High-balance aluminum roller machining method

Abstract

The invention discloses a high-balance aluminum roller machining method, which relates to the technical field of aluminum roller machining, and comprises the following steps: primary machining: carrying out primary turning machining on a bent aluminum roller raw material with an uneven surface to form a cylinder on the surface of the aluminum roller; dynamic balance measurement: carrying out dynamic balance detection on the turned aluminum roller by taking the outer diameter as a reference, and determining the amount of unbalance and the phase; bending treatment: bending the aluminum roller towards an eccentric position by using a machine tool according to a detection result, so that the eccentric position protrudes relative to the roller body; secondary turning is carried out, specifically, secondary turning is carried out on the surface of the bent aluminum roller, protruding materials at the unbalanced part are cut off, and weight distribution is adjusted; and carrying out secondary dynamic balance measurement, and repeating the steps until the dynamic balance performance of the aluminum roller meets the preset standard. The overall dynamic balance of the roller body is improved, the weight does not need to be adjusted through lead injection, the roller body is higher in integrity and more stable, the service life is prolonged, and the stability during high-speed rotation is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum roller processing, and particularly relates to a processing method for high-balance aluminum rollers. Background Art

[0002] As an important industrial equipment, aluminum rollers are mainly made of aluminum alloy materials and are widely used in multiple industries due to their light weight, high strength, and good thermal conductivity. With the continuous progress of industrial technology, the market's requirements for product quality are increasing day by day. Especially in the fields of printing, packaging, and metal processing, aluminum rollers have become an ideal choice to meet the high-standard production requirements due to their unique physical and chemical properties. The use of aluminum rollers not only improves production efficiency but also promotes environmental protection and sustainable development, meeting the pursuit of modern industry for resource conservation and environmental protection.

[0003] Aluminum rollers are mostly used under high-speed rotation conditions, so there are relatively high requirements for the roundness and weight balance of aluminum rollers. If the weight distribution along the circumferential direction of the aluminum roller is unbalanced and the unbalance amount is relatively large, vibrations will occur in the roller body during rotation, and stable operation cannot be achieved, thereby reducing the service life and the stability of the overall structure.

[0004] In the prior art, holes are drilled and lead is injected on the end head of the aluminum roller on the lighter side to adjust the dynamic balance performance of the roller body. However, for some roller bodies with poor raw materials, many holes need to be drilled and adjusted multiple times, and the weight adjustment is concentrated at the end of the roller body. There is still a risk of jitter during the high-speed rotation of the aluminum roller in the later stage. Summary of the Invention

[0005] The present application provides a processing method for high-balance aluminum rollers, which has the effect of improving the service life and the stability of high-speed rotation.

[0006] A processing method for high-balance aluminum rollers provided by the present application adopts the following technical solutions: A processing method for high-balance aluminum rollers includes the following steps: Step 1: Primary processing, initially turning the raw material of the bent and uneven-surface aluminum roller to form a cylinder on the surface of the aluminum roller; Step 2: Dynamic balance measurement, performing dynamic balance detection on the turned aluminum roller based on the outer diameter to determine the unbalance amount and phase; Step 3: Bending treatment, according to the detection results, using a machine tool to bend the aluminum roller towards the heavier position to make the heavier part protrude relative to the roller body; Step 4: Secondary turning, performing secondary turning on the surface of the bent aluminum roller to cut off the protruding material at the heavier part and adjust the weight distribution; Step 5: Secondary dynamic balance measurement, repeating Steps 2 - 4 until the dynamic balance performance of the aluminum roller meets the preset standard.

[0007] By the above method, the dynamic balance of the whole roller body is improved, there is no need to adjust the weight by lead injection, the integrity of the roller body is higher, more stable, and thus the service life and the stability during high-speed rotation are improved.

[0008] Preferably, in step 1, before the first turning process, the aluminum roller raw material needs to be straightened to eliminate the initial bending deformation. For the first round turning process, the cylindricity tolerance of the aluminum roller should be ≤0.05 mm, and the surface roughness Ra should be ≤1.6 μm.

[0009] By the above method, the straightening process eliminates the initial bending deformation of the aluminum roller, providing a good foundation for subsequent processing.

[0010] Preferably, in step 2, the dynamic balance detection adopts three-dimensional vibration analysis technology to synchronously collect axial, radial and axial vibration data, determine the phase of the unbalance amount through Fourier transform, and the rotational speed is set to 30%-50% of the working rotational speed of the aluminum roller.

[0011] By the above method, the three-dimensional vibration analysis technology can comprehensively and accurately collect the vibration data of the aluminum roller, and the Fourier transform can accurately determine the phase of the unbalance amount, providing accurate data support for the subsequent bending process.

[0012] Preferably, in step 3, the bending amount is predicted by finite element analysis, the micro pressure is applied by a hydraulic device, the pressure range is 50-200 MPa, the pressure application direction is perpendicular to the axis of the aluminum roller, the hydraulic device is equipped with a displacement sensor to monitor the bending amount in real time, and a closed-loop control is carried out with the preset protruding height, controlling the plastic deformation amount of the material within the range of 0.1 mm - 0.3 mm to avoid cracking of the roller body caused by excessive bending.

[0013] By the above method, the finite element analysis is used to predict the bending amount, ensuring the accuracy and effectiveness of the bending process.

[0014] Preferably, in step 4, the second turning uses a CNC lathe, and the cutting depth is dynamically adjusted according to the material protruding amount of the heavy part to ensure that the diameter tolerance of the aluminum roller after cutting is within ±0.02 mm.

[0015] By the above method, the use of the CNC lathe improves the accuracy and efficiency of the turning process.

[0016] Preferably, in step 5, if it still does not meet the standard after multiple iterative corrections, the aluminum roller needs to be subjected to low-temperature annealing treatment to eliminate internal stress and then steps 2-4 are executed again.

[0017] By the above method, through multiple iterative corrections, the dynamic balance performance of the aluminum roller is ensured to meet the preset standard.

[0018] Preferably, before the step 1, non-destructive testing is also performed on the aluminum roller raw material to exclude defects such as internal cracks and pores.

[0019] Through the above method, non-destructive testing realizes the early exclusion of internal defects of the aluminum roller raw material, avoids processing problems and safety hazards caused by defects, and improves the overall quality and reliability of the aluminum roller.

[0020] Preferably, when the diameter of the aluminum roller is less than the predetermined range due to multiple turning operations, the local laser cladding technology is adopted to deposit aluminum alloy materials in the non-working area of the roller body, and after restoring the diameter size, the final dynamic balance verification is carried out.

[0021] Through the above method, the local laser cladding technology can restore the diameter size of the aluminum roller without damaging its overall structure, and avoid performance problems caused by too small diameter.

[0022] Preferably, a temperature compensation mechanism is introduced during the dynamic balance detection process. The temperature change of the aluminum roller is monitored in real time through a thermal network model, and a feedback control algorithm is used to adjust the dynamic balance detection parameters to compensate for the influence of temperature change on the unbalance measurement result. A process control database is established to record the key parameters during each processing process, including turning depth, bending amount, dynamic balance detection result and compensation measures, providing a basis for subsequent process optimization and data traceability.

[0023] Through the above method, the temperature compensation mechanism can monitor and adjust the dynamic balance detection parameters in real time, compensate for the influence of temperature change on the unbalance measurement result, and improve the accuracy and reliability of the detection.

[0024] Preferably, after the dynamic balance performance of the aluminum roller meets the preset standard, hard anodizing treatment is carried out on the surface of the aluminum roller to form an alumina layer with a thickness of 15 - 25 μm, and a polytetrafluoroethylene composite coating is coated on the surface of the oxide layer with a coating thickness of 5 - 8 μm. After coating, dynamic balance fine-tuning is carried out again to compensate for the weight distribution of the coating.

[0025] Through the above method, the hard anodizing treatment improves the hardness and wear resistance of the aluminum roller surface, and the polytetrafluoroethylene composite coating has excellent corrosion resistance and lubrication performance.

[0026] In summary, the present application has the following beneficial effects: 1. In the present invention, the overall dynamic balance of the roller body is improved, there is no need to inject lead to adjust the weight, the integrity of the roller body is higher, it is more stable, and thus the service life and the stability during high-speed rotation are improved; 2. In the present invention, by establishing a process control database to record the key parameters during each processing process, iterative optimization and database recording are carried out, reducing the number of repeated processing times and improving the processing efficiency; 3. In the present invention, the thickness of the hard anodic oxidation layer on the side of the aluminum roll is 15 - 25 μm, the microhardness is above 350 HV, the thickness of the polytetrafluoroethylene coating is 5 - 8 μm, and the friction coefficient is 0.05 - 0.2, which significantly improves the wear resistance, corrosion resistance and lubricity of the aluminum roll surface. Description of the Drawings

[0027] Figure 1 is the logic block diagram of the processing method of the high - balance aluminum roll in this embodiment; Figure 2 is the detailed logic block diagram of the processing method of the high - balance aluminum roll in this embodiment; Detailed Embodiment The following further describes the present application in detail with reference to the drawings. It is necessary to point out here that the following specific embodiments are only used to further illustrate the present application and cannot be understood as limiting the protection scope of the present application. Those skilled in the art can make some non - essential improvements and adjustments to the present application according to the above application content. Embodiment

[0028] The present invention discloses a processing method of a high - balance aluminum roll. As shown in Figure 1 and Figure 2 , it includes the following steps: Step 1: First, perform non - destructive testing on the aluminum roll raw material to exclude defects such as internal cracks and pores. For primary processing, perform primary turning on the bent and uneven - surface aluminum roll raw material to form a cylinder on the aluminum roll surface. Before primary turning, the aluminum roll raw material needs to be straightened to eliminate the initial bending deformation. The cylindricity tolerance of the aluminum roll during primary turning should be ≤0.05 mm, and the surface roughness Ra should be ≤1.6 μm; Step 2: Dynamic balance measurement. Perform dynamic balance detection on the turned aluminum roll based on the outer diameter to determine the unbalance amount and phase. The dynamic balance detection uses three - dimensional vibration analysis technology to synchronously collect axial, radial and axial vibration data, and determine the unbalance amount phase through Fourier transform. The rotation speed is set to 30% - 50% of the working speed of the aluminum roll. During the dynamic balance detection process, introduce a temperature compensation mechanism to monitor the temperature change of the aluminum roll in real time through a thermal network model, and use a feedback control algorithm to adjust the dynamic balance detection parameters to compensate for the influence of temperature change on the unbalance amount measurement result. Establish a process control database to record the key parameters during each processing process, including turning depth, bending amount, dynamic balance detection results and compensation measures, providing a basis for subsequent process optimization and data traceability; Step 3: Bending treatment. According to the detection results, use a machine tool to bend the aluminum roller towards the heavy position, making the heavy part protrude relative to the roller body. The bending amount is predicted by finite element analysis, and a micro-pressure is applied through a hydraulic device. The pressure range is 50 - 200 MPa, and the pressure application direction is perpendicular to the axis of the aluminum roller. The hydraulic device is equipped with a displacement sensor to monitor the bending amount in real time and perform closed-loop control with the preset protrusion height, controlling the plastic deformation amount of the material within the range of 0.1 mm - 0.3 mm to avoid cracking of the roller body caused by excessive bending; Step 4: Secondary turning. Perform secondary turning on the surface of the bent aluminum roller to cut off the protruding material at the heavy part and adjust the weight distribution. The secondary turning is carried out on a CNC lathe, and the cutting depth is dynamically adjusted according to the material protrusion amount at the heavy part to ensure that the diameter tolerance of the aluminum roller after cutting is within ±0.02 mm; Step 5: Secondary dynamic balance measurement. Repeat steps 2 - 4 until the dynamic balance performance of the aluminum roller meets the preset standard. If it still does not meet the standard after multiple iterative corrections, the aluminum roller needs to be subjected to low-temperature annealing treatment to eliminate internal stress and then steps 2 - 4 are executed again. When the diameter of the aluminum roller is less than the predetermined range due to multiple turnings, a local laser cladding technology is used to deposit aluminum alloy material in the non-working area of the roller body to restore the diameter size and then perform the final dynamic balance verification. After the dynamic balance performance of the aluminum roller meets the preset standard, perform hard anodizing treatment on the surface of the aluminum roller to form an alumina layer with a thickness of 15 - 25 μm, and coat a polytetrafluoroethylene composite coating on the surface of the oxide layer with a coating thickness of 5 - 8 μm. After coating, perform dynamic balance fine-tuning again to compensate for the weight distribution of the coating.

[0029] Working principle: Step 1: Primary processing Nondestructive testing: Before step 1, perform nondestructive testing on the aluminum roller raw material to exclude internal cracks, pores and other defects. Use an ultrasonic detector with a detection frequency of 5 MHz and a detection sensitivity set to the equivalent of a Φ2 mm flat-bottom hole.

[0030] Straightening treatment: Select a 6061 - T6 aluminum alloy round bar with bending deformation and use a hydraulic straightening machine for straightening to eliminate the initial bending deformation and ensure that the straightness tolerance of the raw material ≤ 0.5 mm / m.

[0031] Primary turning: Install the straightened aluminum roller on a CNC lathe and use a diamond turning tool for primary turning. Set the spindle speed to 800 rpm, the feed rate to 0.2 mm / r, and leave a margin of 0.5 mm for finish turning after rough turning. Use a PCD turning tool for finish turning to ensure that the cylindricity tolerance of the aluminum roller ≤ 0.05 mm and the surface roughness Ra ≤ 1.6 μm.

[0032] Step 2: Dynamic balance measurement Detection device: Use a hard-bearing dynamic balancing machine (model SCHENCK HM10) equipped with a three-dimensional vibration analysis system.

[0033] Detection parameters: Support the aluminum roller through a V-shaped frame, and set the test rotation speed to 50% of the working rotation speed (3000 rpm), that is, 1500 rpm.

[0034] Data acquisition: Synchronously acquire axial, radial, and axial vibration data, with a sampling frequency of 10 kHz and an analysis frequency range of 0 - 5000 Hz.

[0035] Unbalance calculation: Determine the unbalance phase through Fourier transform and calculate the unbalance magnitude. For example, the measured initial unbalance is 28 g·mm, and the phase is at a position 30° to the left of the middle of the aluminum roller.

[0036] Temperature compensation: Real-time monitor the temperature change of the aluminum roller through a thermal network model, and use a feedback control algorithm to adjust the dynamic balance detection parameters to compensate for the influence of temperature change on the unbalance measurement result.

[0037] Step 3: Bending process Finite element analysis: Use ABAQUS software to simulate the bending process and predict the bending amount. According to the unbalance calculation result, determine the bending force to be 12 kN and the bending angle to be 0.05°.

[0038] Hydraulic bending: Apply pressure using a hydraulic servo control system, with a pressure range of 50 - 200 MPa, and the pressure application direction is perpendicular to the axis of the aluminum roller. The hydraulic device is equipped with a displacement sensor to real-time monitor the bending amount and perform closed-loop control with the preset protrusion height.

[0039] Deformation control: Control the plastic deformation amount of the material within the range of 0.1 mm - 0.3 mm to avoid cracking of the roller body caused by excessive bending. For example, the actual bending amount is 0.15 mm, and the length of the deformed area is 50 mm.

[0040] Step 4: Secondary turning Turning parameters: Perform secondary turning using a CNC lathe, and the cutting depth is dynamically adjusted according to the material protrusion amount at the heavy part. For example, when the protrusion amount is 0.15 mm, set the cutting depth to 0.2 mm.

[0041] Processing control: The spindle speed is 1000 rpm, and the feed rate is 0.15 mm / r. Measure the diameter of the aluminum roller after turning to ensure that the diameter tolerance is within ±0.02 mm. For example, the target diameter is Φ150 mm, and the actual measured value is Φ150.01 mm.

[0042] Step 5: Secondary dynamic balance measurement Repeat detection: Perform dynamic balance detection again, and measure the residual unbalance of 8 g·mm and a phase shift of 15°.

[0043] Secondary bending: According to the calculation result of the new unbalance amount, adjust the bending parameters. For example, the bending force is 8 kN and the bending angle is 0.03°.

[0044] Low-temperature annealing treatment: If it still fails to meet the standard after multiple iterative corrections, the aluminum roller needs to be subjected to low-temperature annealing treatment. After eliminating the internal stress, steps 2-4 are performed again. The annealing temperature is set at 250 °C, the holding time is 2 hours, and it is cooled in the furnace.

[0045] Laser cladding technology: When the diameter of the aluminum roller is less than the predetermined range due to multiple turning operations, local laser cladding technology is adopted. For example, the predetermined diameter is Φ150 mm and the actual measured value is Φ149.8 mm. Use a laser cladding device to deposit aluminum alloy material in the non-working area of the roller body. After deposition, it is turned to the target diameter to ensure the final size is Φ150 mm ± 0.05 mm. Final inspection: After three iterative corrections, the measured residual unbalance amount is 3 g·mm, meeting the G2.5 level standard (permissible unbalance amount is 5 g·mm).

[0046] Database record: Establish a process control database to record the key parameters in each processing process, including turning depth, bending amount, dynamic balance detection results, and compensation measures. For example, record the initial turning parameters, the results of each dynamic balance detection, the bending correction parameters, and the final acceptance data.

[0047] Surface coating treatment is carried out after the dynamic balance performance of the aluminum roller meets the preset standard: Hard anodizing: Carry out hard anodizing treatment on the aluminum roller whose dynamic balance performance meets the preset standard. Use sulfuric acid solution, with the concentration controlled at 130 g / L, the aluminum ion content at 5-10 g / L, the bath temperature maintained at 0 °C, the current density set at 5 A / dm², the voltage at 30 V, adopt a pulsed power supply, and the oxidation time is 60 minutes to form an alumina layer with a thickness of 15-25 μm.

[0048] Polytetrafluoroethylene coating: Coat a polytetrafluoroethylene composite coating on the surface of the oxide layer, with the coating thickness controlled at 5-8 μm and the friction coefficient at 0.05-0.2. Before coating, sandblast the surface of the aluminum roller to enhance the coating adhesion.

[0049] Dynamic balance fine-tuning: After coating, perform dynamic balance fine-tuning again to compensate for the weight distribution of the coating. Use three-dimensional vibration analysis technology, and the detection speed is set at 30% of the working speed, that is, 900 rpm. According to the detection results, fine-tune the weight distribution of the aluminum roller to ensure that the final dynamic balance performance meets the G2.5 level standard.

[0050] The above are all the preferred embodiments of this application, and the protection scope of this application is not limited accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. A processing method for a highly balanced aluminum roller, characterized in that: It includes the following steps: Step 1: Primary processing. The raw aluminum roller which is bent and has an uneven surface is subjected to primary turning processing to form a cylinder on the surface of the aluminum roller. Step 2: Dynamic balance measurement. The turned aluminum roller is subjected to dynamic balance detection based on the outer diameter to determine the unbalance amount and phase. Step 3: Bending treatment. According to the detection results, the aluminum roller is bent towards the heavy position by a machine tool, so that the heavy part protrudes relative to the roller body. Step 4: Secondary turning. The surface of the bent aluminum roller is subjected to secondary turning to cut off the protruding material at the heavy part and adjust the weight distribution. Step 5: Secondary dynamic balance measurement. Repeat steps 2 - 4 until the dynamic balance performance of the aluminum roller meets the preset standard.

2. The high-balanced aluminum roller processing method according to claim 1, wherein: In step 1, before the primary turning processing, the raw aluminum roller needs to be straightened to eliminate the initial bending deformation. The primary turning processing should ensure that the cylindricity tolerance of the aluminum roller is ≤0.05mm and the surface roughness Ra is ≤1.6μm.

3. The high-balanced aluminum roller processing method according to claim 1, characterized in that: In step 2, the dynamic balance detection uses three - dimensional vibration analysis technology to synchronously collect axial, radial and axial vibration data, and determines the unbalance amount phase through Fourier transform. The rotational speed is set to 30% - 50% of the working rotational speed of the aluminum roller.

4. The high-balanced aluminum roller processing method according to claim 1, characterized in that: In step 3, the bending amount is predicted by finite element analysis, and the micro - pressure is applied by a hydraulic device. The pressure range is 50 - 200MPa, and the pressure application direction is perpendicular to the axis of the aluminum roller. The hydraulic device is equipped with a displacement sensor to real - time monitor the bending amount and perform closed - loop control with the preset protruding height, controlling the plastic deformation amount of the material within the range of 0.1mm - 0.3mm to avoid cracking of the roller body caused by excessive bending.

5. The high-balanced aluminum roller processing method according to claim 1, characterized in that: In step 4, the secondary turning uses a CNC lathe, and the cutting depth is dynamically adjusted according to the material protrusion amount at the heavy part to ensure that the diameter tolerance of the aluminum roller after cutting is within ±0.02mm.

6. The high-balance aluminum roller processing method according to claim 1, characterized in that: In step 5, if it still does not meet the standard after multiple iterative corrections, the aluminum roller needs to be subjected to low - temperature annealing treatment to eliminate internal stress and then steps 2 - 4 are performed again.

7. The method for processing a high-balance aluminum roller according to claim 1, wherein: Before step 1, it also includes non - destructive testing of the raw aluminum roller to exclude defects such as internal cracks and pores.

8. The high-balanced aluminum roller processing method according to claim 1, characterized in that:

9. The high-balanced aluminum roller processing method according to claim 1, wherein: When the diameter of the aluminum roller is less than the predetermined range due to multiple turnings, local laser cladding technology is used to deposit aluminum alloy material in the non - working area of the roller body, and after restoring the diameter size, the final dynamic balance verification is carried out.

10. The high-balance aluminum roller processing method according to claim 1, wherein: During the dynamic balance detection process, a temperature compensation mechanism is introduced. The temperature change of the aluminum roller is real - time monitored through a thermal network model, and a feedback control algorithm is used to adjust the dynamic balance detection parameters to compensate for the influence of temperature change on the unbalance amount measurement result. A process control database is established to record the key parameters in each processing process, including cutting depth, bending amount, dynamic balance detection results and compensation measures, providing a basis for subsequent process optimization and data traceability. After the dynamic balance performance of the aluminum roller meets the preset standard, the surface of the aluminum roller is subjected to hard anodizing treatment to form an alumina layer with a thickness of 15 - 25μm, and a polytetrafluoroethylene composite coating with a thickness of 5 - 8μm is coated on the surface of the oxide layer. After coating, the dynamic balance is fine - tuned again to compensate for the weight distribution of the coating.

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