阅读说明：本技术 15×k7结构压实股钢丝绳生产工艺 (Production process of compacted strand steel wire rope with 15 XK 7 structure ) 是由 张成宇 郑立茂 杨正延 曾波 于 2021-08-30 设计创作，主要内容包括：15×K7结构压实股钢丝绳生产工艺,步骤如下：钢丝绳配丝-捻股-股压实-合绳。本发明解决了钢丝绳捻制不密实,结构不稳定,钢丝绳旋转、容易出现裂缝及松散问题以及钢丝绳使用过程中内层绳容易破劲,岀现早期断裂等技术问题,提高了钢丝绳破断拉力。15×K7结构压实股钢丝绳在极为寒冷的地方使用,生产该钢丝绳的过程中使用低温专用油脂作为润滑和防锈材料,能保证在零下50℃环境中油脂不龟裂,润滑和防锈作用得以维持,钢丝绳产品能在零下40℃～50℃环境下使用,并且采取股喷油和合绳浸油的双重覆盖油脂方式下,涂覆全面均匀,在寒冷环境下能保证对钢丝绳润滑和防锈,提升钢丝绳使用寿命。(The production process of the compacted strand steel wire rope with the structure of 15 XK 7 comprises the following steps: wire matching of a steel wire rope, stranding, strand compaction and rope combination. The invention solves the technical problems that the steel wire rope is not tightly twisted, the structure is unstable, the steel wire rope rotates and is easy to crack and loosen, the inner layer rope is easy to break in the using process of the steel wire rope, the early fracture occurs and the like, and the breaking tension of the steel wire rope is improved. The compacted strand steel wire rope with the structure of 15 xK 7 is used in a very cold place, special low-temperature grease is used as a lubricating and antirust material in the process of producing the steel wire rope, the grease can be prevented from cracking in the environment of minus 50 ℃, the lubricating and antirust effects can be maintained, the steel wire rope product can be used in the environment of minus 40 ℃ to 50 ℃, in addition, the dual-covering grease mode of strand oil spraying and rope combining oil soaking is adopted, the coating is comprehensive and uniform, the lubrication and the antirust of the steel wire rope can be ensured in the cold environment, and the service life of the steel wire rope is prolonged.)

The production process of the compacted strand steel wire rope with the structure of 1.15 multiplied by K7 is characterized by comprising the following steps: the production process comprises the following steps:

1) steel wire rope wire distribution

The steel wire rope wire matching technological parameters are as follows: center strand of inner layer cord (1-1): 0.93/0.55/1.03 mm;

inner strand (1-2) of inner layer rope: 0.80/0.48/0.93 mm;

inner layer filling strand (1-3) of inner layer rope: 0.45/0.38 mm;

outer strand of outer rope (2-1): 0.90/0.85 mm;

2) strand twisting

The stranding method comprises the following steps that (1) stranding tiles are selected according to the diameters of strands during stranding, the stranding tiles are used in pairs and are compressed, the phenomenon of wire breakage or wire damage cannot occur in the production process, and the strands cannot have the defects of arrises and ellipse; spraying grease on the surface of the strand during stranding;

stranding process parameters: center strand of inner layer cord (1-1): the strand diameter is 3.88mm, and the lay length is 31 mm;

inner strand (1-2) of inner layer rope: the strand diameter is 3.44mm, and the lay length is 27.5 mm;

inner layer filling strand (1-3) of inner layer rope: the strand diameter is 1.21mm, and the lay length is 10 mm;

outer strand of outer rope (2-1): the strand diameter is 2.43mm, and the lay length is 26 mm;

3) strand compaction

Compacting an outer layer strand (2-1) of the outer layer rope by adopting a rolling compaction processing mode, controlling the strand compaction rate to be within a range of 6.5-8.5%, and enabling steel wires after strand compaction to be in a surface contact state;

4) rope combination

The rope combination adopts a tandem unit for one-time twisting, firstly, an inner layer rope (1) of a steel wire rope is twisted by a first basket frame, a 13W branch wire disc is used for twisting, pre-deformation is not carried out on strands, the strands are naturally folded at a wire pressing tile after exiting the branch wire disc, then the strands enter an outer layer rope (2) of the steel wire rope twisted by a second basket frame, pre-deformation is carried out on the outer layer strand (2-1) of the outer layer rope during twisting, grease is coated on the surface of the rope during rope combination, a 18# machine head is used, the diameter of a working roller is 15mm, the distance between the ends of the roller is 0.85 times of the lay length of the steel wire rope, the bending depth is 1.73 times of the diameter of the steel wire rope, the deviation of the diameter of the steel wire rope is controlled within 3% -7%, and the twisting technological parameters of the steel wire rope are as follows: diameter of inner layer rope (1) of the steel wire rope: 10.55mm, the twist pitch multiple is 6.5-7.0 mm, and the twist direction SS; diameter of an outer layer rope (2) of the steel wire rope: 15.0mm, the twist pitch multiple is 6.5-7.0 mm, and the twist direction ZS.

Technical Field

The invention relates to a production process of a compacted strand steel wire rope with a 15 XK 7 structure, and belongs to the technical field of metal product processing.

Background

The compacted strand wire rope with the structure of 15 xK 7 is a compacted strand multi-strand wire rope, 6 strands on the inner layer are twisted outside 1 central strand, 6 filling strands on the inner layer and 15 strands on the outer layer form the compacted strand wire rope, and the compacted strand wire rope has the characteristics that: (1) the toughness coefficient is high, and the flexibility is good; (2) the steel wire rope is compact in interior, high in metal filling rate and higher in breaking tension than a common steel wire rope with the same diameter and the same strength; (3) compared with the common round strand steel wire rope, the steel wire rope has large contact area with a winding drum and a pulley when in use, and has good fatigue resistance ; (4) the steel wire rope has small rotation property, and the hanging rope hardly rotates after being used, thereby being beneficial to high-lift hoisting. The steel wire rope with the structure has rotation resistance, is usually used on a rotary digging machine, a grooving machine, a port loading and unloading machine and various types of high-lift hoisting equipment, but has great production difficulty due to the twisted equipment, the characteristics of the steel wire rope structure, the use of the steel wire rope and other factors in production, and the steel wire rope is usually produced by two times of discontinuous layered twisting, namely twisting an inner layer rope firstly, entering the next procedure after the production is finished, and then redistributing process equipment and then wrapping and twisting 15 outer layer strands when entering the next procedure.

Such a twice-interrupted, layered twisted steel cord has the following problems: (1) the rotation resistance of the steel wire rope is poor, the inner-layer rope strands are pre-deformed during twisting, so that the reverse poking force of the inner-layer rope strands is small, the circumferential surface of the inner-layer rope and the circumferential inner surface of the outer-layer rope cannot be well and compactly combined, and the outer-layer rope strands have no control effect when the inner-layer rope is twisted for one time. (2) The twisted tension of each strand in the steel wire rope is uneven and consistent, so that the twisted structure of the steel wire is not compact and unstable, the breaking tension of the whole steel wire rope is small, and the steel wire rope is easy to loose, crack, crust and the like.

Disclosure of Invention

The invention aims to solve the technical problems that a steel wire rope is not compact in twisting process, the structure is unstable, the breaking tension of the steel wire rope is low, the steel wire rope rotates and is easy to crack and loosen, and an inner layer rope is easy to break and is easy to break in the using process of the steel wire rope.

The production process of the compacted strand steel wire rope with the structure of 15 xK 7 comprises the following steps:

1) steel wire rope wire distribution

The steel wire rope wire matching technological parameters are as follows: center strand of inner layer rope: 0.93/0.55/1.03 mm;

inner strand of inner rope: 0.80/0.48/0.93 mm;

inner layer filling strand of the inner layer rope: 0.45/0.38 mm;

outer strand of outer rope: 0.90/0.85 mm;

2) strand twisting

The stranding method comprises the following steps that (1) stranding tiles are selected according to the diameters of strands during stranding, the stranding tiles are used in pairs and are compressed, the phenomenon of wire breakage or wire damage cannot occur in the production process, and the strands cannot have the defects of arrises and ellipse; spraying grease on the surface of the strand during stranding;

stranding process parameters: center strand of inner layer rope: the strand diameter is 3.88mm, and the lay length is 31 mm;

inner strand of inner rope: the strand diameter is 3.44mm, and the lay length is 27.5 mm;

inner layer filling strand of the inner layer rope: the strand diameter is 1.21mm, and the lay length is 10 mm;

outer strand of outer rope: the strand diameter is 2.43mm, and the lay length is 26 mm;

3) strand compaction

Compacting the outer layer strand of the outer layer rope by adopting a rolling compaction processing mode, wherein the strand compaction rate is controlled within the range of 6.5-8.5%, and the steel wire after strand compaction are in a surface contact state;

4) rope combination

The rope combination adopts a tandem unit for one-time twisting, firstly, an inner layer rope of a steel wire rope is twisted by a first basket frame, a 13W distribution wire disc is used for twisting, pre-deformation is not carried out on strands, the strands are naturally folded at a wire pressing tile after exiting the distribution wire disc, then the strands enter an outer layer rope of the steel wire rope twisted by a second basket frame, the outer layer strand of the outer layer rope is pre-deformed during twisting, grease is coated on the surface of the rope during rope combination, an 18# machine head is used, the diameter of a working roller is 15mm, the distance between the ends of the roller is 0.85 times of the twisting distance of the steel wire rope, the bending depth is 1.73 times of the diameter of the steel wire rope, the deviation of the diameter of the steel wire rope is controlled within 3% -7%, and the twisting technological parameters of the steel wire rope are as follows: inner layer rope diameter of the steel wire rope: 10.55mm, the twist pitch multiple is 6.5-7.0 mm, and the twist direction SS; outer layer diameter of the steel wire rope: 15.0mm, the twist pitch multiple is 6.5-7.0 mm, and the twist direction ZS.

The invention has the beneficial effects that:

1. the invention solves the technical problems that the steel wire rope is not tightly twisted, the structure is unstable, the steel wire rope rotates and is easy to crack and loosen, the inner layer rope is easy to break in the using process of the steel wire rope, the early fracture occurs and the like, and the breaking tension of the steel wire rope is improved.

2. The compacted strand steel wire rope with the structure of 15 XK 7 is used in extremely cold places, low-temperature special grease is used as a lubricating and antirust material in the process of producing the steel wire rope, the grease can be prevented from cracking in the environment of 50 ℃ below zero, the lubricating and antirust effects can be maintained, the steel wire rope product can be used in the environment of 40 ℃ below zero to 50 ℃, the dual grease covering modes of strand oil spraying and rope combining and oil soaking are adopted, the coating is comprehensive and uniform, the lubrication and the antirust of the steel wire rope can be ensured in the cold environment, and the service life of the steel wire rope is prolonged.

Drawings

Fig. 1 is a schematic view of a compacted strand steel cord of 15 xk 7 construction according to the present invention.

In the figure: 1 inner layer rope of a steel wire rope, 1-1 central strand of the inner layer rope, 1-2 inner layer strands of the inner layer rope, 1-3 inner layer filling strands of the inner layer rope, 2 outer layer ropes of the steel wire rope and 2-1 outer layer strands of the outer layer ropes.

Fig. 2 shows the result certificate of the reliability test of the compacted stranded steel wire rope product with the 15 xk 7 structure in russia.

Fig. 3 is the translated chinese version certificate of fig. 2.

Detailed Description

The invention is described in further detail below with reference to the figures and specific examples.

As shown in figure 1, the diameter of the compacted strand steel wire rope with a 15 XK 7 structure is 15m, and the tensile strength is 1770-1960 MPa.

The steel wire rope structure is as follows: the steel wire rope comprises an inner layer rope 1 of a steel wire rope and an outer layer rope 2 of the steel wire rope from inside to outside in sequence;

the inner layer rope 1 of the steel wire rope is of a structure of 1 × 17S +6 × 17S + (6 × 7) Fi and comprises 1-1 central strand of 1 inner layer rope, 1-2 inner layer strands of 6 inner layer ropes and 1-3 inner layer filling strands of 6 inner layer ropes;

the structure of an outer layer rope 2 of the steel wire rope is 15 multiplied by K7, and the outer layer rope comprises 15 outer layer strands 2-1 of the outer layer rope;

the total number of steel wires of the steel cord is 266.

The production process of the compacted strand steel wire rope with the structure of 15 xK 7 comprises the following implementation steps:

1) steel wire rope wire distribution

The steel wire rope wire matching technological parameters are as follows: center strand 1-1 of inner layer rope: 0.93/0.55/1.03 mm;

inner layer strand 1-2 of inner layer rope: 0.80/0.48/0.93 mm;

1-3 of inner layer filling strand of inner layer rope: 0.45/0.38 mm;

outer strand 2-1 of outer layer rope: 0.90/0.85 mm;

the strength grade of the steel wire is 1960 MPa.

2) Strand twisting

The stranding method comprises the following steps that (1) stranding tiles are selected according to the diameters of strands during stranding, the stranding tiles are used in pairs and are compressed, the phenomenon of wire breakage or wire damage cannot occur in the production process, and the strands cannot have the defects of arrises and ellipse; spraying grease on the surface of the strand during stranding;

stranding process parameters: center strand 1-1 of inner layer rope: the strand diameter is 3.88mm, and the lay length is 31 mm;

inner layer strand 1-2 of inner layer rope: the strand diameter is 3.44mm, and the lay length is 27.5 mm;

1-3 of inner layer filling strand of inner layer rope: the strand diameter is 1.21mm, and the lay length is 10 mm;

outer strand 2-1 of outer layer rope: the strand diameter is 2.43mm, and the lay length is 26 mm.

3) Strand compaction

And (3) compacting 2-1 of the outer layer strand of the outer layer rope by adopting a roll compaction processing mode, controlling the strand compaction rate to be 6.5-8.5%, and enabling the compacted steel wire to be in a surface contact state with the steel wire.

The filling coefficient and breaking force of the steel wire rope can be improved by adopting a rolling compaction processing mode, the wear resistance of the steel wire rope is good, the contact area of the steel wire rope with the winding drum and the pulley is increased, and the service life of the steel wire rope is prolonged; the rolling is mainly the effect of pressing on the cross section of the strand, and the quality of the strand processed by rolling is better than that of die drawing.

When the compacted strand is produced by adopting a rolling compaction processing mode, experiments show that: the strand compaction rate is controlled within the range of 6.5-8.5%, the strand compaction effect is optimal, when the strand compaction rate is less than 6.5%, the strand stress is not well eliminated, the steel wires in the strand have reverse poking force, when the strand compaction rate is more than 8.5%, the strand cross section is easy to deform, and a linear side edge phenomenon caused by the accumulation of strand areas can occur on a longitudinal section.

4) Rope combination

The rope combination is twisted by a series unit for one time, firstly, a 13W distribution wire disc is used for twisting the inner layer rope 1 of the steel wire rope on a first basket frame, the strands are not pre-deformed, the strands are naturally folded at a wire pressing tile after exiting the distribution wire disc, then the strands enter an outer layer rope 2 of the steel wire rope twisted on a second basket frame, the outer layer strand 2-1 of the outer layer rope is pre-deformed during twisting, grease is coated on the surface of the rope during rope combination, a 18# machine head is used, the diameter of a working roller is 15mm, the distance between the ends of the roller is 0.85 times of the twisting distance of the steel wire rope, the bending depth is 1.73 times of the diameter of the steel wire rope, and the deviation of the diameter of the steel wire rope is controlled within 3% -7%.

The steel wire rope twisting process parameters are as follows: inner layer diameter of steel wire rope 1: 10.55mm, the twist pitch multiple is 6.5-7.0 mm, and the twist direction SS; outer layer diameter of steel wire rope 2: 15.0mm, the twist pitch multiple is 6.5-7.0 mm, and the twist direction ZS.

The compacted strand steel wire rope is twisted at one time:

1) the inner layer rope 1 of the steel wire rope is not pre-deformed when twisted, the inner layer rope 1 can be stressed to increase the torsion moment, the outer layer rope 2 of the steel wire rope is pre-deformed when twisted, the torsion moment of the outer layer rope 2 can be eliminated, and the torsion moment of the inner layer rope 1 can be weakened when twisted in the interaction direction;

2) meanwhile, the outer layer strand 2-1 of the outer layer rope can resist the torsion of the inner layer rope 1 due to the vertical pressing action towards the circumferential direction of the inner layer rope 1, the outer layer strand 2-1 plays a role in controlling the inner layer rope 1, the torsion moment of the outer layer rope 2 of the steel wire rope is relatively balanced, and the steel wire rope is ensured to be prevented from rotating or slightly rotating;

3) the inner layer rope 1 of the steel wire rope is not pre-deformed when twisted, and the inner layer rope 1-2 of the inner layer rope is stressed when twisted, so that the circumferential surface of the inner layer rope 1 and the circumferential inner surface of the outer layer rope 2 are well and tightly combined, the structure is stable, the strand gaps are uniform, and no crack phenomenon is caused by visual observation.

Performance testing of compacted strand wire ropes of the present invention

(1) And (3) detecting the loosening performance:

respectively detect once system and discontinuous layering system wire rope loose performance, measure wire rope's diameter earlier, then tear out the outer strand that length is greater than 5 lay lengths from wire rope, measure that its maximum rotation is high, calculate the high-degree average value of spiral, again according to formula η = H/D x 100% the deformation rate of calculating the strand, in the formula: eta represents the deformation rate of the strand, H is the average value of the spiral height of the outer strand, and D is the diameter of the steel wire rope.

In practice, when the deformation rate eta of the steel wire rope strands is 82-87%, the steel wire rope has the best non-loosening performance, when the deformation rate eta of the steel wire rope strands is less than 82%, the steel wire rope is loose, and when the deformation rate eta of the steel wire rope strands is more than 87%, the steel wire rope strands are excessively deformed, and the steel wire rope strands are in a loose state.

The steel wire rope deformation rate detection results are shown in the following table:

steel wire rope strand deformation rate parameter detection result table

Steel wire rope twisting mode	Diameter D, mm of steel wire rope	Average height H, mm of outer strand helix	The deformation rate of the strands eta%
				Discontinuous layered twist	15.00～15.4	12.05	78.25～80.33
One-time twisting	15.00～15.4	12.95	84.09～86.33

As can be seen from the above table, the deformation rate η of the steel wire strands during the layered twisting is 78.25 to 80.33%, the steel wire rope is in a loose state, and the deformation rate η of the steel wire strands during the primary twisting is 84.09 to 86.33%, and the steel wire rope is not loose. Obviously, the loosening performance of the steel wire rope is relatively better in one-time twisting than in layered twisting.

(2) Detecting the rotation resistance:

the twisting moment of the outer layer rope of the multi-strand steel wire rope is larger than that of the inner layer rope, which is determined by the structural characteristics of the steel wire rope. The steel wire rope structural design can offset the torsion moment of the inner layer rope and the outer layer rope as much as possible by increasing the torsion moment of the inner layer rope and reducing the torsion moment of the outer layer rope, but the result of increasing the torsion moment of the inner layer rope is that the inner layer rope is loose and cannot be stored as standby products, namely, the process of twisting the outer layer rope cannot be smoothly completed. And to realize increasing inlayer rope torsional moment and reducing outer layer rope torsional moment, offset the torsional moment of inlayer rope as far as possible, need twist with inlayer rope and outer layer rope simultaneously, can not regard as the solitary article of waiting with the inlayer rope, promptly twist with the system and accomplish promptly.

Comparing the primary twisting and the layered twisting of the steel wire rope: when the steel wire rope is twisted for one time, the inner layer rope strand of the steel wire rope is not pre-deformed, the inner layer rope strand is stressed, a large reverse poking force exists, the outer layer rope strand is pre-deformed, stress is fully eliminated, the reverse poking force is small, when the steel wire rope is twisted, the outer layer rope strand plays a role in controlling the inner layer rope, the torsion force of the inner layer rope is offset, the torsion moment of the inner layer rope and the torsion moment of the outer layer rope of the steel wire rope are relatively balanced, and the steel wire rope can not rotate or slightly rotate. When the steel wire rope is twisted in a layered mode, 1, if the inner layer rope is twisted by the steel wire rope without pre-deformation, the internal layer rope strand of the steel wire rope has a large poking force, the internal layer rope is loose and cannot be stored as a finished product, so that the outer layer rope cannot be smoothly combined in the next procedure, and the twisting quality of the steel wire rope is seriously influenced. 2. The inner strand of the steel wire rope needs to be pre-deformed to reduce the reverse poking force, the inner rope of the steel wire rope can not be loosened, so that the normal operation of combining the steel wire rope with the outer rope in the next procedure can be ensured, but simultaneously, after the inner strand of the steel wire rope is pre-deformed, the circumferential surface of the inner rope and the circumferential inner surface of the outer rope cannot be well and compactly combined, so that the breaking force of the steel wire rope can be reduced. 3. The inner layer rope is pre-deformed, the refuting force of the inner layer rope strands cannot be completely eliminated, and under the pre-deformed state of the outer layer rope strands, the balance point is not easy to find out by the rope torsion moment after the rope is twisted in layers and combined, and the rotation is easy to generate. Thus, the rotation resistance of the one-time twist can be relatively well defined compared with the layered twist.

The rotation resistance of the multi-batch one-time twisting and layered twisting steel wire rope is detected and analyzed, and the one-time twisting is better than the layered twisting. The company provides a Russian Kudesnik group client with a 15 XK 7 structure compacted strand steel wire rope product, the client detects the reliability of the actual use of the product, no steel wire rope distortion occurs, and the issued detection result certificate is shown in figures 2 and 3.

(3) And (3) mechanical property detection:

through the internal mechanical property test detection of multiple batches and the Russian Kudesnik group customer detection of the compacted stranded steel wire rope with the structure of 15 xK 7, the reliability requirement of the steel wire rope for the automobile crane is met, and the performance indexes are compared in the following table.

Steel wire rope mechanical property index comparison table

From the above table, the total of the whole rope breaking force and the steel wire breaking force of the steel wire rope twisted at one time is larger than that of the steel wire rope twisted at different layers, and through calculation, the total ratio of the whole rope breaking force and the steel wire breaking force of the steel wire rope twisted at one time is 80.68%, and the ratio of the steel wire rope twisted at different layers is 79.18%, which shows that the loss caused by one-time twisting is smaller than that caused by layered twisting, and the twisting quality of the steel wire rope is relatively good.