CN102357531A - Composite roll forming process of thick-wall deep-groove ring member - Google Patents

Abstract

The invention relates to a composite roll forming process of a thick-wall deep-groove ring member. The process is characterized by comprising the following steps of: (1) blank design of the ring member: based on the principle of constant volume, determining the size of ring member blank according to the size of the ring member and the rolling ratio; (2) groove design: designing the sizes of the working surfaces of a main roller and a core roller according to the rolling deformation conditions of the ring member and the equipment structural requirements; and determining the size and position of the working surface of an auxiliary roller according to the sizes of the ring member blank, ring member and the main roller; (3) design of forming parameters: successively designing the rotation speed of the main roller as well as the feed speed and rolling time of the main roller according to the rolling deformation conditions of the ring member and the size of the main roller; and (4) roll forming. Through the invention, reasonable design of the composite roll forming process of the thick-wall deep-groove ring member can be realized, normal stable roll forming of the thick-wall deep-groove ring member is guaranteed, the rejection rate and defective rate of the rolling are reduced, and the energy-saving material-saving high-quality and efficient roll forming of the mechanical parts such as duplicate gears, bilateral flanges, bilateral supporting wheel bodies, high-pressure ball valves and the like is realized.

Description

A kind of heavy wall deep trouth ring composite rolling forming technology

Technical field

The present invention relates to a kind of heavy wall deep trouth ring composite rolling forming technology.

Background technology

Ring geometric properties shown in Figure 1 is that heavy wall (wall thickness is usually greater than interior pore radius), small-bore, surface have dark groove (groove depth accounts for wall thickness more than 1/4th usually), is called heavy wall deep trouth ring (the present invention abbreviates ring as).Machine components such as the duplicate gear that engineering is used always, bilateral flange, bilateral thrust wheel body, smash valve body all belong to this type of ring.This type of ring surface deep trouth is difficult to through the die forging direct forming, normally adopts die forging simply to be shaped earlier, arrives finished size through cut again.This processing technology energy consumption is high, stock utilization is low, and follow-up cut is lost time and cut off ring metallic fiber streamline not only, causes that production efficiency is low, properties of product are poor.

The ring composite rolling is a kind of plastic working new method of shaping heavy wall deep trouth ring through continuous revolution plastic deformation, and its principle is as shown in Figure 2.Among Fig. 2; King roller 1 is done initiatively to rotatablely move and straight-line feed motion downwards simultaneously; Core roller 2 and right secondary roll 4, left secondary roll 5 are dummy roll; Under ring drives, do passive rotatablely moving, whole deformation process can be divided into two stages: (a)～(b) be the ring rolling stage, king roller 1, core roller 2, right secondary roll 4 constitute common ring rolling deformation pattern with ring blank 3; The ring blank produces the continuous local plastic distortion and attenuate wall thickness, enlarged in the pass that king roller 1 and core roller 2 are formed, right secondary roll 4 has guaranteed the stability of ring deformation process.(b)～(c) it was three roller transverse rolling stages: when ring blank external diameter is extended to after left secondary roll 5 contacts; King roller 1 and right secondary roll 4, left secondary roll 5 constitute three roller transverse rolling deformation patterns with ring blank 3; 3 rolling its enlarged-diameter that limited of rotation of king roller 1 and right secondary roll 4,5 pairs of ring blanks of left secondary roll; Force ring blank surface metal to fill the roll die cavity, the ring blank produces the continuous local plastic distortion and forming pockets in the pass that king roller 1 and right secondary roll 4, left secondary roll 5 constitute, when ring blank metal is full of the roll die cavity; Groove is shaped fully, and whole deformation process finishes.The ring composite rolling combines through the distortion of common ring rolling deformation and three roller transverse rollings; Make ring obtain accurate outside dimension and surperficial deep trouth simultaneously; Break through the limitation that common ring milling method only is applicable to that the simple thin-wall macro-aperture ring of cross sectional shape is shaped, and had numerous technological and economical advantages such as energy consumption is low, stock utilization is high, production efficiency is high, good product quality.Yet it is the deformation process of a complicacy that the ring composite rolling is shaped, and technological parameter is many, and each parameter is different and influence each other to the rolling deformation influence, is easy to generate various rolling defects in rolling, forms useless, substandard products.Therefore, the reasonable technological design is most important to the roll forming of heavy wall deep trouth ring normal and stable.

Summary of the invention

The object of the present invention is to provide a kind of heavy wall deep trouth ring composite rolling forming technology, this technology can ensure that the operation of rolling is stable carries out normally being shaped with ring, can reduce effectively that the roll forming ring is useless, defect rate.

To achieve these goals, technical scheme of the present invention is: a kind of heavy wall deep trouth ring composite rolling forming technology is characterized in that it comprises the steps:

(1) base: the bar section evenly is heated to heat distortion temperature from room temperature, then with hot bar section jumping-up, punching, punching the wad, and stress relief annealing, process the rolling ring blank of using;

The ring blank shape is designed to the square-section, and ring blank dimension design process is following:

A) calculate ring volume V

$V=\frac{\mathrm{\π}}{4}[(D_1^2-d^2)h_1+(D_g^2-d^2)h_g+(D_2^2-d^2)h_2]$

D ₁, D _g, D ₂, d is respectively ring top bar diameter, groove diameter, get out of a predicament or an embarrassing situation diameter and internal diameter, h ₁, h _g, h ₂Be respectively ring top bar the height, groove height and get out of a predicament or an embarrassing situation the height;

B) confirm the rolling k of ratio

Rolling is the ring internal diameter and the ratio of ring blank internal diameter, i.e. k=d/d than k ₀, d wherein ₀Be ring blank internal diameter; Rolling ratio has reflected ring blank deformation extent, and rolling ratio is big more, and ring blank deflection is big more; Because heavy wall deep trouth ring wall thickness is big, internal diameter is little, if k is big more, then ring blank wall thickness is bigger, internal diameter is more little, and ring blank cross section is difficult in rolling is penetrated and produce homogeneous deformation by plasticity, and penetrates that the core roller diameter of ring blank is more little, intensity is low more; Therefore, can produce uniform plastic deformation in order to make the ring blank, guarantee core roller intensity simultaneously, prevent its rolling fracture, it is 1.2～1.5 more suitable that k gets;

C) confirm ring blank height h ₀

Adopt the enclosed groove rolling, get ring blank height h ₀H equates with the ring height, h=h ₁+ h _g+ h ₂

D) confirm ring blank inner diameter d ₀With ring blank D outer diameter ₀

Based on plastic deformation constancy of volume principle, according to rolling than k and ring blank height h ₀, can confirm ring blank inner diameter d ₀And D outer diameter ₀For

d ₀＝d/k，

$D_0=\sqrt{\frac{(D_1^2-d^2)h_1+(D_g^2-d^2)h_g+(D_2^2-d^2)h_2}{{\mathrm{<figure-callout\; id="1"\; label="h"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">h</figure-callout>}}_1+h_g+h_2}+\frac{d^2}{k^2}};$

(2) rolling groove design

Heavy wall deep trouth ring composite rolling pass comprises rolling ring rolling stage and three roller transverse rolling stages, the pass that the rolling ring rolling stage is made up of king roller and core roller, and three roller transverse rolling stages are by king roller and two passes that secondary roll constitutes; In order to prevent that the ring blank from producing sunken end face because of axial metal flow in the operation of rolling, two stage rolling passes all are designed to the enclosed pass; King roller is corresponding with the ring cross sectional shape with two secondary rolling face die cavities, and core roller working face is the face of cylinder; Dimension of roller designs as follows:

A) king roller and core roller working face size

King roller and core roller size design should meet the following conditions

1. penetrate and produce continuous rolling distortion, the then minimum working face radius R of king roller and core roller for the pass that the ring blank can be nipped constitute by king roller and core roller in rolling and by plasticity _M2And R _iShould satisfy following formula,

$\frac{1}{R_{m2}}+\frac{1}{R_i}\&le;\frac{17.5\mathrm{\&beta;}}{{\mathrm{<figure-callout\; id="0"\; label="H"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">H</figure-callout>}}_0}$

In the formula, R _M2Be king roller lower impressions radius surface (being the minimum working face radius of king roller), R _iBe core roller working face radius; β=arctan μ is an angle of friction, and μ is a coefficient of friction, and for steel loop spare, μ gets 0.3～0.35 usually, H ₀=(D ₀-d ₀)/2, H ₀Be ring blank wall thickness;

2. in order to guarantee core roller intensity and can penetrate the ring blank smoothly that core roller working face diameter generally is designed to

R _i＝d ₀/2-3～5mm；

3. according to the requirement of machine for rolling ring device structure, the closed centre-to-centre spacing of king roller and core roller should be in the closed centre-to-centre spacing scope of the machine for rolling ring limit; Minimum die cavity width (B when king roller and core roller are closed _M2And B _i) should not be decided to be usually above the thickest of ring

$R_{m2}+R_i+B_{m2}+B_i=\frac{L_{\max }+L_{\min }}{2},$ B _m2+B _i＝H ₂-1～2mm；

In the formula, L _MaxAnd L _MinMinimum and maximum closed centre-to-centre spacing for the machine for rolling ring permission; B _M2Be king roller lower impressions width, B _iBe core roll shape chamber width; H ₂=(D ₂-d)/2 be the ring thickest;

According to 1., 2., 3. condition is confirmed R _M2, R _i, R _M2, B _iAfter, can further confirm king roller upper impression radius surface R according to geometrical relationship _M1, the boss face radius R _MgWith the upper impression width B _M1As follows

R _m1＝R _m2+(D ₂-D ₁)/2，R _mg＝R _m2+(D ₂-D _g)/2，B _m1＝B _m2-(D ₂-D ₁)/2

In order to guarantee the ring sectional dimension precision that is shaped, according to the ring height h that tops bar ₁, groove height h _gWith the height h that gets out of a predicament or an embarrassing situation ₂Can confirm king roller upper impression height h _M1, boss height h _Mg, lower impressions height h _M2And core roll shape chamber height h _iFor

h _m1＝h ₁+0.3～0.5mm，h _mg＝h _g，h _m2＝h ₂+0.3～0.5mm，h _i＝h _m1+h _mg+h _m2；

In order to guarantee that pass is corresponding, king roller upper side wall height, lower wall height h _Mu, h _MdWith core roller upper side wall height, lower wall height h _Iu, h _IdIdentical respectively, its big I is confirmed according to the concrete installation dimension of equipment;

B) secondary rolling face size and position

Two secondary Roller Design are the same; Secondary rolling face radius is confirmed based on device space size usually, installs and does not interfere with the equipment miscellaneous part to guarantee that secondary roll is convenient, designs secondary roll boss face radius usually and does

R _pg≈1/3～1/5R _mg

R _PgAfter confirming, can confirm secondary roll lower impressions radius surface R according to geometrical relationship _P2=R _Pg-(D ₂-D _g)/2, secondary roll upper impression radius surface R _P1=R _Pg-(D ₁-D _g)/2;

For guaranteeing that pass is corresponding, can confirm

Secondary roll upper impression width B _P1=B _M1, secondary roll lower impressions width B _P2=B _M2, secondary roll upper side wall height h _Pu=h _Mu, secondary roll lower wall height h _Pd=h _Md, secondary roll upper impression height h _P1=h _M1, secondary roll boss height h _Pg=h _Mg, secondary roll lower impressions height h _P2=h _M2

After ring blank, king roller and secondary rolling face size are confirmed; Map through geometrical relationship; Can confirm left secondary roll, right secondary roll home position, king roller home position O in the time of at first can confirming rolling end according to the outer diametric plane of ring blank, ring groove surface (being the groove surface of finished product) and the mapping of king roller boss face geometrical relationship _M1With heavy wall deep trouth ring home position O _R1, O _mThe initial home position of expression king roller; The whole operation of rolling of boss face of right secondary roll 4 contacts with ring always, when rolling beginning with the ring blank outside diametric plane contact, when rolling end, contact, then with ring blank home position O with the ring groove surface _rBe the center of circle, ring blank outer radius and right secondary roll boss face radius sum R ₀+ R _PgFor radius is justified; With O _R1Be the center of circle, ring groove surface radius and secondary roll boss face radius sum R _g+ R _PgFor radius is justified, two circle intersection points are right secondary roll center of circle O _PrContact with the ring groove surface during rolling ends of secondary roll 5 boss face in a left side, confirm that left secondary roll home position needs first the confirm left secondary roll center of circle and ring circle center line connecting and vertical curve angle theta; To consider vertical rolling ring self gravitation, to support ring and shaping effect preferably in order playing, the θ angle can be designed to 45 °～60 °; After the θ angle was confirmed, mapping can be confirmed left secondary roll home position O according to geometrical relationship _Pl

(3) forming parameter design

Forming parameter comprises king roller rotating speed, king roller feed speed, rolling time, designs as follows:

A) king roller rotation speed n _m

In order to guarantee the ring stable rolling, king roller linear velocity V _mUsually get 1.1～1.3m/s; According to king roller working face radius D _Mg, can calculate the king roller rotating speed is n _m=V _m/ 2 π R _Mg

B) king roller feed speed v

In order to guarantee can the nip pass that is made up of king roller and core roller and penetrated and produce the continuous rolling distortion by plasticity of ring blank, the king roller feed speed press following formula design usually

$v=0.1~0.2\frac{{\mathrm{\&beta;}}^2{n}_m{R}_{\mathrm{mg}}^2}{30R_0{(1+\frac{R_{\mathrm{mg}}}{R_i})}^2}(1+\frac{R_{\mathrm{mg}}}{R_i}+\frac{R_{\mathrm{mg}}}{R_0}-\frac{R_{\mathrm{mg}}}{r_0})$

Wherein, r ₀=d ₀/ 2, R ₀=D ₀/ 2 are respectively ring blank inside radius, outer radius;

C) rolling time

The operation of rolling adopts at the uniform velocity feeding, and rolling time T can confirm as T=Δ h/v, and wherein Δ h is rolling total feed amount, can confirm as according to geometrical relationship

$\mathrm{\&Delta;h}=H_0-\frac{D_g-d}{2};$

(4) ring parts rolling forming: by above-mentioned ring blank design blanking base; Press the rolling pass Design and Machining king roller, core roller, left secondary roll and right secondary roll; And king roller, core roller, left secondary roll and right secondary roll be installed in the rolling equipment; The ring blank that processes is put into rolling equipment, be rolled into ring by the rolling parameter.

It is a kind of heavy wall deep trouth ring revolution plastic working new method that the ring composite rolling is shaped, and has advantages such as energy-conservation, material-saving, efficient, high-quality.Can realize the high-quality and efficient shaping manufacturings of machine components energy-saving material-saving such as duplicate gear, bilateral flange, bilateral thrust wheel wheel body, smash valve body.

The invention has the beneficial effects as follows: adopt heavy wall deep trouth ring composite rolling technology of the present invention; Can realize heavy wall deep trouth ring composite rolling technological parameter appropriate design; Ensureing that the operation of rolling is stable carries out normally being shaped with ring, effectively reduces that the roll forming ring is useless, defect rate.

Description of drawings

Fig. 1 is a heavy wall deep trouth ring schematic cross-section;

Fig. 2 is a heavy wall deep trouth ring composite rolling shaping schematic diagram;

The 1-king roller, 2-core roller, 3-ring blank, the right secondary roll (the first secondary roll) of 4-, a 5-left side secondary roll (the second secondary roll), 6-shaping ring;

Fig. 3 is that heavy wall deep trouth ring composite rolling is with ring blank schematic cross-section;

Fig. 4 (a) is the structural representation of king roller;

Fig. 4 (b) is the structural representation of core roller;

Fig. 4 (c) is the structural representation of secondary roll (right secondary roll, left secondary roll);

Fig. 5 is that sketch map is confirmed in right secondary roll 4, left secondary roll 5 positions.

The specific embodiment

A kind of heavy wall deep trouth ring composite rolling forming technology, it comprises the steps:

(1) base: the bar section evenly is heated to heat distortion temperature from room temperature, then with hot bar section jumping-up, punching, punching the wad, and stress relief annealing, process the rolling ring blank of using;

The ring blank shape is designed to the square-section, and ring blank dimension design process is following:

A) calculate ring volume V

$V=\frac{\mathrm{\&pi;}}{4}[({\mathrm{<figure-callout\; id="1"\; label="D"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">D</figure-callout>}}_1^2-d^2){\mathrm{<figure-callout\; id="1"\; label="h"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">h</figure-callout>}}_1+(D_g^2-d^2)h_g+(D_2^2-d^2)h_2]$

D ₁, D _g, D ₂, d is respectively ring top bar diameter, groove diameter, get out of a predicament or an embarrassing situation diameter and internal diameter, h ₁, h _g, h ₂Be respectively ring top bar the height, groove height and get out of a predicament or an embarrassing situation the height;

B) confirm the rolling k of ratio

Rolling is the ring internal diameter and the ratio of ring blank internal diameter, i.e. k=d/d than k ₀, d wherein ₀Be ring blank internal diameter; Rolling ratio has reflected ring blank deformation extent, and rolling ratio is big more, and ring blank deflection is big more; Because heavy wall deep trouth ring wall thickness is big, internal diameter is little, if k is big more, then ring blank wall thickness is bigger, internal diameter is more little, and ring blank cross section is difficult in rolling is penetrated and produce homogeneous deformation by plasticity, and penetrates that the core roller diameter of ring blank is more little, intensity is low more; Therefore, can produce uniform plastic deformation in order to make the ring blank, guarantee core roller intensity simultaneously, prevent its rolling fracture, it is 1.2～1.5 more suitable that k gets;

C) confirm ring blank height h ₀

Adopt the enclosed groove rolling, get ring blank height h ₀H equates with the ring height, h=h ₁+ h _g+ h ₂

D) confirm ring blank inner diameter d ₀With ring blank D outer diameter ₀

Based on plastic deformation constancy of volume principle, according to rolling than k and ring blank height h ₀, can confirm ring blank inner diameter d ₀And D outer diameter ₀For

d ₀＝d/k，

${\mathrm{<figure-callout\; id="0"\; label="D"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">D</figure-callout>}}_0=\sqrt{\frac{({\mathrm{<figure-callout\; id="1"\; label="D"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">D</figure-callout>}}_1^2-d^2){\mathrm{<figure-callout\; id="1"\; label="h"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">h</figure-callout>}}_1+(D_g^2-d^2)h_g+(D_2^2-d^2)h_2}{{\mathrm{<figure-callout\; id="1"\; label="h"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">h</figure-callout>}}_1+h_g+h_2}+\frac{d^2}{k^2}};$

(2) rolling groove design

Heavy wall deep trouth ring composite rolling pass comprises rolling ring rolling stage and three roller transverse rolling stages, the pass that the rolling ring rolling stage is made up of king roller and core roller, and three roller transverse rolling stages are by king roller and two passes that secondary roll constitutes; In order to prevent that the ring blank from producing sunken end face because of axial metal flow in the operation of rolling, two stage rolling passes all are designed to the enclosed pass; King roller is corresponding with the ring cross sectional shape with two secondary rolling face die cavities, and core roller working face is the face of cylinder; Dimension of roller designs as follows:

A) king roller and core roller working face size

King roller and core roller size design should meet the following conditions

1. penetrate and produce continuous rolling distortion, the then minimum working face radius R of king roller and core roller for the pass that the ring blank can be nipped constitute by king roller and core roller in rolling and by plasticity _M2And R _iShould satisfy following formula,

$\frac{1}{R_{m2}}+\frac{1}{R_i}\&le;\frac{17.5\mathrm{\&beta;}}{{\mathrm{<figure-callout\; id="0"\; label="H"\; filenames="HDA0000099595970000031.png"\; state="\{\{state\}\}">H</figure-callout>}}_0}$

In the formula, R _M2Be king roller lower impressions radius surface (being the minimum working face radius of king roller), R _iBe core roller working face radius; β=arctan μ is an angle of friction, and μ is a coefficient of friction, and for steel loop spare, μ gets 0.3～0.35 usually, H ₀=(D ₀-d ₀)/2, H ₀Be ring blank wall thickness;

2. in order to guarantee core roller intensity and can penetrate the ring blank smoothly that core roller working face diameter generally is designed to R _i=d ₀/ 2-3～5mm;

3. according to the requirement of machine for rolling ring device structure, the closed centre-to-centre spacing of king roller and core roller should be in the closed centre-to-centre spacing scope of the machine for rolling ring limit; Minimum die cavity width (B when king roller and core roller are closed _M2And B _i) should not be decided to be usually above the thickest of ring

$R_{m2}+R_i+B_{m2}+B_i=\frac{L_{\max }+L_{\min }}{2},$ B _m2+B _i＝H ₂-1～2mm；

In the formula, L _MaxAnd L _MinMinimum and maximum closed centre-to-centre spacing for the machine for rolling ring permission; B _M2Be king roller lower impressions width, B _iBe core roll shape chamber width; H ₂=(D ₂-d)/2 be the ring thickest;

According to 1., 2., 3. condition is confirmed R _M2, R _i, B _M2, B _iAfter, can further confirm king roller upper impression radius surface R according to geometrical relationship _M1, the boss face radius R _MgWith the upper impression width B _M1As follows

R _m1＝R _m2+(D ₂-D ₁)/2，R _mg＝R _m2+(D ₂-D _g)/2，B _m1＝B _m2-(D ₂-D ₁)/2

In order to guarantee the ring sectional dimension precision that is shaped, according to the ring height h that tops bar ₁, groove height h _gWith the height h that gets out of a predicament or an embarrassing situation ₂Can confirm king roller upper impression height h _M1, boss height h _Mg, lower impressions height h _M2And core roll shape chamber height h _iFor

h _m1＝h ₁+0.3～0.5mm，h _mg＝h _g，h _m2＝h ₂+0.3～0.5mm，h _i＝h _m1+h _mg+h _m2；

In order to guarantee that pass is corresponding, king roller upper side wall height, lower wall height h _Mu, h _MdWith core roller upper side wall height, lower wall height h _Iu, h _IdIdentical respectively, its big I is confirmed according to the concrete installation dimension of equipment;

B) secondary rolling face size and position

Two secondary Roller Design are the same; Secondary rolling face radius is confirmed based on device space size usually, installs and does not interfere with the equipment miscellaneous part to guarantee that secondary roll is convenient, designs secondary roll boss face radius usually and does

R _pg≈1/3～1/5R _mg

R _PgAfter confirming, can confirm secondary roll lower impressions radius surface R according to geometrical relationship _P2=R _Pg-(D ₂-D _g)/2, secondary roll upper impression radius surface R _P1=R _Pg-(D ₁-D _g)/2;

For guaranteeing that pass is corresponding, can confirm

Secondary roll upper impression width B _P1=B _M1, secondary roll lower impressions width B _P2=B _M2, secondary roll upper side wall height h _Pu=h _Mu, secondary roll lower wall height h _Pd=h _Md, secondary roll upper impression height h _P1=h _M1, secondary roll boss height h _Pg=h _Mg, secondary roll lower impressions height h _P2=h _M2

After ring blank, king roller and secondary rolling face size are confirmed; Map through geometrical relationship; Can confirm left secondary roll, right secondary roll home position, king roller home position O in the time of at first can confirming rolling end according to the outer diametric plane of ring blank, ring groove surface (being the groove surface of finished product) and the mapping of king roller boss face geometrical relationship _M1With heavy wall deep trouth ring home position O _R1, O _mThe initial home position of expression king roller; The whole operation of rolling of boss face of right secondary roll 4 contacts with ring always, when rolling beginning with the ring blank outside diametric plane contact, when rolling end, contact, then with ring blank home position O with the ring groove surface _rBe the center of circle, ring blank outer radius and right secondary roll boss face radius sum R ₀+ R _PgFor radius is justified; With O _R1Be the center of circle, ring groove surface radius and secondary roll boss face radius sum R _g+ R _PgFor radius is justified, two circle intersection points are right secondary roll center of circle O _PrContact with the ring groove surface during rolling ends of secondary roll 5 boss face in a left side, confirm that left secondary roll home position needs first the confirm left secondary roll center of circle and ring circle center line connecting and vertical curve angle theta; To consider vertical rolling ring self gravitation, to support ring and shaping effect preferably in order playing, the θ angle can be designed to 45 °～60 °; After the θ angle was confirmed, mapping can be confirmed left secondary roll home position O according to geometrical relationship _Pl

(3) forming parameter design

Forming parameter comprises king roller rotating speed, king roller feed speed, rolling time, designs as follows:

A) king roller rotation speed n _m

In order to guarantee the ring stable rolling, king roller linear velocity V _mUsually get 1.1～1.3m/s; According to king roller working face radius D _Mg, can calculate the king roller rotating speed is n _m=V _m/ 2 π R _Mg

B) king roller feed speed v

In order to guarantee can the nip pass that is made up of king roller and core roller and penetrated and produce the continuous rolling distortion by plasticity of ring blank, the king roller feed speed press following formula design usually

$v=0.1~0.2\frac{{\mathrm{\&beta;}}^2{n}_m{R}_{\mathrm{mg}}^2}{30R_0{(1+\frac{R_{\mathrm{mg}}}{R_i})}^2}(1+\frac{R_{\mathrm{mg}}}{R_i}+\frac{R_{\mathrm{mg}}}{R_0}-\frac{R_{\mathrm{mg}}}{r_0})$

Wherein, r ₀=d ₀/ 2, R ₀=D ₀/ 2 are respectively ring blank inside radius, outer radius;

C) rolling time

The operation of rolling adopts at the uniform velocity feeding, and rolling time T can confirm as T=Δ h/v, and wherein Δ h is rolling total feed amount, can confirm as according to geometrical relationship

$\mathrm{\&Delta;h}=H_0-\frac{D_g-d}{2};$

(4) ring parts rolling forming: by above-mentioned ring blank design blanking base; Press the rolling pass Design and Machining king roller, core roller, left secondary roll and right secondary roll; And king roller, core roller, left secondary roll and right secondary roll be installed in the rolling equipment; The ring blank that processes is put into rolling equipment, be rolled into ring by the rolling parameter.

Specific embodiment 1:

With duplicate gear shown in Figure 1 is specific embodiment, requires the ring of the roll forming diameter D that tops bar ₁, groove diameter D _g, diameter D gets out of a predicament or an embarrassing situation ₂Be respectively 248mm, 258mm, 218mm and 112mm with inner diameter d, ring top bar the height h ₁, groove height h _gWith the height h that gets out of a predicament or an embarrassing situation ₂Be respectively 11mm, 28mm, 11mm, its composite rolling design of Forming Technology method may further comprise the steps:

(1) base

The ring blank shape is a square-section shown in Figure 3 ring, and according to ring blank dimension method for designing, getting rolling is 1.3 than k, designs rolling with ring blank D outer diameter ₀, inner diameter d ₀With height h ₀Be respectively 222.86mm, 86.15mm and 50mm.By the ring blank dimension that designs; Bar section (concrete material is the GCr15 steel) evenly is heated to the heat distortion temperature (1100～1200 ℃) of high-ductility, low resistance from room temperature; Then with hot bar section jumping-up, punching, punching the wad, and stress relief annealing, the rolling ring blank of using processed;

(2) rolling groove design

A) king roller and core roller working face size

According to king roller and core roller dimension design principle and method for designing, design the king roller structure shown in Fig. 4 (a), king roller lower impressions radius surface R _M2, upper impression radius surface R _M1With the boss face radius R _MgBe respectively 152.5mm, 157.5mm and 172.5mm, the upper and lower die cavity width B of king roller _M1And B _M2Be respectively 21mm and 26mm, king roller upper impression height h _M1, boss height h _MgWith lower impressions height h _M2Be respectively 11.5mm, 28mm and 11.5mm; Design the core roll structure shown in Fig. 4 (b), core roller working face radius R _iBe 40mm, die cavity width B _iBe 26mm, die cavity height h _iBe 51mm.

B) secondary rolling face size and position

According to secondary rolling face size design method, design secondary roll structure shown in Fig. 4 (c), secondary roll boss face diameter R _Pg, upper impression radius surface R _P1, lower impressions radius surface R _P2Be respectively 55mm, 40mm, 35mm, upper and lower die cavity width B _P1And B _P2Be respectively 21mm and 26mm, upper impression height h _P1, boss height h _PgWith lower impressions height h _P2Be respectively 11.5mm, 28mm and 11.5mm.Based on the above-mentioned size of confirm, designing left secondary roll angle theta is 60 °, can confirm left and right secondary roll home position through geometrical relationship mapping shown in Figure 5.

(3) forming parameter design

A) king roller rotation speed n _m

Home roll linear velocity V _mGet 1.3m/s, confirm the king roller rotation speed n according to king roller rotating speed design formula _mBe 72r/min.

B) king roller feed speed v

Confirm that according to king roller rotating speed design formula the king roller feed speed is 1mm/s.

C) rolling time T

Rolling total feed amount Δ h is 15.35mm, confirms that according to the rolling time design formula rolling time T is 15.35s.

(4) ring parts rolling forming: by above-mentioned ring blank design blanking base; Press the rolling pass Design and Machining roll; And roll is installed in the rolling equipment, the ring blank that processes is put into rolling equipment, be rolled into duplicate gear shown in Figure 1 by the rolling parameter.

Produce 100 of duplicate gears as stated above, qualification rate is from 95% can be increased to 99% before.This operation of rolling can be stablized and carry out normally being shaped with ring.

Machine components roll forming technologies such as bilateral flange, bilateral thrust wheel wheel body or smash valve body are identical with above-mentioned instance, and its effect is also identical, does not enumerate embodiment one by one at this.

The bound value of each technological parameter of the present invention, with and interval value, can both realize the present invention, do not enumerate embodiment one by one at this.

Claims (1)

1. a heavy wall deep trouth ring composite rolling forming technology is characterized in that it comprises the steps:

(1) base: the bar section evenly is heated to heat distortion temperature from room temperature, then with hot bar section jumping-up, punching, punching the wad, and stress relief annealing, process the rolling ring blank of using;

The ring blank shape is designed to the square-section, and ring blank dimension design process is following:

A) calculate ring volume V

$V=\frac{\mathrm{\&pi;}}{4}[(D_1^2-d^2)h_1+(D_g^2-d^2)h_g+(D_2^2-d^2)h_2]$

D ₁, D _g, D ₂, d is respectively ring top bar diameter, groove diameter, get out of a predicament or an embarrassing situation diameter and internal diameter, h ₁, h _g, h ₂Be respectively ring top bar the height, groove height and get out of a predicament or an embarrassing situation the height;

B) confirm the rolling k of ratio

Rolling is the ring internal diameter and the ratio of ring blank internal diameter, i.e. k=d/d than k ₀, d wherein ₀Be ring blank internal diameter; K gets 1.2～1.5;

C) confirm ring blank height h ₀

Adopt the enclosed groove rolling, get ring blank height h ₀H equates with the ring height, h=h ₁+ h _g+ h ₂

D) confirm ring blank inner diameter d ₀With ring blank D outer diameter ₀

Based on plastic deformation constancy of volume principle, according to rolling than k and ring blank height h ₀, confirm ring blank inner diameter d ₀And D outer diameter ₀For

d ₀＝d/k，

$D_0=\sqrt{\frac{(D_1^2-d^2)h_1+(D_g^2-d^2)h_g+(D_2^2-d^2)h_2}{h_1+h_g+h_2}+\frac{d^2}{k^2}};$

(2) rolling groove design

Heavy wall deep trouth ring composite rolling pass comprises rolling ring rolling stage and three roller transverse rolling stages, the pass that the rolling ring rolling stage is made up of king roller and core roller, and three roller transverse rolling stages are by king roller and two passes that secondary roll constitutes; Rolling ring rolling stage and three roller transverse rolling stage rolling passes all are designed to the enclosed pass; King roller is corresponding with the ring cross sectional shape with two secondary rolling face die cavities, and core roller working face is the face of cylinder; King roller and core roller size design are following:

A) king roller and core roller working face size

King roller and core roller size design should meet the following conditions

1. the working face radius R of king roller and core roller _M2And R _iShould satisfy following formula,

$\frac{1}{R_{m2}}+\frac{1}{R_i}\&le;\frac{17.5\mathrm{\&beta;}}{H_0}$

In the formula, R _M2Be king roller lower impressions radius surface, R _iBe core roller working face radius; β=arctan μ is an angle of friction, and μ is a coefficient of friction, and for steel loop spare, μ gets 0.3～0.35 usually, H ₀=(D ₀-d ₀)/2, H ₀Be ring blank wall thickness;

2. core roller working face diameter is designed to

R _i＝d ₀/2-3～5mm；

3. according to the requirement of machine for rolling ring device structure, the closed centre-to-centre spacing of king roller and core roller should be in the closed centre-to-centre spacing scope of the machine for rolling ring limit; Minimum die cavity width when king roller and core roller are closed should not surpass the thickest of ring, is decided to be usually

$R_{m2}+R_i+B_{m2}+B_i=\frac{L_{\max }+L_{\min }}{2},$ B _m2+B _i＝H ₂-1～2mm；

In the formula, L _MaxAnd L _MinMinimum and maximum closed centre-to-centre spacing for the machine for rolling ring permission; B _M2Be king roller lower impressions width, B _iBe core roll shape chamber width; H ₂=(D ₂-d)/2 be the ring thickest;

According to 1., 2., 3. condition is confirmed R _M2, R _i, B _M2, B _iAfter, further confirm king roller upper impression radius surface R according to geometrical relationship _M1, the boss face radius R _MgWith the upper impression width B _M1As follows

R _m1＝R _m2+(D ₂-D ₁)/2，R _mg＝R _m2+(D ₂-D _g)/2，B _m1＝B _m2-(D ₂-D ₁)/2

According to ring top bar the height h ₁, groove height h _gWith the height h that gets out of a predicament or an embarrassing situation ₂Can confirm king roller upper impression height h _M1, boss height h _Mg, lower impressions height h _M2And core roll shape chamber height h _iFor

h _m1＝h ₁+0.3～0.5mm，h _mg＝hg，h _m2＝h ₂+0.3～0.5mm，h _i＝h _m1+h _mg+h _m2；

King roller upper side wall height, lower wall height h _Mu, h _MdWith core roller upper side wall height, lower wall height h _Iu, h _IdIdentical respectively;

B) secondary rolling face size and position

Two secondary Roller Design are the same; Secondary rolling face radius is confirmed according to device space size, installs and does not interfere with the equipment miscellaneous part to guarantee that secondary roll is convenient, designs secondary roll boss face radius and does

R _pg≈1/3～1/5R _mg

R _PgAfter confirming, can confirm secondary roll lower impressions radius surface R according to geometrical relationship _P2=R _Pg-(D ₂-D _g)/2, secondary roll upper impression radius surface R _P1=R _Pg-(D ₁-D _g)/2;

Secondary roll upper impression width B _P1=B _M1, secondary roll lower impressions width B _P2=B _M2, secondary roll upper side wall height h _Pu=h _Mu, secondary roll lower wall height h _Pd=h _Md, secondary roll upper impression height h _P1=h _M1, secondary roll boss height h _Pg=h _Mg, secondary roll lower impressions height h _P2=h _M2

After ring blank, king roller and secondary rolling face size are confirmed; Map through geometrical relationship; Can confirm left secondary roll, right secondary roll home position, king roller home position O when at first confirming rolling end according to the outer diametric plane of ring blank, ring groove surface and the mapping of king roller boss face geometrical relationship _M1With heavy wall deep trouth ring home position O _R1, O _mThe initial home position of expression king roller; The whole operation of rolling of boss face of right secondary roll contacts with ring always, when rolling beginning with the ring blank outside diametric plane contact, when rolling end, contact, then with ring blank home position O with the ring groove surface _rBe the center of circle, ring blank outer radius and right secondary roll boss face radius sum R ₀+ R _PgFor radius is justified; With O _R1Be the center of circle, ring groove surface radius and secondary roll boss face radius sum R _g+ R _PgFor radius is justified, two circle intersection points are right secondary roll center of circle O _PrContact with the ring groove surface during rolling ends of secondary roll 5 boss face in a left side, confirm that left secondary roll home position needs first the confirm left secondary roll center of circle and ring circle center line connecting and vertical curve angle theta; The θ angle is 45 °～60 °; After the θ angle is confirmed,, confirm left secondary roll home position O according to the geometrical relationship mapping _Pl

(3) forming parameter design

Forming parameter comprises king roller rotating speed, king roller feed speed, rolling time, designs as follows:

A) king roller rotation speed n _m

King roller linear velocity V _mGet 1.1～1.3m/s; According to king roller working face radius D _Mg, calculating the king roller rotating speed is n _m=V _m/ 2 π R _Mg

B) king roller feed speed v

The king roller feed speed is pressed the following formula design

$v=0.1~0.2\frac{{\mathrm{\&beta;}}^2{n}_m{R}_{\mathrm{mg}}^2}{30R_0{(1+\frac{R_{\mathrm{mg}}}{R_i})}^2}(1+\frac{R_{\mathrm{mg}}}{R_i}+\frac{R_{\mathrm{mg}}}{R_0}-\frac{R_{\mathrm{mg}}}{r_0})$

Wherein, r ₀=d ₀/ 2, R ₀=D ₀/ 2 are respectively ring blank inside radius, outer radius;

C) rolling time

The operation of rolling adopts at the uniform velocity feeding, and rolling time T can confirm as T=Δ h/v, and wherein Δ h is rolling total feed amount, can confirm as according to geometrical relationship

$\mathrm{\&Delta;h}=H_0-\frac{D_g-d}{2};$

(4) ring parts rolling forming: press the rolling pass Design and Machining king roller, core roller, left secondary roll and right secondary roll; And king roller, core roller, left secondary roll and right secondary roll be installed in the rolling equipment; The ring blank that processes is put into rolling equipment, be rolled into ring by the rolling parameter.

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