High-fatigue steel wire rope and preparation method thereof

Abstract

The invention discloses a high-fatigue steel wire rope and a preparation method thereof, and the preparation method comprises the following preparation steps: 1) first compaction: carrying out strand compaction on the steel wire rope by adopting four groups of eight rollers so as to realize helical surface contact of steel wires in the steel wire rope; 2) coating (filling) the metal core of the steel wire rope with a mixed modified high polymer material liner; 3) controlling the temperatures of four sections of coating (filling) and heating to be 175 DEG C, 180 DEG C, 195 DEG C and 197 DEG C on an extrusion plastic coating machine; (4) a medium-frequency power supply MSH10-80K / 06-T380 / NW and a heating cabinet MSH10-80K / CL are installed in front of a pay-off device of the rope combining machine; and (5) compacting in an adjustable high-speed forging machine (secondary compacting). The modified high polymer material gasket is extruded and coated on the surfaces of the steel wire rope and the metal core and among the strands, the steel wire rope has impact resistance, the fatigue resistance, extrusion resistance and wear resistance of the steel wire rope are improved, and corrosion of the steel wire rope can be reduced; the fatigue life of the steel wire rope is prolonged to 60.120 thousand times from 19.82 thousand times when the liner is not coated (filled) through a contrast test of a fatigue testing machine.

Description

Technical Field

[0001] The invention relates to the technical field of steel wire ropes, in particular to a high fatigue steel wire rope and a preparation method thereof. Background Art

[0002] The production of steel wire rope has a history of 190 years. As an important tool for lifting and hoisting, steel wire rope is widely used in bridges, machinery, transportation, petroleum, ports, mine hoisting, fisheries, marine engineering, etc. In recent years, the varieties, structures and quantities of steel wire ropes have developed greatly. With the continuous development of science and technology, various industries have put forward higher requirements on the performance of steel wire ropes, especially military industry, machinery, ports, mine hoisting, marine engineering, etc., which have put forward higher requirements on the strength, toughness, breaking tension and fatigue life of steel wire ropes, especially the improvement of fatigue life of compacted steel wire ropes with strength grades above 1960MPa. Only a few manufacturers in China have conducted experimental production. Due to the limitations of process technology, tooling fixtures and preparation methods, there is no obvious improvement in product quality. The country has to rely on imports. The metal core of compacted steel wire rope coated (filled) with polymer liner is the direction to improve the fatigue life of steel wire ropes.

[0003] Metal core wire rope is widely used in port machinery, ships, and large lifting machinery due to its large breaking force and stable structure. However, the metal core inside the wire rope and the outer strands will produce mutual friction and extrusion damage during use, especially when passing through guide pulleys and winches. The wire rope is prone to broken wires from the inside, resulting in a decrease in the fatigue life of the wire rope. The internal damage is not easy to be inspected and discovered, which seriously affects its safe use.

[0004] The metal core coating (filling) liner of the steel wire rope is a way to reduce the mutual friction and extrusion damage between the steel wires inside the steel wire rope, which leads to a reduction in the fatigue life of the steel wire rope, and to increase the fatigue life of the steel wire rope. The present invention focuses on the organic combination of the compaction of the steel wire rope and the metal core coating (filling) mixed modified polymer material liner and the steel wire rope production process method.

[0005] Therefore, a high fatigue steel wire rope and a preparation method thereof are proposed. Summary of the invention

[0006] The object of the present invention is to provide a high fatigue resistance steel wire rope and a preparation method thereof, so as to solve the problems raised in the above background technology.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A high fatigue steel wire rope comprises an outermost steel wire rope outer strand, a middle layer of metal core outer strand and an innermost metal core middle strand, a polymer liner is arranged between the metal core outer strand and the steel wire rope outer strand, and the polymer liner is composed of PA66, glass fiber and toughening agent.

[0009] Furthermore, the glass fiber particles are glass fiber C-type particles.

[0010] Furthermore, the toughening agent is A665 particles.

[0011] Furthermore, the glass fiber is 30%-35%.

[0012] Furthermore, the toughening agent is 8%-12%.

[0013] A high fatigue steel wire rope forging machine comprises a machine base and a slider, wherein the machine base is provided with a variable frequency motor;

[0014] The output end of the variable frequency motor is connected to the second pulley, and the second pulley drives the first pulley to rotate;

[0015] The pulley is connected to the hollow shaft, and the vertex of the slider contacts the vertex of the circumscribed circle of the roller, so that the slider hits the forging die.

[0016] Furthermore, the second pulley is connected to the first pulley via a V-belt.

[0017] Furthermore, the pulley 1 is connected to the hollow shaft via a flat key.

[0018] A method for preparing a high fatigue steel wire rope comprises the following preparation steps:

[0019] 1) First compaction: The steel wire rope is compacted by 4 groups of 8 rollers to achieve spiral contact of the steel wires in the steel wire rope;

[0020] 2) The metal core of the steel wire rope is coated (filled) with a mixed modified polymer material liner, and polyamide 66 (nylon) is selected as the main material for the coating (filling) liner. 30% to 35% of glass fiber C-type particles and 8% to 12% of toughening agent A665 particles are added to PA66 to make PA66 a modified polymer material liner;

[0021] 3) On the extrusion coating machine, control the coating (filling) heating temperature in four stages to 175°C, 180°C, 195°C, and 197°C, so that the modified polymer material liner reaches 1-1.5mm and is evenly coated on the surface of the metal core of the steel wire rope;

[0022] 4) Install the medium frequency power supply MSH10-80K / 06-T380 / NW and heating cabinet MSH10-80K / CL in front of the pay-off device of the rope closing machine to achieve the softening of the heating part of the modified polymer material liner during the rope closing process. The temperature control is the first group: 110℃~117℃, the second group: 120℃~125℃, and the third group: 145℃~150℃;

[0023] 5) Compacting (second compaction) on an adjustable high-speed forging machine makes the wire rope structure more compact, and the filling coefficient is increased to 0.92. After the modified polymer material liner on the surface of the metal core is softened, it is tightly filled between the metal core and the outer strands, so that the modified polymer material liner effectively isolates the metal core steel wire from contact with the outer strand steel wire.

[0024] Furthermore, in the step 5), when forging on a high-speed forging machine, the variable frequency motor (YVP225S-4) rotates, driving the sequence pulley 2 to rotate. Under the V-belt drive, the pulley 1 starts to rotate, and the pulley 1 is connected with a flat key, and the hollow shaft rotates at the same time. Under the influence of centrifugal force and reaction force, two sets of mutually perpendicular sliders (also called mushroom heads) will change direction of movement and quickly hit the forging die when the vertex of one set of sliders contacts the vertex of the circumscribed circle of the roller column, thereby generating a reaction force. The sliders will change direction of movement and quickly hit the forging die, thereby symmetrically hitting the surface of the wire rope. The other set of sliders and the forging die will retreat from the surface of the wire rope under the centrifugal action. The forging machine rotates at a high speed, and the sliders will hit the forging die back and forth to forge the wire rope.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] The modified polymer material liner is extruded and coated on the surface of the steel wire rope and the metal core and between each strand. The steel wire rope has impact resistance. When the steel wire rope is subjected to impact stress, the polymer material mixture liner plays a buffering role in the steel wire rope. The polymer material mixture between each strand in the steel wire rope can reduce the wear of the wheel groove, the steel wire rope and each strand, improve the fatigue resistance, extrusion resistance and wear resistance of the steel wire rope, and also reduce the corrosion of the steel wire rope;

[0027] The fatigue life of the wire rope has been compared with the fatigue testing machine, and it has increased from 198,200 times without lining (filling) to 601,200 times;

[0028] The 8×K26SW+IWRC-Φ8.0mm-2160MPa steel wire rope is used on European cranes, and all indicators meet user requirements. The 6×K36SW+IWRC-Φ25.5mm-1960MPa steel wire rope is used on port machinery (shore container cranes), achieving the normal loading and unloading of 80,000 standard containers and the expected normal use period of 8 months. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the internal structure of the steel wire rope of the present invention;

[0030] Figure 2 It is a schematic diagram of the steel wire rope structure of the present invention;

[0031] Figure 3 It is a schematic diagram of the internal structure of the forging machine of the present invention. DETAILED DESCRIPTION

[0032] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0033] Embodiment 1:

[0034] See also Figure 1 , the present invention provides a technical solution:

[0035] A high fatigue steel wire rope, comprising an outermost steel wire rope strand 1, a middle metal core outer strand 2 and an innermost metal core middle strand 4;

[0036] A polymer liner 3 is arranged between the metal core outer strand 2 and the steel wire rope outer strand 1, wherein the polymer liner 3 is composed of PA66, glass fiber, and toughening agent, the glass fiber particles used are glass fiber C-type particles, the content of which is 30%-35%, and the toughening agent uses A665 particles, the content of which is 8%-12%;

[0037] Through the above method, PA66 becomes a modified polymer material gasket, the size of the gasket is more stable, and the heat resistance and aging resistance are significantly enhanced, thereby improving the tensile strength, bending strength, impact strength and fatigue resistance of the wire rope gasket.

[0038] Embodiment 2:

[0039] A forging machine for a high fatigue steel wire rope comprises a machine base 5 and a slider 17. In order to drive the equipment to operate, a variable frequency motor 52 is arranged on the machine base 5, and the output end of the variable frequency motor 52 is connected to a pulley 2 51, so that the pulley 2 51 is connected to a pulley 1 34 through a V-belt 50;

[0040] The pulley 34 is connected to the hollow shaft 38 through the flat key 35, driving them to rotate at the same time. Under the influence of centrifugal force and reaction force, the vertex of the slider 17 contacts the vertex of the roller circumscribed circle 21, generating a reaction force. The slider 17 will change the direction of movement and quickly hit the forging die 15, thereby symmetrically hitting the surface of the wire rope. The other set of sliders 17 and the forging die 15 will retreat from the surface of the wire rope under the centrifugal effect. The forging machine rotates at a high speed, and the slider 17 hits the forging die 15 back and forth to forge the wire rope, thereby achieving the purpose of radial compaction of the wire rope.

[0041] Embodiment 3:

[0042] A method for preparing a high fatigue steel wire rope comprises the following preparation steps:

[0043] 1) First compaction: The steel wire rope is compacted by 4 groups of 8 rollers to achieve spiral contact of the steel wires in the steel wire rope;

[0044] 2) The metal core of the steel wire rope is coated (filled) with a mixed modified polymer material liner, and polyamide 66 (nylon) is selected as the main material for the coating (filling) liner. 30% to 35% of glass fiber C-type particles and 8% to 12% of toughening agent A665 particles are added to PA66 to make PA66 a modified polymer material liner;

[0045] 3) On the extrusion coating machine, control the coating (filling) heating temperature in four stages to 175°C, 180°C, 195°C, and 197°C, so that the modified polymer material liner reaches 1-1.5mm and is evenly coated on the surface of the metal core of the steel wire rope;

[0046] 4) Install the medium frequency power supply MSH10-80K / 06-T380 / NW and heating cabinet MSH10-80K / CL in front of the pay-off device of the rope closing machine to achieve the softening of the heating part of the modified polymer material liner during the rope closing process. The temperature is controlled as follows: the first group: 110℃~117℃, the second group: 120℃~125℃, the first group: 145℃~150℃;

[0047] 5) Compacting (second compacting) on ​​an adjustable high-speed forging machine. When forging on the high-speed forging machine, the variable frequency motor No. 52 (YVP225S-4) rotates, driving the No. 51 pulley 2 to rotate. Under the transmission of the No. 50 V-belt, the No. 34 pulley 1 rotates. The pulley 1 is connected with the No. 35 flat key, and the No. 38 hollow shaft rotates at the same time. Under the influence of centrifugal force and reaction force, the two sets of sliders No. 17 (also called mushroom heads) perpendicular to each other, when the vertex of one set of sliders 17 contacts the vertex of the circumscribed circle of the No. 21 roller, a reaction force is generated, and the sliders 17 will change its direction and quickly hit the forging die No. 15, thereby symmetrically hitting the surface of the wire rope. Another set of sliders 17 and 15 forging dies will retreat from the surface of the wire rope under the action of centrifugation. The forging machine rotates at high speed, and the slider 17 hits the 15 forging die back and forth to forge the wire rope, making the wire rope structure tighter and the filling coefficient increased to 0.92. After the modified polymer material liner on the surface of the metal core is softened, it is tightly filled between the metal core and the outer strands, so that the modified polymer material liner effectively isolates the metal core steel wire from contact with the outer strand steel wire.

[0048] The fatigue life of the steel wire rope produced by the above preparation method has been compared with the fatigue testing machine, and the fatigue life of the steel wire rope has increased from 198,200 times without lining (filling) to 513,700 times;

[0049] Among them, 8×K26SW+IWRC-Φ8.0mm-2160MPa steel wire rope is used on European cranes, and all indicators meet user requirements. 6×K36SW+IWRC-Φ25.5mm-1960MPa steel wire rope is used on port machinery (shore container crane), achieving the normal loading and unloading of 110,000 standard containers and the expected normal use of 12 months.

[0050] Attached below are the functional parameters of different wire ropes produced by this process:

[0051] 8×K19S+IWRC-Φ8.0mm hot-dip galvanized (AB grade) steel wire rope production process (Table 1)

[0052] 1. Wire rope structure, specifications, strength, length and quantity:

[0053]

[0054] 2. Wire rope production process and wire matching:

[0055] (1) Outer layer strand structure (9+9+1) strand matching wire: (0.56+0.32+0.62), wire tolerance: ±0.01mm.

[0056] (2) Metal core (7×19S) with wire:

[0057] Outer strand (9+9+1), wire: (0.30+0.17+0.33), wire tolerance: ±0.01mm;

[0058] Center strand (9+9+1), matching wire: (0.36+0.20+0.40), wire tolerance: ±0.01mm;

[0059] (3) Strand diameter, strand lay length, metal core diameter, metal core lay length and tolerance (Table 2)

[0060]

[0061]

[0062] Technical requirements

[0063] (1) Spray TG-1306E special grease (A1 oiling method) on the outer strands, and the presence of a small amount of oil film when touched by hand is the standard.

[0064] (2) The outer strands and the center strands of the metal core are not oiled (to ensure that the strand surface is clean). The metal core is twisted into finished products for delivery, and the fixed length of each piece is 2020 meters (0~+5m). The supplier of the outer strands (die-drawn strands) calculates the length according to the twist shrinkage coefficient of 1.06, and the fixed length of each strand is 2120 meters (0~+5m). In the production of the outer strands, the outer steel wire is butt-welded, and the electrical connection distance is ≥10 meters.

[0065] (3) The metal core and outer strands (die-drawn strands) are settled based on the actual weight of the fixed length.

[0066] 8×K26SW+IWRC-Φ11.0mm hot-dip galvanized (AB grade) steel wire rope production process 1. Steel wire rope structure, specification, strength, length, quantity:

[0067]

[0068] 2. Wire rope production process and wire matching:

[0069] (1) Outer layer structure (1+5+5 / 5+10)

[0070] Strand wire: (0.30+0.40+0.37 / 0.47+0.70), wire tolerance: ±0.01mm

[0071] (2) Metal core (7×19S) with wire:

[0072] Outer strand (9+9+1), wire: (0.41+0.23+0.45), wire tolerance: ±0.01mm Center strand (9+9+1), wire: (0.50+0.28+0.55), wire tolerance: ±0.01mm

[0073] (3) Strand diameter, strand lay length, metal core diameter, metal core lay length and tolerance:

[0074]

[0075]

[0076] Technical requirements

[0077] (1) Spray TG-1306E special grease (A1 oiling method) on the outer strands, and the standard is to feel a small amount of oil film when touched.

[0078] (2) The outer strands and the center strands of the metal core are not oiled (to ensure that the strand surface is clean). The metal core is twisted into finished products for delivery, and the fixed length of each piece is 2020 meters (0~+5m). The supplier of the outer strands (die-drawn strands) calculates the length according to the twist shrinkage coefficient of 1.06, and the fixed length of each strand is 2120 meters (0~+5m). In the production of the outer strands, the outer steel wire is butt-welded, and the electrical connection distance is ≥10 meters.

[0079] (3) The metal core and outer strands (die-drawn strands) are settled based on the actual weight of the fixed length.

[0080] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high fatigue steel wire rope, comprising an outermost steel wire rope strand (1), an intermediate metal core outer strand (2) and an innermost metal core middle strand (4), characterized in that: A polymer liner (3) is provided between the outer strands (2) of the metal core and the outer strands (1) of the steel wire rope, and the polymer liner (3) is composed of PA66, glass fiber and a toughening agent.

2. A high fatigue steel wire rope according to claim 1, characterized in that: The glass fiber particles are glass fiber C-type particles.

3. A high fatigue steel wire rope according to claim 1, characterized in that: The toughening agent is A665 particles.

4. A high fatigue steel wire rope according to claim 1, characterized in that: The glass fiber is 30%-35%.

5. The high fatigue resistance steel wire rope according to claim 1, characterized in that: The toughening agent is 8%-12%.

6. A high fatigue steel wire rope forging machine according to claim 1, characterized in that: It comprises a machine base (1) and a slider (3), wherein the machine base (1) is provided with a variable frequency motor (52); The output end of the variable frequency motor (9) is connected to the second pulley (8), and the second pulley (8) drives the first pulley (4) to rotate; The pulley 1 (5) is connected to a hollow shaft (6), and the vertex of the slider (3) contacts the vertex of the roller circumscribed circle (4), so that the slider (3) hits the forging die (2).

7. The high fatigue steel wire rope forging machine according to claim 1, characterized in that: The second pulley (9) is connected to the first pulley (5) via a V-belt (7).

8. The high fatigue steel wire rope forging machine according to claim 1, characterized in that: The pulley 1 (5) is connected to the hollow shaft (6) via a flat key (61).

9. The method for preparing a high fatigue steel wire rope according to claim 6, characterized in that: The method comprises the following preparation steps: 1) First compaction: The steel wire rope is compacted by 4 groups of 8 rollers to achieve spiral contact of the steel wires in the steel wire rope; 2) The metal core of the steel wire rope is coated (filled) with a mixed modified polymer material liner, and polyamide 66 (nylon) is selected as the main material for the coating (filling) liner. 30% to 35% of glass fiber C-type particles and 8% to 12% of toughening agent A665 particles are added to PA66 to make PA66 a modified polymer material liner; 3) On the extrusion coating machine, control the coating (filling) heating temperature in four stages to 175°C, 180°C, 195°C, and 197°C, so that the modified polymer material liner reaches 1-1.5mm and is evenly coated on the surface of the metal core of the steel wire rope; 4) Install a medium frequency induction device before the pay-off device of the rope closing machine to soften the heated part of the modified polymer material liner during the rope closing process. The temperature is controlled as follows: the first group: 110℃~117℃, the second group: 120℃~125℃, and the third group: 145℃~150℃; 5) Compacting (second compaction) on an adjustable high-speed forging machine makes the wire rope structure more compact, and the filling coefficient is increased to 0.

92. After the modified polymer material liner on the surface of the metal core is softened, it is tightly filled between the metal core and the outer strands, so that the modified polymer material liner effectively isolates the metal core steel wire from contact with the outer strand steel wire.

10. The method for preparing a high fatigue steel wire rope according to claim 9, characterized in that: In the step 5), when the high-speed forging machine is forging, the variable frequency motor (52) rotates, driving the second pulley (51) to rotate. Under the transmission of the V-belt (50), the first pulley (34) starts to rotate. When the first pulley (34) is connected with the flat key (35), the hollow shaft (38) rotates at the same time. Under the influence of centrifugal force and reaction force, two groups of mutually perpendicular sliders (17) are in contact with the vertex of the roller circumscribed circle (21) under the influence of centrifugal force and reaction force. When the vertex of one group of sliders (17) contacts the vertex of the roller circumscribed circle (21), a reaction force is generated, and the sliders (17) will change the direction of movement and quickly hit the forging die (15), thereby symmetrically hitting the surface of the wire rope. The other group of sliders (17) and the forging die (17) retreat from the surface of the wire rope under the centrifugal action. The forging machine rotates at a high speed, and the sliders (17) hit the forging die (15) back and forth to forge the wire rope.

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