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外文翻译--粉碎机的三维设计与分析 英文版.pdf

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外文翻译--粉碎机的三维设计与分析 英文版.pdf

3DdesignandanalysisofthecrushingrollerofahighpressuregrindingrollerH.Gaoa,,L.G.QubaSchoolofMechanicalEngineeringandAutomation,NortheasternUniversity,ShenYang110004,PRChinabDepartmentofMechanicalEngineering,ShenYangInstituteofAeronauticalEngineering,ShenYang110034,PRChinaAbstractThecrushingrollerisoneofthemainpartsofahighpressuregrindingroller,whichisatypeofhighlyefficientorecrushingequipment.Intheworkreportedinthispaper,akindofassembledroller,whichismoreconvenientintherenovationofwornsurfacebysimplyreplacingthesegmentedsurfaceoftheroller,wasdeveloped.Thestructuralmodelsoftheassembledrollerscomponentsweredesignedwithsolidworkssoftware,andthestressanddisplacementofthemainshaftandsurfacesegmentsintwodifferentworkingstateswereanalyzedquicklyusingCOSMOS/Workssoftware.Furthermore,anoptimumclearanceof1.0–2.0mmbetweentheconcave–convexstuddedsegmentsisdeterminedtoprolongtheworkinglifeoftheassembledroller.KeywordsHighpressuregrindingroller3DdesignAssembledrollerFiniteelementanalysis1.IntroductionHighpressuregrindingrollerHPGRisatypeofnewhighlyefficientandenergysavingequipment,whichisappliedtocrushinghardorebasedonthestatichighpressureprinciple1–3.TherolleristhemainworkingpartaccordingtotheHPGRsoperatingprincipleseeFig.1.Inordertoimprovetheworkinglifeoftherollermuchefforthasbeenmadetoimprovetheantiabrasionpropertiesoftherollersurface2.Theuseofasegmentedsurfaceoftheroller,whichisconvenientlymaintainedandreplaced,isanothereffectivetrialanderrorprocess.Inthepaperanewkindofassembledroller,onwhichtungstencarbidecolumnsarestuddedtoimprovetheantiabrasionofthesurface,hasbeendevelopedwitha3Ddesignmethodandthestrengthoftheshaftandthesegmentsanalyzedwiththefiniteelementmethodtoensureitsreliabilityunderheavyorecrushingconditions.2.3DvirtualassemblydesignofassembledrollerTheassembledrollerdesigniscomposedofamainshaft,surfacesegments,key,asideholdingblock,ascrewconnectingbar,andtungstencarbiderivets,etc.Therearesixcouplesofradialkeyholesandscreworientationholesinthemiddleofthemainshaft,and12axialconcavedgrooves,inwhichscrewconnectingbarsareputtofixthemainshaftandsurfacesegmentstightlyandsafelywithsideholdingblocks.Thesurfacesegmentisdesignasaconcavo–convexmatingstructuretopreventstressconcentrationatthematingedges.Thecomponentsmodelsarecreatedthroughsolidworks,whichisakindofcurrentlyapplied3Ddesignsoftware.Thebuiltmodelscanbeuseddirectlyforfiniteelementanalysisbywhichthedesignrationalityisensured.Theassembledmodelisthenorganizedwiththeassemblepatternofdowntotop,accordingtothematingandtherestraintrelationshipsoftheparts.Finally,theintervenesbetweenthepartsarecheckedwiththesoftwaretotestthevalidityoftheassemblestructure.Figs.2and3showtheflowdiagramofvirtualassemblydesignandthe3Dvirtualmodeloftheassembledmainshaft,respectively.3.Finiteelementanalysisofthemainshaft3.1.SolidandfiniteelementmodelThesolidandforceloadingmodelofthemainshaftforGM1000C2200HPGRisshowninFig.4,whichiscreatedthrough3DCADsoftwaresolidworks.Therearesixcouplesofradialkeyholesinthemiddleofmainshaftand12axialJournalofMaterialsProcessingTechnology1292002649–652Correspondingauthor.Tel.þ862483684187faxþ862423906969.Emailaddresshanggao4187sohu.comH.Gao.concavedgrooves.Thesedetailfeatureswillmakethestrengthanalysismoredifficultwiththetraditionalmethodbutiseasierwiththefiniteelementmethod4.ThusCOSMOS/Workssoftware,whichisbasedonthefiniteelementprincipleandcantakeinthesolidmodelcreatedbysolidworkswithoutanydisfigurement,waschosentocalculatethestressanddeformationofthemainshaftandsegments,shownlater.FollowingistheprocesstocreatethefiniteelementmodelofthemainshaftwithCOSMOS/Workssoftware1Appendthecharacteristicsofthematerial.Thematerialofthemainshaftis35CrMo,ofwhichtheelasticmodulusEis206MPa,thefrictioncoefficientmis0.3,thedensityris7.9kg/cm3andthelimitationstressssis835MPa.2Loadingandrestraint.Theforcesenduredbythemainshaftcomefromthecrushingpressureaccordingtotheoperatingprinciple,itsterminalvalueFmaxbeing2500kN,theloadingareabeingintheformofanarcofangle608and200mmwidthonthesurfaceoftheshaft.Theboundaryconditionisrestrainedbyasupposedbearing.3Modelmeshing.Themeshingparametersareasfollow38026nodes,24117elementsand114079degreeoffreedomDOF.3.1.1.CalculatedresultsThestressdiagramthatiscalculatedthroughCOSMOS/WorksisshowninFig.5.Themaximumstresssmaxis296MPa,analyzedonVonMisestheory.ItstheoreticalequationissmaxC20ssn1wheresmaxisthemaximumstress,ssthelimitationstress,andnisthesafetycoefficient,usually,nis1.5–2.0.Thecalculatedresultsshowthattheshaftstrengthcansatisfythedesignrequirement.Furthermore,thesafetycoefficientncanachieve2.8accordingtotheVonMisestheory.4.Finiteelementanalysisofthesegment4.1.SolidandfiniteelementmodelThesolidandforceloadingmodelsintwodifferentworkingstatesareshowninFig.5.ThesegmentisdesignFig.1.Principleofhighpressurerollermill.Fig.2.Flowdiagramofvirtualdesign.Fig.3.3Ddesignmodeloftheassembly.Fig.4.Loadingandrestrainofthemainshaft.Fig.5.Loadingandrestraintofasegment.650H.Gao,L.G.Qu/JournalofMaterialsProcessingTechnology1292002649–652asaconcavo–convexmatingstructure.Alsotherearetrapeziumgroovesonbothofitssides.ThefollowingistheprocesstocreatethefiniteelementmodelofasurfacesegmentwithCOSMOS/Workssoftware1Appendthecharacteristicsofthematerial.Thematerialofthesurfacesegmentis42CrMoV,withanelasticmodulusEof206MPa,theshearmodulusGis79.4MPa,thefrictioncoefficientmis0.3,thedensityris7.9kg/cm3andthelimitingstressssis930MPa.2Loadingandrestraint.Twoworkingstatesareassumed.Firstistheidealandrationalstate,showninFig.5a,forwhichtheloadingisFr¼2500,Ft¼1056kN,theloadingareaisof200mmwidthand13mmarclengthonthesurfaceofsegment,andthefixedinternalsurfacebecomesitsrestraintcondition.AnotherstateisshowninFig.5binwhichonlytwoendsofthesegmentbottomarecontactedbytheshaftbecauseofanincorrectmanufacturingprocessorassembly.Forthisconditiontheforceenduredbythetwoendsisequal.Consequently,theothersurfaceandtheconcavogroovesarerestrained.3Modelmeshing.Themeshingparametersinthetwodifferentstatesarethesamebecauseofthesamesolidmodel,andtheyare15367nodes,9792elementsand46101DOF.4.2.Calculatingresults1ThecalculationresultsareshowninFig.6.Accordingtothediagramina,themaximumnodethe8354thstressis860MPaonthesurfaceofthesegmentinthefirstworkingstateandthemaximumnodethe8295thdisplacementis0.2mm.Inthesecondworkingstate,themaximumnodethe15361ststressis5495MPaandthemaximumnodethe417thdisplacementis0.78mm.Therefore,thefirstworkingstateisrational,whilstincontrast,thestressofthesegmentinsecondstateexceedsthelimitingrange.2Accordingtothecalculations,thesegmentonlyendurestheworkingloadinginfirststateandthematingsegmentsdonotactoneachother,whileinthesecondstate,notonlydoesthesegmentendurestheworkingpressure,butalsoitenduresthestressfrommatingsegmentssynchronouslybecauseofitsdeformation.Thegreateristhestressandthedeformationbetweensegmentsandsideconnectingblocks,thelargeristhestressinthesegment.Thereforetheelasticdeformationandextensionofthematerialshouldbeconsideredinthesegmentdesign.Thematingclearancebetweenmatingsegmentsshouldbesuitable.Theoptimizedclearanceof1.0–2.0mmhasbeencalculatedwiththefiniteelementmethod.3Enoughstrengthandhighersurfacehardnessofthesegmentbasebodyarenecessary,orplasticdeformationofthebodywilloccurandthecarbiderivetswillbepressedintothesegmentbodyundertheheavycrushingforce.Asanexample,steel45ss¼300MPaischosentoexamineitsdeformationunderheavycrushingforceinthefirstworkingstate.ThecalculationresultisshowninFig.7.Itsmaximumstressis749MPa,andthesafetycoefficientis0.4,whichisbeyondthesafetylimitationofthematerialaccordingtoVonMisestheory.Heattreatedmaterialof42CrMoVwithHB240–280hardnesshasmorethanthreetimesthestrengthcomparedwithsteel45.Thusitcanbechosentoproducethesurfacesegment.Inordertoimprovetheantiabrasionabilityoftheroller,tungstencarbidecolumnsoff10–20diameter,whichhavehardnessofHRC85–93,arestuddedonthesegmentsurface.Anegativematingclearanceof0.04–0.08mmisnecessarytomakethecolumnsmatetightandfirmly7.5.Conclusions1AnewkindofassembledrollerforaGM1000C2200typeHPGR,inwhichtheworkingsurfaceiscomposedFig.6.Calculatedstressofasegment.Fig.7.Dangerouszoneofthesegment.H.Gao,L.G.Qu/JournalofMaterialsProcessingTechnology1292002649–652651ofseveralsegments,hasbeendevelopedwith3DCADsoftwaresolidworks.Thiskindofsegmentedstructurecanmaketheworkinglifeoftherollerlongerandenablethewornsurfaceoftherollertobereplacedeasily.Thestressandthedeformationofthetwomainpartsoftheassembledrollerthemainshaftandthesurfacesegment,havebeenanalyzedwithCOSMOS/Workssoftware,whichisbasedontheprincipleofthefiniteelementmethod.2Theresultsoffiniteelementanalysisshowthatheattreatedmaterialof42CrMoVwithHB240–280hardnesscanbeusedtoproducethemainshaftandsurfacesegments.3Ifthebottomsurfaceofthesegmentdoesnotcontactuniformlywithmainshaftsurface,thestressofthesegmentmaybeconcentratedanddeformationwilloccur,whichwouldmaketheworkingstateoftherollerunstableandevenresultinbreakage.Forfurtherreadingsee5,6.References1K.Schonert,Int.J.Miner.Process.221988400–412.2Thason,Concr.Technol.2199921–23.3Thompuen,J.Knecht,MiningEng.9199623–25.4L.J.Wang,X.K.Sun,H.Gao,Chin.J.Mech.Eng.364200083–85inChinese.5An.N.Shi,H.Wang,Mech.Des.Manuf.4200018–20inChinese.6Zh.J.Du,Zh.H.Gao,CAD/CAM8200142–43inChinese.7H.Gao,L.G.Qu,X.H.Lan,inProceedingsoftheAsiaPacificVibrationConference,JilingScienceandTechnologyPress,2001,pp.303–305.652H.Gao,L.G.Qu/JournalofMaterialsProcessingTechnology1292002649–652

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