基于正交试验的850吨冷剪机剪切失效机理分析及其优化设计

Shear Failure Mechanism Analysis and Optimum Design of 850 Ton Cold Shear Based on Orthogonal Test

以减小850吨冷剪机剪切力为研究目的,从冷剪机剪切机理及特点出发,采用正交试验法分析剪切间隙、剪刃倾角、剪切速度、剪刃刀面宽度及剪刃重叠量等参数对剪切力的影响,分别以方差、极差及显著性作为影响因素的指标,并对其进行优先级排序,进而优化剪切参数,减小剪切力。优化剪切参数前后的冷剪机现场试验表明,优化前后冷剪机剪切力的实测值与仿真值误差均在5%以内,仿真结果可靠。采用优化后的剪切参数,冷剪机剪切相同规格钢筋时,上剪刃最大剪切力减小了5.84 kN,减小约13%,下剪刃最大剪切力减小了4.77 kN,减小约9.7%。经车间反馈,使用优化后的剪切参数可大幅延长冷剪机剪刃崩刃和磨损的周期,增长剪刃寿命和提高剪切效率。该研究对提高设备经济性和生产效率具有重要意义,可应用于同类型冷剪机的工程设计。

In order to reduce the shear force of 850 ton cold shears,the shearing mechanism and characteristics of the cold shear were studied,the effects of shear parameters such as shear clearance,blade inclination,shear velocity,blade width and blade overlap on shear force were analyzed by orthogonal test.Variance,range and significance were used as the indexes of influencing factors,and the priority of them were given to optimize the shear parameters and reduce the shear force.The experimental verification of the cold shear before and after the optimization of shear parameters were carried out in the workshops which show that the errors between the measured and simulated values of the shear force of the cold shear before and after optimization were within 5%,which verifies the reliability of the simulation analysis.By setting the optimal shear parameters and shearing the same steel bar,the maximum shear force of the upper shear blade is reduced by 5.84 kN,about 13%.The maximum shear force of the lower shear blade is reduced by 4.77 kN,about 9.7%.Feedbacks from workshops show that the optimization greatly prolongs the period of blade broken and blunt and improves the blade life and shearing efficiency.The results are of great significance for improving the economy and production efficiency of the equipment,and may be applied to the engineering design of the same type of cold shears.