CN113941675A - Near-net rolling forming method for large-sized abrupt-change cross-section ring piece - Google Patents
Near-net rolling forming method for large-sized abrupt-change cross-section ring piece Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
- B21H1/00—Making articles shaped as bodies of revolution
- B21H1/06—Making articles shaped as bodies of revolution rings of restricted axial length
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Abstract
The invention discloses a near-net rolling forming method of a large-scale abrupt-change cross-section ring piece, which comprises the following steps of 1) forge piece shape characteristic segmentation: the large-scale sudden-change cross-section ring forging is axially divided into a plurality of special-shaped dividing pieces with typical shape characteristics according to the cross-section shape characteristics; 2) designing a special-shaped ring blank: firstly, respectively designing each sub-ring blank for each partition piece, then combining the obtained sub-ring blanks to obtain the initial size of the whole ring blank, and then correcting the initial size of the whole ring blank to determine the reasonable near-net rolled ring blank size; 3) near net rolling forming: the rolling working surface is formed by the working surfaces of the driving roller and the core roller, the filling of the ring blank abrupt change profile section and the expansion of the inner diameter and the outer diameter are realized by the continuous occlusion of the driving roller and the core roller, and finally the large-scale abrupt change section ring forging is obtained. The method is suitable for processing large-scale ring pieces with abrupt cross sections, realizes the rolling near-net forming of the ring pieces with low cost, high efficiency and high quality, and further improves the comprehensive mechanical property and service life of products.
Description
Technical Field
The invention belongs to the field of plastic forming, and particularly relates to a near-net rolling forming method for a large-sized abrupt-change cross-section ring piece.
Background
The large-scale ring piece with the abrupt change cross section is a key mechanical part, is widely applied to the industrial fields of aerospace, nuclear energy, special carrying equipment and the like, and has high requirements on comprehensive performance. The cross section of the member is extremely complex in shape, the inner surface and the outer surface of the member are both provided with a plurality of shape characteristics of sudden change steps, the radial size of the member is usually more than 1 meter, and the filling difficulty is extremely high.
The rolling of rings is an incremental advanced manufacturing technology, and is a technological method for producing high-quality seamless rings by continuously and plastically deforming blanks. However, for a large ring with an abrupt cross section, the inner surface and the outer surface of the ring have a plurality of abrupt steps, the abrupt steps of the member cannot be formed by a traditional rectangular ring blank, the rolling stability of the traditional rectangular ring blank is poor, and the poor phenomena of eccentricity of the ring, incapability of ensuring the roundness of the ring and the like easily occur during rolling.
At present, the existing method for designing the ring blank of the special-shaped ring piece is mainly based on the fact that the axial volume distribution is equal, the shape of the ring blank is similar to that of a forged piece, and the like, and the designed shape of the ring blank is basically similar to that of the ring piece, so that the ring blank is too complex, and the blank manufacturing difficulty is increased.
Disclosure of Invention
The invention aims to provide a near-net rolling forming method for large-sized ring parts with abrupt cross sections, which is suitable for processing the large-sized ring parts with abrupt cross sections, realizes the near-net rolling forming of the ring parts with low cost, high efficiency and high quality, and further improves the comprehensive mechanical properties and service life of products.
The scheme adopted by the invention is as follows:
a near-net rolling forming method for a large abrupt-section ring piece comprises the following steps: 1) segmenting the shape and characteristics of the forged piece: the large-scale sudden-change cross-section ring forging is axially divided into a plurality of special-shaped dividing pieces with typical shape characteristics according to the cross-section shape characteristics; 2) designing a special-shaped ring blank: firstly, respectively designing each sub-ring blank for each partition piece, then combining the obtained sub-ring blanks to obtain the initial size of the whole ring blank, and then correcting the initial size of the whole ring blank to determine the reasonable near-net rolled ring blank size; 3) near net rolling forming: the rolling working surface is formed by the working surfaces of the driving roller and the core roller, the filling of the ring blank abrupt change profile section and the expansion of the inner diameter and the outer diameter are realized by the continuous occlusion of the driving roller and the core roller, and finally the large-scale abrupt change section ring forging is obtained.
Further, when each sub-ring blank is designed for each partition piece, the inner diameter, the height and the outer diameter of the sub-ring blank corresponding to each partition piece are determined according to the principle that the equivalent rolling ratio, the rolling contact stability, the volume before and after rolling and the height are kept unchanged, the designed sub-ring blank can be formed into the corresponding partition piece, if the designed sub-ring blank cannot be formed into the corresponding partition piece, redesign is needed, and on the premise of ensuring forming, the shape of each sub-ring blank is as simple as possible, so that the blank manufacturing difficulty is reduced.
Further, when the initial size of the integral ring blank is corrected, the size and the height of the integral ring blank are kept unchanged before and after correction, the size and the height of each sub-ring blank are also kept unchanged before and after correction, small-range and small-amplitude correction is carried out on the initial size, size correction is carried out in the sub-ring blank corresponding to each partition piece, the inclined moment formed between two rollers can be reduced after correction is ensured based on the principle of stable contact between the ring blank and each roller, and the forming quality can be improved and the blank making difficulty can be reduced after correction is ensured based on the deformation behavior of metal in the rolling process.
Further, when near-net rolling forming is carried out, the core roller is fed at a low speed in an initial stage to meet the ring blank biting hole pattern condition, then the core roller is fed at a high speed to promote the inner and outer profiles to be gradually filled, the inner diameter and the outer diameter of the ring piece are gradually enlarged, and finally the core roller is fed at a low speed in a full circle stage to ensure that the wall thickness of the ring piece is gradually uniform and the abrupt change profile is gradually filled.
Furthermore, a deep groove is formed near the upper end of the outer side face of the large-scale sudden-change cross-section ring forging, an outer step is arranged at the lower end of the outer side face, an inner step which is expanded in a three-level step-by-step mode is arranged on the inner side face from top to bottom, and the ring groove is located in the range of the first-level inner step and the second-level inner step.
Further, when the shape characteristics of the forged piece are divided:
dividing the large ring forging with the abrupt change section into a first dividing piece and a second dividing piece by taking the interface A-A of the second and third inner steps as a dividing plane, wherein the volume sum of the divided dividing pieces is equal to the volume of the ring forging, and the height sum of the divided dividing pieces is equal to the height of the ring forging, namely,
wherein V, B is the volume and height of the ring forging respectively, V1、V2Volume of the first and second parts, respectively, B1、B2The heights of the first dividing piece and the second dividing piece are respectively;
the volume V and the height B of the ring forging are calculated according to the following formula,
B＝Bfi1+Bfi2+Bfi3＝Bfo1+Bfo2+Bf03+Bfo4
wherein D isf1、Df2、Df3Respectively the outer diameters of the outer steps at the upper end, the deep groove and the lower end of the outer side surface of the ring forging, df1、df2、df3Respectively the inner diameters of three-stage inner steps from top to bottom on the inner side surface of the ring forging, Bfo1、Bfo2、Bfo3、Bfo4The heights of four layers from top to bottom on the outer side surface of the ring forging respectively, Bfi1、Bfi2、Bfi3The heights of the three-stage inner steps of the inner side surface of the ring forging from top to bottom are respectively.
Further, when the initial size of the whole ring blank is obtained by respectively designing each sub-ring blank for each partition piece:
the volumes of the sub-ring blanks corresponding to the first partition piece and the second partition piece are calculated according to the following formula,
wherein, V01、V02The volumes of the sub-ring blanks corresponding to the first partition piece and the second partition piece respectively;
the heights of the sub-ring blanks corresponding to the first partition piece and the second partition piece are calculated according to the following formula,
wherein, B01、B02The heights of the sub-ring blanks corresponding to the first dividing part and the second dividing part respectively;
volume V of a sub-ring blank corresponding to a segment01And a height B01The following calculation is carried out,
B01＝Bfi1+Bfi2
the inner diameter and the outer diameter of the sub-ring blank corresponding to the first partition piece are calculated according to the following formula,
wherein K is the equivalent rolling ratio and is 1.2-2.5, d01、D01The inner diameter and the outer diameter of the sub-ring blank are respectively corresponding to the first dividing piece;
volume V of sub-ring blank corresponding to the second partition piece02And a height B02The following calculation is carried out,
B02＝Bfi3
according to d02-d01＝df3-df2The inner diameter of the sub-ring blank corresponding to the second partition piece is calculated according to the following formula,
d02＝df3-df2+d01
the outer diameters and the heights of the large ring and the small ring of the sub-ring blank corresponding to the second dividing piece are calculated according to the following formula,
wherein D is02And D03Respectively the outer diameters of the small ring and the large ring of the sub-ring blank corresponding to the second divided piece B03And B04The heights of the small ring and the large ring of the sub-ring blank corresponding to the second dividing piece are respectively;
and obtaining the initial size of the whole ring blank according to the sizes of the sub ring blanks corresponding to the first dividing part and the second dividing part.
Further, when determining a reasonable near net rolled ring billet size:
according to the principle that the volume and the height of the whole ring blank are kept unchanged before and after correction, the volume and the height of the nearly net rolled ring blank are calculated according to the following formula,
wherein, V0And B0Respectively the volume and the height of the near-net rolled ring blank;
when the initial size of the integral ring blank is corrected, the volume V is subtracted from the large ring of the sub-ring blank corresponding to the second partition piecemSo as to increase it to the volume V of the small ring of the two corresponding sub-ring blanks of the segmentnThe above step (1);
volume V according to corresponding geometric and dimensional relationshipsnThe calculation of (a) is as follows,
volume VmIs calculated as follows:
according to the principle of volume equality, i.e. Vm＝VnThe outer diameter D can be determinedf03The calculation method is as follows,
further, when the near net roll forming is performed:
the total rolling feed quantity DeltaH is calculated according to the following formula,
wherein D is01The outer diameter of a sub ring blank corresponding to a cutting piece is the outer diameter of the thick wall part of the ring blank which is nearly completely rolled;
the rolling feed speed v is determined as follows,
wherein R ismaxTo drive the roller to a maximum radius, n1To drive the roller speed, R2Is the radius of the second step on the core roll, beta is the contact friction angle, vminMinimum feed speed of core roller, vmaxThe maximum feed speed of the core roll.
The invention has the beneficial effects that:
the method can effectively reduce the difficulty in designing and manufacturing the ring blank of the large-scale ring piece with the sudden change cross section, and greatly improve the production efficiency of the large-scale ring piece with the sudden change cross section; the method ensures reasonable volume distribution of the ring blank in the divided area, further ensures more accurate forming of the ring section profile, enables a forming member to obtain complete metal streamline distribution, can effectively improve the filling effect of the sudden change step of the ring, greatly improves the mechanical property and the service life of the product, has higher quality and more stable whole forming process; the method can greatly reduce the post machining and improve the utilization rate of raw materials; the method is suitable for processing large-scale ring pieces with abrupt cross sections, realizes the rolling near-net forming of the ring pieces with low cost, high efficiency and high quality, and further improves the comprehensive mechanical property and service life of products.
Drawings
FIG. 1 is a schematic diagram of a large abrupt cross-section ring forging in the embodiment of the invention.
FIG. 2 is a schematic view of an exemplary divider in an embodiment of the present invention; (a) a first dividing part and a second dividing part.
FIG. 3 is a schematic view of a corresponding sub-ring blank of a divider in an embodiment of the present invention; (a) a first sub-ring blank corresponding to the dividing piece, and (b) a second sub-ring blank corresponding to the dividing piece.
FIG. 4 is a schematic diagram of the initial size of the ring blank of the large-scale abrupt-section ring forging in the embodiment of the invention.
FIG. 5 is a schematic diagram of size correction of a ring blank of a large-scale ring forging with an abrupt cross section in the embodiment of the invention.
FIG. 6 is a final dimension schematic diagram of a ring blank of a large abrupt cross-section ring forging in the embodiment of the invention.
FIG. 7 is a schematic design flow diagram of a ring blank of a large ring with an abrupt cross section in an embodiment of the invention.
Fig. 8 is a schematic view of near-net roll forming (initial stage) of a large abrupt cross-section ring in an embodiment of the present invention.
Fig. 9 is a schematic view of near-net roll forming (end stage) of a large abrupt cross-section ring in an embodiment of the present invention.
FIG. 10 is a schematic diagram of a core roll feeding speed curve of a large abrupt cross-section ring in an embodiment of the invention.
In the figure: 1-a drive roller; 2-rolling the ring blank nearly cleanly; 3-core roller; 4-ring forging with abrupt change section.
Detailed Description
The invention is further described below with reference to the figures and examples.
A near-net rolling forming method for a large-sized abrupt-section ring part is shown in figures 7 to 10 and comprises the following steps:
1) segmenting the shape and characteristics of the forged piece: the large-scale sudden-change cross-section ring forging 4 is axially divided into a plurality of special-shaped dividing pieces with typical shape characteristics according to the cross-section shape characteristics;
when each sub-ring blank is designed for each partition piece, the inner diameter, the height and the outer diameter of the sub-ring blank corresponding to each partition piece are determined according to the principle that the equivalent rolling ratio, the rolling contact stability, the volume before and after rolling and the height are kept unchanged, the designed sub-ring blank can be formed into the corresponding partition piece, if the designed sub-ring blank cannot be formed into the corresponding partition piece, redesign is needed, and on the premise of ensuring forming, the shape of each sub-ring blank is as simple as possible, so that the blank manufacturing difficulty is reduced.
2) Designing a special-shaped ring blank: firstly, respectively designing each sub-ring blank for each partition piece, then combining the obtained sub-ring blanks to obtain the initial size of the whole ring blank, and then correcting the initial size of the whole ring blank to determine the size of a reasonable near-net rolled ring blank 2;
when the initial size of the integral ring blank is corrected, the size and the height of the integral ring blank are kept unchanged before and after correction, the size and the height of each sub-ring blank are also kept unchanged before and after correction, small-range and small-amplitude correction is carried out on the initial size, size correction is carried out in the sub-ring blank corresponding to each partition piece, the tilting moment formed between two rollers can be reduced after correction is ensured based on the stable contact principle between the ring blank and each roller, and the forming quality can be improved and the blank making difficulty can be reduced after correction is ensured based on the deformation behavior of metal in the rolling process.
3) Near net rolling forming: the working surfaces of a driving roller 1 and a core roller 3 form a rolling working surface, the driving roller 1 drives the core roller 3 to continuously engage with the core roller 3, the filling of the ring blank abrupt change profile section and the expansion of the inner diameter and the outer diameter are realized, and finally, a large-scale abrupt change section ring forging 4 is obtained;
when the near-net rolling forming is carried out, the core roller 3 is fed at a low speed in the initial stage to meet the ring blank biting hole pattern condition, then the core roller 3 is fed at a high speed to promote the inner and outer profiles to be gradually filled, the inner diameter and the outer diameter of the ring piece are gradually enlarged, and finally the core roller 3 is fed at a low speed in the full circle stage to ensure that the wall thickness of the ring piece is gradually uniform and the abrupt change profile is gradually filled.
As shown in fig. 1, in this embodiment, a deep groove is provided near the upper end of the outer side surface of the large abrupt-section ring forging 4, an outer step is provided at the lower end of the outer side surface, an inner step that is expanded in three stages is provided on the inner side surface from top to bottom, and the ring groove is located within the range of the first and second inner steps.
When the shape feature of the forging is divided, as shown in fig. 1 and 2:
dividing the large-scale ring forging 4 with the abrupt cross section into a first dividing piece and a second dividing piece by taking the interface A-A of the second and third-stage inner steps as a dividing plane, wherein the sum of the volumes of the dividing pieces is equal to the volume of the ring forging, and the sum of the heights of the dividing pieces is equal to the height of the ring forging, namely,
wherein V, B is the volume and height of the ring forging respectively, V1、V2Volume of the first and second parts, respectively, B1、B2The heights of the first dividing piece and the second dividing piece are respectively;
the volume V and the height B of the ring forging are calculated according to the following formula,
B＝Bfi1+Bfi2+Bfi3＝Bfo1+Bfo2+Bf03+Bfo4
wherein D isf1、Df2、Df3Respectively the outer diameters of the outer steps at the upper end, the deep groove and the lower end of the outer side surface of the ring forging, df1、df2、df3Respectively the inner diameters of three-stage inner steps from top to bottom on the inner side surface of the ring forging, Bfo1、Bfo2、Bfo3、Bfo4The heights of four layers from top to bottom on the outer side surface of the ring forging respectively, Bfi1、Bfi2、Bfi3The heights of the three-stage inner steps of the inner side surface of the ring forging from top to bottom are respectively.
When the initial size of the whole ring blank is obtained by designing each sub ring blank for each partition piece, as shown in fig. 3 and 4:
the volumes of the sub-ring blanks corresponding to the first partition piece and the second partition piece are calculated according to the following formula,
wherein, V01、V02The volumes of the sub-ring blanks corresponding to the first partition piece and the second partition piece respectively;
the heights of the sub-ring blanks corresponding to the first partition piece and the second partition piece are calculated according to the following formula,
wherein, B01、B02The heights of the sub-ring blanks corresponding to the first dividing part and the second dividing part respectively;
volume V of a sub-ring blank corresponding to a segment01And a height B01The following calculation is carried out,
B01＝Bfi1+Bfi2
the inner diameter and the outer diameter of the sub-ring blank corresponding to the first partition piece are calculated according to the following formula,
wherein K is the equivalent rolling ratio and is 1.2-2.5, d01、D01The inner diameter and the outer diameter of the sub-ring blank are respectively corresponding to the first dividing piece;
volume V of sub-ring blank corresponding to the second partition piece02And a height B02The following calculation is carried out,
B02＝Bfi3
according to d02-d01＝df3-df2The inner diameter of the sub-ring blank corresponding to the second partition piece is calculated according to the following formula,
d02＝df3-df2+d01
the outer diameters and the heights of the large ring and the small ring of the sub-ring blank corresponding to the second dividing piece are calculated according to the following formula,
wherein D is02And D03Respectively the outer diameters of the small ring and the large ring of the sub-ring blank corresponding to the second divided piece B03And B04The heights of the small ring and the large ring of the sub-ring blank corresponding to the second dividing piece are respectively;
and obtaining the initial size of the whole ring blank according to the sizes of the sub ring blanks corresponding to the first dividing part and the second dividing part.
When a reasonable near net rolled ring blank 2 size is determined, as shown in fig. 5 and 6:
according to the principle that the volume and the height of the whole ring blank are kept unchanged before and after correction, the volume and the height of the nearly net rolled ring blank are calculated according to the following formula,
wherein, V0And B0The volume and the height of the near-net rolled ring blank 2 are respectively;
when the initial size of the integral ring blank is corrected, the volume V is subtracted from the large ring of the sub-ring blank corresponding to the second partition piecemSo as to increase it to the volume V of the small ring of the two corresponding sub-ring blanks of the segmentnThe above step (1);
according to the corresponding geometrical and dimensional relationships,volume VnThe calculation of (a) is as follows,
volume VmIs calculated as follows:
according to the principle of volume equality, i.e. Vm＝VnThe outer diameter D can be determinedf03The calculation method is as follows,
when the near-net rolling forming is performed, as shown in fig. 8 to 10:
the total rolling feed quantity DeltaH is calculated according to the following formula,
wherein D is01The outer diameter of a sub ring blank corresponding to a cutting piece is the outer diameter of the thick wall part of the ring blank 2 which is nearly rolled completely;
the rolling feed speed v is determined as follows,
wherein R ismaxTo drive the roller 1 to the maximum radius, n1To drive the roller 1 at speed, R2Is the radius of the second step on the core roll 3, beta is the contact friction angle, vminMinimum feed speed v of the core roller 3maxThe maximum feed speed of the core roller 3.
Examples
As shown in fig. 1, the dimensions of the abrupt cross-section ring forging 4 required to be obtained are as follows: df1＝4280mm，Df2＝4230mm，Df3＝4390mm，df1＝3905mm，df2＝3960mm，df3＝4080mm，Bi1＝230mm，Bi2＝340mm，Bi3＝430mm，Bo1＝175mm，Bo2＝215mm，Bo3＝450mm，Bo4＝160mm。
When the shape characteristics of the forged piece are segmented: as shown in fig. 2, the section a-a is taken as a dividing plane, the large-scale ring forging 4 with the abrupt cross section is divided along the axial direction according to the characteristics of the cross section shape, and is divided into a first dividing part and a second dividing part, and the size of the first dividing part after division is Df1＝4280mm，Df2＝4130mm，df1＝3905mm，df2＝3960mm，Bi1＝230mm，Bi2＝340mm，Bo1＝175mm，Bo2215 mm. The size of the second partition is Df1＝4280mm，Df3＝4390mm，df3＝4080mm，Bi3＝430mm，Bo4＝160mm。
Designing a special-shaped ring blank 3: calculating the size of a sub-ring blank corresponding to the partition piece as D01＝2520mm，d01＝2000，B01570mm, as shown in fig. 3 (a); calculating the size of the sub-ring blank corresponding to the second partition piece as D02＝2480mm，D03＝2670mm，d02＝2120mm，B02＝430mm，B04160mm as shown in fig. 3 (b); according to the geometric dimensions of the two sub-ring blanks, the initial geometric dimension D of the ring blank of the ring forging can be obtained01＝2520mm，D02＝2480mm，D03＝2670mm，d01＝2000mm，d02＝2120mm，B01＝570mm，B02＝430mm，B04160mm, as shown in fig. 4; in the initial size of the ring blank, the size correction is performed in the sub-ring blank corresponding to each division piece, specifically, as shown in fig. 5, the volume V is subtracted from the large ring of the sub-ring blank corresponding to the division piece twomAdding the volume V to the small ring volume V of the corresponding sub-ring blank of the second partitionnThe above step (1); the final dimensions of the ring blank 3 after correction are shown in fig. 6, the dimensions of the ring blank after correction being Df01＝2520mm，Df03＝2610mm，d01＝2000mm，d02＝2120mm，B01＝570mm，B02＝430mm，B04＝160mm。
And (3) rolling and forming the large sudden-change section ring forging 4 in a near-net mode: as shown in fig. 8 and 9, in the initial stage, the core roll 3 is fed at a low speed to satisfy the ring blank bite pass condition; then, the core roller 3 is fed at a high speed to promote the inner and outer contours to be gradually filled, and the inner diameter and the outer diameter of the ring piece are gradually enlarged; and entering a rounding stage, feeding the core roller 3 at a low speed, so that the wall thickness of the ring piece becomes uniform gradually, and the abrupt contour is filled gradually. The feeding speed of the core roll 3 in the near net roll forming process was fed as shown in fig. 10, the total feeding amount was 175mm, the feeding speed in the initial stage of rolling was 2mm/s, the feeding speed in the main rolling stage was 4mm/s, and the feeding speed in the round finishing stage was 1 mm/s.
The method can effectively reduce the difficulty in designing and manufacturing the ring blank of the large-scale ring piece with the sudden change cross section, and greatly improve the production efficiency of the large-scale ring piece with the sudden change cross section 4; the method ensures reasonable volume distribution of the ring blank in the divided area, further ensures more accurate forming of the ring section profile, enables a forming member to obtain complete metal streamline distribution, can effectively improve the filling effect of the sudden change step of the ring, greatly improves the mechanical property and the service life of the product, has higher quality and more stable whole forming process; the method can greatly reduce the post machining and improve the utilization rate of raw materials; the method is suitable for processing the large-sized ring piece 4 with the abrupt cross section, realizes the rolling near-net forming of the ring piece with low cost, high efficiency and high quality, and further improves the comprehensive mechanical property and service life of the product.
It will be understood that modifications and variations can be made by persons skilled in the art in light of the above teachings and all such modifications and variations are intended to be included within the scope of the invention as defined in the appended claims.
Claims (9)
1. A near-net rolling forming method for large-sized abrupt-change cross-section ring pieces is characterized by comprising the following steps of: the method comprises the following steps of 1) segmentation of the shape characteristics of the forged piece: the large-scale sudden-change cross-section ring forging is axially divided into a plurality of special-shaped dividing pieces with typical shape characteristics according to the cross-section shape characteristics; 2) designing a special-shaped ring blank: firstly, respectively designing each sub-ring blank for each partition piece, then combining the obtained sub-ring blanks to obtain the initial size of the whole ring blank, and then correcting the initial size of the whole ring blank to determine the reasonable near-net rolled ring blank size; 3) near net rolling forming: the rolling working surface is formed by the working surfaces of the driving roller and the core roller, the filling of the ring blank abrupt change profile section and the expansion of the inner diameter and the outer diameter are realized by the continuous occlusion of the driving roller and the core roller, and finally the large-scale abrupt change section ring forging is obtained.
2. The near-net roll forming method of the large-sized abrupt-section ring member according to claim 1, wherein: when each sub-ring blank is designed for each partition piece, the inner diameter, the height and the outer diameter of the sub-ring blank corresponding to each partition piece are determined according to the principle that the equivalent rolling ratio, the rolling contact stability, the volume before and after rolling and the height are kept unchanged, the designed sub-ring blank can be formed into the corresponding partition piece, if the designed sub-ring blank cannot be formed into the corresponding partition piece, redesign is needed, and on the premise of ensuring forming, the shape of each sub-ring blank is as simple as possible, so that the blank manufacturing difficulty is reduced.
3. The near-net roll forming method of the large-sized abrupt-section ring member according to claim 1, wherein: when the initial size of the integral ring blank is corrected, the size and the height of the integral ring blank are kept unchanged before and after correction, the size and the height of each sub-ring blank are also kept unchanged before and after correction, small-range and small-amplitude correction is carried out on the initial size, size correction is carried out in the sub-ring blank corresponding to each partition piece, the tilting moment formed between two rollers can be reduced after correction is ensured based on the stable contact principle between the ring blank and each roller, and the forming quality can be improved and the blank making difficulty can be reduced after correction is ensured based on the deformation behavior of metal in the rolling process.
4. The near-net roll forming method of the large-sized abrupt-section ring member according to claim 1, wherein: when the near-net rolling forming is carried out, the core roller is fed at a low speed in the initial stage to meet the ring blank biting hole pattern condition, then the core roller is fed at a high speed to promote the inner and outer profiles to be gradually filled, the inner and outer diameters of the ring piece are gradually enlarged, and finally the core roller is fed at a low speed in the full circle stage to ensure that the wall thickness of the ring piece is gradually uniform and the abrupt change profile is gradually filled.
5. The near-net roll forming method of the large-scale abrupt-section ring forging as claimed in any one of claims 1 to 4, wherein: the outer side surface of the large-sized abrupt-change cross-section ring piece is provided with a deep groove near the upper end, the lower end of the outer side surface is provided with an outer step, the inner side surface is provided with three-stage inner steps which are gradually enlarged from top to bottom, and the ring groove is positioned in the range of the first and second inner steps.
6. The near-net roll forming method of the large-sized abrupt-section ring piece according to claim 5, wherein: when the shape characteristics of the forged piece are segmented:
dividing the large ring forging with the abrupt change section into a first dividing piece and a second dividing piece by taking the interface A-A of the second and third inner steps as a dividing plane, wherein the volume sum of the divided dividing pieces is equal to the volume of the ring forging, and the height sum of the divided dividing pieces is equal to the height of the ring forging, namely,
wherein V, B is the volume and height of the ring forging respectively, V1、V2Volume of the first and second parts, respectively, B1、B2The heights of the first dividing piece and the second dividing piece are respectively;
the volume V and the height B of the ring forging are calculated according to the following formula,
B＝Bfi1+Bfi2+Bfi3＝Bfo1+Bfo2+Bf03+Bfo4
wherein D isf1、Df2、Df3Respectively the outer diameters of the outer steps at the upper end, the deep groove and the lower end of the outer side surface of the ring forging, df1、df2、df3Respectively the inner diameters of three-stage inner steps from top to bottom on the inner side surface of the ring forging, Bfo1、Bfo2、Bfo3、Bfo4The heights of four layers from top to bottom on the outer side surface of the ring forging respectively, Bfi1、Bfi2、Bfi3The heights of the three-stage inner steps of the inner side surface of the ring forging from top to bottom are respectively.
7. The near-net roll forming method of the large-sized abrupt-section ring member according to claim 6, wherein: when each sub-ring blank is designed aiming at each partition piece so as to obtain the initial size of the whole ring blank:
the volumes of the sub-ring blanks corresponding to the first partition piece and the second partition piece are calculated according to the following formula,
wherein, V01、V02The volumes of the sub-ring blanks corresponding to the first partition piece and the second partition piece respectively;
the heights of the sub-ring blanks corresponding to the first partition piece and the second partition piece are calculated according to the following formula,
wherein, B01、B02The heights of the sub-ring blanks corresponding to the first dividing part and the second dividing part respectively;
volume V of a sub-ring blank corresponding to a segment01And a height B01The following calculation is carried out,
B01＝Bfi1+Bfi2
the inner diameter and the outer diameter of the sub-ring blank corresponding to the first partition piece are calculated according to the following formula,
wherein K is the equivalent rolling ratio and is 1.2-2.5, d01、D01The inner diameter and the outer diameter of the sub-ring blank are respectively corresponding to the first dividing piece;
volume V of sub-ring blank corresponding to the second partition piece02And a height B02The following calculation is carried out,
B02＝Bfi3
according to d02-d01＝df3-df2The inner diameter of the sub-ring blank corresponding to the second partition piece is calculated according to the following formula,
d02＝df3-df2+d01
the outer diameters and the heights of the large ring and the small ring of the sub-ring blank corresponding to the second dividing piece are calculated according to the following formula,
wherein D is02And D03Respectively the outer diameters of the small ring and the large ring of the sub-ring blank corresponding to the second divided piece B03And B04The heights of the small ring and the large ring of the sub-ring blank corresponding to the second dividing piece are respectively;
and obtaining the initial size of the whole ring blank according to the sizes of the sub ring blanks corresponding to the first dividing part and the second dividing part.
8. The near-net roll forming method of the large-sized abrupt-section ring member according to claim 7, wherein: when determining the reasonable near net rolling ring blank size:
according to the principle that the volume and the height of the whole ring blank are kept unchanged before and after correction, the volume and the height of the nearly net rolled ring blank are calculated according to the following formula,
wherein, V0And B0Respectively the volume and the height of the near-net rolled ring blank;
when the initial size of the integral ring blank is corrected, the volume V is subtracted from the large ring of the sub-ring blank corresponding to the second partition piecemSo as to increase it to the volume V of the small ring of the two corresponding sub-ring blanks of the segmentnThe above step (1);
volume V according to corresponding geometric and dimensional relationshipsnThe calculation of (a) is as follows,
volume VmIs calculated as follows:
according to the principle of volume equality, i.e. Vm＝VnThe outer diameter D can be determinedf03The calculation method is as follows,
9. the near-net roll forming method of the large-sized abrupt-section ring member according to claim 8, wherein: when the near net rolling forming is carried out:
the total rolling feed quantity DeltaH is calculated according to the following formula,
wherein D is01The outer diameter of a sub ring blank corresponding to a cutting piece is the outer diameter of the thick wall part of the ring blank which is nearly completely rolled;
the rolling feed speed v is determined as follows,
wherein R ismaxTo drive the roller to a maximum radius, n1To drive the roller speed, R2Is the radius of the second step on the core roll, beta is the contact friction angle, vminMinimum feed speed of core roller, vmaxThe maximum feed speed of the core roll.
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| CN114535472A (en) * | 2022-01-29 | 2022-05-27 | 武汉理工大学 | Method for forming large-sized outer contour rapid-change ring by rolling through multi-roller radial-axial cooperation near net |
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