CN102615221B - Radial and axial rolling forming method for large-sized double-groove ring piece - Google Patents
Radial and axial rolling forming method for large-sized double-groove ring piece Download PDFInfo
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Abstract
本发明涉及一种大型双沟槽环件径轴向轧制成形方法。大型双沟槽环件径轴向轧制成形方法,主要包括以下实现步骤:(1)制坯:将棒料段从室温均匀加热到热锻变形温度,然后将热态料段在压力机上经镦粗、冲孔、冲连皮,制成轧制用环件毛坯,环件毛坯尺寸根据环件尺寸、轧制比、径向和轴向进给量比值确定;(2)轧制孔型设计:轧制孔型由驱动辊工作面和芯辊工作面组成,驱动辊和芯辊工作面尺寸根据轧制线速度、设备参数、轧制变形条件、环件毛坯尺寸和环件尺寸确定;(3)轧制成形:将制好的环件毛坯放上轧环机进行轧制,轧制过程按预轧制、主轧制、整形轧制三个阶段合理分配进给速度和进给量进行控制,当所测环件外径达到预定值时,轧制过程结束。本发明具有生产效率高、生产成本低、产品质量好的特点。
The invention relates to a radial and axial rolling forming method of a large double-groove ring. The radial and axial rolling forming method of large double-groove rings mainly includes the following realization steps: (1) Billet making: uniformly heating the bar section from room temperature to the hot forging deformation temperature, and then passing the hot section on a press Upsetting, punching, punching and continuous skin to make ring blanks for rolling. The size of the ring blanks is determined according to the ring size, rolling ratio, and the ratio of radial and axial feeds; (2) Rolling pass Design: The rolling pass is composed of the working surface of the driving roll and the working surface of the core roll. The dimensions of the working surface of the driving roll and the core roll are determined according to the rolling line speed, equipment parameters, rolling deformation conditions, ring blank size and ring size; (3) Roll forming: put the prepared ring blank on the ring rolling machine for rolling, and the rolling process is divided into three stages: pre-rolling, main rolling, and shaping rolling. The feed speed and feed amount are reasonably distributed Control is carried out, and when the outer diameter of the measured ring reaches a predetermined value, the rolling process ends. The invention has the characteristics of high production efficiency, low production cost and good product quality.
Description
技术领域 technical field
本发明涉及一种大型双沟槽环件径轴向轧制成形方法。 The invention relates to a radial and axial rolling forming method of a large double-groove ring. the
背景技术 Background technique
直径超过1米,内表面带有对称沟槽的大型双沟槽环件,作为回转支承环、大型轴承套圈等,在工程机械、港口机械、风力发电设备等应用广泛。此类环件工作条件恶劣,长期承受低温、重载、高冲击等,对其性能和使用寿命要求较高。环件径轴向轧制(图1所示)是生产大型环件的一种先进塑性加工工艺,它通过连续局部塑性变形可在较短时间内获得几何精度高、组织性能好的优质大型环件。然而,环件径轴向轧制过程是多工艺参数耦合作用下的复杂变形过程,轧制工艺参数设计和过程控制难度大,尤其对于异形截面环件轧制,容易因为工艺参数设计或过程控制不合理,导致环件直径达到尺寸要求时,截面轮廓不能充满,甚至导致轧制过程不稳定,形成轧制缺陷,废、次品率较高。因此,目前多数大型异形截面环件均是先通过径轴向轧制成矩形截面环件,再切削加工出截面轮廓,上述大型双沟槽环件即是如此。通过机械切削加工沟槽,切削材料损耗和加工工时消耗大,两个沟槽加工精度难以保持一致,而且切削加工破坏了环件金属流线分布,降低了环件机械性能,从而导致生产效率低,成本高,质量和寿命难以保证。 A large double-groove ring with a diameter of more than 1 meter and symmetrical grooves on the inner surface is widely used as a slewing support ring, a large bearing ring, etc. in construction machinery, port machinery, and wind power generation equipment. Such rings have harsh working conditions and are subjected to low temperature, heavy load, high impact, etc. for a long time, and have high requirements on their performance and service life. Diameter and axial rolling of rings (shown in Figure 1) is an advanced plastic processing technology for producing large rings. It can obtain high-quality large rings with high geometric accuracy and good structural properties in a short period of time through continuous local plastic deformation. pieces. However, the radial and axial rolling process of rings is a complex deformation process under the coupling of multiple process parameters, and the design and process control of rolling process parameters are difficult, especially for rings with special-shaped cross-sections. Unreasonable, when the diameter of the ring reaches the size requirement, the cross-sectional profile cannot be filled, and even the rolling process is unstable, forming rolling defects, and the rate of scrap and defective products is high. Therefore, at present, most large rings with special-shaped cross-sections are rolled into rectangular cross-section rings through radial and axial rolling, and then cut to form the cross-section profile, such as the above-mentioned large double-groove rings. Grooves are processed by mechanical cutting, which consumes a lot of cutting material and processing time. It is difficult to maintain the same machining accuracy of the two grooves. Moreover, the cutting process destroys the metal flow distribution of the ring and reduces the mechanical properties of the ring, resulting in low production efficiency. , the cost is high, and the quality and life are difficult to guarantee. the
发明内容 Contents of the invention
针对上述不足,本发明的目的在于提供一种大型双沟槽截面环件径轴向轧制成形方法,通过合理地设计轧制工艺参数和优化轧制过程,可实现由矩形截面环件毛坯直接轧制成形为双沟槽环件,显著减少了沟槽切削加工材料和工时消耗,且可获得较好的金属流线分布,提高了生产效率和产品质量,降低了生产成本。 In view of the above-mentioned deficiencies, the object of the present invention is to provide a radial and axial rolling forming method of a large-scale double-groove cross-section ring. By rationally designing the rolling process parameters and optimizing the rolling process, the direct Rolling is formed into a double-groove ring, which significantly reduces the consumption of groove cutting materials and man-hours, and can obtain better metal streamline distribution, improve production efficiency and product quality, and reduce production costs. the
为了实现上述目的,本发明的技术方案是:大型双沟槽截面环件(以下简称环件)径轴向轧制成形方法,包括以下实现步骤: In order to achieve the above purpose, the technical solution of the present invention is: a large-scale double-groove cross-section ring (hereinafter referred to as the ring) radial and axial rolling forming method, including the following realization steps:
(1)制坯:将棒料段从室温均匀加热到热锻变形温度,然后将热态料段在压力机上经镦粗、冲孔、冲连皮,制成轧制用环件毛坯。环件毛坯尺寸按如下步骤确定 (1) Billet making: uniformly heat the bar section from room temperature to the hot forging deformation temperature, and then the hot section is subjected to upsetting, punching, punching and skinning on a press to make a ring blank for rolling. The size of the ring blank is determined according to the following steps
1)计算环件体积和截面积 1) Calculate the ring volume and cross-sectional area
环件体积 按下式计算 ring volume Calculate according to the formula
其中,为环件宽度;、分别为环件内、外半径;为环件沟槽半径;为沟槽截面圆心角。 in, is the ring width; , are the inner and outer radii of the ring, respectively; is the ring groove radius; is the central angle of the groove section.
环件截面积按下式计算 Ring cross-sectional area Calculate according to the formula
,其中为环件壁厚。 ,in is the ring wall thickness.
2)确定轧制比 2) Determine the rolling ratio
轧制比为环件毛坯截面积与环件截面积之比,它反映了环件毛坯轧制变形程度,轧制比越大,环件毛坯变形量越大。轧制比太小,环件毛坯不能产生充分变形而获得细小且分布均匀的晶粒组织;轧制比太大,环件毛坯容易因过量变形产生内部损伤、裂纹等组织缺陷。对于大型双沟槽环件径轴向轧制,值一般取为2.5~4。 Rolling ratio is the cross-sectional area of the ring blank cross-sectional area of the ring The ratio, which reflects the degree of rolling deformation of the ring blank, the greater the rolling ratio, the greater the deformation of the ring blank. If the rolling ratio is too small, the ring blank cannot be fully deformed to obtain a fine and evenly distributed grain structure; if the rolling ratio is too large, the ring blank is prone to internal damage, cracks and other structural defects due to excessive deformation. For large double-groove ring diameter axial rolling, The value is generally taken as 2.5-4.
3)确定径向和轴向进给量比值 3) Determine the ratio of radial and axial feeds
环件毛坯在轧制过程中,其径向壁厚和轴向高度同时减小,径向和轴向变形量的合理分配对轧制过程稳定性和成形环件几何精度十分重要。对于大型双沟槽环件径轴向轧制,径向和轴向进给量比值可按下式确定: During the rolling process of the ring blank, its radial wall thickness and axial height decrease at the same time, and the reasonable distribution of radial and axial deformation is very important for the stability of the rolling process and the geometric accuracy of the formed ring. For radial and axial rolling of large double-groove rings, the ratio of radial and axial feeds It can be determined as follows:
其中,、分别为环件轧制径向和轴向总进给量,、为环件毛坯壁厚和高度。 in, , are the total radial and axial feeds of ring rolling, respectively, , is the wall thickness and height of the ring blank.
4)确定环件毛坯壁厚和高度 4) Determine the wall thickness and height of the ring blank
根据轧制比、径向和轴向进给量比值,可确定环件毛坯壁厚和高度为 According to the rolling ratio , Ratio of radial and axial feed , the wall thickness of the ring blank can be determined and height for
, ,
5)确定环件毛坯内、外半径 5) Determine the inner and outer radius of the ring blank
根据毛坯壁厚、高度和环件体积,结合塑性变形体积不变原理,可确定环件毛坯外半径、内半径为 According to blank wall thickness ,high and ring volume , combined with the principle of plastic deformation volume invariance, the outer radius of the ring blank can be determined , inner radius for
, ,
(2)轧制孔型设计:轧制孔型由驱动辊工作面和芯辊工作面组成。其中,驱动辊工作面为圆柱面,芯辊工作面由圆柱面与两个沟球面组合而成,驱动辊和芯辊结构如图4所示。驱动辊和芯辊工作面尺寸按如下确定: (2) Rolling pass design: The rolling pass is composed of the working surface of the driving roller and the working surface of the core roller. Among them, the working surface of the driving roller is a cylindrical surface, and the working surface of the core roller is composed of a cylindrical surface and two grooved spherical surfaces. The structure of the driving roller and the core roller is shown in Figure 4. The dimensions of the working surface of the driving roll and the core roll are determined as follows:
1)确定驱动辊工作面半径和宽度 1) Determine the radius and width of the working surface of the driving roller
为了保证环件稳定轧制成形,驱动辊线速度通常取1.1~1.3m/s,根据驱动辊线速度可确定驱动辊工作面半径,其中,为驱动辊转速,为电机转速,为传动比,、由设备参数确定。驱动辊工作面宽度 In order to ensure stable rolling forming of the ring, the linear speed of the driving roll Usually take 1.1 ~ 1.3m/s, according to the linear speed of the driving roller The radius of the working surface of the drive roller can be determined ,in, is the driving roller speed, is the motor speed, is the transmission ratio, , Determined by device parameters. Driving roller face width
2)确定芯辊沟球尺寸 2) Determine the size of the core roller groove ball
芯辊沟球用来成形环件沟槽,其尺寸与环件沟槽尺寸相对应,可确定如下 The core roller groove ball is used to form the groove of the ring, and its size corresponds to the size of the groove of the ring, which can be determined as follows
,,, , , ,
其中,、分别为环件沟槽深度与宽度,、、、分别为芯辊沟球深度、高度、半径和截面圆心角。 in, , are the ring groove depth and width, respectively, , , , Respectively, the depth, height, radius and center angle of the section center of the groove ball of the core roll.
3)确定芯辊沟球面半径和宽度 3) Determine the spherical radius and width of the core roller groove
为了保证环件毛坯在径向孔型产生连续轧制变形,驱动辊工作面半径和芯辊沟球面半径应满足如下条件。 In order to ensure that the ring blank produces continuous rolling deformation in the radial pass, the radius of the working surface of the driving roll and the radius of the spherical surface of the core roll groove should meet the following conditions.
式中,为芯辊沟球面半径;为摩擦角,为摩擦系数。为了使芯辊能顺利穿入环件毛坯内孔进行轧制,芯辊最大工作面半径通常应保证。根据上述条件可确定芯辊沟球面半径取值范围为 In the formula, is the spherical radius of the core roll groove; is the friction angle, is the coefficient of friction. In order to enable the core roll to smoothly penetrate the inner hole of the ring blank for rolling, the maximum working surface radius of the core roll should generally be guaranteed . According to the above conditions, it can be determined that the value range of the spherical radius of the core roller groove is
从而可确定芯辊圆柱面半径为。根据几何关系,可确定芯辊各段工作面轴向宽度为 Therefore, the radius of the cylindrical surface of the core roller can be determined as . According to the geometric relationship, the axial width of each section of the core roller can be determined as
,, , ,
(3)轧制成形:将制好的环件毛坯放上轧环机进行轧制,轧制过程按预轧制、主轧制、整形轧制三个阶段进行控制。预轧制阶段,控制芯辊和上锥辊分别沿径向和轴向慢速进给,逐渐消除锻造制坯产生的壁厚差和高度差;主轧制阶段,充分利用设备能力,控制芯辊和上锥辊分别沿径向和轴向以较快进给,使环件产生充分变形;整形轧制阶段,当环件外径距预定值100~200mm时,控制芯辊和上锥辊分别沿径向和轴向慢速进给,消除环件变形产生的壁厚差和椭圆度,保持环件缓慢长大,当所测环件外径达到预定值时,径向和轴向停止进给,轧制过程结束。轧制过程中,各阶段进给速度与进给量控制曲线如图5所示,图中各参数按如下确定: (3) Rolling and forming: put the prepared ring blank on the ring rolling machine for rolling, and the rolling process is controlled in three stages: pre-rolling, main rolling, and shaping rolling. In the pre-rolling stage, the core roll and the upper tapered roll are controlled to feed slowly along the radial and axial directions, gradually eliminating the wall thickness difference and height difference caused by forging billets; in the main rolling stage, the equipment capacity is fully utilized to control the core The roller and the upper tapered roller are fed at a relatively fast speed in the radial direction and axial direction respectively, so that the ring is fully deformed; in the shaping and rolling stage, when the outer diameter of the ring is 100-200mm from the predetermined value, the core roller and the upper tapered roller are controlled. Feed at a slow speed in the radial direction and axial direction respectively, eliminate the wall thickness difference and ellipticity caused by ring deformation, keep the ring growing slowly, and stop radially and axially when the outer diameter of the measured ring reaches a predetermined value Feed, the rolling process ends. During the rolling process, the control curves of feed speed and feed amount at each stage are shown in Figure 5, and the parameters in the figure are determined as follows:
径向进给速度:,, Radial feed rate: , ,
径向进给量:,,, Radial feed: , , ,
轴向进给速度:,, Axial feed rate: , ,
轴向进给量:,,, Axial feed: , , ,
其中, in,
为使环件产生轧制变形所需要的最小进给速度,。 The minimum feed rate required to cause rolling deformation of the ring, .
本发明采用环件径轴向轧制工艺加工大型双沟槽环件,通过合计设计环件毛坯和轧制孔型以及控制轧制过程,实现由矩形环件毛坯直接轧制成形为双沟槽环件,减少了材料和加工工时消耗,改善了环件金属流线分布,提高了生产效率和产品质量,降低了生产成本。 The present invention adopts ring diameter and axial rolling process to process large-scale double-groove rings, and realizes direct rolling and forming of rectangular ring blanks into double grooves by designing ring blanks and rolling passes and controlling the rolling process. The ring piece reduces the consumption of materials and processing hours, improves the metal flow distribution of the ring piece, improves the production efficiency and product quality, and reduces the production cost. the
附图说明 Description of drawings
图1是本发明实施例的环件径轴向轧制原理图; Fig. 1 is the principle diagram of axial rolling of the diameter of the ring part of the embodiment of the present invention;
1-驱动辊,2-芯辊,3-导向棍,4-环件毛坯,5-上锥辊,6-下锥辊,7-测量辊; 1-driving roller, 2-core roller, 3-guiding roller, 4-ring blank, 5-upper cone roller, 6-lower cone roller, 7-measurement roller;
图2是本发明实施例的环件截面图; Fig. 2 is a ring sectional view of an embodiment of the present invention;
图3是本发明实施例的环件毛坯截面图; Fig. 3 is a sectional view of a ring blank according to an embodiment of the present invention;
图4是本发明实施例的驱动辊工作面结构图; Fig. 4 is a structural diagram of the working surface of the driving roller in the embodiment of the present invention;
图5是本发明实施例的芯辊工作面结构图; Fig. 5 is a structural diagram of the working surface of the core roll of the embodiment of the present invention;
图6是本发明实施例的环件轧制径向进给量与径向进给速度控制曲线图; Fig. 6 is a control curve diagram of radial feed amount and radial feed speed in ring rolling according to an embodiment of the present invention;
图中①预轧制阶段、②主轧制阶段、③整形轧制阶段; In the figure, ① pre-rolling stage, ② main rolling stage, ③ shaping rolling stage;
图7是本发明实施例的环件轧制轴向进给量与轴向进给速度控制曲线图; Fig. 7 is a control curve diagram of axial feed amount and axial feed speed of ring rolling according to an embodiment of the present invention;
图中①预轧制阶段、②主轧制阶段、③整形轧制阶段。 In the figure, ① pre-rolling stage, ② main rolling stage, ③ shaping rolling stage.
具体实施方式 Detailed ways
以如图2所示大型双沟槽环件(简称环件)为具体实施对象,环件几何尺寸为:外半径为1050mm,内半径为944,宽度为178mm、为40.25mm、为18.5mm,沟槽圆心角为,沟槽圆弧半径为20mm、沟槽深度为17mm、沟槽宽度为39.5mm。其径轴向轧制成形方法按如下步骤实现: Taking the large double-groove ring (referred to as the ring) as shown in Figure 2 as the specific implementation object, the geometric dimensions of the ring are: outer radius 1050mm, inner radius 944, width 178mm, 40.25mm, 18.5mm, groove central angle for , groove arc radius 20mm, groove depth 17mm, groove width It is 39.5mm. The radial and axial rolling forming method is realized in the following steps:
1)制坯:将棒料段从室温均匀加热到热锻变形温度,然后将热态料段在压力机上经镦粗、冲孔、冲连皮,制成轧制用环件毛坯4。根据环件毛坯4尺寸设计方法,取轧制比为3.5,确定环件毛坯4尺寸为:外半径为409.51mm,内半径为162.87mm,宽度为251.63mm。(图3所示)。 1) Billet making: evenly heat the bar section from room temperature to the hot forging deformation temperature, then upsetting, punching, and punching the hot section on a press to make a ring blank 4 for rolling. According to the 4 size design method of the ring blank, take the rolling ratio is 3.5, determine the size of the ring blank 4 as: outer radius 409.51mm, inner radius 162.87mm, width It is 251.63mm. (shown in Figure 3).
2)轧制孔型设计:取轧制线速度为1.2m/s,根据轧制孔型设计方法,按图4所示结构设计轧制孔型,其中:驱动辊1工作面半径为350mm、宽度为178mm;芯辊2沟球深度为17mm、沟球宽度为39.5mm,沟球圆心角为、沟球半径为20mm, 芯辊2沟球面半径为150mm,圆柱面半径为133mm,芯辊2宽度为178mm、为113.88mm、为18.5mm、为40.25mm。 2) Rolling pass design: Take the rolling line speed is 1.2m/s, according to the rolling pass design method, the rolling pass is designed according to the structure shown in Figure 4, where: the radius of the driving roller 1 working surface 350mm, width 178mm; core roller 2 groove ball depth 17mm, groove ball width 39.5mm, center angle of groove ball for , ball radius 20mm, core roller 2 groove spherical radius 150mm, cylindrical surface radius 133mm, core roll 2 width 178mm, 113.88mm, 18.5mm, It is 40.25mm.
3)轧制成形:将按上述尺寸制好的环件毛坯4放上轧环机进行轧制,轧制过程按预轧制、主轧制、整形轧制三个阶段进行控制。轧制过程各阶段径向和轴向进给速度与进给量按图6所示曲线进行控制,其中:预轧制阶段,径向和轴向进给速度、分别为0.65mm/s、0.38mm/s,径向和轴向进给量、分别为6.18mm、3.68mm;主轧制阶段,径向和轴向进给速度、分别为3.78mm/s、2.24mm/s,径向和轴向进给量、分别为105.09mm、62.59mm;整形轧制阶段,径向和轴向进给速度、分别为0.54mm/s、0.32mm/s,径向和轴向进给量、分别为12.36mm、7.36mm。当测量辊7所测环件外径达到预定值时,径向和轴向停止进给,轧制过程结束。 3) Roll forming: put the ring blank 4 made according to the above dimensions on the ring rolling machine for rolling, and the rolling process is controlled in three stages: pre-rolling, main rolling, and shaping rolling. The radial and axial feed speed and feed rate at each stage of the rolling process are controlled according to the curve shown in Figure 6, where: the pre-rolling stage, the radial and axial feed speed , Respectively 0.65mm/s, 0.38mm/s, radial and axial feed , 6.18mm, 3.68mm respectively; main rolling stage, radial and axial feed speed , Respectively 3.78mm/s, 2.24mm/s, radial and axial feed , 105.09mm and 62.59mm, respectively; during the shaping and rolling stage, the radial and axial feed rates , Respectively 0.54mm/s, 0.32mm/s, radial and axial feed , They are 12.36mm and 7.36mm respectively. When the outer diameter of the ring measured by the measuring roller 7 reaches a predetermined value, the radial and axial feeds are stopped, and the rolling process ends.
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