内凹带式急冷技术的创意灵感来源于单辊甩带法。单辊甩带时，将材料在 单辊内表面甩制时效果更好。内凹带快速凝固技术利用内凹带代替单辊内表面， 在具有单辊内表面甩带优点的同时，可实现连续甩带。铝箔广泛应用于食品、 家电、建筑等领域，传统铝箔采用轧制方式生产，工艺复杂，流程长，设备投 资大，对技术要求比较高。 将内凹带急冷技术应用到铝箔材的生产上，不仅能够大大缩短箔材生产工 艺，降低设备投资，而且所生产箔材在一定程度上具有快速凝固组织的优点， 性能得到了提高。 通过对承载带和铝箔温度进行理论分析，建立了数学模型。研究分析表明， 承载带和铝箔温度随时间呈 e 指数形式变化，铝箔完全凝固时间随承载带比热、 密度、导热率、厚度以及接触界面换热系数的增大而减小。应用所建立数学模 型，当采用 0.4mm 铜带作为承载带时，建立了铝箔与承载带温度随时间的变化 曲线，此时，铝箔完全凝固前冷却速率为 4770℃ /s，达到急冷所需冷却速率。 这也从理论上验证了内凹带急冷制备铝箔的可行性。 由于铜带焊接性较差以及暂无市场来源的原因，暂时选用 304 不锈钢带作 为承载带。运用 AYNSYS 软件对承载带和铝箔温度场进行了模拟分析，以弥补 理论模型的不足。结果表明，采用 304 不锈钢作为承载带时，铝箔冷却 0.018s 即可完成完全凝固，完全凝固前冷却速率为 7000℃ /s，满足急冷要求；承载带 采用铝制带轮冷却，温度在 50℃ ~250℃范围内循环变化。根据以上结果，对 内凹带式急冷设备进行初步设计。所设计的实验装置包括，动力与传动系统， 本体部分以及喷射系统。采用 YVP90S-4 变频调速电机作为动力来源，用 V 带 传动，实现了带速的无级变速。采用气浮垫结构限制承载带内凹段的弯曲变形， 设置保护罩，使喷射在保护氛围下进行。采用 310S 型不锈钢作为坩埚材料， 具有良好的可加工性，可长时间使用。对装置的强度和刚度校核表明，所设计 装置满足要求。 关键字，快速凝固；铝箔材；急冷技术；可行性；装置设计哈尔滨工业大学工学硕士学位报告 -II- Abstract The quenching technology with inner concaved belt was inspired by single roller method. In single roller melt spinning, the product sprayed onto inner surface is better than outer. The rapid solidification with inner concave belt substitutes the single roller for concave belt, making continuous manufacture possible. The traditional foil production methods has a complex long process, high investment in equipment, and the technical requirements are relatively high. Applying the rapid solidification with inner concave belt to producing aluminum foil, not only can shorten production process and lower investment in equipment, but also can make foil, to some extent, with some advantages of rapid solidification phase. Through the theoretical analysis of carrier tape and aluminum foil in temperature, mathematical model is established. The mathematical model analysis show that the temperature of carrier strip and aluminum foil changes exponentially with time. Complete solidification time of aluminum foil decreases with the specific heat, density, thermal conductivity of carrier tap and the heat transfer coefficient. According to the mathematical model, when using 0.4mm copper tape as the carrier tape, the temperature curve of aluminum foil was obtained. Before complete solidification, the cooling rate of aluminum foil is 4770 ℃ /s, meeting the requirement of rapid solidification. This is also theoretically verified the feasibility. Because of the poor weldability and no resource, 304 stainless steel tap was used as carrier tap. ANSYS was used to do the temperature simulation, to compensate for the lack of theoretical models. The results show that the time needed before complete solidification is 0.018s, the cooling rate reaching to 7000℃/s. The carrier belt was cooled by the aluminum pulley, with temperature range of 50℃ ~250℃. Based on the above results, the preliminary design of device was complete. The experimental design includes: power and transmission system, body portion and injection system. Using YVP90S-4 variable speed motor as power source, with V-belt drive, a continuously variable belt speed was achieved. Flotation was used to restrict the carrier belt, and setting a protective cover makes the injection under the protective atmosphere. 310S stainless steel was used as the material of the crucible,哈尔滨工业大学工学硕士学位报告 -III- with good workability and prolonged use.The strong and rigidity checking of each part and the vibration analysis showed that the device can meet the requirements. Keywords: rapid solidification, splatcooling, aluminum foil, feasibility study, design of device哈尔滨工业大学工学硕士学位报告 -IV- 目 录 摘要.......................................................................................................................I Abstract ............................................................................................................... II 第 1 章 绪 论 ....................................................................................................1 1.1 引言 ................................................................................................................. 1 1.2 快速凝固技术简介......................................................................................... 1 1.2.1 深过冷快速凝固技术 ........................................................................ 2 1.2.2 急冷快速凝固技术 ............................................................................ 3 1.3 快速凝固技术组织特征................................................................................. 5 1.4 铝箔的生产..................................................................................................... 7 1.4.1 铝箔坯料生产 .................................................................................... 7 1.4.2 铝箔轧制 ............................................................................................ 7 1.5 急冷快速凝固技术方法................................................................................. 8 1.5.1 单辊法 ................................................................................................ 9 1.5.2 双辊法 ................................................................................................ 9 1.5.3 双带法 .............................................................................................. 10 1.6 内辊面甩制箔带........................................................................................... 12 1.7 课题的目的和意义....................................................................................... 14 1.8 主要研究内容 ............................................................................................... 15 第 2 章 内凹带式快速凝固技术传热模型........................................................16 2.1 概述 ............................................................................................................... 16 2.2 模型假设 ....................................................................................................... 16 2.3 建立模型 ....................................................................................................... 16 2.4 各参数对凝固过程的影响........................................................................... 19 2.4.1 导热率 .............................................................................................. 21 2.4.2 界面接触换热系数 .......................................................................... 21 2.4.3 承载带材料比热 .............................................................................. 22 2.4.4 承载带密度 ...................................................................................... 23 2.5 模型缺陷 ....................................................................................................... 23 2.6 模型应用 ....................................................................................................... 25 2.7 本章小节 ....................................................................................................... 26 第 3 章 装置理论计算与温度场模拟 ...............................................................28哈尔滨工业大学工学硕士学位报告 -V- 3.1 引言 ............................................................................................................... 28 3.2 承载带 ........................................................................................................... 28 3.2.1 承载带材料的选择 .......................................................................... 28 3.2.2 承载带受力分析 .............................................................................. 29 3.2.3 铝箔受力分析 .................................................................................. 31 3.2.4 承载带宽度与厚度的选择 .............................................................. 32 3.2.5 理论温度 .......................................................................................... 32 3.3 铝液冷却过程模拟....................................................................................... 33 3.3.1 模拟假设 .......................................................................................... 34 3.3.2 熔化潜热的处理 .............................................................................. 34 3.3.3 初始边界条件 .................................................................................. 35 3.3.4 模拟结果 .......................................................................................... 36 3.4 承载带冷却过程模拟................................................................................... 38 3.5 模拟结果总结与装置设计参数................................................................... 39 3.6 本章小结 ....................................................................................................... 40 第 4 章 内凹带式快速凝固装置结构设计........................................................41 4.1 引言 ............................................................................................................... 41 4.2 动力与传动................................................................................................... 41 4.2.1 动力设计 .......................................................................................... 41 4.2.2 传动的设计 ...................................................................................... 42 4.3 本体结构 ....................................................................................................... 44 4.3.1 承载带轮及其周边 .......................................................................... 44 4.3.2 压辊部分 .......................................................................................... 46 4.3.3 机架 .................................................................................................. 47 4.4 喷射系统 ....................................................................................................... 48 4.4.1 加热和测温 ...................................................................................... 48 4.4.2 坩埚及喷嘴 ...................................................................................... 49 4.4.3 坩埚位置调节 .................................................................................. 50 4.4.4 保护罩与气浮垫 .............................................................................. 51 4.5 本章小结 ....................................................................................................... 52 第 5 章 结构的校核与振动分析 .......................................................................53 5.1 引言 ............................................................................................................... 53 5.2 强度与刚度分析........................................................................................... 53哈尔滨工业大学工学硕士学位报告 -VI- 5.2.1 承载带 .............................................................................................. 53 5.2.2 气浮垫 .............................................................................................. 55 5.2.3 主从动轴 .......................................................................................... 56 5.3 振动分析 ....................................................................................................... 58 5.3.1 气浮垫与保护罩模态分析 .............................................................. 59 5.3.2 压辊支架模态分析 .......................................................................... 61 5.3.3 从动带轮及安装部分振动分析 ...................................................... 62 5.4 本章小结 ....................................................................................................... 63 结论....................................................................................................................64