圆钢切分轧制技术的研究与开发
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摘要
棒材生产中，切分轧制技术能大幅提高小断面品种的产量，圆钢切分技术需要高精度控制。本文研究了国内外棒材切分轧制技术的发展概况及其技术成果，认为螺纹钢切分轧制技术较为成熟，圆钢切分轧制技术研究应用较少。在此基础上，对在八钢引进的小型连轧机上进行圆钢切分轧制技术工业性试验的可行性，以及开发难度进行了分析。
结合现场试验，在研究与开发中认为，梅花方孔型系统适用于延伸系数大、面缩率大的小规格品种和需要精确控制的圆钢切分轧制。切分机架宜选择K3道次，轧件在预切分孔型中变形的初始阶段和最终阶段强迫宽展明显，在切分孔型中宽展基本上呈线性关系。在切分孔型中应调节切分水平分力和切分垂直分力的大小和比例，尽量避免轧件充满孔型，延伸系数取1.2～1.39，保证轧件在孔型中处于自由宽展状态。孔型设计时要均匀分配预切分和切分孔型中切分楔处的压下量，切分楔顶角选择在55°～65°较为合适。切分孔型金属质点移动的中立面B_P位置为：B_p≈(0.4～0.48)B。
经生产检验和测算，认为由筱仓宽展公式建立的K8、K7圆-椭圆孔型宽展模型，由B. K.斯米尔诺夫宽展公式建立的K6、K5菱形-梅花方孔型宽展模型，采用Z．乌萨托夫斯基宽展公式建立的K4、K3预切分-切分孔型宽展模型，适用于圆钢切分宽展计算。同时在实践中得出，确保圆钢切分轧制的尺寸精度，在精轧切分孔型系统宜使用硬质合金组合轧辊，并精确控制切分后轧件的活套量。
最后通过成品检验证明，采用圆钢切分轧制技术生产的建筑用圆钢完全能满足产品质量要求。切分轧制技术应成为现代化棒材轧机生产小规格圆钢的主要方法。该技术发展与应用前景广阔，技术价值和经济价值较大，优越性明显。本研究开发的圆钢切分轧制技术代表国内切分技术发展的新高度。
In bar rolling production, the output of small-size products can be greatly increased by slitting technology. High precision in round bar slitting technology is extremely wanted. This paper researches the development condition and technological achievements in bar slitting technology at home and abroad. It is thought that the technology for rebar slitting is much more matured than that of bar slitting and the research and application in round bar slitting is much less at present, the industrial and experimental feasibility and the exploiting difficulties of round bar slitting technology in the continuous bar mill of Bayi Iron & Steel Co. Ltd. have been analyzed carefully.
In combination with the experiments on site, it is thought that club-square pass sequence is suited for the small-size product with high coefficient of elongation and large reduction of area and the round bar slitting rolling with high precision controlling. Pass K3 is chosen for slitting stand. The coercive spread of the rolling piece is evident in pre-slitting pass during the beginning and final periods of rolling. In slitting pass, the spread is basically linear with draught. Dimension and proportion of horizontal and vertical component of force should be well adjusted in slitting pass, which should avoid the rolling piece full in the pass. Spread coefficient should be 1.2-1.39, and the rolling piece is in the condition of free spread. The draught of the slitting wedge is well distributed in pre-slitting and slitting pass. The suitable vertex angle range of slitting wedge is 55 -65 . Position Bp of the neutral surface for metal particle moving in slitting pass is Bp =(0.4 ~0.48 )B.
Through production test and calculation, it is thought that spread models of Pass K8 and K7 in round-oval set up by T.K.Shinokura's formula , that of Pass K6 and K5 in
diamond-club square set up by B.K.Smianoph's formula and that of Pass K4 & K3 in pre-slitting and slitting set up by Z.Wusatowski's formula are suited for the spreading calculation of round bar slitting . In the meanwhile we got from practice that to guarantee the dimension precision of round bar slitting, carbide composite rolls should be used in finishing slitting pass sequence and loop height of the rolling piece should be preciously controlled after slitting.
Finally through the test of finishing products, it is proven that the round bar produced by slitting technology can completely meet the requirement of the quality . The slitting rolling will become the main method in production of small-size products in modern bar mill and has great value , superiority and prosperity in technology and economy. The research and exploitation of technology for round bar slitting rolling stands for the new high level in domestic slitting technology.
结合现场试验，在研究与开发中认为，梅花方孔型系统适用于延伸系数大、面缩率大的小规格品种和需要精确控制的圆钢切分轧制。切分机架宜选择K3道次，轧件在预切分孔型中变形的初始阶段和最终阶段强迫宽展明显，在切分孔型中宽展基本上呈线性关系。在切分孔型中应调节切分水平分力和切分垂直分力的大小和比例，尽量避免轧件充满孔型，延伸系数取1.2～1.39，保证轧件在孔型中处于自由宽展状态。孔型设计时要均匀分配预切分和切分孔型中切分楔处的压下量，切分楔顶角选择在55°～65°较为合适。切分孔型金属质点移动的中立面B_P位置为：B_p≈(0.4～0.48)B。
经生产检验和测算，认为由筱仓宽展公式建立的K8、K7圆-椭圆孔型宽展模型，由B. K.斯米尔诺夫宽展公式建立的K6、K5菱形-梅花方孔型宽展模型，采用Z．乌萨托夫斯基宽展公式建立的K4、K3预切分-切分孔型宽展模型，适用于圆钢切分宽展计算。同时在实践中得出，确保圆钢切分轧制的尺寸精度，在精轧切分孔型系统宜使用硬质合金组合轧辊，并精确控制切分后轧件的活套量。
最后通过成品检验证明，采用圆钢切分轧制技术生产的建筑用圆钢完全能满足产品质量要求。切分轧制技术应成为现代化棒材轧机生产小规格圆钢的主要方法。该技术发展与应用前景广阔，技术价值和经济价值较大，优越性明显。本研究开发的圆钢切分轧制技术代表国内切分技术发展的新高度。
In bar rolling production, the output of small-size products can be greatly increased by slitting technology. High precision in round bar slitting technology is extremely wanted. This paper researches the development condition and technological achievements in bar slitting technology at home and abroad. It is thought that the technology for rebar slitting is much more matured than that of bar slitting and the research and application in round bar slitting is much less at present, the industrial and experimental feasibility and the exploiting difficulties of round bar slitting technology in the continuous bar mill of Bayi Iron & Steel Co. Ltd. have been analyzed carefully.
In combination with the experiments on site, it is thought that club-square pass sequence is suited for the small-size product with high coefficient of elongation and large reduction of area and the round bar slitting rolling with high precision controlling. Pass K3 is chosen for slitting stand. The coercive spread of the rolling piece is evident in pre-slitting pass during the beginning and final periods of rolling. In slitting pass, the spread is basically linear with draught. Dimension and proportion of horizontal and vertical component of force should be well adjusted in slitting pass, which should avoid the rolling piece full in the pass. Spread coefficient should be 1.2-1.39, and the rolling piece is in the condition of free spread. The draught of the slitting wedge is well distributed in pre-slitting and slitting pass. The suitable vertex angle range of slitting wedge is 55 -65 . Position Bp of the neutral surface for metal particle moving in slitting pass is Bp =(0.4 ~0.48 )B.
Through production test and calculation, it is thought that spread models of Pass K8 and K7 in round-oval set up by T.K.Shinokura's formula , that of Pass K6 and K5 in
diamond-club square set up by B.K.Smianoph's formula and that of Pass K4 & K3 in pre-slitting and slitting set up by Z.Wusatowski's formula are suited for the spreading calculation of round bar slitting . In the meanwhile we got from practice that to guarantee the dimension precision of round bar slitting, carbide composite rolls should be used in finishing slitting pass sequence and loop height of the rolling piece should be preciously controlled after slitting.
Finally through the test of finishing products, it is proven that the round bar produced by slitting technology can completely meet the requirement of the quality . The slitting rolling will become the main method in production of small-size products in modern bar mill and has great value , superiority and prosperity in technology and economy. The research and exploitation of technology for round bar slitting rolling stands for the new high level in domestic slitting technology.
引文
[1] 曲克．轧钢工艺学[M]．北京：冶金工业出版社，1991：230～235
[2] 赵松筠，唐文林．型钢孔型设计[M]．北京：冶金工业出版社，2000：236～245
[3] G. Matsuo. New Technology of Slit Rolling [J]. SEAISI, 1995, (2)
[4] 张翰书．螺纹钢筋的切分轧制[J]．轧钢，1995，(5)：5～9
[5] 黄武军．水平连轧机应用切分轧制技术的探讨[J]．轧钢，2001，(4)：60～62．
[6] 龚永平．采用辊切轧制提高轧机吃坯能力[J]．轧钢，1995，(2)：12～13
[7] 龚永平．多线切分轧制对棒材连轧的影响[J]．轧钢，1996，(1)：31～33
[8] 沙新生，王兴．带肋钢筋3线切分工艺设计及实践[J]．轧钢，2003，(4)：58～59
[9] 刘京华，李子文．小型连轧机的工艺与电器控制[M]．北京：冶金工业出版社，2000：141～145
[10] 高伟，王玉峰．三切分棒材轧制活套高度差与预切分轧件偏移[J]．轧钢，2002，(5)：9～10
[11] 肖国栋，姜振峰．四线切分轧制技术的工艺分析[J]．新疆钢铁，2002，(4)：4～6
[12] 李方春．关于辊切分法的探讨[J]．辽宁冶金，1991，(6)：33～35
[13] 黄振晖，马刚等．四切分棒材轧制技术在连轧厂的应用[J]．轧钢，2002，(5)：31～32
[14] 肖国栋，李子文．切分轧制技术在八钢小型连轧机上的应用及开发[J]．新疆钢铁，1998，(4)
[15] 黄守汉．塑性变形与轧制原理[M]．北京：冶金工业出版社，1991：172～200
[16] 赵志业．金属塑性变形与轧制理论[M]．北京：冶金工业出版社，2002：248～250
[17] 王纯等．低成本、高效益棒材生产线新模式[C]．第七届轧钢年会论文集．北京：冶金工业出版社，2002：365～366
[18] 宋义．切分轧制技术的应用[J]．轧钢，1998，(2)：57～58
[19] 张荣杰．应用切分轧制技术实现节能降耗[J]．轧钢，1995，(6)：43～45
[20] 林原茂．中小型轧机切分轧制的应用[J]．安徽冶金，1990，(1)
[21] 崔忠圻．金属学与热处理[M]．北京：机械工业出版社，1990：356～362
[22] 谢贻权．金属学与热处理[M]．北京：机械工业出版社，1990：356～362
[23] 刘战英．开口切分孔型在轧制角钢中的应用[J]．轧钢，1996，(5)：21～23
[24] Badische. Four Times Slit Rolling in One Step at BSW [J]. Steel Times International, 1995, (9)
[25] G Matsuo. Method of Manufacturing Metal Bars Apparatus Therefor[P]. EUROPEAN PATENT APPLICATION: 0597093A1
[26] Nippon steel corporation, New slit miring technology for producing deformed bars [J]. Steel Times, Junury 1986: 31～36
[27] 篠倉恒樹．综材．棒鋼压延幅特性数式化[J]．铁鋼，1981，67(15)：2477～2482
[28] 师莉．浅谈先进的切分工艺及其孔型设计[C]．第六届轧钢年会论文集，北京：冶金工业出版社，2000：342～345
[29] 方德法．切分轧制技术在武钢棒材连轧生产线的应用[C]．第七届轧钢年会论文集，北京：冶金工业出版社，2002：299～300
[30] 姜振峰，李江源．两线切分轧制几个关键问题的探讨[J]．新疆钢铁，2001，(4)：12～15
[31] 孙印明．棒材切分轧制技术及其应用[C]．第六届轧钢年会论文集，北京：冶金工业出版社，2000：35～37
[32] 白光润．型钢孔型设计[M]．北京：冶金工业出版社，1995：245～273
[33] 张红梅，胡林．切分轧制的实验研究——预切分孔中的金属变形[J]．轧钢，1998，(1)：27～29
[34] 乔端，钱仁根．弹性和塑性力学中的有限单元法[M]．北京：冶金工业出版社，1981：185～188
[35] 刘宏民．三维轧制理论及其应用[M]．北京：科学出版社，1999：40～48．
[36] 王兵，杨乐彬等．深入讨论切分机理优化切分轧制工艺参数[C]．第六届轧钢年会论文集，北京：冶金工业出版社，2000：32～34
[37] 吴耀华．三切分轧制中预切分导卫的选型与应用[J]．轧钢，2003，(6)：64～65．
[38] 李芳春，徐林平．切分轧制[M]．北京：冶金工业出版社，1995：59～71
[39] 易明中，刘健．首钢第一型材厂活套系统调试[J]．轧钢，1999，(6)：23～24．
[40] 肖国栋，姜振峰．硬质合金辊环用于棒材热轧分析[C]．第七届轧钢年会论文集，北京：冶金工业出版社，2002：540～545
[41] 王盘鑫．粉末冶金学[M]．北京：冶金工业出版社，1997：318～320
[42] 姜振峰，赵坤．硬质合金组合轧辊的结构分析[J]．轧钢，2003，(6)：49～51
[43] 姜振峰，肖国栋，李子文．可优化棒材生产的实用技术[J]．新疆钢铁，2003，(4)：21～23
[44] 姜振峰．切分孔型系统设计实践与分析[J]．轧钢，2003，(2)：69～71
[2] 赵松筠，唐文林．型钢孔型设计[M]．北京：冶金工业出版社，2000：236～245
[3] G. Matsuo. New Technology of Slit Rolling [J]. SEAISI, 1995, (2)
[4] 张翰书．螺纹钢筋的切分轧制[J]．轧钢，1995，(5)：5～9
[5] 黄武军．水平连轧机应用切分轧制技术的探讨[J]．轧钢，2001，(4)：60～62．
[6] 龚永平．采用辊切轧制提高轧机吃坯能力[J]．轧钢，1995，(2)：12～13
[7] 龚永平．多线切分轧制对棒材连轧的影响[J]．轧钢，1996，(1)：31～33
[8] 沙新生，王兴．带肋钢筋3线切分工艺设计及实践[J]．轧钢，2003，(4)：58～59
[9] 刘京华，李子文．小型连轧机的工艺与电器控制[M]．北京：冶金工业出版社，2000：141～145
[10] 高伟，王玉峰．三切分棒材轧制活套高度差与预切分轧件偏移[J]．轧钢，2002，(5)：9～10
[11] 肖国栋，姜振峰．四线切分轧制技术的工艺分析[J]．新疆钢铁，2002，(4)：4～6
[12] 李方春．关于辊切分法的探讨[J]．辽宁冶金，1991，(6)：33～35
[13] 黄振晖，马刚等．四切分棒材轧制技术在连轧厂的应用[J]．轧钢，2002，(5)：31～32
[14] 肖国栋，李子文．切分轧制技术在八钢小型连轧机上的应用及开发[J]．新疆钢铁，1998，(4)
[15] 黄守汉．塑性变形与轧制原理[M]．北京：冶金工业出版社，1991：172～200
[16] 赵志业．金属塑性变形与轧制理论[M]．北京：冶金工业出版社，2002：248～250
[17] 王纯等．低成本、高效益棒材生产线新模式[C]．第七届轧钢年会论文集．北京：冶金工业出版社，2002：365～366
[18] 宋义．切分轧制技术的应用[J]．轧钢，1998，(2)：57～58
[19] 张荣杰．应用切分轧制技术实现节能降耗[J]．轧钢，1995，(6)：43～45
[20] 林原茂．中小型轧机切分轧制的应用[J]．安徽冶金，1990，(1)
[21] 崔忠圻．金属学与热处理[M]．北京：机械工业出版社，1990：356～362
[22] 谢贻权．金属学与热处理[M]．北京：机械工业出版社，1990：356～362
[23] 刘战英．开口切分孔型在轧制角钢中的应用[J]．轧钢，1996，(5)：21～23
[24] Badische. Four Times Slit Rolling in One Step at BSW [J]. Steel Times International, 1995, (9)
[25] G Matsuo. Method of Manufacturing Metal Bars Apparatus Therefor[P]. EUROPEAN PATENT APPLICATION: 0597093A1
[26] Nippon steel corporation, New slit miring technology for producing deformed bars [J]. Steel Times, Junury 1986: 31～36
[27] 篠倉恒樹．综材．棒鋼压延幅特性数式化[J]．铁鋼，1981，67(15)：2477～2482
[28] 师莉．浅谈先进的切分工艺及其孔型设计[C]．第六届轧钢年会论文集，北京：冶金工业出版社，2000：342～345
[29] 方德法．切分轧制技术在武钢棒材连轧生产线的应用[C]．第七届轧钢年会论文集，北京：冶金工业出版社，2002：299～300
[30] 姜振峰，李江源．两线切分轧制几个关键问题的探讨[J]．新疆钢铁，2001，(4)：12～15
[31] 孙印明．棒材切分轧制技术及其应用[C]．第六届轧钢年会论文集，北京：冶金工业出版社，2000：35～37
[32] 白光润．型钢孔型设计[M]．北京：冶金工业出版社，1995：245～273
[33] 张红梅，胡林．切分轧制的实验研究——预切分孔中的金属变形[J]．轧钢，1998，(1)：27～29
[34] 乔端，钱仁根．弹性和塑性力学中的有限单元法[M]．北京：冶金工业出版社，1981：185～188
[35] 刘宏民．三维轧制理论及其应用[M]．北京：科学出版社，1999：40～48．
[36] 王兵，杨乐彬等．深入讨论切分机理优化切分轧制工艺参数[C]．第六届轧钢年会论文集，北京：冶金工业出版社，2000：32～34
[37] 吴耀华．三切分轧制中预切分导卫的选型与应用[J]．轧钢，2003，(6)：64～65．
[38] 李芳春，徐林平．切分轧制[M]．北京：冶金工业出版社，1995：59～71
[39] 易明中，刘健．首钢第一型材厂活套系统调试[J]．轧钢，1999，(6)：23～24．
[40] 肖国栋，姜振峰．硬质合金辊环用于棒材热轧分析[C]．第七届轧钢年会论文集，北京：冶金工业出版社，2002：540～545
[41] 王盘鑫．粉末冶金学[M]．北京：冶金工业出版社，1997：318～320
[42] 姜振峰，赵坤．硬质合金组合轧辊的结构分析[J]．轧钢，2003，(6)：49～51
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