高速线材工艺设计

高速线材车间工艺设计及帘线钢质量控制技术摘要本设计是依据鞍钢线材厂设计的年产量55万吨的高速线材车间工艺。

典型产品为Q235、Φ6mm的线材。

设计说明书包括文献综述，车间工艺设计，专题三个部分。

在综述部分叙述了线材的基本知识和当前线材生产的状况。

设计部分（从第二章到第九章）主要包括产品方案及工艺流程的设计及制定、生产设备的选择、工艺参数的计算及校核、年产量计算、导位装置及轧机调整、车间平面布局设计及图纸绘制，还有技术经济指标与环保措施。

专题部分主要阐述了对帘线钢质量控制的方法及研究。

关键词：高速线材；生产方案；孔型设计；校核；帘线钢High-speed wire rod plant process design and quality control of steel cordAbstractThis design which is based on Anshan Iron and Steel Wire Factory is planted 550,000 t annual workshop for high-speed wire rod plant technology. Typical produce is the Q235,Φ6mm wire. Design specification includs literature review, workshop process design andproject. The literature review part describes the basic knowledge of wire rod production andthe current situation. Design part (from chapter to chapter IX) describes the main program andthe process of product design and development, production and equipment selection, process parameter calculation and checking, annual basis, the guide position adjusting device andmill,shop flat design and layout drawings, as well as technical and economic indicators and environmental protection measures. The major topics describes method and technology in quality control of steel cord.Keyword：High-speed wire; production program; pass design; check;Steel Cord目录摘要............................................................................................................................................I Abstract...................................................................................................................................II 1文献综述..............................................................................................................................1 1.1线材生产的基本知识...................................................................................................1 1.1.1线材的定义.........................................................................................................1 1.1.2线材的种类.........................................................................................................1 1.1.3线材的品种与用途.............................................................................................1 1.2生产工艺.......................................................................................................................4 1.2.1线材的生产工艺流程.........................................................................................4 1.2.2线材的生产特点.................................................................................................4 1.2.3线材生产轧机布置.............................................................................................5 1.3产品的质量控制...........................................................................................................6 1.3.1坯料控制.............................................................................................................6 1.3.2加热控制.............................................................................................................7 1.3.3轧制控制.............................................................................................................8 1.3.4冷却控制.............................................................................................................8 1.4生产的发展...................................................................................................................9 1.4.1轧制速度进一步提高 (9)1.4.2采用减径定径机组 (10)1.4.3无扭轧机...........................................................................................................12 1.4.4低温轧制技术...................................................................................................12 1.4.5采用控制轧制和控制冷却...............................................................................12 1.4.6无头轧制 (13)1.4.7采用低温轧制和温控轧制技术.......................................................................13 1.4.8广泛采用在线测径及涡流探伤仪...................................................................13 1.4.9高线轧机的其他新设备...................................................................................13 1.5本设计的目的和意义.................................................................................................14 2产品大纲及金属平衡表制定......................................................................................15 2.1产品方案的确定.........................................................................................................15 2.1.1产品方案...........................................................................................................15 2.1.2产品大纲...........................................................................................................15 2.2坯料的确定.................................................................................................................15 2.2.1坯料的选择 (15)2.2.2坯料的技术条件...............................................................................................16 2.2.3对表面质量与内部质量的要求.......................................................................17 2.3生产方案的确定.........................................................................................................18 2.4金属平衡表的制定................................................................................. (19)3主要设备选择及其参数设定......................................................................................20 3.1加热炉.........................................................................................................................20 3.2轧机参数.....................................................................................................................22 3.2.1粗轧机组设备参数...........................................................................................22 3.2.2中轧机组设备参数...........................................................................................23 3.2.3预精轧机组设备参数.......................................................................................24 3.2.4精轧机组设备参数...........................................................................................25 3.3冷却设备.....................................................................................................................26 3.4辅助设备性能参数.....................................................................................................28 3.4.1飞剪、摆动剪、卡断剪 (28)3.4.2吐丝机...............................................................................................................28 3.4.3集卷筒...............................................................................................................29 3.4.4立活套、侧活套...............................................................................................29 4产品工艺制度制定.........................................................................................................30 4.1生产工艺流程.............................................................................................................30 4.2加热制度的制定.........................................................................................................31 4.2.1加热目的...........................................................................................................31 4.2.2加热温度...........................................................................................................31 4.2.3钢坯的加热速度和加热时间...........................................................................32 4.3轧制温度的确定.........................................................................................................33 4.4延伸系数的确定 (34)4.4.1轧制道次的确定...............................................................................................34 4.4.2各道次延伸量的确定.......................................................................................34 4.5冷却工艺的确定.........................................................................................................35 5孔型设计............................................................................................................................36 5.1孔型设计的基本内容.................................................................................................36 5.1.1孔型设计的内容...............................................................................................36 5.1.2孔型设计的要求...............................................................................................36 5.1.3孔型的分类.......................................................................................................36 5.1.4孔型设计的原则...............................................................................................36 5.2线材生产中的孔型系统.............................................................................................37 5.2.1孔型类型...........................................................................................................37 5.2.2线材中孔型系统选择分析...............................................................................37 5.3孔型设计.....................................................................................................................38 5.3.1圆孔型设计.......................................................................................................38 5.3.2椭圆孔型设计...................................................................................................39 5.3.3箱型孔型设计...................................................................................................40 5.3.4连轧常数及轧制速度.......................................................................................40 6轧制力能参数及设备校核...................................................................... (42)6.1摩擦系数确定.............................................................................................................42 6.2轧制力计算.................................................................................................................42 6.3咬入能力校核.............................................................................................................44 6.4轧辊强度校核.............................................................................................................45 6.4.1粗轧机组轧辊强度校核...................................................................................46 6.4.2中轧机组轧辊强度校核...................................................................................47 7年产量计算.......................................................................................................................50 7.1轧机工作图表的绘制.................................................................................................50 7.1.1轧制节奏时间的确定.......................................................................................50 7.1.2轧机工作图表的绘制.......................................................................................51 7.2轧机年产能力计算 (52)7.2.1轧机平均小时产量...........................................................................................52 7.2.2车间年产量计算...............................................................................................53 7.3加热炉生产能力计算.................................................................................................53 7.4仓库面积计算.............................................................................................................54 8车间平面布置及主要技术经济指标........................................................................55 8.1车间平面布置.............................................................................................................55 8.1.1主要设备间距的确定.......................................................................................55 8.1.2车间原料仓库和成品仓库面积的确定...........................................................55 8.2 车间主要技术经济指标和环保..............................................................................56 8.2.1车间主要技术经济指标...................................................................................56 8.2.2能源消耗...........................................................................................................56 8.3环境保护对车间设计的要求.....................................................................................58 9专题 帘线钢的质量控制技术.............................................................................60 9.1生产工艺.....................................................................................................................60 9.1.1钢帘线的生产工艺...........................................................................................60 9.1.2钢帘线钢的生产技术.......................................................................................61 9.2对钢帘线钢的质量要求及控制措施.........................................................................61 9.2.1钢帘线钢的化学成分 (61)9.2.2夹杂物控制.......................................................................................................62 9.2.3中心偏析...........................................................................................................62 9.2.4有害气体含量及残余元素的控制...................................................................63 9.2.5表面质量及内部缺陷.......................................................................................63 9.2.6结构特性...........................................................................................................63 9.3钢帘线钢生产的现状和展望.....................................................................................63 9.3.1国内外部分钢厂生产钢帘线钢的概况...........................................................63 9.3.2钢帘线钢高强度化的努力方向.......................................................................64 9.3.3钢帘线钢生产今后的展望...............................................................................64 9.4结论.............................................................................................................................65 附录A 计算机C 程序代码...................................................................... (66)附录B 孔型图 (70)参考文献 (73)结束语...................................................................... (74)1文献综述1.1线材生产的基本知识1.1.1线材的定义线材是热轧型钢中断面尺寸最小的一种。