Development of Ironing System with Ultorasonic Vibration and without Process of Washing Products

对A3003铝合金挤压管材进行了多道次变薄拉深试验，以考察管材和工艺在感光鼓生产中的适用性。为提高挤压管材的减薄成形性，对工件进行了三种预处理：常规温度（410 ℃）退火、500 ℃退火和车削去除表层。通过在500 ℃下退火，挤压管在减薄过程中的抗拾取性显著提高。通过3阶段减薄工艺可以获得Ry<0.5 μ m的所需表面光洁度。使用探针扫描显微镜对产品的表面轮廓进行三维测量和分析。一个相当光滑的表面获得使用6级熨烫过程中，而约1微米深的凹槽时，保留3或4级熨烫过程中使用。微凸体的形状、分布及其在整个变薄过程中的变化 ...更多信息 使用轴承图来说明ESS。挤压管的圆度精度和厚度均匀性优于深冲杯。为了减少感光鼓挤压减薄过程中的减薄级数，利用自行研制的减薄装置，进行了超声波振动单级减薄的初步试验。将整个振动系统作为一个轴对称特征值问题进行有限元分析，研究了固有频率与固有振型之间的关系。超声波振动的频率设定为20.0kHz。在无负载下，模具轴对称地振动，在轴向方向上具有约5 μ m的振幅，并且在径向方向上具有约0.5 μ m的振幅。在熨烫过程中，两个方向上的振幅都减少了大约一半。通过施加超声波振动获得以下事实。(1)熨烫负荷显著降低35%~ 55%。(2)对于具有高粘度的润滑剂，产品的表面粗糙度更大，但是随着润滑剂的粘度降低，逐渐达到与常规熨烫的产品相同的水平。(3)产品的圆度误差降低到10 μ m以下。少

Multi-stage ironing experiments are carried out using an aluminum alloy (A3003) extruded pipe in order to examine the applicability of the pipe and prcess to the production of photosensitive drums. Three kinds of pretreatment of workpice are tested to improve the formability during ironing of the extruded pipe : annealing at the conventional temperature (410ﾟC), annealing at 500ﾟC and removal of the surface layr of the pipe by turning. The pickup resistance of the extruded pipe during ironing is markedly improved by annealing at 500ﾟC.The desired surface finish of Ry<0.5 mum can beobtained by a 3-stage ironing process. Three-dimensional measurement and analysis of the surface profiles of the products are performed using a probe scanning microscope. A fairly smooth surface is obtained using a 6-stage ironing process, whereas grooves about 1mum deep remain when a 3-or 4-stage ironing process is used. The shape and distribution of asperities and their variation throughout the ironing proc … More ess are illustrated using a bearing diagram. The roundness accuracy and a thickness uniformity of the extruded pipe are demonstrated to be better than those of a deep-drawn cup. Preliminary experiments of single-stage ironing with ultrasonic vibration are carried out using an aparatus constructed for these trials to reduce the number of ironing stages in the extruded and ironing process for photosensitive drums. The whole vibrating system is analyzed by Finite Element Method as an axisymmetric eigenvalue problem to examine the relationship between the natural frequencies and the natural modes of vibration. The frequency of the ultrasonic vibration is set at 20.0 kHz. A die vibrates axisymmetrically with about 5 mum amplitude in the axial direction and with about 0.5 mum amplitude in the radial direction under no load. The amplitudes in both directions are diminished by about half during ironing. The following facts are obtained by applying ultrasonic vibration. (1) The ironing load is markedly decreased by 35%-55%. (2) The surface roughness of the products is greater for lubricants with a high viscosity, but gradually reaches the same level as that of the products of conventional ironing as the viscosity of the lubricants decreases. (3) The roundness error of the products is reduced to below 10mum. Less