CN102179681A - Pipe mold manufacturing process adopting continuous-casting blank to forge and roll rough blank periodically - Google Patents
Pipe mold manufacturing process adopting continuous-casting blank to forge and roll rough blank periodically Download PDFInfo
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Abstract
The invention relates to a pipe mold manufacturing process adopting a continuous-casting blank to forge and roll a rough blank periodically, belonging to the technical field of pipe mold manufacture. The manufacturing process comprises the process steps of: smelting of the continuous casting blank in a blast furnace, reinspecting, blanking, heating in a ring-shaped furnace, mannesmann piercing, periodically rolling a pipe, straightening, detecting flaws with magnetic powder, cutting the head and the tail, roughly processing, boring, carrying out ultrasonic flaw detection, thermally treating, sampling and reinspecting, finish processing, carrying out surface strengthening treatment, inspecting, spraying and printing, weighing and warehousing. The pipe mold manufacturing process has the advantages that the continuous casting blank replaces the mold casting blank adopted by the existing process, the characteristics that the yield is high, the cost is low, the energy consumption is less, the structure property is stable and the like are fully exerted, and the cost is reduced in the two aspects of the process and raw materials; in addition, the forging and rolling of a Pilger type rolling machine and the structure characteristics of a classic T-shaped pipe mold are effectively combined, the condition that the pipe mold blank forged and rolled by the process periodically has the performance close to the forged blank of the traditional pipe mold is guaranteed, and the Pilger head which needs to be cut in rolling is fully utilized simultaneously, so that the production efficiency is improved greatly.
Description
Technical field
The invention belongs to pipe die manufacturing technology field, a kind of pipe die manufacturing process that adopts continuous casting billet cycle forging rolling blank particularly is provided.
Background technology
At present, cold modulus method spun cast pipe technology is very ripe, and its rhythm of production is fast in addition, the efficient height, all basically in, small dimension ball die casting pipe all adopts this technology.And utilizing centrifugal casting method to produce in the ball die casting pipe, the parts of most critical are exactly the centrifugal ductile cast iron pipes pipe die.
Centrifugal ductile cast iron pipes pipe die (the raw material trade mark is 21CrMo10) is to be used to cast the mould of ductile iron pipe, is large-scale thermal technology's frock of producing ductile iron pipe on centrifugal tube casting machine.In the production, pipe die is under the bad working environments all the time, promptly under the high speed rotation status, outer surface is a cooling water, inner surface contacts with 1350～1400 ℃ high temperature liquid iron, bears alternating thermal stress, tensile stress, distorting stress composite condition for a long time, so extremely harsh to raw-material requirement.
At present, industry generally adopts carries out deep hole machining technology manufacturing pipe die to the die casting base, because it is low to forge the yield rate of base, raw material loss big (about 30%) and have problems such as follow-up process for machining spillage of material, machined cost height, cause pipe die thus cost high.This makes cast tube enterprise when cost accounting, requirement must reach more than 3000 times the access times of the above pipe die of DN450 and just scrap, and after access times reach about 1700 times, pipe die makes cast tube and pipe die surface need a large amount of reconditionings could satisfy instructions for use because the heat fatigue surface will produce a large amount of spot corrosion or crackle.Like this, under prior art and technological level, because the expensive cast tube enterprise practical operation cost that causes of pipe die significantly increases.Thereby the cost performance (life-span height, cost is low) that how to improve pipe die will have fundamental influence to economic benefit of enterprises.
Existing pipe die manufacturing process has been worked out the strict process flow process at the higher instructions for use of pipe die, may further comprise the steps: 1) smelt the die casting base; 2) forge; 3) rough turn; 4) flaw detection; 5) roughing; 6) modified; 7) check; 8) semifinishing; 9) oscillating aging; 10) fine finishining; 11) check; 12) warehouse-in.
Usually, according to different pipe die specifications, need take different processing technologys and method: 1) for the pipe die of specification less than DN150mm, blank adopts solid forging, and the process of deep hole drilling, bore hole is adopted in machined; 2) for the pipe die of specification in DN150～DN500mm scope, the blank solid forging adopts the process of jacking, bore hole, and has made the cover stub bar of all kinds of specifications according to actual conditions.The core material of extracting can be used as the blank of little a kind of specification pipe die, has realized the secondary utilization; 3) for the pipe die of specification greater than DN600mm, adopt hollow forging, on high efficiency deep hole building-block machine, process, realized the whole body processing that No. one time positions such as pipe die endoporus, cylindrical are finished in clamping, location, guarantee the requirement of pipe die axiality, and improved production efficiency.
Existing pipe die manufacturing process mainly has the following disadvantages:
(1) the die casting base is adopted in existing pipe die manufacturing more, not only technology cost height, complex process, and die casting base stock utilization is low, and the material deterioration inside rate is generally 30～40%, and this makes the pipe die manufacturing cost significantly improve.
(2) deep hole machining technology is adopted in existing pipe die manufacturing, though in big caliber pipe die manufacturing, adopted jacking technology to improve utilization rate of raw materials, but in general, still have very big machined losing quantity, the general because raw material coefficient of losses that existing deep hole machining technology causes is 5%～10%.
(3) there is not easy-formation of pipe die female end in existing pipe die manufacturing, needs technologies such as extra employing is earnestly thick, expander to finish the manufacturing of pipe die trumpet type female end, and this just makes that having the pipe die manufacturing process now exists complex process, problems such as manufacturing cycle long tube.
Summary of the invention
The object of the invention is to provide a kind of pipe die manufacturing process that adopts continuous casting billet cycle forging rolling blank, realized with short production cycle, the utilization rate of raw materials height, comprehensive operation cost is low.
The present invention adopts continuous casting billet to substitute the die casting base that traditional handicraft adopts, and characteristics such as giving full play to continuous casting billet and have that lumber recovery height, cost are low, less energy consumption, structure property are stable reduce cost from technology and raw material two aspects; In addition, effective design feature in conjunction with Pilger milling train forging rolling and typical T type pipe die, guaranteed that not only the pipe die blank of these forging and pressing of following cycle of technology after rolling has and the close performance of traditional die forging base, make full use of simultaneously the Pierre's wresting that should excise when rolling again, significantly improved rolling yield rate.This technology has shortened the production cycle of pipe die, has increased substantially raw-material utilization rate, and the existing technology of pipe die manufacturing cost has reduced about 30%.
Processing step of the present invention comprises blast furnace process continuous casting billet, reinspection, blanking, annular furnace heating, graceful formula perforation, pilger mill, aligning, magnetic powder inspection, crop end, roughing, bore hole, super flaw detection, heat treatment, sampling reinspection, fine finishining, surface Hardening Treatment, check, spray printing, weighs, puts in storage; It is characterized in that the following technical parameter of control in technology:
Pipe derives from continuous casting billet;
Adopt annular furnace that heating of pipe blank is arrived 830～870 ℃ of perforation extrusion temperatures;
Pipe with graceful be this graceful Mannesmann piercing mill perforation;
Pilger mill adopts the Pilger milling train to pipe cycle forging rolling, keeps Pierre's wresting that rolling end forms naturally;
Heat treatment is adopted to quench and is added tempering process:
The quenching system: heating of pipe blank to 600～650 ℃, be incubated 1～1.5 hour, be heated to 900～950 ℃ again, be incubated 4～5 hours, air cooling 3 minutes, water-cooled is 14～15 minutes again, last oil cooling 28～32 minutes;
The tempering system: heating of pipe blank to 300～350 ℃, be incubated 0.5～1 hour, continue to be heated to 550～600 ℃, be incubated 9～10 hours, again air cooling; The tempered sorbite tissue that is finally possessed high strength, high-ductility, high tenacity simultaneously
The pipe die inner surface is adopted the method for thermalization or electrification, the pipe die inner surface is carried out metallic cementation or plated metal, oozes intensity, hardness and wearability that the nonmetalloid mode improves the pipe die inner surface, to guarantee that pipe die can possess enough antioxygenic properties and cold-and-heat resistent fatigue behaviour under high-temperature work environment.
Innovative point of the present invention is as follows:
(1) adopt bigbore continuous casting billet to substitute existing die casting base on the pipe die blank, in view of characteristics such as continuous cast round billets have that lumber recovery height, cost are low, less energy consumption, structure property are stable, not only significantly improved utilization rate of raw materials (the continuous casting billet stock utilization is 95%～97%), and accomplished from the dual purpose that saves production cost of technology and raw material two aspects.
(2) utilizing graceful is that this graceful punch perforation is good to disposition, the hollow billet wall thickness is characteristics uniformly, adopt graceful formula piercing process to substitute existing deep hole machining technology to pipe, can shorten the production cycle when guaranteeing pipe endoporus quality, further reduce the raw material loss, saved cost.
(3) utilize the Pilger milling train that pipe is carried out the cycle forging rolling, keep Pierre's wresting that nature forms, saved pipe die female end horn mouth moulding process thus, that this has not only improved utilization rate of raw materials and simplified the Tube Mold Technology flow process simultaneously, improved production efficiency, shorten the production cycle, saved cost.
(4) the pipe die inner surface is carried out intensive treatment, the pipe die after the intensive treatment not only has outside high rigidity, the high-wearing feature, and because its infiltration layer densification (not having loose) has improved antioxygenic property and the cold-and-heat resistent fatigue behaviour of pipe die under high-temperature work environment.
Compare with existing pipe die manufacturing process, the present invention adopts large diameter continuous casting billet to substitute existing die casting base on the pipe die base, significantly improves raw-material utilization rate; The continuous casting billet endoporus adopts the mode of Man punch perforation to substitute existing process for machining, further improves stock utilization; On the rolling mill practice, utilize the Pilger milling train can form Pierre's wresting to the pipe die base cycle of carrying out naturally during forging rolling, promptly Tong Cheng bell-mouthed characteristics are carried out cycle forging and pressing roll forming to hollow billet mould base, guarantee that blank has the close compression ratio of forging stock, guarantees the raw-material performance of pipe die; At last, in view of pipe die condition of work abominable (especially with the inner surface of direct contact high temperature liquid iron for very), the pipe die inner surface is carried out intensive treatment to reach the purpose of raising pipe die service life, combination property.
Description of drawings
Fig. 1 be graceful among the present invention be this graceful perforation working motion schematic diagram.
Fig. 2 is that the A-A of Fig. 1 is to view.Wherein, guide plate 5.
Fig. 3 is the vertical view of Fig. 1.Wherein, barrel shaped roll 1, top 2, push rod 3, pipe 4.
Fig. 4 is a pilgrim rolling machine course of work schematic diagram among the present invention.Wherein, pipe 4, roll 6, plug 7.
Fig. 5 is 2-2-2-1 type tunable center distance seven a cross-roll straightening machine course of work schematic diagrames among the present invention.Pipe 4, smoothing roll 8.
Fig. 6 is the semi-finished product pipe die schematic diagram after aligning among the present invention.Wherein, Pierre's wresting 9, blank outer surface 10, inner surface 11.
Fig. 7 is the burning hot treatment process curve synoptic diagram of quenching add-back among the present invention.
Fig. 8 is a pipe die finished product schematic diagram of the present invention.Wherein, pipe die inner via hole 12, female end 13, socket end 14, pattern draft 15.
Fig. 9 is the vertical view of Fig. 8.Wherein, pipe die cylindrical raceway 16.
The specific embodiment
1, blast furnace process continuous casting billet is considered the working environment that the cast tube model is different, requires also corresponding higher in the pipe die actual production.So should strict control phosphorus on the pipe production technology, the content of sulphur, Given this, continuous casting billet adopts following technology to produce: converter or electric furnace steel making, LF refining, ladle are skimmed, the VD refining, feed a silk processing, continuous casting round steel billet, inspection, reconditioning;
2, recheck, pipe is bored a hole, rolling before, recheck surface quality, physical dimension, weight and the grade of steel (outsourcing pipe) of pipe;
3, blanking is because continuously cast billet for pipe-making is generally longer, so need blanking, the length that soon the long tube base is cut, saw, car, folding or oxyacetylene metal-cutting become the rolling mill practice requirement;
4, annular furnace heating before to the pipe perforation, be carried out heat treated to it, is heated to 850 ℃ of pipe extrusion temperatures;
5, graceful formula perforation, the pipe after the heating with graceful be that this graceful punch is bored a hole;
6, pilger mill utilizes the Pilger milling train to pipe cycle forging rolling, and keeps Pierre's wresting of rolling end;
7, aligning to the pipe aligning, guarantees that pipe total length flexibility is not more than 8mm on cross-roll straightening machine;
8, magnetic powder inspection is carried out magnetic to pipe and is detected, and guarantees that its surface and nearly surface conform to quality requirements;
9, crop end, with comb saw to pipe in rolling, produce, tail and physical dimension, shape and surface etc. exist the position of defective to excise or will remove through the pipeline section that flaw detection is defined as waste product;
10, roughing should be excised the pipe surplus fast when roughing;
11, bore hole carries out rough bore to the pipe endoporus, reaches the purposes such as deflection that enlarge the aperture, improve precision, reduce surface roughness, correct axially bored line;
12, after super flaw detection, pipe were carried out rough cut, bore hole and removed the outer oxide skin, GB/T6402 did ultrasonic flaw detection by GB, guarantees that pipe internal structure liver mass is qualified;
13, heat treatment is adopted the burning hot treatment process of quenching add-back to pipe.
Wherein, the quenching system adopts: 1) heating of pipe blank to 630 ℃, insulation: 1.3 hours; 2) be heated to 930 ℃ again, be incubated 4.5 hours; 3) air cooling is 3 minutes, and water-cooled is 5 minutes again, last oil cooling 30 minutes.
The tempering system adopts: 1) heating of pipe blank to 325 ℃ is incubated 0.8 hour; 2) continue to be heated to 575 ℃, be incubated 9.5 hours, again air cooling.The tempered sorbite tissue that is finally possessed high strength, high-ductility, high tenacity simultaneously;
14, sampling is rechecked, and for fully checking the pipe die performance, respectively stays 150～200mm surplus to do mechanics performance determining at pipe die base two ends, from reserving sampling assessment pipe comprehensive mechanical property.1) by GB GB/T 228-2002 sample is carried out tension test, measure its tensile strength Rm, guarantee Rm 〉=750MPa; Yield strength Re guarantees Re 〉=650MPa; Section percentage elongation A guarantees A 〉=16%; Contraction percentage of area Z guarantees Z 〉=60%.2) carry out hardness test by 231 pairs of samples of GB GB/T, guarantee that its hardness is between 235～265HB.3) sample is carried out impact test, guarantee sample impact absorbing energy Ak 〉=90J/cm
2
15, fine finishining, by pipe is finish grinded, micro cutting, make the surface roughness Ra of cast tube mould inner surface and cylindrical raceway and the surface roughness Ra≤1.6 μ m of female end and socket end sealing surface, the surface roughness Ra of remaining surface≤6.3 μ m;
16, surface Hardening Treatment, the pipe die inner surface is adopted the method for thermalization or electrification, the pipe die inner surface is carried out metallic cementation or plated metal, oozes intensity, hardness and wearability that modes such as nonmetalloid improve the pipe die inner surface, to guarantee that pipe die can possess enough antioxygenic properties and cold-and-heat resistent fatigue behaviour under high-temperature work environment, finally significantly improve pipe die service life;
17, it is poor desk checking, 1) to survey the pipe die wall thickness, and promptly the maximum average wall thickness on each cross section of pipe die and the difference of minimum average B configuration wall thickness are guaranteed its value≤0.3mm.2) survey pipe die through hole pattern draft, guarantee gradient direction unanimity, negative taper does not have.3) survey pipe die inner surface and cylindrical raceway axiality, guarantee its value≤0.2mm.4) size detection, promptly cast tube die topography size should meet the product design document that the user provides;
Step 18: spray printing, weigh;
Step 19: warehouse-in.
Shown in Fig. 1～3, solid pipe on inspection and remove blemish is cut into Len req, feels relieved on pipe threaded end end face, is sent to the heating furnace heating then, bores a hole on punch.Constantly rotate simultaneously and advance in perforation, under the effect of roll and top, pipe inside forms cavity gradually, claims hollow billet.The barrel shaped roll about 1 of graceful formula punch arranges that guide plate 5 is arranged up and down and maintained static.Punch barrel shaped roll 1 rotates to same direction, barrel shaped roll 1 axis tilts with respect to roll line, after pipe 4 enters barrel shaped roll 1, driven by the frictional force between metal and the barrel shaped roll 1 on the one hand, do the rotation of anti-roll direction of rotation, because barrel shaped roll 1 axis has an inclination angle (advancing angle) to pipe 4 axis (rolling axis), pipe moves again vertically, so pipe 4 moves in the shape of a spiral in the graceful formula perforation procedure simultaneously.Pipe 4 constantly rotates simultaneously and advances in perforation, and under the effect of barrel shaped roll 1 and top 2 and push rod 3, pipe inside forms cavity gradually.In view of the perforation characteristics of graceful formula punch, can make pipe perforation back obtain wall thickness uniformly.
As shown in Figure 4, the Pilger milling train course of work is formed by sending blank stage A (arrow shown on the figure is the blank feeding direction), the stage B of nipping, rolling sequence C (arrow shown on the figure is the capillary migration direction) three phases to.The basic characteristics of Pilger milling train are forging rollings, and roll 6 direction of rotation are opposite with the blank feeding direction, and for becoming section, the anti-feeding direction of blank moves roll pass when rolling along circumference.When rolling, at first by the roll tup hollow billet is carried out forging deformation, be rolled then and crimp, whole process deformed area metal is in the three-dimensional compressive stress state all the time, helps suppressing crackle.When rolling week of roll 6, pipe 4 is sent to once more, is reversed 90 ° simultaneously, and so forth.Wherein the feeding in this process is finished by plug 7 feed mechanisms that move reciprocatingly.
As shown in Figure 5,2-2-2-1 type tunable center is a smoothing roll 8 apart from seven cross-roll straightening machine main working parts.Cross-roll straightening machine is owing to adopt smoothing roll 8 to be in tilted layout, and pipe 4 forward travel of spinning can make pipe carry out repeatedly alternating bending 8 of smoothing rolls in the aligning process, and leveling effect is good.In addition, smoothing roll is adjustable about in the of 8, can effectively eliminate ovality and flexibility, and smoothing roll 8 distinctive roll formings can guarantee that pipe 4 fully contacts with smoothing roll 8, and straightening quality is improved.
As shown in Figure 6, the pipe die blank behind the aligning has kept the Pierre's wresting 9 that obtains under the pepriodic rolling technology, and this can provide convenience for the moulding of follow-up pipe die female end, and blank outer surface 10, inner surface 11 should stay the allowance about 20mm in addition.
As shown in Figure 7, the pipe Technology for Heating Processing mainly is divided into quenching and tempering two parts.
Wherein, the quenching system adopts: 1) heating of pipe blank to 630 ℃, insulation: 1.3 hours; 2) be heated to 930 ℃ again, be incubated 4.5 hours; 3) air cooling is 3 minutes, and water-cooled is 5 minutes again, last oil cooling 30 minutes.
The tempering system adopts: 1) heating of pipe blank to 325 ℃ is incubated 0.8 hour; 2) continue to be heated to 575 ℃, be incubated 9.5 hours, again air cooling.The tempered sorbite tissue that is finally possessed high strength, high-ductility, high tenacity simultaneously;
Shown in Fig. 8～9, pipe die finished product principal character is made up of pipe die inner via hole 12, female end 13, socket end 14, pattern draft 15, pipe die cylindrical raceway 16.
Claims (1)
1. pipe die manufacturing process that adopts continuous casting billet cycle forging rolling blank, processing step comprises blast furnace process continuous casting billet, reinspection, blanking, annular furnace heating, graceful formula perforation, pilger mill, aligning, magnetic powder inspection, crop end, roughing, bore hole, super flaw detection, heat treatment, sampling reinspection, fine finishining, surface Hardening Treatment, check, spray printing, weighs, puts in storage; It is characterized in that the following technical parameter of control in technology:
Pipe derives from continuous casting billet;
Adopt annular furnace that heating of pipe blank is arrived 830～870 ℃ of perforation extrusion temperatures;
Pipe with graceful be this graceful Mannesmann piercing mill perforation;
Pilger mill adopts the Pilger milling train to pipe cycle forging rolling, keeps Pierre's wresting that rolling end forms naturally;
Heat treatment is adopted to quench and is added tempering process:
The quenching system: heating of pipe blank to 600～650 ℃, be incubated 1～1.5 hour, be heated to 900～950 ℃ again, be incubated 4～5 hours, air cooling 3 minutes, water-cooled is 14～15 minutes again, last oil cooling 28～32 minutes;
The tempering system: heating of pipe blank to 300～350 ℃, be incubated 0.5～1 hour, continue to be heated to 550～600 ℃, be incubated 9～10 hours, again air cooling;
The pipe die inner surface is adopted the method for thermalization or electrification, the pipe die inner surface is carried out metallic cementation or plated metal, oozes intensity, hardness and wearability that the nonmetalloid mode improves the pipe die inner surface, to guarantee that pipe die can possess enough antioxygenic properties and cold-and-heat resistent fatigue behaviour under high-temperature work environment.
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