CN117961085A - Manufacturing process of lightweight steel wire rope adopting 3D printing mode - Google Patents

Abstract

A lightweight wire rope manufacturing process using 3D printing can reduce the overall weight of the wire rope while increasing its bearing strength by mixing nanomaterials into metal materials to form a basic wire. In addition, the wire rope can be directly manufactured through 3D printing, which has a lower manufacturing cost than the traditional multi-strand twisting method. Finally, the combination of heat treatment and corrosion-resistant coating makes the structural strength of the wire rope higher and corrosion-resistant.

Description

A lightweight steel wire rope manufacturing process using 3D printing

Technical Field

The present invention relates to the technical field of steel wire ropes, and in particular to a lightweight steel wire rope manufacturing process using a 3D printing method.

Background technique

As is known, steel wire rope is a kind of metal product with high strength and high toughness, which is widely used in the crane hoisting industry. In recent years, with the development of science and technology, the application scope of cranes has become more and more extensive, and cantilever cranes used in a small range have gradually become more popular with users. Although cantilever cranes occupy a small area, they sometimes have to carry heavy objects, so the requirements for the performance of steel wire ropes are also higher, and high breaking and lightweight steel wire ropes have gradually attracted attention.

Traditional steel wire ropes are generally made by twisting multiple strands of alloy ropes into one rope through a rope twisting machine. The load-bearing capacity of the steel wire rope is proportional to the number of alloy ropes. However, the increase in the number of alloy ropes will increase the weight of the steel wire rope, thereby increasing the overall weight of the drum. Then, a larger counterweight is required at the other end of the crane to maintain balance, which in turn affects the miniaturization of the cantilever crane. In addition, the steel wire rope twisted from alloy ropes has low softness, poor load-bearing capacity, and poor tightening ability when hoisting some flexible objects.

A Chinese patent (BN105887525A) discloses a carbon fiber core steel wire rope, which can significantly improve the softness and toughness of the steel wire rope by using a carbon fiber core and a carbon fiber tow core of the outer rope strands, and the weight of the steel wire rope is also greatly reduced, and the service life of the steel wire rope is long; however, the cost of carbon fiber is too high and is not suitable for use in small cranes;

Therefore, in summary, the market currently needs a steel wire rope that is lightweight, low in cost, and has a strong load-bearing capacity.

Summary of the invention

In order to overcome the deficiencies in the background technology, the present invention discloses a lightweight steel wire rope manufacturing process using a 3D printing method.

In order to achieve the above-mentioned invention object, the present invention adopts the following technical scheme:

A lightweight steel wire rope manufacturing process using 3D printing.

Specific steps are as follows:

Step 1: Mix 5-7% nanomaterial, 65-68% iron, 18-19.5% chromium and 8.3-9.5% nickel, smelt them at high temperature with a dispersant, extrude them through an extruder and cool them to form a basic wire;

Step 2: Place the base wire and aluminum alloy wire as printing materials into the metal 3D printer;

Step 3: Use the melt extrusion molding technology of the 3D printer to print out the steel wire rope, wherein the steel wire rope is a two-layer cylindrical structure, the inner rope core is composed of the basic wire material, and the outer rope skin is composed of the aluminum alloy wire material;

Step 4: Clean and polish the surface of the wire rope, and then heat treat the wire rope;

Step 5: Apply a corrosion-resistant coating on the surface of the heat-treated steel wire rope.

Preferably, the nanomaterial is graphene or carbon nanotube.

Preferably, the 3D printer used in step 3 comprises a printer body, an extrusion nozzle, a transition tube, a frame and a wire-taking mechanism, wherein the printer body is capable of melting the basic wire and the aluminum alloy wire; the extrusion nozzle is composed of an inner nozzle and an outer nozzle, wherein the outer nozzle is sleeved outside the inner nozzle, the inner nozzle is used to extrude the basic material, and the outer nozzle is used to extrude the aluminum alloy material, and the discharge end of the inner nozzle is higher than the discharge end of the outer nozzle; the transition tube is correspondingly connected to the discharge end of the outer nozzle, the material is cooled and formed in the transition tube, and the wire-taking mechanism is used to roll up and collect the cooled and formed steel wire rope.

Preferably, the wire-taking mechanism comprises a partition, a positioning wheel group, a guiding component and a winding drum, wherein the partition is located below the transition tube and is provided with a through hole for the wire rope to pass through; the positioning wheel group is composed of two symmetrical rollers, the two rollers are installed on the top surface of the partition, and the outer edge surfaces of the two rollers are in corresponding contact with the rope body of the wire rope output from the transition tube; the bottom surface of the partition is provided with a guiding component for guiding the wire rope to be wound up by the winding drum.

Preferably, the guiding component is composed of two symmetrical clamping units, the clamping unit includes a fixing rod, a spring, a probe rod, a pressure block and a rolling ball, wherein the tail end of the fixing rod is installed on the bottom surface of the partition, the head end of the fixing rod is provided with a bottom block, the bottom block is vertically provided with a probe rod, and the outer sleeve of the probe rod is provided with a spring; the tail end of the pressure block is provided with a countersunk groove for placing the spring, wherein the countersunk head of the countersunk groove corresponds to the bottom block, the groove of the countersunk groove is used to place the spring, and the head end surface of the pressure block is provided with a plurality of rolling balls.

Preferably, the heat treatment method in step 4 is:

a. Place the manufactured steel wire rope in an annealing furnace, where the annealing temperature is 800-950℃;

b. After maintaining the temperature for 80-100 minutes, turn off the annealing furnace and let the wire rope cool naturally;

c. When the wire rope is cooled to 630-720℃, immerse the wire rope in the quenching medium for 10 minutes;

d. Put the quenched steel wire rope into the tempering furnace, and the tempering temperature is 280-300℃, and the tempering time is 40-60min;

e. After tempering is completed, close the tempering furnace and wait for the wire rope to cool to room temperature to complete the heat treatment of the wire rope.

Preferably, the relationship between the current temperature of the annealing furnace and the annealing furnace heating time t is as follows:

;

Where A is the thermal efficiency coefficient of the wire rope, T is the current temperature of the annealing furnace, and K is the thermal conductivity constant of the wire rope.

Preferably, the coating in step 5 is a galvanized coating and is completed by magnetron sputtering technology.

Due to the adoption of the above-mentioned technical solution, the present invention has the following beneficial effects:

The present invention discloses a lightweight steel wire rope manufacturing process using 3D printing. By mixing nanomaterials into metal materials to form basic wire materials, the overall weight of the steel wire rope can be reduced and the bearing strength of the steel wire rope can be improved. In addition, the steel wire rope can be directly manufactured by 3D printing, and the manufacturing cost is lower than that of the traditional multi-strand twisting method.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a schematic structural diagram of a 3D printer of the present invention;

FIG. 2 is an enlarged schematic diagram of the structure of section A in FIG. 1 .

In the figure: 1. printer body; 2. extruder nozzle; 201. inner nozzle; 202. outer nozzle; 3. transition tube; 4. frame; 5. wire take-up mechanism; 501. partition; 502. positioning wheel group; 503. guide component; 5031. fixing rod; 5032. bottom block; 5033. probe rod; 5034. spring; 5035. pressure block; 50351. countersunk groove; 5036. rolling ball; 504. take-up drum; 6. wire rope.

Detailed ways

The technical solution of the present invention will be described below in conjunction with the drawings in the embodiments of the present invention. In the description, it should be understood that if there are terms such as "upper", "lower", "front", "rear", "left", "right" and the like indicating directions or positional relationships, they are only corresponding to the drawings of the present invention, for the convenience of describing the present invention, and do not indicate or imply that the device or element referred to must have a specific direction:

In conjunction with the 3D printing method for manufacturing lightweight steel wire ropes described in Figures 1-2,

Specific steps are as follows:

Step 1: 5-7% nanomaterial, 65-68% iron, 18-19.5% chromium and 8.3-9.5% nickel are mixed, and then smelted at high temperature together with a dispersant, and then extruded and cooled by an extruder to finally form a basic wire material. By mixing the nanomaterial into the metal material to form the basic wire material, the overall weight of the steel wire rope 6 can be reduced, and the bearing strength of the steel wire rope 6 can be improved; in particular, the nanomaterial is graphene or carbon nanotubes;

Step 2: Place the base wire and aluminum alloy wire as printing materials into the metal 3D printer;

Step 3: Print out the steel wire rope 6 by using the melt extrusion molding technology of the 3D printer, wherein the steel wire rope 6 is a two-layer cylindrical structure, the inner rope core is composed of the basic wire material, and the outer rope skin is composed of the aluminum alloy wire material. The steel wire rope 6 can be directly produced by 3D printing. Combined with the structure of the steel wire rope 6, the production cost is lower than that of the traditional multi-strand twisting method;

Step 4: Clean and polish the surface of the steel wire rope 6, and then heat treat the steel wire rope 6 to improve the strength and durability of the steel wire rope 6;

Step 5: A layer of corrosion-resistant coating is applied to the surface of the heat-treated steel wire rope 6 to effectively protect the steel wire rope 6 body; in particular, the coating in step 5 is set as a galvanized coating and is completed by magnetron sputtering technology.

Embodiment 1 is: the 3D printer used in step 3 comprises a printer body 1, an extrusion nozzle 2, a transition tube 3, a frame 4 and a wire taking-up mechanism 5, wherein the printer body 1 is capable of melting the basic wire and the aluminum alloy wire; the extrusion nozzle 2 is composed of an inner nozzle 201 and an outer nozzle 202, wherein the outer nozzle 202 is sleeved outside the inner nozzle 201, the inner nozzle 201 is used to extrude the basic material, and the outer nozzle 202 is used to extrude the aluminum alloy material, and the discharge end of the inner nozzle 201 is higher than the discharge end of the outer nozzle 202, so that the basic material will be first extruded from the inner nozzle 201 and located in the hollow position of the transition tube 3, and gradually move downward , and the aluminum alloy material extruded from the outer nozzle 202 is in a ring shape, and flows into the transition tube 3 along the gap between the outer nozzle 202 and the inner nozzle 201, so that the aluminum alloy material covers the base material in the center. Since the material has not cooled and solidified at this time, a steel wire rope 6 prototype with an inner and outer cylindrical structure is formed; the transition tube 3 is correspondingly connected to the discharge end of the outer nozzle 202, and the material is cooled and formed in the transition tube 3. The steel wire rope 6 prototype is gradually cooled to become the steel wire rope 6 body during the movement in the transition tube 3 under the influence of gravity, and the wire take-up mechanism 5 is used to roll up and collect the cooled and formed steel wire rope 6;

In addition, the wire-taking mechanism 5 includes a partition 501, a positioning wheel group 502, a guide component 503 and a winding drum 504, wherein the partition 501 is located below the transition tube 3, and the partition 501 is provided with a through hole for the wire rope 6 to pass through; the positioning wheel group 502 is composed of two symmetrical rollers, the two rollers are installed on the top surface of the partition 501, and the outer edge surfaces of the two rollers are in corresponding contact with the rope body of the wire rope 6 output from the transition tube 3; the bottom surface of the partition 501 is provided with a guide component 503 for guiding the wire rope 6 to be wound by the winding drum 504, wherein the positioning wheel group 502 can preliminarily guide the main body of the wire rope 6 to be output from the transition tube 3, and the guide component 503 is for secondary guidance of the wire rope 6, so that the wire rope 6 is sent into the winding mechanism more smoothly, and it should be noted that since the relative level of the winding position needs to be gradually changed during the winding process, the guide component 503 for secondary guidance is provided to prevent the wire rope 6 from swinging during the winding process;

As required, the guide component 503 is composed of two symmetrical clamping units, which include a fixed rod 5031, a spring 5034, a probe rod 5033, a pressure block 5035 and a rolling ball 5036, wherein the tail end of the fixed rod 5031 is installed on the bottom surface of the partition 501, the head end of the fixed rod 5031 is provided with a bottom block 5032, the bottom block 5032 is vertically provided with a probe rod 5033, and the outer sleeve of the probe rod 5033 is provided with a spring 5034; the tail end of the pressure block 5035 is provided with a spring for placing The countersunk groove 50351 of 5034, wherein the countersunk head portion of the countersunk groove 50351 corresponds to the bottom block 5032, and the groove portion of the countersunk groove 50351 is used to place the spring 5034. The head end surface of the pressure block 5035 is provided with a plurality of rolling balls 5036. Through the action of the spring 5034, the two pressure blocks 5035 can clamp the wire rope 6 accordingly to fix the relative position of the wire rope 6 on the horizontal plane, and the plurality of rolling balls 5036 can allow the wire rope 6 to move smoothly toward the winding mechanism.

Embodiment 2: The heat treatment process in step 4 is:

a. Place the manufactured steel wire rope 6 in an annealing furnace, where the annealing temperature is 800-950°C, and the heat in the annealing furnace should rise slowly over time, so that the steel wire rope 6 has sufficient preheating space;

b. After maintaining the temperature for 80-100 minutes, the crystal structure changes, the annealing furnace is closed, and the steel wire rope 6 is allowed to cool naturally;

c. When the steel wire rope 6 is cooled to 630-720°C, immerse the steel wire rope 6 in a quenching medium for 10 minutes, wherein the quenching medium may be water, oil or a polymer salt solution;

d. Place the quenched steel wire rope 6 into a tempering furnace at a tempering temperature of 280-300°C and a tempering time of 40-60min;

e. After the tempering is completed, the tempering furnace is closed and the heat treatment of the wire rope 6 is completed when the wire rope 6 cools to room temperature.

In addition, the relationship between the current temperature of the annealing furnace and the annealing furnace heating time t is as follows:

;

Wherein A is the thermal efficiency coefficient of the steel wire rope 6, T is the current temperature of the annealing furnace, and K is the thermal conductivity constant of the steel wire rope 6.

Embodiment 3:

An embodiment of the steel wire rope manufacturing process is:

Step 1: Mix 5% nanomaterial, 66.5% iron, 19% chromium and 9.5% nickel, smelt them at high temperature with a dispersant, extrude them through an extruder and cool them to form a basic wire;

Step 2: Place the base wire and aluminum alloy wire as printing materials into the metal 3D printer;

Step 3: Print out the steel wire rope 6 using the melt extrusion molding technology of the 3D printer, wherein the steel wire rope 6 is a two-layer cylindrical structure, the inner rope core is composed of the basic wire material, and the outer rope skin is composed of the aluminum alloy wire material;

Step 4: Clean and polish the surface of the steel wire rope 6, and then perform heat treatment on the steel wire rope 6;

Step 5: Coat a corrosion-resistant coating on the surface of the heat-treated steel wire rope 6.

Embodiment 4:

The second embodiment of the steel wire rope manufacturing process is:

Step 1: Mix 7% nanomaterial, 65% iron, 19% chromium and 9% nickel, smelt them at high temperature with a dispersant, extrude them through an extruder and cool them to form a basic wire;

Step 2: Place the base wire and aluminum alloy wire as printing materials into the metal 3D printer;

Step 3: Print out the steel wire rope 6 using the melt extrusion molding technology of the 3D printer, wherein the steel wire rope 6 is a two-layer cylindrical structure, the inner rope core is composed of the basic wire material, and the outer rope skin is composed of the aluminum alloy wire material;

Step 4: Clean and polish the surface of the steel wire rope 6, and then perform heat treatment on the steel wire rope 6;

Step 5: Coat a corrosion-resistant coating on the surface of the heat-treated steel wire rope 6.

The parts of the present invention that are not described in detail are prior art. It is obvious to those skilled in the art that the present invention is not limited to the details of the above-mentioned exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention; therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is limited by the attached claims rather than the above description. Therefore, it is intended to include all changes within the meaning and scope of the equivalent elements of the claims in the present invention, and any figure marks in the claims should not be regarded as limiting the claims involved.

Claims (7)

1. A lightweight steel wire rope manufacturing process adopting a 3D printing mode is characterized in that:

the method comprises the following specific steps:

step 1: mixing 5-7% of nano material, 65-68% of iron, 18-19.5% of chromium and 8.3-9.5% of nickel, then smelting at high temperature together with a dispersing agent, extruding through an extruder, and cooling to finally form a base wire;

Step 2: placing the base wire and the aluminum alloy wire into a metal 3D printer as printing materials;

Step 3: printing out a steel wire rope (6) by using a fusion extrusion molding technology of a 3D printer, wherein the steel wire rope (6) is of a two-layer cylindrical structure, an inner layer rope core is formed by a basic wire, and an outer layer rope skin is formed by an aluminum alloy wire;

step 4: cleaning and polishing the surface of the steel wire rope (6), and then performing heat treatment on the steel wire rope (6);

Step 5: and coating a corrosion-resistant coating on the surface of the steel wire rope (6) after heat treatment.

2. The process for manufacturing the lightweight steel wire rope by adopting the 3D printing mode as claimed in claim 1, wherein the process comprises the following steps of: the nano material is graphene or carbon nano tube.

3. The process for manufacturing the lightweight steel wire rope by adopting the 3D printing mode as claimed in claim 1, wherein the process comprises the following steps of: the 3D printer used in the step 3 comprises a printer body (1), an extrusion nozzle (2), a transition pipe (3), a frame body (4) and a wire collecting mechanism (5), wherein the printer body (1) can melt a base wire and an aluminum alloy wire; the extrusion nozzle (2) is composed of an inner nozzle (201) and an outer nozzle (202), wherein the outer nozzle (202) is sleeved outside the inner nozzle (201), the inner nozzle (201) is used for extruding a base material, the outer nozzle (202) is used for extruding an aluminum alloy material, and the discharge end of the inner nozzle (201) is higher than the discharge end of the outer nozzle (202); the transition pipe (3) is correspondingly matched and connected with the discharge end of the outer nozzle (202), materials are cooled and formed in the transition pipe (3), and the wire winding mechanism (5) is used for winding and collecting the cooled and formed steel wire ropes (6).

4. A process for manufacturing a lightweight steel wire rope by adopting a 3D printing mode as claimed in claim 3, wherein the process comprises the following steps: the wire winding mechanism (5) comprises a partition plate (501), a positioning wheel set (502), a guide part (503) and a winding drum (504), wherein the partition plate (501) is positioned below the transition pipe (3), and a through hole for a steel wire rope (6) to pass through is formed in the partition plate (501); the positioning wheel set (502) consists of two symmetrical rollers, the two rollers are arranged on the top surface of the partition plate (501), and the outer edge surfaces of the two rollers are correspondingly abutted against the rope body of the steel wire rope (6) output by the transition pipe (3); the bottom surface of the partition plate (501) is provided with a guide component (503) for guiding the steel wire rope (6) to be wound by a winding drum (504).

5. The process for manufacturing the lightweight steel wire rope by adopting the 3D printing mode as claimed in claim 4, which is characterized in that: the guide component (503) is composed of two symmetrical clamping units, each clamping unit comprises a fixing rod (5031), a probe rod (5033), a spring (5034), a pressing block (5035) and a rolling ball (5036), the tail end of the fixing rod (5031) is arranged on the bottom surface of the partition plate (501), a bottom block (5032) is arranged at the head end of the fixing rod (5031), the probe rod (5033) is vertically arranged on the bottom block (5032), and the spring (5034) is sleeved outside the probe rod (5033); the tail end of the pressing block (5035) is provided with a countersunk head groove (50351) for placing a spring (5034), the countersunk head part of the countersunk head groove (50351) is correspondingly matched with the bottom block (5032), the groove part of the countersunk head groove (50351) is used for placing the spring (5034), and the head end surface of the pressing block (5035) is provided with a plurality of rolling balls (5036).

6. The process for manufacturing the lightweight steel wire rope by adopting the 3D printing mode as claimed in claim 1, wherein the process comprises the following steps of: the heat treatment method in the step 4 is as follows:

a. Placing the manufactured steel wire rope (6) in an annealing furnace, wherein the annealing temperature is 800-950 ℃;

b. after the temperature is maintained for 80-100min, the annealing furnace is closed, and the steel wire rope (6) is naturally cooled;

c. When the steel wire rope (6) is cooled to 630-720 ℃, immersing the steel wire rope (6) in a quenching medium for 10min;

d. Placing the quenched steel wire rope (6) into a tempering furnace, wherein the tempering temperature is 280-300 ℃ and the tempering time is 40-60min;

e. And closing the tempering furnace after tempering, and finishing the heat treatment of the steel wire rope (6) after the steel wire rope (6) is cooled to normal temperature.

7. The process for manufacturing the lightweight steel wire rope by adopting the 3D printing mode as claimed in claim 6, wherein the process is characterized in that: the change relation of the current temperature of the annealing furnace along with the heating time t of the annealing furnace is as follows:

；

wherein A is the thermal efficiency coefficient of the steel wire rope (6), T is the current temperature of the annealing furnace, and K is the thermal conduction constant of the steel wire rope (6).