The influence of the leading coefficient setting of the high-line spinning machine and the service life of the spinning tube
The Influence of the leading Coefficient on the Spinning Process
The leading coefficient refers to the ratio of the speed of the wire winding machine to the outlet speed of the finishing mill or the actual speed of the wire (usually 1.02-1.10). Its core function is to ensure that the wire forms a stable spiral coil inside the spinning tube, avoiding coil disorder or jamming caused by speed mismatch.
1. Coil forming and stability: The lead coefficient of the spinning machine (usually set at 1.02-1.10) directly affects the coil diameter and distribution direction. When the leading coefficient is too large, the coil diameter decreases and shifts to the left. Conversely, the coil diameter increases and shifts to the right. If the setting is improper, it will cause the coil to be unbalanced and stand sideways or deviate from the axis center line, triggering the vibration of the winding tube or the jamming of the wire, thereby accelerating wear.
2. Dynamic characteristics and force distribution: The leading coefficient affects the speed matching of the wire in the spinning tube. According to Fink's forward sliding formula, the actual speed of the wire rod is slightly higher than the exit speed of the finishing mill. If the speed of the spinning machine does not match the speed of the wire, it will cause uneven force distribution on the wire inside the spinning tube (such as abnormal normal pressure, friction force, and centrifugal force), thereby changing the wear distribution law of the spinning tube. Studies show that the deviation of the leading coefficient will significantly increase the stress concentration in the easily worn sections of the spinning tube.
3. Vibration and fatigue failure: Coil offset or unstable trajectory can cause the spinning machine to vibrate (such as eccentric spinning discs or unbalanced spinning tubes), leading to loose tube clamps or material fatigue. Research shows that when the deviation of the leading coefficient exceeds 1.05, the vibration value of the silk reeling machine may exceed the safety threshold, accelerating the wear at the bolt connection of the silk reeling tube.
The Specific Influence of the leading coefficient on the service life of the spinning tube
Wear intensifies
Improper setting of the leading coefficient can cause the running trajectory of the wire in the winding tube to deviate from the design curve, increasing the local friction frequency and intensity. Especially in the deformation zone (Archimedes spiral section), concentrated wear is prone to occur.
Vibration and imbalance: Coil offset may cause the wire winding machine to vibrate, leading to mechanical fatigue at the connection between the wire winding tube and the tube clamp and accelerating material wear.
2. Adaptability to working conditions
Small-sized production: When manufacturing small-sized wire rods such as Φ6.5mm, the lead coefficient needs to be more precisely controlled. If the speed of the clamping roller and the spinning machine is not properly matched (such as insufficient lead of the clamping roller), it is easy to cause the tail coil to lose control, increase the risk of iron oxide scale accumulation inside the spinning tube, and shorten the service life.
Low-temperature rolling: Under the controlled cooling process, the hardness of the wire rod increases, and the leading coefficient needs to be dynamically adjusted (such as fine-tuning after passing 200 bars of steel) to reduce the frictional heat effect between the wire rod and the wire drawing tube and delay wear.
Optimization Strategies and Cases
1. Dynamically adjust the leading coefficient
For the rolling of φ10mm wire: The wire feeding temperature is 870±20℃. By adjusting the leading coefficient in stages (initially 1.04-1.05, and gradually reducing to 1.02-1.03 subsequently), the wire trajectory can be optimized and local wear can be reduced.
By integrating atomization cooling technology (such as atomization of water and air mixture), the temperature of the spinning tube is reduced, further extending its service life.
2. Collaborative control of process parameters
Ensure that the speeds of the finishing mill, the clamping roller and the wire winding machine are matched (the clamping roller leads by 1.01-1.09) to avoid steel stacking or loss of control at the tail.
Regularly clean the iron oxide scale inside the spinning tube to prevent foreign objects from getting stuck and causing abnormal wear.
Research and Practical Verification
Dynamic model: Through the analysis of mechanical modeling and Matlab simulation, it was found that the deviation of the leading coefficient would significantly change the acceleration and bending deformation distribution of the wire inside the filament feeding tube, which is highly consistent with the actual wear law. When the leading coefficient decreases from 1.05 to 1.03, the friction force in the deformation zone of the spinning tube decreases by 15% and the wear rate decreases by 25%.
On-site data: A certain steel company has increased the service life of φ10mm wire drawing tubes from 3,000 tons to a higher level by optimizing the lead coefficient, with a significant reduction in costs. The service life of the φ6.5mm small-sized wire drawing tube has been increased from 2,000 tons to 2,800 tons, and the vibration value has been reduced by 40%.
Conclusion
The leading coefficient is a key parameter affecting the service life of the wire drawing tube and needs to be dynamically adjusted in combination with wire specifications, rolling temperature, speed matching, etc. Reasonable setting can optimize the wire trajectory and reduce abnormal forces, thereby prolonging the service life of the wire drawing tube. Conversely, it will lead to intensified wear and tear and a decline in production efficiency. In the future, intelligent algorithms (such as BP neural networks) can be further combined to achieve adaptive optimization of the leading coefficient.
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