CN113458878B - Machining process of variable-pitch output shaft forging for wind power - Google Patents

Machining process of variable-pitch output shaft forging for wind power Download PDF

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Publication number
CN113458878B
CN113458878B CN202110736979.9A CN202110736979A CN113458878B CN 113458878 B CN113458878 B CN 113458878B CN 202110736979 A CN202110736979 A CN 202110736979A CN 113458878 B CN113458878 B CN 113458878B
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grinding
workpiece
wind power
output shaft
forging
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CN113458878A (en
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沈杰
汤扬
刘晓
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Jiangyin Suheng Die Forging Co ltd
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Jiangyin Suheng Die Forging Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/006—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the speed
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/18—Hardening; Quenching with or without subsequent tempering
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/26—Methods of annealing
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/26—Methods of annealing
    • C21D1/28—Normalising
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/005—Modifying the physical properties by deformation combined with, or followed by, heat treatment of ferrous alloys
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/28—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for plain shafts
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction

Abstract

The invention relates to a processing technology of a variable-pitch output shaft forged piece for wind power, which comprises the steps of raw material incoming inspection, blanking forging, turning, heat treatment, grinding, flaw detection, final inspection before loading, assembly, inspection after loading, packaging and warehousing, wherein in the blanking forging process, an equal-volume blanking device comprises two mutually-perpendicular light transmission type measuring sensors, and the average value of the measurements of the two sensors is taken as a measurement result; the grinding procedure comprises coarse grinding, primary additional tempering, fine grinding, secondary additional tempering and final grinding; in the grinding process, the waviness of the surface of the workpiece is theoretically analyzed. In the blanking forging process, an isometric blanking device is adopted to ensure the dimensional accuracy of the forge piece; the process requirement is met, the ratio of the rotating speed n1 of the workpiece to the rotating speed n2 of the grinding wheel is controlled to be infinite non-circulating decimal during grinding, and the waviness of the workpiece is controlled by grinding.

Description

Machining process of variable-pitch output shaft forging for wind power
Technical Field
The invention relates to a machining process of a variable-pitch output shaft forging for wind power. Belongs to the technical field of mechanical equipment.
Background
Wind power generation refers to converting kinetic energy of wind into electric energy. Wind energy is a clean and pollution-free renewable energy source, is very environment-friendly by utilizing wind power for power generation, and has huge wind energy content, so that the wind energy is increasingly paid attention by various countries in the world.
The principle of wind power generation is that wind power drives windmill blades to rotate, and then the rotating speed is increased through a speed increaser, so that a generator is promoted to generate electricity.
The variable pitch system is one of the core parts of a large-scale wind turbine control system, and plays an important role in safe, stable and efficient operation of the wind turbine.
The pitch control technology is simply that the attack angle of airflow to the blades is changed by adjusting the pitch angle of the blades, and then the aerodynamic torque and the aerodynamic power captured by the wind wheel are controlled.
The size precision of the existing variable-pitch output shaft forged piece for wind power is poor; the grinding process can not meet the process requirements and can not well control the waviness of the workpiece.
Disclosure of Invention
The invention aims to overcome the defects and provides a machining process of a variable-pitch output shaft forging for wind power.
The purpose of the invention is realized as follows:
a processing technology of a variable pitch output shaft forging for wind power is characterized in that: the method comprises the following process steps: raw material entering inspection, blanking forging, turning, heat treatment, grinding, flaw detection, final inspection before loading, assembly, inspection after loading, packaging and warehousing;
in the blanking forging process, an isometric blanking device is adopted; the equal-volume blanking device comprises two mutually perpendicular light transmission type measuring sensors, and the average value of the measurements of the two sensors is taken as a measurement result; the instantaneous measured volume av is as follows:
Figure 713360DEST_PATH_IMAGE002
in the formula (I), the compound is shown in the specification,
Figure 630500DEST_PATH_IMAGE004
the average diameter of the bar stock measured instantaneously,
Figure 206975DEST_PATH_IMAGE006
the distance of the bar material conveyed by a servo motor controlled by an encoder is the bar material distance;
expected feed volume
Figure 677883DEST_PATH_IMAGE008
The following were used:
Figure 492256DEST_PATH_IMAGE010
in the formula (I), the compound is shown in the specification,
Figure 377035DEST_PATH_IMAGE012
is the measured instantaneous diameter;
Figure 644068DEST_PATH_IMAGE014
is a single step feed length;
the grinding procedure comprises coarse grinding, primary additional tempering, fine grinding, secondary additional tempering and final grinding;
in the grinding step, the rotational speed of the grinding wheel is n1, the rotational speed of the workpiece is n2, and in the finish grinding, when the workpiece rotates for the second cycle, the ratio of the rotational speed n1 of the grinding wheel to the rotational speed n2 of the workpiece is infinite acyclic decimal, and the phase shift is phi =90 °.
Further, the heat treatment process comprises normalizing, annealing and quenching;
in the normalizing procedure, a spray cooling device is arranged for each forged piece to be cooled after forging;
further, when the grinding wheel rotates at n1, a vibration displacement X = Asin (ω τ) occurs in the horizontal direction due to problems such as grinding wheel balance.
Furthermore, the annealing temperature is ensured to be 780-800 ℃, the heat preservation time is not less than 4 hours, and then the product is naturally cooled.
Furthermore, a rotary hearth type protective atmosphere quenching furnace is adopted for quenching and heating.
Compared with the prior art, the invention has the beneficial effects that:
according to the processing technology of the variable-pitch output shaft forged piece for the wind power, in the blanking forging process, an isometric blanking device is adopted, and the size precision of the forged piece is ensured; the grinding process comprises coarse grinding, primary additional tempering, fine grinding, secondary additional tempering and final grinding, the process requirements are met, the ratio of the rotating speed n1 of the workpiece to the rotating speed n2 of the grinding wheel is controlled to be infinite non-circulating decimal during grinding, and the waviness of the workpiece is controlled by the grinding process.
Drawings
FIG. 1 shows an isometric blanking apparatus of the present invention.
Fig. 2 is a schematic diagram of the grinding of the present invention.
FIG. 3 is a development view of a general grinding surface waviness.
FIG. 4 is an expanded view of the modified abrasive surface corrugation.
Detailed Description
The following description of the embodiments of the present invention will be made with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present invention is not limited thereby.
The invention relates to a processing technology of a variable pitch output shaft forged piece for wind power.
In the blanking forging process, in order to ensure the dimensional accuracy of the forge piece, referring to fig. 1, an isometric blanking device is adopted; the equal-volume blanking device comprises two mutually perpendicular light transmission type measuring sensors, and the average value of the measurements of the two sensors is taken as a measurement result; the instantaneously measured volume av is estimated as follows:
Figure 842968DEST_PATH_IMAGE002
in the formula (I), the compound is shown in the specification,
Figure 324897DEST_PATH_IMAGE004
the average diameter of the bar stock measured instantaneously,
Figure 318260DEST_PATH_IMAGE006
the distance of the bar material conveyed by a servo motor controlled by an encoder is the bar material distance;
expected feed volume
Figure 72590DEST_PATH_IMAGE008
The following were used:
Figure 137498DEST_PATH_IMAGE010
in the formula (I), the compound is shown in the specification,
Figure 473932DEST_PATH_IMAGE012
is the measured instantaneous diameter;
Figure 903777DEST_PATH_IMAGE014
a single step feed length;
by adopting the equal-volume blanking device, the blanking precision can be improved to 1% from 3% at present. Not only ensures the processing precision of the forged piece, but also saves about 2 percent of materials.
The heat treatment process comprises normalizing, annealing and quenching;
normalizing: in order to improve the quenching quality, normalizing the forged piece after the forged piece is machined; in order to avoid the occurrence of coarse grains in reticular carbide and forgings of materials, a spray cooling device is arranged for each forging needing to be cooled after forging, the fact that each surface of the forging has the same cooling speed is guaranteed, specifically, each machined forging is hung on a hook in sequence, all-around and multi-angle spatial cooling is formed in a spray box, the cooled comprehensiveness and uniformity are guaranteed, after the forging is cooled to 650 ℃ by the spray device, the forging is driven to be separated from a unhooking device at a constant speed, then the forging is rolled down to a placing area through a slide carriage and stacked, and the last stage of a cooling process is completed automatically.
And (3) annealing: in order to further reduce the hardness and refine the lattice structure, the forge piece is completely spheroidized and tempered. The annealing temperature is maintained at 780-800 ℃, the heat preservation time is not less than 4 hours, and then the product is naturally cooled.
Quenching: the quenching adopts a multistage isothermal salt bath martensite quenching process to refine the structure; the quenching heating adopts a rotary hearth type protective atmosphere quenching furnace. The method can reduce the surface oxidation and decarburization of the heat treatment material by heating, and simultaneously, the material is uniformly heated, and the occurrence of heat treatment cracks is reduced.
The grinding procedure comprises coarse grinding, primary additional tempering, fine grinding, secondary additional tempering and final grinding;
the rough grinding process adopts a domestic common grinding machine, and mainly aims to remove the residual grinding quantity after heat treatment in a large proportion. The process has low requirements on the size, the form and position precision and the surface quality of the product. Because the grinding amount of the rough grinding process is large and the grinding efficiency is high, the heat generated by grinding is large, the heat dissipation of a grinding area needs to be enhanced, and the generation of grinding burn is avoided. Meanwhile, in order to eliminate grinding stress generated in the coarse grinding process, an additional tempering process is carried out after the coarse grinding, and a foundation is laid for ensuring the processing quality of the fine grinding process.
The fine grinding process adopts a domestic common grinding machine and a domestic numerical control grinding machine, and mainly aims to further reduce the residual grinding amount after heat treatment on the basis of coarse grinding, and greatly improve the size, the form and position precision and the surface quality of a product. Although the grinding amount is not large in comparison with the rough grinding, the stability and consistency of the processing accuracy of the fine grinding process are also affected to a certain extent due to the large size difference of the rough grinding process and the combined action of factors such as the grinding mode, the grinding parameters, the selected grinding wheel and the cutting fluid, and therefore, the control of each quality characteristic in the fine grinding process needs to be enhanced. In order to eliminate grinding stress generated in the fine grinding process, a secondary additional tempering process is carried out after the fine grinding, and a foundation is laid for the final grinding process.
The final grinding process adopts a foreign high-precision numerical control grinding machine, and the main purpose is to greatly improve the size, the form and position precision and the surface quality of a product on the basis of fine grinding so that the related technical indexes reach the process requirements. The final grinding process is also influenced by a plurality of factors such as grinding parameters, tools and the like in the previous working procedure and the grinding process. Therefore, various technical measures should be adopted to strictly control various process requirements of the final grinding process, particularly the working surface of the shaft, so as to meet the requirements.
Referring to fig. 2, in the grinding process, when the grinding wheel rotates at n1, due to problems such as grinding wheel balance, a vibration displacement X = Asin (ω τ) may occur in the horizontal direction; generally, the grinding wheel rotates at a much higher speed than the shaft, and if the shaft rotates one revolution and the grinding wheel is vibrationally displaced 1000 times a reciprocation, 1000 waves per revolution are produced on the grinding surface of the shaft. The ripple amplitude is the horizontal vibration displacement A of the grinding wheel; generally, the wheel balancing accuracy cannot be zero, that is, the oscillation displacement a of the wheel is always present. Therefore, waviness of the surface of the workpiece machined under the above conditions seems unavoidable.
In the actual grinding process, in order to improve the geometric accuracy of the raceway surface, a final grinding process without feeding is added at last, in the process, the grinding feeding amount is zero, and the elastic deformation left by feeding in the previous period in the whole grinding process completes the grinding process of zero-gradual zero-return grinding. During finish grinding, the workpiece is typically rotated through a dozen or more revolutions. At the beginning of finish grinding, the ground surface is left open as shown in fig. 3 when the workpiece is rotated a first revolution. If we do nothing during finish grinding, the final workpiece surface will be rippled as shown in FIG. 3.
If we rotate the workpiece for the first revolution during finish grinding as shown in fig. 3 and rotate the workpiece for the second revolution, we shift the phase by phi =90 deg., and then the workpiece is ground for the second revolution, leaving ripples on the workpiece surface as shown in fig. 4.
In fig. 4, it can be seen that, due to the effect of the initial phase angle, in the grinding of the second round of the workpiece, the wave crests of the waves left in the grinding of the first round are ground off, so that the amplitude of the waves is reduced to half of the original amplitude, and the number of waves is doubled.
When the workpiece rotates one circle, the phase shift of 90 degrees is formed, and after the cycle is repeated for a plurality of times, the amplitude of the ripple is reduced to the micro geometric precision allowed by the workpiece. Thereby achieving the purpose of controlling the waviness. Therefore, in actual work, the purpose of shifting the initial phase angle can be achieved by only making the ratio of the rotating speed n1 of the grinding wheel to the rotating speed n2 of the workpiece infinite non-cyclic decimal. Finally, the waviness of the workpiece is controlled by the grinding processing. The rotating speed of a workpiece of the existing numerical control grinding machine can be regulated in a stepless manner, so that the control of the ratio of the rotating speed n1 of the workpiece to the rotating speed n2 of a grinding wheel to be an infinite non-circulating decimal is easy to realize.
According to the processing technology of the variable-pitch output shaft forged piece for wind power, in the blanking forging process, an isometric blanking device is adopted, and the size precision of the forged piece is ensured; the grinding process comprises coarse grinding, primary additional tempering, fine grinding, secondary additional tempering and final grinding, the process requirements are met, the ratio of the rotating speed n1 of the workpiece to the rotating speed n2 of the grinding wheel is controlled to be infinite non-circulating decimal during grinding, and the waviness of the workpiece is controlled by the grinding process.
In the above embodiments, the present invention is described only by way of example, but those skilled in the art, after reading the present patent application, may make various modifications to the present invention without departing from the spirit and scope of the present invention.

Claims (5)

1. The machining process of the variable-pitch output shaft forging for wind power is characterized by comprising the following steps of: the method comprises the following process steps: raw material entering inspection, blanking forging, turning, heat treatment, grinding, flaw detection, final inspection before loading, assembly, inspection after loading, packaging and warehousing;
in the blanking forging procedure, an isometric blanking device is adopted; the equal-volume blanking device comprises two mutually perpendicular light transmission type measuring sensors, and the average value of the measurements of the two sensors is taken as a measurement result; volume obtained by instantaneous measurement
Figure 141175DEST_PATH_IMAGE002
The following:
Figure 478616DEST_PATH_IMAGE004
in the formula (I), the compound is shown in the specification,
Figure 122087DEST_PATH_IMAGE006
the average diameter of the bar stock measured instantaneously,
Figure 457253DEST_PATH_IMAGE008
the distance between the bars conveyed by a servo motor controlled by an encoder is the length of the bars;
expected feed volume
Figure 999224DEST_PATH_IMAGE010
The following:
Figure 78038DEST_PATH_IMAGE012
in the formula (I), the compound is shown in the specification,
Figure 435070DEST_PATH_IMAGE014
is the measured instantaneous diameter;
Figure 206717DEST_PATH_IMAGE016
a single step feed length;
the grinding procedure comprises coarse grinding, primary additional tempering, fine grinding, secondary additional tempering and final grinding;
in the grinding step, the rotation speed of the grinding wheel is n1, the rotation speed of the workpiece is n2, and in the final grinding, when the workpiece rotates for the second round, the ratio of the rotation speed n1 of the grinding wheel to the rotation speed n2 of the workpiece is infinite acyclic decimal, and the phase shift is phi =90 °.
2. The machining process of the wind power variable pitch output shaft forging piece according to claim 1, characterized in that: the heat treatment process comprises normalizing, annealing and quenching;
in the normalizing procedure, a spray cooling device is arranged for each forged piece to be cooled after forging.
3. The machining process of the wind power variable pitch output shaft forging piece according to claim 1, characterized in that: when the grinding wheel rotates at n1, a vibration displacement X = Asin (ω τ) occurs in the horizontal direction due to problems such as grinding wheel balance.
4. The machining process of the wind power variable pitch output shaft forging piece according to claim 2, characterized in that: the annealing temperature is ensured to be 780-800 ℃, the heat preservation time is not less than 4 hours, and then the product is naturally cooled.
5. The machining process of the wind power variable pitch output shaft forging piece according to claim 2, characterized in that: the quenching heating adopts a rotary hearth type protective atmosphere quenching furnace.
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