Production method for high-strength steel wire

Abstract

The invention discloses a production method for a high-strength steel wire, and relates to the technical field of steel wire machining, through the machining links of pretreatment, cold drawing treatment, heat treatment, surface treatment, quality detection, machining treatment and packaging storage treatment on a wire rod, in the cold drawing treatment link, an initial image and a real-time image are obtained and based on the initial image and the real-time image; adjusting the first initial working parameter; in the heat treatment link, detecting decarburized layer depth data of the wire rod through a preset method to obtain a detection result, and adjusting the second initial working parameter based on the detection result; and in the surface treatment link, a working camera is also arranged to shoot a surface image of the wire rod, and a third initial working parameter is adjusted based on the surface image and the initial image. The initial working parameters of the preset working links are adjusted in real time in the wire rod production process, so that the problems prone to occurring in the wire rod are solved in time, and the percent of pass of the high-strength steel wires is increased on the premise that the production efficiency of the high-strength steel wires is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of wire processing, and particularly to a production method for high-strength wire. Background Art

[0002] High-strength wire is a metal material with significantly improved tensile strength, toughness, and fatigue resistance through special process treatment and alloying design, and is widely used in fields that need to withstand high loads or harsh environments. The production process of high-strength wire is a complex and precise process, involving multiple key steps and process controls, including raw material preparation, cold drawing treatment, heat treatment, surface treatment, processing treatment, quality inspection, and packaging and storage.

[0003] However, for the production of high-strength wire at present, working parameters are set for each link, and then the final quality inspection link is used to detect whether the product is qualified. Although this method can ensure the production efficiency of high-strength wire, it also reduces the qualified rate of high-strength wire. Unqualified wire needs to be processed again, which is time-consuming and laborious. Especially in the current cold drawing treatment, heat treatment, and surface treatment links, there are more or less the following problems: Cold working hardening is likely to occur during cold drawing treatment, resulting in the accumulation of internal residual stress, microcracks are formed on the surface, and the wire breakage rate is relatively high; Oxidation during the heat treatment process causes the surface decarburized layer to exceed the standard, reducing the mechanical properties of the wire; Incomplete pickling or secondary pressing of oxides leads to surface pitting, reducing the corrosion resistance. Therefore, in the production process of high-strength wire, how to find a process flow that can control the products of each link and adjust the working parameters of subsequent links in real time, so as to improve the qualified rate of high-strength wire on the premise of ensuring the production efficiency of high-strength wire. Summary of the Invention

[0004] To solve the deficiencies of the above-mentioned existing technologies, the present invention provides a production method for high-strength wire, including: Obtaining the wire to be processed for pretreatment; Setting the first initial working parameters, performing continuous drawing treatment on the wire after pretreatment, and taking the initial image and real-time image of the wire by installing an industrial camera; Based on the initial image and the real-time image, adjusting the first initial working parameters by using the first method; Setting the second initial working parameters, performing heat treatment on the wire after continuous drawing treatment, and detecting the decarburized layer depth data of the wire by a preset method to obtain a detection result, and adjusting the second initial working parameters based on the detection result; Set the third initial working parameters, perform surface treatment on the wire after heat treatment, and capture the surface image of the wire by installing an industrial camera; based on the initial image and the surface image, adjust the third initial working parameters by using the second method; Perform quality inspection, processing, and packaging and storage processing on the wire after surface treatment.

[0005] The present invention is realized through the following technical solutions: First, the wire to be processed is pretreated, including pickling, water washing and neutralization, and phosphating (saponification) treatment; set the first initial working parameters, and continuously draw the pretreated wire through a die, aiming to draw the wire to the target diameter. During the continuous drawing process, cold work hardening is likely to occur, resulting in the accumulation of internal residual stress, thereby forming microcracks on the wire surface. Therefore, an industrial camera is installed to capture the initial image and the real-time image of the wire, and by processing the initial image and the real-time image, it is judged whether microcracks are formed during the continuous drawing process of the wire, and then the first initial working parameters are adjusted accordingly.

[0006] Set the second initial working parameters, and perform heat treatment on the wire after continuous drawing, aiming to improve the strength and toughness of the wire and eliminate internal stress; however, during the heat treatment of the wire, oxidation is likely to occur, resulting in an excessive decarburized layer on the surface, thereby reducing the mechanical properties of the wire. Therefore, in this solution, a preset method (chemical and spectroscopic analysis methods) is used to detect the depth data of the decarburized layer of the wire after heat treatment to obtain the detection result, and based on the detection result, the second initial working parameters are adjusted.

[0007] Set the third initial working parameters, and perform surface treatment on the wire after heat treatment. The surface treatment includes plating, coating, and polishing treatment. However, during the surface treatment process, pitting is likely to occur on the wire surface, thereby reducing the corrosion resistance of the wire. Therefore, in this solution, an industrial camera is installed to capture the surface image of the wire, and by comparing the initial image and the surface image, it is judged whether there are pits on the wire surface, and the third initial working parameters are adjusted by using the second method.

[0008] Finally, perform quality inspection, processing, and packaging and storage processing on the wire after surface treatment.

[0009] As an optional technical solution, obtaining the pretreatment of the wire to be processed includes: pickling, water washing and neutralization, and phosphating treatment on the wire to be processed, and then forming a lubricating layer.

[0010] As an optional technical solution, the first method includes: Obtain the initial image of the wire and put it into the first set, and obtain the real-time image of the wire and put it into the second set; Obtain the first frame image in the second set, and based on the shooting timeline, filter a number of real-time images starting from the first frame image at a preset time frequency; Store all the filtered real-time images in the third set; Based on the shooting timeline, subtract all the real-time images in the third set from the initial image in turn to obtain multiple first feature images containing the first difference region; Count the number of first difference regions in all the first feature images to obtain the first statistical result, and based on the statistical result, construct the first curve graph of the change of the first difference region with time; Count the length of the same first difference region in all the first feature images to obtain the second statistical result, and based on the second statistical result, construct multiple second curve graphs of the length of the same first difference region with time; Adjust the first initial working parameters based on the first curve graph and the second curve graph.

[0011] As an optional technical solution, adjust the first initial working parameters based on the first curve graph and the second curve graph; Perform fitting processing on the first curve graph to obtain the first slope; Judge whether the first slope exceeds the first threshold. If so, perform shutdown adjustment. If not, perform fitting processing on all the second curve graphs to obtain multiple second slopes; Judge whether there is a corresponding slope value in all the second slopes that exceeds the second threshold. If so, perform shutdown adjustment. If not, adjust the first initial working parameters.

[0012] As an optional technical solution, the preset method is chemical and spectroscopic analysis methods.

[0013] As an optional technical solution, adjusting the second initial working parameters based on the detection result includes: Obtain the decarburized layer depth data of the wire rod as d, and the real-time diameter data of the wire rod as r; Judge whether the decarburized layer depth data d is less than or equal to 0.01r. If so, do not perform any action. If not, adjust the second initial working parameters.

[0014] As an optional technical solution, the second method includes: Subtract the surface image from the initial image to obtain a second feature image; Enlarge the second feature image and judge whether there is a second difference region. If not, do not perform any action. If so, obtain the number of second difference regions; Determine whether the number of the second difference regions exceeds a third threshold. If so, adjust the third initial working parameters. If not, do not perform any action.

[0015] As an alternative technical solution, the quality inspection of the wire after surface treatment includes: dimension inspection and mechanical property test of the wire.

[0016] As an alternative technical solution, the processing of the wire after surface treatment includes: rust prevention treatment and winding treatment of the wire.

[0017] One or more technical solutions provided by the present invention have at least the following technical effects or advantages: The present invention discloses a production method for high-strength steel wires. By setting production links such as pre-treatment, cold drawing treatment, heat treatment, surface treatment, quality inspection, processing treatment, and packaging and storage treatment for the wire, and in the cold drawing treatment link, an industrial camera is set to capture the initial image and real-time image of the wire, and then based on the initial image and real-time image, the first initial working parameters are adjusted; in the heat treatment link, the decarburized layer depth data of the wire is detected by a preset method to obtain a detection result, and based on the detection result, the second initial working parameters are adjusted; in the surface treatment link, a working camera is also set to capture the surface image of the wire, and based on the surface image and the initial image, the third initial working parameters are adjusted. By adjusting the initial working parameters of the preset working links in real time during the wire production process, the problems that are likely to occur in the wire can be solved in a timely manner, and the qualified rate of the high-strength steel wire can be improved on the premise of ensuring the production efficiency of the high-strength steel wire. Description of the Drawings

[0018] The drawings described herein are used to provide a further understanding of the embodiments of the present invention, form a part of the present invention, and do not limit the embodiments of the present invention; Figure 1 It is a schematic flowchart of a production method for high-strength steel wires in the present invention. Detailed Embodiments

[0019] In order to more clearly understand the above-mentioned objects, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the drawings and specific embodiments. It should be noted that, without conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other.

[0020] Many specific details are set forth in the following description in order to fully understand the present invention. However, the present invention can also be implemented in other ways different from those described within the scope hereof. Therefore, the protection scope of the present invention is not limited by the specific embodiments disclosed below.

[0021] Embodiment Please refer to Figure 1 , Figure 1 which is a schematic flow chart of a production method for high-strength steel wires in the present invention, including: Obtain the wire to be processed and perform pre-treatment; Set the first initial working parameters, perform continuous drawing on the wire after pre-treatment, and capture the initial image and real-time image of the wire by installing an industrial camera; based on the initial image and the real-time image, adjust the first initial working parameters by using the first method; Set the second initial working parameters, perform heat treatment on the wire after continuous drawing, and detect the decarburized layer depth data of the wire by a preset method to obtain a detection result, and adjust the second initial working parameters based on the detection result; Set the third initial working parameters, perform surface treatment on the wire after heat treatment, and capture the surface image of the wire by installing an industrial camera; based on the initial image and the surface image, adjust the third initial working parameters by using the second method; Perform quality inspection, processing, and packaging and storage on the wire after surface treatment.

[0022] The specific embodiments of the present invention are as follows: Wire pre-treatment: Perform pre-treatment on the wire to be processed, specifically including pickling, water washing and neutralization, and phosphating. Among them, pickling is to remove the scale (oxide layer formed by hot rolling) on the wire surface by hydrochloric acid or sulfuric acid; water washing and neutralization is to rinse with clean water and neutralize the residual acid solution after pickling to prevent corrosion; phosphating is to immerse the wire in a phosphate solution to form a porous phosphating film to improve lubricity.

[0023] Wire continuous drawing: Set the first initial working parameters, draw the wire to the target diameter through multiple dies. During continuous drawing, cold working hardening is likely to occur, resulting in the accumulation of internal residual stress, thus forming microcracks on the wire surface; in this embodiment, an industrial camera is installed to capture the initial image and real-time image of the wire, and based on the initial image and the real-time image, the first initial working parameters are adjusted by using the first method (such as the number of dies and the pulling force). The first method includes: Obtain the initial image of the wire and put it into the first set, obtain the real-time image of the wire and put it into the second set; Obtain the first frame image in the second set, and based on the shooting time axis, screen several frames of real-time images starting from the first frame image at a preset time frequency; Store all the screened real-time images into the third set; Based on the captured time axis, subtract all the real-time images in the third set from the initial image in sequence to obtain multiple first feature images each containing a first difference region; Count the number of first difference regions in all the first feature images to obtain a first statistical result, and based on this statistical result, construct a first curve graph of the change of the first difference region with time; Count the lengths of the same first difference region in all the first feature images to obtain a second statistical result, and based on this second statistical result, construct multiple second curve graphs of the lengths of the same first difference region with time; Adjust the first initial working parameters based on the first curve graph and the second curve graph.

[0024] Further, adjust the first initial working parameters based on the first curve graph and the second curve graph; Perform a fitting process on the first curve graph to obtain a first slope; Judge whether the first slope exceeds a first threshold. If so, perform a shutdown adjustment. If not, perform a fitting process on all the second curve graphs to obtain multiple second slopes; Judge whether there is a corresponding slope value among all the second slopes that exceeds a second threshold. If so, perform a shutdown adjustment. If not, adjust the first initial working parameters.

[0025] Among them, the initial image and all real-time images of the wire are captured by an industrial camera. By subtracting the real-time images from the initial image, it is judged whether there are micro-cracks on the surface of the wire. However, due to the large amount of data of the real-time images, if they are subtracted from the initial image one by one, the processing efficiency will be affected. Therefore, in this embodiment, by establishing a time axis, several frames of real-time images are screened at a certain time frequency (such as obtaining one frame of real-time image every 10 s); all the screened real-time images are subtracted from the initial image in sequence to obtain multiple first feature images. The first curve graph is obtained by analyzing the change of the number of first difference regions in all the first feature images with time, and the second curve graph is obtained by analyzing the change of the length of the same difference region in all the first feature images with time. Perform a fitting process on the first curve graph to obtain a first slope, and judge whether the first slope exceeds a first threshold. If so, it means that the number of micro-cracks on the wire is gradually increasing, and at this time, a shutdown adjustment is required. If not, it means that although there are micro-cracks on the wire, there is no trend of continuous growth. At this time, a fitting process needs to be performed on the second curve graph to obtain a second slope, and judge whether there is a slope exceeding the second threshold among the second slopes. If so, it means that a single difference region (micro-crack) has a trend of continuous cracking, so a shutdown adjustment is also required. If not, only the first initial working parameters need to be adjusted.

[0026] Wire heat treatment: Set the second initial working parameters, heat the wire to the austenitizing temperature, immerse it in a molten lead bath for quenching to obtain a fine pearlite structure, improving strength and toughness; subject the wire to tempering / annealing treatment to eliminate stress and adjust hardness; subject the wire to normalizing treatment to homogenize the structure and improve machinability. However, during the heat treatment of the wire, oxidation easily occurs, resulting in an excessive decarburized layer on the surface, thereby reducing the mechanical properties of the wire. Therefore, in this solution, a preset method (chemical and spectroscopic analysis) is used to detect the depth data of the decarburized layer for the heat-treated wire to obtain a detection result, and based on the detection result, the second initial working parameters are adjusted.

[0027] Furthermore, based on the detection result, adjusting the second initial working parameters includes: Obtain the decarburized layer depth data of the wire as d, and the real-time diameter data of the wire as r; Judge whether the decarburized layer depth data d is less than or equal to 0.01r. If so, no action is taken. If not, the second initial working parameters are adjusted.

[0028] Among them, during the heat treatment process, oxidation causes the decarburized layer on the wire surface to exceed the standard, that is, when the decarburized layer depth data exceeds 1% of the wire diameter, the mechanical properties of the wire will be reduced. At this time, the second initial working parameters need to be adjusted.

[0029] Wire surface treatment: Set the third initial working parameters, and perform surface treatment on the heat-treated wire. The surface treatment includes plating, coating, and polishing. However, during the surface treatment process, pits are likely to appear on the wire surface, thereby reducing the corrosion resistance of the wire. Therefore, in this solution, an industrial camera is installed to capture the surface image of the wire. By comparing the initial image and the surface image, it is judged whether there are pits on the wire surface, and the third initial working parameters are adjusted by a second method. The second method includes: Subtract the surface image from the initial image to obtain a second feature image; Enlarge the second feature image and judge whether there is a second difference region. If not, no action is taken. If so, obtain the number of second difference regions; Judge whether the number of second difference regions exceeds a third threshold. If so, adjust the third initial working parameters. If not, no action is taken.

[0030] Among them, when performing surface treatment on the wire, if it is determined based on the surface image and the initial image that the number of second difference regions (pockmarks) on the wire exceeds the third threshold, it indicates that the corrosion resistance of the wire has decreased too much at this time, and the third initial working parameters need to be adjusted.

[0031] Wire quality inspection, processing, and packaging and storage: The quality inspection of the wire after surface treatment includes: dimension inspection and mechanical property testing of the wire.

[0032] The processing of the wire after surface treatment includes: rust prevention treatment and winding treatment of the wire.

[0033] Furthermore, qualified high-strength steel wires need to be stored in a dry and ventilated environment to avoid moisture and corrosion.

[0034] Although the preferred embodiments of the present invention have been described, those skilled in the art can make additional changes and modifications to these embodiments once they learn the basic creative concept. Therefore, the appended claims are intended to be construed as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0035] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention also intends to include these modifications and variations.

Claims

1. A production method for high-strength steel wires, characterized in that, Including: Obtain the wire to be processed and perform pre - treatment. Set the first initial working parameters, perform continuous drawing on the pre - treated wire, and capture the initial image and real - time image of the wire by installing an industrial camera; based on the initial image and the real - time image, adjust the first initial working parameters by using the first method. Set the second initial working parameters, perform heat treatment on the wire after continuous drawing, and detect the decarburized layer depth data of the wire by a preset method to obtain a detection result; based on the detection result, adjust the second initial working parameters. Set the third initial working parameters, perform surface treatment on the wire after heat treatment, and capture the surface image of the wire by installing an industrial camera; based on the initial image and the surface image, adjust the third initial working parameters by using the second method. Perform quality inspection, processing, and packaging and storage processing on the wire after surface treatment.

2. The production method for high-strength steel wire according to claim 1, characterized in that, Obtaining the wire to be processed and performing pre - treatment includes: pickling, water washing and neutralizing, and phosphating the wire to be processed to form a lubricating layer.

3. A production method for high-strength steel wires according to claim 1, characterized in that, The first method includes: Obtain the initial image of the wire and put it into the first set, obtain the real - time image of the wire and put it into the second set; Obtain the first frame image in the second set, and based on the shooting time axis, screen a number of real - time images starting from the first frame image at a preset time frequency; Store all the screened real - time images into the third set; Based on the shooting time axis, subtract all the real - time images in the third set from the initial image in turn to obtain multiple first feature images containing the first difference region; Count the number of first difference regions in all the first feature images to obtain the first statistical result, and based on the statistical result, construct the first curve graph of the change of the first difference region with time; Count the length of the same first difference region in all the first feature images to obtain the second statistical result, and based on the second statistical result, construct multiple second curve graphs of the length of the same first difference region with time; Based on the first curve graph and the second curve graph, adjust the first initial working parameters.

4. A production method for high-strength steel wires according to claim 3, characterized in that, Based on the first curve graph and the second curve graph, adjust the first initial working parameters; Perform fitting processing on the first curve graph to obtain the first slope; Judge whether the first slope exceeds the first threshold. If so, perform shutdown adjustment. If not, perform fitting processing on all the second curve graphs to obtain multiple second slopes; Judge whether there is a corresponding slope value in all the second slopes that exceeds the second threshold. If so, perform shutdown adjustment. If not, adjust the first initial working parameters.

5. A production method for high-strength steel wires according to claim 1, characterized in that, The preset method is chemical and spectroscopic analysis method.

6. A production method for high-strength steel wires according to claim 1, characterized in that, Based on the detection result, adjusting the second initial working parameters includes: Obtain the decarburized layer depth data of the wire as d, and the real - time diameter data of the wire as r; Judge whether the decarburized layer depth data d is less than or equal to 0.01r. If so, do not perform any action. If not, adjust the second initial working parameters.

7. A production method for high-strength steel wires according to claim 1, characterized in that, The second method includes: Subtracting the surface image from the initial image to obtain a second feature image; Performing magnification processing on the second feature image and determining whether there is a second difference region. If not, no action is taken. If so, the number of second difference regions is obtained; Determining whether the number of second difference regions exceeds a third threshold. If so, the third initial working parameter is adjusted. If not, no action is taken.

8. A production method for high-strength steel wire according to claim 1, characterized in that, Quality inspection of the wire after surface treatment includes: dimension inspection and mechanical property testing of the wire.

9. A production method for high-strength steel wires according to claim 1, characterized in that, Processing the wire after surface treatment includes: rust prevention treatment and winding treatment of the wire.

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