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装订线长春光华学院 毕业设计（论文）译文纸附录一 英文原文New Method for Evaluating Thermal Wear of Roils in Rolling ProcessAbstract: A new method was developed by a thermal wear machine to evaluate the thermal wear of rolls in steel rolling process .The steel strip and rolls were simulated by upper and lower heating disks .The upper heating disk could be kept at a temperature of over 900 by induction heating .The pressure between the disks as high as 323.2 MPa could be achieved and the slipping rate could be 12.7 The thermal wear of high speed steel(HSS)roll material ,the wear rate of the HSS roll , and the SEM morphology of a worn HSS roll surface were investigated .This method was useful and could be employed to simulate friction and wear between strip and roll during the strip roiling process.Keywords: thermal wear; roll; friction ; strip rolling ; Induction heating；ring rolling mill ; theory of ring rolling; ring rolling process ; PLCThe roll is one of the most important tools in the rolling process .Its surface may get worn out because of the relative slip between the roll surface and steels for the fast changes in both rolling force and temperature . In designing and calculating the wear crown of rolls , the roll wear is a very important factor and has to be taken into consideration ,as it can reduce the difficulty in controlling steel shape and increase the accuracy in the calculation model of the roll wear crown . Furthermore ,the accuracy in the calculation model of the roll wear crown .Furthermore ,the wear of the roll surface will directly affect the surface quality of steel . Therefore , it is significant to develop an approach method to evaluate the roll wear and to study the mechanism of roll wear based on friction theory.To date , many studies have been carried out concerning roll wear . For example , Kato developed a thermal wear equipment . Which is a disk shaped machine . However , it is difficult to simulate the wear between steel and toll during the rolling process , as the disk is small and thin , and the load is not very large . Glottal E and Li et alE . Studied the thermal wear attribution of wear resistant materials 9Cr2 and 3Cr2W 8V , and the thermal wear equipment they used was a pin disk machine , which could not be used to simulate the thermal wear of the roll . Liao used a small mill to roll the wire and studied the thermal wear of the roll with high Cr cast iron . However , this wquipment was a mill and the work piece that needed to be heated and rolled for stud ring the frictional wear . Thus , for some work pieces it was almost impossible to study the wear under different slipping rate and load for a long period.In this paper , the thermal wear test method is developed , which is a disk-like machine . The upper and lower disks are used to simulate the workpiece and the roll , respectively . The upper disk can be heated up to 900 through an induction coil . The load can be exerted as high as 323.2 MPa between disks , and the maximum slippage ratio is 12.7 .1.PrincipleTo evaluate the thermal wear of rolls , a new test machine was developed , which was disk-like on the basis of the 2-high 160 mm mill . The disk , drive shaft , bearing block , and forcing equipment were designed and manufactured . And the induction heating equipment was designed with a special shape to heat and lower disks could be used to simulate the workpiece and the rolls during hot rolling , respectively . The ratio of the slip between disks could be determined by the forward slip . The lower disk with different embedded materials could be employed to study the wear of the roll under some rolling condition .The original 2-high160 mm mill consists of motor-driven equipment , a reducer , and junctor The devices to be designed are disk , shaft , beraing block , forcing equipment , balancing spring , end cap , cushion ring , junction box , back plate , and so on . The high frequency induction equipment is designed as a special heating mode . (1)The dimension of the upper disk is 160 mm 30 mm and that of lower disk is 160 mm 50 mm . The disk material is 45 steel and the dimension of the experimental roll material is 10 mm 10 mm , which is embedded on the periphery of the lower disk . (2)The material of the drive shaft is 40Cr steel which is hollow for water cooling . The bearing block , the forcing equipment ,and the balancing spring are also designed .For this purpose . The GP10-C1 high-frequency induction apparatus is employed , and the induction power source and the parameters are listed in Table 1.The surface of the inverse upper disk is heated by the GP10-C1 induction power source according to the theory of skin effect of electromagnetic induction heating . The induction coil is specially designed as a semicircle for a continuous heating of the inverse upper disk . The experimental setup for testing thermal wear including the heater and water cooling system of the disks is schematically illustrated in Fig . 1 .The conductor material is T1 or T2 pure copper tube and the dimension is 10 mm 1 mm .2. Experimental To test the validity of the machine performance . Roll material of high speed steel(HSS) was embedded in the lower disk .The chemical composition of the roll material ( mass percent ) is listed in Table 2 .The original hardness of the experimental material was HRC 51.3 measured by HR-150ARockwell hard meter .The worn amount of HSS roll material under different loads and slipping rate was measured using the SARTORINS BSIIOS electronic balance after cleaning and drying . The morphology of the worn surface of the specimen was observed through a scanning electron microscope ( PHILIPS 505 ).3. Results and DiscussionThe wear ratio curve is presented in Fig.2 , which indicates the wear ratio as a function of cycles for in different slipping rates of S = 4.8 % - 12.7 % and loads of=141.5 323.2 MPa . In the experiment , the temperature of the upper disk was 900 , at which the wear was most severe . However , a decrease in the thermal wear owing to the oxide layer did not occur in this experiment . It could be seen that the wear ratio curve increased with increasing slippage and loads . Loads played a more important role than slipping rate for thermal wear . Some interesting effects were observed , for instance , wear ratio increased slightly before 1680 cycles . The reason could be that the roll surface was protected from wearing by the thin black oxide layer generated on it . The microstructure of the HSS roll surface has been investigated under different rotational speeds of the roll between the lower disk at 530 580 and the upper disk at 880 930 . Fig . 3 shows the SEM morphology of the HSS surface under variable rotational speeds when the slipping rate S is 12.7 and the load is 323.2 MPa . From Fig.3(a) , it can be seen that there is oxidized frictional wear on the HSS roll surface . From Fig.3(b)and Fig.3(c), it can be seen that it forms grain abrasion of the cavity for the oxide dropping as rotational speed increases . Fig.(d) shows that there is adhesive wear on the HSS roll surface for increased loads , and the wear mechanism is of oxidation wear grain abrasion of the cavity for the oxide dropping as the rotational speed increases . Fig.3(d)shows that there is adhesive wear on the HSS roll surface for increased loads , and the wear mechanism is of oxidation wear rain abrasion wear , and adhesive wear at the same time.The effect of abrasion occurs in contact situation where direct physical contact between two surfaces is given , and one of the surfaces is considerably harder than the other . The harder surface asperities press into the other surface wit plastic flow of the soft surface occurring around the asperities of the harder surface . When a tangential motion is imposed on the harder surface . The soft material is removed because of the combined effect of “ micro cutting ”and “ micro cracking ”.It is quite difficult to relate adhesive wear processes with elementary bulk properties of materials . The oxidation wear occurs because of high temperature of the combined effect of “ micro cutting ”and “ micro cracking ”.It is quite difficult to relate adhesive wear processed with elementary bulk properties of materials . The oxidation wear occurs because of high temperature of the roll . The oxide is diffused in the matrix the black oxide layer is exfoliated from the roll surface . Plasticity deformation slippage wear is caused by the deformation of the roll surface and the relative motion between the strip and roll .4.Conclusions(1)A new method was developed to test the roll s thermal wear by a test machine with a disk pattern . High frequency induction equipment was used to heat the upper disk . The temperature of the disk could be over 900 .(2)The thermal wear of the high speed steel roll was investigated . The wear rate curve and the SEM morphology of the HSS roll surface wear were obtained .(3)It is useful to investigate the mechanism of roll wear in strip steel roiling process by this method . The authors would like to thank the National Natural Science Foundation of China ( Grant No. 0534020 )and the Shanghai Baosteel Group for their financial support .The ring rolling process has important influence on quality and cost of the forging ring .To improve quality and induce cost , it must be done to change the old ring rolling process and heighten the automation level of ring rolling mill . This paper , to meet the need of the factory project , does a research on the new ring rolling process and carries it out.First , this paper makes a summary of all disadvantages that exit on old ring rolling mill in the producing process . According to the theory of ring rolling , this paper does a research on these questions , finds a new ring rolling process , and makes a total scheme to carry it out . Secondly , according to the total scheme , this paper makes a design on the mechanism of the numerical ring rolling mill , and according to new ring rolling process , does a detailed design for every mechanism . The ring rolling process , does a detailed design for every mechanism . The ring rolling mill mechanism includes active roller mechanism , feed mechanism , support mechanism , hold mechanism and so on .Then , according to original parameters , this paper calculates working load and running speed of hydraulic cylinders , designs the hydraulic circuit that meet the needs , draws the schematic diagram of hydraulic system and the table of the working sequence of electromagnets . After these , this paper calculates working parameters of hydraulic system , and chooses the style of hydraulic cylinders , hydraulic pump , driving motor .Finally , according to the new ring rolling process , this paper designs the automatic control system and writes program codes . It disassembles the whole mission of the automatic control system , chooses the style of PLC controller and other electrical equipments , designs input and output electrical circuit , assembles the hardware , and writes the program codes , designs the desk of the touch screen .Through doing a research on the theory of ring rolling , this paper finds these disadvantages could be avoided by improving the old ring rolling process . Through making a design on mechanism , hydraulic system , and automatic control system , this paper finds this scheme of numerical ring rolling mill is enable to carry out , is not complex , and its cost is acceptable . So , the new ring rolling process is significant and valuable to true production in the factory .Cold ring rolling is a technology to produce high precision and performance seamless ring ,which is widely used in machinery , automobile ,boat and ship , metallurgy , chemical industry , aeronautics and astronautics . Cold ring rolling machine is an equipment to realize cold ring rolling , whose numerical control system characteristics have great effect on processing precision , processing stability and processing efficiency . With the development of cold ring rolling , it has provided some new ideas in this field . According to the actual working conditions of t e vertical cold ring rolling machine with single following guide roller ,the kinematical models of cold rolling rectangular cross section ring and ball ring were established respectively , the diameter variation rules of both rings were analyzed and the guide roller motion rule under certain rolling condition was researched . A systematical design method of the guide roller motion was developed according to the ring rolling process , and a MATLAB program was programmed to solve the design parameters . Accurate control of the guide roller motion has great benefit to the precision of cold rolling ring . The research can be used as a guideline for design and manufacturing of cold ring rolling machine . According to the heating problems of annular blanks formed by isothermal extrusion technology with the copper alloy solid roller bearing cage , a automatic heating equipment is presented to combine the process of delivering automatically with the process of heating organically, with the purpose of improving the heating quality , raising the heating efficiency , reducing the labor intensity , as well as satisfying the require of industrial production .The appropriate pre tightening of the composite housing can ensure steady operation and high machining precision of machine tools . In this paper , the analysis and design of the tightening bolt joints were carried out about the housing of precision cold ring rolling mill , and the mechanical behaviors of the housing when it was working in six cases of preload were analyzed by the method of three dimension finite element , the optimal preload and coefficient of tightening are presented , the magnitude of system error produced by elastic deformation is ascertained ,the method of improving machining precision was discussed , references were provided for the design of precision cold ring rolling mill . Base on the nonlinear characteristic of cold ring rolling machines manufacturing procedure , Design the numerical real -time measurement and online control system of cold ring rolling machine . The center of system is PLC . The PLC corporates with human machine interface . They control hydraulic system , measurement system , feeding servo system effectively . It makes cold ring rolling machine realize co-loop and automatic operation . The numerical control system can provide high precision and high efficiency of ring rolling . Cold ring rolling is a high-efficiency metal plastic forming technology for manufacturing seamless rings , which is widely employed in many industrial fields of machinery , automobile , metallurgy , chemical engineering , energy sources , aeronautics and so on. Ring rolling mill is the indispensable equipment for ring rolling production , as well as the working parameters are the core references for mill design .In order to suit the manufacturing needs of medium and smalt batch production with a variety of products and improve the manufacturing efficiency and flexibility ，a hierarchical distributed computer control system hardware and integrated software are developed . In 1842 , the ring rolling technique was invented in Britain .Beside the railway wheels , the technique was used to produce the seamless rings such as bearing ring, gear r ing, aircraft turbine ring , press vessel ring , weld-neck flange ring , etc . The machine has improved quite remarkably after an experimental research done by Hawkyard and Johnson in 1950 . This has thus appeared some sequence of numerical control machines for rolling different across-section seamless rings . The traditional trail-and-error method was replaced last 15 years as a result of numerical simulation research method of the ring rolling process with the development of the finite element (FE) theory and the wide application of the commercial finite element codes . However , the ring rolling process not only holds the attributes of the plate rolling, asynchronous rolling and multi-way rolling ,but also relates to the feed movement of the mandrel roll and axial rolls , the rotating movement of the main roll , the guiding movement of the guide rolls as well as the rotation of the ring itself with the diameter expanding movement . Therefore , it is rather complicated to simulate the metal flowing process in Corresponding author. Which integrated with the real-time change of movement parameters of all rollers, so it is also still a bottleneck in the virtual ring rolling research. In this paper, some key technologies on the virtual ring rolling are firstly presented . Secondly , related solution schemes are given out accordingly . Lastly , three different profile rings are simulated by the virtual ring rolling method . The structure design of a high flex stretch forming machine with multiple clamps has been described in the text . Firstly , the configuration and the stretching mode of the usual skin stretch forming machine have been analyzed in order to find out the shortages which could be improved . Secondly , the corresponding stretch forming process has been studied as per the needs of different aircraft skin shapes , which is to determine the structural arrangement of the stretch forming machine . The clamps of the stretch forming machine have been designed correctly to realize the high flexible forming process . Finally , the test proves the good stretching result . Perform design by the three-dimensional finite element method has been carried out for plain ring rolling and T-section profiled ring rolling . The application of the backward tracing scheme for perform design in ring rolling processes demonstrates , for the first time , the extension of the scheme into three dimensions . The preform design in plain ring rolling aims at obtaining a preform which simulates a final plain ring product with uniform axial height . Loading simulations were carried out for two progressively modified preforms derived from the result of loading simulations with a rectangular-shaped ring . Then , backward tracing was applied to obtain a final preform for the specified product configuration of uniform axial height . The preform in the T-section profiled ring rolling process was to be designed to simulate a final profiled ring product with complete filling in the groove and uniform axial height . The final preform shape for plain ring rolling was selected as a trial preform in T-section profiled ring rolling . A more satisfactory preform was obtained from the backward tracing results . It was shown by forward simulation that the final preform was good enough to satisfy the design criteria .Cold rolling is at room temperature, the ring parts squash and stretch, forming a processing method. Currently, the precision cold rolling can be divided into two kinds of closed and open. Due to open cold rolling pressure is less than closed, longer die life, it is now rolling in the axisymmetric part using more. In the open rolling process, the main parameters should be controlled rolling rolling speed and the final size of the workpiece. Because the stability of ring rolling speed, reasonable, and determines the shape of the workpiece accuracy and processing efficiency in non-closed loop control will also affect the size of dimensional accuracy. Dimensional accuracy of cold rolling of the workpiece has been plagued precision cold rolling process bottlenecks, the generalProcess control of a fixed size of less than desired accuracy. 1. The process control system in the more advanced open-precision cold ring rolling machine, mainly used by computer-controlled electro-hydraulic proportional control technology. 1.1 It is the one command parameter computer or PLC through the cold rolling process according to the given control signal. It is with the feedback signal has the same form and magnitude. One can advance into control commands from the computer (or PLC) have instructions to read parameters can also be keyboard input and revision. 1. 2 regulator Setting the signal and the actual value achieved (feedback) between the comparison, the deviation value and deviation value after a certain transmission characteristics of the amplifier, as a control input proportional valve. Transfer characteristic is usually determined by the PID regulator adjusted by the adjustment of the PID regulator to make the system stable, sensitive and accurate work. 1. 3 internal proportional valve is divided into two parts, namely, electrical - mechanical and hydraulic magnification converter components for general use with the valve components within the detection feedback proportional valves in order to improve control precision. Electro - mechanical converter is to convert the amplified electrical signals proportional to the amount of its electrical power or displacement by the force or displacement control to change the hydraulic fluid resistance amplifier stage, the hydraulic amplification, the small electrical control signal amplification to the required rolling force. Now commonly used cold ring rolling machine than the Closed-loop flow control valve and the proportion of cases the direction of the valve, from the use of effect, the closed-loop proportional directional control valve has a better, which is due to zero overlap with the control medium, no dead zone. 1. 4the implementation of the hydraulic cylinder hydraulic cylinder components, used to drive the main block have rolling pressure, the cold rolled over in the heavy load of the working stroke, the return load is small, it is commonly used single-rod hydraulic cylinders. In order to improve system response, the hydraulic cylinder to reduce friction as possible.1. 5 detection feedback in the process of cold rolling, rolling on the workpiece to detect the speed and size, usually by rolling speed of grating and size of the detection and feedback. With a proportional valve spool displacement sensor itself also provides a testing and feedback, it can also feedback into the regulator, the formation rate of semi-closed loop control. 2.speed control According to open cold rolling process requirements, cold ring rolling process is generally divided into four stages, each stage has its own rolling speed requirements. Open cold ring rolling machine speed control is usually three, that is, open-loop control, semi-closed loop control and closed loop control. In Figure 1, without the detection of the feedback signal, and non-proportional valve spool position feedback, is the open-loop control. Since open-loop speed control system without feedback, can not be made to various disturbances automatic correction and compensation, the control accuracy is not high, workpiece accuracy, has been less used. Semi-closed loop control using a proportional valve spool position on the detection device as a feedback for speed controlSystem, in some interfering factors are under control to meet the needs of cold rolling process. In Figure 1, as long as there is a feedback speed signal detection, can be considered a closed-loop speed control. Closed loop speed control is usually done by direct measurement of the slider displacement, or grating size of the workpiece. The displacement signals are received on time, real-time micro-processing speed signal as feedback, used for speed control, speed control in the three highest accuracy in its control, the strongest anti-interference ability, but its implementation is more complex. 3 Size Control In the cold rolling process to the end, not only speed control is more important is to control the size of the workpiece.Precision cold rolling because one of the purposes is to be the same size piece of cold rolling. In precision cold ring rolling machine size control valve is usually used. In theory, only the closed-loop system is controlled with a true sense of the size control. In the non-closed loop control system is usually positioning control. Size in cold ring rolling machine control, a deceleration is proportional electro-hydraulic position control positioning, it is the use of closed-loop system in the non-travel switch a stop signal, and then transfer control object by pre-uniform deceleration ramp signal to stop. In this position control in general there is a slow deceleration control and secondary control points. Second deceleration is to use two limit switch, at the second deceleration control, that is, after the first deceleration rate to be reduced to a variety of the same speed, and then continued forward movement in this low-speed short distance at the second limit switch for final braking. This is because the deceleration position control, the constant availability of high speed braking final positioning accuracy. The other is the end of travel position feedback position control, this is the real sense of self-control position control. As the cold rolling process, only the final size of the workpiece to size control of the final forming of the workpiece position control, so the workpiece into the final period before rolling, the starting position of footInch feedback, the feedback in Figure 1 2 shows the size of the feedback detection, the size of the brake and signal feedback to the regulator input, feedback loop control system constitutes a dimension. This slope is independent of time and electronic braking, only size, and therefore, can overcome the braking speed, friction and temperature changes and other factors of interference, by accurate stops. According to the requirements of cold rolling technology, when in the ring rolling rolling rolling amount is greater than the minimum amount (ie, rolling a certain speed), less than the minimum amount of rolling will affect the stability of forming and rolling. However, positioning the front brake in the final rolling process will produce less than the minimum amount of rolling rollingThe amount of pressure situation, in order to reduce its negative effects, as far as possible to shorten braking rolling rolling is less than the minimum amount of time and size of the control order system does not vibrate, then the natural frequency is to limit the transmission time of the main brake factors. High natural frequency can be obtained not only shorter braking time, but also help to improve control precision size, so should be considered during the design to maximize the transmission system natural frequency (typically rolling machine tools inherent in the transmission system lower frequency). As cold ring rolling machine drive system, mainly through a single rod hydraulic cylinders to achieve, can be seen from the above analysis, in order toGet a better process control, cold ring rolling machine in the design phase of mechanical and electrical integration technologies should be applied to the machine tool mechanical structure, electrical and hydraulic system control and feedback analysis of the integrated whole, the best use of computer technology to measure the system , simulated and should reach all parts of the performance index, and the overall system is optimized.From a theoretical prospective there is no restriction in simulating the process by the Inite element method . In practice however, without application of some special assumptions, simulating the M.R. Forouzan et al. / International Journal of Mechanical Sciences 45 (2003) 19751998Fig. 1. Schematic illustration of radialaxial ring rolling machine.Process is highly time consuming due to the following reasons:1. Complicated geometry of the tooling andthat of the work-piece, which requires huge amount of elements.2. Variations in geometry of the work-piece make it impossible to have a steady-state solution .3. Large number of ring rotations due to small actual closure rate of the roll gap.4. Complications in contacts associated with very high strains, distortions, displacements and rotations during the process .Yang and Kim gave the Irst FE solution. In this two-dimensional solution, the simulation wascarriedout only within andvery adjacent regions of the roll gap. The microstructure changes could then be anticipated for a very short rolling time. Using similar idea, Xu et al. gave a three-dimensional solution for a rigidplastic material and a thermo-coupled rigid visco plastic material .Among the ideas that were proposed to reduce the solution time are the pseudo-plane strain and the axi symmetric forging approach given by Tszeng and Altan and Joun et al. Kimet al. undertook the Irst complete solution of ring rolling by using two mesh systems, one set as the computational mesh within the roll gap vicinity which does not rotate and another Ine set of mesh all through the body as the material mesh in which the elements history are preserved.This technique was also usedby Hu et al. andLim et al . Xie et al. considerably reduced the computational cost by assuming a steady-state condition for each revolution of the ring and as a result they were able to analyze rather complicated ring shapes. Arbitrary Lagrangian Eulerian (ALE) formulation in which mesh distortion is independent of metal 7ow so that the mesh distortion is avoided and the Ine mesh can be maintained with in the roll gap has been considered by Hu and Liu , Davey and Ward.1.1. Previous works concerning the guide rolls simulation Guide rolls are part of the main equipment of a rolling mill. The mechanism, which moves these rolls,is shown in Fig. 2. The task of this mechanism is to keep the ring central with respect to the symmetrical plane of the mill, keep contact with the ring and prevent it from tilting. Experimental investigations verify that under ordinary conditions the guide roll forces are several times lower than that of the rolling forces. This is why in most of the theoretical analysis and numerical simulations the guide roll e4ects are not considered. Some investigators have proposed a few methods for simulation of this part of the mill but none of them has considered the guide rolls e4ect on process parameters.Hu et al. Tried to model the guide rolls with two frictionless cylindrical surfaces. As the hydraulic pressure keeps the rolls in contact with the ring, the position of these cylindrical surfaces has to change with respect to the increase in ring diameter. He approximately computed the guide rolls positions by assuming volume constancy of the ring. The method that was used by Lim et al. Is very similar to the one used by Hu et al. He also modeled the guide rolls by two frictionless cylindrical surfaces and the guide rolls positions were estimated by the FE solution of the previous step. Xie et al. used two solid cylinders for the guide rolls simulation. Davey and Ward were able to stabilize the process by applying special boundary condition to some of the nodes,which are located on a radial plane using special features of the ALE method. TraorPe et al. Included an additional independent equation to the FE formulation, which applies a kinematical constraint to the ring geometrical center.2. The thermal spokes methodThe thermal spokes method, which was Irst proposed and used by the authors, was shown to be an Hcient method for simulating of the guide rolls in two-dimensional simulation of plain ring rolling process. In this method, a number of one-dimensional elastic elements connecting a central point of a ring to a series of nodes equally distributed around the circumference. These elements are introduced to with stand any load arising from the guide rolls whose purpose is to maintain the ring in a centralized location with respect to the mill. In order to compensate for elongation arising from ring expansion these elements are subject to temperature change. The use of temperature change is to compensate for expansion to avoid any unwanted forces on the ring from these elements. If the number of links is high, the sti4ness of each links becomes so small that small error in prediction of the temperature will not in7uence the deformation behavior local to the spokes connection points. Hence, for the FE simulation the guide rolls are replaced by these imaginary links as an adapter of the guide rolls e4ect on the work-piece during the process. The spokes prevent tilting of the ring proportional to the actual of the mill components.Fig. 2. Schematic illustration of guide rolls adjustment mechanism.附录二中文原文在轨制过程轨辊磨损热评价的新方法摘要：新方法是有热磨损及其发展到评价在轨刚过程中的热辊的磨损。在带钢和卷，模拟了上下加热盘。上部加热盘可能维持在超过900感应加热温度。高达323.2兆帕斯卡的压力磁盘可以实现，下滑速度可能是12.7%。在高速钢热磨损（高速钢）辊材料，高速钢辊的磨损率和磨损的高速钢轨辊表面的SEM形貌进行了研究。这种方法是有益的，可以用来模拟之间的摩擦和磨损带翻滚过程。关键词：热磨损；辊；摩擦；带轨制；感应加热；辗环机；环件轨制；轨制工艺；PLC在轨制过程中辗轨是最重要的工具之一。它的表面可能会磨坏，由于刚辊表面和相对滑移出两个轨制力以及温度变化较快。在设计和计算扎辊磨损量时，轨辊磨损是一个非常重要的因素。在控制钢铁形状以及辊磨损计算模型的准确性时它可以降低难度。此外，辊面得磨损将直接影响钢材表面质量。因此，重要的是建立一个适当的方法评价辊磨损，并且基于摩擦理论基础研究滚动磨损。到目前为止，已经开展了许多关于辊磨损的研究。例如，加藤发展无热磨损设备，这是一种盘状成型机。然而，很难模拟轨制过程中的钢辊之间磨损磁盘，因为它不但小而且薄，而且负载不是很大。郭，李等人研究了磨损的热磨损的归属，耐磨材料9Cr2和3Cr2W 8V和热磨损的设备，他们使用的磁盘机的引脚，不能用来模拟轨辊的热磨损。廖某使用了一个小厂推出的电线，并研究了以高铬铸铁轨辊的热磨损。然而，这一设备是为了工件加热和辗轨进行磨损研究而推出的。因此，对一些工件，研究不同滑移率和长期负载的磨损这几乎是不可能的。在这篇论文中，热磨损测试方法很先进，它像一个计算机磁盘。上下磁盘来模拟工件和辗轨，分别是 上层磁盘可以通过加热到900诱导线圈。在可以达到323.2兆帕斯卡的磁盘之间产生高负载，最大滑移率为12.7%。1.原则评价热辊磨损的一个新的实验机研制成功，这是一个类似于盘型的直径为60毫米的轨机。有磁盘，传动轴，轴承座和感应加热设备。设计了有特殊形状的上盘其温度可以高于900摄氏度。上下盘可以用来模拟在热轨工件和辗轨的分别，它们之间的滑移率磁盘可以由前滑决定。嵌有不同材料的低磁盘可以用来研究在某些条件下轨制辊的磨损。原来的2米高的直径为160毫米的轨机由马达驱动，交连设计的设备是磁盘，轴，轴承座，平衡弹簧，端盖，垫环，接线盒，背部板等等。高频感应加热装置的目的是为一个特殊的加热方式。（1）上盘的尺寸是直径为160毫米乘以30毫米，低磁盘的直径为160毫米乘以50毫米。磁盘材料为45号钢和实验卷筒材料它的直径为10毫米乘以10毫米，嵌入到下盘的边缘。（2）驱动轴是40Cr钢材料及其空心水冷却。轴承座，受压设备，以及弹簧的设计也是这样的。为了这一目的，GP10-C1采 用的是高频的感应设备以及感应电源的参数见表1.在磁盘的表面上加热的GP10-C1的感应电源是根据皮肤的电磁感应加热效果的理论。感应线圈是专门为了一个磁盘上的逆持续加热半圆形来设计的。实验热磨损测试时，包括磁盘的热水器和冷却水系统图1做了简单的说明。导体材料的T1或者T2纯铜管的尺寸为10毫米乘以1毫米。2.实验 为了测试机器的性能有效性。辊高速钢（HSS）材料嵌入在较低的磁盘。这个项目的材料（质量百分数）的化学成分于表2.实验材料是原来的硬度通过HR150ARockwell的硬度计测量。高速钢的辊磨损量的材料在不同的载荷和滑动率测定后使用，对试样的磨损表面的形貌是通过扫描电子显微镜（PH值为ILIPS 505）观察。3.结果与讨论磨损率曲线图提出，这种显现表明在不同的下滑率样本中作为一个周期函数的磨损率S是从4.8%到12.7%之间以及载荷为141.5到323.2兆帕斯卡。在实验中，上盘的温度为900，磨损最为严重。然而，在氧化层的保护下热磨损会减少这个现象在本实验中没有表现出来。可以看到磨损率滑动的曲线随着负载而增加。负荷比下滑起到了更重要的作用。我们观察到了一些有意思的现象。例如，转速在1680转以下，它的磨损率上升较小。原因可能是轨辊表面由黑色的薄氧化层保护。在不同的旋转速度下观察高速钢轨辊表面的微观结构，其下盘温度在530摄氏度到580摄氏度之间，上盘温度在880摄氏度到930摄氏度之间。图3显示了可以改变转速的高速钢下面的高速钢表面的SEM的形貌，其打滑率S为12.7%以及负载为323.2帕斯卡，图3（a）中可以看到表面氧化摩擦，磨损的高速钢轨辊可以由 图3（b）和图3（c）看到，提高转速氧化磨损率会下降。图3（b）表明，在有负载增加时高速钢轨辊表面有黏着磨损时候，它的磨损机理是氧化磨损。当两个表面发生直接的物理接触时，并且当认为是其中一个表面比另一个表面硬时，磨损现象就会发生。随着比较柔软的表面在比较坚硬的表面的粗糙物的周围发生塑性变形时，后者的粗糙物压入前者的表面。当比较坚硬的表面发生切向的运动时，由于微犁削、微切削和微崩裂的联合作用时候，比较柔软的部分被去除。由于高温碾压会发生氧化磨损，将粘合磨损与材料的基本属性联系时是很困难的。氧化物在模具中扩散，随即黑色氧化层就会从轨辊表面脱落下来。塑性滑动磨损是由于轨辊表面的塑性变形和辊子之间的相对运动而引起的。4.结论（1）一种新的方法来测试测试机器磁盘模式辊的热磨损。高频感应加热装置是用来加热上盘。盘的温度可以超过900摄氏度。（2）高速钢轨辊的热磨损的影响。磨损率曲线和高速钢轨辊的表面获得了SEM形貌。（3）在带钢轨制过程中，用这种方法研究辊的磨损机理是很有效果的。辗环机环件轨制工艺对环件的质量和生产成本有重大的影响。为了改善产品的质量，减小生产的成本，必须改进现有的环件的轨制工艺过程，提高辗环机的自动化程度。本文基于对实际工程项目的需要，对数控辗环机的新型环件的轨制工艺动作进行了研究，并且予以实现。首先，这部分调研和总结了普通辗环机在实际生产中存在的各种工艺问题，根据环件的轨制理论对现有问题进行分析和研究，提出了一种新型的规制工艺，给出了实现这一工艺的数控辗环机的总体实际方案。其次，根据总体设计方案设计了数控辗环机的机械结构。根据工艺要求对每个机构进行详细的设计，确定了机构的尺寸以及彼此之间的位置关系。新型辗环机的结构部分包括了主动辊机构，推进机构，支撑机构，抱紧机构等等。然后，根据原始参数，计算各个液压缸工作的负载和运行的速度，设计出满足环件轨制工艺要求的液压回路，制定液压系统原理图和电磁铁的动作表，再进行液压系统参数的计算，确定液压缸，液压泵，驱动电机的型号。最后，根据工艺要求进行辗环机的电气控制系统的设计。把控制系统的任务进行分解，选择PLC控制器和其他的电气设备型号，设计PLC输入输出电路并且组建硬件的部分，编写PLC程序，设计触摸屏的控制界面等等。对环件的轨制理论的研究，发现普通的辗环机中存在的问题可以通过改进环件的轨制工艺动作予以避免。通过对数控辗环机的结构，液压和控制系统的设计，发现满足这套工艺的机械设备在设计方面是可以实现的，操作不是很复杂，成本也是在可以接受的范围之内。为此也会提出这一新型环件轨制工艺具有很好的实际意义和应用价值。冷辗扩是一种生产高精度、高性能无缝环件的技术，该技术在机械、汽车、船舶、冶金、化工、航空航天等领域中有着广泛的应用。冷辗环机是冷辗扩加工技术的具体实现设备，辗环机的数字控制系统的好坏将直接影响到辗环机的加工精度、辗环加工过程的稳定性以及辗环机的加工效率。随着智能控制技术的发展，智能控制技术逐渐应用到了多种的机械设备控制中。根据立式单导向辊的随动导向冷辗环机的实际工况，建立了矩形截面环件和深沟球截面的冷辗扩的运动学模型，分析两种环件的直径变化规律，研究了一定的辗扩工艺条件下导向辊的运动规律。建立了根据冷辗扩工艺来确定导向辊运动的一整套设计方案，并且运用MATLAB来编写求解程序用以求解所有的设计参数。精确地控制了导向辊的运动规律有利于提高环件冷辗扩的精度。研究结果为冷辗环机的设计制造提供了依据。组合式机架适当的预紧对保证机床的稳定运行和高精度的加工要求十分重要。对精密冷辗环机机架的螺柱联接进行了分析和设计，并且运用三维有限元法对6种预紧力工况下机架工作时的力学进行了分析和研究，给出了适当的预紧力和预紧系数，确定了机架工作时弹性变形造成的系统误差的大小，讨论了提高加工精度的方法，为了精密冷辗环机的设计提供了参考。针对冷辗环加工过程非线性的特点,设计了对冷辗环机加工过程实时测量和在线控制的数字控制系统。该控制系统以PLC 为核心,通过PLC 与人机界面相互配合有效地控制液压系统、测量系统、进给伺服系统,实现冷辗环机闭环控制下的全自动加工,应用证明该系统实现了环件轧制的高精度、高效率。冷辗扩成形是无缝环件生产的先进塑性加工方法,在机械、汽车、船舶、冶金、化工、航空航天等领域中有着广泛的应用。辗环机是冷辗扩成形加工的必需装备,其工作参数的确定是辗环机设计的核心问题,为了高效率生产出高质量的环件,辗环机除了需要具有良好的运动学特性外,还要具备良好的环件加工的动力学特性。为了适应多品种、中小批量环件的生产、提高生产的效率与柔性，已经开发了辗环机的分布式多机控制系统硬件及相应的集成软件。系统硬件与软件模块化 智能化设计思想，有利于提高系统的实时处理能力及运行可靠性、同时系统扩充容易，维护方便，为建立辗环机柔性制造单元与系统提供了良好的条件。1842年，环轧制技术发明于英国。旁边的铁路车轮，该技术被用来制造。如轴承环，齿圈，飞机涡轮机的无缝环响，按下船环，焊颈法兰圈等该机具有相当显着改善实验后研究通过Hawkyard和约翰逊在1950年。这从而出现了一些数控机床序列在轧制不同截面的无缝环。传统的径和误差的方法取代过去的15年为一个数值模拟研究方法的结果环滚动的有限元（FE）的发展过程理论和有限元广泛的商业应用然而，环轧制过程不但拥有的属性板的轧制，异步轧制与多路滚动，而且还涉及到芯棒辊和进给运动轴向辊，主辊旋转运动的指导该指南的运动辊以及轮换环的直径扩大运动本身。因此，是相当复杂的模拟过程中的金属流动 。这与运动参数的实时变化的一个综合 。所有滚