CN114535471A - Multi-roller flexible near-net composite rolling forming method for abrupt-profile thin-wall ring piece - Google Patents
Multi-roller flexible near-net composite rolling forming method for abrupt-profile thin-wall ring piece Download PDFInfo
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- 238000005096 rolling process Methods 0.000 title claims abstract description 148
- 238000000034 method Methods 0.000 title claims abstract description 33
- 239000002131 composite material Substances 0.000 title claims abstract description 19
- 238000007493 shaping process Methods 0.000 claims abstract description 64
- 238000004513 sizing Methods 0.000 claims abstract description 26
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- 239000002184 metal Substances 0.000 claims description 12
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
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Abstract
The invention discloses a multi-roller flexible near-net composite rolling forming method for a thin-wall ring with a sudden change profile, wherein the shape and the size of a ring blank are designed according to the principles of similar shape and equal volume; the method comprises the following steps that a rolling pass is formed by a driving roller, a core roller, an auxiliary roller and a shaping roller, the sizes and the shapes of working surfaces of the driving roller, the core roller, the auxiliary roller and the shaping roller are determined according to the sizes and the shapes of a forge piece and a ring blank, and the ring blank is limited from axially moving by outer flanges of the driving roller and the auxiliary roller; the method comprises the steps of limiting the increase of the outer diameter of a ring blank by a constraint ring rolling mode to promote the contour forming of the ring blank, carrying out reaming rolling until the outer diameter reaches a target size, shaping and sizing the ring blank by the constraint ring rolling mode to realize the near-net forming of the abrupt-change contour thin-wall ring piece, and flexibly regulating and controlling the movement of each roller according to the three-stage forming characteristics in the rolling process. The method realizes the high-precision, high-performance, high-efficiency and low-cost manufacture of the abrupt-change profile thin-wall ring piece.
Description
Technical Field
The invention belongs to the technical field of plastic processing, and particularly relates to a multi-roller flexible near-net composite rolling forming method for a sudden-change profile thin-wall ring piece.
Background
The abrupt contour thin-wall ring is commonly used for key core components of major equipment such as an aircraft engine casing, the outer surface of the annular component is generally provided with an upper and lower double-step abrupt structure, the middle of the annular component is an equal-diameter straight wall or a reducing non-straight wall structure, the annular component is made of a high-temperature alloy, a titanium alloy and other difficult-to-process materials, and the requirement on the mechanical property of the ring is high due to harsh service conditions, particularly the requirement on the severe environments such as high temperature, high pressure and the like of a combustion chamber casing, a turbine casing and the like.
The ring rolling technology is an advanced technology for manufacturing high-performance integral seamless rings, but the near-net forming of the abrupt-profile thin-wall rings by adopting the traditional ring rolling technology faces a plurality of difficulties, such as: (1) the thin-wall ring piece has low rigidity and poor stability, and the holding angle of the guide rollers is gradually reduced along with the increase of the outer diameter of the ring piece, so that the stability of the rolling process of the ring piece is difficult to maintain through a pair of guide rollers; (2) the metal flow resistance along the circumferential direction in the ring rolling process is small, the diameter expansion is easy to realize, and the metal flow resistance along the axial direction is large, so that the abrupt change step profile is difficult to form. At present, the forging shape is simplified, the forging wall thickness is increased, the blank making and rolling forming difficulty is reduced, and the rolling stability is improved, but more metal materials are cut off subsequently to form the forging, so that the integrity of a metal streamline is damaged, the material utilization rate is low, the processing efficiency is low, the manufacturing cost is high, and the mechanical property is weakened. Therefore, it is desirable to develop a method for near-net-shape forming of an abrupt contour thin-walled ring.
Disclosure of Invention
The invention aims to provide a multi-roller flexible near-net composite rolling forming method for a thin-wall ring with an abrupt change profile, which solves the problems that the rigidity of a thin-wall structure is low and stable forming is difficult in the ring rolling process, and the formability of the abrupt change profile is poor and accurate forming is difficult, and realizes the high-precision, high-performance, high-efficiency and low-cost manufacturing of the thin-wall ring with the abrupt change profile.
The technical scheme adopted by the invention is as follows:
a multi-roller flexible near-net composite rolling forming method for a sudden change profile thin-wall ring piece comprises the following steps:
s1, ring blank design: designing the shape and size of the ring blank according to the principles of similar shape and equal volume;
s2, roller design: the method comprises the following steps that a rolling pass is formed by a driving roller, a core roller, an auxiliary roller and a shaping roller, the sizes and the shapes of working surfaces of the driving roller, the core roller, the auxiliary roller and the shaping roller are determined according to the sizes and the shapes of a forge piece and a ring blank, and the ring blank is limited from axially moving by outer flanges of the driving roller and the auxiliary roller;
s3, rolling and forming: the method comprises the steps of limiting the increase of the outer diameter of a ring blank by a constraint ring rolling mode to promote the contour forming of the ring blank, carrying out reaming rolling until the outer diameter reaches a target size, shaping and sizing the ring blank by the constraint ring rolling mode to realize the near-net forming of the abrupt-change contour thin-wall ring piece, and flexibly regulating and controlling the movement of each roller according to the three-stage forming characteristics in the rolling process.
In step S1, the ring blank designing method includes the steps of:
s1.1 design the shape of the ring blank according to the principle of similarity of shape
The ring piece is provided with an upper asymmetric step, a lower asymmetric step, a cylindrical inner hole and a conical inner hole, a circular table top and an upper cylindrical surface and a lower cylindrical surface which have the same outer contour taper angle of the ring blank and the ring piece are designed according to the principle of similar shape, and the ring blank is in line contact with a roller during assembly so as to ensure the stability of the rolling process and prevent the ring blank from axially shifting;
s1.2 design ring blank size according to equal volume principle
Inner radius of upper end cylindrical surface of ring blank
Wherein K is the rolling ratio, the value of K is 1.20-3, r1The inner radius of the cylindrical surface at the upper end of the ring piece is the inner radius of the cylindrical surface at the upper end of the ring piece;
total height B of ring blank0B, height of upper end cylindrical surface of ring blank10＝B1+B2Conical angle theta of ring blank0θ; wherein B is the total height of the ring member, B1Is the step height of the upper end of the ring member, B2The height of the cylindrical surface at the upper end of the ring piece is theta, the conical angle of the conical surface of the ring piece is theta, and the inner radius r of the cylindrical surface at the lower end of the ring blank is r20＝r10+(B0-2B10)tanθ0；
Ring volume V:
wherein H1The depth of the step groove r at the upper end and the lower end of the ring piece2The inner radius of a cylindrical surface at the lower end of the ring piece is as follows: r is2＝r1+[B-2(B1+B2)]tanθ，R1And R2Respectively the outer radius of the bosses at the upper end and the lower end of the ring piece, and R2＝R1+[B-2(B1+B2)]tanθ；
Volume V of ring blank0：
Taking into account the thermal oxidation burning loss of the ring blank, i.e. V0(1+ ω) V, thereby determining the outer radius R of the cylindrical surface at the upper end of the ring blank10And R20Wherein R is20＝R10+(B0-2B10)tanθ0Omega is the burning loss coefficient, and the value of omega is 5 per mill.
In step S1, the ring blank is obtained by heating, upsetting, extruding, and punching the blanked bar.
In step S2, the roll designing method includes the steps of:
s2.1, designing a rolling pass into a semi-closed pass, wherein the rolling pass consists of a driving roller, a core roller and an auxiliary roller working surface in the contour forming and diameter expanding stages, the rolling pass consists of the driving roller, the core roller, an auxiliary roller and a shaping roller working surface in the shaping and sizing stages, the driving roller, the auxiliary roller and the shaping roller are all designed into I-shaped structures, the shapes of the working surfaces are consistent with the shape of the outer surface of the sudden-change contour ring piece, flanges are arranged at the upper end and the lower end of the auxiliary roller and the upper end and the lower end of the shaping roller, and are matched with the driving roller to respectively carry out axial constraint on two end surfaces of the ring blank so as to prevent the ring blank from moving up and down and ensure the stable rolling of the ring blank;
s2.2 drive roller conical angle thetadThe groove depth H of the upper and lower ends of the driving roller is equal to thetad＝H110-20 mm, height of driving roller BdB + (20-80) mm, and the height B of the cavities at the upper end and the lower end of the driving rollerd1＝B1Height B of cylindrical surfaces at upper and lower endsd2＝B2Height of flange Bdu(0.1-0.3) B, the length L of the flanges at the upper and lower ends of the drive rollerd＝Hd+(R1-r1-H1)；
Core roller cone angle thetamTheta, core roll working surface height Bm＝B，Bm1＝B10Circular table top L at upper and lower ends of core rollerm＝Ld-H1+ (10-30) mm to prevent the driving roller flange from interfering with the core roller;
taper angle theta of conical surface of auxiliary rollercTheta, the groove depth H of the upper and lower ends of the secondary rollc＝H110-20 mm, height of secondary roller Bc＝BdThe height B of the cavity at the upper end and the lower end of the auxiliary rollerc1＝B1Height B of cylindrical surfaces at upper and lower endsc2＝B2Length of flange of auxiliary roll Lc＝LdHeight B of flanges at both ends of the auxiliary rollc＝BduThe number of the auxiliary rollers is determined according to the size of the ring piece, and the larger the size of the ring piece is, the more auxiliary rollers can be arranged to increase the number of supporting points, so that the rolling stability is improved;
shaping roller cone angle thetapTheta, the groove depth H of the upper and lower ends of the sizing rollerp＝H1Height B of dressing rollp＝BdThe height B of the cavity at the upper end and the lower end of the shaping rollerp1＝B1Height B of cylindrical surfaces at upper and lower endsp2＝B2The length L of the flange of the sizing rollerp＝LdHeight B of flanges at two ends of shaping rollerp＝Bdu；
Wherein theta is the conical angle of the conical surface of the ring piece; r1Is the outer radius of the upper end of the ring member, B is the total height of the ring member, B1The step height of the upper and lower ends of the ring member, B2The height of the circular table top at the upper end and the lower end of the ring piece is B10The height of the cylindrical surfaces at the upper end and the lower end of the ring blank.
In step S3, when rolling forming is carried out, the driving roller rotates to drive the ring blank to rotate, the core roller carries out radial feed motion to reduce the wall thickness of the ring blank, the auxiliary roller is fixed in the early stage and the later stage of rolling and does follow-up motion along with the expansion of the outer diameter of the ring blank in the middle stage of rolling, and the shaping roller is fixed in the position all the time at the end of rolling and comprises the following steps:
s3.1 Profile shaping
Installing a rolling pass on a rolling device, and arranging a driving roller and a secondary roller at an equal angle theta1The circumference is enclosed at intervals, and the radius of the enclosed circumference is larger than the maximum outer radius R of the ring blank20Placing the ring blank in a circumference surrounded by the driving roller and the auxiliary roller, and adjusting the positions of the driving roller and the auxiliary roller to be circumscribed with the ring blank;
the abrupt change profile is formed by adopting a restrained ring rolling mode in the early stage of rolling, the core roller is fed at a medium speed, and the feeding speed v is1Biting the ring blank into the rolling pass when the ring blank is equal to (0.3-0.5) v; the plurality of fixed auxiliary rollers restrain the ring blank from growing in outer diameter to promote metal to flow axially to form a sudden change profile, the ring blank generates local deformation under the restraint of the plurality of rollers, the outer diameter of the ring blank is not changed, the wall thickness is reduced, the metal mainly flows axially to fill the roller cavity for profile forming until the profile of the outer surface of the ring blank is filled with the roller cavity of the driving roller; the contour forming stage can effectively avoid the phenomenon of ring blank plasticity instability caused by constraint rolling, and the formed mutation step length is greater than the target forging mutation step length;
s3.2 diameter enlargement
The common ring rolling mode is adopted in the middle stage of rolling to promote the diameter of the ring blank to be enlarged, the auxiliary rollers perform following movement along with the increase of the outer diameter of the ring blank to play a role in guiding, the number of supporting points is increased compared with that of a pair of guide rollers, so that the rolling stability of the ring blank is improved, the core rollers feed at a high speed, and the feeding speed v2And (0.6-1) v, performing broaching rolling until the outer diameter of the ring blank is increased to a target size, namelyThe step area is contacted with the shaping roller cavity; when the ring blank is subjected to reaming deformation in a rolling pass formed by the driving roller and the core roller, the wall thickness of the ring blank is reduced, the inner diameter and the outer diameter of the ring blank are increased, the radial length of the mutation step is gradually shortened, and the formed mutation step is close to the target forging step length when the diameter expansion stage is finished due to the longer length of the mutation step formed in the early stage of rolling;
s3.3 sizing
When the sudden change step area on the outer surface of the ring blank is gradually contacted with the shaping roller at a fixed position, the ring blank enters the later rolling stage, the shaping and sizing are carried out in a restraining ring rolling mode, the auxiliary roller stops moving and cooperates with the shaping roller to restrain the outer diameter of the ring blank, the core roller feeds at a low speed, and the feeding speed v3(0.05-0.1) v; the outer diameter of the ring blank is unchanged, the wall thickness is reduced a little, under the common constraint action of a plurality of rollers, local precise shaping is carried out on a sudden change step area with an irregular shape after the diameter expansion stage is stretched and contracted, and precise sizing is carried out on the radial dimension of the ring blank; after the boss area is shaped and the radial dimension is accurately sized, the whole rolling process is finished, the auxiliary roller and the shaping roller move backwards to increase the radius of the circumference, and the shaped ring piece is obtained;
wherein the core roller feed speed v is determined according to the following formula:
wherein n is the rotating speed of the driving roller, and the driving roller rotates at a low speed in order to ensure the rolling stability of the ring piece
Wherein the linear velocity v of the driving rollerd0.5 to 1 m/s; beta is the angle of friction, Rm1Radius of upper working surface of core roller, Rd1The radius of the cylindrical surface at the upper end of the driving roller and the radius R of the working surface at the lower end of the core rollerm2＝Rm1+[Bm-2(Bm1+Bm2)]tanθmRadius R of the lower end cylindrical surface of the driving rollerd2＝Rd1-[Bd-2(Bd1+Bd2+Bdu)]tanθd。
The invention has the beneficial effects that:
the invention solves the problems that the rigidity of the thin-wall structure is low and the stable forming is difficult in the ring rolling process, and the forming performance of the abrupt contour is poor and the accurate forming is difficult, and can realize the high-precision, high-performance, high-efficiency and low-cost manufacture of the abrupt contour thin-wall ring: the outer diameter of the ring piece is restrained to grow through the multiple rollers in the early stage of rolling, the axial flow forming of the metal is promoted to form a sudden change step profile, the ring blank in the stage is small in diameter, large in wall thickness and good in rigidity, the multiple auxiliary rollers participate in deformation, and the rolling stability can be greatly improved, so that the ring piece is prevented from being flattened and unstably; the outer diameter of the ring piece is enlarged through a common rolling ring in the middle rolling stage, the rolling stability is further improved through the follow-up guiding of a plurality of auxiliary rollers, although the sudden change step profile can be drawn and shrunk in the rolling process, the sudden change step formed in the early rolling stage is longer in length, and the loss of the length of the sudden change step can be compensated; and in the later rolling stage, the profile of the sudden change step after the drawing and the shrinking is precisely shaped and sized through the shaping roller, and because metal mainly flows in the region of the sudden change step profile in a short distance in the stage, and the stability is better under the supporting action of a plurality of auxiliary rollers, the flattening instability of the ring piece can be avoided.
Drawings
FIG. 1 is a schematic cross-sectional view of an abrupt contour thin-walled ring member in an embodiment of the present invention.
FIG. 2 is a schematic cross-sectional view of a conical ring blank in an embodiment of the present invention.
Fig. 3 is a schematic view of the configuration of the working surface of the drive roller in an embodiment of the present invention.
FIG. 4 is a schematic view of the configuration of the working surface of the core roll in the embodiment of the present invention.
FIG. 5 is a schematic view of the construction of the work surface of the secondary roll in an embodiment of the present invention.
FIG. 6 is a schematic illustration of the configuration of the work surface of the shaping roll in an embodiment of the present invention.
Fig. 7 is a schematic view of the profile shaping stages of a staged multi-roll constrained roll ring, with a front view of 6a and a side view of 6 b.
Fig. 8 is a schematic view of the diameter expansion stage of a staged multi-roll constrained roll ring, with a front view of 7a and a side view of 7 b.
Fig. 9 is a schematic illustration of the sizing stage of the staged multi-roll constrained ring, with 8a front view and 8b side view.
FIG. 10 is a graph showing the core roller feed in the embodiment of the present invention.
In the figure: 1-driving roller, 2-core roller, 3-auxiliary roller, 4-shaping roller and 5-ring blank.
Detailed Description
The invention is further described below with reference to the figures and examples.
Referring to fig. 1 to 10, the invention provides a multi-roller flexible near-net composite rolling forming method for a sudden-change profile thin-wall ring piece, which comprises the following steps:
s1 ring blank design
As shown in fig. 1, the shape of the ring blank is designed according to the principle of shape similarity, the abrupt-change profile thin-wall ring piece is provided with an upper asymmetric step and a lower asymmetric step, the ring piece is provided with a cylindrical inner hole and a conical inner hole, a circular table top and an upper cylindrical surface and a lower cylindrical surface which are equal in outer contour cone angle of the ring blank and the ring piece are designed according to the principle of shape similarity, and the ring blank is in line contact with a roller during assembly so as to ensure the stability of the rolling process and prevent axial movement;
as shown in figure 2, the size of the ring blank is designed according to the equal volume principle, and the inner radius of the upper end cylindrical surface of the ring blank
Wherein K is the rolling ratio, the value of K is 1.20-3, r1The inner radius of the cylindrical surface at the upper end of the ring piece is the inner radius of the cylindrical surface at the upper end of the ring piece;
total height B of ring blank0B, height of upper end cylindrical surface of ring blank10＝B1+B2Conical angle theta of ring blank0θ; wherein B is the total height of the ring member, B1Is the step height of the upper end of the ring member, B2The height of the cylindrical surface at the upper end of the ring piece is theta, the conical angle of the conical surface of the ring piece is theta, and the inner radius r of the cylindrical surface at the lower end of the ring blank is r20＝r10+(B0-2B10)tanθ0；
Ring volume V:
wherein H1The depth of the step groove r at the upper end and the lower end of the ring piece2The inner radius of a cylindrical surface at the lower end of the ring piece is as follows: r is2＝r1+[B-2(B1+B2)]tanθ，R1And R2Respectively the outer radius of the bosses at the upper end and the lower end of the ring piece, and R2＝R1+[B-2(B1+B2)]tanθ；
Volume V of ring blank0：
Taking into account the thermal oxidation burning loss of the ring blank, i.e. V0(1+ ω) V, thereby determining the outer radius R of the cylindrical surface at the upper end of the ring blank10And R20Wherein R is20＝R10+(B0-2B10)tanθ0Omega is the burning loss coefficient, and the value of omega is 5 per mill.
In the step S1, the ring blank is obtained by heating, upsetting, extruding, and punching a blanked bar material, where the bar material is Gcr 15.
S2 roll design
The rolling pass is formed by a driving roller, a core roller, a secondary roller and a shaping roller, and the shape and the size of the working surface of the driving roller, the core roller, the secondary roller and the shaping roller are determined according to the size of a forge piece and a ring blank.
The rolling pass is designed into a semi-closed pass, the rolling pass consists of a driving roller, a core roller and a working surface of an auxiliary roller in the contour forming and diameter expanding stage, and the rolling pass consists of a driving roller, a core roller, an auxiliary roller and a working surface of a shaping and sizing stage. The driving roller, the auxiliary roller and the shaping roller are all designed into I-shaped structures, the shape of the working surface is consistent with that of the outer surface of the abrupt-change-contour thin-wall ring piece, flanges are arranged at the upper end and the lower end of the auxiliary roller and the shaping roller, and are matched with the driving roller to axially restrain two end faces of the ring blank respectively so as to prevent the ring blank from moving up and down and ensure the stable rolling of the ring blank;
as shown in FIG. 3, the drive roller taper angle θdThe groove depth H of the upper and lower ends of the driving roller is equal to thetad＝H110-20 mm, height of driving roller BdB + (20-80) mm, and the height B of the cavities at the upper end and the lower end of the driving rollerd1＝B1Height B of cylindrical surfaces at upper and lower endsd2＝B2Height of flange Bdu(0.1-0.3) B, the length L of the flanges at the upper and lower ends of the drive rollerd＝Hd+(R1-r1-H1)；
As shown in FIG. 4, the core roller taper angle θmTheta, core roll working surface height Bm＝B，Bm1＝B10Circular table top L at upper and lower ends of core rollerm＝Ld-H1+(10～30)mm；
As shown in fig. 5, the taper angle θ of the sub rollcTheta, depth H of bosses at upper and lower ends of the secondary rollerc＝H110-20 mm, height of secondary roller Bc＝BdThe height B of the cavity at the upper end and the lower end of the auxiliary rollerc1＝B1Height B of cylindrical surfaces at upper and lower endsc2＝B2Length of flange of auxiliary roll Lc＝LdHeight B of flanges at both ends of the auxiliary rollc＝BduSetting 4 auxiliary rollers to participate in multi-roller flexible near-net composite rolling forming according to the size of the ring piece;
as shown in FIG. 6, the dressing roll taper angle θpTheta, the depth of the bosses at the upper and lower ends of the sizing rollerp＝H1Height B of dressing rollp＝BdThe height B of the cavity at the upper end and the lower end of the shaping rollerp1＝B1Height B of cylindrical surfaces at upper and lower endsp2＝B2The length L of the flange of the sizing rollerp＝LdHeight B of flanges at both ends of sizing rollp＝BduAccording to the size of the ring piece, 2 shaping rollers are arranged to participate in multi-roller flexible near-net composite rolling forming;
wherein theta is the taper angle of the inner conical surface and the outer conical surface of the ring piece; r1Is the outer radius of a boss at the upper end of the ring member, B is the total height of the ring member, B1The step height of the upper and lower ends of the ring member, B2The height of the circular table top at the upper end and the lower end of the ring piece is B10The height of the cylindrical surfaces at the upper end and the lower end of the ring blank.
S3 roll forming
As shown in fig. 7a to 9b, the profile forming and the diameter expansion of the abrupt-profile thin-wall ring are realized by adopting a multi-roller flexible near-net composite rolling forming method and through three-stage composite rolling of profile forming, diameter expansion and reshaping and sizing. The driving roller rotates to drive the ring blank to rotate in the rolling process, the core roller radially feeds to reduce the wall thickness of the ring blank, the position of the auxiliary roller is fixed in the early stage and the later stage of rolling, the shaping roller always keeps fixed in position after the ring piece is expanded in the middle stage of rolling.
As shown in FIG. 7, a rolling pass is installed in a rolling mill, and a drive roll and a counter roll are arranged at an equal angle θ1The circumference is enclosed at intervals, and the radius of the enclosed circumference is larger than the maximum outer radius R of the ring blank20And placing the ring blank in a circumference surrounded by the driving roller and the auxiliary roller, and adjusting the positions of the driving roller and the auxiliary roller to be circumscribed with the ring blank.
The abrupt change profile is formed by adopting a restrained ring rolling mode in the early stage of rolling, the core roller is fed at a medium speed, and the feeding speed v is1And (0.3-0.5) v, and enabling the ring blank to bite into the rolling pass. The outer diameter of the ring blank is restrained by the plurality of fixed auxiliary rollers to grow, so that metal flows axially to form a sudden change profile, the ring blank is locally deformed under the restraint of the plurality of rollers, the outer diameter of the ring blank is not changed, the wall thickness is reduced, the metal flows in the axial direction mainly to fill the roller cavity for profile forming until the outer surface profile of the ring blank is filled with the roller cavity of the driving roller, and the length of a sudden change step formed at the stage is larger than that of a target forged piece sudden change step;
as shown in figure 8, the diameter of the ring blank is expanded by adopting a common ring rolling mode in the middle rolling stage, a plurality of auxiliary rollers perform following movement along with the increase of the outer diameter of the ring blank to play a role in guiding, the core roller feeds at a high speed, and the feeding speed v is2And (0.6-1) v, performing broaching rolling until the outer diameter of the ring blank is increased to a step area and is contacted with a shaping roller. With ring blank formed between drive roller and core rollerWhen the broaching deformation is carried out in the rolling pass, the wall thickness of the ring blank is reduced, the inner diameter and the outer diameter are increased, the radial length of the mutation step can be gradually shortened, and the length of the mutation step formed in the early stage of rolling is longer, so that the length of the mutation step formed at the end of the stage is close to the length of the target ring step.
As shown in fig. 9, the shaping and sizing are carried out by adopting a restrained ring rolling mode in the later rolling stage, the auxiliary roller stops moving and cooperates with the shaping roller to restrain the outer diameter of the ring blank, the core roller feeds at a low speed, and the feeding speed v3(0.05-0.1) v. The outer diameter of the ring blank is unchanged, the wall thickness is reduced a little, a plurality of rollers are jointly constrained to carry out local precise shaping on a sudden change step area, and precise sizing is carried out on the radial size of the ring blank. And after the boss area is shaped and the radial size is accurately sized, finishing the whole rolling process, and moving the auxiliary roller and the shaping roller backwards to increase the enclosed circumferential radius to obtain the shaped ring piece.
Wherein the core roller feed speed v is determined according to the following formula:
wherein n is the rotating speed of the driving roller, and the driving roller rotates at a low speed in order to ensure the rolling stability of the ring piece
Wherein the linear velocity v of the drive rollerdGenerally 0.5 to 1 m/s; beta is the angle of friction, Rm1Radius of upper working surface of core roller, Rd1The radius of the cylindrical surface at the upper end of the driving roller and the radius R of the working surface at the lower end of the core rollerm2＝Rm1+[Bm-2(Bm1+Bm2)]tanθmRadius R of the cylindrical surface at the lower end of the driving rollerd2＝Rd1-[Bd-2(Bd1+Bd2+Bdu)]tanθd。
Examples
When the invention is applied specifically, taking a certain abrupt contour thin-wall ring piece in figure 1 as an example, the outer radius R of the step at the lower end of the ring piece is2500mm, radius r in the cylinder surface of the lower end of the ring piece2455mm, outer radius of step at upper end of ring1446.4mm, radius r in the upper end cylindrical surface of the ring piece1401.4mm, the total height B of the ring piece is 350mm, and the height B of the steps at the upper end and the lower end of the ring piece115mm, height of cylinder B260mm, the taper angle theta of the middle outer conical surface of the ring piece is 15 degrees, and the groove depth H of the steps at the upper end and the lower end of the ring piece is1＝30mm。
The multi-roller flexible near-net composite rolling forming method comprises the following steps:
(1) blank making
Designing a ring blank structure as shown in fig. 2, according to a ring blank size design method, determining the outer radius R of a boss at the upper end of a ring blank by taking the rolling ratio K as 2.676 and the burning loss coefficient omega as 5 ‰10191.2mm, radius r in the upper end cylindrical surface of the ring blank10150mm, radius r in the cylindrical surface at the lower end of the ring blank20203.6mm, and the outer radius R of a boss at the lower end of the ring blank20244.8mm, total ring blank height B0350mm, height B of cylindrical surfaces at the upper end and the lower end of the ring blank1075mm, the taper angle theta of the middle outer conical surface of the ring piece0＝15°；
Uniformly heating a bar section (made of Gcr15) from room temperature to the initial forging temperature of 1050-1100 ℃ according to the size of a ring blank, and then upsetting, reversely extruding and punching the hot bar section to forge the bar section into a ring blank for rolling;
(2) design of rolling pass
The driving roller has a structure as shown in FIG. 3, wherein the bosses at the upper and lower ends of the driving roller have a depth Hd45mm, working radius R of upper end of driving rollerd1240mm, convex surface taper angle thetad15 degrees, the height B of the cavity at the upper end and the lower end of the driving rollerd115mm, height of cylindrical surface Bd260mm, drive roll flange length Ld60mm, drive roller flange height BduTotal height B of drive roller of 40mmd＝430mm；
The core roller has a convex mesa taper angle theta as shown in FIG. 4m15 DEG total core roll height Bm430, height B of the upper and lower cylindrical surfacesm1＝75mm，Bm2Radius R of upper working surface of core roller of 40mmm1140mm, core roller upper and lower end flange height Lm＝40mm；
The auxiliary roll has a structure as shown in FIG. 5, wherein the depth of the upper and lower end bosses of the auxiliary roll is HC45mm, working radius R of upper end of bossC160mm, lug face taper angle thetaC15 degrees, the height B of the upper and lower end cavities of the auxiliary rollerc115mm, height of cylindrical surface Bc260mm, the length L of the flange of the auxiliary rollerC60mm, height B of flanges at two ends of the auxiliary rollercu40mm, total height B of auxiliary rollcAccording to the size of the ring piece, 4 auxiliary rollers are arranged to participate in multi-roller flexible near-net composite rolling forming;
the shaping roller has a structure as shown in FIG. 6, wherein the bosses at the upper and lower ends of the shaping roller have a depth HP30mm, the working radius R of the upper end of the bossP160mm, lug face taper angle thetaP15 degrees, the height B of the cavity at the upper end and the lower end of the shaping rollerP115mm, height of cylindrical surface Bp260mm, the length L of the flange of the sizing rollerP60mm, height B of flange at two ends of shaping rollerPuTotal height B of the dressing roll of 40mmpSetting 2 shaping rollers to participate in multi-roller flexible near-net composite rolling forming according to the size of the ring piece, wherein the diameter of the ring piece is 430 mm;
(3) roll forming
As shown in FIGS. 7a-9b, the rolling mill is provided with a rolling pass, and the drive roll and the secondary roll are arranged at equal angle of 72 degrees to form a rolling pass with a radius larger than R20The ring blank is placed in the circumference enclosed by the driving roller and the auxiliary roller, and the positions of the driving roller and the auxiliary roller are adjusted to be circumscribed with the ring blank.
In the early stage of rolling, a constraint ring rolling mode is adopted to form a sudden change profile, a driving roller rotates to drive a ring blank to rotate, a core roller feeds at a speed of 3mm/s at a medium speed in the stage to enable the ring blank to bite into a rolling pass, a secondary roller is fixed in the stage, the ring blank generates local deformation under the constraint of multiple rollers, the wall thickness of the ring blank is reduced, the outer diameter is unchanged in the stage, metal mainly flows in the axial direction to fill a roller cavity, and the profile forming is carried out until the profile of the outer surface of the ring blank is filled with the roller cavity;
the diameter of the ring blank is expanded by adopting a common ring rolling mode in the middle rolling stage, the auxiliary roller moves along with the expansion of the outer diameter of the ring blank in the process, the core roller feeds at a high speed of 6mm/s in the stage to perform the rolling in the reaming stage, and the ring blank is reamed and deformed in a rolling pass formed by the driving roller and the core roller until the outer diameter of the ring blank is increased to a step to be contacted with the shaping roller;
and (3) shaping and sizing are carried out in the later rolling stage by adopting a constraint ring rolling mode, the shaping roller is always fixed at the final rolling position, the core roller feeds at a low speed of 1mm/s, the position of the auxiliary roller is fixed and cooperates with the shaping roller to constrain the ring blank to carry out shaping and sizing rolling until the upper step and the lower step are full of the shaping roller cavity, finally, the core roller stops feeding, the whole rolling process is finished, the auxiliary roller and the shaping roller are controlled to move backwards to increase the radius of the enclosed circumference, and the shaped ring piece is taken out.
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 (5)
1. A multi-roller flexible near-net composite rolling forming method for a sudden change profile thin-wall ring piece is characterized by comprising the following steps of: comprises the steps of (a) carrying out,
s1, ring blank design: designing the shape and size of the ring blank according to the principles of similar shape and equal volume;
s2, roller design: the method comprises the following steps that a rolling pass is formed by a driving roller, a core roller, an auxiliary roller and a shaping roller, the sizes and the shapes of working surfaces of the driving roller, the core roller, the auxiliary roller and the shaping roller are determined according to the sizes and the shapes of a forge piece and a ring blank, and the ring blank is limited from axially moving by outer flanges of the driving roller and the auxiliary roller;
s3, rolling and forming: the method comprises the steps of limiting the increase of the outer diameter of a ring blank by a constraint ring rolling mode to promote the contour forming of the ring blank, carrying out reaming rolling until the outer diameter reaches a target size, shaping and sizing the ring blank by the constraint ring rolling mode to realize the near-net forming of the abrupt-change contour thin-wall ring piece, and flexibly regulating and controlling the movement of each roller according to the three-stage forming characteristics in the rolling process.
2. The multi-roller flexible near-net composite rolling forming method for the abrupt-profile thin-wall ring piece according to claim 1, wherein the method comprises the following steps: in step S1, when the ring blank design is performed, the method includes the steps of,
s1.1 design the shape of the ring blank according to the principle of similarity of shape
The ring piece is provided with an upper asymmetric step, a lower asymmetric step, a cylindrical inner hole and a conical inner hole, a circular table top and an upper cylindrical surface and a lower cylindrical surface which have the same outer contour taper angle of the ring blank and the ring piece are designed according to the principle of similar shape, and the ring blank is in line contact with a roller during assembly so as to ensure the stability of the rolling process and prevent the ring blank from axially shifting;
s1.2 design ring blank size according to equal volume principle
Inner radius of upper end cylindrical surface of ring blank
Wherein K is the rolling ratio, the value of K is 1.20-3, r1The inner radius of the cylindrical surface at the upper end of the ring piece is the inner radius of the cylindrical surface at the upper end of the ring piece;
total height B of ring blank0B, height of upper end cylindrical surface of ring blank10＝B1+B2Conical angle theta of ring blank0θ; wherein B is the total height of the ring member, B1Is the step height of the upper end of the ring member, B2The height of the cylindrical surface at the upper end of the ring piece is theta, the conical angle of the conical surface of the ring piece is theta, and the inner radius r of the cylindrical surface at the lower end of the ring blank is r20＝r10+(B0-2B10)tanθ0；
Ring volume V:
wherein H1The depth of the step groove r at the upper end and the lower end of the ring piece2The inner radius of a cylindrical surface at the lower end of the ring piece is as follows: r is2＝r1+[B-2(B1+B2)]tanθ，R1And R2Respectively outside the upper and lower end bosses of the ring pieceRadius, and R2＝R1+[B-2(B1+B2)]tanθ；
Volume V of ring blank0：
Taking into account the thermal oxidation burning loss of the ring blank, i.e. V0(1+ ω) V, thereby determining the outer radius R of the cylindrical surface at the upper end of the ring blank10And R20Wherein R is20＝R10+(B0-2B10)tanθ0Omega is the burning loss coefficient, and the value of omega is 5 per mill.
3. The multi-roller flexible near-net composite rolling forming method for the abrupt-profile thin-wall ring piece according to claim 1, wherein the method comprises the following steps: in step S1, the ring blank is obtained by heating, upsetting, extruding, and punching the blanked bar.
4. The multi-roller flexible near-net composite rolling forming method for the abrupt-profile thin-wall ring piece according to claim 1, wherein the method comprises the following steps: in step S2, when roll design is performed, the method includes the steps of,
s2.1, designing a rolling pass into a semi-closed pass, wherein the rolling pass at the contour forming and diameter expanding stage consists of a driving roller, a core roller and a working surface of an auxiliary roller, the rolling pass at the reshaping and sizing stage consists of the driving roller, the core roller, the auxiliary roller and the working surface of a reshaping roller, the driving roller, the auxiliary roller and the reshaping roller are all designed into an I-shaped structure, the shape of the working surface is consistent with that of the outer surface of the sudden-change contour ring piece, flanges are arranged at the upper end and the lower end of the auxiliary roller and the upper end and the lower end of the reshaping roller, and are matched with the driving roller to respectively carry out axial restraint on two end surfaces of the ring blank so as to prevent the ring blank from moving up and down and ensure the stable rolling of the ring blank;
s2.2 drive roller conical angle thetadThe groove depth H of the upper and lower ends of the driving roller is equal to thetad＝H110-20 mm, height of driving roller BdB + (20-80) mm, and the height B of the cavities at the upper end and the lower end of the driving rollerd1＝B1Upper and lower end cylindrical surfacesHeight Bd2＝B2Height of flange Bdu(0.1-0.3) B, the length L of the flanges at the upper and lower ends of the drive rollerd＝Hd+(R1-r1-H1)；
Core roller cone angle thetamTheta, core roll working surface height Bm＝B，Bm1＝B10Circular table top L at upper and lower ends of core rollerm＝Ld-H1+ (10-30) mm to prevent the driving roller flange from interfering with the core roller;
taper angle theta of conical surface of auxiliary rollercTheta, the groove depth H of the upper and lower ends of the secondary rollc＝H110-20 mm, height of secondary roller Bc＝BdThe height B of the cavity at the upper end and the lower end of the auxiliary rollerc1＝B1Height B of cylindrical surfaces at upper and lower endsc2＝B2Length of flange of auxiliary roll Lc＝LdHeight B of flanges at both ends of the auxiliary rollc＝BduThe number of the auxiliary rollers is determined according to the size of the ring piece, and the larger the size of the ring piece is, the more auxiliary rollers can be arranged to increase the number of supporting points, so that the rolling stability is improved;
conical angle theta of shaping rollerpTheta, the groove depth H of the upper and lower ends of the sizing rollerp＝H1Height B of dressing rollp＝BdThe height B of the cavity at the upper end and the lower end of the shaping rollerp1＝B1Height B of cylindrical surfaces at upper and lower endsp2＝B2The length L of the flange of the sizing rollerp＝LdHeight B of flanges at two ends of shaping rollerp＝Bdu；
Wherein theta is the conical angle of the conical surface of the ring piece; r1Is the outer radius of the upper end of the ring member, B is the total height of the ring member, B1The step height of the upper and lower ends of the ring member, B2The height of the circular table top at the upper end and the lower end of the ring piece is B10The height of the cylindrical surfaces at the upper end and the lower end of the ring blank.
5. The multi-roller flexible near-net composite rolling forming method for the abrupt-profile thin-wall ring piece according to claim 1, wherein the method comprises the following steps: in step S3, during rolling, the driving roller rotates to drive the ring blank to rotate, the core roller feeds radially to reduce the wall thickness of the ring blank, the auxiliary roller is fixed in the early and late stages of rolling and follows the outer diameter of the ring blank during the middle stage of rolling, the shaping roller is fixed in the final stage of rolling,
s3.1 Profile shaping
Installing a rolling pass on a rolling device, and arranging a driving roller and a secondary roller at an equal angle theta1The circumference is enclosed at intervals, and the radius of the enclosed circumference is larger than the maximum outer radius R of the ring blank20Placing the ring blank in a circumference surrounded by the driving roller and the auxiliary roller, and adjusting the positions of the driving roller and the auxiliary roller to be circumscribed with the ring blank;
the abrupt change profile is formed by adopting a restrained ring rolling mode in the early stage of rolling, the core roller is fed at a medium speed, and the feeding speed v is1Biting the ring blank into the rolling pass when the ring blank is equal to (0.3-0.5) v; the plurality of fixed auxiliary rollers restrain the ring blank from growing in outer diameter to promote metal to flow axially to form an abrupt contour, the ring blank generates local deformation under the restraint of the plurality of rollers, the outer diameter of the ring blank is not changed, the wall thickness is reduced, the metal mainly flows axially to fill a roller cavity for contour forming until the contour of the outer surface of the ring blank is filled with the roller cavity of the driving roller; the phenomenon of ring blank plasticity instability caused by constraint rolling can be effectively avoided in the profile forming stage, and the formed mutation step length is greater than that of the target forge piece;
s3.2 diameter enlargement
The diameter of the ring blank is expanded by adopting a common ring rolling mode in the middle rolling period, the auxiliary rollers perform following motion along with the increase of the outer diameter of the ring blank to play a role in guiding, the number of supporting points is increased compared with that of a pair of guide rollers, so that the rolling stability of the ring blank is improved, the core rollers feed at a high speed, and the feeding speed v2Carrying out reaming rolling until the outer diameter of the ring blank is increased to a target size, namely, the step area is in contact with the shaping roller cavity; when the ring blank is subjected to reaming deformation in a rolling pass formed by the driving roller and the core roller, the wall thickness of the ring blank is reduced, the inner diameter and the outer diameter of the ring blank are increased, the radial length of the mutation step is gradually shortened, and the formed mutation step is close to the target forging step length when the diameter expansion stage is finished due to the longer length of the mutation step formed in the early stage of rolling;
s3.3 sizing
When the sudden change step area on the outer surface of the ring blank is gradually contacted with the shaping roller at a fixed position, the ring blank enters the later rolling stage, the shaping and sizing are carried out in a restraining ring rolling mode, the auxiliary roller stops moving and cooperates with the shaping roller to restrain the outer diameter of the ring blank, the core roller feeds at a low speed, and the feeding speed v3(0.05-0.1) v; the outer diameter of the ring blank is unchanged, the wall thickness is reduced a little, under the common constraint action of a plurality of rollers, local precise shaping is carried out on a sudden change step area with an irregular shape after the diameter expansion stage is stretched and contracted, and precise sizing is carried out on the radial dimension of the ring blank; after the boss area is shaped and the radial dimension is accurately sized, the whole rolling process is finished, the auxiliary roller and the shaping roller move backwards to increase the radius of the circumference, and the shaped ring piece is obtained;
wherein the core roller feed speed v is determined according to the following formula:
wherein n is the rotating speed of the driving roller, and the driving roller rotates at a low speed in order to ensure the rolling stability of the ring piece
Wherein the linear velocity v of the driving rollerd0.5 to 1 m/s; beta is the angle of friction, Rm1Radius of upper working surface of core roller, Rd1The radius of the cylindrical surface at the upper end of the driving roller and the radius R of the working surface at the lower end of the core rollerm2＝Rm1+[Bm-2(Bm1+Bm2)]tanθmRadius R of the cylindrical surface at the lower end of the driving rollerd2＝Rd1-[Bd-2(Bd1+Bd2+Bdu)]tanθd。
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| CN111318630A (en) * | 2020-03-18 | 2020-06-23 | 武汉理工大学 | Near-net composite rolling forming method for inner ring of tapered roller bearing |
| CN113941676A (en) * | 2021-09-29 | 2022-01-18 | 武汉理工大学 | Multi-roller constrained flexible step-by-step rolling near-net forming method for inner contour catastrophe ring piece |
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|---|---|---|---|---|
| CN102601278A (en) * | 2012-03-20 | 2012-07-25 | 武汉理工大学 | Method for radially and axially rolling and forming large-sized double-edge stepped ring parts |
| CN105964841A (en) * | 2016-05-12 | 2016-09-28 | 武汉理工大学 | Combined feeding precise rolling forming method for chute section ring part |
| CN111318630A (en) * | 2020-03-18 | 2020-06-23 | 武汉理工大学 | Near-net composite rolling forming method for inner ring of tapered roller bearing |
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