CN115990748A

CN115990748A - Wind power generation gear ring processing method

Info

Publication number: CN115990748A
Application number: CN202310114045.0A
Authority: CN
Inventors: 钱建南
Original assignee: Wuxi Muyan Machinery Co ltd
Current assignee: Wuxi Muyan Machinery Co ltd
Priority date: 2023-02-15
Filing date: 2023-02-15
Publication date: 2023-04-21

Abstract

The invention discloses a processing method of a wind power generation gear ring, which belongs to the field of wind power generation accessory processing, and comprises the following steps: s1, milling a reference surface: placing a plurality of support rollers and guide wheels positioned at one end of the support rollers along a circumferential array at one end of the numerical control gantry processing machine tool, taking annular cast iron, horizontally placing the annular cast iron on the plurality of support rollers, and supporting the inner wall of the annular cast iron by the guide wheels while rotating and flying; s2, turning over: turning over the annular cast iron, and attaching the smooth surface to the upper surfaces of the plurality of support rollers; s3, rough machining: the numerical control gantry processing machine tool is used for profiling and milling the annular cast iron, and rough machining of teeth, inner walls and end faces of the annular cast iron is realized, so that a reference surface can be milled at one time, steps on the reference surface are reduced, and the rough turning precision of the wind power generation gear ring during processing is improved.

Description

Wind power generation gear ring processing method

Technical Field

The invention relates to the field of wind driven generator accessory machining, in particular to a wind driven generator gear ring machining method.

Background

With the high-speed development of wind power construction in China, the investment enthusiasm of wind power equipment manufacturing industry is increased unprecedentedly, particularly, a large-capacity megawatt large-scale wind power generator set is further subjected to the fierce and tourbillon in the market, and mainly comprises a cabin, rotor blades, an axle center, a low-speed shaft, a gear box, a high-speed shaft and a mechanical brake thereof, a generator, a yaw device, an electronic controller, a hydraulic system, a tower and a cooling element, wherein the gear box runs without leaving an internal gear ring, and needs to bear the load of the low-speed shaft and the high-speed shaft, so that the processing requirement is high in hardness;

the patent search finds that China patent with publication number of CN114505658A discloses a processing method of a segmented gear ring, which comprises the following steps: the gear ring is designed in a segmented mode, a single tooth segment after segmentation is cast and molded, and a blank piece of the molded tooth segment is left with allowance; step two, rough milling the joint surface: rough milling is carried out on the end joint surface of each tooth segment, and a margin is reserved on the end joint surface; step three, rough turning of the excircle: connecting the joint surfaces of two adjacent tooth sections, turning the outer circle of the joint surfaces on a vertical lathe, and leaving a margin on the outer circle; fourthly, quenching and tempering; finish milling the joint surface of part of the tooth segments to a designed size, and performing semi-finish milling on part of the joint surface; step six, semi-finish turning: connecting the two semicircular ring pieces in the fifth step at the joint surfaces of the two ends to form an integral annular ring piece, performing semi-finish turning on the outer circle of the integral annular ring piece on a vertical lathe, and leaving a margin for the size of the outer circle after turning; step seven, rough tooth punching: taking one joint surface of the two semicircular ring pieces in the step six as a reference, carrying out tooth forming on the outer circle of the semicircular ring piece on a gear hobbing machine, leaving allowance at the tooth position after the gear hobbing is finished, and carrying out finish milling on the rest joint surfaces; step nine, finish turning; step ten, fine hobbing; the method comprises the steps of finish milling part of the joint surfaces to the designed size, then butting the finish-milled joint surfaces, so that the segmented gear ring is formed into two semicircular ring pieces, the processing difficulty of the subsequent working procedures is reduced, the design requirement that the joint surfaces are positioned in the middle of the tooth root is guaranteed, the probability of fracture of teeth at the joint surface due to stress is reduced, and the service life of the whole gear ring is prolonged;

however, the problem that in the existing machining method, in the process of machining the wind power generation gear ring, rough turning is performed by taking a turned plane as a reference plane, subsequent machining is performed, the wind power generation gear ring is large in diameter and heavy in weight, and is inconvenient to manually rotate, segmented machining is often performed, one reference plane is subjected to multiple milling, steps are easy to occur, deflection is caused, and rough turning precision is reduced due to the occurrence of the steps in the machining process of the wind power generation gear ring is solved.

Disclosure of Invention

1. Technical problem to be solved

Aiming at the problems in the prior art, the invention aims to provide a processing method of a wind power generation gear ring, which can mill a reference surface at one time, reduce steps on the reference surface and is beneficial to improving the precision of rough turning of the wind power generation gear ring during processing.

2. Technical proposal

In order to solve the problems, the invention adopts the following technical scheme.

A method of processing a wind power generation ring gear, the method comprising the steps of:

s1, milling a reference surface: placing a plurality of support rollers and guide wheels positioned at one end of the support rollers along a circumferential array at one end of the numerical control gantry processing machine tool, taking annular cast iron, horizontally placing the annular cast iron on the plurality of support rollers, and supporting the inner wall of the annular cast iron by the guide wheels while rotating and flying;

s2, turning over: turning over the annular cast iron, and attaching the smooth surface to the upper surfaces of the plurality of support rollers;

s3, rough machining: profiling milling the annular cast iron by a numerical control gantry processing machine tool, roughly processing the teeth, the inner wall and the end face of the annular cast iron, and processing the annular cast iron section by section to prepare a gear ring blank;

s4, surface modification treatment: placing the blank into a heating furnace, introducing carrier gas with BRN penetrating agent, heating for a certain time, and cooling;

s5, finish machining: placing one end face of the rough machining of the blank downwards on a plurality of supporting rollers, finely machining the other end, the inner wall and the teeth of the blank by using a numerical control gantry machining machine tool, drilling, carrying out section-by-section machining, and finely machining the lower end face to prepare a gear ring;

s6, mechanical flaw detection: and (3) placing the gear ring part on a workbench of a fluorescent magnetic powder flaw detector, and carrying out flaw detection section by section.

Furthermore, the guide wheels in the step S1 are connected to the output end of the horizontal hydraulic cylinder through the rotating seat, and the radius of a circle formed by the guide wheels can be adjusted.

Further, the annular cast iron in the step S1 is clamped by the driving roller which is matched with the supporting roller downwards, and the driving roller is rotated by the driving element to drive the annular cast iron to rotate around the plurality of guide wheels.

Further, the annular cast iron turned to the vertical state in S2 is cleaned with an air gun and the scrap iron on the supporting roller and the guide wheel is blown off.

Furthermore, in the step S3, the 1/8 area of each section of processed annular cast iron is staggered with the teeth of the blank on the section surface, so that the margin of 0.1-0.15mm is conveniently reserved for the teeth.

Further, the working temperature of the heating furnace in the step S4 is 510-670 ℃, and tempering is carried out at 150-250 ℃ during cooling.

Further, in the step S4, the BRN penetrating agent is 42CrMoV or 20CrMnTiA, and the carrier gas is nitrogen, so that the blank can be nitrided.

Further, in the step S5, 1/8 area of each section of the blank is finished, the blank rotates around a guide wheel on a supporting roller, teeth of the blank are staggered on a section surface, and the feeding amount is 0.02mm.

Further, the feeding amount of finish machining of the lower end face in the step S5 is 0.02mm, and the lower end face rotates around the guide wheel while machining on the support roller.

Further, a plurality of supporting rollers are also arranged on one side of the fluorescent magnetic particle inspection machine in the step S6 along the circumferential array for horizontally arranging the gear ring, and the part of the gear ring arranged on the fluorescent magnetic particle inspection machine is covered by the light shielding curtain to form a dark environment.

3. Advantageous effects

Compared with the prior art, the invention has the advantages that:

(1) According to the scheme, the guide wheels support the inner wall of the annular cast iron so as to horizontally support the annular cast iron, the driving rollers are downwards matched with the supporting rollers to clamp the annular cast iron, the driving rollers are rotated through the driving elements to drive the annular cast iron to rotate around the guide wheels, the numerical control gantry processing machine tool is controlled to mill the upper end face of the annular cast iron, the reference surface can be milled out at one time while the annular cast iron is rotated, steps on the reference surface are reduced, the skew degree of blanks is reduced conveniently, and the precision of rough turning of the wind power generation gear ring during processing is improved.

(2) The scheme is characterized in that tempering is carried out at 150-250 ℃ during cooling, so as to keep high hardness and wear resistance of a quenched workpiece, reduce quenching residual stress and brittleness, obtain tempered martensite after tempering, namely a structure obtained during low-temperature tempering of the quenched martensite, and have mechanical properties: 58-64 HRC, and is convenient to have high hardness and wear resistance.

(3) The BRN penetrating agent is 42CrMoV or 20CrMnTiA, has high strength and toughness, good hardenability, no obvious tempering brittleness, high fatigue limit and multiple impact resistance after tempering, good low-temperature impact toughness, nitrogen carrier gas, capability of nitriding a blank, deburring of the blank, chamfering, surface roughness Ra of less than 1.6 mu m, and good continuity of a convenient nitriding layer, and can better resist external impact.

(4) In this scheme, the next terminal surface finish machining feed is 0.02mm, can not excessively cut the nitriding layer, rotates the blank through drive roller cooperation backing roll to processing is rotatory around the leading wheel on the backing roll, can cut the terminal surface in succession, reduces the step that produces on the terminal surface, is favorable to improving the finish of terminal surface.

Drawings

FIG. 1 is a flow chart of the processing method of the present invention;

fig. 2 is a schematic front view of the gear ring according to the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention; it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments, and that all other embodiments obtained by persons of ordinary skill in the art without making creative efforts based on the embodiments in the present invention are within the protection scope of the present invention.

Examples:

referring to fig. 1-2, a method for processing a wind power generation gear ring includes the following steps:

s1, milling a reference surface: the method comprises the steps that a plurality of support rollers and guide wheels positioned at one end of the support rollers are arranged at one end of a numerical control gantry processing machine tool along a circumferential array, the support rollers are horizontally suspended through a base, a horizontal hydraulic cylinder is arranged at one side of a rotating seat through a flange plate, the guide wheels are connected to the output end of the horizontal hydraulic cylinder through the rotating seat and can rotate when pushed, the radius of a circle formed by the plurality of guide wheels can be adjusted, the radius of the circle is reduced, annular cast iron is conveniently inserted, the annular cast iron is taken out and horizontally placed on the plurality of support rollers, part of the annular cast iron is positioned on the numerical control gantry processing machine tool, the output end of the horizontal hydraulic cylinder is controlled to extend, the guide wheels support the inner wall of the annular cast iron so as to horizontally support the annular cast iron, the annular cast iron is clamped by the drive rollers in a downward matching manner, the drive rollers rotate through drive elements to drive the annular cast iron to rotate around the plurality of guide wheels, the upper end face of the annular cast iron is controlled to mill, a datum plane is milled while the annular cast iron is flown, and steps on the datum plane are reduced;

s2, turning over: the annular cast iron is turned over, the annular cast iron turned over to be in a vertical state is cleaned by an air gun, scrap iron on the supporting rollers and the guide wheels is blown off, the smooth surface is stuck to the upper surfaces of the supporting rollers to serve as a reference surface, the scrap iron is prevented from being padded with the annular cast iron, and the skew degree of the annular cast iron is reduced;

s3, rough machining: the annular cast iron is subjected to profile milling by a numerical control gantry processing machine tool, the teeth, the inner wall and the end face of the annular cast iron are roughly processed, a certain margin is reserved for section by section processing, so that finish processing is performed, a gear ring blank is manufactured, the skew degree of the blank is conveniently reduced, and the precision of rough turning of the wind power generation gear ring during processing is improved;

s4, surface modification treatment: putting the blank into a heating furnace, performing quenching and tempering to obtain tempered sorbite tissues, eliminating internal stress generated in the machining process to the greatest extent to stabilize the size of a part, then introducing carrier gas with BRN penetrating agent, heating for a certain time, performing nitriding treatment, forming a nitriding layer with the thickness of 0.3-0.68mm on the surface so as to have high hardness, high wear resistance and high fatigue strength, keeping the temperature for longer than tempering time, and slowly cooling to room temperature;

s5, finish machining: one end face of rough machining of the blank is downwards placed on a plurality of supporting rollers to serve as a second reference face, precision is improved compared with that of the first reference face, a numerical control gantry machining machine tool is used for finish machining of the other end, the inner wall and teeth of the blank, drilling is conducted, hole position precision is high, machining is conducted section by section, the lower end face is finished, the first reference face is milled to manufacture a gear ring, scrap iron on the supporting rollers is removed in the whole process, and the blank is prevented from being padded;

s6, mechanical flaw detection: the gear ring is partially placed on a workbench of a fluorescent magnetic particle inspection machine, the model of the fluorescent magnetic particle inspection machine is CDG-20000AT, the machine is suitable for flaw detection and shading of a large gear ring, a plurality of groups of clamped circumferential magnetization, longitudinal magnetization of a magnetic yoke coil and a detection method for sectional magnetization observation are adopted, composite magnetization is adopted, defects of the inner surface and the outer surface of the gear ring and the near surface of the gear ring are detected AT one time, the large gear ring has large weight, the machine adopts a horizontal lathe bed structure from the safety point of view, the sensitivity of magnetic particle detection on the defects of the surface and the near surface is high, current can be directly set in a touch screen, a current closed loop tracking system and a digital gauge head display are greatly higher than those of similar products, the required current value can be directly input in an intelligent touch screen control system, the automatic tracking is carried out, the set value of the current can be stored, the stored current value is directly called according to the sizes of different workpieces, and the operation is simple and convenient.

Referring to FIG. 1, in S3, 1/8 area of each section of processed annular cast iron is convenient to stagger hole sites, the teeth of the blank are staggered on the sectional surface, a margin of 0.1-0.15mm is conveniently reserved for the teeth, and a nitriding layer can penetrate through the surface layer.

Referring to fig. 1, the working temperature of the heating furnace in S4 is 510-670 ℃, alloy steel containing chromium, nickel, manganese and other elements is tempered at 500-650 ℃ after quenching, reversible tempering brittleness is easy to generate by slow cooling, in order to prevent the alloy steel, large parts can be selected from alloy steel containing tungsten or molybdenum, the alloy steel is tempered at 150-250 ℃ during cooling, the aim is to keep high hardness and wear resistance of a quenched workpiece, reduce quenching residual stress and brittleness, obtain tempered martensite after tempering, namely the structure obtained during low-temperature tempering of the quenched martensite, and the mechanical properties are as follows: 58-64 HRC, is convenient to have high hardness and wear resistance, and is easy to generate irreversible tempering brittleness when tempered at about 300 ℃ after quenching, and is generally not tempered within the range of 250-350 ℃ in order to avoid the irreversible tempering brittleness.

Referring to fig. 1, the BRN-penetrating agent in S4 is 42CrMoV or 20CrMnTiA, which has high strength and toughness, better hardenability, no obvious tempering brittleness, higher fatigue limit and multiple impact resistance after tempering, good low-temperature impact toughness, nitrogen carrier gas, capability of nitriding a blank, deburring the blank, chamfering, and surface roughness Ra less than 1.6 μm, and good continuity of a convenient nitriding layer, and can better resist external impact.

Referring to fig. 1, in the step S5, 1/8 area of each section of finished blank is convenient to stagger hole sites, a horizontal hydraulic cylinder is controlled to push a guide wheel to tightly prop against the inner wall of the blank, the guide wheel rotates on a support roller, teeth of the blank are staggered on a sectional surface, the feeding amount is 0.02mm, a nitriding layer cannot be excessively cut, the gantry machine tool cannot be fed too forcefully, and the effect of clearing the residual angle of the tooth root is good.

Referring to fig. 1, the feeding amount of finish machining of the lower end surface in S5 is 0.02mm, the nitriding layer is not excessively cut, the driving roller is matched with the supporting roller to rotate the blank, and the blank is processed on the supporting roller and rotates around the guide wheel, so that the end surface can be continuously cut, steps generated on the end surface are reduced, and the finish of the end surface is improved.

Referring to fig. 1 and 2, a plurality of support rollers are also placed along a circumferential array on one side of the fluorescent magnetic particle inspection machine in S6, and are used for horizontally placing a gear ring, while the part of the gear ring placed on the fluorescent magnetic particle inspection machine is covered by a light shielding curtain to form a dark environment, the gear ring can be directly observed while magnetization, and can also be observed after the magnetization is finished, then, the gear ring is rotated on the support rollers, the gear ring is low in rotating difficulty and small in friction, and then, lifting can be performed, so that the gear ring can be turned over, and the omnibearing inspection is convenient.

The above description is only of the preferred embodiments of the present invention; the scope of the invention is not limited in this respect. Any person skilled in the art, within the technical scope of the present disclosure, may apply to the present invention, and the technical solution and the improvement thereof are all covered by the protection scope of the present invention.

Claims

1. A wind power generation gear ring processing method is characterized in that: the processing method comprises the following steps:

2. The method for processing the wind power generation gear ring according to claim 1, wherein: the guide wheels in the S1 are connected to the output end of the horizontal hydraulic cylinder through the rotating seat, and the radius of a circle formed by the guide wheels can be adjusted.

3. The method for processing the wind power generation gear ring according to claim 1, wherein: the annular cast iron in the S1 is clamped by the driving roller which is downwards matched with the supporting roller, and the driving roller is rotated by the driving element to drive the annular cast iron to rotate around the guide wheels.

4. The method for processing the wind power generation gear ring according to claim 1, wherein: the annular cast iron turned to be in a vertical state in the step S2 is cleaned by an air gun, and scrap iron on the supporting roller and the guide wheel is blown off.

5. The method for processing the wind power generation gear ring according to claim 1, wherein: and (3) in the S3, the 1/8 area of each section of the processed annular cast iron is staggered with the teeth of the blank on the sectional surface, so that the margin of 0.1-0.15mm is conveniently reserved for the teeth.

6. The method for processing the wind power generation gear ring according to claim 1, wherein: the working temperature of the heating furnace in the step S4 is 510-670 ℃, and tempering is carried out at 150-250 ℃ during cooling.

7. The method for processing the wind power generation gear ring according to claim 1, wherein: in the step S4, the BRN penetrating agent is 42CrMoV or 20CrMnTiA, and the carrier gas is nitrogen, so that the blank can be nitrided.

8. The method for processing the wind power generation gear ring according to claim 1, wherein: and (5) finishing 1/8 area of each section of blank in the step (S5), rotating the blank around a guide wheel on a supporting roller, and staggering the teeth of the blank on the segment surface, wherein the feeding amount is 0.02mm.

9. The method for processing the wind power generation gear ring according to claim 1, wherein: and (5) finishing the lower end surface in the step (S5) with the feeding amount of 0.02mm, and rotating around the guide wheel while machining the upper end surface of the support roller.

10. The method for processing the wind power generation gear ring according to claim 1, wherein: and S6, a plurality of supporting rollers are also arranged on one side of the fluorescent magnetic particle inspection machine along the circumferential array and used for horizontally arranging the gear rings, and the part of the gear rings, which is arranged on the fluorescent magnetic particle inspection machine, is covered by the light shielding curtain to form a dark environment.