CN102865301B - 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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CN102865301B
CN102865301B CN201210342001.5A CN201210342001A CN102865301B CN 102865301 B CN102865301 B CN 102865301B CN 201210342001 A CN201210342001 A CN 201210342001A CN 102865301 B CN102865301 B CN 102865301B
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steel ball
hardness
cooling
offshore wind
manufacturing process
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CN102865301A (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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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
Due to 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 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, international market need to approximately 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.As horizontal axis wind-driven generator, must go off course and realize wind, driftage bearing is the vitals in 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 starts deflection, yaw acceleration will produce very large moment, also will bear quite large gyro power simultaneously and know in yaw gear, easily causes 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 that marine salt fog and life-span were over 20 years, the same for set pitch control bearing, when work, also can bear larger running torque, is prone in advance and loses efficacy.
The work of dynamo bearing continuous high speed, therefore requires to implement between highi degree of accuracy, low vibration and low noise.Due to wind power generating set dust storm in high altitude environment in the wild, rainwater, salt fog, under the rugged environment such as humidity, work, want it to operate steadily simultaneously, safe and reliable, life-span long (General Requirements 20 years), failure-free operation is below 130,000 hours, reliability reaches 99.9%, be arranged on tens of rice high aerial simultaneously, extremely inconvenience of its lifting and replacing, so requirement of the steel ball of using for wind power bearing, (1) (7) the good dimensional stability of hardness (5) high impact toughness (6) that high contact fatigue strength (2) high wear resistance (3) high elastic limit (4) is suitable resists the features 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 domestic market is common GCr15 Bearing Steel selecting raw-material material, oxygen content is all at 10-15PPM, from steel ball processing operation, is hot rolling molding process and tarry matter operation, heat treatment process or the tradition of the eighties.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 large inflow grinding; But from technology application, the diameter dimension of wind energy special-purpose steel ball is large, and substantially all, more than 36mm, because its stamping press in cold-heading process is excessive, ball base cannot normally form, and obviously cold-heading molding technology is immalleable; What on market, use at present is all a kind of by the steel ball of hot rolling technology, its weakness is that moulds of industrial equipment technology is immature, steel ball surface defect is higher and dark, particularly steel ball the two poles of the earth there will be more serious sparse phenomenon, can form the fatiguability inefficacy district in steel ball using process, steel ball stays mill amount high simultaneously, causes the increase of material and later process processing cost.
3. traditional processing way that heat treatment step is still continued to use, the oil still using aspect quenching medium 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 steel ball surface crackle.
4. Quadratic Stability tempering is not set, easily forms steel ball retained austenite higher, poor dimensional stability can be produced steel ball size and change, thereby be caused 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 is to provide a kind of long service life, high contact fatigue strength, high wear resistance, high tenacity, dimensional stability is high and the large-scale offshore wind farm unit bearing special-purpose steel ball of low cost of manufacture, and a kind of technique of manufacturing large-scale offshore wind farm unit bearing special-purpose steel ball is also 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 is 0.8HRC, criticizing difference of hardness is 1.2HRC, centre hardness is 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 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 grinding, polishing, eddy current testing, twice grinding, cleaning, check and oiling packing; Described raw material adopt 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 to being transferred to the raw material at cutter place, by cutter, to cut into impartial segment, then use material loading, compress material section, by shaping die, carry out upsetting pressure shaping; Described heat treatment stages is incubated steel ball in electric furnace at 830-860 ℃, make steel ball heat penetration, again grain of steel ball is poured in quenching bath, carry out cooling, after cooling stage completes, in quenching bath, hang out and put air tempering furnace guipure, carry out at 200 ~ 230 ℃, being incubated 240-270 minute again after low-temperature tempering; Described double tempering temperature 150 ~ 160 degree, the time is at 120-150 minute.
Further, described cooling stage is divided into three phases: the first stage: the steel ball of heat penetration is poured into the water-soluble quenching agent of 35-45 ℃, formed liquid phase evaporation, occur the steam blanket that one deck is thin; 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, rely on conduction and convection to carry out cooling.
Further, described water-soluble quenching agent is that concentration is the NACO3 solution of 4-8%.
The invention has the advantages that: while utilizing raw-material selection, the moulding of ball base, adopt that hot extrusion is continuously shaped, adopt in heat treatment water-soluble quenching agent to carry out multistage quenching, increase and in Quadratic Stability tempering technology and technological process, increase the multiple technologies such as vortex nondestructive flaw 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, makes it have good high contact fatigue strength, high wear resistance, high elastic limit, suitable hardness, high impact toughness and the good features 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 comprises the following 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: 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 the precision of ball bearing, dynamic performance and working life, 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 G40 level, the of paramount importance wind-power electricity generation reliability and safety that relates to, therefore institute higher to the requirement of performance to wind-power electricity generation special-purpose steel ball, the raw material that use in the present invention adopt GCr15 Bearing Steel, its oxygen content is no more than 10ppm, and Ti content is no more than 30ppm.The slag inclusion DS of large particle shape has been carried out to clearly regulation simultaneously and be less than 1.5 grades (maximum diameter is less than 27um).
B. moulding: adopt hot extrusion continuously shaped, concrete to raw material: first heating: to seal intermediate-frequency heating furnace by 760 ℃ ~ 800 ° C of bar rapid heating; Segment: adopt alloy open type cutting knife then to cut into impartial segment by cutter, material loading to being transferred to the raw material at cutter place: to worktable, compress material section by induction heater product slideway, slide block down, when drift presses 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 ball base: when drift returns to origin-location with slide block, ball base is pushed out ball-and-socket; Cooling: to adopt the first method of air-cooled air cooling again to carry out the cooling generation of eliminating or suppressing 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, before machining, adopt spheroidizing annealing to process, hardness number is reduced to 220 ~ 250HBW, has carried out Quenching Treatment after machining, and after Quenching Treatment, the hardness number of material reaches 63 ~ 64HRC, finally cutter has been carried out to 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 and in hot upsetting process, visit the impact of raw material slenderness ratio on 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 minimizing raw material to metal lattice distortion in upsetting pressure forming process, worked out rule, even, symmetrical steel fiber flows to.
C. spheroidizing annealing: carry out stress relief annealing after hot extrusion is continuously shaped, annealing temperature is 550 ℃ ± 30 ℃, 3~5 hours time, object: the comprehensive grinding stress of the material deformation stress when eliminating the moulding of high speed cold heading sphere blank and tarry matter processing, guarantee the raising of steel ball surface hardness after heat-treatment quenching, improve the uniformity of hardness.
D. after tarry matter step, enter e. heat treatment stages.
E. heat treatment stages: carry out hardness and control heat treatment, steel ball is incubated in electric furnace at 830-860 ℃, make steel ball heat penetration, again grain of steel ball is poured in quenching bath, carry out cooling, wherein, cooling stage is divided into three phases: the first stage: the steel ball of heat penetration is poured into the water-soluble quenching agent of 35-45 ℃, formed liquid phase evaporation, occur the steam blanket that one deck is thin; 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, rely on conduction and convection to carry out cooling.After cooling stage completes, in quenching bath, hang out and put air tempering furnace guipure, enter immediately the tempering stage one time, carry out at 200 ~ 230 ℃, being incubated 240-270 minute again after low-temperature tempering.When fully removing steel ball quenching and thermal stress and the structural stress of cryogenic treatment, impel steel ball structural transformation abundant, stablize ball size, guarantee that the hardness of steel ball is with a grain ball scattered error≤0.8HRC, with batch ball hardness poor≤1.2HRC.
In above-mentioned heat treatment stages, there are two important steps: heating is with cooling.The cooling medium adopting when product is cooling and the type of cooling play an important role to the performance of heat treatment part.For the important channel of improving the usability of Project Product and better bringing into play material potentiality, our team takes the medium of variable concentrations to analyze and research on the impact of product hardness, hardenability, amount of deformation and tissue: use the steel ball of 50.8mm to test, as following table:
The final NACO3 solution of determining that concentration is 4-8% arranges cooler, heater and circulation means in quenching bath, by changing concentration and temperature moment, adjusts cold characteristic, slow, faster than oil at hot stage cooling raio water; Product is cooling fast in second stage, obtains quenched martensite; When cooling while entering the phase III, with temperature, reduce, polymer solution quenchant can form gelatinous membrane, thereby makes the temperature of workpiece cooling slack-off, has not only kept the physical modification advantage of major diameter steel ball salt bath hardening technique more fundamentally to solve the quick cooling and poor technological difficulties of centre hardness.
E. heat treatment stages carries out f. hard grind after completing; We enter g. double tempering after hard grind completes: low temperature double tempering temperature 150 ~ 160 degree, and temper time is controlled at 120-150min, is mainly 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 of testing below before and after comparative experiment:
Finally carrying out 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.
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 features such as high wear resistance, highi degree of accuracy, high reliability, long lifetime.
The steel ball finally making 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 (3)

1. a manufacturing process that realizes 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 grinding, polishing, eddy current testing, twice grinding, cleaning, check and oiling packing; Described raw material adopt 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 to being transferred to the raw material at cutter place, by cutter, to cut into impartial segment, then use material loading, compress material section, by shaping die, carry out upsetting pressure shaping; Described heat treatment stages is incubated steel ball in electric furnace at 830-860 ℃, make steel ball heat penetration, again grain of steel ball is poured in quenching bath, carry out cooling, after cooling stage completes, in quenching bath, hang out and put air tempering furnace guipure, carry out at 200 ~ 230 ℃, being incubated 240-270 minute again after low-temperature tempering; Described double tempering temperature 150 ~ 160 degree, the time was at 120 minutes.
2. the manufacturing process that realizes large-scale offshore wind farm unit bearing special-purpose steel ball according to claim 1, it is characterized in that: described cooling stage is divided into three phases: the first stage: the steel ball of heat penetration is poured into the water-soluble quenching agent of 35-45 ℃,, there is the steam blanket that one deck is thin 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, rely on conduction and convection to carry out cooling.
3. the manufacturing process that realizes large-scale offshore wind farm unit bearing special-purpose steel ball according to claim 2, is characterized in that: described water-soluble quenching agent is that concentration is the NaCO of 4-8% 3solution.
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CN102537069A (en) * 2012-03-13 2012-07-04 江苏力星通用钢球股份有限公司 Steel ball special for bearing of large-scale offshore wind power generator group and manufacturing process for steel ball
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