～461
[33] P. Andersson, J. Koskinen, S. Varjus, et al. Microlubrication effect bylaser-textured steel surfaces. Wear, 2007, 262:369～379
[34] U Popp, U Engel. Microtexturing of cod-forging tools-influence on tool life. Proquest Science Journals, 2006, 220: 28～29
[35] A. D. McNickle I. Etsion. Near-Contact Laser Surface Textured Dry Gas Seals. Transactions of the ASME, 2004, 126: 788～789
[36] H. Trumpold. Process related assessment and supervision of surface textures. International Journal of Machine Tools & Manufacture, 2001, (41) :1981～1993
[37] A. Erdemir. Review of engineered tribological interfaces for improved boundary lubrication. Tribology International, 2005, (38): 249～256
[38] Izhak Etsion. State of the art in laser surface texturing. Journal of Tribology, 2005, (127): 248～249
[39] Wan Yi, Xiong Dang Sheng. The effect of laser surface texturing on frictional performance of face seal. Journal of Materials Processing Technology, 2007, (368): 537～539
[40] ANDRIY KOVAL, CHENKO, OYELAYO AJAY, et al.The effect of laser texturing of steel surfaces and speed-load parameters on the transition of lubrication regime from boundary to hydrodynamic.Tribology Transactions, 2004, (47): 299～307
[41] Y. Feldman, Y. Kligerman, I. Etsion, et al. The validity of the Reynolds equation in modeling hydrostatic effects in gas lubricated textured parallel surfaces. Journal of Tribology, 2006, (128): 345～346
[42]友清.激光加工应用的聚焦透镜.激光与光电子学进展, 1999, (3): 31～34
[43]张旭东,陈武柱,任家烈.热透镜效应对激光焊接模式及其过程稳定性的影响.清华大学学报, 1997, 37(8): 99～102
[44] Langhorn C, Gruhike R. How to reduce the thermal focusing in high-power laser welding, Laser Focus World, 1993, 2(2): 89～93
[45]丘军林,程祖海.工业激光技术.武汉:华中科技大学出版社, 2002. 39～42
[2]曹国辉,赵万生,王振龙等.冷轧辊毛化技术的对比研究.电加工与模具, 2002, (4): 1～3
[3]颜永根.冷轧辊毛化技术现状与进展.宝钢技术, 1995, (6): 2～4
[4]谢琼,许振鄂,周新军.高功率轴快流CO2激光器气体压力控制.应用激光, 2001, 21(2): 100～102
[5]陈培锋,王英,朱明珠.高功率激光辊类表面多头毛化加工方法及其装置.中国专利,专利号: 200610018261.1, 2006. 1～11
[6]姚贵升.钢板表面形貌对冲压成型性能和油漆后外观质量的影响.宝钢技术, 2001, (12): 16～17
[7]林子光.激光毛化与摩擦学设计.机械设计, 2000, (4): 26～27
[8]陈光南,沈还,朱怀清.激光毛面钢板的使用性能.轧钢, 1996, (5): 13～15
[9]周家碂.冷轧轧辊毛化技术.钢铁钒鈦, 1996, (5):13～15
[10]高宏,陈光南.利用激光毛化技术在普通冷带轧机上实现异步轧制.钢铁, 1998, 33(3): 63～64
[11]陈光南.毛化轧辊的新方法及其应用.应用激光, 1995, 16(4): 156～157
[12]王旭,赵冰,柳春芳.汽车冷轧深冲激光毛化钢板的试验研究.汽车工艺与材料, 1996, (8): 19～20
[13]朱大庆.快速激光该花的理论与实验研究: [博士学位论文].武汉:华中科技大学图书馆, 2000
[14]徐安定.新型大功率CO2激光毛化成套设备及工艺.冶金设备, 2004, 12(6): 35～37
[15]朱大庆,李适民,左都罗等.高功率CO2激光快速刻花实验研究.红外与激光, 1996, 26(3): 172～174
[16]刘莹,陈大融,杨文言等.轧辊表面微凸体形貌激光毛化技术的试验研究.机械工程学报, 2003, 39(7): 107～110
[17]丘军林,程祖海.工业激光技术.武汉:华中科技大学出版社, 2002. 39～40
[18]林子光,郭炎.表面形貌对抗擦伤能力影响的实验研究.机械设计, 1999, (11) : 1～3
[19]何云峰,都东,岁波等.轧辊表面冠状微凸形貌的激光加工.应用激光, 2002, 22(3): 327～330
[20]林子光.网纹状激光毛化轧辊.中国, 99257952. X1, 1999. 5～11
[21]郑启光,辜建辉.激光与物质相互作用.武汉:华中理工大学出版社, 1996. 13～20
[22]姚远.激光加工技术在汽车工业中的应用.汽车工艺与材料, 2004, (2): 19～21
[23]杨森,黄卫东,刘文今等.激光表面快速熔凝过程中熔区组织重构.应用激光, 2001, 21(4): 224～228
[24] Ravinder B. Siripuram, Lyndon S. Stephens. Effect of Deterministic Asperity Geometry on Hydrodynamic Lubrication. Journal of Tribology, 2004, 126: 527～528
[25] Da-ping Wana, Hong-bin Liua, Yu-ming Wangb, et al. CO2 laser beam modulating for surface texturing machining. Otipics&laser technology, 2007, 27: 572～573
[26] Sameera Chilamakuri, Bharat Bhushan. Effect of peak radius on design of W-type donut shaped laser textured surfaces. Wear, 1999, 43: 119～120
[27] Davi Neves, Anselmo Eduardo Diniz b, Milton Sergio Fernandes de Limac. Efficiency of the laser texturing on the adhesion of the coated twist drills. Journal of Materials Processing Technology, 2006, 179: 139～145
[28] Y. Kligerman, I. Etsion, A. Shinkarenko. Improving Tribological Performance of Piston Rings by Partial Surface Texturing. Transactions of the ASME, 2005,127: 632～633
[29] Hiroshi Ike, Kunio Tsuji, Makoto Takase. In situ observation of a rolling interface and modeling of the surface texturing of rolled sheets. Wear, 2002, 43:49～50
[30] Zhengyang Lia, Yang Mingjiang, Wenjin Liu, et al. Investigation on crater morphology by high repetitive rate laser-induced discharge texturing. Surface & Coatings Technology, 2006, 200: 4493～4499
[31] A.A. Voevodin, J.S. Zabinski. Laser surface texturing for adaptive solid lubrication. Wear, 2006, 261: 1285～1292
[32] D. Du, Y.F. He, B. Sui, et al. Laser texturing of rollers by pulsed Nd:YAG laser.Journal of Materials Processing Technology, 2005, 161:456～461
[33] P. Andersson, J. Koskinen, S. Varjus, et al. Microlubrication effect bylaser-textured steel surfaces. Wear, 2007, 262:369～379
[34] U Popp, U Engel. Microtexturing of cod-forging tools-influence on tool life. Proquest Science Journals, 2006, 220: 28～29
[35] A. D. McNickle I. Etsion. Near-Contact Laser Surface Textured Dry Gas Seals. Transactions of the ASME, 2004, 126: 788～789
[36] H. Trumpold. Process related assessment and supervision of surface textures. International Journal of Machine Tools & Manufacture, 2001, (41) :1981～1993
[37] A. Erdemir. Review of engineered tribological interfaces for improved boundary lubrication. Tribology International, 2005, (38): 249～256
[38] Izhak Etsion. State of the art in laser surface texturing. Journal of Tribology, 2005, (127): 248～249
[39] Wan Yi, Xiong Dang Sheng. The effect of laser surface texturing on frictional performance of face seal. Journal of Materials Processing Technology, 2007, (368): 537～539
[40] ANDRIY KOVAL, CHENKO, OYELAYO AJAY, et al.The effect of laser texturing of steel surfaces and speed-load parameters on the transition of lubrication regime from boundary to hydrodynamic.Tribology Transactions, 2004, (47): 299～307
[41] Y. Feldman, Y. Kligerman, I. Etsion, et al. The validity of the Reynolds equation in modeling hydrostatic effects in gas lubricated textured parallel surfaces. Journal of Tribology, 2006, (128): 345～346
[42]友清.激光加工应用的聚焦透镜.激光与光电子学进展, 1999, (3): 31～34
[43]张旭东,陈武柱,任家烈.热透镜效应对激光焊接模式及其过程稳定性的影响.清华大学学报, 1997, 37(8): 99～102
[44] Langhorn C, Gruhike R. How to reduce the thermal focusing in high-power laser welding, Laser Focus World, 1993, 2(2): 89～93
[45]丘军林,程祖海.工业激光技术.武汉:华中科技大学出版社, 2002. 39～42