CN102865301A - Steel ball special for large-sized offshore wind turbine generator bearing and manufacturing process of steel ball - Google Patents

Steel ball special for large-sized offshore wind turbine generator bearing and manufacturing process of steel ball Download PDF

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CN102865301A
CN102865301A CN2012103420015A CN201210342001A CN102865301A CN 102865301 A CN102865301 A CN 102865301A CN 2012103420015 A CN2012103420015 A CN 2012103420015A CN 201210342001 A CN201210342001 A CN 201210342001A CN 102865301 A CN102865301 A CN 102865301A
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steel ball
hardness
offshore wind
manufacturing process
grain
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CN102865301B (en
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王嵘
周勇
苏银建
赵高明
马林
李薛俊
卢国杰
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Jiangsu Lixing General Steel Ball Co Ltd
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/70Wind energy
    • Y02E10/72Wind turbines with rotation axis in wind direction
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/20Recycling
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50Manufacturing or production processes characterised by the final manufactured product

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Abstract

The invention relates to a steel ball special for a large-sized offshore wind turbine generator bearing and a manufacturing process of the steel ball. The roundness of the steel ball is less than or equal to 0.8 mum, the hardness is 59-64 HRC, the single-grain hardness grain difference is less than or equal to 0.8 HRC, the batch hardness difference is less than or equal to 1.2 HRC, the core hardness is 54-60 HRC, the retained austenite is 8-13 percent, the metallographic structure is 2-3 grade, the surface roughness is less than or equal to 0.8 mum, and the crush load and the compression ratio of the steel ball are 1.2 times greater than international crush load and compression ratio. By selecting raw materials, adopting hot extrusion continuous forming during ball billet forming, adopting a water soluble quenching agent to perform multi-stage quenching during thermal treatment, increasing a secondary stable tempering technology, increasing various technologies such as eddy current nondestructive flaw detection in a process flow, the steel ball has the characteristics of good high contact fatigue strength, high wear resistance, high elastic limit, proper hardness, high impact toughness, good dimensional stability and the like.

Description

Large-scale offshore wind farm unit bearing special-purpose steel ball and manufacturing process thereof
Technical field
The present invention relates to a kind of large-scale offshore wind farm unit bearing special-purpose steel ball, also relate to the manufacturing process that realizes above-mentioned large-scale offshore wind farm unit bearing special-purpose steel ball.
Background technique
Because its environmental protection, wind-power electricity generation has been subject to the great attention of world's every country in recent years, and it is quite rapid that the wind-powered electricity generation industrial situation is sent out.3,000 ten thousand of the about demand wind power bearing of China's wind-power market special-purpose steel balls, the international market needs about 1,500,000,000.Therefore steel balls special for wind power generation has wide market prospects.Steel ball bearing on wind-driven generator generally has: driftage bearing, pitch variable bearings, dynamo bearing.Must go off course realization to wind such as horizontal axis wind-driven generator, the driftage bearing is the vitals in the yaw system, it is positioned at the bottom in cabin, carrying the all-mass of wind-driven generator main transmission, and transmitting the pneumatic pylon that arrives, the Windward angle of wind-driven generator is adjusted in time ground, when wind-driven generator begins deflection, yaw acceleration will produce very large moment, also will bear quite large gyro power on the yaw gear simultaneously and know, easily cause the fatigue failure of bearing.
According to the work characteristics of unit bearing, this bearing should have high reliability, go slick and be strictly on guard against marine salt fog and life-span above 20 years, and is the same for the set pitch control bearing, also can bear larger running torque when work, is prone in advance and loses efficacy.
Therefore the work of dynamo bearing continuous high speed require to implement between highi degree of accuracy, low vibration and low noise.Because wind power generating set is dust storm in the high altitude environment in the open air, rainwater, salt fog, work under the rugged environment such as humidity, want simultaneously it to operate steadily, safe and reliable, life-span long (General Requirements 20 years), failure-free operation is below 130,000 hours, reliability reaches 99.9%, it is high aerial to be installed in simultaneously tens of rice, extremely inconvenience of its lifting and replacing, so the requirement of the steel ball of using for wind power bearing, the good dimensional stability ⑺ of hardness (5) high impact toughness (6) that (1) high contact fatigue strength (2) high wear resistance (3) high elastic limit (4) is suitable is the anti-characteristics such as corrosion-resistant preferably.
The shortcoming of wind power steel ball technique was in the past:
1. the car special bearing steel ball on the domestic market is common GCr15 Bearing Steel selecting raw-material material, oxygen content is all at 10-15PPM, is on hot rolling molding process and tarry matter operation, the heat treatment process or the tradition of the eighties from the steel ball processing operation.Raw material adopt common GCr15 Bearing Steel, and its quality of materials is poor, oxygen content is high, and slag inclusion is many, and the life-span of steel is lower.
2. current international advanced little endless belt is bored drum type automatic moulding cold-heading new process, although solved the technical barrier of the damaged surface layer in large allowance grinding and the large inflow grinding; But the diameter dimension of using upper wind energy special-purpose steel ball from technology is large, and substantially all more than 36mm, because its stamping press in the cold-heading process is excessive, the ball base can't normally form, and obviously the cold-heading molding technology is immalleable; What use in market at present all is a kind of steel ball by the hot rolling technology, its weakness is that the moulds of industrial equipment technology is immature, steel ball surface defect is higher and dark, particularly more serious sparse phenomenon can appear in steel ball the two poles of the earth, can form the fatiguability inefficacy district in the steel ball using process, steel ball stays the mill amount high simultaneously, causes the increase of material and later process processing cost.
3. traditional processing way of still continuing to use of heat treatment step, the oil that aspect quenching medium, still uses or water, but use oil can cause wind power steel ball (diameter is greater than 36MM) hardenability not enough as medium, but purely make water, easily cause the steel ball surface crackle.
4. the Quadratic Stability tempering is not set, and it is higher easily to form the steel ball retained austenite, and poor dimensional stability can be produced steel ball size and change, thereby be caused the steel ball early fatigue in long-time using process.
Therefore also not having in the market can complete standard compliant wind energy plant special-purpose steel ball and technique thereof.
Summary of the invention
The technical problem to be solved in the present invention provides the large-scale offshore wind farm unit bearing special-purpose steel ball of a kind of long service life, high contact fatigue strength, high wear resistance, high tenacity, dimensional stability height and low cost of manufacture, and a kind of technique of making large-scale offshore wind farm unit bearing special-purpose steel ball also is provided.
For solving the problems of the technologies described above, technological scheme of the present invention is: a kind of large-scale offshore wind farm unit bearing special-purpose steel ball, its innovative point is: described steel ball circularity is 0.4~0.8um, and hardness is 59-64HRC, and simple grain hardness grain is poor to be 0.8HRC, criticizing difference of hardness is 1.2HRC, centre hardness greater than 54HRC, retained austenite 8-13%, metallographic structure 2-3 level, surface roughness is greater than 0.8um, and steel ball crushing load and compression ratio are greater than 1.2 times of GB.
A kind of manufacturing process that realizes above-mentioned large-scale offshore wind farm unit bearing special-purpose steel ball, its innovative point is that process step is followed successively by: raw material selection, moulding, spheroidizing annealing, tarry matter, heat treatment, hard grind, double tempering, once grind, polishing, eddy current testing, twice grinding, cleaning, check and oiling packing; Described raw material adopt the GCr15 Bearing Steel, and its oxygen content is no more than 10ppm, and Ti content is no more than 30ppm, and large particle shape slag inclusion DS class is less than 1.5 grades; Described formative stage is to seal intermediate frequency to quickly heat up to 760 ℃ ~ 800 ° C, adopt alloy open type cutting knife then the raw material that are transferred to the cutter place to be cut into impartial segment by cutter, then use material loading, compress the material section, carry out upsetting pressure by shaping die and be shaped; Described heat treatment stages is incubated steel ball in electric furnace under 830-860 ℃, make the steel ball heat penetration, again grain of steel ball is poured in the quenching bath and cooled off, after cooling stage is finished, hang out in the quenching bath and put on the air tempering furnace guipure, carry out under 200 ~ 230 ℃, being incubated 240-270 minute again after the low-temperature tempering; Described double tempering temperature 150 ~ 160 degree, the time was at 120-150 minute.
Further, described cooling stage is divided into three phases: the phase I: pour the steel ball of heat penetration into 35-45 ℃ water-soluble quenching agent, form the liquid phase evaporation, the thin steam blanket of one deck occurs; Second stage: pass into new quenching medium and constantly substitute steam blanket as cooling liquid, steel ball surface forms a large amount of steam bubbles; Phase III: steel ball surface directly contacts with cooling liquid, relies on conduction and convection to cool off.
Further, described water-soluble quenching agent is that concentration is the NACO3 solution of 4-8%.
The invention has the advantages that: adopt when utilizing raw-material selection, the moulding of ball base that hot extrusion is continuously shaped, adopt in the heat treatment water-soluble quenching agent to carry out the multistage to quench, increase multiple technologies such as increasing vortex nondestructive flaw in Quadratic Stability tempering technology and the technological process and combine, making hardness is 59-64HRC; Same grain difference of hardness≤0.8HRC; Criticize difference of hardness≤1.2HRC; Retained austenite 8-13%; Metallographic microstructure 2-3 level; The large-scale offshore wind farm unit bearing special-purpose steel ball of circularity≤0.8um is so that it has good high contact fatigue strength, high wear resistance, high elastic limit, suitable hardness, high impact toughness and good characteristics such as dimensional stability.
Embodiment
The manufacturing process of the medium-and-large-sized offshore wind farm unit of the present invention bearing special-purpose steel ball mainly may further comprise the steps: a. raw material selection; B. moulding; C. spheroidizing annealing; D. tarry matter; E. heat treatment; F. hard grind; G. double tempering; H. once grind; I. polishing; J. eddy current testing; K. twice grinding; L. clean; M. check; N. oiling is packed.
A. raw material selection: at first carry out the selected of raw material, offshore wind farm unit bearing special-purpose steel ball is the vitals of bearing, the quality of steel ball is most important on the impact in precision, dynamic performance and the working life of ball bearing, a large amount of bearings uses, test shows that steel ball affects 70% of the whole factors of bearing, the ratio of bearing failure invar ball fractured accounts for 58.8%, this just illustrates the critical role of steel ball in bearing, and significance, so steel ball quality is to weigh an important indicator of ball bearing quality.Its performance index: grade of accuracy must reach the G40 level, the of paramount importance wind-power electricity generation reliability and safety that relates to, so institute higher to the requirement of performance to the wind-power electricity generation special-purpose steel ball, the raw material that use among the present invention adopt the GCr15 Bearing Steel, its oxygen content is no more than 10ppm, and Ti content is no more than 30ppm.Simultaneously the slag inclusion DS of large particle shape carried out clear namely less than 1.5 grades (maximum diameter is less than 27um).
B. moulding: adopt hot extrusion continuously shaped, concrete to raw material: at first heating: to seal intermediate-frequency heating furnace with 760 ℃ ~ 800 ° C of bar rapid heating; Segment: adopt alloy open type cutting knife then the raw material that are transferred to the cutter place to be cut into impartial segment by cutter, material loading: to worktable, compress the material section by induction heater product slideway, slide block down when drift is pressed to die, compresses the section of expecting; Upsetting pressure is shaped: drift continues to press down, will the section of expecting upsetting balling-up base under slipper push; Release the ball base: when drift returns the origin-location with slide block, the ball base is pushed out ball-and-socket; Cooling: the method for the air-cooled again air cooling of employing elder generation cools off to eliminate or suppress the generation of Carbide network.
The material that above-mentioned alloy open type cutting knife adopts is the 7Cr7Mo2V2Si steel that employing and Shanghai University's material are developed, hardness number 50 ~ the 60HRC of steel, adopt spheroidizing annealing to process before the machining, hardness number is reduced to 220 ~ 250HBW, has carried out Quenching Treatment after the machining, and the hardness number of material reaches 63 ~ 64HRC after the Quenching Treatment, at last cutter has been carried out temper, tempering 2 ~ 3 times, temper number value 57 ~ 63HRC, what cutter adopted is integral module.In addition, in the continuously shaped process of hot extrusion, angle from the long-life, primary study belong to the research of fiber flow direction, by DEFORM three-dimensional finite element design software simulate in the hot upsetting process and to visit the raw material slenderness ratio to the impact of ball base moulding situation, temperature field distribution, Stress Field Distribution, major principal stress field pattern, five indexs of upset force, select the parameters of best compression ratio and mould, cutting knife, thereby realized the metal lattice distortion in the upsetting pressure forming process of minimizing raw material, worked out rule, even, symmetrical steel fiber flows to.
C. spheroidizing annealing: after hot extrusion is continuously shaped, carry out stress relief annealing, annealing temperature is 550 ℃ ± 30 ℃, 3~5 hours time, purpose: the material deformation stress during with the moulding of elimination high speed cold heading sphere blank and the comprehensive grinding stress of tarry matter processing, guarantee the raising of steel ball surface hardness behind the heat-treatment quenching, improve the uniformity of hardness.
D. enter the e. heat treatment stages after the tarry matter step.
E. heat treatment stages: carry out hardness control heat treatment, steel ball is incubated under 830-860 ℃ in electric furnace, make the steel ball heat penetration, again grain of steel ball is poured in the quenching bath and cooled off, wherein, cooling stage is divided into three phases: the phase I: pour the steel ball of heat penetration into 35-45 ℃ water-soluble quenching agent, form the liquid phase evaporation, the thin steam blanket of one deck occurs; Second stage: pass into new quenching medium and constantly substitute steam blanket as cooling liquid, steel ball surface forms a large amount of steam bubbles; Phase III: steel ball surface directly contacts with cooling liquid, relies on conduction and convection to cool off.After cooling stage is finished, hang out in the quenching bath and put on the air tempering furnace guipure, enter immediately the tempering stage one time, carry out under 200 ~ 230 ℃, being incubated 240-270 minute again after the low-temperature tempering.During with abundant removal steel ball quenching and thermal stress and the structural stress of cryogenic treatment, impel the steel ball structural transformation abundant, stablize ball size, guarantee the hardness of steel ball with a grain ball scattered error≤0.8HRC, with batch ball hardness poor≤1.2HRC.
In above-mentioned heat treatment stages, two important steps are arranged: heating and cooling.The cooling medium that adopts when product cools off and the type of cooling play an important role to the performance of heat treatment part.For the usability of improving Project Product and the important channel of better bringing into play the material potentiality, our team takes the medium of variable concentrations that the impact of product hardness, hardenability, amount of deformation and tissue is analyzed and researched: use the steel ball of 50.8mm to test, such as following table:
Figure 129635DEST_PATH_IMAGE001
Final determine that concentration is the NACO3 solution of 4-8%, cooler, heater and circulation means are set in quenching bath, adjust cold characteristic by changing concentration and temperature moment, namely slow, faster than oil at hot stage cooling raio water; Product cools off fast in second stage, obtains quenched martensite; When cooling enters the phase III, reduce with temperature, polymer solution quenchant can form gelatinous membrane, thereby makes the temperature cooling of workpiece slack-off, has not only kept the physical modification advantage of major diameter steel ball salt bath hardening technique more fundamentally to solve quick cooling and the poor technological difficulties of centre hardness.
E. carry out the f. hard grind after heat treatment stages is finished; We enter the g. double tempering after hard grind is finished: low temperature double tempering temperature 150 ~ 160 degree, and temper time is controlled at 120-150min, mainly is to eliminate surface stress, and thinning microstructure improves dimensional stability and retained austenite.
The advantage of double tempering is:
Can be with reference to the dimensional changes before and after the following test comparative experiment:
Figure 109092DEST_PATH_IMAGE002
Carrying out at last h. once grinds again; I. polishing; J. eddy current testing; K. twice grinding; L. clean; M. check; N. oiling is packed.This part process step particular content is conventional method, repeats no more here.
The final finished steel ball must be guaranteed to reach working life more than 20 years through 100% harmless eddy current testing, surface finish electro-detection, and reliability reaches 99.9%, and this product must have the characteristics such as high wear resistance, highi degree of accuracy, high reliability, long lifetime.
The steel ball that finally makes has following index: steel ball circularity≤0.8um, hardness is 59-64HRC, simple grain hardness grain is poor≤0.8HRC, criticize difference of hardness≤1.2HRC, centre hardness is 54-60HRC, retained austenite 8-13%, metallographic structure 2-3 level, surface roughness≤0.8um, steel ball crushing load and compression ratio are greater than 1.2 times of GB.

Claims (4)

1. one kind large-scale offshore wind farm unit bearing special-purpose steel ball, it is characterized in that: described steel ball circularity≤0.8um, hardness is 59-64HRC, simple grain hardness grain is poor≤0.8HRC, and crowd difference of hardness≤1.2HRC, centre hardness is 54-60HRC, retained austenite 8-13%, metallographic structure 2-3 level, surface roughness≤0.8um, steel ball crushing load and compression ratio are greater than 1.2 times of GB.
2. manufacturing process that realizes above-mentioned large-scale offshore wind farm unit bearing special-purpose steel ball is characterized in that process step is followed successively by: raw material selection, moulding, spheroidizing annealing, tarry matter, heat treatment, hard grind, double tempering, once grind, polishing, eddy current testing, twice grinding, cleaning, check and oiling packing; Described raw material adopt the GCr15 Bearing Steel, and its oxygen content is no more than 10ppm, and Ti content is no more than 30ppm, and large particle shape slag inclusion DS class is less than 1.5 grades; Described formative stage is to seal intermediate frequency to quickly heat up to 760 ℃ ~ 800 ° C, adopt alloy open type cutting knife then the raw material that are transferred to the cutter place to be cut into impartial segment by cutter, then use material loading, compress the material section, carry out upsetting pressure by shaping die and be shaped; Described heat treatment stages is incubated steel ball in electric furnace under 830-860 ℃, make the steel ball heat penetration, again grain of steel ball is poured in the quenching bath and cooled off, after cooling stage is finished, hang out in the quenching bath and put on the air tempering furnace guipure, carry out under 200 ~ 230 ℃, being incubated 240-270 minute again after the low-temperature tempering; Described double tempering temperature 150 ~ 160 degree, the time was at 120-150 minute.
3. the manufacturing process of the above-mentioned large-scale offshore wind farm unit bearing special-purpose steel ball of realization according to claim 2, it is characterized in that: described cooling stage is divided into three phases: the phase I: the steel ball of heat penetration is poured into 35-45 ℃ water-soluble quenching agent, the thin steam blanket of one deck appears in the evaporation of formation liquid phase; Second stage: pass into new quenching medium and constantly substitute steam blanket as cooling liquid, steel ball surface forms a large amount of steam bubbles; Phase III: steel ball surface directly contacts with cooling liquid, relies on conduction and convection to cool off.
4. the manufacturing process of the above-mentioned large-scale offshore wind farm unit bearing special-purpose steel ball of realization according to claim 3, it is characterized in that: described water-soluble quenching agent is that concentration is the NACO3 solution of 4-8%.
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CN107287393A (en) * 2017-07-16 2017-10-24 芜湖市宇恒特种钢球有限公司 Abrasion-proof steel ball and its processing method
CN110508742A (en) * 2019-07-29 2019-11-29 沛县祥龙矿山机械配件有限公司 A kind of steam power plant special-purpose steel ball manufacturing process
CN110814644A (en) * 2019-10-15 2020-02-21 常熟市宝丰精工钢球有限公司 High-strength austenitic steel ball
CN111519001A (en) * 2020-05-14 2020-08-11 山东理工大学 Manufacturing method of small-size strong-toughness eccentric motor shaft

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CN107287393A (en) * 2017-07-16 2017-10-24 芜湖市宇恒特种钢球有限公司 Abrasion-proof steel ball and its processing method
CN110508742A (en) * 2019-07-29 2019-11-29 沛县祥龙矿山机械配件有限公司 A kind of steam power plant special-purpose steel ball manufacturing process
CN110814644A (en) * 2019-10-15 2020-02-21 常熟市宝丰精工钢球有限公司 High-strength austenitic steel ball
CN111519001A (en) * 2020-05-14 2020-08-11 山东理工大学 Manufacturing method of small-size strong-toughness eccentric motor shaft

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