Preparation method of steel wire with S-shaped section
Through the continuous cold rolling and solid mold drawing composite process, combined with the hole-type optimization design, the problem of uneven rolling in the production of S-shaped cross-section steel wire is solved, and high-precision steel wire products are achieved, which improves process stability and production efficiency.
Patent Information
- Application Number
- CN202510402037.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-01
- Publication Date
- 2025-05-30
AI Technical Summary
The existing production methods of S-shaped cross-section steel wires are prone to rolling and cannot be filled or overfilled, resulting in low dimensional accuracy of steel wire products and uneven deformation.
The continuous cold rolling and solid-mold drawing composite process is adopted, combined with the hole type optimization design and parameter regulation, and the diamond-shaped hole billet rolling and three consecutive cold rolling processing are used to obtain a blank form suitable for solid-mold drawing, and finally a high-precision S-shaped cross-section steel wire is produced through solid-mold drawing.
It significantly improves process stability, avoids twisting during rolling, improves the shape and dimensional accuracy of the product, reduces defective rate and equipment wear, and increases production efficiency and economy.
Smart Images
Figure CN120055071A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of special-shaped steel wire preparation, and in particular to a method for preparing an S-shaped cross-section steel wire. Background Art
[0002] Most of the steel wires produced and used in industry have round cross sections, and some of them have non-circular special-shaped steel wires. S-shaped cross-section steel wire is a type of special-shaped steel wire. The S-shaped cross-section steel wire has a complex shape and is asymmetric. The torque direction generated by the grooves on both sides when subjected to the force of the rollers during forming is the same. During the rolling process, the force is often uneven, the deformation is large, and it is easy to cause torsion and large dimensional errors. At present, S-shaped cross-section steel wire is often used in sealing steel wire ropes, fuselage winding of large forging equipment, winding of main cable steel wire of suspension bridges, winding of aircraft cabins, and flexible composite hoses for marine oil transportation. It exhibits better sealing performance and tensile strength than round steel wire.
[0003] During the production and use of special-shaped steel wire, various defects may occur due to process complexity, material characteristics or processing conditions. The most common of these are surface defects: cracks and scratches. During the drawing or rolling process, cracks or mechanical scratches may appear on the surface due to mold wear, poor lubrication or insufficient material ductility. Stress concentration at the corners of special-shaped cross-sections is more likely to cause cracks. Uneven metal flow during molding and unreasonable mold design lead to overlapping materials to form folds or wrinkles.
[0004] At present, there are many ways for domestic enterprises to produce S-shaped cross-section steel wire. The first method is the continuous cold rolling method, which has a large deformation amount of the steel wire and can increase the one-time deformation rate of the steel wire. However, it is easy to fail to fill or overfill during rolling, and the final product size accuracy is not high; the second method is the full-mold drawing method. Although it reduces the cost, the investment in the mold is large, and the size of the steel wire fluctuates greatly, which cannot meet the high-precision requirements of special industries; the third method is the solid mold drawing method. The dimensional tolerance of this method is small, and the product accuracy of the steel wire is high, but the friction and residual stress of the metal surface during the deformation process are large, and complex cross-sections cannot be produced; the fourth method is the rolling and drawing composite method, which first rolls out the front shape of the product, and then uses the drawing method to obtain the finished product. It is suitable for special-shaped steel wires with complex shapes and large width and thickness ratios. Summary of the invention
[0005] The purpose of the present invention is to provide a method for preparing S-shaped cross-section steel wire to solve the problem that the existing production method of S-shaped cross-section steel wire is prone to rolling failure or overfilling, resulting in low dimensional accuracy and uneven deformation of the steel wire product.
[0006] A method for preparing an S-shaped cross-section steel wire comprises the following steps:
[0007] Step 1: Pretreat the wire rod material before pickling to remove the scale, rust and other impurities adhering to its surface;
[0008] Step 2: Perform a single-pass cold rolling treatment on the wire rod processed in Step 1 through a diamond-shaped hole to flatten the originally round blank;
[0009] Step 3: Perform three consecutive cold rolling processes on the flattened blank obtained in Step 2 to obtain a blank shape suitable for fixed die drawing;
[0010] Step 4: Perform fixed die drawing on the blank processed in Step 3 to produce a high-precision steel wire with a cross-section presenting a continuous periodic S-shaped geometric structure.
[0011] Preferably, the α angle of the diamond-shaped hole used in the cold rolling in Step 2 is 120° to 140°, and the chamfer radius of the α angle of the diamond-shaped hole is set to 2 mm to 4 mm. By setting the cooperation of the diamond-shaped hole and the special-shaped hole, the phenomenon that the reduction in subsequent passes is uneven due to the non-porous rolling in the first pass of the wire rod is reduced.
[0012] Preferably, the deformation rate of each pass during the continuous cold rolling process in Step 3 is between 1.2 and 1.3, and the inclination angle range is set to 15° to 35°. This improves the torsion and drawing-in of the rolled piece caused by the uneven force during the rolling process, reduces the Y-axis force of the rolling mill during the rolling process, and at the same time the reduction of the rolled piece is uniform. The problem of stress density concentration of the blank is also improved, and surface cracks caused by stress concentration can be effectively prevented.
[0013] Preferably, the cross-section compression ratio of the fixed die drawing in Step 4 is set to 10% to 25%, and the die taper range of the fixed die drawing is set to 5° to 15°. Limiting the cross-section compression ratio of the fixed die drawing. When the cross-section compression ratio is too low, due to insufficient deformation, the grains are not fully refined, and coarse grains remain, reducing the comprehensive mechanical properties and production efficiency, and it is difficult to obtain uniform surface deformation; when the cross-section compression ratio is higher than 25%, it will lead to excessive grain refinement, a sharp increase in dislocation density, a significant decrease in the toughness of the steel wire, an increase in brittleness, and easy brittle fracture. Increasing the drawing force on the die surface will accelerate the wear or rupture of the die and will cause a significant difference in the microstructure between the core and the surface of the material, such as coarse grains remaining undeformed in the core, which easily affects the overall performance consistency of the steel wire.
[0014] The advantages of the present invention are as follows: In the method for preparing an S-shaped cross-section steel wire of the present invention, through a combined process of continuous cold rolling and fixed-die drawing, combined with optimized design of the pass and parameter regulation, a remarkable technical effect of improving process stability is achieved. The use of a diamond-shaped pass for blooming rolling significantly enhances the stability of the rolling process, effectively avoiding the torsional phenomenon that is prone to occur during the rolling of profiled steel wires. With a scientific and reasonable pass design, the smoothness of rolling is further ensured. By reducing the subsequent processing passes through the combined forming process, the consumption of raw materials and energy is directly reduced. The forming process is precisely controlled, significantly reducing the wear of the rolling rolls and drawing dies, reducing the maintenance frequency and spare part replacement cost, and improving the economy. By utilizing the synergistic effect of the diamond-shaped pass and the profiled pass, the problem of uneven reduction in the first pass of traditional passless rolling is solved, making the metal flow more uniform. By regulating the rolling inclination angle and limiting the cross-section deformation rate, the forming process of the S-shaped cross-section is precisely controlled, avoiding dimensional out-of-tolerance, surface folding or wrinkling. The scientific bite-in and groove-release design reduces the risk of wire breakage and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Figure 1 It is a flow chart for the preparation of the S-shaped cross-section steel wire in the present invention.
[0016] Figure 2 It is a schematic diagram of the shape of the diamond-shaped pass rolling in the present invention.
[0017] Figure 3 It is a pass schematic diagram of the cold rolling tandem mill in Example 1 of the present invention Figure 1 。
[0018] Figure 4 It is a pass schematic diagram of the cold rolling tandem mill in Example 1 of the present invention Figure 2 。
[0019] Figure 5 It is a pass schematic diagram of the cold rolling tandem mill in Example 1 of the present invention Figure 3 。
[0020] Figure 6 It is a drawing schematic diagram of the wire drawing of the steel wire in Example 1 of the present invention.
[0021] Figure 7 It is a schematic diagram of the shape of the S-shaped cross-section steel wire in Example 1 of the present invention.
[0022] Figure 8 It is a schematic diagram of the shape of the passless rolling in the present invention.
[0023] Figure 9 It is a pass schematic diagram of the cold rolling tandem mill in Comparative Example 1 of the present invention.
[0024] Figure 10 It is a pass schematic diagram of the cold rolling tandem mill in Comparative Example 2 of the present invention Figure 1 。
[0025] Figure 11 Schematic diagram of the pass of cold tandem rolling for Comparative Example 2 in the present invention Figure 2 。
[0026] Figure 12 Schematic diagram of the pass of cold tandem rolling for Comparative Example 2 in the present invention Figure 3 。 Specific embodiments
[0027] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with specific embodiments.
[0028] Example 1:
[0029] Step 1: Select SWRM6 wire rod with a radius of 6.5 mm as the blank. SWRM6 is a low-carbon steel wire rod, which is produced according to Japanese Industrial Standard (JIS) G 3505 and belongs to the category of low-carbon steel in structural steel. This material is valued for its good welding performance and forming performance and is widely used in the manufacture of various steel wires, welded meshes, binding wires, springs and other components that require good plastic processing performance. The wire rod material is pretreated by pickling to remove the scale, rust and other impurities attached to its surface;
[0030] Step 2: Perform a single-pass diamond-hole cold rolling treatment on the wire rod processed in Step 1 to flatten the originally circular blank. Set the α angle of the diamond hole to 140° and the chamfer radius to 2 mm. Use the diamond hole to flatten the original 13-mm-diameter circular wire rod into an intermediate blank with a height of 11.81 mm and a width of 13.68 mm. The area of the finished product is 123.36 mm 2 , this pass is blooming rolling, and its spread is 0.68 mm and the reduction is 1.19 mm, as Figure 2 shown;
[0031] Step 3: Perform three-pass continuous cold rolling on the flattened blank obtained in Step 2. The area of the blank obtained in Step 2 is 123.36 mm 2 , and the area of the blank after the first pass of rolling is 99.16 mm 2 , and the area of the blank after the second pass of rolling is 78.55 mm 2 , and the area of the blank after the third pass of rolling is 64.74 mm 2, the area deformation rates of its rolling are 1.24, 1.26, and 1.21 respectively. The inclination angle of each pass is set to 15°. Setting the inclination angle of 15° reduces the maximum axial force during rolling by 17% compared to an inclination of 30°, thereby reducing the wear of the rolls, improving the production efficiency of rolling, and having great economic value. The spreads of the three passes are 1.68 mm, 0.35 mm, and 0.32 mm respectively, and the reduction amounts are 1.1 mm, 1.62 mm, and 1.13 mm respectively to obtain a blank shape suitable for fixed die drawing. The pass shape diagrams of these three passes are respectively as Figure 3 , Figure 4 , Figure 5 shown;
[0032] Step 4: Perform fixed die drawing on the blank processed in Step 3. The die taper is set to 10°. The blank is drawn from an area of 64.74 mm 2 to a finished product of 55.95 mm 2 . Its cross-sectional compression rate is 13.58%, meeting the requirement that for wire materials with complex cross-sectional shapes and difficult deformation, the cross-sectional compression rate per pass does not exceed 25%. Thus, high-precision steel wires with a continuous periodic S-shaped geometric structure in the cross-section are produced. The drawing schematic diagram is as Figure 6 shown, and the shape dimensions of the final finished S-shaped cross-section steel wires are as Figure 7 shown.
[0033] Comparative Example 1:
[0034] Step 1: Select an SWRM6 wire rod with a radius of 6.5 mm as the blank, and perform pre-treatment of pickling on the wire rod material to remove the oxide scale, rust, and other impurities attached to its surface;
[0035] Step 2: Perform a single-pass non-groove rolling treatment on the wire rod processed in Step 1 to obtain a single-drum-shaped blank. The reduction amount of non-groove rolling is 2 mm, and the spread is measured to be 0.6 mm through experiments. The area after rolling is 127.19 mm 2 , and the area of the blank is 132.73 mm 2 . Therefore, the deformation rate of non-groove rolling is 1.04, and its shape is as Figure 8 shown;
[0036] Step 3: Perform three-pass continuous cold rolling on the single-drum-shaped blank obtained in Step 2. The schematic diagram of the first-pass pass shape is as Figure 9 shown, and its deformation rate is 1.28. The spread of this pass is 1.76 mm, and the reduction amount is 1.1 mm;
[0037] Step 4: Perform fixed die drawing on the blank processed in Step 3 to obtain S-shaped cross-section steel wires.
[0038] By comparing non-groove rollingFigure 9 and rolling of diamond-shaped holes Figure 3 It can be clearly seen that the rolling reduction of the diamond-shaped holes is more uniform. On the premise of equally enhancing the rolling stability, the use of diamond-shaped holes reduces the uneven wear of the rolls. By calculation, the local maximum rolling reduction in the non-groove rolling is 4.3 mm, and the minimum rolling reduction is 0.55 mm. While in the first embodiment, the maximum rolling reduction is 3.29 mm and the minimum rolling reduction is 0.62 mm. The more uniform distribution of the rolling reduction makes the distribution of deformation uniform, avoiding the occurrence of drawing-in phenomenon during the rolling process. At the same time, the stress density is uniform, improving the quality of the rolled product.
[0039] Comparative Example 2:
[0040] Step 1: Select SWRM6 wire rod with a radius of 6.5 mm as the blank, and perform pre-treatment on the wire rod material by pickling to remove the oxide scale, rust and other impurities adhering to its surface;
[0041] Step 2: Directly perform three-pass cold rolling of special-shaped holes on the wire rod processed in Step 1, and set the cross-sectional area of the rolled piece to be 105.4 mm 2 , 92.1 mm 2 , 73.78 mm 2 . The deformation rates of the three passes are respectively: 1.26, 1.14, 1.25, and the set rolling rotation angles are respectively 30°, 15°, 15°. The schematic diagrams of its rolling are respectively as Figure 10 , Figure 11 , Figure 12 shown. The spread amounts are respectively 1.64, 0.83, 0.86 mm, and the rolling reductions are respectively 2.84, 1.17, 1.44 mm;
[0042] Step 3: Perform fixed-die drawing on the blank processed in Step 2 to obtain an S-shaped cross-section steel wire.
[0043] During the trial production process, a serious torsion problem occurred in the first pass, which was due to the low rolling stability. In addition, problems such as non-conforming die sticking and ear formation at the roll gap also occurred in the second and third passes. Modifying the pass still could not completely solve the problem, and the rolling effect of this comparative example was poor.
[0044] To sum up, the combined method of continuous cold rolling and fixed-die drawing is used to produce special-shaped steel wires. After the blooming rolling pass with diamond-shaped holes, the rolling stability is greatly improved, preventing the occurrence of torsion phenomenon during the rolling process. The pass design is reasonable, which can effectively reduce the production cost of S-shaped cross-section steel wires and the maintenance cost of equipment, can significantly improve the shape and size accuracy of products, prevent problems such as out-of-tolerance dimensions, surface folding or wrinkling of products, can effectively reduce the defective rate, reduce the wear of rolls or drawing dies during production, and at the same time improve the production efficiency.
[0045] As is known by common technical knowledge, the present invention can be implemented by other embodiments that do not depart from its spirit or essential features. Therefore, the above-disclosed embodiments are illustrative in all respects and not exclusive. All changes within the scope of the present invention or within the scope equivalent to the present invention are encompassed by the present invention.
Claims
1. A method for preparing an S-shaped cross-section steel wire, characterized in that: The following steps are involved: Step 1: pre-pickling the wire rod material to remove scale, rust and other impurities attached to its surface; Step 2: Perform a diamond hole cold rolling process on the wire rod processed in step 1 to flatten the originally round billet; Step 3: performing three consecutive cold rolling processes on the flattened blank obtained in step 2 to obtain a blank shape suitable for fixed die drawing; Step 4: The blank processed in step 3 is subjected to die drawing to obtain a high-precision steel wire having a continuous periodic S-shaped geometric structure in cross section.
2. The method for preparing an S-shaped cross-section steel wire according to claim 1, characterized in that: The α angle of the diamond-shaped holes used for cold rolling in step 2 is 120° to 140°.
3. The method for preparing an S-shaped cross-section steel wire according to claim 2, characterized in that: The chamfer radius of the angle α of the rhombus hole is set to 2 mm to 4 mm.
4. The method for preparing an S-shaped cross-section steel wire according to claim 1, characterized in that: In the step 3, the deformation rate of each pass during the continuous cold rolling process is between 1.2 and 1.
3.
5. The method for preparing an S-shaped cross-section steel wire according to claim 4, characterized in that: The tilt angle range is set to 15° to 35°.
6. The method for preparing an S-shaped cross-section steel wire according to claim 1, characterized in that: The cross-sectional compression rate of the solid die drawing in step 4 is set to 10% to 25%.
7. The method for preparing an S-shaped cross-section steel wire according to claim 6, characterized in that: The die taper range of the solid die drawing is set to 5° to 15°.