CN112756459A - Method for determining fillet radius of internal and external spinning wheels in spinning of cylindrical part - Google Patents
Method for determining fillet radius of internal and external spinning wheels in spinning of cylindrical part Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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Abstract
A method for determining the radius of the fillet of internal and external spinning wheels in spinning a cylindrical part includes such steps as considering the diameter D of cylindrical part and the initial wall thickness t of spinning blank0The method defines a calculation method of the fillet radius of the inner spinning wheel and the outer spinning wheel when the thin-wall cylindrical part is spun, and provides basis for calculation and selection of the fillet radius of the inner spinning wheel and the outer spinning wheel when the high-precision thin-wall cylindrical part is spun. The method is used for guiding the practical production and processing process of the thin-wall cylindrical part in the spinning of the pair wheel, conveniently and quickly setting the fillet radius parameters of the inner spinning wheel and the outer spinning wheel, and is used for stably forming the high-precision spinning cylindrical part of the pair wheel.
Description
Technical Field
The invention relates to the spinning manufacturing industry, in particular to a method for calculating the fillet radius of an inner spinning wheel and an outer spinning wheel when a cylindrical part is spun for guiding the spinning production and processing of the cylindrical part.
Background
Along with the rapid development of the aviation and aerospace technology and the national economy in China, the demands on thin-wall metal spinning cylindrical parts with the diameter of 2500mm or more are more and more urgent, the precision requirements of parts are higher and higher, the problem can be effectively solved by adopting a core-free paired wheel spinning process, and the core-free paired wheel spinning process has the advantages of flexible processing, simple equipment, high forming precision and the like. At present, for the cylinder with the diameter of 2500mm or above, the opposite-wheel spinning forming process without core mould is adopted, the process technology is developed by powerful spinning, the spinning wheels are used for replacing the traditional spinning core mould, and one or more pairs of spinning wheels are adopted for simultaneously processing and thinning the inner surface and the outer surface of the blank of the cylindrical part, so that the blank is elongated into a thin-wall cylindrical part. The spinning forming process of the pair wheel is not limited by the diameter of the cylindrical part, the wall thickness of the blank and the length, and thin-wall metal cylindrical parts with different diameters can be formed without a spinning die; the flexible forming of the thin-wall cylindrical part can be realized, the structure compactness and the mechanical property of the metal material are improved by the pair wheel spinning forming process, and the overall weight of the solid engine shell can be reduced; when the pair wheel is spun, the metal material symmetrically flows and deforms, and the processing precision of the cylindrical part is high; the spinning wheels are formed by spinning inside and outside in pairs, so that the single-pass cold machining deformation amount can be up to 90%, and the production efficiency is greatly improved. Therefore, the requirements on the thin-wall metal cylindrical part on the wheel spinning process, the stability and the applicability of tool parameters, the scientificity and the rapidness of parameter selection and the like are higher and higher.
The fillet radius of the inner spinning wheel and the outer spinning wheel is an important tool structure parameter of the spinning process of the thin-wall metal cylindrical part. The selection of the parameters has the basic characteristics of the traditional cylinder strong spinning forming mode, for example, in a certain range, when the fillet radius of the spinning wheel is large, the spinning pass thinning amount can be effectively increased, the deformation of the large thinning amount is realized, the production efficiency is high, the apparent quality of the cylinder is relatively high, the apparent quality defects such as spinning corrugation and the like are not easy to occur, the diameter of the cylinder is relatively difficult to shrink, and the service life of the spinning wheel is long. When the fillet radius of the spinning wheel is small, the axial flow of the spinning cylindrical part is good, the diameter shrinkage of the cylindrical part is relatively easy, the apparent quality of the cylindrical part is reduced, thick apparent spinning lines appear, the wall thickness deviation of a product is large, the shape and position accuracy such as roundness and straightness is poor, even the spinning part is distorted, unstable and cracked, the rigidity of the spinning wheel is poor, the abrasion is severe, and the service life of the spinning wheel is greatly reduced. Meanwhile, the selection of the fillet radius of the inner spinning wheel and the outer spinning wheel also needs to comprehensively consider the remarkable characteristics of the spinning process of the cylindrical part, for example, because the inner surface and the outer surface of the cylindrical part simultaneously participate in deformation during the spinning of the pair wheel and the cylindrical part is effectively supported without a spinning core mold, the stress balance and the deformation stability of metal in a deformation area are the most critical factors influencing the forming precision of the cylindrical part, and the selection of each process and tool parameters ensures the stress balance and the stable deformation as a first principle; the metal deformation area of the cylindrical part is symmetrical when the pair wheel is spun, the residual stress state of the cylindrical part is obviously improved, the shape and the size precision of the cylindrical part are higher, but because the diameters of the metals in the deformation areas of the inner surface and the outer surface of the cylindrical part are different, the diameter of the inner surface is relatively smaller, the curvature is larger, the fluidity of the metal of the inner surface is slightly worse than that of the outer surface under the same process and tool parameters, the spinning pressure and the residual stress have certain deviation, and when the deviation is larger, the distortion instability is easy to occur, so the structural parameters of the inner spinning wheel and the outer spinning wheel need to be adjusted to improve the fluidity of the metal inside and the outer surface of the thin-wall cylindrical part, balance the spinning pressure and reduce the residual stress, further ensure the; meanwhile, when the pair wheel is spun, effective support of a spinning die is not provided, the internal and external apparent masses of the cylindrical part are ensured by the spinning wheel, the internal spinning wheel needs to bear the support effect of part of the spinning die while participating in plastic deformation of the metal on the inner surface, and the design and selection of the structural parameters, particularly the fillet radius of the spinning wheel, can also influence the spinning forming precision of the pair wheel of the cylindrical part. Therefore, the reasonable, effective and accurate fillet radius of the inner and outer spinning wheels has important significance for controlling the quality of the spinning product of the thin-wall cylindrical part.
In the prior art, two sets of schemes are mainly adopted for calculating and setting the radius of the circular bead of the spinning wheel when the thin-wall cylindrical part is spun by the spinning wheel: 1. directly taking values according to the traditional cylinder strong spinning production experience; 2. the value is obtained after simple computer numerical simulation, and the two schemes have the following defects:
1. directly taking values according to the traditional cylinder strong spinning production experience. Each production unit summarizes the radius value experience of the inner and outer spinning wheel fillet radius of a certain relatively stable cylindrical part during traditional powerful spinning according to the specification and size, material strength and type, diameter of the cylindrical part, wall thickness reduction condition of each pass, processing capacity of equipment and other special conditions of a product processed by the production unit, and guides selection of the radius of the inner and outer spinning wheel fillet radius of the cylindrical part during spinning of the cylindrical part according to the empirical parameters and the processing capacity of the spinning tool and equipment of the production unit.
2. And simple computer numerical simulation is carried out to obtain values. The computer numerical simulation can effectively guide the production practice without paying the cost of production data such as spinning dies, tools, spinning blanks and the like, and is a mainstream process and tool parameter optimization mode in the manufacturing industry at present. The numerical simulation result of the computer can generally judge the structure, parameters and the like of the spinning wheel, but the setting of parameters such as the material of the spinning cylindrical part, the diameter of the cylindrical part, the initial wall thickness of a spinning blank, the pass reduction and the like needs to be fully considered, the phenomena of incomplete consideration and the like exist, the model building process is complex, the calculated amount is large, time and labor are wasted, the requirement on the professional capacity of process technicians is high, the rapid and convenient practicability is not achieved, the fillet radius of the inner and outer spinning wheels of the thin-wall cylindrical part obtained through calculation needs to be further adjusted according to the repeated spinning test processing results, and the guiding significance of the actual production is not achieved sufficiently.
Disclosure of Invention
In order to overcome the defects of low precision, poorer scientificity and no significance in practical popularization and guidance of production in the prior art, the invention provides a method for determining the fillet radius of an internal spinning wheel and an external spinning wheel of the spinning of a cylindrical part.
The specific process of the invention is as follows:
first, determining the influence factors of the radius of the rotary wheel.
The influencing factors of the fillet radius of the spinning wheel comprise the diameter D of the cylindrical part and the initial wall thickness t of the spinning blank0Pass reduction, type and strength of metal material, rigidity of spinning machine, number of spinning wheels, cooling mode and flow of cooling liquid.
Determining the total pass thinning amount to be 10 mm; the number of the rotary wheels is four; the cooling mode is water cooling; the flow rate of the cooling liquid is more than or equal to 360L/min.
And secondly, determining values of all constants.
The constants include:
i influence factor K of spinning blank D on fillet radius of spinning wheel1；
The influence factor K1Is a constant term. The influencing factor K1When the diameter of the spinning cylindrical part of the pair wheel is changed between 2000mm and 5000mm, taking the diameter of the spinning cylindrical part of the pair wheel as 0.005-0.01; the influencing factor K1Increases with increasing spinning blank diameter D. The factor K is given for every 500mm increase in the diameter of the spinning cylinder1The value of (a) increases by 0.001;
II spinning blank initial spinning wall thickness t0Influence factor K on fillet radius of inner and outer spinning wheels during spinning of paired wheels2；
Said K2Is a constant term. Influencing factor K2When the diameter of the spinning cylindrical part of the pair wheel is 2500mm-5000mm and the initial wall thickness of the spinning blank is 20 mm-50 mm, the thickness is 0.07-0.12, and the initial wall thickness t of the spinning blank is taken along with the spinning0Is increased. Spinning blank initial wall thickness t of spinning cylindrical part of opposite wheel0The effect is caused by every 10mm increaseSeed K2The value of (a) increases by 0.01;
III influence factor K of thickness reduction delta t of spinning pass on fillet radius of inner and outer spinning wheels during spinning of the pair of spinning wheels3。
Said K3Is a constant term. The influencing factor K3When the diameter of the pair wheel spinning cylindrical part is 2500mm-5000mm and the spinning pass thinning amount delta t is 0-30 mm, the diameter is 0-0.3, and the initial wall thickness t of the blank is spun0Is increased. The influence factor K is obtained when the reduction quantity delta t of the spinning pass of the spinning cylindrical part of the wheel is increased by 1mm3The value of (a) increases by 0.01;
IV influence factors K of the type and the strength of the metal material, the rigidity of the spinning machine, the number and the structural parameters of the spinning wheels, the parameters of the spinning core mold, the cooling mode and the cooling speed on the thinning amount of the inner spinning wheel and the outer spinning wheel during spinning the pair wheels4。
The influence factor K4Is a constant term, and the value range is-2 to 2. The influencing factor K4Decreasing with increasing spinning machine and its stiffness, decreasing with increasing number of spinning wheels, decreasing with increasing amount of spinning wheel springback, decreasing with increasing spinning material and its strength.
V influence factor K of fillet radius of inner spinning wheel during spinning of pair wheel0。
Said K0Is a constant. 1.0-1.2 when the diameter of the spinning cylinder is 2500mm-5000mm, and the diameter of the spinning cylinder is reduced with the increase of the diameter D of the spinning cylinder, namely the larger the diameter of the spinning cylinder is, the larger K is0The closer the value is to 1, the more the thinning of the inner and outer rollers tends to be the same.
And step two, calculating the fillet radius of each spinning wheel:
R＝K1D+K2t0+K3Δt+K4 (1)
R1＝K0R (2)
R2＝KR (3)
the parameters in the formula are defined as follows:
K1the factor is the influence factor of the diameter D of the spinning cylindrical part on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the pair of spinning wheels;
d is the diameter of the cylindrical part blank spun by the pair wheel;
K2influence factors of the thickness of the primary rotating wall of the spinning blank of the cylindrical part on the fillet radius of the inner and outer spinning wheels during spinning of the pair wheels are provided;
Δt0the initial wall thickness of a spinning blank of the cylindrical part is obtained when the cylindrical part is spun by the pair wheel;
K3the influence factor of the total reduction of the spinning pass of the cylindrical part on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the cylindrical part is shown;
delta t is the total reduction of the cylindrical part in the wheel spinning pass;
K0the factors of factors such as the rigidity of the spinning machine, the rebound quantity of the spinning rollers, the types and the strength of spinning materials, the number of the spinning rollers, the cooling mode, the flow of cooling liquid and the like on the fillet radius of the inner spinning roller and the outer spinning roller during spinning the pair of rollers;
R1the radius of a round corner of an external spinning wheel is the radius of the round corner of the external spinning wheel when the opposite wheel is spun;
R2is the fillet radius of an outward spinning wheel when the opposite wheel is spun.
The determined fillet radius of the internal rotating wheel is 22mm, and the determined fillet radius of the external rotating wheel is 20 mm.
The invention relates to the spinning manufacturing industry, which comprehensively considers the diameter D of a thin-wall cylindrical part and the initial wall thickness t of a spinning blank in the spinning of a pair wheel0The method defines a calculation method of the fillet radius of the inner spinning wheel and the outer spinning wheel when the thin-wall cylindrical part is spun, and provides basis for calculation and selection of the fillet radius of the inner spinning wheel and the outer spinning wheel when the high-precision thin-wall cylindrical part is spun. The method is used for guiding the practical production and processing process of the thin-wall cylindrical part in the spinning of the pair wheel, conveniently and quickly setting the fillet radius parameters of the inner spinning wheel and the outer spinning wheel, and is used for stably forming the high-precision spinning cylindrical part of the pair wheel.
Compared with the prior art, the invention has the following advantages:
1. the fillet radius of the inner spinning wheel and the outer spinning wheel is determined and selected to carry out quantitative calculation when the cylindrical part is spun. The existing selection modes are generally two, and the value is directly taken according to the traditional cylinder strong spinning production experience or is taken according to the numerical simulation result of a computer. When values are taken according to traditional experiences, the summarized radius taking experience of the rotary wheel fillet in traditional strong spinning of some relatively stable cylindrical parts often does not have reference due to the differences of specification and size, material strength and type, diameter of the cylindrical part, wall thickness reduction condition of each pass, processing capacity of a spinning machine and other special conditions of processed products. For example, when the traditional cylindrical part is subjected to powerful spinning, the fillet radius of the spinning wheel is selected according to the diameter of the processed cylindrical part and the thickness of a spinning blank, the numerical value is generally 1-3 times of the thickness of the spinning blank when the cylindrical part is subjected to powerful spinning, and generally, the larger the diameter of the processed cylindrical part is, the thicker the thickness of the wall of the spinning blank is, the larger the fillet radius of the spinning wheel is; for example, in a certain range, when the fillet radius of the spinning wheel is large, the spinning pass thinning amount can be effectively increased, deformation with large thinning amount is realized, the production efficiency is high, the apparent mass of the cylindrical part is relatively high, the apparent quality defects such as spinning corrugation and the like are not easy to occur, the diameter of the cylindrical part is relatively difficult to shrink, and the service life of the spinning wheel is long. When the fillet radius of the spinning wheel is small, the axial flow of the spinning cylindrical part is good, the diameter shrinkage of the cylindrical part is relatively easy, the apparent quality of the cylindrical part is reduced, thick apparent spinning lines appear, the wall thickness deviation of a product is large, the shape and position accuracy such as roundness and straightness is poor, even the spinning part is distorted, unstable and cracked, the rigidity of the spinning wheel is poor, the abrasion is severe, and the service life of the spinning wheel is greatly reduced. Meanwhile, the selection of the fillet radius of the inner spinning wheel and the outer spinning wheel also needs to comprehensively consider the remarkable characteristics of the spinning process of the cylindrical part, for example, because the inner surface and the outer surface of the cylindrical part simultaneously participate in deformation during the spinning of the pair wheel and the cylindrical part is effectively supported without a spinning core mold, the stress balance and the deformation stability of metal in a deformation area are the most critical factors influencing the forming precision of the cylindrical part, and the selection of each process and tool parameters ensures the stress balance and the stable deformation as a first principle; the metal deformation area of the cylindrical part is symmetrical when the pair wheel is spun, the residual stress state of the cylindrical part is obviously improved, the shape and the size precision of the cylindrical part are higher, but because the diameters of the metals in the deformation areas of the inner surface and the outer surface of the cylindrical part are different, the diameter of the inner surface is relatively smaller, the curvature is larger, the fluidity of the metal of the inner surface is slightly worse than that of the outer surface under the same process and tool parameters, the spinning pressure and the residual stress have certain deviation, and when the deviation is larger, the distortion instability is easy to occur, so the structural parameters of the inner spinning wheel and the outer spinning wheel need to be adjusted to improve the fluidity of the metal inside and the outer surface of the thin-wall cylindrical part, balance the spinning pressure and reduce the residual stress, further ensure the; meanwhile, when the pair wheel is spun, effective support of a spinning die is not provided, the internal and external apparent masses of the cylindrical part are ensured by the spinning wheel, the internal spinning wheel needs to bear the support effect of part of the spinning die while participating in the plastic deformation of the metal on the inner surface, and the design and selection of the structural parameters, particularly the fillet radius of the spinning wheel, can also influence the spinning forming precision of the pair wheel of the cylindrical part; the numerical simulation result of the computer can make a preliminary quantitative judgment on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the pair of wheels, but because the setting of spinning process parameters such as spinning temperature, cylinder material, cylinder diameter, initial wall thickness of spinning blank, the number and the structure parameters of the spinning wheels, spinning core mold parameters, rigidity of the spinning machine, a cooling mode and a cooling speed, the rotating speed of a spindle of the spinning machine, the feeding speed of the spinning wheels, spinning clearance, offset of the spinning wheels and the like needs to be fully considered during the numerical simulation, and most of the parameters are set to be in an ideal state, for example, the spinning mold and the spinning wheels are set to be in an ideal rigid body, metal materials are set to be in an ideal elastic body, the deformation temperature is generally set to be a fixed temperature without changing during normal temperature spinning, the rigidity of the spinning machine and the rebound of the spinning wheels are not involved, and because the, the method has the advantages that the model building process is complex, the calculated amount is large, time and labor are wasted, the requirement on the professional ability of process technicians is high, and the method does not have the practicability of rapidness and convenience, the fillet radius of the inner spinning wheel and the outer spinning wheel of the thin-wall cylindrical part obtained through calculation is often required to be further adjusted and corrected according to the multiple trial spinning processing results, the replacement of the spinning wheels is time and labor consuming, the labor intensity is high, and the method does not have the practical guidance and popularization significance of production. According to the invention, a plurality of influence factor parameters are set, a plurality of key factors influencing the cylindrical part diameter of the radius of the internal and external spinning wheel fillet of the spinning of the thin-wall cylindrical part are quantitatively analyzed, the wall thickness of a spinning blank and the like, and the principle of determining the radius of the internal and external spinning wheel fillet of the thin-wall cylindrical part is quantitatively analyzed, so that the final radius of the internal and external spinning wheel fillet of the thin-wall cylindrical part and the radius of each internal and external spinning wheel fillet are determined, and the production and processing of the strong spinning of the thin-wall cylindrical part can.
2. When determining the fillet radius of the inner spinning wheel and the outer spinning wheel in the spinning of the cylindrical part, the calculation method fully considers the influence rule of the diameter of the cylindrical part, the initial wall thickness of a spinning blank, pass reduction, the type and the strength of metal materials, the rigidity of a spinning machine, the number of the spinning wheels, the cooling mode, the flow of cooling liquid and the like on the spinning forming precision of the cylindrical part, is consistent with actual production, and has better applicability. When the traditional cylindrical part is formed by powerful spinning, under the conditions that the pass wall thickness reduction is certain and the metal deformation is sufficient, the diameter of the cylindrical part is smaller, the plastic deformation stress strain state is more complex, the metal close to the inner layer can generate the phenomenon of staggered layer cracking due to the support and the constraint of a spinning core mold and the flowing difficulty caused by larger curvature, the plastic forming quality of the cylindrical part is poorer, and when the diameter of the cylindrical part is 200mm, the wall thickness forming precision of the cylindrical part in the prior art can reach +/-0.10 mm; the larger the diameter of the cylindrical part is, the closer the plastic deformation of the cylindrical part is to the plane stress strain state of plate rolling, the better the plastic forming effect is, and when the diameter of the cylindrical part is 2000mm, the wall thickness forming precision of the cylindrical part in the prior art can reach +/-0.10 mm. The diameter of a cylindrical part product processed by the pair-wheel spinning method is generally larger than 2500mm, for a cylindrical part blank spun by the pair-wheel spinning within the diameter size range, the difference value of the inner diameter and the outer diameter is smaller relative to the value of the diameter, for example, for the cylindrical part with the diameter of 3000mm and the initial wall thickness of the spun blank of 50mm, the diameter-wall thickness ratio is 60, which is far larger than the diameter-wall thickness ratio value formed by the traditional cylindrical part through strong spinning; for the roller spinning cylindrical part product with the diameter larger than 2500mm, the curvature difference of the metal in the inner and outer layer deformation areas is smaller, the fluidity difference of the metal in the inner and outer layer deformation areas is smaller, the larger the diameter is, the smaller the fluidity difference is,when the diameter is increased to 5000mm, the flow of the metal of the inner and outer layers can be substantially equivalent to plate rolling. Therefore, a constant K is adopted1Representing an influence factor of the diameter D of the spinning cylindrical part on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the pair of wheels, wherein when the diameter of the spinning cylindrical part is 2500mm-5000mm, the influence factor is 0.005-0.01 and is increased along with the increase of the diameter D of a spinning blank; the value of this impact factor increases by 0.001 for every 500mm increase in the diameter of the spinning cylinder. The wall thickness forming precision of the spinning cylindrical part of the pair wheel processed by the round corner radius of the inner spinning wheel and the outer spinning wheel determined by the invention is +/-0.05 mm.
The initial wall thickness of the spinning blank of the cylindrical part determines the formulation of the whole spinning process scheme flow and the selection of process parameters of each pass, and is an important index for ensuring the precision requirement of the cylindrical part product. When the initial wall thickness of the spinning blank of the cylindrical part is thicker, the spinning blank is short and thick, the utilization rate of raw materials is high, the production cost is effectively reduced, but the number of corresponding spinning passes and the number of intermediate heat treatment times are required to be increased, the production cost is increased, meanwhile, the thickness of the spinning blank is increased according to the requirement on the spinning pressure of a spinning machine, for example, the ultrahigh-strength steel 31Si2MnCrMoVE is taken, and the spinning pressure is increased by 10 tons when the wall thickness of the spinning blank is increased by 5 mm; for the spinning forming of the cylindrical part, the initial wall thickness of a spinning blank is an important reference for determining the fillet radius of each spinning wheel, the selection of the fillet radius of each spinning wheel ensures that the spinning blank is completely pressed and fully deformed, the defects of accumulation, bulging and the like cannot occur due to overlarge spinning blank, the defects of tension fracture and the like due to undersize spinning blank cannot occur, the wall thickness deviation of the cylindrical part is large, and the shape and position accuracy of the roundness, straightness and the like of the cylindrical part is poor; for the spinning forming process of the cylindrical part by the pair of wheels, a constant K is adopted2To characterize the initial wall thickness t of the spinning blank of the cylindrical part0For the influence factor of the fillet radius of the inner spinning wheel and the outer spinning wheel during the spinning of the pair wheel, when the diameter of a spinning cylindrical part of the pair wheel is 2500mm-5000mm and the initial wall thickness of a spinning blank is 20 mm-60 mm in the case of ultrahigh strength steel 31Si2MnCrMoVE, the influence factor has a constant K20.01 to 0.15, and the initial wall thickness t of the blank is spun0Is increased with an increase in; spinning blank initial wall thickness t of spinning cylindrical part of opposite wheel0For every 10mm increase, the influencing factorThe value increases by 0.001. The wall thickness forming precision of the spinning cylindrical part of the pair wheel processed by the round corner radius of the inner spinning wheel and the outer spinning wheel determined by the invention is +/-0.05 mm.
The pass wall thickness reduction of the cylindrical part is an important index for ensuring the precision requirement of the cylindrical part product. When the pass reduction of the cylindrical part is large, the production efficiency is high, but the requirements on performance indexes such as spinning pressure and rigidity of a spinning machine are high, and in the case of ultrahigh-strength steel 31Si2MnCrMoVE, the large pass reduction of the cylindrical part needs the corresponding large fillet radius of each spinning wheel, and the selection of the fillet radius of each spinning wheel ensures that a spinning blank can be completely pressed through under the pass reduction, the deformation is sufficient, and the defects of accumulation and bulging cannot occur due to overlarge pass reduction. For the cylindrical part pair wheel spinning forming process, a constant K is adopted3Representing the influence factor of the pass reduction delta t of the cylindrical part on the fillet radius of the internal and external spinning wheels during spinning of the pair wheel, taking 31Si2MnCrMoVE of ultrahigh strength steel as an example, when the diameter of the cylindrical part for spinning of the pair wheel is 2500mm-5000mm, and the pass reduction of spinning is 0-30 mm, the constant K is constant30 to 0.3, and the initial wall thickness t of the blank is spun0Is increased with an increase in; the value of the influence factor is increased by 0.01 every time the spinning pass thinning amount delta t of the pair wheel spinning cylindrical part is increased by 1mm, and the wall thickness forming precision of the pair wheel spinning cylindrical part processed by the fillet radius of the inner and outer spinning wheels determined by the method is +/-0.05 mm.
When the cylindrical part is spun and formed by the pair of wheels, factors such as the rigidity of a spinning machine, the resilience of the spinning wheels, the type and the strength of spinning materials, the number of the spinning wheels, the cooling mode, the flow of cooling liquid and the like have another important influence factor on the fillet radius of the inner and outer spinning wheels during spinning of the pair of wheels. For the roller spinning forming process of the cylindrical part, the factors interact with each other and comprehensively influence the forming precision of the roller spinning of the cylindrical part. By using a constant K3Representing influence factors of the type and the strength of a metal material, the rigidity of a spinning machine, the number of spinning wheels, a cooling mode and the flow of cooling liquid on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the spinning wheels, wherein the constant is reduced along with the increase of the rigidity of the spinning machine, the increase of the number of the spinning wheels, the increase of the rebound quantity of the spinning wheels and the increase of the strength of the spinning material; with increasing coolant flowAnd increase, affecting the factor K3Is-2 to 2.
When the pair-wheel spinning forming process is adopted, the basic characteristics of the traditional cylinder strong spinning forming mode need to be considered, under the condition that the total pass reduction is constant, the obvious characteristics of the cylinder pair-wheel spinning process need to be comprehensively considered in the distribution of the fillet radius of the inner spinning wheel and the outer spinning wheel, for example, because the inner surface and the outer surface of the cylinder participate in deformation at the same time during pair-wheel spinning and no effective support of a spinning core die exists, the stress balance and the deformation stability of metal in a deformation area are the most critical factors influencing the forming precision of the cylinder, and the matching of the fillet radius of the inner spinning wheel and the outer spinning wheel ensures the stress balance and the stable deformation as a first principle; because the metal deformation areas of the cylindrical part are symmetrical when the pair wheels are spun, the metal diameters of the deformation areas on the inner surface and the outer surface of the cylindrical part are different, the diameter of the inner surface is relatively smaller, the curvature is larger, the inner spinning wheels and the outer spinning wheels are mutually supported under the same process and tool parameters, and the fillet radius of the inner spinning wheels is slightly larger than that of the outer spinning wheels to balance the unstable stress; the diameter of a cylindrical part product processed by the pair-wheel spinning method is generally larger than 2500mm, for a cylindrical part blank of the pair-wheel spinning within the diameter size range, the difference value of the inner diameter and the outer diameter is smaller relative to the diameter value, the difference of the fluidity of the metal in the deformation areas of the inner layer and the outer layer is smaller, the larger the diameter is, the more stable the deformation force under the same thinning amount is, and when the diameter is increased to 5000mm, the flow of the metal is still stable under the condition that the thinning amount of the metal in the inner layer and the outer layer is the same. Therefore, the reasonable, effective and accurate round corner radius matching of the inner spinning wheel and the outer spinning wheel has important significance for controlling the quality of the spinning product of the thin-wall cylindrical part. Setting constant K0The influence factor of the fillet radius of the internal and external spinning wheels during spinning the pair wheel is represented, and when the diameter of the spinning cylindrical part of the pair wheel is 2500mm-5000mm, the constant K is01.0 to 1.2; and decreases with increasing diameter D of the spinning cylinder, the larger the diameter, the factor K0The closer to 1, the more the fillet radius of the inner rotor and the outer rotor tend to be the same. The invention fully considers the stress balance problem during the pair wheel spinning, and adopts the ultrahigh strength steel 31Si2MnCrMoVE processed by the determined fillet radius of the internal and external spinning wheels to form the wall thickness of the pair wheel spinning cylindrical partThe precision is +/-0.05 mm.
3. Through simple input and calculation of parameters, the fillet radius parameters of the inner spinning wheel and the outer spinning wheel of the cylindrical part in the spinning process can be obtained. The operation is simple, fast and convenient, and the efficiency is improved by more than 80% compared with the original efficiency. The method can simply and quickly determine the fillet radius of the inner spinning wheel and the outer spinning wheel of the cylindrical part with a certain diameter range and the initial thickness of the spinning blank in the process of spinning the cylindrical part, and the fillet radius parameter of the inner spinning wheel and the outer spinning wheel can be corrected by combining simple trial spinning processing, so that reasonable parameters meeting the requirements of product design of the cylindrical part spun by the pair of wheels and control indexes of a spinning process can be obtained, the number of times of trial spinning is reduced by 3-5, the efficiency is improved by more than 80%, and the labor intensity is reduced by more than 60% due to the reduction of the number of times of replacing the spinning wheels.
4. The wall thickness precision of the pair wheel spinning cylindrical part processed by the method reaches +/-0.05 mm level, the diameter precision reaches +/-0.15 mm level, the method basically covers higher precision and a larger range which can be reached by spinning wheels and spinning machines when the pair wheel spinning cylindrical part is frequently prepared in factories, the wall thickness precision of the pair wheel spinning cylindrical part processed by parameters obtained by empirical parameter selection and numerical simulation calculation of the traditional power spinning process reaches +/-0.10 mm level, and the diameter precision reaches +/-0.30 mm level. The invention has higher processing precision and stability.
Detailed Description
Example 1
The embodiment is a method for determining the fillet radius of an internal spinning wheel and an external spinning wheel when spinning an ultrahigh-strength steel 31Si2MnCrMoVE cylindrical part.
The diameter D of the ultrahigh-strength steel 31Si2MnCrMoVE cylindrical part is 2500mm, the initial wall thickness of a spinning blank is 40mm, the total single-pass thinning amount is 10mm, the thinning amount of the inner spinning wheel is 5.2mm, the thinning amount of the outer spinning wheel is 4.8mm, and the opposite-wheel spinning forming process of synchronous reverse spinning of four pairs of spinning wheels is adopted.
The specific process of this embodiment is:
first, determining the influence factors of the radius of the rotary wheel.
The influencing factors of the fillet radius of the spinning wheel comprise the diameter D of the cylindrical part and the initial wall thickness t of the spinning blank0Pass reduction, type and strength of metal material, rigidity of spinning machine, number of spinning wheels, cooling mode and flow of cooling liquid.
In the embodiment, the diameter D of the cylindrical part is 2500 mm; initial wall thickness t of spinning blank040 mm; the total thinning amount of a single pass is 10 mm; the cylindrical part is made of ultrahigh-strength steel 31Si2MnCrMoVE, the annealing-state hardness of the ultrahigh-strength steel 31Si2MnCrMoVE is less than or equal to HB220, and the quenched and tempered tensile strength is greater than or equal to 1620 MPa. The heat treatment state of the 31Si2MnCrMoVE ultrahigh-strength steel in the embodiment is an annealed state. A vertical opposite-wheel powerful spinning machine is adopted, and the maximum rigid rebound of the vertical opposite-wheel powerful spinning machine is 0.8 mm. The number of the rotary wheels is four; without a spinning core die. The cooling mode is water cooling; the flow rate of the cooling liquid is more than or equal to 360L/min.
And secondly, determining values of all constants.
The constants include:
i influence factor K of spinning blank D on fillet radius of spinning wheel1；
The influence factor K1Is a constant term. The influencing factor K1When the diameter of the spinning cylindrical part of the pair wheel is changed between 2000mm and 5000mm, taking the diameter of the spinning cylindrical part of the pair wheel as 0.005-0.01; the influence factor K increases with the diameter D of the spinning blank1And (4) increasing. The factor K is given for every 500mm increase in the diameter of the spinning cylinder1The value of (a) increases by 0.001; in this embodiment, the influence factor K10.006 was taken.
II spinning blank initial spinning wall thickness t0Influence factor K on fillet radius of inner and outer spinning wheels during spinning of paired wheels2；
Said K2Is a constant term. Influencing factor K2When the diameter of the spinning cylindrical part of the pair wheel is 2500mm-5000mm and the initial wall thickness of the spinning blank is 20 mm-50 mm, the thickness is 0.07-0.12, and the initial wall thickness t of the spinning blank is taken along with the spinning0Is increased. Spinning blank initial wall thickness t of spinning cylindrical part of opposite wheel0For every 10mm increase, the influencing factor K2The value of (a) increases by 0.01; the initial wall thickness of the spinning blank in this example is 40mm, this influence factor K2Take 0.1.
III spinning pass thinning amount delta t pairsInfluence factor K of fillet radius of internal and external spinning wheels during wheel spinning3。
Said K3Is a constant term. The influencing factor K3When the diameter of the pair wheel spinning cylindrical part is 2500mm-5000mm and the spinning pass thinning amount delta t is 0-30 mm, the diameter is 0-0.3, and the initial wall thickness t of the blank is spun0Is increased. The influence factor K is obtained when the reduction quantity delta t of the spinning pass of the spinning cylindrical part of the wheel is increased by 1mm3The value of (a) increases by 0.01; the flow-forming pass reduction quantity delta t in the embodiment is 10mm, and the influence factor K3Take 0.1.
IV influence factors K of the type and the strength of the metal material, the rigidity of the spinning machine, the number and the structural parameters of the spinning wheels, the parameters of the spinning core mold, the cooling mode and the cooling speed on the thinning amount of the inner spinning wheel and the outer spinning wheel during spinning the pair wheels4。
The influence factor K4Is a constant term, and the value range is-2 to 2. The influencing factor K4Decreasing with increasing spinning machine and its stiffness, decreasing with increasing number of spinning wheels, decreasing with increasing amount of spinning wheel springback, decreasing with increasing spinning material and its strength. The influence factors in the embodiment are combined, and the influence factor K4Take 0.
V influence factor K of fillet radius of inner spinning wheel during spinning of pair wheel0。
Said K0Is a constant. 1.0-1.2 when the diameter of the spinning cylinder is 2500mm-5000mm, and the diameter of the spinning cylinder is reduced with the increase of the diameter D of the spinning cylinder, namely the larger the diameter of the spinning cylinder is, the larger K is0The closer the value is to 1, the more the thinning of the inner and outer rollers tends to be the same. In this example, 1.1 is taken.
And step two, calculating the fillet radius of each spinning wheel:
R＝K1D+K2t0+K3Δt+K4 (1)
R1＝K0R (2)
R2＝KR (3)
in the present embodiment, the first and second electrodes are,
R＝K1D+K2t0+K3Δt+K4＝0.006×2500+0.1×40+0.1×10+0＝20 (1)
R1＝K0R＝1.1×20＝22 (2)
R2＝R＝20 (3)
in the formulas (1) to (3), the parameters in the formulas are defined as follows:
K1the factor is the influence factor of the diameter D of the spinning cylindrical part on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the pair of spinning wheels;
d is the diameter of the cylindrical part blank spun by the pair wheel;
K2influence factors of the thickness of the primary rotating wall of the spinning blank of the cylindrical part on the fillet radius of the inner and outer spinning wheels during spinning of the pair wheels are provided;
Δt0the method is characterized in that the initial wall thickness of a spinning blank of the cylindrical part is represented when the cylindrical part is spun by a pair of wheels;
K3the influence factor of the total reduction of the spinning pass of the cylindrical part on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the cylindrical part is shown;
delta t is the total reduction of the cylindrical part in the wheel spinning pass;
K0the factors of factors such as the rigidity of the spinning machine, the rebound quantity of the spinning rollers, the types and the strength of spinning materials, the number of the spinning rollers, the cooling mode, the flow of cooling liquid and the like on the fillet radius of the inner spinning roller and the outer spinning roller during spinning the pair of rollers;
R1the radius of a round corner of an external spinning wheel is the radius of the round corner of the external spinning wheel when the opposite wheel is spun;
R2is the fillet radius of an outward spinning wheel when the opposite wheel is spun.
Through the known methods (1) to (3), the fillet radius of the internal spinning wheel is 22mm, and the fillet radius of the external spinning wheel is 20 mm.
The round corner radius of the inner spinning wheel and the outer spinning wheel determined by the method is adopted to process the spinning test piece, the wall thickness precision of the processed spinning cylindrical piece of the pair wheel reaches +/-0.05 mm level, and the actual measured value range of the wall thickness is 25.03 mm-25.10 mm; the diameter precision reaches the grade of +/-0.15 mm, and the diameter measured value is 2500.12 mm-2500.36 mm.
Example 2
The embodiment is a determination method for determining the fillet radius of an internal spinning wheel and an external spinning wheel when spinning an ultrahigh-strength steel 31Si2MnCrMoVE cylindrical part by using the prior art.
The diameter D of the ultrahigh-strength steel 31Si2MnCrMoVE cylindrical part is 2500mm, the initial wall thickness of a spinning blank is 40mm, the total single-pass thinning amount is 10mm, the thinning amount of the inner spinning wheel is 5.2mm, the thinning amount of the outer spinning wheel is 4.8mm, and the opposite-wheel spinning forming process of synchronous reverse spinning of four pairs of spinning wheels is adopted.
The specific process of this embodiment is:
firstly, determining the fillet radius of the inner and outer spinning wheels.
During powerful spinning of a traditional cylindrical part, the radius of the circular bead of the spinning wheel is selected according to the diameter of the processed cylindrical part and the thickness of a spinning blank, the radius of the circular bead of the spinning wheel is 1-3 times of the thickness of the spinning blank during powerful spinning of the cylindrical part, the larger the diameter of the processed cylindrical part is, the thicker the wall thickness of the spinning blank is, and the larger the radius of the circular bead of the spinning wheel is. In the embodiment, the fillet radius R of the inner and outer spinning wheels is determined to be 40 mm;
second, test piece processing
And (4) carrying out spinning processing on the test piece according to the round corner radius R of the inner spinning wheel and the outer spinning wheel determined in the first step. The wall thickness precision of the processed spinning cylindrical part of the pair wheel reaches +/-0.10 mm level, and the measured value of the wall thickness is 25.04 mm-25.20 mm. The wall thickness reduction amount is smaller than the radius of the fillet of the spinning wheel, the precision reaches +/-0.30 mm level, the diameter reduction effect is poor, the diameter exceeds the process and design requirements, 2mm is 2502.10 mm-2502.45 mm, and the process control requirements cannot be met.
Compare example one with example two. The method has the advantages that the round corner radius parameters of the inner spinning wheel and the outer spinning wheel determined by the method have high processing precision and quality stability when the cylindrical part is spun.
Claims (6)
1. A method for determining the fillet radius of an internal spinning wheel and an external spinning wheel of the spinning of a cylindrical part is characterized by comprising the following specific processes:
firstly, determining influence factors of the radius of a circular bead of a spinning wheel;
the influencing factors of the fillet radius of the spinning wheel comprise the diameter D of the cylindrical part and the initial wall thickness t of the spinning blank0Pass reduction, type and strength of metal materials, rigidity of a spinning machine, number of spinning wheels, cooling mode and flow of cooling liquid;
secondly, determining values of constants;
the constants include:
i influence factor K of spinning blank D on fillet radius of spinning wheel1；
The influence factor K1Is a constant term; the influencing factor K1When the diameter of the spinning cylindrical part of the pair wheel is changed between 2000mm and 5000mm, taking the diameter of the spinning cylindrical part of the pair wheel as 0.005-0.01; the influencing factor K1Increases with increasing spinning blank diameter D;
II spinning blank initial spinning wall thickness t0Influence factor K on fillet radius of inner and outer spinning wheels during spinning of paired wheels2；
Said K2Is a constant term; influencing factor K2When the diameter of the spinning cylindrical part of the pair wheel is 2500mm-5000mm and the initial wall thickness of the spinning blank is 20 mm-50 mm, the thickness is 0.07-0.12, and the initial wall thickness t of the spinning blank is taken along with the spinning0Is increased with an increase in;
III influence factor K of thickness reduction delta t of spinning pass on fillet radius of inner and outer spinning wheels during spinning of the pair of spinning wheels3；
Said K3Is a constant term; the influencing factor K3When the diameter of the pair wheel spinning cylindrical part is 2500mm-5000mm and the spinning pass thinning amount delta t is 0-30 mm, the diameter is 0-0.3, and the initial wall thickness t of the blank is spun0Is increased with an increase in;
IV influence factors K of the type and the strength of the metal material, the rigidity of the spinning machine, the number and the structural parameters of the spinning wheels, the parameters of the spinning core mold, the cooling mode and the cooling speed on the thinning amount of the inner spinning wheel and the outer spinning wheel during spinning the pair wheels4；
The influence factor K4Is a constant term, and the value range is-2 to 2; the influencing factor K4Decreases with increasing spinning machine and its rigidity, decreases with increasing number of spinning wheelsThe spinning material and the strength of the spinning material are increased and reduced along with the increase of the rebound quantity of the spinning wheel;
v influence factor K of fillet radius of inner spinning wheel during spinning of pair wheel0；
Said K0Is a constant; 1.0-1.2 when the diameter of the spinning cylinder is 2500mm-5000mm, and the diameter of the spinning cylinder is reduced with the increase of the diameter D of the spinning cylinder, namely the larger the diameter of the spinning cylinder is, the larger K is0The more the value approaches to 1, the more the thinning amount of the inner rotating wheel and the outer rotating wheel approaches to the same;
and step two, calculating the fillet radius of each spinning wheel:
R＝K1D+K2t0+K3Δt+K4 (1)
R1＝K0R (2)
R2＝KR (3)
in equations (1) to (3), the parameters are defined as follows:
K1the factor is the influence factor of the diameter D of the spinning cylindrical part on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the pair of spinning wheels;
d is the diameter of the cylindrical part blank spun by the pair wheel;
K2influence factors of the thickness of the primary rotating wall of the spinning blank of the cylindrical part on the fillet radius of the inner and outer spinning wheels during spinning of the pair wheels are provided;
Δt0the initial wall thickness of a spinning blank of the cylindrical part is obtained when the cylindrical part is spun by the pair wheel;
K3the influence factor of the total reduction of the spinning pass of the cylindrical part on the fillet radius of the inner spinning wheel and the outer spinning wheel during spinning of the cylindrical part is shown;
delta t is the total reduction of the cylindrical part in the wheel spinning pass;
K0the factors of factors such as the rigidity of the spinning machine, the rebound quantity of the spinning rollers, the types and the strength of spinning materials, the number of the spinning rollers, the cooling mode, the flow of cooling liquid and the like on the fillet radius of the inner spinning roller and the outer spinning roller during spinning the pair of rollers;
R1the radius of a round corner of an external spinning wheel is the radius of the round corner of the external spinning wheel when the opposite wheel is spun;
R2is the fillet radius of an outward spinning wheel when the opposite wheel is spun.
2. A method of determining the radius of a spinning roller fillet in a tubular member according to claim 1, wherein the total reduction in thickness is 10 mm; the number of the rotary wheels is four; the cooling mode is water cooling; the flow rate of the cooling liquid is more than or equal to 360L/min.
3. A method of determining the fillet radius of spinning cones and spinning cones in accordance with claim 1, wherein said factor K is applied to each 500mm increase in diameter of a spinning cylinder1The value of (a) increases by 0.001.
4. A method of determining the fillet radius of spinning inner and outer spinning wheels of a tubular member according to claim 1, wherein the initial wall thickness t of the spinning blank of the tubular member is determined by spinning the tubular member0For every 10mm increase, the influencing factor K2The value of (a) increases by 0.01.
5. The method of claim 1, wherein the influence factor K is determined for every 1mm increase in the reduction Δ t for the spinning pass of the spinning cylinder3The value of (a) increases by 0.01.
6. A method of determining the radius of a spinning inner and outer spinning roller of a tubular member as claimed in claim 1, wherein the radius of the determined inner spinning roller is 22mm and the radius of the determined outer spinning roller is 20 mm.
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