Application of ultrasonic technology in steel drum process (2)
Wang Chengxian, a barrel factory of Baoji Company, a Sinopec sales company
V. Application of ultrasonic technology in steel drum manufacturing
1. Use ultrasonic cleaning to clean the steel drum. In 1992, the author discussed the ultrasonic cleaning steel drum and reached a cooperation intention with Shanghai Ultrasonic Instrument Factory. After the funds were not implemented, it was unsuccessful.
Among the hundreds of steel drum production plants in the country, there are not many enterprises whose surface coating quality is stable, and the poor quality of pre-coating treatment is an important reason. Many manufacturers do not carry out pretreatment (deoiling, descaling and phosphorus). ()). Most manufacturers with cleaning equipment use old-fashioned spray cleaning with degreasing aids. Due to insufficient heating, the effect of degreaser is not good, and the treatment effect is very poor. It is difficult to ensure the surface quality of the steel drum.
Ultrasonic cleaning leather is used in addition to the strong acid, organic solvent, gasoline and other environmentally friendly cleaning agents used in traditional degreasing, descaling and decontamination methods. It is equipped with special water-based cleaning agents to remove degreasing, descaling, decontamination and phosphating. The processing process becomes fast, clean, improves the environment, is simple and easy, reduces labor intensity and can be automated, thereby improving labor productivity and economic efficiency.
The structure of the ultrasonic cleaning device is shown in Figure 2.
Figure 2 Schematic diagram of ultrasonic steel drum washing machine
1-suspension conveying device; 2-steel crucible; 3-cleaning liquid; 4-ultrasonic electric pool; 5-bathing waste heat exchanger; 6-filter; 7-water pump; 8-pipe
2. Ultrasonic steel barrel spot welding machine. At present, the barrel industry uses resistor welding spot welders. The installed capacity is between 31-100 kVA, which consumes a lot of energy. Due to grid instability and spot welding operations in many areas, over-welding, over-burning and soldering are caused, which affects product quality. If the steel barrel ultrasonic spot welding machine is used, the power can be reduced to 1~3kW and the energy saving is 90%. With the PC, the welding parameters such as ultrasonic frequency, specific vibration power, duration and pressure can be automatically controlled to ensure the welding quality.
Ultrasonic welding uses a frequency of 20 to 100 kHz and an amplitude of 1 to several tens of micrometers. It does not generate heat during welding. It does not require careful cleaning of the surface of the steel sheet. Physical and chemical changes do not occur on the welded surface. If welding steel drums can save the bottom process, the benefits are obvious in terms of investment and processing costs.
The principle of ultrasonic welding is to use the waveguide perpendicular to the interface of the two workpieces to be welded to guide the ultrasonic vibration into the contact area of ​​the workpiece to be welded, press the workpiece against static pressure, and modulate the specified ultrasonic gauge for welding. Time (10 seconds) can be welded. Ultrasonic welding is to improve the plasticity and fluidity of the two contact surface materials, the contact surface diffusion bonding or mechanical mutual penetration and chemical activity to firmly weld the two together, see Figure 3.
Figure 3 Schematic diagram of ultrasonic spot welding
1-connected ultrasonic flow generator; 2-transducer; 3-main horn; 4-replaceable horn (welding head); 5-welded workpiece; 6-support
3. Ultrasonic steel barrel seam welding machine. See Figure 4.
Figure 4 Schematic diagram of ultrasonic seam welding
The currently used seam welder has an installed capacity of 150kVA and requires a water-cooled transformer and a welding wheel. The smoke is severe when welding, and the welding quality is determined almost entirely by the operator's level and responsibility. Practice has proved that seam welding is a key process in the production of steel drums. The scrap rate has been high, which directly affects the quality and cost of the products, and damages the health of workers and wastes energy.
With ultrasonic seam welding machine, the installed capacity can be reduced to less than 10kW, energy saving is more than 60%, smokeless dust, improve working environment and eliminate environmental pollution. With the welding fixture (or welding robot) and the PC programmer on the ultrasonic seam welder, automatic welding can be realized, and the spot welding process can be eliminated to improve the product quality.
4. Ultrasonic steel barrel crimping online detector. In 1992, the author and the University of Science and Technology of China jointly discussed the installation of detectors on the steel drum production line, but the investment problem was unsuccessful. The idea is to use the ultrasonic flaw detection method to change the forming condition of the bead during the process of rolling the steel drum to the screen through computer processing, and instantly change the curling parameters when an abnormality occurs. The device can truly reveal the crimping process and various parameter dimensions, and can fully guarantee the quality of the crimping, so that the pass rate of the steel drum is almost 100%.
5. Ultrasonic steel barrel phosphating strengthening machine (device). The structure is similar to that of an ultrasonic steel drum washing machine. The difference is that the liquid tank and other parts immersed in the phosphating solution are electrical insulators to prevent these parts from being phosphatized. The introduction of ultrasonic waves into the phosphating solution can shorten the phosphating time by l/3 to 1/2, and the life of the phosphating solution is prolonged without heating, thereby improving the fastness of the phosphating film and the coverage of the phosphating layer, even at the slit. Good phosphating.
6, ultrasonic pressure steel barrel closure. It is difficult to achieve a high yield by using a mold lock method on the top of the screw to the top of the barrel. Sometimes the screw is not qualified (the height is too low), the mold installation error, the mold wear, etc., the locking is not strong.
Introducing the upper core into the ultrasonic wave and making it into the ultrasonic horn to amplify the ultrasonic energy. When the lock is completed, the upper mold is not lifted immediately, and the ultrasonic source is started to introduce the ultrasonic pressure for a certain period of time, and the coil and the top of the barrel are welded. Together, enhance the tightness and tightness of the barrel.
7. Ultrasonic quenching roller and die. Due to the poor quality of the quenching of the rollers and the mold, the low service life affects the quality of the steel drum and increases the cost of the product, which is plagued by many steel drum factories.
The introduction of ultrasonic vibration in the quenching liquid can increase the heat transfer coefficient of the quenching liquid medium by several times, so that the steel part can be rapidly transformed into martensite by the quenched surface lattice, reduce the generation of retained austenite, and obviously accelerate the hardening process, and The process is stable, reducing workpiece deformation and cracks, and improving the mechanical properties of the workpiece.
Due to the introduction of ultrasonic radiation (using a transducer), the hardened portion of the grooved part is also subjected to good quenching hardness, and the life of the hemming wheel and the mold is improved.
Ultrasonic can also be applied to heat treatment and chemical heat treatment such as annealing, tempering, aging, shortening the heat treatment time and improving the quality of heat treatment.
8, ultrasonic coating thickness gauge. The principle of ultrasonic thickness measurement is similar to the principle of ultrasonic flaw detection. Both of them use ultrasonic waves to propagate in the ring body to encounter discontinuities, produce strong reflection, and convert the reflection data parameters into coating thickness by using a scaling mechanism. Ultrasonic thickness measurement and flaw detection are non-destructive tests.
The above ultrasonic processing and testing are also applicable to the automobile, tractor, motorcycle, bicycle and household appliance industries, and the ultrasonic water tank and the ultrasonic washing machine are even more flagged, which is of great significance for energy saving and environmental pollution elimination.
Reference material
l, "Piezoelectric effect and its application", Popular Science Press, Mi Daoren, Xiao Mingshan, 1987, 1st edition.
2, "Electric Processing Manual", [Su] H. Baobi Luofu, Mechanical Industry Press, 1st edition, 1989.
3, "Mechanical Engineering Handbook" Volume 2, Section 8, "Acoustics", the first edition of 1932, Mechanical Industry Press.
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