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关键词：: 钢管切管机设计图纸钢管切管机

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钢管切管机设计

49页 15000字数+说明书+6张CAD图纸【详情如下】

传动系统装配图.dwg

外文翻译--中国石油管的现状和前景.doc

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1 绪论1

1.1 引言1

1.2 切管机的作用1

1.3 国内外切管机的发展状况2

1.4 研究内容与方法2

1.4.1切管机在现场的布置2

1.4.2研究内容与方法3

2方案选择与评述5

2.1切管机功能原理设计5

2.2 切管机的结构设计8

3 主要参数选择与计算9

3.1电机容量选择9

3.2传动装置的设计10

3.2.1分配传动比10

3.2.2 传动装置的整体布置10

3.2.3 传动装置的运动和动力参数计算11

4 主要零件的设计及强度计算13

4.1 V带传动的设计计算13

4.2齿轮传动的设计计算15

4.2.1高速轴与中间轴之间的齿轮啮合15

4.2.2低速轴与中间轴之间的齿轮啮合23

4.2.3齿轮的润滑27

4.3轴的设计及轴承的选择28

4.3.1轴的设计28

4.3.2轴的强度校核29

4.4轴承的强度校核37

4.4.1高速轴上的轴承强度校核37

4.4.2中间轴上的轴承强度校核38

4.5键的较核39

4.5.1高速轴上的键校核40

4.5.2中间轴上的键校核40

5 减速器齿轮轴的应力分析41

结束语44

致谢45

参考文献46

摘要

　　　钢管是一种多功能的经济断面钢材。它在国民经济各部门应用愈来愈广泛，需求量也越来越大。管材的需要量之所以急剧增长，是因为管子能用各种材料来制造。而且质量和精度也高。随着钢管的需求量的日益增大，钢管的生产也显得尤其的重要，至此，这里先对切管机这一钢管生产中的设备做一下介绍。首先，切管机在钢管精整工段中占有很重要的地位。根据钢管产品标准的规定，凡是成品钢管共两端必须切齐整，且切头断面应与钢管中心线垂直。而热轧并经矫直后的管子均达不到上述技术条件的要求，钢管两端往往有裂纹、撕破、结疤和壁厚不均等缺陷，故需要切头尾。成品钢管按订货要求的定尺或倍尺，还有待处理品的改尺，均需要切断。此外，冷拔冷轧钢管生产时，中间管料和成品钢管都需切断和切头尾。本设计对钢管固定式Q119型切管机的主传动部分进行原理性设计。包括切削功率的计算，主传动部分的设计和校核等。详细内容见正文部分。

关键词：钢管；切管机；切削功率；校核

　　　钢管主要用来输送流体(一般叫做输送管、英文叫“pipe”)和用作锅炉等的热交换器管(叫做管子，英文叫“tube”)。

　　　钢管是一种多功能的经济断面钢材。它在国民经济各部门应用愈来愈广泛，需求量也越来越大。管材的需要量之所以急剧增长，是因为管子能用各种材料来制造。而且质量和精度也高。

　　　钢管作为输送管广泛地用于输送油、气、水等各种流体，如石油及天然气的钻探开采与输送、锅炉的油水与蒸汽管道、一般的水煤气管道。化工部门一般用管道化方式生产与运输各种化工产品。所以钢管被人们称为工业的“血管”。

　　　钢管作为结构管大量地用于机械制造业和建筑工业，如用于制作房架、塔吊、钢管柱、各种车辆的构架等。在断面面积相同的条见下，钢管比圆钢、方钢等的抗弯能力大，刚性好，其单位体积的重量轻。因此，钢管是一种抗弯能力较强的结构材料。

　　　钢管还作为中空的零件毛坯用于制造滚动轴承、液压支柱、液压缸简体、空心轴、花键套、螺母以及手表壳等，这既节约金属又节省加工工时。

　　　钢管又是军队工业中的重要材料，如用于制造枪管、炮筒及其他武器。随着航空、火箭、导弹、原子能与宇宙空间技术等的发展，精密、薄壁、高强度钢管的需求量正迅速增长。

　　　随着钢管的需求量的日益增大，钢管的生产也显得尤其的重要，至此，本文将对切管机这一生产设备做一下介绍。

1.2 切管机的作用

首先，切管机在钢管精整工段中占有很重要的地位。根据钢管产品标准的规定，凡是成品钢管共两端必须切齐整，且切头断面应与钢管中心线垂直。而热轧并经矫直后的管子均达不到上述技术条件的要求，钢管两端往往有裂纹、撕破、结疤和壁厚不均等缺陷，故需要切头尾。成品钢管按订货要求的定尺或倍尺，还有待处理品的改尺，均需要切断。此外，冷拔冷轧钢管生产时，中间管料和成品钢管都需切断和切头尾。

　　　其次，在长距离输油气管线建设与维护作业中，管材必须经切管机切断，然后才能使用。

总体上讲切管机的作用是：

(1)按合同要求将飞锯、矫直后的钢管切成定尺长度或通常长度；

(2)对钢管端而进行加工，使符合技术标准的要求；

(3)对有缺陷的待修钢管进行中间切断，切除缺陷部分，钢管改尺(通常长度或短尺长度)交货；

　　　　(4)将飞锯切断的倍尺长度的钢管切成单倍尺长度。

内容简介：: 中国石油管产业的现状和前景1.概述1.1 钢管是石油工业的基础石油管主要有两种：油井用管(钻杆、钻铤、套管、配管等等),和石油和天然气输送管。在油探险和开发期间需要钻杆和钻铤, 油井的加强需要套管,而油的回收需要配管。依照统计学数据，以1米深的油井为例，62公斤的油井用管是不可或缺的,包括48公斤套管、10公斤油管、3公斤钻杆、0.5公斤钻铤等等。近几年来，油井用管的年消费量是大约一百三十万吨。管道输送是石油和天然气运输的最经济的而且最合理的方法。在中国由于管道运输的迅速发展，石油和天然气输送管的需求大幅地在中国增加。几年以前，输送管的需求量只有油井用管的1/3,而在2003年，对输送管的需求量却超过一百四十万吨。2003 年，中国无缝管的消费量是六千六百万吨, 包括19%油井用管(一百二十六万吨)。中国的焊接管消费量是一千万吨，包括14%石油和天然气输送管,一百四十万吨。用于石油工业钢管用量仅少于建筑业。1.2 钢管的质量和特性对石油工业有着重要的影响第一，石油管在石油工业中无论从量上还是价值上都扮演着重要的角色。石油管的投资在石油工业中约占投资总数的20%。第二，石油管的质量和特性对石油工业的发展产生重要的影响。OCTG的服务情况非常严厉。举例来说，套管和配管除了承受内部和外部的压力之外,还有数百至数以千计的大气压力，连同数百吨的拉力，同时，它们长期受到高温和腐蚀的影响。在1985年之前，每年在中国大约有1000个意外事件发生, 被归结为管的破裂。依照 IADC的统计数据，每件意外事件的损失大概是106000美元。一方面，与钻杆或套管有关的意外事件有时可能导致油井的报废。除此之外，套管的寿命直接地决定油井的寿命，而且油井的寿命决定油田的寿命。另一方面，与输送管有关的意外事件更损失惨重。石油管的安全性和可靠度、寿命和经济性都关系到石油工业。 1.3 严格的质量和特性要求促使钢铁工业的发展为了满足油井管和输送管的性能要求, 对化学成分、机械性能、治金质量和尺寸精度的要求越来越严格。钢铁工业一直支撑着石油工业, 而且是它的基础。在同时中，石油工业的发展也推动钢铁工业的发展(油钢管工业)。举例来说，石油和天然气的输送提出越来越严格的质量要求推动了测线管和输送管发展。在最近的30年中，渠道钢已经变得低合金钢领域和高强度钢以及微合金钢中最有潜力的而且最重要的分支。在世界上，钢管厂是以他们的先进技术而闻名并备受所有的钢制造业者的关注。在中国,为实现钢管的自己自足, 政府投资建立天津无缝钢管厂和宝钢,并引进了当时的先进外国的设备和技术。2.石油和天然气输送管的现状中国的螺旋钢管和大口径直缝埋弧焊管的生产能力在技术改造之后每年已经超过二百万吨。而且等级含盖了美国石油协会制定的5 LA，B，X42-X80。生产标准按美国石油协会制定的5L系列，IS03183系列, GB9711系列和消费者的补充技术上的需求而定。对螺旋钢管而言，只有6家钢管厂年产量超过133万吨，钢管直径和管厚分别在219- 2400毫米, 5.2- 25.4毫米, 产品种类超过50个品种。直到2003底，螺旋钢管的总产量和销售量已经达到八百万吨。而大口径直缝埋弧焊管才刚刚投产年产量已经超过七十万吨, 产品直径和厚度分别在304-1422毫米,6.0-26.4毫米。从2001年到2003年，总产量和销售量总计三十六万吨。每个钢管生产商已被授权使用美国石油协会标志，而且已经获得IS09002个质量系统证书,IS014001环境制度证书, 而且得到由中国政府发行的工业生产的产品许可证书。随着中国管线钢的迅速发展，现在已不仅供给国内市场, 而且还对外输出数千计吨管线钢超过50个国家。比如苏丹、印度、韩国、蒙古、美国、意大利、澳洲、菲律宾人、巴基斯坦、哈萨克, 等等。在1998年,苏丹Muglad 盆地石油发展计划, X65型，711毫米10.72毫米,1040公里；在2002年, Kenkiyak-Atyrau 的管线,X65型, 610毫米7.1-11.9毫米,725公里；在2003年，苏丹 Fula 领域原油输出管线, X65型，610毫米, 7.1-11.9毫米，725公里。3.中国石油管产业的发展前景面对石油工业的越来越严格的产品技术要求，中国的钢管制造业和研究学会正在开发新的产品，以使中国油钢管制造工业复兴。目前，输送管面对的挑战是天然气输送管道过长，高压，寒冷的天气，深海，沙漠和地质学灾难。因此，输送管线下列类型需要发展。1.高强度的管线钢 (X80以上)。2.用于低温环境下的管线钢。3.有着适应环境能力的管线钢。4.抗HIC的管线钢。5.抗CO2的管线钢。6.有着高防腐能力的管线钢。7.钢和玻璃纤维结构的复杂管。3.1.1 油管和套管用高表现不可或缺的高性能的套管和油管被用于深井作业和其他严峻的情况：用超过Q125或它的等级的超级高强度套管(同时具有高强度和高性能)。困难的点依下列各项：(1)使套管与它的超过Q125的等级相配的有黏性问题是当今世界级难题。(2)较高强度的钢难以改善SSCC抵抗,它的坚硬超过 HRC25硬度。强度和可塑性和钢的有黏性成反比例。因为钻孔机以在S135钻机上面的钢管，它的等级和用在Q125上面的它的等级套管，黏性需要极端地高，这近几年来已经成为一个焦点。那教英国能源部的科技文件规定给压力管的横截面最小的CVN被表达成计算式:CVN(J)= y(MPa)/10。一些年以前，深处的油田在中国西部被发现，V150套管产生的螺旋形的裂缝导致了油井的报废，这导致损失超过了一亿元。根据分析，螺旋形的裂缝起因是由于高的负载和潜在的螺旋管上的缺陷。固有的缺点或损害对油管和套管的影响是不可避免的。它的关键性能是与(KIC/ y)2有关，即套管是具有较高的强度，和较高的黏性。中国石油协会的研究中心现在正在致力于油井管的强度和黏性实验，包括改良黏性的方法。3.1.2 可扩张的套管可扩张的管状技术是近几年来一种新的尖端的技术。可扩张的套管线在洞中内部穿梭，看起来好像包含扩充圆锥体串联而成，液体被抽入工作线路。水压的压力强迫圆锥体上升套管,借此扩张套管。可扩张的套管包括坚硬的可扩张的套管，坚硬可扩张的套管的主要用途依下列各项：小型地域封闭和高度淤水排除，粉碎的封闭的地域，套管片则穿孔于套管封隔器，此法为传统的尾管吊骨和尾管吊骨封隔器维持洞大小。当改善油井生产时，可扩张的套管新技术主要被用于封闭的粉碎的地域和撒沙网状组织的扩充。在可扩张套管的产生之前，钻杆必须以比较小直径管前进到指定区域，然后再深入其中,造成一个被嵌进的导管。凭借钻进期间使用的可扩张管状技术，洞的大小能被很好的维护而且到达的目标有了很好的保障。面临21世纪的挑战，套管与可扩张的能力设计显得势在必行。研究员估计的坚硬的可扩张的套管技术，可以大量减少钻进费用，能减少装备领域费用和水泥，用水量等方面的费用。该如何为可扩张的套管选择钢种是主要技术之一。可扩张的套管在洞中被扩大,即发生了塑性变形损坏。然后是它在恶劣的环境，腐蚀媒体的感应和外部的外力、内在的压力和腐蚀等。可扩张的套管有塑性毁坏的适应能力。在扩充许用范围、它的机械特性和尺寸精密区间上应该符合美国石油协会标准或其他的有关的产品规格。在可扩张的套管上的研究已经在中国持续了3年，整体而言仍然停留在实验阶段，并没有投入实际的生产。4. 结论石油管生产正在迅速的发展。油井管和石油和天然气的输送管的生产已经达到一个较高水平了。许多新的类型已经被研发，几乎包含的所有的等级和尺寸。几乎所有的钢铁公司、钢管制造业公司和研究学会正在研发性能优异的钢管，并提供较好的服务给用户。The current situation and prospect of oil steel pipe in china1. introduction 1.1 Steel pipe is the base of petroleum industryOil steel pipe mainly includes two kinds of pipes: oil-well pipe (drill pipe, drill collar, casing, tubing, etc.),and the transportation pipe of oil and gas. The well drilling during the oil exploration and exploitation needs drill pipes and drill collars, well reinforcing needs casing, and the oil recovery needs tubing. According to the statistics data, for 1 meter well, 62 kg oil well pipes are needed, including 48kg casing, 10kg tubing, 3kg drill pipes, 0.5 kg drill collars, etc. In recent years, the annual consumption of oil well pipes is about 1.3million tons. The pipeline transportation is the most economical and reasonable method for oil and gas. With the rapid development of pipeline, the demand of oil and gas transportation line pipe increases greatly in China. Several years ago, line pipes accounted for only 1/3 of oil well pipes in the demand, and in 2003, the demand for transportation line pipes exceeded 1.4 million tons.In 2003, the consumption of seamless pipes in China is 6. 6 million tons, including 19% oil well pipes (1.26 million tons).The welded pipes consumption of China is 10 million tons, including 14% oil and gas transportation pipes, 1.4 million tons. The quantity of pipes used in petroleum industry is only less than that in architecture industry.1.2 The quality and performance of steel pipe have important effect on the petroleum industryFirstly, the oil steel pipe plays steel pipe an important effect on the petroleum industry an important role large quantity and costs more money. The investment in the oil pipe accounts for about 20% of the total in the petroleum industry.Secondly, the quality and property of oil steel pipe have important effect on the development of the petroleum industry. The service condition of OCTG is very strict. For example, the tubing and casing strings are required to support the inside and outside pressure, up to hundreds to thousands of atmosphere pressure, as well as hundreds tons of tensile loads, and meanwhile they are always affected by high temperature and severe corrosion medium. Before 1985, there were about 1000 accidents in China every year, which were related to the drilling strings rupture. According to the statistics released by IADC, the mean value of the expense for every accident was 106000 $.On one hand, the accidents relating to the drill strings or the casing strings may sometimes lead to the discarding of the oil well. In addition, the life of casing directly determines that of the oil well, and the life of the oil well determines that of the oil field. On the other hand, the accidents relating to transportation pipe are more disastrous. The safety and reliability, the life and the economy of oil steel pipes are related to the petroleum industry closely. 1.3 The strict quality and property requirements to OCTG by petroleum industry push the development of steel & iron industryTo satisfy the severe service condition of oil well and transportation pipes, the requirements to chemical composition, mechanical properties, metallurgical quality and dimension precision are all strict. Iron & Steel industry has been supporting the petroleum industry, and is the base of it. In the mean time, the development of the petroleum industry also pushes the technical progress of iron & steel industry (oil steel pipe industry).For example, the main drive of line pipe and pipeline steel development is the more and more strict quality requirements put forward by oil and gas transportation projects. In the recent 30 years, pipeline steel has become the most vigorous and important embranchment in the field of low alloy & high strength steel and micro alloy steel. In the world, the oil steel pipes manufacturing corporations are all steel manufacturers famous for their advanced technique and having enjoyed high farces. In China, to realize the self-supporting of oil steel pipes, the government invested to build TPCO and BAOSTFFT, with the most advanced foreign equipment and technologies at that time.2. current situation of the oil and gas transportation pipelineChinas current total capacity for manufacturing SSAW and LSAW pipes has exceeded 2 million tons every year after a vast technology reconstruction. And the grades have coverd API spec 5L A, B, X42-X80. The production standards confirm to API SPEC 5L, IS03183, GB9711 and the supplemental technical requirement of consumers. For SSAW pipes, there are only 6 manufactures mentioned in above paragraph which annual capacity has exceeded 1. 33 million tons, and diameter and thickness range of pipe that they produced are 219- 2400mm, 5. 2- 25. 4 mm respectively, and the type is above 50 kinds. Till the end of 2003, the total quantity of SSAW for manufacturing and selling has been 8 million tons. LSAW pipes now are only in its birth phase in while the production capacity has already exceeded 0.7 million t/ year, with 304-1422 mm diameter, 6.0-26.4 mm thickness. From 2001 to 2003, the total quantity of LSAW for manufacturing and selling was 0.36 million tons. Each manufacturer has been granted the right to use the APT Monogram, and has obtained the IS09002 quality system certificate, IS014001 environment system certificate, and gained the manufacture permission certificate of industry production issued by the Chinese government. With rapid development, Chinese manufacturing industry of oil and gas transportation line pipe, can not only supply pipes to the domestic pipelines, but also export thousands of tons pipes to more than 50 countries. Such as, Sudan, India, Korea, Mongolia, America, Italian, Australia, Philippine, Pakistan, Kazakstan, etc.In 1998, Muglad Basin Oil Development Project, Sudan, X65, 711 mm10. 72 mm, 1040 km; In 2002, Kenkiyak-Atyrau Pipeline,65, 610 mm7. 1 mm, 86 km; In 2003, Sudan Fula Field Crude oil Export pipeline, X65, 610mm, 7. 1-11. 9 mm. 725 km.3. The prospect of the development of Chinese of oil steel pipeFacing the more and more strict technical requirements of the petroleum industry in oil pipe, Chinas steel pipe manufacturers and research institutes are developing new products now，which reveal the prosperity of the Chinese oil steel pipe manufacturing industry. At present, the challenge faced by the oil and gas pipeline industry is to build the gas pipeline with long distance, high pressure, and large flux in the harsh environment with cold weather, deep sea, desert and the other geological disaster. Hence, the following types of oil and gas transportation pipeline need to be developed.1. Pipeline steel and pipeline(X80 and above it) with high strength.2. Pipeline steel and pipeline used under the low temperature environment.3. Pipeline steel and pipeline with suitable cracking controlled performance.4. Pipeline steel and pipeline with the HIC resistant capability.5. Pipeline steel and pipeline with the CO2 resistant capability.6. Pipeline steel and pipeline with the high deformability.7. Complex pipe of steel and fiberglass.3.1.1 Tubing and casing with high performanceThe high performance casing and tubing needed by the deep well and the other strict servicing conditions :the super-high strength casing with its grade exceeding Q125(improving toughness greatly, increasing strength and the same time).Difficult points are as follows:(1)The toughness matching the casing with its grade exceeding Q125 is extremely high, known as the world-class puzzle;(2)The higher the strength of the steel is, it is the more difficult to improve SSCC resistance, it is the forbidden zone that the hardness exceeds HRC25.The strength is inversely proportional to the plasticity and toughness of steel. For drill pipe with its grade above S135 and the casing with its grade above Q125,the toughness needed matching is extremely high, which has been a focus in recent years. The instructing technological file of British Energy Ministry stipulates that transverse minimum CVN for pressure pipe is calculated by the expression: CVN(J)=y (MPa)/10.Several years ago, during well completion of a deep well in the western China,V150 casing produced the spiral crack and caused this well to abandon, which led to lose more than one hundred million Yuan directly.Fig.3 shows down hole photograph of the casing. According to failure analysis, the spiral crack was induced by high load (internal pressure) on potential spiral defect in steel pipe, which resulted from the hole-injection process.Inherent defect or damage is unavoidable for the tubing and casing. Its critical value is relevant to (KIC/y)2,namely the casing is the higher in strength, and the higher the toughness needed matching is.Tubular Goods Research Center of CNPC is now working on strength-toughness match of oil well pipes, including the way of improving toughness.3.1.2 Expandable casingExpandable tubular technology is a new practical drilling technology in recent years. The expandable casing string is run in the hole on an inner-string with a launcher as sembly containing the expansion cone. Fluid is pumped down the work string. The force of hydraulic pressure pushes the cone up the casing, thereby expanding the casing. Expandable Casing includes solid expandable casing and slotted one. The main purposes of solid expandable casing are as follows: thief zone sealing and high pressure water exclusion, crushed zone sealing, casing patch and perforating casing packer, the substatute for conventional liner hanger and liner hanger packer in order to maintain hole size. As a new completion technique to improve oil well production, slotted expandable casing is mainly used in crushed zone sealing and sand meshwork expansion.Before the advent of expandable casing, operators had to use sections of progressively smaller-diameter pipe as they drilled deeper, resulting in a telescoped conduit. By using expandable-tubular technology during drilling, the size of the hole can be maintained and the target reached with minimal well tapering. The break through of this industry meets urgent 21st-century challenges posed by drilling.Fig.4 shows conventional design, casing design with nested expandable current capability, and the mono bore design(from left to right).Solid expandable casing technology, estimated by Shell researchers, promises to significantly reduce the cost of drilling, which can decrease rig field by 75%,drilling fluid by 20%,drilling cuttings by50% and cement by 50%.How to choose steel for expandable casing is one of the key technologies. Expandable casing is expanded in the hole, namely produces plastic deformation. Then it serves in the harsh environment, which must endure external force, internal pressure and corrosion induced by corrosion medium. Expandable casing processes adequate ability of plastic deformation. During the expansion process, its mechanical property and dimension precision should meet API standard or other relevant specification.Research on expandable casing technology has lasted 3 years in China, as a whole still stayed in the laboratory.4. ConclusionThe oil steel pipe production develops with a high speed. The oil well pipe and the oil & gas transportation pipe (include steel plate and coil) have already achieved a high level with a high self-support ratio. Many new types have been developed, almost covering all APT grades and dimensions. All the iron & steel corporations, pipe manufacturing corporations and research institutes are making their efforts to develop more and more steel pipe types to offer better service to consumers.摘要钢管是一种多功能的经济断面钢材。它在国民经济各部门应用愈来愈广泛，需求量也越来越大。管材的需要量之所以急剧增长，是因为管子能用各种材料来制造。而且质量和精度也高。随着钢管的需求量的日益增大，钢管的生产也显得尤其的重要，至此，这里先对切管机这一钢管生产中的设备做一下介绍。首先，切管机在钢管精整工段中占有很重要的地位。根据钢管产品标准的规定，凡是成品钢管共两端必须切齐整，且切头断面应与钢管中心线垂直。而热轧并经矫直后的管子均达不到上述技术条件的要求，钢管两端往往有裂纹、撕破、结疤和壁厚不均等缺陷，故需要切头尾。成品钢管按订货要求的定尺或倍尺，还有待处理品的改尺，均需要切断。此外，冷拔冷轧钢管生产时，中间管料和成品钢管都需切断和切头尾。本设计对钢管固定式Q119型切管机的主传动部分进行原理性设计。包括切削功率的计算，主传动部分的设计和校核等。详细内容见正文部分。关键词：钢管；切管机；切削功率；校核The abstractsteel pipe is one kind of multi-purpose economic section steel products. It applies in the various branches and sectors of a nation

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