CN102489638B - Radial and axial roll-forming method for large internal-stage annular piece - Google Patents

Radial and axial roll-forming method for large internal-stage annular piece Download PDF

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Publication number
CN102489638B
CN102489638B CN 201110444732 CN201110444732A CN102489638B CN 102489638 B CN102489638 B CN 102489638B CN 201110444732 CN201110444732 CN 201110444732 CN 201110444732 A CN201110444732 A CN 201110444732A CN 102489638 B CN102489638 B CN 102489638B
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rolling
ring
roller
radial
axial
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CN 201110444732
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CN102489638A (en
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钱东升
吴君三
汪小凯
吴剑
毛华杰
华林
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张家港海陆环形锻件有限公司
武汉理工大学
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Abstract

The invention relates to a radial and axial roll-forming method for a large internal-stage annular piece. The method comprises the following steps of: (1) making a blank, namely performing hot-forging, upsetting, punching and slug-stamping on a bar material, and thus obtaining an annular piece blank for rolling; (2) designing a roll hole pattern, namely determining the size of the roll hole pattern according to a roll linear speed, an equipment parameter, a roll deformation condition and the size of the annular piece blank, and determining the size of the axial roll hole pattern according to the roll linear speed, the equipment parameter, the annular piece blank and the size of the annular piece blank; and (3) roll-forming, namely putting the obtained annular piece blank on an annular rolling machine for rolling, controlling an upper conical roller and a lower conical roller to move backwards in real time during rolling to make the bottom end of the annular rolling machine always contact outer diameters of the upper end face and the lower end face of the annular piece, controlling the rolling process by rationally distributing a feeding speed and a feeding amount according to three stages, namely pre-rolling, rolling and shaping rolling, and when the outer diameter of the detected annular piece reaches a preset value, finishing the rolling process. The method has the characteristics of high production efficiency, low production cost and high product quality.

Description

A kind of large-scale interior step ring radial-axial rolling manufacturing process

Technical field

The present invention relates to a kind of machining process of large-scale workpiece, be specifically related to a kind of large-scale interior step ring radial-axial rolling manufacturing process.

Background technology

Diameter surpasses 1 meter and inner surface with the large-scale interior step ring of darker step, such as engineering machinery rotating support ring, combustion turbine retaining ring, wind tower flange ring etc., has a wide range of applications in fields such as engineering machinery, boats and ships, wind-power electricity generation, petrochemical industry.This type of ring is to adopt to forge first base, again reaming, the then method processing of machining inner surface step at present mostly.By the machine cut processing step, machining period consumption is large, stock utilization is low, and machining cut off the metallic fiber streamline, has reduced the ring mechanical performance, causes production efficiency low, and cost is high, poor product quality.

Summary of the invention

Technical problem to be solved by this invention provides a kind of large-scale interior step ring radial-axial rolling manufacturing process, the method can effectively reduce material and the expenditure of time of step in the follow-up machining, and avoid machining to the destruction of metallic fiber streamline, improve production efficiency and product quality.

For solving the problems of the technologies described above, the technical solution used in the present invention is:

A kind of large-scale interior step ring radial-axial rolling manufacturing process by the continuous rotary plastic deformation, realizes that by means of axially rolled pass ring inner surface step Direct Rolling is shaped, and is characterized in that mainly comprising the steps:

(1) base: with bar forge hot, jumping-up, punching, punching the wad, make the rolling ring blank of using by setting size;

(2) rolling groove design: the rolling groove size determines according to roll line speed, device parameter, rolling deformation condition, ring blank size, and axially rolled pass size is determined by roll line speed, device parameter, ring blank and ring size;

(3) roll forming: the ring blank that makes is put machine for rolling ring be rolled, controlling in real time upper and lower cone roller in the operation of rolling retreats, its bottom is remained with the upper and lower end face outer radius of ring to be contacted, the operation of rolling is by rolling, main rolling, shaping rolling three phases reasonable distribution feed speed and the amount of feeding are controlled in advance, when survey ring external diameter reached predetermined value, the operation of rolling finished.

By technique scheme, above-mentioned steps is specially:

(1) base: determine the ring blank size; The bar section from the room temperature homogeneous heating to the forge hot deformation temperature, then with hot material section jumping-up, punching, punching the wad on hydraulic press, is made the rolling ring blank of using; The ring blank size is determined according to ring size, rolling ratio, radial and axial amount of feeding ratio;

(2) rolling groove design: comprise the design of radial rolling pass and axially rolled pass; Radial rolling pass design parameter comprises king roller and the core roller working face that is the face of cylinder, and the pass design size is determined according to roll line speed, device parameter, rolling deformation condition, ring blank size; Axially rolled pass design parameter comprises the working face of a pair of upper and lower cone-shaped roll, and the pass design size is determined by roll line speed, device parameter, ring blank and ring size;

(3) roll forming: the ring blank that makes is put radial-axial ring rolling mill be rolled; Ring blank is placed horizontally between king roller and the core roller stepped hole is formed; The epicone roller is processed the horizontal upper end face of ring blank; Lower cone roller is processed the horizontal lower surface of ring blank; Surveying the upper and lower cone roller roller of the real-time control of ring external diameter value according to measuring roller in the operation of rolling retreats, its bottom is remained with the upper and lower end face outer radius of ring to be contacted, the operation of rolling is by rolling, main rolling, shaping rolling three phases reasonable distribution feed speed and the amount of feeding are controlled in advance, when survey ring external diameter reached predetermined value, the operation of rolling finished.

By technique scheme, the ring blank size is determined as follows in the step (1):

1) calculates the ring volume

Ring volume V is calculated as follows

V = π [ B b ( R 2 - r b 2 ) + B s ( R 2 - r s 2 ) ]

Wherein, B b, B sBe respectively the large bore portion of ring and aperture section axial height; r b, r sBe respectively ring macropore and little pore radius; R is the ring external diameter;

2) determine rolling ratio

Rolling is ring blank sectional area A than λ 0Be shaped after the ratio of ring sectional area A, namely

λ = A 0 A = H 0 B 0 H b B b + H s B s

Wherein, H 0, B 0Be ring blank wall thickness and axial height, H b, H sFor being respectively ring macropore and aperture part wall thickness, B b, B sFor being respectively ring macropore and aperture section axial height; For the non-rectangular cross-section ring rolling, if rolling than too small, then the ring cross section profile is not easy to be full of; Rolling than excessive, the rolling deformation condition then is difficult for satisfying, and ring blank easily produces tissue damage, defects i.e.cracks because of excessive deformation; For large-scale interior step ring radial-axial rolling, it is 2~4 more suitable that λ value is taken as;

3) determine radial and axial amount of feeding ratio

Ring blank is in the radial-axial rolling process, and its radial thickness and axial height all reduce; In step ring radial-axial rolling in the present invention, the ring blank wall thickness namely radially has material impact with axial feeding ratio η to step shaping degree in the ring with the reduction ratio of height; For guaranteeing that step can better be shaped in the ring, η can determine by following formula:

η = Δh Δb = H 0 - H s B 0 - B s = B b + B s H s

Wherein, Δ h=H 0-H s, Δ b=B 0-B sBe respectively the radial and axial amount of feeding;

4) determine the ring blank size

According to plastic deformation constancy of volume principle, determine that ring blank is of a size of

H 0 = H s 2 - ( B b + B s ) B s 2 H s + ( B b + B s ) λ H s + ( H s 2 - ( B b B s + B s 2 ) 2 4 H s 2

B 0 = λ ( H b B b + H s B s ) H 0 , R 0 = V 2 π B 0 H 0 + H 0 2 , r 0 = V 2 π B 0 H 0 - H 0 2 .

By technique scheme, rolling groove designs as follows in the step (2):

1) radial rolling pass design

The radial rolling pass is comprised of the king roller that is the face of cylinder and core roller working face; King roller working face radius R mCan determine by following formula:

R m = V m γ 2 πn

In the formula, V mBe king roller roll line speed, be shaped V in order to guarantee the ring stable rolling mUsually get 1.1~1.3m/s; N and γ are respectively equipment master motor speed and gearratio;

In order to guarantee that ring blank is at radially pass generation continuous rolling distortion, king roller working face radius R mWith core roller working face radius R iShould satisfy following condition:

1 R m + 1 R i ≤ 17.5 β H 0

In the formula, β=arctan μ is angle of friction, and μ is coefficient of friction;

In addition, core roller working face radius R iShould guarantee that the core roller can penetrate smoothly the ring blank endoporus and be rolled, R is arranged usually i≤ r 0-10; Can determine that according to above-mentioned condition core roller working face radius span is:

H 0 R m 17.5 β R m - H 0 ≤ R i ≤ r 0 - 10

King roller working face axial height B mWith core roller working face axial height B iEqual ring blank axial height B 0

2) axially rolled pass design

Axially rolled pass is comprised of a pair of upper and lower cone-shaped roll; The epicone roll structure is double-deck stack taper, and the horizontal upper end face of ring blank is processed; Lower cone roller is the individual layer taper, and the horizontal lower surface of ring blank is processed;

Epicone roller working face is with the type groove step in the ring that is used for being shaped, and type groove size can be defined as according to the ring step dimension:

L 2=H b,L 3=B b

In order to guarantee stable rolling, epicone rolling linear velocity processed is epicone roller and ring cylindrical contact position linear velocity, should be identical with king roller roll line speed; In the operation of rolling, epicone roller tapered bottom end remains with ring upper surface outer radius and contacts, then have to guarantee the step forming dimension:

2πR uc??n 11=V m

In the formula, n 1And γ 1Be respectively epicone roller motor rotating speed and gearratio;

According to geometrical relationship, all the other are of a size of can to determine epicone roller working face:

R uc = V m γ 1 2 πn 1 , L 1 = V m γ 1 2 πn 1 sin ( θ / 2 ) + L 3 ctg ( θ / 2 ) - L 2

R uc1=L 1sin(θ/2),R uc2=R uc1-L 2sin(θ/2)

In the formula, θ gets 35 ° usually for cone roller cone angle;

Lower cone roller working face is the banding pattern groove not, and its maximum gauge is identical with epicone roller maximum gauge, and is consistent to guarantee upper and lower cone roller linear velocity, can determine that then its working face is of a size of:

R dc = R uc , L = R uc sin θ / 2 .

By technique scheme, in the process of roll forming, each stage feed speed and amount of feeding control parameter can be determined as follows in the step (3):

Radial feed speed: v R1=(0.5~0.8) v Rmin, v R2=(2~4) v Rmin, v R3=(0.3~0.5) v Rmin

Radial feeds: Δ H 1=0.05 Δ H, Δ H 2=0.85 Δ H, Δ H 3=0.1 Δ H

Axial feed velocity: v A1=(0.5~0.8) v Amin, v A2=(2~4) v Amin, v A3=(0.3~0.5) v Amin

Axial feeding: Δ B 1=0.05 Δ B, Δ B 2=0.85 Δ B, Δ B 3=0.1 Δ B

Wherein, For making ring produce the needed smallest radial feed speed of rolling deformation; v Amin=v Rmin/ η produces the needed minimum axial direction feed speed of rolling deformation for making ring;

Δ H=H 0-H s, Δ B=B 0-B sBe respectively the radial and axial total feed amount of ring rolling.

The present invention adopts the large-scale interior step ring of ring radial-axial rolling manufacturing process roll forming, by appropriate design ring blank, rolling groove and controlled rolling process, realization is by step ring in the ring blank Direct Rolling molding large, material and the expenditure of time of step in the follow-up machining have been reduced, improve the ring metal streamline and distributed, improved production efficiency and product quality.

Description of drawings:

Below in conjunction with accompanying drawing and each embodiment the present invention is described in further detail.

Fig. 1 is large-scale interior step ring radial-axial rolling shaping schematic diagram of the present invention;

Among Fig. 1, the 1-king roller, 2-core roller, the 3-guide bars, the 4-ring blank, 5-epicone roller is bored roller under the 6-, the 7-measuring roller

Fig. 2 is the ring inner wall section figure that the present invention has been shaped

Fig. 3 is ring blank sectional view of the present invention

Fig. 4 is radial rolling pass king roller face structure figure of the present invention

Fig. 5 is radial rolling pass core roller face structure figure of the present invention

Fig. 6 is axially rolled pass epicone roller face structure figure of the present invention

Fig. 7 is cone roller face structure figure under the axially rolled pass of the present invention

Fig. 8 is radial feed direction feeding amount of rolling of the present invention and feed speed control curve map

Fig. 9 is axial feed direction feeding amount of rolling of the present invention and feed speed control curve map.

The specific embodiment:

Real-time manufacturing process adopts be shaped as shown in Figure 2 large-scale interior step ring of radial-axial ring rolling mill as shown in Figure 1 according to the present invention.

Ring blank 4 is placed horizontally between the king roller 1 and core roller 2 of radial-axial ring rolling mill among Fig. 1, and both sides guide bars 3 leads to ring blank 4 from fore-and-aft direction; Epicone roller 5 is double-deck stack taper, and the horizontal upper end face of ring blank 4 is processed; Lower cone roller 6 is the individual layer taper, and the horizontal lower surface of ring blank 4 is processed; Measuring roller 7 is measured it in real time from the right side of ring blank 4.

The ring physical dimension that will be shaped shown in Figure 2 is: outer radius R is 2348mm, the macropore radius r bBe 2008mm, the aperture radius r sBe 1848mm, macropore axial height B bBe 50mm, small hole shaft is to height B sBe 90mm.Its radial-axial rolling manufacturing process is realized as follows:

1) base: from the room temperature homogeneous heating to the forge hot deformation temperature, then with hot material section jumping-up, punching, punching the wad on hydraulic press, make rolling with ring blank 4 the bar section.

According to ring blank 4 size design methods, getting rolling is 3 than λ, determines that ring blank 4 is of a size of: outer radius R 0Be 527.76mm, inside radius r 0Be 178.88mm, axial height B 0Be 266.57mm.(shown in Figure 3).

2) rolling groove design: according to the rolling groove method for designing, get roll line speed V dBe 1.3m/s, press the radial rolling of structural design shown in Figure 4 and 5 pass, king roller 1 working face radius R mBe 500mm, core roller 2 working face radius Rs iBe 150mm, king roller 1 working face axial height B mWith core roller 2 working face axial height B iBe 266.57mm.Then press the axially rolled pass of structural design shown in Fig. 6 and 7, epicone roller 5 working face dimensional parameters are: L 1Be 520.69mm, L 2Be 170mm, L 3Be 50mm, R Uc1Be 156.57mm, R Uc2Be 105.45mm, R UcBe 160mm; Lower cone roller 6 working face dimensional parameters are: R DcBe 160mm, L is 532.09mm.

3) roll forming: will put machine for rolling ring by the ring blank 4 that above-mentioned size makes and be rolled, and adjust upper and lower cone roller 5 and 6 horizontal levels, making separately, tapered bottom end contacts with the upper and lower end face outer radius of ring blank respectively.In the operation of rolling, according to the measuring roller 7 ring external diameter value of surveying in real time the upper and lower cone roller 5 and 6 of control retreat, tapered bottom end is remained with the upper and lower end face outer radius of ring contacts.The operation of rolling is controlled by pre-rolling, main rolling, the rolling three phases of shaping.

Radial and axial feed speed of each stage of the operation of rolling and the amount of feeding are controlled by curve shown in Fig. 8 and 9.Pre-rolling sequence, radial and axial feed speed v R1, v A1Be respectively 0.82mm/s, 1.46mm/s, radial and axial amount of feeding Δ H 1, Δ B 1Be respectively 4.94mm, 8.83mm; Main rolling sequence, radial and axial feed speed v R2, v A2Be respectively 3.28mm/s, 5.86mm/s, radial and axial amount of feeding Δ H 2, Δ B 2Be respectively 84.05mm, 150.08mm; The shaping rolling sequence, radial and axial feed speed v R3, v A3Be respectively 0.49mm/s, 0.88mm/s, radial and axial amount of feeding Δ H 3, Δ B 3Be respectively 9.88mm, 17.66mm.When the measuring roller 7 ring external diameter of surveying reaches predetermined value, stop radial and axial feeding, the operation of rolling finishes.

Above disclosed only is preferred embodiment of the present invention, certainly can not limit with this interest field of the present invention, and the equivalence of therefore doing according to the present patent application claim changes, and still belongs to protection scope of the present invention.

Claims (3)

1. one kind large-scale interior step ring radial-axial rolling manufacturing process by the continuous rotary plastic deformation, realizes that by means of axially rolled pass ring inner surface step Direct Rolling is shaped, and is characterized in that mainly comprising the steps:
(1) base: determine the ring blank size; The bar section from the room temperature homogeneous heating to the forge hot deformation temperature, then with hot material section jumping-up, punching, punching the wad on hydraulic press, is made the rolling ring blank of using; The ring blank size is determined according to ring size, rolling ratio, radial and axial amount of feeding ratio;
(2) rolling groove design: comprise the design of radial rolling pass and axially rolled pass; Radial rolling pass design parameter comprises king roller and the core roller working face that is the face of cylinder, and the pass design size is determined according to roll line speed, device parameter, rolling deformation condition, ring blank size; Axially rolled pass design parameter comprises the working face of a pair of upper and lower cone-shaped roll, and the pass design size is determined by roll line speed, device parameter, ring blank and ring size;
(3) roll forming: the ring blank that makes is put radial-axial ring rolling mill be rolled; Ring blank is placed horizontally between king roller and the core roller stepped hole is formed; The epicone roller is processed the horizontal upper end face of ring blank; Lower cone roller is processed the horizontal lower surface of ring blank; Surveying the upper and lower cone roller of the real-time control of ring external diameter value according to measuring roller in the operation of rolling retreats, its bottom is remained with the upper and lower end face outer radius of ring to be contacted, the operation of rolling is by rolling, main rolling, shaping rolling three phases reasonable distribution feed speed and the amount of feeding are controlled in advance, when survey ring external diameter reached predetermined value, the operation of rolling finished;
The ring blank size is determined as follows in the step (1):
1) calculates the ring volume
Ring volume V is calculated as follows
V = π [ B b ( R 2 - r b 2 ) + B s ( R 2 - r s 2 ) ]
Wherein, B b, B sBe respectively the large bore portion of ring and aperture section axial height; r b, r sBe respectively ring macropore and little pore radius; R is the ring external diameter;
2) determine rolling ratio
Rolling is ring blank sectional area A than λ 0Be shaped after the ratio of ring sectional area A, namely
λ = A 0 A = H 0 B 0 H b B b + H s B s
Wherein, H 0, B 0Be ring blank wall thickness and axial height, H b, H sFor being respectively ring macropore and aperture part wall thickness, B b, B sFor being respectively ring macropore and aperture section axial height; For the non-rectangular cross-section ring rolling, if rolling than too small, then the ring cross section profile is not easy to be full of; Rolling than excessive, the rolling deformation condition then is difficult for satisfying, and ring blank easily produces tissue damage, crack defect because of excessive deformation; For large-scale interior step ring radial-axial rolling, it is 2~4 more suitable that λ value is taken as;
3) determine radial and axial amount of feeding ratio
Ring blank is in the radial-axial rolling process, and its radial thickness and axial height all reduce; In interior step ring radial-axial rolling, the ring blank wall thickness namely radially has material impact with axial feeding ratio η to step shaping degree in the ring with the reduction ratio of height; For guaranteeing that step can better be shaped in the ring, η presses following formula and determines:
η = Δh Δb = H 0 - H s B 0 - B s = B b + B s H s
Wherein, Δ h=H 0-H s, Δ b=B 0-B sBe respectively the radial and axial amount of feeding;
4) determine the ring blank size
According to plastic deformation constancy of volume principle, determine that ring blank is of a size of
H 0 = H s 2 - ( B b + B s ) B s 2 H s + ( B b + B s ) λ H s + ( H s 2 - ( B b B s + B s 2 ) 2 4 H s 2 ; B 0 = λ ( H b B b + H s B s ) H 0 , The ring blank outer radius R 0 = V 2 π B 0 H 0 + H 0 2 , The ring blank inside radius r 0 = V 2 π B 0 H 0 - H 0 2 .
2. manufacturing process according to claim 1 is characterized in that rolling groove designs as follows in the step (2):
1) radial rolling pass design
The radial rolling pass is comprised of the king roller that is the face of cylinder and core roller working face; King roller working face radius R mDetermine by following formula:
R m = V m γ 2 πn
In the formula, V mBe king roller roll line speed, be shaped V in order to guarantee the ring stable rolling mGet 1.1~1.3m/s; N and γ are respectively equipment master motor speed and gearratio;
In order to guarantee that ring blank is at radially pass generation continuous rolling distortion, king roller working face radius R mWith core roller working face radius R iShould satisfy following condition:
1 R m + 1 R i ≤ 17.5 β H 0
In the formula, β=arctan μ is angle of friction, and μ is coefficient of friction;
In addition, core roller working face radius R iShould guarantee that the core roller can penetrate smoothly the ring blank endoporus and be rolled, R is arranged i≤ r 0-10; Determine that according to above-mentioned condition core roller working face radius span is:
H 0 R m 17.5 β R m - H 0 ≤ R i ≤ r 0 - 10
King roller working face axial height B mWith core roller working face axial height B iEqual ring blank axial height B 0
2) axially rolled pass design
Axially rolled pass is comprised of a pair of upper and lower cone-shaped roll; The epicone roll structure is double-deck stack taper, and the horizontal upper end face of ring blank is processed; Lower cone roller is the individual layer taper, and the horizontal lower surface of ring blank is processed;
Epicone roller working face is with the type groove step in the ring that is used for being shaped, and type groove size is defined as according to the ring step dimension:
L 2=H b,L 3=B b
In order to guarantee stable rolling, epicone rolling linear velocity processed is epicone roller and ring cylindrical contact position linear velocity, should be identical with king roller roll line speed; In the operation of rolling, epicone roller tapered bottom end remains with ring upper surface outer radius and contacts, then have to guarantee the step forming dimension:
2πR ucn 11=V m
In the formula, n 1And γ 1Be respectively epicone roller motor rotating speed and gearratio;
According to geometrical relationship, all the other are of a size of to determine epicone roller working face:
R uc = V m γ 1 2 πn 1 , L 1 = V m γ 1 2 πn 1 sin ( θ / 2 ) + L 3 ctg ( θ / 2 ) - L 2
R uc1=L 1sin(θ/2),R uc2=R uc1-L 2sin(θ/2)
In the formula, θ gets 35 ° for cone roller cone angle;
Lower cone roller working face is the banding pattern groove not, and its maximum gauge is identical with epicone roller maximum gauge, and is consistent to guarantee upper and lower cone roller linear velocity, determines that then its working face is of a size of:
R dc=R uc L = R uc sin θ / 2 .
3. manufacturing process according to claim 2 is characterized in that in the process of roll forming in the step (3), and each stage feed speed and amount of feeding control parameter are determined as follows:
Radial feed speed: v R1=(0.5~0.8) v Rmin, v R2=(2~4) v Rmin, v R3=(0.3~0.5) v Rmin
Radial feeds: Δ H 1=0.05 Δ H, Δ H 2=0.85 Δ H, Δ H 3=0.1 Δ H
Axial feed velocity: v A1=(0.5~0.8) v Amin, v A2=(2~4) v Amin, v A3=(0.3~0.5) v Amin
Axial feeding: Δ B 1=0.05 Δ B, Δ B 2=0.85 Δ B, Δ B 3=0.1 Δ B
Wherein, v r min = 0.003275 V m H 0 2 π R 0 ( 1 R m + 1 R i + 1 R 0 - 1 r 0 ) , For making ring produce the needed smallest radial feed speed of rolling deformation; v Amin=v Rmin/ η produces the needed minimum axial direction feed speed of rolling deformation for making ring;
Δ H=H 0-H s, Δ B=B 0-B sBe respectively the radial and axial total feed amount of ring rolling.
CN 201110444732 2011-12-27 2011-12-27 Radial and axial roll-forming method for large internal-stage annular piece CN102489638B (en)

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