CN114367792A - Machining method for main bearing retainer of super-huge type tunneling machine - Google Patents
Machining method for main bearing retainer of super-huge type tunneling machine Download PDFInfo
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- CN114367792A CN114367792A CN202210088001.0A CN202210088001A CN114367792A CN 114367792 A CN114367792 A CN 114367792A CN 202210088001 A CN202210088001 A CN 202210088001A CN 114367792 A CN114367792 A CN 114367792A
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Abstract
The invention provides a method for processing a main bearing retainer of an extra-large type tunneling machine, which comprises the following steps: step S1: casting a blank casting of the retainer: smelting an electrolytic copper plate, a nickel plate and a copper alloy, and then carrying out solid solution treatment on the smelted copper water; performing continuous casting drawing forming on the semi-solid and semi-liquid state after the solution treatment, and performing straightening forming on a straightening track; after aging treatment, cutting the continuous casting drawn long plate into small sections according to the size requirement of the retainer to obtain a multi-section blank casting; step S2: and (4) carrying out rough milling, aging stress removal and finish milling on the blank casting in sequence to finish the processing of the single-section blank casting. The blank casting cast by adopting the casting process of smelting and continuous casting and drawing has obvious effects on mechanical performance and the qualification rate of the blank casting, the problem that the retainer taking bronze as a main material is difficult to form from a casting blank to a machining machine is solved, the surface quality of the machined retainer is good, the machining precision is high, and the machining requirement of the super-large retainer is met.
Description
Technical Field
The invention relates to the technical field of main bearings of heading machines, in particular to a method for machining a retainer of a main bearing of an extra-large heading machine.
Background
The tunnel boring machine construction is a main method for constructing urban subway tunnels, river-crossing highway tunnels, river-crossing water or gas pipelines in China, a main drive bearing serving as one of the core components of the tunnel boring machine provides torque for the rotation of a cutter head and simultaneously bears all thrust of a propulsion system, the main bearing of the tunnel boring machine mainly comprises an inner bearing ring, an outer bearing ring, three rows of rolling bodies and a retainer, wherein the retainer enables the rolling bodies to be uniformly distributed in the whole bearing so as to optimize load distribution and reduce friction heating.
At present, the traditional bearing retainer can be divided into a metal retainer, a nonmetal retainer, a composite material retainer and the like according to materials. The metal retainer mainly comprises a steel retainer and a nonferrous metal retainer, and the nonmetal retainer mainly comprises nylon, phenolic aldehyde rubberized fabric, polytetrafluoroethylene and the like. The manufacturing method can be divided into a die-casting retainer and a plastic casting method to manufacture the retainer according to the processing and manufacturing method, but a large-scale die is needed when the retainer is die-cast, the service life of the formed retainer is lower when the formed retainer bears the conditions of impact, vibration and variable speed, and the application field of the plastic casting retainer is greatly limited due to the defects of thermal deformation, aging, brittle fracture and the like of the plastic. The retainer is generally of a segmented fan-shaped or integral structure, the split design mainly considers the machinability, and the integral design is beneficial to improving the performances of friction, running, bearing and the like.
The size of the main bearing of the super-huge type tunneling machine is generally between phi 3m and phi 7m, and as the retainer has rigid index requirements on mechanical properties such as tensile strength, yield strength, elongation, Brinell hardness, impact energy and the like, the traditional bearing retainer production and processing method is not suitable for processing the main bearing retainer of the super-huge type tunneling machine, and mainly has the technical problems that: 1. the all-copper retainer of the main bearing of the super-huge type tunneling machine is large in size, large in processing difficulty and large in finished product deformation by adopting an integral forming type processing method; 2. the main component of the raw material of the all-copper retainer of the main bearing of the super-huge type heading machine is bronze, the traditional copper plate adopts a die casting process, and a blank cast by the process has poor internal structure performance and has the defects of air holes, cracks and the like. Therefore, due to the particularity of raw materials and the high requirement on product performance, the extra-large type heading machine all-copper retainer has great difficulty from the initial blank casting to the machining addition.
In conclusion, a method for processing a main bearing retainer of an extra-large type heading machine is urgently needed to solve the problems in the prior art.
Disclosure of Invention
The invention aims to provide a method for processing a main bearing retainer of an extra-large type tunneling machine, which aims to solve the processing problem of the main bearing retainer of the extra-large type tunneling machine, and the specific technical scheme is as follows:
a processing method of a main bearing retainer of an oversize tunneling machine comprises the following steps:
step S1: casting a blank casting of the retainer: smelting an electrolytic copper plate, a nickel plate and a copper alloy, and then carrying out solid solution treatment on the smelted copper water; performing continuous casting drawing forming on the semi-solid and semi-liquid state after the solution treatment, and performing straightening forming on a straightening track; after aging treatment, cutting the continuous casting drawn long plate into small sections according to the size requirement of the retainer to obtain a multi-section blank casting;
step S2: and (4) carrying out rough milling, aging stress removal and finish milling on the blank casting in sequence to finish the processing of the single-section blank casting.
The machining method for the main bearing retainer of the extra-large type heading machine according to claim 1, wherein in the step S1: the smelting temperature is 1200-1250 ℃; when the temperature is cooled to 800-900 ℃, continuous casting and drawing forming are carried out; the aging treatment is 24-48 hours.
Preferably, in the above technical solution, the step S2 is specifically as follows:
step S2.1: clamping and fixing: horizontally placing the blank casting on a workbench and fixing the blank casting by using a clamping tool;
step S2.2: processing a front positioning hole: forming a positioning threaded hole in the allowance position of the front landing leg of the blank casting by using a screw tap;
step S2.3: processing a back positioning hole: turning over the blank casting, clamping the blank casting, and fixing by using the positioning threaded hole processed in the step S2.2; milling the back leg part of the blank casting by using a face milling cutter, and forming a positioning threaded hole in the allowance position of the back leg part of the blank casting by using a screw tap;
step S2.4: and (3) rough milling of the reverse side: milling the allowance around the supporting leg on the back side by using an end mill, milling the allowance on the end face of the back side of the blank casting by using a face mill, milling a pocket by using the end mill, milling the pocket incompletely, and milling the side face on the periphery of the blank casting by using the end mill;
step S2.5: and (3) front rough milling: turning over the blank casting, clamping the blank casting, and fixing by using the positioning threaded hole processed in the step S2.3; milling the allowance around the front supporting leg by using an end mill, milling the front end face of the blank casting by using a face mill, and after the allowance of the front end face is milled, opening the pocket until rough milling is finished;
step S2.6: aging and stress relief: after the rough milling is finished, placing the blank casting at a dry and ventilated position for aging stress relief;
step S2.7: finish milling of the front and the back sides: finish milling the allowance of the end face, the periphery of the supporting leg, the inner wall of the pocket and the peripheral side face;
step S2.8: removing burrs and chamfering edges and corners;
step S2.9: and processing a threaded hole at the connecting block along the radial direction, so that the single-section blank casting is processed, and obtaining a single-section retainer monomer.
Preferably, in the above technical solution, the pocket in the step S2.4 has a margin with a thickness of 7-9 mm.
Preferably, in the above technical solution, the aging stress removal is performed for at least 7 days in the step S2.6.
Preferably, in the step S2.7, the blank casting is fixed by a clamping tool during finish milling.
Preferably, in the above technical solution, the positioning threaded holes processed in step S2.2 and step S2.3 are milled away during the finish milling in step S2.7.
Preferably, in the above technical solution, the step S2.8 specifically includes: and removing burrs of all sharp corners by using a burr cutter, performing R2 chamfering on edges and corners of the pocket, the supporting leg and the guide block by using a chamfer cutter, and performing R1 chamfering on the rest edges and corners.
Preferably, in the above technical solution, the threaded hole is used for connection between adjacent single cage bodies.
The technical scheme of the invention has the following beneficial effects:
the blank casting cast by adopting the casting process of smelting and continuous casting drawing has obvious effects on mechanical property and the qualification rate of the blank casting, solves the problem that the retainer taking bronze as a main material is difficult to form from a casting blank to a machine, is beneficial to refining metal grains by adopting the continuous casting drawing process, improves the comprehensive performance of products, and is a saving type processing technology and can obtain high precision and high surface quality; the retainer processed by the processing method provided by the invention has the advantages of good surface quality and high processing precision, improves the wear resistance and the service life of the retainer, and meets the processing requirement of an extra-large retainer.
Locating threaded holes are formed in the front face and the back face of the blank casting, and the blank casting is matched with a clamping tool, so that the blank casting is more stable and cannot generate displacement in the machining process, the machining precision is guaranteed, the locating threaded holes are milled in the finish milling process, and the whole finished product is not affected. Because the removal rate of the blank reaches 75%, the aging stress removal is carried out after the rough milling is finished, and the processing precision of the product can be ensured.
Compared with the common segmented retainer which is not mutually connected in the later assembly process, the segmented retainer has the advantages that the connecting blocks are arranged at the two ends of the retainer body, the threaded holes are formed in the connecting blocks, and the retainer monomers in each segment are mutually connected through bolts in the subsequent assembly process, so that the friction and the collision among the retainer monomers can be effectively avoided.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a front view of a cage;
FIG. 2 is a side view of the cage;
the cage comprises a cage body 1, a cage body 2, a guide block 3, a pocket 4, a support leg 5 and a connecting block.
Detailed Description
In order that the invention may be more fully understood, a more particular description of the invention will now be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
Example 1:
the embodiment provides a method for processing a main bearing retainer of an oversize tunneling machine, in particular to a method for processing a main bearing retainer of a tunneling machine with the diameter between phi 3m and phi 7 m.
Referring to fig. 1 and 2, the retainer in this embodiment is formed by connecting a plurality of segments of retainer units end to end, each retainer unit includes a retainer body 1, guide blocks 2, pockets 3, support legs 4 and a connecting block 5, the guide blocks 2 are disposed on the inner diameter side and the outer diameter side of the retainer body 1, the retainer body 1 is provided with a plurality of pockets 3, the pockets penetrate through the thickness direction of the retainer body, the support legs 4 are disposed on both end faces of the retainer body 1, the connecting blocks 5 are disposed on both ends of the retainer body 1 in the length direction, the connecting blocks 5 and the end portions of the retainer body 1 form an L shape, and the connecting blocks 5 are used for connecting adjacent retainer units.
In this embodiment, a continuous casting and drawing casting method is adopted to form a blank, and then a machining process is adopted to obtain a single cage body, where the machining method specifically includes the following steps:
step S1: casting a blank casting of the retainer: adding an electrolytic copper plate, a nickel plate and a copper alloy (namely bronze alloy) into an induction furnace for smelting at the smelting temperature of 1200-1250 ℃, then pouring the smelted copper water into a continuous casting and drawing cooling furnace for solid solution treatment, cooling to the temperature of 800-900 ℃, carrying out continuous casting and drawing forming on the semi-solid and semi-liquid state after the solid solution treatment, and carrying out straightening forming on a straightening track; after 24-48 hours of aging treatment, cutting the continuous casting drawn long plate into small sections according to the size requirement of the retainer to obtain a multi-section blank casting;
the blank casting cast by adopting the casting process of smelting and continuous casting and drawing has obvious effects on the mechanical property and the qualification rate of the blank casting, and the all-copper retainer adopting bronze as a main raw material has high wear resistance and long service life; the skilled person knows that the continuous casting and drawing process has higher requirements for controlling the melting temperature, the cooling water temperature and the like, so that the process has higher difficulty, the selection of parameters of melting, continuous casting and drawing and aging treatment in the step S1 is very important, and the numerical values in the embodiment are not selected according to a plurality of test results, so that the copper plate drawn by continuous casting and drawing has the defects of air holes, cracks, insufficient mechanical properties and the like. For the composition of the electrolytic copper plate, the nickel plate and the copper alloy, reference is made to the prior art (see the composition of the existing all-copper retainer).
Step S2: and (4) carrying out rough milling, aging stress removal and finish milling on the blank casting in sequence to finish the processing of the single-section blank casting.
Preferably, the step S2 is specifically as follows:
step S2.1: clamping and fixing: horizontally placing the blank casting on a workbench of a numerical control machine tool, fixing the blank casting by using a clamping tool, and ensuring that the length direction of the blank casting is in the same direction with the X-axis direction of the workbench during clamping;
step S2.2: processing a front positioning hole: forming a positioning threaded hole in the allowance position of the front landing leg of the blank casting by using a screw tap;
step S2.3: processing a back positioning hole: turning over the blank casting, clamping the blank casting, and fixing by using the positioning threaded hole processed in the step S2.2; milling the back leg part of the blank casting by using a face milling cutter, and forming a positioning threaded hole in the allowance position of the back leg part of the blank casting by using a screw tap;
step S2.4: and (3) rough milling of the reverse side: milling the allowance around the supporting leg on the back side by using an end mill, milling the allowance on the end face of the back side of the blank casting by using a face mill, milling a pocket by using the end mill, wherein the pocket is not completely milled, the allowance with the thickness of 7-9mm is reserved in the pocket, and milling the peripheral side face of the blank casting (the peripheral side face refers to the peripheral side face of the retainer body and the connecting block) by using the end mill;
step S2.5: and (3) front rough milling: turning over the blank casting, clamping the blank casting, and fixing by using the positioning threaded hole processed in the step S2.3; milling the allowance around the front supporting leg by using an end mill, milling the front end face of the blank casting by using a face mill, and after the allowance of the front end face is milled, opening the pocket until rough milling is finished;
step S2.6: aging and stress relief: after the rough milling is finished, placing the blank casting at a dry and ventilated position for aging stress relief for at least 7 days, and avoiding the deformation of the single retainer;
step S2.7: finish milling of the front and the back sides: finish milling the allowance of two end surfaces, the peripheries of all supporting legs, the inner walls of all pockets and the peripheral side surfaces; in the finish milling process, the complete finish milling is realized by turning over the blank casting, and in the step S2.7, the blank casting is fixed by a clamping tool during finish milling; and the positioning threaded holes machined in the step S2.2 and the step S2.3 are milled in the step S2.7 of finish milling. After the rough milling is finished, the retainer monomer is basically formed, and the finish milling only needs to remove a small amount of allowance, so that the requirement of the surface roughness of the retainer monomer is met.
Step S2.8: deburring to carry out the chamfer to the edges and corners, specifically be: and removing burrs of all sharp corners by using a burr cutter, performing R2 chamfering on edges and corners of the pocket, the supporting leg and the guide block by using a chamfer cutter, and performing R1 chamfering on the rest edges and corners.
Step S2.9: and processing a threaded hole at the connecting block along the radial direction, so that the single-section blank casting is processed, and obtaining a single-section retainer monomer. Preferably, the threaded holes are used for connecting adjacent single retainer bodies, and the adjacent single retainer bodies are fixed through bolts, so that mutual friction and collision between the single retainer bodies can be effectively avoided.
In this embodiment, it is preferable that the diameter of the positioning threaded hole is 10mm, and the depth is 20 mm. According to the processing method, the removal amount of the blank casting is large during rough milling, and the clamping tool is matched with the positioning threaded hole for fixing, so that the blank casting is stably fixed in the rough milling process; the removal amount during finish milling is small, the fine milling fixture can be used for fixing, and meanwhile, the positioning threaded holes can be milled, so that the quality of finished products of subsequent retainer monomers is not affected.
The length of the blank casting in the embodiment is 1800mm, the width of the blank casting is 150mm, the mechanical properties of the retainer such as tensile strength, yield strength, elongation, Brinell hardness and impact energy have hard index requirements, and the problems of cracks, shrinkage cavities and the like can not be met by the traditional copper plate casting process. The blank casting cast by the smelting and continuous casting and drawing casting process has obvious effects on mechanical performance and the qualification rate of the blank casting, and the retainer processed by the processing method of the embodiment has good surface quality and high processing precision, improves the wear resistance of the retainer and prolongs the service life of the retainer.
The front and back surfaces of the single retainer body are the same, the front and back surfaces in the embodiment are only used for distinguishing the processing sequence, the structure of the single retainer body is not affected, and the processing method is not limited.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
1. A processing method of a main bearing retainer of an oversize tunneling machine is characterized by comprising the following steps:
step S1: casting a blank casting of the retainer: smelting an electrolytic copper plate, a nickel plate and a copper alloy, and then carrying out solid solution treatment on the smelted copper water; performing continuous casting drawing forming on the semi-solid and semi-liquid state after the solution treatment, and performing straightening forming on a straightening track; after aging treatment, cutting the continuous casting drawn long plate into small sections according to the size requirement of the retainer to obtain a multi-section blank casting;
step S2: and (4) carrying out rough milling, aging stress removal and finish milling on the blank casting in sequence to finish the processing of the single-section blank casting.
2. The machining method for the main bearing retainer of the extra-large type heading machine according to claim 1, wherein in the step S1: the smelting temperature is 1200-1250 ℃; when the temperature is cooled to 800-900 ℃, continuous casting and drawing forming are carried out; the aging treatment is 24-48 hours.
3. The machining method for the main bearing retainer of the extra-large type heading machine according to claim 2, wherein the step S2 is as follows:
step S2.1: clamping and fixing: horizontally placing the blank casting on a workbench and fixing the blank casting by using a clamping tool;
step S2.2: processing a front positioning hole: forming a positioning threaded hole in the allowance position of the front landing leg of the blank casting by using a screw tap;
step S2.3: processing a back positioning hole: turning over the blank casting, clamping the blank casting, and fixing by using the positioning threaded hole processed in the step S2.2; milling the back leg part of the blank casting by using a face milling cutter, and forming a positioning threaded hole in the allowance position of the back leg part of the blank casting by using a screw tap;
step S2.4: and (3) rough milling of the reverse side: milling the allowance around the supporting leg on the back side by using an end mill, milling the allowance on the end face of the back side of the blank casting by using a face mill, milling a pocket by using the end mill, milling the pocket incompletely, and milling the side face on the periphery of the blank casting by using the end mill;
step S2.5: and (3) front rough milling: turning over the blank casting, clamping the blank casting, and fixing by using the positioning threaded hole processed in the step S2.3; milling the allowance around the front supporting leg by using an end mill, milling the front end face of the blank casting by using a face mill, and after the allowance of the front end face is milled, opening the pocket until rough milling is finished;
step S2.6: aging and stress relief: after the rough milling is finished, placing the blank casting at a dry and ventilated position for aging stress relief;
step S2.7: finish milling of the front and the back sides: finish milling the allowance of the end face, the periphery of the supporting leg, the inner wall of the pocket and the peripheral side face;
step S2.8: removing burrs and chamfering edges and corners;
step S2.9: and processing a threaded hole at the connecting block along the radial direction, so that the single-section blank casting is processed, and obtaining a single-section retainer monomer.
4. The machining method for the main bearing cage of the extra-large type heading machine according to claim 3, wherein the allowance of 7-9mm thickness is reserved in the pocket in the step S2.4.
5. The method for machining the main bearing cage of the extra-large excavator according to claim 3, wherein the aging stress relief is performed for at least 7 days in the step S2.6.
6. The machining method for the main bearing retainer of the extra-large excavator according to claim 3, wherein in the step S2.7, the blank casting is fixed through a clamping tool during finish milling.
7. The machining method for the main bearing retainer of the extra-large excavator according to claim 6, wherein the positioning threaded holes machined in the step S2.2 and the step S2.3 are milled in the step S2.7 of finish milling.
8. The machining method for the main bearing retainer of the extra-large type heading machine according to claim 3, wherein the step S2.8 is specifically as follows: and removing burrs of all sharp corners by using a burr cutter, performing R2 chamfering on edges and corners of the pocket, the supporting leg and the guide block by using a chamfer cutter, and performing R1 chamfering on the rest edges and corners.
9. The machining method of the main bearing retainer of the extra-large type heading machine according to claim 3, wherein the threaded holes are used for connecting adjacent retainer units.
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| CN106239068A (en) * | 2016-08-31 | 2016-12-21 | 中航工业哈尔滨轴承有限公司 | A kind of processing technique of ball bearing solid cage |
| CN107790975A (en) * | 2017-11-16 | 2018-03-13 | 西安方元明科技股份有限公司 | A kind of bay section and its processing method |
| CN108161368A (en) * | 2018-01-26 | 2018-06-15 | 洛阳富海合精工机械有限公司 | A kind of processing method of integral type shield arbor bearing retainer |
| CN111482775A (en) * | 2020-05-09 | 2020-08-04 | 中国航发哈尔滨轴承有限公司 | Method for machining metal solid cage with special-shaped pocket holes |
| CN112548509A (en) * | 2020-12-08 | 2021-03-26 | 大连瑞谷科技有限公司 | Ball cage pocket hole machining process |
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