CN114789259A - Tapered roller machining method for tapered roller bearing of high-power wind driven generator - Google Patents
Tapered roller machining method for tapered roller bearing of high-power wind driven generator Download PDFInfo
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- CN114789259A CN114789259A CN202210647904.8A CN202210647904A CN114789259A CN 114789259 A CN114789259 A CN 114789259A CN 202210647904 A CN202210647904 A CN 202210647904A CN 114789259 A CN114789259 A CN 114789259A
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- 238000000034 method Methods 0.000 title claims abstract description 47
- 238000003754 machining Methods 0.000 title description 9
- 238000003672 processing method Methods 0.000 claims abstract description 14
- 238000010438 heat treatment Methods 0.000 claims abstract description 12
- 238000005242 forging Methods 0.000 claims abstract description 6
- 239000002994 raw material Substances 0.000 claims abstract description 5
- 230000009191 jumping Effects 0.000 abstract description 8
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- 230000008602 contraction Effects 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B5/00—Turning-machines or devices specially adapted for particular work; Accessories specially adapted therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B25/00—Accessories or auxiliary equipment for turning-machines
- B23B25/06—Measuring, gauging, or adjusting equipment on turning-machines for setting-on, feeding, controlling, or monitoring the cutting tools or work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B31/00—Chucks; Expansion mandrels; Adaptations thereof for remote control
- B23B31/02—Chucks
- B23B31/10—Chucks characterised by the retaining or gripping devices or their immediate operating means
- B23B31/103—Retention by pivotal elements, e.g. catches, pawls
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Abstract
The invention provides a tapered roller processing method of a tapered roller bearing of a high-power wind driven generator, which comprises the steps that a tapered roller is blanked from a raw material and sequentially subjected to forging, rough turning, fine turning, heat treatment, hard turning and ultra-precision grinding; in the fine turning process, inwards recessed recesses are machined in the center positions of two end parts of the tapered roller, and a tip hole is machined in the center position of the root of the recess at one end of the spherical base surface; the invention replaces the rough grinding and accurate grinding procedures of the prior tapered roller after heat treatment with the turning processing mode, namely, a high-precision numerical control lathe is adopted to clamp and position the roller once, the outer diameter surface and the end part ball base surface of the roller are turned in the positioning state, after the roller is processed, the jumping quantity of the ball base surface to the outer diameter surface can reach 0.002mm, the precision requirement of the I-grade roller is met, the processing precision of the roller is improved, and the processing method can shorten the whole processing time of the roller and improve the production efficiency.
Description
Technical Field
The invention belongs to the technical field of tapered roller processing methods for wind driven generators, and particularly relates to a tapered roller processing method for a tapered roller bearing of a high-power wind driven generator.
Background
The tapered roller bearing belongs to a separated bearing, the inner ring and the outer ring of the bearing are both provided with tapered raceways, and the bearing is divided into different structural types such as single row, double row, four rows and the like according to the row number of the mounted rollers. The single-row tapered roller bearing can bear radial load and single-direction axial load. When the bearing is subjected to a radial load, an axial component will be generated, so that another bearing capable of bearing an opposite axial force is required for balancing. The common and small tapered roller bearings are standardized and can meet the normal use under various working conditions. However, in the field of wind power generation, since wind farms are generally located in relatively remote areas, the generators are greatly influenced by the environment during the operation process, and once a fault occurs, serious economic loss can be caused. The service performance of the tapered roller bearing for the main shaft of the wind driven generator is an important part which directly influences whether the generator normally operates, and at present, the service life of the bearing is generally required to be more than 25 years.
In the bearing structure, the precision of the tapered roller inside the bearing structure is a key factor for limiting the service life of the bearing, at present, the machining process of the tapered roller sequentially comprises the working procedures of forging, rough turning, fine turning, heat treatment, rough grinding, fine grinding and ultra-fine grinding, namely, the tapered roller needs to be roughly ground and finely ground on different grinding machines after being subjected to heat treatment, but because the size of the roller is larger, the required precision is high, the required reliability is high, and the service life is long, the method cannot ensure that the actual precision of the roller reaches the design precision because the roller needs to be respectively ground on the outer diameter surface and the ball base surface in different clamping and positioning modes after being subjected to heat treatment, after the machining is finished, the jumping quantity of the ball base surface of the finished roller to the outer diameter surface cannot meet the designed requirement, and through practical tests, the jumping quantity can only reach about 0.05mm, the precision of the roller belongs to III-grade precision, and the quality requirement of I-grade precision of the roller can not be met. Because the precision of the roller does not meet the design requirement, the probability of bearing fatigue and abrasion is accelerated in the using process after the roller is installed in the bearing, and the service life of the bearing is influenced. In addition, the processing method of rough grinding and finish grinding the roller by using different devices also causes the problem of low processing efficiency of the roller, so a tapered roller processing method of the tapered roller bearing of the high-power wind driven generator is needed to solve the problem.
Disclosure of Invention
The invention aims to solve the technical problems and provides a tapered roller processing method of a tapered roller bearing of a high-power wind driven generator, which replaces the rough grinding and accurate grinding processes of the prior tapered roller after heat treatment with a turning processing mode, namely, a high-precision numerical control lathe is adopted to clamp and position the roller once, the outer diameter surface and the end part ball base surface of the roller are turned in the positioning state, after the roller is processed, the jumping quantity of the ball base surface to the outer diameter surface can reach 0.002mm, the precision requirement of an I-grade roller is met, the processing precision of the roller is favorably improved, the whole processing time of the roller can be shortened, and the production efficiency is improved.
The technical scheme adopted by the invention is as follows: a tapered roller processing method of a tapered roller bearing of a high-power wind driven generator comprises the steps that a tapered roller is blanked from a raw material and sequentially subjected to forging, rough turning, fine turning, heat treatment, hard turning and ultra-precision grinding;
in the fine turning process, inwards recessed recesses are machined in the center positions of two end parts of the tapered roller, and a tip hole is machined in the center position of the root of the recess at one end of the spherical base surface;
the hard turning process comprises the following steps: step one, clamping and positioning the roller, namely correspondingly assembling a recess at the non-working end of the roller on a three-jaw chuck of a lathe, wherein three clamping jaws of the three-jaw chuck extend into the recess and cling to the inner wall of the recess; correspondingly inserting the lathe center into a center hole in the middle of a recess at one end of the ball base surface of the roller to finish the clamping and positioning of the roller;
turning the outer diameter circumferential surface of the roller; starting the lathe, enabling the roller to rotate along with the lathe spindle in the clamping and positioning state in the step one, and turning the outer diameter surface of the roller by using a turning tool in the rotating process of the roller until the roller is turned to a specified size;
turning the ball base surface of the roller; and (4) replacing the turning tool, wherein the roller rotates along with the lathe spindle in the clamping and positioning state in the step one, and the turning tool turns the spherical base surface of the roller until the roller is turned to the specified size in the rotating process of the roller.
In the fine turning procedure, the recess is of a cylindrical blind hole structure, the depth of the recess is 3mm, the vertical distance from the inner wall of the recess to the outer wall of the roller is 10-20mm, and the center line of the recess and the center line of the center point hole are coincident with the central axis of the tapered roller.
In the first step, after the roller is clamped and positioned, a tool withdrawal gap is reserved between the edge of the concave cavity at one end of the base surface of the roller ball and the outer surface of the center of the lathe.
In the second step, the turning process of the turning tool on the outer diameter surface of the roller comprises two procedures of rough turning and finish turning, after the rough turning is finished, the size of the outer diameter surface of the roller is 0.08-0.10mm relative to the reserved processing amount of a finished product, after the finish turning is finished, the size of the outer diameter surface of the roller is 0.003-0.006mm relative to the reserved processing amount of the finished product, and the residual amount is the ultra-precision grinding residual amount.
In the third step, the turning process of the base surface of the roller ball by the turning tool comprises two procedures of rough turning and fine turning, and after the rough turning is finished, the reserved processing amount of the size of the base surface of the roller ball relative to a finished product is 0.04-0.05 mm; after finish turning, the size of the base surface of the roller ball is 0.002-0.004mm relative to the reserved processing amount of a finished product; the residual amount is the ultra-precision grinding residual amount.
In the fine turning process, inwards recessed cavities are machined in the center positions of two end parts of the tapered roller, and a tip hole is machined in the center position of the root of the cavity at one end of the spherical base surface; the purpose of this is to: one end of the non-spherical base surface of the roller is processed with a recess structure so that a three-jaw chuck of a lathe can be arranged in the recess and is tightly attached to the inner wall of the recess; a centre hole is processed at one end of the ball base surface, so that a centre of a lathe can be correspondingly inserted into the centre hole and is matched with a three-jaw chuck of the lathe to realize clamping and positioning of the roller; and processing out the cave structure in ball base face one end, the leading cause lies in that the ball base face of roller also need carry out the turning, sets up this cave and can insert the downthehole back at top, and the sufficient space is reserved with the edge of cave to top outer wall, when the lathe tool carries out the turning to the ball base face, can play the effect of moving back the sword, avoids lathe tool and top production interference.
In the second step and the third step, the roller is turned in the clamping and positioning state in the first step, and the purpose is to improve the machining precision of the roller and mainly improve the jumping precision of the ball base surface relative to the outer diameter surface; because the turning of the outer diameter surface and the turning of the spherical basal surface are both in the same clamping and positioning state of the roller, the conditions that different grinding machines and different clamping and positioning modes of the roller are adopted in the prior art can be replaced, so that the jumping quantity of the spherical basal surface relative to the outer diameter surface reaches the precision requirement of the I-grade roller, the form and position tolerance requirement during the design of the tapered roller is met, and the precision machining requirement of the tapered roller is met; in addition, the mode of one-time clamping, positioning and turning molding is adopted, so that the processing time of the roller after heat treatment and before ultra-precision grinding can be shortened, the cost input of equipment is reduced, and the processing efficiency is improved.
The beneficial effects of the invention are as follows:
the invention replaces the rough grinding and the accurate grinding processes of the prior tapered roller after heat treatment with the turning processing mode, namely, a high-precision numerical control lathe is adopted to clamp and position the roller once, the outer diameter surface and the end part ball base surface of the roller are turned in the positioning state, after the roller is processed, the jumping quantity of the ball base surface to the outer diameter surface can reach 0.002mm, the precision requirement of the I-grade roller is met, the processing precision of the roller is favorably improved, the whole processing time of the roller can be shortened, and the production efficiency is improved.
Drawings
FIG. 1 is a structural view of a tapered roller of the present invention;
fig. 2 is a schematic diagram of the tapered roller of the present invention after being mounted and positioned.
In the figure, 1, a first cavity; 2. a second recess; 3. a tip hole; 4. a tip; 5. A three-jaw chuck.
Detailed Description
The following detailed description of embodiments of the invention is provided in connection with the accompanying drawings.
As shown in the figure, the tapered roller processing method of the tapered roller bearing of the high-power wind driven generator is suitable for processing the tapered roller of the high-power wind driven generator, the diameter range of the tapered roller is 60-130mm, the material of the tapered roller is GCr5SiMn steel, the surface hardness finally obtained by the roller is 60-64HRC, and the processing method comprises the steps that the tapered roller is subjected to forging, rough turning, fine turning, heat treatment, hard turning and ultra-precision grinding in sequence from raw material blanking;
the raw material blanking, forging, roller rough turning, heat treatment and ultra-precision grinding processes all adopt conventional processing modes in the prior art, and are not described in detail herein.
In the fine turning process, after the end part plane, the end part spherical base surface and the outer diameter surface of the roller are machined to specified dimensions in a conventional mode, inward concave recesses are machined in the center positions of two end parts of the tapered roller, and a tip hole 3 is machined in the center position of the root part of the recess at one end of the spherical base surface;
specifically, as shown in fig. 1, during finish turning, a first recess 1 is machined at the center of the end surface a of the roller, a second recess 2 is machined at the center of the spherical base surface b of the roller, both the recesses are of cylindrical blind hole-shaped structures, a tip hole 3 is machined at the middle position of the root of the second recess 2 at the center of the spherical base surface b, and the center lines of both the recesses and the tip hole 3 coincide with the central axis of the tapered roller;
more specifically, the depth of the two pockets is 3mm, the diameter of the pockets is determined according to the actual size of the roller, and the perpendicular distance from the inner wall of the pocket to the outer surface of the roller is 10-20mm, for example, when the maximum outer diameter of the roller is 60mm, the diameter of the pocket is 40 mm.
The hard turning process comprises the following steps: step one, clamping and positioning the roller, namely correspondingly assembling a recess I1 of the non-working end face a of the roller on a three-jaw chuck 5 of a lathe as shown in figures 1-2, enabling the outer sides of three jaws of the lathe to cling to the inner wall of the recess I1, and correspondingly inserting a lathe center 4 into a center hole 3 in the middle of a recess II 2 at one end of a roller ball base surface b to finish clamping and positioning the roller;
after the roller is clamped and positioned, a tool retracting gap d is reserved between the edge of the second recess 2 at one end of the ball base surface of the roller and the outer surface of the tip 4 of the lathe, so that when the ball base surface b is turned, the phenomenon that a turning tool interferes with the tip 4 during feeding can be avoided, and the safety factor is improved.
Turning the outer diameter circumferential surface c of the roller; starting the lathe, enabling the roller to rotate along with the lathe spindle in the clamping and positioning state in the step one, and turning the outer diameter circumferential surface c of the roller by using a turning tool in the roller rotating process until the roller is turned to a specified size; because the roller is a tapered roller, the turning tool needs to perform turning processing on a linear motion track which forms a certain included angle with the axis of the roller so as to meet the processing requirement of the tapered roller;
in the step, the turning process of the turning tool on the outer diameter surface of the roller comprises two procedures of rough turning and finish turning, after the rough turning is finished, the size of the outer diameter surface of the roller is 0.08-0.10mm relative to the reserved machining amount of a finished product, after the finish turning is finished, the size of the outer diameter surface of the roller is 0.003-0.006mm relative to the reserved machining amount of the finished product, and the rest machining amount is machined in the super-grinding procedure;
the purpose of adopting twice turning is to control the consistency of the allowance before the second processing, prevent the inconsistent expansion and contraction caused by the different temperatures in the process of processing the cutter relieving and the parts due to the overlarge allowance dispersion degree, improve the processing precision and avoid the problem that the turning precision cannot meet the requirement caused by one-time turning.
Step three, turning the ball base surface b of the roller; and (3) replacing the turning tool, wherein the roller rotates along with the lathe spindle in the clamping and positioning state in the step one, and in the rotating process of the roller, the turning tool turns the ball base surface b of the roller until the turning is in a specified size, and the movement track of the turning tool is an arc line so as to meet the processing requirement of the ball base surface b.
The turning process of the lathe tool on the base surface of the roller ball also comprises two procedures of rough turning and finish turning, after the rough turning is finished, the size of the base surface b of the roller ball is 0.04-0.05mm relative to the reserved processing amount of a finished product, after the finish turning is finished, the size of the base surface of the roller ball is 0.002-0.004mm relative to the reserved processing amount of the finished product, and the rest processing amount is processed in the super-grinding procedure;
the purpose of adopting twice turning is to control the consistency of the allowance before the second processing, prevent the inconsistent expansion and contraction caused by the different temperatures in the process of processing the cutter relieving and the parts due to the overlarge allowance dispersion degree, improve the processing precision and avoid the problem that the turning precision cannot meet the requirement caused by one-time turning.
The turning process is carried out on a high-precision numerical control lathe, and parameter data such as the feed amount, the motion trail, the main shaft rotating speed and the like are input into a program of the numerical control lathe through programming, so that the high-precision turning of the roller is realized.
Through actual test comparison, the traditional rough grinding and fine grinding processes are adopted, and after the roller is completely formed, the bounce amount of the ball base surface of the tapered roller relative to the outer diameter surface is about 0.05mm, and the precision is III-grade precision. By adopting the hard turning process, the jumping quantity of the ball base surface relative to the outer diameter surface can reach 0.002mm, the precision standard of the I-grade roller is reached, the precision grade of the tapered roller is greatly improved, the equipment investment cost of the roller in the production process is reduced, and the processing time is shortened.
Claims (5)
1. A tapered roller processing method of a tapered roller bearing of a high-power wind driven generator is characterized by comprising the following steps: the method comprises the following steps that the tapered roller is subjected to forging, rough turning, fine turning, heat treatment, hard turning and ultra-precision grinding in sequence from raw material blanking;
in the fine turning process, inwards recessed recesses are machined in the center positions of two end parts of the tapered roller, and a tip hole is machined in the center position of the root of the recess at one end of the spherical base surface;
the hard turning process comprises the following steps: step one, clamping and positioning the roller, namely correspondingly assembling a recess at the non-working end of the roller on a three-jaw chuck of a lathe, wherein three clamping jaws of the three-jaw chuck extend into the recess and cling to the inner wall of the recess; correspondingly inserting the top of the lathe into a top hole in the middle of a concave cavity at one end of the base surface of the roller ball to complete the clamping and positioning of the roller;
turning the outer diameter circumferential surface of the roller; starting the lathe, enabling the roller to rotate along with the lathe spindle in the clamping and positioning state in the step one, and turning the outer diameter surface of the roller by using a turning tool in the rotating process of the roller until the roller is turned to a specified size;
turning the ball base surface of the roller; and (4) replacing the turning tool, wherein the roller rotates along with the lathe spindle in the clamping and positioning state in the step one, and in the rotating process of the roller, the turning tool turns the base surface position of the ball of the roller until the turning is carried out to the specified size.
2. The tapered roller processing method of the tapered roller bearing of the high-power wind driven generator according to claim 1, characterized in that: in the fine turning process, the recess is of a cylindrical blind hole structure, the depth of the recess is 3mm, the vertical distance from the inner wall of the recess to the outer wall of the roller is 10-20mm, and the center line of the recess and the center line of the center hole coincide with the central axis of the tapered roller.
3. The method for processing the tapered roller of the tapered roller bearing of the high-power wind-driven generator as claimed in claim 1, wherein in the first step, after the roller is clamped and positioned, a clearance for tool withdrawal is left between the edge of the recess at one end of the ball-based surface of the roller and the outer surface of the lathe center.
4. The tapered roller processing method of the tapered roller bearing of the high-power wind driven generator according to claim 1, wherein in the second step, the turning process of the turning tool on the outer diameter surface of the roller includes two processes of rough turning and finish turning, after the rough turning is completed, the dimension of the outer diameter surface of the roller is 0.08-0.10mm relative to the reserved processing amount of the finished product, after the finish turning is completed, the dimension of the outer diameter surface of the roller is 0.003-0.006mm relative to the reserved processing amount of the finished product, and the residual amount is the ultra-precision grinding allowance.
5. The tapered roller processing method of the tapered roller bearing of the high-power wind-driven generator as claimed in claim 1, wherein in the third step, the turning process of the roller sphere base surface by the turning tool includes two procedures of rough turning and fine turning, and after the rough turning is finished, the size of the roller sphere base surface is 0.04-0.05mm relative to the reserved processing amount of a finished product; after finish turning, the reserved processing amount of the roller ball base surface size relative to the finished product is 0.002-0.004 mm; the residual amount is the ultra-precision grinding residual amount.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210647904.8A CN114789259A (en) | 2022-06-09 | 2022-06-09 | Tapered roller machining method for tapered roller bearing of high-power wind driven generator |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210647904.8A CN114789259A (en) | 2022-06-09 | 2022-06-09 | Tapered roller machining method for tapered roller bearing of high-power wind driven generator |
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| CN114789259A true CN114789259A (en) | 2022-07-26 |
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| CN202210647904.8A Pending CN114789259A (en) | 2022-06-09 | 2022-06-09 | Tapered roller machining method for tapered roller bearing of high-power wind driven generator |
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