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

为了考察铝合金(A3003)挤压管材及其工艺在感光鼓生产中的适用性，进行了多阶段拉深试验。为提高挤压管拉深时的成形性，试验了常规温度(410ﾟC)退火、500ﾟ℃退火和车削去表层三种工艺。挤压管材经500ﾟ℃退火后，其抗拉伸性能显著提高。采用三步拉深工艺可获得所需的Ry&lt；0.5um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。使用6级熨烫工艺可获得相当光滑的表面，而使用3级或4级熨烫工艺时，仍有大约1微米深的凹槽。拉深…过程中粗糙度的形状、分布及其变化更多的ESS用方位图进行了说明。结果表明，挤压管的圆度精度和厚度均匀度均好于拉深筒形管。为了减少感光滚筒挤压熨烫过程中的熨烫次数，进行了超声波振动单级熨烫的初步实验。将整个振动系统作为轴对称的特征值问题进行有限元分析，以考察固有频率与固有振型之间的关系。超声波振动的频率被设置为20.0 kHz。空载下轴对称振动，轴向振幅约5微米，径向振幅约0.5微米。在熨烫过程中，两个方向的振幅都减小了大约一半。通过应用超声振动，获得了以下事实。(1)熨烫负荷显著降低35%~55%。(2)润滑剂粘度越高，产品表面粗糙度越大，但随着润滑剂粘度的降低，产品表面粗糙度逐渐达到常规熨烫产品的水平。(3)产品圆度误差降至10微米以下。较少

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