xk350開煉機加料段機筒設(shè)計【含3張CAD圖紙】
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摘要 XK-350開煉機是橡膠、塑料機械中最常用、最基本的設(shè)備之一,主要用于生膠的塑煉、膠料的混煉、混煉膠的熱煉等。目前,我國開煉機技術(shù)雖然發(fā)展很快、生產(chǎn)品種也較多,但與工業(yè)發(fā)達國家相比還有一定差距,有向著個性化與智能化方向發(fā)展的趨勢。本文主要對XK-350開煉機進行了設(shè)計和計算,包括電機和減速器的選用,工作機的設(shè)計工作機主要的零部件和輔助部件設(shè)計,制圖軟件的使用等。本文在結(jié)構(gòu)設(shè)計方面,采用少齒差行星齒輪減速器替代以往的圓柱齒輪減速器,結(jié)構(gòu)更為簡單緊湊,降低了生產(chǎn)成本。并針對安全生產(chǎn)問題,增加了安全裝置,為以后該機械的設(shè)計提供參考依據(jù)。隨著技術(shù)的不斷發(fā)展,開煉機的結(jié)構(gòu)和性能有了很大改進。在新式開煉機中,采用液壓馬達作為動力傳動裝置,使傳動平穩(wěn),噪音降低;采用自動調(diào)心滾柱軸承火填充MC尼龍軸襯作為輥筒軸承,以節(jié)約電能或軸襯銅材,并簡化維護保養(yǎng);調(diào)距裝置采用液壓結(jié)構(gòu),具有過載保護功能,調(diào)距方便,并可指示工作橫壓力值;為了適應(yīng)煉膠工藝的要求,大規(guī)格開煉機采用圓周鉆孔輥筒,提高溫控效果。此外,為安裝方便,采用橡膠防震墊取代地腳螺栓;在中小規(guī)格開煉機上采用電氣制動,簡化了制動裝置,提高了制動效果。開煉機的一系列改進,使其在技術(shù)上達到了一個新的水平。使用開煉機對膠料進行塑煉,是最早應(yīng)用的一種塑煉方法。它是將生橡膠膠塊置于兩輥筒之間,借助于輥筒的剪切力作用使橡膠的分子鏈?zhǔn)艿嚼於鴶嗔?,從而獲得可塑性。使用開煉機塑煉,其塑煉溫度通??刂圃?00以下,這種塑煉屬于低溫機械式塑煉。 采用開煉機塑煉的優(yōu)點是塑煉膠的可塑性均勻、熱可塑性??;所得膠料的收縮性能小; 設(shè)備的工藝靈活性較強,適用面寬,投資;較小。因此,開煉機適用于膠種變化多、生產(chǎn)(膠料)用量較少的橡膠制品企業(yè)。開煉機塑煉的缺點是操作勞動強度大、生產(chǎn)效率較低、工作條件差。網(wǎng)上查詢青島科技大學(xué)學(xué)報(自然科學(xué)版),書中提到:開煉機是一種古老的橡膠、塑料加工設(shè)備,隨著科學(xué)技術(shù)的發(fā)展,各種各樣的新型煉膠、煉塑設(shè)備層出不窮,但開煉機并沒因此被淘汰,而是隨著橡膠、塑料工業(yè)的迅速發(fā)展,以及橡塑并用的興起而日益興旺。其原因是開煉機有著它自身的獨到之處:結(jié)構(gòu)簡單,設(shè)備投資少,易操作,易觀察。我認為這恰恰是開煉機在今天能仍有一席之地的原因。查閱橡膠工業(yè)手冊:其中關(guān)于開煉機安全裝置的敘述不叫詳盡以及先進;為保護開煉機主要零部件在機器由于發(fā)生意外情況而過載時不受損壞,在輥筒軸承前端裝有安全裝置?;緳C構(gòu)有兩種(一)安全片。對安全片的技術(shù)要求:1,材料采用HT150;2,厚度誤差不大于0.05mm;3,每批材料要經(jīng)過試驗后確定厚度;4,安全片的破壞載荷Q為每個軸承最大水平橫壓力的1.5倍。(二)液壓安全裝置。其原理是當(dāng)機器發(fā)生故障,油壓上升,電接點壓力表指示動針與調(diào)定最大橫壓力值的固定針相接處時,機器立即停車,放大輥距是負壓降低。其中液壓調(diào)距裝置我比較感興趣讓我想起液壓可所學(xué)知識結(jié)合起來分析一下,感覺很有意思。又重新學(xué)習(xí)一下淡忘的知識。沈陽化工大學(xué)科亞學(xué)院學(xué)士學(xué)位論文 Abstract 關(guān)鍵詞:開煉機;液壓馬達;塑煉;減速器;調(diào)心滾珠軸承;Abstract XK-350 open mill rubber, plastics machinery of the most common and one of the most basic equipment,mainly for raw rubber mastication, rubber mixing, mix the soak and the like. At present,open mill technology has developed rapidly, producing more varieties, but compared with theindustrialized countries there is a gap, there is a tendency toward personalization and intelligent direction of development. This paper focuses on XK-350 mill machine design and calculations, including the motor and gear selection, working machine design, Pro / ENGINEER wlife assisted design software, the main working machine components and accessories design, mapping software use and so on. In this paper, the structural design, the use of small teeth difference planetary gear reducer replace conventional cylindrical gear reducer, the structure is more simple and compact, reducing production costs. And for safety issues, increased safety device, provide a reference for the future of mechanical design. With the continuous development of technology, structure and properties of open mill has been greatly improved. In the new open mill, a hydraulic motor as a power transmission device, so smooth transmission, noise reduction; using self-aligning roller bearings fire filled MC nylon bushing as roller bearings, bushings to save power or copper, and simplify maintenance; pitch device hydraulic structure, with overload protection, easy to pitch, and may direct the work of the cross pressure; mixing process in order to meet the requirements of large-sized open mill using roller circumferential drilling, raise temperature control effect. In addition, easy installation, replace the bolt with rubber shock pad; use in small and medium size electric brake on the open mill, simpler braking device to increase the braking effect. Open mill a series of improvements to the technology has reached a new level. Use of rubber open mill mastication, mastication is a method of the first application. It is the raw rubber block is placed between two rollers, shear force by means of the roll so that the molecular chain of rubber is stretched and broken to obtain plasticity. Use open mill mastication, which mastication temperature is generally controlled at below 100 , belonging to such a low temperature mechanical mastication mastication. The advantages of using open mill mastication plasticity Plastic compounds are uniformly thermoplastic small; small shrinkage properties of the resulting plastic material; the flexibility of the process equipment is strong for wide investment; small. Accordingly, a refining machine for plastic types changing, production (rubber) less the amount of rubber products businesses. The disadvantage of open mill mastication operating labor-intensive, low productivity, poor working conditions. Online inquiry Qingdao University of Science and Technology (Natural Science Edition), mentioned in the book: the open mill is an old rubber, plastics processing equipment, with the development of science and technology, a variety of new mixing, refining plastic device after another, but did not open mill therefore be eliminated, but with the rubber, the rapid development of the plastics industry, as well as the rise of rubber and used increasingly prosperous. The reason is an open mill has its own unique: simple structure, less investment in equipment, easy to operate, easy to observe. I think this is precisely the open mill is still in place today can cause. Now Rubber Industry Handbook: which describes the safety devices on the open mill is not called exhaustive and advanced; for the protection of open mill major components in the machine as a result of unforeseen circumstances overload from damage, the front end of the roller bearing mounted safety devices. There are two basic mechanisms (a) security chip. Security sheet Technical requirements: 1, the material used HT150; 2, the thickness error is less than 0.05mm; 3, each batch of material to go through a test to determine the thickness; 4, the safety sheet for each bearing failure load Q maximum horizontal transverse pressure 1.5 times. (B) a hydraulic safety device. The principle is that when a machine fails, the oil pressure rises, electric contact pressure gauge needle move and set-largest cross-pressure phase at a fixed needle, the machine stop immediately, amplifying negative roll gap is reduced. Hydraulic pitch which means I am more interested reminds me of hydraulic pressure can combine the knowledge to analyze, I feel very interesting. Again learning about the forgotten knowledge.Key words:Rolling Mill; Hydraulic Motor; Plastic Refining; Reducer; Aligning Ball Bearing;目 錄 第一章 概述 1 第二章 主要參數(shù)確定 4 第三章 傳動系統(tǒng) 5 3.1減速器設(shè)計計算 5 3.2一級齒輪傳動 6 3.3二級齒輪傳動 9 3.4軸校核 13 3.4.1軸1 13 3.4.2軸 16 3.4.3軸 20 3.5鍵的校核 25 第四章 主要零部件設(shè)計 26 4.1輥筒 26 4.2輥筒軸承 30 4.3機架和橫梁 30 4.4輥距調(diào)節(jié)裝置 30 4.5輥溫調(diào)節(jié)裝置 30 4.6潤滑系統(tǒng) 31 結(jié)論 33 參考文獻 34 致謝 35沈陽化工大學(xué)科亞學(xué)院學(xué)士學(xué)位論文 第一章 概述 第一章 概述開煉機主要用于:生膠的塑煉、膠料的混煉;混煉膠的熱煉、供膠;膠料的壓片;膠料中雜質(zhì)的清除;生膠的破碎、洗滌;再生膠的粉碎、混煉、壓片;升橡膠的壓片等。此外,它還廣泛用于塑料加工和油漆顏料工業(yè)生產(chǎn)中。由此將開煉機分為:熱煉機、壓片機、破膠機、開煉機、粉碎機、提煉機、精煉機和實驗用開煉機等。開煉機工作原理:膠料在兩個相對回轉(zhuǎn)的輥筒上,依靠不同的速度,在摩擦力作用下被拉入輥距,通過輥距斷面的不斷縮小,是膠料受到強烈的剪切與擠壓,同時在一定溫度條件下發(fā)生氧化斷鏈,增加可塑性,從而達到煉膠的目的。開煉機的工作條件:1、 膠料與輥筒的接觸角必須小于摩擦角,即,此時的膠料能被拉入輥距,輥筒與膠料的摩擦角一般為3840。要求輥筒與膠料的接觸角s 安全校核V剖面的疲勞強度 V剖面應(yīng)力集中系數(shù) (3-34) 故按配合引起的扭應(yīng)力、應(yīng)力幅、平均應(yīng)力: (3-35)絕對尺寸影響系數(shù) 表面質(zhì)量 V剖面安全系數(shù): (3-36)取S=1.5-1.8 Ss 安全軸承的校核:(選用深溝球軸承,型號:6216) e Y 0.028 0.22 1.99 Y=1.82 0.056 0.26 1.71 e=0.24 (3-37) (3-38) 合格3.4.2軸圖3-4 軸和受力分析圖 (3-39) R1v=2091.55N R2v=8155.41N 合成彎矩圖: 圖3-5 扭矩圖 校核軸的強度: (3-40) 查表b-1=59MPa caS 安全校核、剖面: 剖面因H7/k6配合的應(yīng)力集中系數(shù): 剖面因過渡圓角的應(yīng)力集中系數(shù): 故按剖面過渡圓角校核: (3-44) 剖面產(chǎn)生的扭應(yīng)力,應(yīng)力幅,平均應(yīng)力為: (3-45) (3-46)絕對尺寸影響系數(shù): =0.68 =0.68表面質(zhì)量 =0.941 =0.941 (3-47) 取S=1.5-1.8 S S 安全軸承的校核:(選用深溝球軸承,型號:6124) Y 0.028 0.22 1.99 Y=1.82 0.056 0.26 1.71 e=0.247 (3-48) 合格3.4.3軸圖3-6 軸和受力分析圖 圖3-7 扭矩圖 查表b-1=59MPa caS 安全校核、剖面 剖面因配合( ) 剖面 剖面因鍵槽 按剖面的圓角校核: T=613800 剖面產(chǎn)生的扭應(yīng)力、應(yīng)力幅、平均應(yīng)力為: 絕對尺寸影響系數(shù) 表面質(zhì)量 取S=1.5-1.8 SS 剖面安全軸承的校核:(選用深溝球軸承,型號:6220) A=4620.94, Y 0.056 0.26 1.71 Y=1.70 0.084 0.28 1.55 e=0.261 合格3.5鍵的校核 p=100-120 軸上的鍵: (3-50) 軸上的鍵(兩個): 軸上的鍵兩個 鍵的校核全部合格驅(qū)動齒輪小齒輪材料 45# 調(diào)質(zhì) HBS1=240大齒輪材料 45# 常化 HBS2=200選取小齒輪齒數(shù)Z1=22 I=3.54則Z2=22x3.54=77.8 取Z2=78 因是齒輪硬度小于HBS350的閉式齒輪傳動,所以按齒面接觸疲勞強度設(shè)計,然后按傳動的齒根彎曲強度校核。速比齒輪 速比齒輪的速比為1.27.兩齒輪中心距a=450mm,傳遞。扭矩是通過速比齒輪傳動的,當(dāng)速比很小時,可以近似的認為:兩輥筒的扭矩相等。速比齒輪的扭矩之和即為大驅(qū)動齒輪扭矩。選小齒輪 45# 調(diào)質(zhì) HBS1=240;大齒輪 45# 常化 HBS2=200 取Z2=28 (3-51) 又速比齒輪為滿足輥距調(diào)整要求,大輥距的開煉機速比齒輪應(yīng)采用漸開線長齒形。其齒全高H=(2.5-2.6)m 齒頂高H1=(1.1-1.2)m 齒根高h2=1.4m 。齒寬b=(12-15)m。否則,會由于輥距過大造成齒的嚙合條件惡化,影響齒輪壽命。齒全高h=2.5m=45mm,h1=1.1m=19.8mm取h1=20mm,則h2=25mm,齒寬b=15m=270mm。按彎曲強度校核Hh,強度滿足。按彎曲強度校核強度滿足。沈陽化工大學(xué)科亞學(xué)院學(xué)士學(xué)位論文 第四章 主要零部件設(shè)計 第四章 主要零部件設(shè)計4.1輥筒輥筒的材料一般采用冷硬鑄鐵。他的特點是內(nèi)部韌性好,強度大。表面堅強,耐磨耐腐蝕。冷硬鑄鐵輥筒分為普通冷硬鑄鐵和合金冷硬鑄鐵,本設(shè)計中采用合金冷硬鑄鐵。輥筒的結(jié)構(gòu)有兩種:中空結(jié)構(gòu)和圓周鉆孔結(jié)構(gòu)。本設(shè)計采用中空結(jié)構(gòu)。輥筒的受力分析:開煉機的輥筒工作時守有較大的橫壓力,摩擦力,溫度手里,大小驅(qū)動齒輪和速比齒輪的作用力。此外,輥筒的自重作用必須考慮。膠料對輥筒的橫壓力:Pp=109666.1千克 = 驅(qū)動齒輪的作用力 大驅(qū)動齒輪的圓周作用力經(jīng)電機、減速器、大驅(qū)動齒輪傳來的扭矩,是提供前后混加工膠料的需要,故由前后輥共同承擔(dān),既Mk=Mk1+Mk2 在煉膠時刻近似的認為Mk1=Mk2。 (4-1) 為大驅(qū)動齒輪軸線與垂直先偏移角 徑向力 -壓力角20 T=332.8kg 速比齒輪的作用力:當(dāng)速比很小時刻近似的認為:兩滾筒的扭矩之和即為大驅(qū)動齒輪的扭矩Mk。則Mk=Mk1+Mk2 (4-2) 徑向力 T1=458.9kg自重 后輥重: (4-3) 速比齒輪重: 大驅(qū)動齒輪重: 輥筒的強度計算:輥筒的強度計算包括:支反力,彎矩,扭矩和危險斷面強度的計算。計算時,雖然前后輥筒的工作條件相似,為安全起見,看做后滾筒沿全長傳遞全部扭矩。此外它的一端要承受驅(qū)動齒輪的作用力。另一端又要承受速比齒輪的作用力,起工作條件較前輥惡劣。所以只對后輥計算就可以了。輥筒的支反力計算: 水平方向支反力; (4-4)垂直支反力 合成支反力: =55132.9kg =56029.0kg輥筒彎矩和彎應(yīng)力計算:a) 彎矩圖:圖4-1 受力分析圖如圖,以輥筒中部位計算斷面,其最大彎矩為 (4-5) (4-6)DH-計算外徑。 a- 內(nèi)外徑比 b) 剪應(yīng)力計算: (4-7) (4-8)C) 輥筒的強度計算:根據(jù)輥筒的抽離狀態(tài)時屬于彎曲和扭轉(zhuǎn)聯(lián)合作用下的符合應(yīng)力。根據(jù)力學(xué)強度理論,可按修正后的第二強度理論計算工作用力。 (4-9) 強度滿足D)考慮溫度應(yīng)力對其強度的影響輥筒的溫度應(yīng)力是由于輥筒內(nèi)外表面的溫度差產(chǎn)生的。機械應(yīng)力與溫度應(yīng)力同時作用于輥筒。 強度條件應(yīng)符合:機+溫 溫度應(yīng)力 (4-10) -線膨脹系數(shù)。 在煉膠機正常
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