年产90万吨棒材车间设计毕业设计说明书摘要.doc

学 号：HEBEI UNITED UNIVERSITY毕业设计说明书摘要设计题目：年产90万吨棒材车间设计学生姓名： 专业班级：08金属材料工程2班 学 院：冶金与能源学院指导教师： 2012 年 5 月 31 日1河北联合大学毕业设计说明书（论文）目录I摘 要冶金工业是现代工业的重要组成部分。我国棒材的总产量在钢材总量中的比例超过40，在世界上是最高的。这是国内经济建设和出口需要所决定，我国过去底子薄、经济落后，基础建设任务重，必然在一定阶段，对建筑用棒材和机械加工用棒材需求较大。棒材的70%用作建筑，其余用作各种零部件用材。除螺纹钢筋直接应用于建筑之外，有相当部分加工成各种轴类零件。棒材的断面形状简单，比起线材一般断面大很多，因此散热慢，允许轧制时间长，头尾温差大的问题不突出，但上限产品容易压缩比不足。采用主要工艺流程为坯料 加热除鳞轧制（粗中、预精、精轧）冷却（水冷、风冷）打捆检查入库 。与其他热轧一样，为能轧制高尺寸精度的产品，必须保证加热均匀一致，轧机刚度尽可能的高，轧制中，做到冷却一致。轧制中还有磨损带来孔型的变化，影响轧制的持久稳定。棒材以直条交货，轧制单根棒条可以使用最小坯料，轧制道次也不是很多，降温不是主要考虑问题，因而把棒材轧制是所有轧材中最容易实现的品种。它可以有多种方式，从三辊横列式，到扭转二重式，从各种半连续式到全连续式，都能生产棒材，但其产量、尺寸精度、成材率、合格率却都大不一样。三辊轧机刚度低，加热温度的波动必然带来严重的产品尺寸波动，加上横列式速度慢、轧制时间长，导致轧件头、尾温差加大，容易尺寸不一致，并且性能不均，产量很低，质量波动很大，优质率极低。全连续轧机一般采用平立交替，轧件无扭，事故少、产量高，可以实现了大规模的专业化生产，这类车间一般达到年产95万吨左右。同时轧机采用高刚度，控制自动化程度较高，使尺寸精度和合格率得到很大提高。本设计按照任务书要求，设计年产90万t全连续式合金棒材车间。设计的主要依据是现代棒材生产工艺过程的理论，参阅了国内有关棒材轧机的先进工艺、轧机的装备、技术、孔型系统及一些辅助设备的论述。设计内容包括产品大纲分配，原料尺寸选择、轧机方式选择预布置比较。之后进行压下分配和孔型设计，完成速度和轧辊转速计算，绘制轧制图标，计算轧制节奏和年产量计算。进行各道温降计算，进而完成抗力和轧制力计算。接着进行轧辊力能校核，电机功率校核。最后进行辅助设备选择和车间布置设计，包括原料跨面积、加热炉能力、倍尺飞剪力能参数、冷床形式与面积等计算，还有金属平衡、水电消耗计算。设计规格分别为1232mm圆钢，在此选择16mm的圆钢作为典型产品进行该车间的设计。设计附有孔型图、配辊图及车间平面图。在设计说明书中，较详细地论述棒材生产的不同用途对尺寸精度、组织性能的不同要求。特别论述不同产量、不同精度、不同组织性能时，对棒材生产工艺、设备的各种对应设计。选择步进加热炉，保证坯料加热均匀，不出现低温水印。轧机全线平立交替，使轧件无扭转顺利行进。全线高刚度轧机，保证温度轻微波动时，弹跳变化较小。中轧到精轧留出20米穿水冷却段，可以采用控制轧制与控制冷却工艺，降低终轧前温度，使轧后轧件迅速进入单相区冷却。高刚度轧机还能实现全线低温轧制，进行特殊钢种的各种性能控制轧制。下面介绍一下棒材轧机的工艺和装备：1. 直接使用连铸坯直接以连铸坯为原料，已是小型棒材轧机可能在市场竞争中存在的必要条件。普钢小型轧机使用的坯料断面应在130mm130mm180mm180mm左右，坯料单重1.52.0 t，甚至达2.5 t。单重增加切头尾量相对减少，定尺率高，有利于提高金属的收得率。2.连铸坯的热装热送连铸坯在6501000的温度下，直接装入小型轧机的加热炉中加热，可使加热燃料消耗降低25 %75 %，同时，直接热装还可减少加热的氧化损失，减少或取消中间存贮面积，减少操作设备和人员，使基建和经营费用降低。直接热送热装的前提条件是：生产无缺陷的连铸坯。炉外精炼和连铸技术的进步，已能为小型轧机提供无缺陷的连铸坯。3.采用步进式加热炉可供选择的小型轧机钢坯加热炉炉型有：推钢式加热炉和步进式加热炉。步进式加热炉较推钢式加热炉有如下优点：1)加热均匀，断面温差小于20；无水冷黑印和阴阳面。2)加热速度快，氧化少，可减少脱碳。3)不会产生拱钢、粘钢事故；可防止划伤。4)操作灵活方便。4.高压水除鳞为了保证小型型材特别是优质钢的表面质量，在加热炉后粗轧机组之前设置了高压水除磷装置，以去除加热产生的表面氧化铁皮。高压水的工作压力达2022Mpa。5.低温轧制把轧件温度从10001100降低至900950，加热炉可大幅度节约燃料，综合平衡后可节约能源20% 左右。6.在线测径激光的单向性和抗干扰性优于其他任何波长的光波，以此为原理设计的激光测径仪用于在线测量轧件尺寸。总的看来，棒材生产的发展趋向和特点如下：1)过程日趋连续化，产量高、自动化程度高的连续轧制已经占取了主流，出现了连续钢坯轧机和连续棒材轧机，使效率大为提高。2)轧制速度不断提高，生产过程的连续化，为提高轧制速度创造了条件。3)生产过程自动化日益完善，大大减少了劳动强度，提高了质量，减少了车间定员，提高了经济效益。4)生产过程日趋大型化，炼铁炼钢能力大幅度提高。5)采用自动控制，不断提高产品的精度和质量，采用计算机控制可以大幅度提高产品的精度和质量。6)不断扩大钢材的品种规格和增加合金钢产品的比重。7)大力发展新工艺新技术，节约能源，减少金属消耗，降低成本。本设计年产量90万t ，品种为圆钢小型棒材厂，其规格分别为1250mm圆钢，1250mm螺纹钢，在此选择16mm的圆钢作为典型产品进行该车间的设计。本设计选用了18架高刚度短应力线轧机，采用全连续化布置的方式来进行生产，把16mm圆钢作为典型产品，进行孔型设计、轧制力计算、轧辊校核与控轧控冷。采用全连续式平立交替布置轧机，以保证产量减少事故。ABSTRACTThe metallurgical industry is an important part of modern industry. Our bars more than 40 percent of total output ratio of total steel is the highest in the world. This is the domestic economic construction and export needs of the decision; China has a weak economic foundation, economic backwardness, infrastructure and heavy task, inevitable at a certain stage of construction bars and machining large bar needs.70 percent of the bars used as a building, the rest used for a variety of parts materials.In addition to thread steel used in the construction, a considerable part of the processing into a variety of shaft parts. Requirements of standing timber in the higher yield strength, and to maintain a certain elongation. Mechanical parts require good machining performance; the organization also has certain requirements. As a construction material, improve the dimensional accuracy and mechanical properties of uniform, you can save a lot of steel, the same processing shaft, can also reduce turning and reduce costs.Sectional shape of the bars is much larger than the wire section, heat slowly, allowing the rolling time, temperature difference between head and tail of the problem is not prominent, but the maximum product easy compression ratio of less than. And other hot-rolled and can be rolled products of high dimensional accuracy, we must ensure that the heating uniform mill modulus as high as possible, rolling, so that the cooling consistent. Rolling, there is wear to pass the changes, affecting the lasting stability of the rolling.Bar to be delivered straight, rolling can be a single use of the smallest rod blank, rolling pass is not a lot of cool is not the main consideration, which is rolled in all the species most likely to achieve. It can have a variety of ways to reverse the double-row type from the three-roll, to a completely continuous, can produce bars from various semi-continuous, but its production, dimensional accuracy, and finished product rate, the qualified rate a big difference. Three roll mill stiffness is low, the heating temperature fluctuations will inevitably bring about serious size fluctuations, coupled with the row-type slow, rolling a long time, resulting in rolling the head, tail temperature increase, easy to match the size and performance is uneven. Yields are low, fluctuations in the quality; high-quality rate is very low. Completely continuous rolling mill generally flat stand alternately, rolling, twisting, fewer accidents, high yield, you can achieve a large-scale specialized production, the type of shop in general to reach an annual output of 950,000 tons. Mill at the same time high stiffness and a higher degree of control automation, dimensional accuracy and the passing rate is greatly improved.A simple bar shape of the cross-section than the general cross-section much larger wire, so slow cooling, allowing rolling a long time and big temperature difference between the beginning and end of the issue is not prominent, but the upper limit of compression ratio product less than easy.Bar may have a variety of modes of production for rolling. The past, the use of bar rolling mill bar, and then changed to double-type, semi-continuous and continuous whole. Low stiffness of three-roll mill, there will always be fluctuations in the heating temperature, combined with bar-style slow rolling a long time, resulting in rolling-piece, the end of temperature increase, size, inconsistent and uneven performance. Caused by the quality of difficult to meet the requirement. Continuous mill flat legislation generally alternate, rolled piece without twisting, fewer accidents, high output, thereby achieving a large-scale specialized production, these workshops generally reach an annual output of around 950,000 tons. The basic bar mill be eliminated.Here are some of the new bar rolling mill technology and new equipment.1. Direct the use of continuous casting As a raw material directly to continuous casting, rolling mill has a small bar in the market competition may be a necessary condition for existence. Normal steel mini-mill steel billet cross-section should be used in 130mm 130mm 180mm 180mm around single billet 1.5 2.0t, even up to 2.5t. Single-cut head and tail to increase the relative amount of reduction in length is high, will help improve the metal yield.2. Billet hot charging of hot delivery Billet 650 1000 in temperature directly into the mini-mill in the heat of the furnace can reduce heating fuel consumption by 25% 75% at the same time, DHCR can reduce the heat loss of the oxidation, reduction or the abolition of intermediate storage area to reduce the operation of equipment and personnel to reduce infrastructure and operating costs.Directly HCR is a prerequisite: the defect-free billet production. Secondary refining and continuous casting technology, mini-mill has been able to provide the continuous casting slab defect-free.3. The use of reheating furnace Choice of small-scale furnace steel mill furnace is: Pusher-type furnace and reheating furnace. Walking Beam Furnace Pusher-type furnace than the following advantages:1) Uniform heating, thermal cross-section of less than 20 ; no black mark and the water-cooled surface of yin and yang.2) Fast heating, less oxidation can reduce decarburization.3) Will not have arch steel, steel stick accidents; prevent scratches.4) Flexible and convenient operation.4. High-pressure water decalingIn order to ensure high-quality mini-profiles, especially the surface quality of steel in the furnace after the rough rolling mill group set up high-pressure water before removal device to remove heat generated by the surface oxide skin. High-pressure water working pressure up to 20 22Mpa.5. Low-temperature rolling High speed rolling mill, rolling in the rolling process of the thermal deformation, so that the basic rolling temperature remained unchanged or even to heat up, thus creating conditions for low-temperature juice. The rolling temperature from 1000 1100 lowered to 900 950 , furnace fuel savings can be substantial, comprehensive energy balance can be about 20%.6. Online caliper Laser and anti-interference of one-way better than any other wavelength of light as a design principle of the laser measuring diameter instrument for online measurement of rolling size pieces. Overall, bar production trends and characteristics of the development are as follows: 1) the process of becoming more continuous, high yield, high degree of automation of the continuous rolling has been allowed to crowd out the mainstream, there has been continuous steel bar rolling mill and continuous mill, so that the efficiency greatly improved. 2) Continuously improve the rolling speed, the continuous production process, to enhance the creation of the conditions of rolling speed. 3) The improvement in the production process automation, greatly reducing the labor intensity and improves the quality and reduces the number of the workshop to improve the cost-effectiveness. 4) The increasingly large-scale production proc