CN102357531B - 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-groovering 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 suchas 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 by the die forging direct forming, normally adopts die forging simply to be shaped earlier, arrives finished size through machining again.This processing technology energy consumption height, stock utilization are low, and follow-up machining is lost time and cut off ring metallic fiber streamline not only, cause 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 by continuous revolution plastic deformation, and its principle 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 driving, ring does 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 diameter in the pass that king roller 1 and core roller 2 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 the secondary roll 5 in a left side contacts, king roller 1 and right secondary roll 4, the secondary roll 5 in a left side constitutes three roller transverse rolling deformation patterns with ring blank 3, king roller 1 and right secondary roll 4,3 rolling its enlarged-diameter that limited of rotation of 5 pairs of ring blanks of the secondary roll in a left side, force ring blank surface metal to fill the roll die cavity, the ring blank is at king roller 1 and right secondary roll 4, produce the continuous local plastic distortion and forming pockets in the pass that the secondary roll 5 in a left side constitutes, when ring blank metal is full of the roll die cavity, groove is shaped fully, and whole deformation process finishes.The ring composite rolling is by the combination of common ring rolling deformation and the distortion of 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 complexity 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 parameter design is shaped most important to the normal stable rolling of heavy wall deep trouth ring.

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, make the rolling ring blank of using;

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

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) determine 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 more big, and ring blank deflection is more big; Because heavy wall deep trouth ring wall thickness is big, internal diameter is little, if k is more big, then ring blank wall thickness is more big, internal diameter is more little, rolling in ring blank cross section be difficult for being penetrated by plasticity and producing homogeneous deformation, and penetrate that the core roller diameter of ring blank is more little, intensity is more low; 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) determine 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) determine 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 determine 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 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; The dimension of roller design is 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 for the pass that the ring blank can be nipped constituted by king roller and core roller in rolling and by plasticity and produce continuous rolling distortion, the then minimum working face radius R of king roller and core roller _M2And R _iShould satisfy following formula,

$\frac{1}{R_{m2}}+\frac{1}{R_i}\≤\frac{17.5\mathrm{\β}}{H_0}$

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 angle of friction, and μ is coefficient of friction, and for steel loop spare, μ gets 0.3～0.35, H usually 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 determined R _M2, R _i, R _M2, B _iAfter, can further determine 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 determine 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 the pass correspondence, 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 determined 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 determined according to 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 is

R _pg≈1/3～1/5R _mg

R _PgAfter determining, can determine 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 the pass correspondence, can determine

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 determined, map by geometrical relationship, can determine left secondary roll, right secondary roll home position, king roller home position O in the time of at first can determining 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, contacts with diametric plane outside the ring blank when rolling beginning, contacts with the ring groove surface when rolling end, then with ring blank home position O _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, determine that left secondary roll home position needs first the determine 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 determined, mapping can be determined 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 of king roller and core roller and penetrated by plasticity and produce the continuous rolling distortion of ring blank, the king roller feed speed press following formula design usually

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

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 be defined as T=Δ h/v, and wherein Δ h is rolling total feed amount, can be defined as according to geometrical relationship

$\mathrm{\Δh}=H_0-\frac{D_g-d}{2};$

(4) ring parts rolling forming: by above-mentioned ring blank design blanking base, press the rolling pass design processing 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 heavy wall deep trouth ring schematic cross-section;

Fig. 2 is 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 heavy wall deep trouth ring composite rolling 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 schematic diagram is determined 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, make the rolling ring blank of using;

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

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) determine 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 more big, and ring blank deflection is more big; Because heavy wall deep trouth ring wall thickness is big, internal diameter is little, if k is more big, then ring blank wall thickness is more big, internal diameter is more little, rolling in ring blank cross section be difficult for being penetrated by plasticity and producing homogeneous deformation, and penetrate that the core roller diameter of ring blank is more little, intensity is more low; 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) determine 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) determine 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 determine 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 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; The dimension of roller design is 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 for the pass that the ring blank can be nipped constituted by king roller and core roller in rolling and by plasticity and produce continuous rolling distortion, the then minimum working face radius R of king roller and core roller _M2And R _iShould satisfy following formula,

$\frac{1}{R_{m2}}+\frac{1}{R_i}\≤\frac{17.5\mathrm{\β}}{H_0}$

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 angle of friction, and μ is coefficient of friction, and for steel loop spare, μ gets 0.3～0.35, H usually 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 determined R _M2, R _i, B _M2, B _iAfter, can further determine 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 determine 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 the pass correspondence, 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 determined 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 determined according to 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 is

R _pg≈1/3～1/5R _mg

R _PgAfter determining, can determine 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 the pass correspondence, can determine

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 determined, map by geometrical relationship, can determine left secondary roll, right secondary roll home position, king roller home position O in the time of at first can determining 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, contacts with diametric plane outside the ring blank when rolling beginning, contacts with the ring groove surface when rolling end, then with ring blank home position O _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, determine that left secondary roll home position needs first the determine 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 determined, mapping can be determined 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 of king roller and core roller and penetrated by plasticity and produce the continuous rolling distortion of ring blank, the king roller feed speed press following formula design usually

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

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 be defined as T=Δ h/v, and wherein Δ h is rolling total feed amount, can be defined as according to geometrical relationship

$\mathrm{\Δh}=H_0-\frac{D_g-d}{2};$

(4) ring parts rolling forming: by above-mentioned ring blank design blanking base, press the rolling pass design processing 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:

Be specific embodiment with duplicate gear shown in Figure 1, require 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 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 designed ring blank dimension, 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 made;

(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.According to the above-mentioned size of determine, designing left secondary roll angle theta is 60 °, can determine left and right secondary roll home position by 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, determine the king roller rotation speed n according to king roller rotating speed design formula _mBe 72r/min.

B) king roller feed speed v

Determine 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, determines 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 processing 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% being 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 example, 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, make the rolling ring blank of using;

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

A) calculate the ring volume

Be respectively ring top bar diameter, groove diameter, get out of a predicament or an embarrassing situation diameter and internal diameter, Be respectively ring top bar the height, groove height and get out of a predicament or an embarrassing situation the height;

B) determine rolling ratio

Rolling ratio Be the ratio of ring internal diameter with ring blank internal diameter, namely , wherein Be ring blank internal diameter; Get 1.2～1.5;

C) determine ring blank height

Adopt the enclosed groove rolling, get ring blank height With the ring height Equate,

D) determine ring blank internal diameter With ring blank external diameter

Based on plastic deformation constancy of volume principle, according to rolling ratio With ring blank height , determine ring blank internal diameter And external diameter For

，

；

(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 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 as follows:

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 of king roller and core roller With Should satisfy following formula,

In the formula, Be king roller lower impressions radius surface, Be core roller working face radius; Be angle of friction, Be coefficient of friction, for steel loop spare, Usually get 0.3～0.35, , H ₀Be ring blank wall thickness;

2. core roller working face radial design is

-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

，? -1～2mm；

In the formula, With Minimum and maximum closed centre-to-centre spacing for the machine for rolling ring permission; Be king roller lower impressions width, Be core roll shape chamber width; Be the ring thickest;

According to 1., 2., 3. condition is determined , , , After, further determine king roller upper impression radius surface according to geometrical relationship , the boss face radius With the upper impression width As follows

， ，

Top bar highly according to ring , groove height With the height of getting out of a predicament or an embarrassing situation Determine king roller upper impression height , the boss height , the lower impressions height And core roll shape chamber height For

+0.3～0.5mm， ， +0.3～0.5mm， ；

King roller upper side wall height, lower wall height With core roller upper side wall height, lower wall height Identical respectively;

B) secondary rolling face size and position

Two secondary Roller Design are the same; Secondary rolling face radius is determined 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 is

1/3～1/5

After determining, determine secondary roll lower impressions radius surface according to geometrical relationship , secondary roll upper impression radius surface

Secondary roll upper impression width , secondary roll lower impressions width , secondary roll upper side wall height , secondary roll lower wall height , secondary roll upper impression height , secondary roll boss height , secondary roll lower impressions height

After ring blank, king roller and secondary rolling face size are determined, map by geometrical relationship, determine left secondary roll, right secondary roll home position, king roller home position when at first determining rolling end according to the outer diametric plane of ring blank, ring groove surface and the mapping of king roller boss face geometrical relationship With heavy wall deep trouth ring home position , The initial home position of expression king roller; The whole operation of rolling of boss face of right secondary roll contacts with ring always, contacts with diametric plane outside the ring blank when rolling beginning, contacts with the ring groove surface when rolling end, then with ring blank home position Be the center of circle, ring blank outer radius and right secondary roll boss face radius sum For radius is justified; With Be the center of circle, ring groove surface radius and secondary roll boss face radius sum For radius is justified, two circle intersection points are the right secondary roll center of circle Contact with the ring groove surface during rolling ends of secondary roll 5 boss face in a left side, determine that left secondary roll home position needs first the determine left secondary roll center of circle and ring circle center line connecting and vertical curve angle The angle is 45 °～60 °; After the angle is determined, according to the geometrical relationship mapping, determine left secondary roll home position

(3) forming parameter design

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

A) king roller rotating speed

The king roller linear velocity Get 1.1～1.3m/s; According to king roller boss face radius , calculating king roller rotating speed is

B) king roller feed speed

The king roller feed speed is pressed the following formula design

0.1～0.2

Wherein, , Be respectively ring blank inside radius, outer radius;

C) rolling time

The operation of rolling adopts at the uniform velocity feeding, rolling time Be defined as , wherein For rolling total feed amount, be defined as according to geometrical relationship

；

(4) ring parts rolling forming: press the rolling pass design processing 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.