Article(id=1187088800556663321, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1187088798216241684, articleNumber=1009-5438(2022)04-0022-04, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1650816000000, receivedDateStr=2022-04-25, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1760953625096, onlineDateStr=2025-10-20, pubDate=1661356800000, pubDateStr=2022-08-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1760953625096, onlineIssueDateStr=2025-10-20, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1760953625096, creator=13701087609, updateTime=1760953625096, updator=13701087609, issue=Issue{id=1187088798216241684, tenantId=1146029695717560320, journalId=1185652524569653253, year='2022', volume='48', issue='4', pageStart='1', pageEnd='98', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1760953624537, creator=13701087609, updateTime=1760953945042, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1187090142570365089, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1187088798216241684, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1187090142570365090, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1187088798216241684, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=22, endPage=25, ext={EN=ArticleExt(id=1187340473359282783, articleId=1187088800556663321, tenantId=1146029695717560320, journalId=1185652524569653253, language=EN, title=Analysis and Improvement on Wave Bending of Finished Products with KOCKS Rolling Mill, columnId=1187340472918880861, journalTitle=Science & Technology of Baotou Steel, columnName=Production Practice and Management, runingTitle=null, highlight=null, articleAbstract=

In this paper, the influences of equipment failure for rolling mill on product quality and improvement measures are discussed by analyzing the relative movement of roll collar for KOCKS rolling mill and flange plate, detection and classification of movement through CAPAS system as well as vibration detection rules of transmission shaft for C module. The results showed that the bending of bars above Φ19 mm was caused by the deterioration of working condition for rolling mill as well as the wave bending of finished product could be effectively improved through maintaining the shaft sleeve and flange plate of rolling mill; the bending of bars below Φ19 mm was caused by the vibration of rolling mill as well as the wave bending of finished product could be obviously improved through repairing the movement and drive system of rolling mill. The axial drifting of roller is determined by strength of rolling bearing of drive shaft so that the vibration of rolling mill is affected. As a result, the wave bending of finished products could be obviously improved through using high quality rolling bearing.

, correspAuthors=null, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, authorCompany=null, fund=null, authors=null, authorsList=Yi-qian Wang, Wen-hu Wang, Jie Gao), CN=ArticleExt(id=1187089063078150250, articleId=1187088800556663321, tenantId=1146029695717560320, journalId=1185652524569653253, language=CN, title=KOCKS轧机成品波浪弯曲分析及改善, columnId=1185882039552193444, journalTitle=包钢科技, columnName=生产实践与管理, runingTitle=null, highlight=null, articleAbstract=通过对KOCKS轧机轧辊辊环与法兰盘的相对运动、机芯经过CAPAS系统检测分级和C模块传动轴振动检测规律进行分析,探讨轧机设备故障对产品质量的影响及改进措施。结果表明,规格Φ19 mm以上棒材弯曲为轧机工况恶化产生,对轧机轴套、法兰盘进行维护可以有效改善成品波浪弯;规格Φ19 mm以下棒材弯曲为轧机振动产生,通过对轧机机芯、传动系统维修可以明显改善成品弯曲,传动轴滚动轴承强度决定了轧辊轴向窜动,影响轧机震动,使用高质量滚动轴可承明显改善成品轧材波浪弯曲。, correspAuthors=null, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=r3vd/Ob6A7spYDs7Wzdwgg==, magXml=xNWoFzBty72vALfE3UHGbA==, pdfUrl=null, pdf=G6ttfe+nS6O0G1bEUkDqCQ==, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=hqWkMcd8NoV58Sz/6rfnCg==, mapNumber=null, authorCompany=null, fund=null, authors=

王一谦(1987-),男,江苏省盐城市人,硕士,工程师,主要从事压力加工工作。

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王一谦(1987-),男,江苏省盐城市人,硕士,工程师,主要从事压力加工工作。

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王一谦(1987-),男,江苏省盐城市人,硕士,工程师,主要从事压力加工工作。

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机芯分类 机架号 使用架次
A类 2、3、9、11、13、
19、22、24、25
成品两架精度要求高
B类 8、23 5架次的K3
C类 1、6、12、14、18、20 机前两架精度要求低
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机芯按精度分类

, figureFileSmall=null, figureFileBig=null, tableContent=
机芯分类 机架号 使用架次
A类 2、3、9、11、13、
19、22、24、25
成品两架精度要求高
B类 8、23 5架次的K3
C类 1、6、12、14、18、20 机前两架精度要求低
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KOCKS轧机成品波浪弯曲分析及改善
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王一谦 , 王文虎 , 高洁
包钢科技 | 生产实践与管理 2022,48(4): 22-25
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包钢科技 | 生产实践与管理 2022, 48(4): 22-25
KOCKS轧机成品波浪弯曲分析及改善
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王一谦, 王文虎, 高洁
作者信息
  • 中天钢铁集团有限公司,江苏 常州 213001
  • 王一谦(1987-),男,江苏省盐城市人,硕士,工程师,主要从事压力加工工作。

Analysis and Improvement on Wave Bending of Finished Products with KOCKS Rolling Mill
Yi-qian Wang, Wen-hu Wang, Jie Gao
Affiliations
  • Zenith Steel Group Co., Ltd., Changzhou 213001, Jiangsu, China
出版时间: 2022-08-25
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通过对KOCKS轧机轧辊辊环与法兰盘的相对运动、机芯经过CAPAS系统检测分级和C模块传动轴振动检测规律进行分析,探讨轧机设备故障对产品质量的影响及改进措施。结果表明,规格Φ19 mm以上棒材弯曲为轧机工况恶化产生,对轧机轴套、法兰盘进行维护可以有效改善成品波浪弯;规格Φ19 mm以下棒材弯曲为轧机振动产生,通过对轧机机芯、传动系统维修可以明显改善成品弯曲,传动轴滚动轴承强度决定了轧辊轴向窜动,影响轧机震动,使用高质量滚动轴可承明显改善成品轧材波浪弯曲。
KOCKS轧机  /  设备故障  /  振动  /  弯曲

In this paper, the influences of equipment failure for rolling mill on product quality and improvement measures are discussed by analyzing the relative movement of roll collar for KOCKS rolling mill and flange plate, detection and classification of movement through CAPAS system as well as vibration detection rules of transmission shaft for C module. The results showed that the bending of bars above Φ19 mm was caused by the deterioration of working condition for rolling mill as well as the wave bending of finished product could be effectively improved through maintaining the shaft sleeve and flange plate of rolling mill; the bending of bars below Φ19 mm was caused by the vibration of rolling mill as well as the wave bending of finished product could be obviously improved through repairing the movement and drive system of rolling mill. The axial drifting of roller is determined by strength of rolling bearing of drive shaft so that the vibration of rolling mill is affected. As a result, the wave bending of finished products could be obviously improved through using high quality rolling bearing.

KOCKS rolling mill  /  equipment failure  /  vibration  /  bending
王一谦, 王文虎, 高洁. KOCKS轧机成品波浪弯曲分析及改善. 包钢科技, 2022 , 48 (4) : 22 -25 .
Yi-qian Wang, Wen-hu Wang, Jie Gao. Analysis and Improvement on Wave Bending of Finished Products with KOCKS Rolling Mill[J]. Science & Technology of Baotou Steel, 2022 , 48 (4) : 22 -25 .
KOCKS轧机为一种三个轧辊互成120°角布置的轧机[1],可用于精密轧制,能使产品的尺寸偏差小于±0.15 mm,椭圆度可达到0.15 mm。但是在轧制过程中,钢材易出现波浪弯现象,即一根轧材长度方向相邻波峰间距1 000~1 300 mm,弯曲呈规律性、周期性分布,且弯曲度超出国标0.4%的要求。“波浪弯”问题严重影响生产及产品质量控制[2],如出现波浪弯曲后现场调整难度极大,波浪弯曲的棒材外观质量差及难以通过矫直恢复。针对本厂使用5架次KOCKS轧机轧制最终规格成品(部分规格使用3—4架次轧机)产生的“波浪弯”问题,通过对生产过程进行跟踪,观察轧材出KOCKS轧机时抖动情况,分析轧材弯曲原因,并通过对轧机轴套、法兰盘进行维护,传动轴使用高强度轴承可以明显改善成品轧材波浪弯。
通过CAPAS测量系统对上线前KOCKS机芯的径向、轴向跳动数据进行测量,通过在法兰盘与辊环划线做标记,对比分析辊环有无窜动及轧材的实际弯曲与辊环窜动的相关性[3]
对现有机芯进行质量分类[4],进而合理安排优质机芯与普通机芯的上线分布,降低波浪弯产生的可能性。
跟踪KOCKS的C模块传动轴承的振动情况、KOCKS各机架电流曲线,优化轧线料型,稳定机架间张力。
图1图2为成品波浪弯实物图,可以看出成品棒材弯曲呈周期性。经测量每米弯曲6~10 mm,超出标准每米弯曲不大于4 mm的要求。
在安装满足标准要求状态下,轧机安装好后在轧辊与对应法兰盘(法兰盘即机芯长短轴与轧辊接触工具)用防水油漆笔划线进行标识,见图3,跟踪上下线之后相对位置偏移状态,若下线后两条线不在同一位置,说明该机芯发生窜动偏移,则该机芯为不合格机芯。图4为轧机上下线的机芯利用CAPAS系统测量机芯轴向、径向波动,上线前三个轧辊波动值调整为0,下线后检测出现波动数值,则该机芯出现跳动,为不合格机芯。
图5为轧机机芯下线跟踪结果,可以发现状态差的轧机机芯中辊环与法兰盘出现明显的错位,表明在生产过程中发生了窜动,从而引起成品波浪弯的形成。图6为轧机下线后法兰盘磨损状态,表面出现磨损凹坑并形成台阶,此法兰盘与辊环挤压接触摩擦力不足,在轧机高速轧制过程中形成窜动。
为保证尺寸精度且不发生波浪弯,根据跟踪结果的机芯轴向、径向波动数据,将分厂所有机芯分为A、B、C三类,安装机芯时按指定机架安装。轴向、径向波动数据小于0.05 mm的机芯分为A类,可在成品架次使用,保证成品尺寸;轴向、径向波动数据在0.05~0.1 mm的机芯分为B类,在中间对尺寸精度要求低的第三架K3道次机架使用;对轴向、径向波动数据在0.1~0.2 mm的机芯分为C类,在前面对尺寸精度要求最低的两架道次使用。波动数值超过0.2 mm机芯安排拆解维修。表1为机芯按精度分类情况。
分厂对分类出通过内部检测、跟踪状态不能满足生产要求的轧机机芯进行拆解维修。
机架的径向轴承的外圈都出现了转动,拆开偏心套里面的轴承发现轴承的外圈在偏心套内孔发生了相对转动,导致了偏心套内孔变大和轴承外圈磨损变小的情况,偏心套的内孔出现了锥度偏差。
轧辊环在卡盘两边相对转动,导致机芯三根主轴的卡盘与轧辊接触部位摩擦损伤,而机芯的长短轴受力轴承磨损、偏心套内孔变大和轴承外圈磨损变小、径向轴承磨损是引起辊环受载时径向波动的因素。
对轧机机芯维修、工况升级后,安装合格后上线使用,规格Φ19 mm以上棒材波浪弯曲明显好转,轧制后成品弯曲度满足标准要求。但规格Φ19 mm以下棒材,波浪弯曲还存在,特别是小规格四机架次成品波浪弯明显存在。
在发生波浪弯情况时,通过监测KOCKS轧机机芯的中、下传动轴,其中每个传动轴有上下两个轴承,观察轴承的振动曲线,发现第二架轧机机芯的下传动轴及第四架轧机下传动轴的轴承振动异常。传动连接轴长时间使用存在磨损,在传动过程中出现振动,见图7图8
根据图7图8振动监测结果来看,第二架、第四架下传动轴轴承振动超出设备要求的振动范围。现有的四机架成品后的过渡导槽进口尺寸较大(大规格为Φ110 mm,小规格为Φ50 mm),规格Φ18~Φ40 mm之间轧材在通过空过导槽时振荡空间大,易形成抖动弯曲。通过改进过渡导槽进口,使得导槽进口开口比成品大1 mm,成品通过该空过导槽时限制了棒材振动,成品波浪弯明显改善。针对检测结果对C模块的第二架、第四架下传动轴进行维修更换。第二架、第四架下传动连接轴更换后,转动轴轴承的振动及振幅明显降低,满足设备生产要求的振动范围,成品波浪弯曲现象得到解决,见图9图10
统计2021年1—10月份因弯曲度超过0.4%的国标要求、需要矫直的轧材重量为1 125.38 t,较去年同期降低了63.6%,11—12月份经过轧机机芯维护、过程控制,成品棒材未再出现弯曲度超出国标0.4%要求。
(1)对轧机按工况质量分级使用,可以有效的改善成品波浪弯。
(2)规格Φ19 mm以上棒材弯曲为轧机工况恶化产生,规格Φ19 mm以下小规格棒材弯曲为轧机振动产生。
(3)轧机机芯偏心套及法兰盘的磨损对成品波浪弯曲影响明显,对机芯维修可以明显改善成品弯曲。
(4)轧机振动对小规格棒材成品弯曲影响较大,更换轧机的连接轴机芯轴承可以消除振动,成品棒材弯曲度低于标准0.4%的要求。
参考文献 引证文献
排序方式:
[1]
李海锋, 汤铁军, 刘立新. KOCKS轧机的工作原理[A].河南省金属学会.2010年学术年会论文集[C]. 郑州: 2010.107-109.
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李平, 蔚鲲, 李凯. 钢轨波浪弯曲成因及应对措施[J]. 包钢科技, 2003, 29(4):47-50.
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遇铁基, 李文博, 方言, 等. KOCKS三辊减定径机组创新改进[A].2016年全国轧钢生产技术会议论文集[C]. 贵阳: 2016.151-160.
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冯圣才. KOCKS减定径轧机存在的问题及改进[J]. 冶金管理, 2021,(11):76-77.
2022年第48卷第4期
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  • 接收时间:2022-04-25
  • 首发时间:2025-10-20
  • 出版时间:2022-08-25
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  • 收稿日期:2022-04-25
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    中天钢铁集团有限公司,江苏 常州 213001
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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