Processing method of graphite valve plate for polycrystalline silicon reduction furnace

Abstract

The application relates to a processing method of a graphite card valve for a polycrystalline silicon reduction furnace, which comprises the following steps: placing a long strip material on a platform of a trapezoidal cutting die, and making the side edge of the long strip material abut against a trapezoidal baffle; pushing the long strip material to move along the trapezoidal baffle until one end of the long strip material abuts against a fixed-distance baffle; starting the trapezoidal cutting die to make a saw blade cut and move along an avoiding groove to obtain a semi-finished product; turning the semi-finished product by 180 DEG with the length direction as the rotating shaft to pass through the trapezoidal cutting die again to obtain a trapezoidal block material; clamping the trapezoidal block material on a lathe to perform turning processing to obtain a circular table material; and cutting the circular table material into four parts along the radial direction to obtain four card valves. The material utilization rate of each trapezoidal block material processed into the circular table material is 61.0%, and the waste material rate is 39.0%, which greatly saves the material, improves the material utilization rate, reduces the waste material, reduces the waste material rate, and thus reduces the production cost.

Description

Technical Field

[0001] This application relates to the field of graphite product processing technology, and in particular to a method for processing graphite clips for a polycrystalline silicon reduction furnace. Background Technology

[0002] High-purity graphite possesses advantages such as high strength, good thermal shock resistance, high temperature resistance, oxidation resistance, low resistivity, corrosion resistance, and ease of precision machining, making it an ideal inorganic non-metallic material. It is used in the fabrication of electric heating elements, structural casting molds, crucibles and boats for smelting high-purity metals, polycrystalline silicon reduction furnace fixtures, heaters for single crystal furnaces, graphite for electrical discharge machining, sintering molds, electron tube anodes, metal coating, graphite crucibles for semiconductor technology, graphite anodes and grids for electron tubes, thyristors, and mercury arc rectifiers, etc. With the rapid development of the photovoltaic industry, the demand for graphite fixtures, a major consumable in polycrystalline silicon material production equipment, has also increased significantly. Graphite fixtures are one of the important components of polycrystalline silicon material production equipment—the reduction furnace—and their main function is to fix the silicon core and conduct electricity during production. Each set of graphite fixtures consists of clamping segments and clamping caps.

[0003] During the silicon core mounting process, one clamping cap and four clamping segments are required to form a graphite clamp. The clamping segments and the clamping cap are detachably connected by clamping or threaded connections, facilitating later disassembly and separation, and enabling the clamping cap to be reused. In applications where the clamping segments clamp the bottom end of the silicon core, after polycrystalline silicon growth, the bottom end of the silicon core becomes fused with the clamping segments and cannot be separated. The clamping segments must be separated from the clamping cap, and the clamping cap can be reused. However, for the next batch of polycrystalline silicon growth, four new clamping segments are needed to clamp the silicon core, resulting in significant consumption of the clamping segments.

[0004] Currently, the processing of graphite fixtures required in polysilicon production mainly uses cylindrical or square blanks. A material removal method (such as the material removal method disclosed in Chinese Invention Patent 201510118129.7, "A Processing Method and Special Tool for Graphite Caps and Splinters for Polysilicon Production") is used to process one cap and four splinters at a time, achieving full utilization of raw materials. However, after the splinters are used, multiple splinters need to be supplied separately. It is understood that for polysilicon manufacturers, if one cap is reused four times, 4*4 splinters are needed to match it, meaning an additional 3*4=12 splinters need to be supplied separately. The production of individual splinters cannot be carried out using the aforementioned material removal method.

[0005] In the existing technology, only cylindrical or square blanks can be used to process the card segments. First, the cylindrical or square blank needs to be turned into a frustum shape, and then it needs to be precision machined and cut into 4 card segments. In the process of turning the cylindrical or square blank into a frustum shape, there are problems of extremely low raw material utilization and high cost. Summary of the Invention

[0006] Therefore, it is necessary to address the problems of extremely low raw material utilization and high cost in the current process of machining graphite card segments from cylindrical or square blanks into frustum shapes. A method for machining graphite card segments for polycrystalline silicon reduction furnaces is provided, which enables a raw material utilization rate of 61.0% and a scrap rate of 39.0% for each trapezoidal block material machined into a frustum shape. This significantly saves materials, improves raw material utilization, reduces waste, and lowers the scrap rate, thereby reducing production costs.

[0007] A method for processing graphite card segments for a polycrystalline silicon reduction furnace includes the following steps:

[0008] S10. The graphite block is cut into plate-shaped material by wire cutting saw, and then the plate-shaped material is cut into strip material by wire cutting saw, wherein the cross-sectional shape of the strip material is square.

[0009] S20. Place the long strip on the platform of the trapezoidal cutting mold, and make the side of the long strip abut against the trapezoidal stop of the trapezoidal cutting mold. Push the long strip along the trapezoidal stop until one end of the long strip abuts against the fixed-distance stop of the trapezoidal cutting mold. Start the trapezoidal cutting mold and make the saw blade of the trapezoidal cutting mold move along the clearance groove to cut and obtain a semi-finished product.

[0010] S30. The semi-finished material is rotated 180° around its length axis and then cut again through the trapezoidal cutting mold to obtain trapezoidal block material, the bottom surface of which is square;

[0011] S40. The trapezoidal block material is clamped on a lathe and machined to obtain a frustum-shaped material;

[0012] S50. The frustum-shaped material is cut into four equal parts along its radial direction to obtain four card segments.

[0013] Preferably, in the above-mentioned processing method of graphite clips for polycrystalline silicon reduction furnace, the trapezoidal cutting mold includes a platform, a trapezoidal side, a fixed-distance side, and a saw blade. The trapezoidal side and the fixed-distance side are both disposed on the platform. The platform has an avoidance groove that extends along the straight line where the top edge of the trapezoidal side is located. The saw blade moves along the avoidance groove. There is a preset distance between the fixed-distance side and the top edge of the trapezoidal side, and the preset distance is adjustable.

[0014] Preferably, in the above-mentioned method for processing graphite clips for a polycrystalline silicon reduction furnace, the following step is further included before step S20:

[0015] S10-20. Adjust the preset distance so that in step S20, when one end of the long strip abuts against the fixed-distance retaining edge, the projection surface of the portion of the long strip end that extends beyond the clearance groove is triangular.

[0016] Preferably, in the above-mentioned method for processing graphite card segments for a polycrystalline silicon reduction furnace, step S30 specifically includes the following steps:

[0017] The semi-finished material is rotated 180° around its length axis and placed on the platform, with the side of the semi-finished material abutting against the trapezoidal stop. The semi-finished material is pushed to move along the trapezoidal stop until the end of the semi-finished material that was cut in step S20 abuts against the fixed-distance stop. The trapezoidal cutting mold is then activated, causing the saw blade to move along the clearance groove to cut and obtain the trapezoidal block material.

[0018] Preferably, in the above-mentioned method for processing graphite clips for a polycrystalline silicon reduction furnace, the following step is further included before step S30:

[0019] S20-30. Adjust the preset distance so that in step S30, when the end of the semi-finished material cut in step S20 abuts against the fixed-distance retaining edge, the projection surface of the part of the semi-finished material end that extends beyond the clearance groove is an isosceles trapezoid, and meets the dimensional requirements for turning the frustum-shaped material in step S40.

[0020] Preferably, in the above-mentioned method for processing graphite clips for a polycrystalline silicon reduction furnace, the lathe includes a special fixture for trapezoidal block materials. The special fixture for trapezoidal block materials includes a four-jaw chuck, two block jaws, and two trapezoidal jaws. The two block jaws and the two trapezoidal jaws are all disposed on the four-jaw chuck, and the two block jaws and the two trapezoidal jaws are disposed opposite each other.

[0021] Preferably, in the above-mentioned method for processing graphite card segments for a polycrystalline silicon reduction furnace, step S40 specifically includes the following steps:

[0022] S41. The trapezoidal block material is clamped in the special fixture for trapezoidal block material, the two trapezoidal jaws are clamped on the two oblique sides of the trapezoidal block material, the two block jaws are clamped on the two flat sides of the trapezoidal block material, and the machine tool is started;

[0023] S42. One end of the trapezoidal block is machined to produce a circular bottom;

[0024] S43. Remove the trapezoidal block material from the special fixture for trapezoidal block material, remove the special fixture for trapezoidal block material from the machine tool, and replace it with a three-jaw chuck for clamping the columnar material;

[0025] S44. The circular bottom of the trapezoidal block material is clamped in the three-jaw chuck, the machine tool is started, and the conical side is machined to obtain a frustum-shaped material.

[0026] Preferably, in the above-mentioned method for processing graphite clips for a polycrystalline silicon reduction furnace, step S41 further includes using the center of the lathe to press against the end face of the trapezoidal block material.

[0027] The technical solution adopted in this application can achieve the following beneficial effects:

[0028] In a method for processing graphite ferrules for a polycrystalline silicon reduction furnace disclosed in this application, trapezoidal block material is processed into frustum-shaped material to achieve material saving. Compared with processing frustum-shaped material from square blanks, the method disclosed in this application can increase the yield by 28.6%. The raw material utilization rate of each square blank processed into frustum-shaped material is 45.8%, and the scrap rate is 54.2%, while the raw material utilization rate of each trapezoidal block material processed into frustum-shaped material is 61.0%, and the scrap rate is 39.0%. Similarly, the raw material utilization rate of a long strip material processed into a square blank is 45.8%, and the scrap rate is also 54.2%; while the raw material utilization rate of the same long strip material processed into a trapezoidal block material is 58.9%, and the scrap rate is also 41.1%. Meanwhile, compared to processing frustum-shaped materials from cylindrical blanks, the method disclosed in this application can increase the yield by 12.5%. The raw material utilization rate of each cylindrical blank processed into a frustum-shaped material is 58.3%, and the scrap rate is 41.7%. In contrast, the raw material utilization rate of each trapezoidal block processed into a frustum-shaped material is 61.0%, and the scrap rate is 39.0%. For materials of the same volume, the raw material utilization rate is 52.3% and the scrap rate is 47.7% when processed from cylindrical blanks, while the raw material utilization rate is 58.9% and the scrap rate is 41.1% when processed from trapezoidal blocks.

[0029] In summary, the processing method disclosed in this application can greatly save materials, improve the utilization rate of raw materials, reduce waste, and lower the waste rate, thereby reducing production costs. Attached Figure Description

[0030] Figure 1 This is a schematic flowchart of a method for processing graphite card segments for a polycrystalline silicon reduction furnace disclosed in an embodiment of this application;

[0031] Figure 2 This is a schematic diagram of the trapezoidal cutting mold disclosed in the embodiments of this application;

[0032] Figure 3 This is a schematic diagram of the special fixture for trapezoidal block materials disclosed in the embodiments of this application;

[0033] Figure 4 This is a flowchart illustrating steps S20 and S30 as disclosed in the embodiments of this application;

[0034] Figure 5 This is a schematic diagram of the trapezoidal block material disclosed in the embodiments of this application;

[0035] Figure 6 This is a schematic diagram of the frustum-shaped material disclosed in the embodiments of this application;

[0036] Figure 7 This is a schematic diagram showing the cutting process for square billets and trapezoidal blocks.

[0037] Among them: trapezoidal cutting mold 100, platform 110, clearance groove 111, trapezoidal side guard 120, fixed distance side guard 130, saw blade 140, special clamp for trapezoidal block material 200, four-jaw chuck 210, block clamp 220, trapezoidal clamp 230. Implementation

[0038] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings. Preferred embodiments of this application are shown in the drawings. However, this application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this application.

[0039] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," "top," "bottom," "end," "top," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0041] Please refer to Figure 2 and Figure 4This application discloses a trapezoidal cutting mold 100 for cutting long strips of material into trapezoidal blocks to save material. The trapezoidal cutting mold 100 disclosed in this application includes a platform 110, a trapezoidal retaining edge 120, a fixed-distance retaining edge 130, and a saw blade 140, wherein:

[0042] Please refer to this again. Figure 2 Both the trapezoidal guard 120 and the fixed-distance guard 130 are set on the platform 110. The platform 110 has a clearance groove 111, which extends along the straight line where the top edge of the trapezoidal guard 120 is located. The saw blade 140 moves along the clearance groove 111 to cut. There is a preset distance between the fixed-distance guard 130 and the top edge of the trapezoidal guard 120, and the preset distance is adjustable.

[0043] Please refer to this again. Figure 4 In the specific processing, firstly, adjust the preset distance between the top edge of the fixed-distance retaining edge 130 and the trapezoidal retaining edge 120. After adjusting it appropriately (specifically, reducing it), place the long strip on the platform 110, and make the side of the long strip abut against the trapezoidal retaining edge 120. Push the long strip along the trapezoidal retaining edge 120 until one end of the long strip abuts against the fixed-distance retaining edge 130. Start the trapezoidal cutting mold 100, so that the saw blade 140 moves along the clearance groove 111 to cut and obtain the semi-finished product. Then adjust the fixed-distance retaining edge 130. After adjusting the preset distance between the top edge of the trapezoidal retaining edge 120 and the semi-finished material, rotate it 180° with its length direction as the axis of rotation and place it on the platform 110. Make the side of the semi-finished material abut against the trapezoidal retaining edge 120 and push the semi-finished material along the trapezoidal retaining edge 120 until the end of the semi-finished material that was cut in the previous step (the tip of the inclined edge) abuts against the fixed-distance retaining edge 130. Start the trapezoidal cutting mold 100 and make the saw blade 140 cut and move along the clearance groove 111 to obtain a trapezoidal block material.

[0044] In the process of processing individual card segments, they first need to be processed into a frustum shape (frustum-shaped material mentioned later). Please refer to [reference needed]. Figure 7 Suppose there are two strips of material of the same size. If one strip is processed into individual card segments using existing techniques, it first needs to be cut into square blanks, resulting in 7 square blanks. However, if the other strip is cut using the trapezoidal cutting die 100 disclosed in this application, it can be cut into 9 trapezoidal blocks. That is, the same strip, when cut using existing methods, can produce 7 card segments, while the same strip, when cut using the method disclosed in this application, can produce 9 card segments, increasing the yield by 28.6%. If the strip is longer, the yield will be even higher, exceeding 28.6%. It should be noted that trapezoidal blocks can be used to process frustum-shaped pieces (hereinafter referred to as frustum-shaped pieces).

[0045] In the processing of individual card segments, in the existing technology, when turning a square blank into a frustum shape, most of the material is wasted during turning, especially at the top of the frustum. This position results in the largest amount of material wasted from the square blank, leading to extremely low raw material utilization. However, by using trapezoidal blocks, when turning at the top of the frustum, the material wasted at the sloping sides of the trapezoidal blocks can be reduced, thereby saving material and increasing the yield by 28.6%. This improves the raw material utilization rate in the processing of individual card segments and helps to reduce production costs.

[0046] Please refer to Figure 3 and Figure 5 This application discloses a special fixture 200 for trapezoidal block materials, used to clamp trapezoidal block materials. After the trapezoidal block materials are clamped in the special fixture 200, they are machined on a lathe. The special fixture 200 for trapezoidal block materials disclosed in this application includes a four-jaw chuck 210, two block jaws 220, and two trapezoidal jaws 230, wherein:

[0047] Please refer to this again. Figure 3 Two block-shaped jaws 220 and two trapezoidal jaws 230 are both disposed on the four-jaw chuck 210, with the two block-shaped jaws 220 being disposed opposite to each other and the two trapezoidal jaws 230 being disposed opposite to each other.

[0048] During the specific clamping process, the two oblique sides of the trapezoidal block material correspond to the two trapezoidal jaws 230, and the two flat sides of the trapezoidal block material correspond to the two block jaws 220. That is, the two trapezoidal jaws 230 clamp the two oblique sides of the trapezoidal block material, and the two block jaws 220 clamp the two flat sides of the trapezoidal block material, thereby achieving the clamping of the trapezoidal block material. The special fixture 200 for trapezoidal block materials is used on a lathe; that is, the lathe includes the special fixture 200 for trapezoidal block materials. The lathe clamps the trapezoidal block material using the special fixture 200 for trapezoidal block materials and then performs turning operations.

[0049] By clamping the two flat sides of the trapezoidal block material with two block-shaped jaws 220, the inclined sides of the trapezoidal block material can be prevented from being subjected to force and slipping out of the special clamp 200 for trapezoidal block material, thereby avoiding unstable clamping. The special clamp 200 for trapezoidal block material can stably clamp the trapezoidal block material, improving the stability and reliability of the processing.

[0050] To further improve the stability and reliability of the processing, optionally, after the lathe clamps the trapezoidal block material using the special fixture 200 for trapezoidal block material, the lathe's center presses against the end face of the trapezoidal block material, thereby restricting the trapezoidal block material from sliding out of the special fixture 200, thus further avoiding unstable clamping and further improving the stability and reliability of the processing.

[0051] Please refer to Figures 1 to 7 This application discloses a method for processing graphite card segments for a polycrystalline silicon reduction furnace, comprising the following steps:

[0052] S10. Cut the graphite block into plate-shaped material using a wire EDM saw, and then cut the plate-shaped material into strip-shaped material using a wire EDM saw. The cross-sectional shape of the strip-shaped material is square.

[0053] S20. Place the long strip on the platform 110 of the trapezoidal cutting mold 100, and make the side of the long strip abut against the trapezoidal stop 120 of the trapezoidal cutting mold 100. Push the long strip along the trapezoidal stop 120 until one end of the long strip abuts against the fixed stop 130 of the trapezoidal cutting mold 100. Start the trapezoidal cutting mold 100, and make the saw blade 140 of the trapezoidal cutting mold 100 cut and move along the clearance groove 111 to obtain a semi-finished product.

[0054] Furthermore, the following steps are included before step S20:

[0055] S10-20. Adjust the preset distance so that in step S20, when one end of the long strip abuts against the fixed-distance retaining edge 130, the projection surface of the part of the long strip end that extends beyond the clearance groove 111 is triangular. The part of the long strip end that extends beyond the clearance groove 111 is cut off and becomes waste. Therefore, minimizing the part of the long strip end that extends beyond the clearance groove 111 can reduce waste and achieve the purpose of saving material. The placement position with the minimum part of the long strip end that extends beyond the clearance groove 111 is the placement position when the projection surface of the part of the long strip end that extends beyond the clearance groove 111 is triangular. Therefore, this method can minimize waste and achieve the purpose of saving material.

[0056] In the specific processing, firstly, adjust the preset distance between the fixed-distance stop 130 and the top edge of the trapezoidal stop 120. After the adjustment is appropriate (specifically, the projection surface of the part of the long strip that extends beyond the clearance groove 111 is triangular), place the long strip on the platform 110 and make the side of the long strip abut against the trapezoidal stop 120. Push the long strip along the trapezoidal stop 120 until one end of the long strip abuts against the fixed-distance stop 130. Start the trapezoidal cutting mold 100 and make the saw blade 140 cut and move along the clearance groove 111 to obtain the semi-finished material.

[0057] S30. The semi-finished material is rotated 180° along its length axis and then cut again through the trapezoidal cutting die 100 to obtain a trapezoidal block material with a square base.

[0058] Specifically, step S30 includes the following steps:

[0059] The semi-finished material is rotated 180° around its length axis and placed on the platform 110. The side of the semi-finished material is then pressed against the trapezoidal retaining edge 120. The semi-finished material is pushed along the trapezoidal retaining edge 120 until the end of the semi-finished material that was cut in step S20 comes into contact with the fixed-distance retaining edge 130. The trapezoidal cutting mold 100 is then activated, and the saw blade 140 moves along the clearance groove 111 to cut and obtain a trapezoidal block material.

[0060] Furthermore, the following steps are included before step S30:

[0061] S20-30. Adjust the preset distance so that in step S30, when the end of the semi-finished material cut in step S20 abuts against the fixed-distance retaining edge 130, the projection surface of the part of the semi-finished material end that exceeds the clearance groove 111 is an isosceles trapezoid, and meets the dimensional requirements for turning the frustum-shaped material in step S40.

[0062] Before step S30, the preset distance is adjusted so that the trapezoidal block material obtained by the final cutting meets the size requirements for turning the frustum-shaped material in step S40. This avoids the problem of the size being too small to meet the size requirements for turning the frustum-shaped material, and also avoids the problem of the size being too large, which would result in a lot of waste material during the turning of the frustum-shaped material.

[0063] In the specific processing, firstly, the preset distance between the fixed-distance stop 130 and the top edge of the trapezoidal stop 120 is adjusted. After the adjustment is appropriate (specifically, the projection surface of the part of the semi-finished material that extends beyond the relief groove 111 is an isosceles trapezoid, and meets the size requirements for turning the frustum-shaped material in step S40), the semi-finished material is rotated 180° with its length direction as the axis of rotation and placed on the platform 110. The side of the semi-finished material is then placed against the trapezoidal stop 120. The semi-finished material is pushed along the trapezoidal stop 120 until the end of the semi-finished material that was cut in step S20 (the tip of the inclined side) abuts against the fixed-distance stop 130. The trapezoidal cutting mold 100 is then activated, and the saw blade 140 moves along the relief groove 111 to cut and obtain a trapezoidal block material.

[0064] S40. The trapezoidal block material is clamped on a lathe and machined to obtain a frustum-shaped material;

[0065] The trapezoidal block material can be clamped using the aforementioned trapezoidal block material special fixture 200, so that the trapezoidal block material special fixture 200 can stably clamp the trapezoidal block material, thereby improving the stability and reliability of the processing.

[0066] Specifically, step S40 includes the following steps:

[0067] S41. Clamp the trapezoidal block material in the trapezoidal block material special fixture 200, with two trapezoidal jaws 230 clamping the two oblique sides of the trapezoidal block material and two block jaws 220 clamping the two flat sides of the trapezoidal block material, and start the machine tool;

[0068] By clamping the two flat sides of the trapezoidal block material with two block-shaped jaws 220, the inclined sides of the trapezoidal block material can be prevented from being subjected to force and slipping out of the special clamping fixture 200, thereby avoiding unstable clamping. The special clamping fixture 200 can stably clamp the trapezoidal block material, improving the stability and reliability of the lathe machining process.

[0069] To further improve the stability and reliability of the lathe machining process, step S41 may optionally include using the lathe's center to hold the end face of the trapezoidal block material. That is, after the lathe clamps the trapezoidal block material using the special fixture 200 for trapezoidal block material, the lathe's center holds the end face of the trapezoidal block material, restricting the trapezoidal block material from sliding out of the special fixture 200, thereby further avoiding unstable clamping and further improving the stability and reliability of the machining process.

[0070] S42. Turn one end of the trapezoidal block material to create a round bottom;

[0071] S43. Remove the trapezoidal block material from the special clamp 200 for trapezoidal block material, remove the special clamp 200 for trapezoidal block material from the machine tool, and replace it with a three-jaw chuck for clamping the columnar material.

[0072] Alternatively, first remove the trapezoidal block material from the machine tool along with the trapezoidal block material using the special fixture 200, and then remove the trapezoidal block material from the special fixture 200.

[0073] S44. Clamp the circular bottom of the trapezoidal block material into a three-jaw chuck, start the machine tool, and turn to machine the conical side to obtain a frustum-shaped material.

[0074] S50. The frustum-shaped material is cut into four equal parts along its radial direction to obtain four card segments.

[0075] In a method for processing graphite ferrules for a polycrystalline silicon reduction furnace disclosed in this application, trapezoidal block material is processed into frustum-shaped material to achieve material saving. Compared with processing frustum-shaped material from square blanks, the method disclosed in this application can increase the yield by 28.6%. The raw material utilization rate of each square blank processed into frustum-shaped material is 45.8%, and the scrap rate is 54.2%, while the raw material utilization rate of each trapezoidal block material processed into frustum-shaped material is 61.0%, and the scrap rate is 39.0%. Similarly, the raw material utilization rate of a long strip material processed into a square blank is 45.8%, and the scrap rate is also 54.2%; while the raw material utilization rate of the same long strip material processed into a trapezoidal block material is 58.9%, and the scrap rate is also 41.1%. Meanwhile, compared to processing frustum-shaped materials from cylindrical blanks, the method disclosed in this application can increase the yield by 12.5%. The raw material utilization rate of each cylindrical blank processed into a frustum-shaped material is 58.3%, and the scrap rate is 41.7%. In contrast, the raw material utilization rate of each trapezoidal block processed into a frustum-shaped material is 61.0%, and the scrap rate is 39.0%. For materials of the same volume, the raw material utilization rate is 52.3% and the scrap rate is 47.7% when processed from cylindrical blanks, while the raw material utilization rate is 58.9% and the scrap rate is 41.1% when processed from trapezoidal blocks.

[0076] In summary, the processing method disclosed in this application can greatly save materials, improve the utilization rate of raw materials, reduce waste, and lower the waste rate, thereby reducing production costs.

[0077] To further illustrate the effects of the method disclosed in this application, the applicant provides the following embodiments:

[0078] Regardless of whether the blank is cylindrical, square, or trapezoidal, the process always begins by machining a frustum shape, followed by machining the flaps. The machining of flaps from the frustum shape follows the same method, and this process is identical. Therefore, the following examples illustrate the waste or material savings during the machining of frustum shapes from cylindrical, square, or trapezoidal blanks. It should be noted that all length units mentioned below are in centimeters, and all volume units are in cubic centimeters.

[0079] Suppose we need to process a frustum-shaped material with a base diameter of 4, a top diameter of 2, and a height of 4. We would need a 4*4*4 square blank; a cylindrical blank with a base diameter of 4 and a height of 4; and a trapezoidal block with a shortest side of 2 on the top base, a shortest side of 4 on the bottom base, and a height of 4.

[0080] Example 1: Take a strip of material with a length of 28, a width of 4, and a height of 4, and cut it into square blanks (4*4*4). This strip of material is then cut into 7 square blanks, which can be processed into 7 frustum-shaped pieces. The waste is calculated as follows (pi is taken as 3.14):

[0081] The volume of each frustum-shaped piece is approximately 29.3, and the volume of 7 frustum-shaped pieces is 7 * 29.3 = 205.1.

[0082] The volume of each square billet is equal to 64, and the volume of 7 square billets (i.e., the volume of the long strip) is equal to 448.

[0083] The waste material from processing each square billet into a frustum shape is 64 - 29.3 = 34.7. Therefore, the total waste material from processing 7 square billets (i.e., long strips) is 34.7 * 7 = 242.9, or 448 - 205.1 = 242.9.

[0084] The raw material utilization rate for processing each square blank into a frustum shape is 45.8%, and the scrap rate is 54.2%.

[0085] The raw material utilization rate of processing the long strip into 7 frustum-shaped pieces is 45.8%, and the waste rate is 54.2%.

[0086] Example 2: A long strip of material with a length of 28 mm, a width of 4 mm, and a height of 4 mm is taken and cut according to the method disclosed in this application, resulting in exactly 9 trapezoidal blocks (see reference). Figure 7 Given a base with an upper base length of 2 and a lower base length of 4, 7 frustum-shaped pieces can be machined. The waste material is calculated as follows (pi is taken as 3.14):

[0087] The volume of each frustum-shaped piece is approximately 29.3, and the volume of 9 frustum-shaped pieces is 9 * 29.3 = 263.7.

[0088] The volume of each trapezoidal block is 48, the volume of 9 trapezoidal blocks is 432, the volume of the long strip is 448, and the waste material here is 448-432=16.

[0089] The waste material from processing each trapezoidal block into a frustum shape is 48 - 29.3 = 18.7. Therefore, the total waste material from 9 trapezoidal blocks is 18.7 * 9 = 168.3, or 448 - 263.7 - 16 = 168.3. The total waste material from the long strip is 16 + 168.3 = 184.3.

[0090] The raw material utilization rate for processing each trapezoidal block into a frustum shape was 61.0%, and the scrap rate was 39.0%.

[0091] The raw material utilization rate of processing the long strip into nine frustum-shaped pieces was 58.9%, and the waste rate was 41.1%.

[0092] From Examples 1 and 2, we can obtain:

[0093] (1) The same long strip can be processed into 9 frustum-shaped pieces, increasing the yield by 28.6%. If the strip is longer, the yield will be even greater, exceeding 28.6%.

[0094] (2) When processing a single frustum-shaped material, the raw material utilization rate of each square blank processed into a frustum-shaped material is 45.8%, and the waste rate is 54.2%; while the raw material utilization rate of each trapezoidal block processed into a frustum-shaped material is 61.0%, and the waste rate is 39.0%. The raw material utilization rate is improved, thereby achieving the purpose of saving materials. Improving the raw material utilization rate in the processing of individual card segments is beneficial to reducing production costs.

[0095] (3) The same long strip material has a raw material utilization rate of 45.8% and a waste rate of 54.2% when it is made into square blanks; while the same long strip material has a raw material utilization rate of 58.9% and a waste rate of 41.1% when it is made into trapezoidal block material; from the perspective of the same long strip material, the raw material utilization rate can also be improved.

[0096] Example 3: Take a cylindrical blank with a bottom diameter of 4 and a height of 4, and machine it into a frustum-shaped piece with a bottom diameter of 4, a top diameter of 2, and a height of 4. Calculate the waste material as follows (pi is taken as 3.14):

[0097] The volume of each frustum-shaped blank is approximately 29.3, and the volume of each cylindrical blank is 50.24. The waste material from processing each cylindrical blank into a frustum-shaped blank is 50.24 - 29.3 = 20.94. The raw material utilization rate from processing each cylindrical blank into a frustum-shaped blank is 58.3%, and the waste rate is 41.7%.

[0098] Through Examples 2 and 3, we can obtain:

[0099] When processing a single frustum-shaped piece, the raw material utilization rate of each cylindrical blank into a frustum-shaped piece is 58.3%, and the scrap rate is 41.7%; while the raw material utilization rate of each trapezoidal block into a frustum-shaped piece is 61.0%, and the scrap rate is 39.0%. The improved raw material utilization rate achieves the goal of saving materials. Improving the raw material utilization rate in the processing of individual card segments is beneficial to reducing production costs.

[0100] Based on Example 3, the total volume of the material is calculated to be 448, which is the total waste material processed into 8 frustum-shaped pieces:

[0101] In Example 2, the overall volume of the material is 448. Based on this volume, a cylindrical piece with a base diameter of 4 and a length of 35.7 can be obtained. Cutting this cylindrical piece yields a maximum of 8 (35.7 / 4 = 8.925) cylindrical blanks with a base diameter of 4 and a height of 4. The waste is calculated as follows (pi is taken as 3.14):

[0102] The volume of each frustum-shaped piece is approximately 29.3, and the volume of 8 frustum-shaped pieces is 8 * 29.3 = 234.4.

[0103] The volume of each cylindrical billet is 50.24, and the volume of 8 cylindrical billets is 8 * 50.24 = 401.92. The total waste here is 448 - 401.92 = 46.08.

[0104] The waste material from processing each cylindrical billet into a frustum shape is 50.24 - 29.3 = 20.94. Therefore, the total waste material from the 8 cylindrical billets is 20.94 * 8 = 167.52, or 448 - 234.4 - 46.08 = 167.52, and the total waste material is 46.08 + 167.52 = 213.6.

[0105] The raw material utilization rate for processing each cylindrical blank into a frustum shape was 58.3%, and the scrap rate was 41.7%.

[0106] The raw material utilization rate of the material with a volume of 448 was 52.3% when it was processed into 8 frustum-shaped pieces, and the waste rate was 47.7%.

[0107] Therefore, it can be seen that:

[0108] (1) For the same volume of material (volume is 448), 8 frustum-shaped pieces can be processed from cylindrical blanks, while 9 frustum-shaped pieces can be processed from long strips to trapezoidal blocks, increasing the yield by 12.5%. If the long strip is longer, the yield will be even greater, exceeding 12.5%.

[0109] (2) When processing a single frustum-shaped material, the raw material utilization rate of each cylindrical blank processed into a frustum-shaped material is 58.3%, and the waste rate is 41.7%; while the raw material utilization rate of each trapezoidal block processed into a frustum-shaped material is 61.0%, and the waste rate is 39.0%. The raw material utilization rate is improved, thereby achieving the purpose of saving materials. Improving the raw material utilization rate in the processing of individual card segments is beneficial to reducing production costs.

[0110] (3) For materials of the same volume (volume is 448), the raw material utilization rate is 52.3% and the waste rate is 47.7% when using cylindrical blanks; while for materials of the same volume using trapezoidal block blanks, the raw material utilization rate is 58.9% and the waste rate is 41.1%; from the perspective of materials of the same volume, the raw material utilization rate can also be improved.

[0111] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0112] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for processing a graphite segment for a polysilicon reduction furnace, characterized by, The method comprises the following steps: S10. Cutting a graphite block into a plate-shaped material by a wire cutting saw bed, and then cutting the plate-shaped material into a long strip-shaped material by the wire cutting saw bed, wherein a cross-sectional shape of the long strip-shaped material is a square; S20. Placing the long strip-shaped material on a platform (110) of a trapezoidal cutting mold (100), and making side edges of the long strip-shaped material abut against trapezoidal blocking edges (120) of the trapezoidal cutting mold (100), and pushing the long strip-shaped material to move along the trapezoidal blocking edges (120) until one end of the long strip-shaped material abuts against a fixed-distance blocking edge (130) of the trapezoidal cutting mold (100), and starting the trapezoidal cutting mold (100) to make a saw blade (140) of the trapezoidal cutting mold (100) cut and move along an avoiding groove (111), thereby obtaining a semi-finished material; S30. Turning the semi-finished material by 180 degrees around a rotation axis in a length direction of the semi-finished material, and then re-cutting the semi-finished material by the trapezoidal cutting mold (100), thereby obtaining a trapezoidal block-shaped material, wherein a bottom surface shape of the trapezoidal block-shaped material is a square; S40. Clamping the trapezoidal block-shaped material on a lathe to perform turning processing, thereby obtaining a circular table-shaped material; S50. Dividing the circular table-shaped material into four petals along a radial direction of the circular table-shaped material, thereby obtaining four clamping petals; The trapezoidal cutting mold (100) comprises the platform (110), the trapezoidal blocking edges (120), the fixed-distance blocking edge (130) and the saw blade (140), wherein the trapezoidal blocking edges (120) and the fixed-distance blocking edge (130) are arranged on the platform (110), the platform (110) is provided with the avoiding groove (111) extending along a straight line where top edges of the trapezoidal blocking edges (120) are located, the saw blade (140) cuts and moves along the avoiding groove (111), and the fixed-distance blocking edge (130) has a preset distance from the top edges of the trapezoidal blocking edges (120), and the preset distance is adjustable; Before the step S20, the method further comprises the following step: S10-20. Adjusting the preset distance, so that, in the step S20, when the one end of the long strip-shaped material abuts against the fixed-distance blocking edge (130), a projection plane of a part of the long strip-shaped material beyond the avoiding groove (111) is a triangle; The step S30 specifically comprises the following steps: turning the semi-finished material by 180 degrees around the rotation axis in the length direction of the semi-finished material, and placing the semi-finished material on the platform (110) and making side edges of the semi-finished material abut against the trapezoidal blocking edges (120), and pushing the semi-finished material to move along the trapezoidal blocking edges (120) until a tip of an oblique edge of one end of the semi-finished material cut in the step S20 abuts against the fixed-distance blocking edge (130), and starting the trapezoidal cutting mold (100) to make the saw blade (140) cut and move along the avoiding groove (111), thereby obtaining the trapezoidal block-shaped material; Before the step S30, the method further comprises a step S20-30 of adjusting the preset distance, so that when the half-finished workpiece is cut in the step S20 and the end of the half-finished workpiece abuts against the distance-limiting edge (130) with the bevel tip, the projection surface of the part of the end of the half-finished workpiece that exceeds the avoiding groove (111) is a isosceles trapezoid, and the size requirement of the circular-truncated-cone-shaped workpiece in the step S40 is met.

2. The method of claim 1, wherein the graphite segment is used in a polycrystalline silicon reduction furnace. The lathe comprises a trapezoidal block-shaped workpiece special fixture (200), the trapezoidal block-shaped workpiece special fixture (200) comprises a four-jaw chuck (210), two block-shaped clamping jaws (220) and two trapezoidal clamping jaws (230), the two block-shaped clamping jaws (220) and the two trapezoidal clamping jaws (230) are arranged on the four-jaw chuck (210), and the two block-shaped clamping jaws (220) are arranged oppositely, and the two trapezoidal clamping jaws (230) are arranged oppositely.

3. The method of claim 2, wherein the graphite segment is formed by cutting a graphite block into a predetermined shape. The step S40 specifically comprises the following steps: S41, clamping the trapezoidal block-shaped workpiece on the trapezoidal block-shaped workpiece special fixture (200), the two trapezoidal clamping jaws (230) are clamped on the two inclined sides of the trapezoidal block-shaped workpiece, the two block-shaped clamping jaws (220) are clamped on the two flat sides of the trapezoidal block-shaped workpiece, and the lathe is started; S42, turning one end of the trapezoidal block-shaped workpiece to process a circular bottom; S43, taking the trapezoidal block-shaped workpiece off the trapezoidal block-shaped workpiece special fixture (200), and taking the trapezoidal block-shaped workpiece special fixture (200) off the lathe, and replacing the three-jaw chuck for clamping a columnar workpiece; S44, clamping the circular bottom of the trapezoidal block-shaped workpiece on the three-jaw chuck, starting the lathe, and turning a conical side surface to obtain a circular-truncated-cone-shaped workpiece.

4. The method for processing graphite card segments for a polycrystalline silicon reduction furnace according to claim 3, characterized in that, In the step S41, the top of the lathe is used to abut against the end surface of the trapezoidal block-shaped workpiece.

Images