槽鋼加工說(shuo)明：

槽(cao)鋼(gang)(gang)是截(jie)面為凹槽(cao)形的長(chang)條鋼(gang)(gang)材，屬(shu)建(jian)造(zao)用(yong)(yong)和機械用(yong)(yong)碳素結構鋼(gang)(gang)，是復雜斷面的型鋼(gang)(gang)鋼(gang)(gang)材，其斷面形狀(zhuang)為凹槽(cao)形。槽(cao)鋼(gang)(gang)主要用(yong)(yong)于建(jian)筑結構、幕墻工(gong)程、機械設(she)備和車輛(liang)制造(zao)等。

中國(guo)槽鋼(gang)的進口量大于出口量。主要產地是唐鋼(gang)、包鋼(gang)、山鋼(gang)、黃特、馬鋼(gang)、宣(xuan)鋼(gang)、日鋼(gang)等幾家鋼(gang)廠。

剪(jian)切工(gong)藝(yi)優化

問題分析

某(mou)鋼(gang)(gang)廠中400mm機(ji)組(zu)是(shi)(shi)以生產中號角鋼(gang)(gang)和槽鋼(gang)(gang)為(wei)(wei)主(zhu)的(de)型材(cai)機(ji)組(zu)，年產量(liang)65萬噸，其中槽鋼(gang)(gang)產品(pin)(pin)規格為(wei)(wei)638～1208，產量(liang)約占(zhan)總產量(liang)的(de)25%。成品(pin)(pin)槽鋼(gang)(gang)的(de)分段作業采用1臺400t冷剪(jian)機(ji)進行(xing)。槽鋼(gang)(gang)剪(jian)切(qie)質量(liang)對后續工藝，特別是(shi)(shi)焊接質量(liang)影(ying)響較(jiao)大(da)，若剪(jian)切(qie)斷口(kou)處存(cun)在(zai)塌肩、毛刺(ci)、撕(si)裂、切(qie)斜等缺陷，則會使槽鋼(gang)(gang)對接時存(cun)在(zai)較(jiao)大(da)縫隙(xi)，影(ying)響焊接質量(liang)，特別是(shi)(shi)強度指標，從而造(zao)成較(jiao)大(da)的(de)安全隱(yin)患。

安鋼垂400mm機組隨生產(chan)節奏和(he)(he)產(chan)量的提(ti)高，上(shang)述剪切缺(que)陷越(yue)來越(yue)突出(chu)，剪切質量內控達標率僅為94.2%。而且剪刃的使用壽命越(yue)來越(yue)短，平均每(mei)班更換一次，造(zao)成(cheng)生產(chan)成(cheng)本和(he)(he)職工勞動強度增(zeng)加。針對這(zhe)些問題，從(cong)工藝、技術和(he)(he)操作上(shang)進(jin)(jin)行(xing)了(le)認真分析，并提(ti)出(chu)了(le)相應改進(jin)(jin)措施(shi)，取(qu)得(de)了(le)較好(hao)效果。

1、工藝原因(yin)

該(gai)機組的(de)設計能(neng)力(li)(li)為20萬t/a，但產(chan)量達到了(le)60萬t/a，冷(leng)床區(qu)生(sheng)產(chan)能(neng)力(li)(li)不足的(de)問題(ti)很突出(chu)，與生(sheng)產(chan)角鋼相(xiang)比(bi)，槽鋼的(de)冷(leng)卻速度(du)較(jiao)慢(man)，從而造成剪切(qie)時槽鋼溫度(du)較(jiao)高，極易出(chu)現塌肩、毛刺(ci)、撕裂(lie)等缺陷，并且對剪刃壽命的(de)影響(xiang)較(jiao)大。

2、剪刃設(she)計(ji)原因

槽(cao)鋼(gang)(gang)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)刃(ren)(ren)設(she)計(ji)的(de)基(ji)本依據(ju)是(shi)(shi)槽(cao)鋼(gang)(gang)成品孔(kong)(kong)型形狀，如圖1所示(以(yi)100#槽(cao)鋼(gang)(gang)為例)。這(zhe)種設(she)計(ji)在(zai)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)過(guo)程中(zhong)易(yi)出(chu)現以(yi)下(xia)問題：一是(shi)(shi)槽(cao)鋼(gang)(gang)兩肩(jian)(jian)部(bu)(bu)與(yu)其他部(bu)(bu)分相(xiang)比，相(xiang)對較(jiao)厚，所需(xu)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)力也較(jiao)大(da)，剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)刃(ren)(ren)磨(mo)(mo)損較(jiao)快，剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)刃(ren)(ren)使用一段(duan)時間(jian)(jian)后(hou)。這(zhe)一部(bu)(bu)分相(xiang)對磨(mo)(mo)損量大(da)，致(zhi)使肩(jian)(jian)部(bu)(bu)間(jian)(jian)隙較(jiao)大(da)，易(yi)出(chu)現塌(ta)肩(jian)(jian)現象；二是(shi)(shi)槽(cao)鋼(gang)(gang)兩腿與(yu)腰部(bu)(bu)處相(xiang)比，由于(yu)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)角度的(de)影響(xiang)，當剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)刃(ren)(ren)磨(mo)(mo)損后(hou)，在(zai)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)兩腿時，剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)量變小，腿部(bu)(bu)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)由通常的(de)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)斷變成了撕斷，槽(cao)鋼(gang)(gang)腿端面極(ji)易(yi)出(chu)現毛刺；三是(shi)(shi)上(shang)、下(xia)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)刃(ren)(ren)腿部(bu)(bu)斜度與(yu)槽(cao)鋼(gang)(gang)成品孔(kong)(kong)型基(ji)本一致(zhi)，這(zhe)樣在(zai)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)時腿部(bu)(bu)基(ji)本同時受(shou)力，剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)力較(jiao)大(da)，剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)刃(ren)(ren)磨(mo)(mo)損較(jiao)快，一方面腿端剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)壓痕(hen)嚴(yan)重，另(ling)一方面剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)刃(ren)(ren)老化(hua)后(hou)，極(ji)易(yi)出(chu)現槽(cao)鋼(gang)(gang)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)部(bu)(bu)分撕裂、毛刺較(jiao)多的(de)現象。后(hou)兩點(dian)是(shi)(shi)影響(xiang)槽(cao)鋼(gang)(gang)剪(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)切(qie)(qie)(qie)(qie)(qie)質量的(de)主要原(yuan)因。