高速铁路用铜合金接触网导线及铜扁线的产业化研究
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摘要
随着我国高速铁路网的快速发展,对接触网导线的要求越来越高。铜合金导线材料由于性能优良,成为研究热点,高品质接触线的开发成为迫切需要解决的课题。同时高速列车的牵引变压器绕组对铜扁线也提出了更高的要求,铜合金扁线的研究也是热点之一。本文为国家科技支撑计划项目“高速铁路专用铜合金导线产业化开发”(2007BAE23B00)中的课题1——铜银、铜锡合金导线产品产业化技术研究(2007BAE23B01)和课题3——连续挤压铜合金扁线产业化技术研究(2007BAE23B03)的部分研究内容。
铜合金接触网导线的关键技术是：掌握SCR连铸连轧工艺生产铜银、铜锡等高铁用铜合金导线的配方；形成连续化生产条件下微合金配置的成套技术和工艺装备；形成柔性化的SCR连铸连轧工艺制备铜合金的技术和装备：解决制备微合金化铜合金材料强化技术,满足高铁对高强高导材料的需求。
连续挤压铜合金扁线的关键技术是：掌握铜及铜银合金在挤压轮槽、腔体、模具中流动及热力场分布规律；实现腔体、模具材料与腔体、模具结构的最佳组合；掌握影响挤压合金产品质量因素；实现连续挤压铜合金扁线的产业化生产。进行铜包钢导线材料连续挤压的工程问题研究,利用法向连续挤压机进行铜包钢线生产的探索和实验。
论文的主要研究工作及研究成果如下：
通过开展产业化条件下的铜银、铜锡、合金导线制备技术及装备研究,解决主要关键技术,即在合金配方、微合金化技术、强化技术、柔性化生产等产业化技术研究方面和产品生产工艺、质量控制技术研究、在线实时检测等方面进行研究。在国内率先提出并实现“强电磁搅拌+SCR连铸连轧+冷拉／冷轧工艺”制备铜合金导线的工艺路线,并将研究成果应用到了实际生产之中。课题研究期间累计生产铜合金导线产品13349.712吨(其中：铜银合金8936.077吨,铜锡合金4298.072吨),累计实现销售收入8.83亿元,利润6181.75万元。
通过开展“双进多出工艺”研究,在单轮槽连续挤压上,实现“超小截面、超大宽窄比”的铜及铜银合金扁线挤压生产,在连续挤压材料制备工艺上具有创新性。
在云南铜业的TLJ-300Conform连续挤压机上,通过开展创新设计腔体结构,采用嵌入组合的方式将关键部位材料升级,设计开发出组合腔体,提高了腔体的高温性、易修复性,提高寿命降低成本。大大提高了生产效率和产量,获得了很好的经济和社会效益(课题完成后累计生产铜及铜合金扁线产品4821.905吨,实现销售收入2.39亿元,税收560万元,利润498万元)。
通过数值模拟研究获得了连续挤压过程中压力场、温度场、金属流动等规律,开发出适于高强铜银合金生产的高强、高性能模具及合理的腔体结构,在模具制备方面具有创新性。
通过开展连续挤压包覆材料(铜包钢)变形过程机理的研究,利用昆明理工大学自制的LJ350型法向连续挤压机,开展连续挤压铜包钢线的研究,掌握优化了相关参数,解决了相关工程化的关键问题,得到了铜包钢线材样品。
As the electric train develops to high-speed and heavy haul, it require the material quality of contact wire to be finer and it promote contact wire develop constantly High strength and high conduct contact wire is the hot spot of research all the time because of its superior physical properties and mechanical properties. The research of superior performance contact wire that need to solve imperatively by the railway interests and factories. The drawing transformer winding of high-speed train has stricter requirements on the copper flat wire at the same time, so the research on copper flat wire is also one of hot spots. The content of this paper is some of the topic1(number:2007BAE23B01) which is the study on industrialization technology of Cu-Ag alloy contact wire and Cu-Sn alloy contact wire and the topic3(number:2007BAE23B03) which is the study on industrialization technology of continuous extrusion forming about copper alloy flat wire, topic1and topic3is belong of National Science and Technology Support Plan Program which is the study on industrialization technology in copper alloy contact wire only for high-speed railway (project number:2007BAE23B03).
The key technology of copper alloy contact wire is that mastering the alloy formula of Cu-Ag alloy contact wire and Cu-Sn alloy contact wire by continuous casting and rolling processing; mastering whole technologies about of alloy configuration and equipment in continue manufacturing; mastering flexible production technology and equipment of producing copper alloy by continuous casting and rolling; Solve strengthening technology of producing copper alloy material by micro alloying technology. So it is satisfied with the requirement of high-speed railway in high strengthen and high conductivity material.
The key technology of manufacture copper alloy bar by continuous extrusion and forming:The study focus on the distribution of temperature field、pressure field and the metal flow process,Create a new chamber structure, achieve the best combination of die and Chamber; Researche the copper clad steel wire based on the radial continuous extrusion.
The main content and research fruit of the paper is that:(1) being finished with study on producing technologies and equipments of Cu-Ag alloy conduct material and Cu-Sn alloy conduct material, it mainly studied on industrialization technology such as copper alloy formula technology, micro alloying technology, strengthening technology, flexible production technology and so on, and studied on manufacturing technique, production quality, detecting on line and so on.(2) it comed up with firstly internal and achieved the manufacturing technique that manufacturing copper alloy conducting wire by "electromagnetic stirring+SCR continue casting and roll+cold draw/roll" process,and it applied the research fruit to manufacturing in factory. It manufactured copper alloy conducting wire13349.72ton (including:Cu-Ag alloy conducting wire8936.077ton, Cu-Sn alloy conducting wire4298.072ton), the sale revenue added up to RMB8.83billion yuan and it create profits RMB6181.75million yuan.
According to the research on the two feedstock to extrude four products. The problem of small bore sectional bar and large width-thickness ratios bar with single groove CONFORM machine is settled. It is technically innovative.
And to do continuous extrusion research in JL300type Conform machine in Yunnan Copper. By the way of adopt embed Super alloy in the key parts and create a new chamber structure, it improve the high temperature performance, also improve the chamber life. The production efficiency enhanced.
A year after the completion of the subject, Total4821.905dun of copper alloy bar have been produced, sales revenue0.239billion yuan, over5.6million tax and over4.98million profit have been hand over.It get a good economic and social benefits.
Numerical simulation of temperature field of copper flat wire continuous extrusion forming has been studied:The study focus on the distribution of temperature field、pressure field and the metal flow process was simulated. By the study develop High-performance die and Reasonable chamber structure; make innovations in die and machine.
Study of Copper clad steel wire During Continuous Extrusion
The study of copper clad steel wire mechanism of deformation process based on the radial continuous extrusion:Through the establishment of continuous extrusion clad research in JL350type continuous extrusion machine which was kungongmade, The experiment process contains the single wheel double grove and single wheel single grove clad. The study mainly focuses on:
(1) The running clearance;(2) Steel and copper preheated and speed matching problem with extrusion wheel;(3) the process parameters of initial bite into the extrusion wheel.
During the researching time the engineering problems of continuous extrusion clad possess is solved. Copper clad steel wire sample have been produced.
铜合金接触网导线的关键技术是：掌握SCR连铸连轧工艺生产铜银、铜锡等高铁用铜合金导线的配方；形成连续化生产条件下微合金配置的成套技术和工艺装备；形成柔性化的SCR连铸连轧工艺制备铜合金的技术和装备：解决制备微合金化铜合金材料强化技术,满足高铁对高强高导材料的需求。
连续挤压铜合金扁线的关键技术是：掌握铜及铜银合金在挤压轮槽、腔体、模具中流动及热力场分布规律；实现腔体、模具材料与腔体、模具结构的最佳组合；掌握影响挤压合金产品质量因素；实现连续挤压铜合金扁线的产业化生产。进行铜包钢导线材料连续挤压的工程问题研究,利用法向连续挤压机进行铜包钢线生产的探索和实验。
论文的主要研究工作及研究成果如下：
通过开展产业化条件下的铜银、铜锡、合金导线制备技术及装备研究,解决主要关键技术,即在合金配方、微合金化技术、强化技术、柔性化生产等产业化技术研究方面和产品生产工艺、质量控制技术研究、在线实时检测等方面进行研究。在国内率先提出并实现“强电磁搅拌+SCR连铸连轧+冷拉／冷轧工艺”制备铜合金导线的工艺路线,并将研究成果应用到了实际生产之中。课题研究期间累计生产铜合金导线产品13349.712吨(其中：铜银合金8936.077吨,铜锡合金4298.072吨),累计实现销售收入8.83亿元,利润6181.75万元。
通过开展“双进多出工艺”研究,在单轮槽连续挤压上,实现“超小截面、超大宽窄比”的铜及铜银合金扁线挤压生产,在连续挤压材料制备工艺上具有创新性。
在云南铜业的TLJ-300Conform连续挤压机上,通过开展创新设计腔体结构,采用嵌入组合的方式将关键部位材料升级,设计开发出组合腔体,提高了腔体的高温性、易修复性,提高寿命降低成本。大大提高了生产效率和产量,获得了很好的经济和社会效益(课题完成后累计生产铜及铜合金扁线产品4821.905吨,实现销售收入2.39亿元,税收560万元,利润498万元)。
通过数值模拟研究获得了连续挤压过程中压力场、温度场、金属流动等规律,开发出适于高强铜银合金生产的高强、高性能模具及合理的腔体结构,在模具制备方面具有创新性。
通过开展连续挤压包覆材料(铜包钢)变形过程机理的研究,利用昆明理工大学自制的LJ350型法向连续挤压机,开展连续挤压铜包钢线的研究,掌握优化了相关参数,解决了相关工程化的关键问题,得到了铜包钢线材样品。
As the electric train develops to high-speed and heavy haul, it require the material quality of contact wire to be finer and it promote contact wire develop constantly High strength and high conduct contact wire is the hot spot of research all the time because of its superior physical properties and mechanical properties. The research of superior performance contact wire that need to solve imperatively by the railway interests and factories. The drawing transformer winding of high-speed train has stricter requirements on the copper flat wire at the same time, so the research on copper flat wire is also one of hot spots. The content of this paper is some of the topic1(number:2007BAE23B01) which is the study on industrialization technology of Cu-Ag alloy contact wire and Cu-Sn alloy contact wire and the topic3(number:2007BAE23B03) which is the study on industrialization technology of continuous extrusion forming about copper alloy flat wire, topic1and topic3is belong of National Science and Technology Support Plan Program which is the study on industrialization technology in copper alloy contact wire only for high-speed railway (project number:2007BAE23B03).
The key technology of copper alloy contact wire is that mastering the alloy formula of Cu-Ag alloy contact wire and Cu-Sn alloy contact wire by continuous casting and rolling processing; mastering whole technologies about of alloy configuration and equipment in continue manufacturing; mastering flexible production technology and equipment of producing copper alloy by continuous casting and rolling; Solve strengthening technology of producing copper alloy material by micro alloying technology. So it is satisfied with the requirement of high-speed railway in high strengthen and high conductivity material.
The key technology of manufacture copper alloy bar by continuous extrusion and forming:The study focus on the distribution of temperature field、pressure field and the metal flow process,Create a new chamber structure, achieve the best combination of die and Chamber; Researche the copper clad steel wire based on the radial continuous extrusion.
The main content and research fruit of the paper is that:(1) being finished with study on producing technologies and equipments of Cu-Ag alloy conduct material and Cu-Sn alloy conduct material, it mainly studied on industrialization technology such as copper alloy formula technology, micro alloying technology, strengthening technology, flexible production technology and so on, and studied on manufacturing technique, production quality, detecting on line and so on.(2) it comed up with firstly internal and achieved the manufacturing technique that manufacturing copper alloy conducting wire by "electromagnetic stirring+SCR continue casting and roll+cold draw/roll" process,and it applied the research fruit to manufacturing in factory. It manufactured copper alloy conducting wire13349.72ton (including:Cu-Ag alloy conducting wire8936.077ton, Cu-Sn alloy conducting wire4298.072ton), the sale revenue added up to RMB8.83billion yuan and it create profits RMB6181.75million yuan.
According to the research on the two feedstock to extrude four products. The problem of small bore sectional bar and large width-thickness ratios bar with single groove CONFORM machine is settled. It is technically innovative.
And to do continuous extrusion research in JL300type Conform machine in Yunnan Copper. By the way of adopt embed Super alloy in the key parts and create a new chamber structure, it improve the high temperature performance, also improve the chamber life. The production efficiency enhanced.
A year after the completion of the subject, Total4821.905dun of copper alloy bar have been produced, sales revenue0.239billion yuan, over5.6million tax and over4.98million profit have been hand over.It get a good economic and social benefits.
Numerical simulation of temperature field of copper flat wire continuous extrusion forming has been studied:The study focus on the distribution of temperature field、pressure field and the metal flow process was simulated. By the study develop High-performance die and Reasonable chamber structure; make innovations in die and machine.
Study of Copper clad steel wire During Continuous Extrusion
The study of copper clad steel wire mechanism of deformation process based on the radial continuous extrusion:Through the establishment of continuous extrusion clad research in JL350type continuous extrusion machine which was kungongmade, The experiment process contains the single wheel double grove and single wheel single grove clad. The study mainly focuses on:
(1) The running clearance;(2) Steel and copper preheated and speed matching problem with extrusion wheel;(3) the process parameters of initial bite into the extrusion wheel.
During the researching time the engineering problems of continuous extrusion clad possess is solved. Copper clad steel wire sample have been produced.
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