槽(cao)鋼(gang)加工說明(ming)：

槽鋼(gang)是截面(mian)(mian)為(wei)凹槽形(xing)的長條鋼(gang)材(cai)，屬建造用(yong)和機械用(yong)碳素結構鋼(gang)，是復(fu)雜(za)斷(duan)(duan)面(mian)(mian)的型鋼(gang)鋼(gang)材(cai)，其(qi)斷(duan)(duan)面(mian)(mian)形(xing)狀為(wei)凹槽形(xing)。槽鋼(gang)主要用(yong)于建筑結構、幕墻(qiang)工程、機械設備(bei)和車輛制(zhi)造等。

中國槽(cao)鋼(gang)(gang)(gang)(gang)的進口量大(da)于出口量。主要產地是唐鋼(gang)(gang)(gang)(gang)、包(bao)鋼(gang)(gang)(gang)(gang)、山鋼(gang)(gang)(gang)(gang)、黃(huang)特、馬鋼(gang)(gang)(gang)(gang)、宣鋼(gang)(gang)(gang)(gang)、日鋼(gang)(gang)(gang)(gang)等幾(ji)家鋼(gang)(gang)(gang)(gang)廠(chang)。

剪(jian)切工藝優化

問題分析

某鋼(gang)(gang)廠中(zhong)400mm機(ji)(ji)組是(shi)以(yi)生產(chan)中(zhong)號(hao)角(jiao)鋼(gang)(gang)和槽(cao)(cao)鋼(gang)(gang)為主的(de)型材機(ji)(ji)組，年產(chan)量65萬噸(dun)，其中(zhong)槽(cao)(cao)鋼(gang)(gang)產(chan)品規格為638～1208，產(chan)量約占總產(chan)量的(de)25%。成品槽(cao)(cao)鋼(gang)(gang)的(de)分(fen)段作業采用1臺400t冷剪(jian)機(ji)(ji)進(jin)行。槽(cao)(cao)鋼(gang)(gang)剪(jian)切(qie)(qie)質量對后(hou)續工藝，特別(bie)(bie)是(shi)焊接質量影(ying)響(xiang)較(jiao)大，若(ruo)剪(jian)切(qie)(qie)斷(duan)口處存(cun)在(zai)塌肩、毛(mao)刺、撕裂、切(qie)(qie)斜等缺(que)陷(xian)，則會使槽(cao)(cao)鋼(gang)(gang)對接時存(cun)在(zai)較(jiao)大縫隙，影(ying)響(xiang)焊接質量，特別(bie)(bie)是(shi)強度指標，從而(er)造成較(jiao)大的(de)安全隱患。

安鋼垂400mm機組隨生產節奏(zou)和產量的提(ti)高(gao)，上(shang)述剪切缺陷越(yue)來越(yue)突出，剪切質量內控達標率僅為94.2%。而且剪刃(ren)的使用(yong)壽命越(yue)來越(yue)短，平(ping)均每班更換一次，造成生產成本和職(zhi)工勞動強度(du)增加。針對這(zhe)些(xie)問題，從工藝、技術和操(cao)作(zuo)上(shang)進行(xing)了(le)認真分(fen)析，并提(ti)出了(le)相應(ying)改進措施，取得了(le)較(jiao)好效果。

1、工藝原因

該機組的(de)設(she)計能(neng)力為20萬(wan)t/a，但產量達到了(le)60萬(wan)t/a，冷床區生產能(neng)力不足(zu)的(de)問題很突出(chu)，與生產角鋼相比，槽鋼的(de)冷卻(que)速度較(jiao)慢，從而(er)造成剪切(qie)時槽鋼溫度較(jiao)高，極易出(chu)現塌肩、毛(mao)刺、撕裂(lie)等缺陷，并(bing)且對剪刃壽命(ming)的(de)影響較(jiao)大。

2、剪刃設計原(yuan)因

槽(cao)(cao)(cao)鋼(gang)剪(jian)(jian)(jian)(jian)(jian)刃(ren)設計的(de)基本(ben)依據是(shi)槽(cao)(cao)(cao)鋼(gang)成品(pin)孔(kong)型形狀，如圖(tu)1所(suo)示(以100#槽(cao)(cao)(cao)鋼(gang)為例(li))。這種設計在剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)過程中易(yi)出現(xian)(xian)(xian)以下問題：一(yi)是(shi)槽(cao)(cao)(cao)鋼(gang)兩(liang)(liang)肩(jian)(jian)部(bu)(bu)(bu)與其(qi)他部(bu)(bu)(bu)分相(xiang)比，相(xiang)對較厚，所(suo)需(xu)剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)力(li)也較大(da)(da)，剪(jian)(jian)(jian)(jian)(jian)刃(ren)磨(mo)損(sun)(sun)較快(kuai)，剪(jian)(jian)(jian)(jian)(jian)刃(ren)使(shi)用一(yi)段時(shi)間后(hou)。這一(yi)部(bu)(bu)(bu)分相(xiang)對磨(mo)損(sun)(sun)量大(da)(da)，致(zhi)使(shi)肩(jian)(jian)部(bu)(bu)(bu)間隙(xi)較大(da)(da)，易(yi)出現(xian)(xian)(xian)塌肩(jian)(jian)現(xian)(xian)(xian)象(xiang)；二是(shi)槽(cao)(cao)(cao)鋼(gang)兩(liang)(liang)腿與腰部(bu)(bu)(bu)處相(xiang)比，由(you)于(yu)剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)角(jiao)度的(de)影(ying)響，當剪(jian)(jian)(jian)(jian)(jian)刃(ren)磨(mo)損(sun)(sun)后(hou)，在剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)兩(liang)(liang)腿時(shi)，剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)量變小，腿部(bu)(bu)(bu)剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)由(you)通常的(de)剪(jian)(jian)(jian)(jian)(jian)斷(duan)(duan)變成了撕斷(duan)(duan)，槽(cao)(cao)(cao)鋼(gang)腿端面(mian)極易(yi)出現(xian)(xian)(xian)毛刺(ci)；三是(shi)上(shang)、下剪(jian)(jian)(jian)(jian)(jian)刃(ren)腿部(bu)(bu)(bu)斜(xie)度與槽(cao)(cao)(cao)鋼(gang)成品(pin)孔(kong)型基本(ben)一(yi)致(zhi)，這樣在剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)時(shi)腿部(bu)(bu)(bu)基本(ben)同(tong)時(shi)受力(li)，剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)力(li)較大(da)(da)，剪(jian)(jian)(jian)(jian)(jian)刃(ren)磨(mo)損(sun)(sun)較快(kuai)，一(yi)方(fang)面(mian)腿端剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)壓痕(hen)嚴重(zhong)，另一(yi)方(fang)面(mian)剪(jian)(jian)(jian)(jian)(jian)刃(ren)老化后(hou)，極易(yi)出現(xian)(xian)(xian)槽(cao)(cao)(cao)鋼(gang)剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)部(bu)(bu)(bu)分撕裂、毛刺(ci)較多的(de)現(xian)(xian)(xian)象(xiang)。后(hou)兩(liang)(liang)點是(shi)影(ying)響槽(cao)(cao)(cao)鋼(gang)剪(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)質量的(de)主(zhu)要(yao)原(yuan)因。