CN117161277A - Rolling forming process for shell flange - Google Patents
Rolling forming process for shell flange Download PDFInfo
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- CN117161277A CN117161277A CN202311229055.5A CN202311229055A CN117161277A CN 117161277 A CN117161277 A CN 117161277A CN 202311229055 A CN202311229055 A CN 202311229055A CN 117161277 A CN117161277 A CN 117161277A
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- 238000005096 rolling process Methods 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 22
- 230000008569 process Effects 0.000 title claims abstract description 21
- 238000005242 forging Methods 0.000 claims abstract description 82
- 238000010438 heat treatment Methods 0.000 claims abstract description 15
- 238000009987 spinning Methods 0.000 claims abstract description 12
- 238000007493 shaping process Methods 0.000 claims abstract description 11
- 238000004080 punching Methods 0.000 claims abstract description 4
- 238000003825 pressing Methods 0.000 claims description 13
- 230000009471 action Effects 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 21
- 238000004519 manufacturing process Methods 0.000 abstract description 7
- 230000008901 benefit Effects 0.000 abstract description 2
- 230000007547 defect Effects 0.000 description 15
- 238000001514 detection method Methods 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 9
- 230000009286 beneficial effect Effects 0.000 description 5
- 239000000956 alloy Substances 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 239000013078 crystal Substances 0.000 description 3
- 238000003754 machining Methods 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 238000001953 recrystallisation Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 241000519995 Stachys sylvatica Species 0.000 description 1
- 238000003889 chemical engineering Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009659 non-destructive testing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
Abstract
The invention discloses a process for roll forming a shell flange, which relates to the field of shell flange manufacture, and is characterized by comprising the following steps: s1, blanking; s2, heating; step S3, upsetting and pulling: firstly drawing out a blank, then carrying out primary upsetting, secondly drawing out the blank, reversing the blank in eight directions, secondarily upsetting the blank, and rounding the outer edge of the blank; step S4, punching: s5, spinning; step S6, returning to the furnace and heating: heating and preserving the blank in a furnace; step S7, ring rolling: the special-shaped main roller and the special-shaped core roller are used for ring rolling, the initial stage of rolling is a blank rounding stage a, the shaping stage b is carried out at a high speed, the shape of the forging piece is completely shaped, the forging piece enters a direct growing stage, and the core is reducedThe roll feeding speed, and the forging enters a shaping stage c; the rolling curve being an exponential functionWherein x is radial rolling quantity and y is axial rolling quantity, and the invention has the advantage of improving the material utilization rate and quality of the shell flange.
Description
Technical Field
The invention relates to the field of shell flange manufacturing, in particular to a process for roll forming of a shell flange.
Background
A housing flange is an element for connecting or securing a housing structure. It is typically made of metal and the housing flange is of annular construction. Housing flanges are widely used in many industries and applications, such as in mechanical manufacturing, chemical engineering, energy fields, etc.
At present, a large-sized shell flange of a certain model is required to be subjected to single-piece blank special-shaped rolling by adopting a traditional ring rolling process, and two special-shaped dies are prepared: an outer edge special-shaped die and an inner edge special-shaped die. The outer edge special-shaped die is matched with the outer edge shape of the shell flange, the inner edge special-shaped die is matched with the inner edge shape of the shell flange, the outer edge of the blank is rolled by the outer edge special-shaped die on the ring rolling machine, then the inner edge of the blank is rolled by the inner edge special-shaped die on the ring rolling machine, and finally machining shaping is performed.
But there are the following problems in rolling:
1. the inner edge and the outer edge of the blank are not synchronously formed, so that the stress of the blank is asymmetric in the ring rolling process, dynamic instability is easy to occur, uneven weight distribution of the blank or deviation of geometric shapes are caused, the internal stress distribution of the blank is unbalanced, the uniformity of the structure is poor, and further processing defects such as folding and grooves are caused, so that the quality of the blank is affected.
2. After the rolling is finished, more additional machining processes are needed, the blank is shaped to the target size, the blanking weight is 5000 kg/piece for example, the finished product weight is 2768 kg/piece, and the material utilization rate is low.
Disclosure of Invention
In view of the above-mentioned drawbacks of the prior art, it is an object of the present invention to provide a process for roll forming a housing flange, which has the advantage of improving the material utilization and quality of the housing flange.
The technical aim of the invention is realized by the following technical scheme:
a process for roll forming a flange of a housing, comprising the steps of:
s1, blanking;
step S2, heating: heating and preserving heat of the plate blank;
step S3, upsetting and pulling: the blank is subjected to primary drawing, the forging ratio of the primary drawing is 3.6 at the lowest, then primary upsetting is carried out, the forging ratio of the primary upsetting is 1.6 at the lowest, then the blank is subjected to secondary drawing, the forging ratio of the secondary drawing is 1.6 at the lowest, then the blank is subjected to eight directions, the blank is subjected to secondary upsetting, the forging ratio of the secondary upsetting is 1.8 at the lowest, and finally the outer edge of the blank is rounded;
step S4, punching:
step S5, spinning: taking the center of the wall thickness as a reference, pressing one side (L1) of the outer edge firstly, pressing one side (L2) of the inner edge afterwards, pressing down the same amount (L1) and (L2), and turning over the blank to perform the same spinning action;
step S6, returning to the furnace and heating: heating and preserving the blank in a furnace;
step S7, ring rolling: rolling rings by using a special-shaped main roller and a special-shaped core roller, wherein the initial rolling stage is a blank rounding stage a, then accelerating to form a stage b, when the shape of a forging piece is completely formed, the forging piece enters a direct growing stage, the feeding speed of the core roller is reduced, and finally, the forging piece enters a shaping stage c;
the rolling curve being an exponential functionWherein x is the radial rolling amount and y is the axial rolling amount.
Further, in step S2, the slab is heated to 1230℃for 3-4 hours.
Further, in step S3, the total forging ratio of the billet is 8.6 or more.
Further, in step S5, the deformation amount of the spinning is 36%.
Further, in step S6, the blank was heated to 1230℃for a holding time of 1.5h.
Further, in step S7, the blank is rounded, the roller feeding speed is set to 0.8mm/S, and the feeding speed is rapidly increased to 2mm/S after the blank rotates 3-5 turns.
Further, in the forming stage b, the core roll feeding speed is reduced to 1mm/S after the forging shape is completely formed, and then the direct growth stage is entered in step S7.
Further, in step S7, when the diameter of the forging piece is still 100mm different from the finished product, the feeding speed of the core roller is reduced to 0.6mm/S, and the forging piece enters a shaping stage.
In summary, the invention has the following beneficial effects:
1. in the upsetting and drawing processes, the forging ratio of single upsetting and drawing is ensured, the total forging ratio reaches 8.6, and the defects in the center of the blank can be subjected to stretching, compression and deformation, so that the materials in the defect area are rearranged and redistributed. This facilitates bonding of the defective areas to surrounding materials, reducing or eliminating defects; the applied pressure facilitates compaction of the material in the defect area, reduces the size and extent of the defect, and strain and thermal effects may promote recrystallization of the material. The recrystallization can improve the grain structure of the material, so that grains in the defect area grow again or are rearranged, the three work together to lead the material structure to be more uniform, the grains are refined, and the mechanical property of the forging piece is improved.
2. The strain of the material can be locally increased by the applied pressure in the spinning of the end face of the forging piece, so that the fluidity of the material is improved, the two ends of the blank form corresponding bulging degree, the shape adjustment and deformation of the blank are easier to realize in the subsequent forging process, and the forming of the forging piece is promoted.
3. In the ring rolling, the ring rolling enters a rounding stage at a low speed, then the ring rolling is accelerated, only radial rolling is performed, no axial rolling is performed, the material in the middle part flows to two ends due to the extrusion of the main roller and the core roller, and the material is most concentrated at the positions close to the two end surfaces; and then entering a forming stage, wherein a large feeding speed and the drum degrees at the two ends of the previous spinning are beneficial to forming of the forging, the axial pressing speed is changed from high speed to low speed until zero, and the purpose is that after the main roller and the core roller are completely contacted with the forging, the phenomenon that the center cannot be completely forged to generate grooves easily occurs in the rolling process due to the wide wall thickness of the upper end wall and the lower end wall, and the end face grooves can be eliminated through axial rolling. And along with the rolling, the wall thickness is gradually thinned, the groove phenomenon is gradually lightened until the groove phenomenon disappears, and finally, the groove phenomenon enters a shaping stage, and the groove is similar to a rounding stage, so that the symmetrical rolling is realized overall, and the rolling stability is improved. And the rolling curve is designed, so that the forming of the forging is facilitated, the dimensional and shape tolerance of the forging is guaranteed, and the quality of the forging is guaranteed while the rolling difficulty is reduced.
4. Reasonable rolling parameters and design rolling curves are beneficial to forming the forging, ensuring the size and the shape of the forging, controlling the tolerance, designing the appearance of the part more after rolling is finished, and reducing the material consumption.
5. The blanking selects the plate blank, and a large number of machining operations are not needed to process the plate blank to the specified size, so that the blanking weight is reduced, the material utilization rate is improved, and the raw material cost is reduced.
Drawings
Fig. 1 is a schematic illustration of the process steps for roll forming a housing flange.
Fig. 2 is a schematic diagram of the structure of the blank in step S5.
Fig. 3 is a schematic diagram of the structure of the blank in step S7.
Fig. 4 is a schematic structural view of the part after roll forming.
Fig. 5 is a rolling graph.
FIG. 6 is a metallographic examination of example 1.
FIG. 7 is a metallographic examination of example 2.
FIG. 8 is a metallographic examination of comparative example 1.
FIG. 9 is a metallographic examination of example 2.
Detailed Description
Example 1:
a process for roll forming a flange of a housing, as shown in fig. 1, comprising the steps of:
s1, blanking;
the material specification is as follows: and blanking a 14Cr1Mo slab, wherein the weight is 8000kg, and the size is 1500mm multiplied by 450mm.
Step S2, heating: the slab is heated and insulated, in particular to heat the slab to 1230 ℃, and the heat preservation time ranges from 3 h to 4h.
Step S3, upsetting and pulling:
the blank is drawn for the first time, and drawn to 800mm×800mm×1600mm along the thickness direction, and the forging ratio of the first drawing is 3.6 at the minimum.
Then, the billet was upset to a height h=1000, and the forging ratio was 1.6.
Then, the billet was drawn to 800mm×800mm×1600mm, and the forging ratio was 1.6.
After the blank is drawn, the blank is inverted, and the blank is thick to a height h=920 mm, and the manufacturing ratio is 1.6.
Finally, the outer circle of the blank is rounded to phi 1200mm, and the total forging ratio of the blank is 8.6.
Through the upsetting process, the defects of white spots, shrinkage holes and the like in the center of the slab are effectively forged, so that the defects of NB/T47013.3-2017 flaw detection requirements are met. Meanwhile, the material structure is more uniform, crystal grains are refined, and the mechanical property of the forging is improved.
Step S4, punching: the size phi of the inner hole of the blank is 550mm.
Step S5, spinning: based on the center of the wall thickness, as shown in FIG. 2, the outer edge side (L1) is pressed first, and the inner edge side (L2) is pressed later, the pressing amounts of (L1) and (L2) are the same, and the pressing amount is 95mm. The cross-sectional area of the blank is 311025mm 2 The sectional area of the forging piece is 198717mm when in forming 2 The deformation amount was 36%. And turning over the blank to perform the same spinning action, and pressing down the blank in two steps, wherein the outer wall and the inner wall of the inner hole of the blank are provided with a certain degree of bulge, and a deformation allowance is reserved for subsequent roll forming.
Step S6, heating: and returning the forged blank to the furnace, heating to 1230 ℃, and preserving heat for 1.5h.
Step S7, ring rolling: as shown in the figure 3 of the drawings,
and rolling the ring by using the special-shaped main roller and the special-shaped core roller.
The initial stage of rolling is a blank rounding stage a, the roller feeding speed is set to be 0.8mm/s, and the feeding speed is rapidly increased to 2mm/s after the blank rotates for 3-5 circles. Only radial rolling and no axial rolling. At this time, due to the extrusion of the main roller and the core roller, the material in the middle part flows to the two ends, and the material gathers most at the positions close to the two end surfaces, if the axial rolling is carried out, more material gathers at the near end surfaces, and a folding phenomenon is formed.
And then accelerating to carry out a forming stage b, when the shape of the forging piece is completely formed, and the larger feeding speed is matched with the drum degree of the inner side wall and the outer side wall of the forging piece, enough deformation materials are given, the forging piece enters a direct growing stage, the feeding speed of the core roller is reduced to 1mm/s, the forging piece enters the growing stage, and the reduction of the feeding speed of the core roller is more beneficial to the stable rolling of the forging piece. In the forming stage b, the axial pressing speed is changed from fast to slow until zero, and the purpose is that after the main roller and the core roller are completely contacted with the forging piece, the phenomenon that the center cannot be completely forged to generate grooves easily occurs in the rolling process due to the wide wall thickness of the upper end wall and the lower end wall, and the end face grooves can be eliminated through axial rolling. And the wall thickness is gradually thinned along with the rolling, so that the groove phenomenon is gradually lightened until the groove phenomenon disappears.
When the diameter of the forging piece is 100mm away from the finished product, the feeding speed of the core roller is rapidly reduced to 0.6mm/s, and the forging piece enters a shaping stage c which is similar to the deformation of a rounding stage a, but the length change of the forging piece in the shaping stage c is smaller than the length change of the forging piece in the rounding stage a, and the reduction of the increasing speed of the diameter of the forging piece is more beneficial to ensuring the roundness and the planeness of the forging piece. The final formed forging structure is shown in figure 4,
as shown in FIG. 5, the rolling curve in the b stage is an exponential functionWherein x is the radial rolling amount and y is the axial rolling amount.
The comprehensive detection results of the forgings are shown in table 1:
TABLE 1
Conclusion:
1. the tensile strength, the yield strength and the impact energy in the tangential (0 DEG) and tangential (180 DEG) detection directions are all satisfied and are in the high position of the design index, the alloy is proved to be strengthened, and the alloy has good mechanical properties, so that the side surfaces prove that the grain structure is refined, and the strengthening mechanism is effective.
2. The elongation in both tangential (0) and tangential (180) directions is indicative of the tensile deformation of the alloy under stress. The alloy with high elongation can be processed into a required shape more easily in the manufacturing process, and has better deformation resistance.
3. The difference value between the detection data of the tangential (0 degree) and the tangential (180 degree) detection directions is small, which indicates that the tissue of each part of the forging is uniform.
4. The forging has a grain size of 7.5 grade, a fine grain structure, and the grains in the defect area are proved to be regrown or rearranged, the grains are refined, and no excessive nonmetallic inclusion exists in the structure.
5. And carrying out nondestructive testing after the deformation of the forging is finished, wherein the feedback of the detection acoustic signals in each detection area meets the detection standard, and the side surface shows that forging defects are not caused in the process of finishing the deformation of the forging.
Example 2:
the steps different from example 1 are:
step S3, upsetting and pulling:
the blank was drawn to 750mm×750mm×1800mm in the thickness direction for the first time, and the forging ratio for the first time was 4.0 at the minimum.
Then, the blank was upset to a height h=1000 mm with a forging ratio of 1.8.
Then, the billet was drawn to 750mm×750mm×1800mm, and the forging ratio was 1.8.
After the blank is drawn, the blank is inverted, and the blank is thick to a height h=920 mm, and the manufacturing ratio is 1.9.
Finally, the outer circle of the blank is rounded to phi 1200mm, and the total forging ratio of the blank is 9.5.
Step S5, spinning: based on the center of the wall thickness, as shown in FIG. 2, the outer edge side (L1) is pressed first, and the inner edge side (L2) is pressed later, the pressing amounts of (L1) and (L2) are the same, and the pressing amount is 95mm. Step S7, ring rolling: as shown in the figure 3 of the drawings,the forging detection results are as follows:
TABLE 2
Comparative example 1:
the steps different from example 1 are:
step S3, upsetting and pulling:
the blank is drawn for the first time, and drawn to 1000mm multiplied by 1025mm along the thickness direction, and the forging ratio of the first drawing is 2.3 at the lowest.
Then, the billet was upset to a height h=920 mm, and the forging ratio was 1.1.
Then, the billet was drawn to 1000mm×1000mm×1025mm, and the forging ratio was 1.1.
After the blank is drawn, the blank is inverted, and the blank is thick to a height h=920 mm, and the manufacturing ratio is 1.1.
Finally, the outer circle of the blank is rounded to phi 1200mm, and the total forging ratio of the blank is 5.6.
The forging detection results are as follows:
TABLE 3 Table 3
Conclusion:
1. the main difference between comparative example 1 and example 1 is that the ratio of forging by forging is different, and the test result of comparative example 1 has a lower grain size and lower mechanical properties than the test result of example 1.
2. Echo signals exceeding standards appear in a plurality of areas in the forge piece, and more defects appear. The side proves that when the forging ratio does not reach the set window, the ideal defect eliminating effect cannot be achieved.
Comparative example 2:
the steps different from example 1 are:
step S3, upsetting and pulling:
the blank is drawn for the first time, and drawn to 800mm×800mm×1600mm along the thickness direction, and the forging ratio of the first drawing is 3.6 at the minimum.
Then, the billet was upset to a height h=920, and the forging ratio was 1.7.
Finally, the outer circle of the blank is rounded to phi 1200mm, and the total forging ratio of the blank is 5.3.
Step S7, ring rolling: the uniform speed ring rolling mode is adopted, and the speed is 1.5mm/s.
The forging detection results are as follows:
TABLE 4 Table 4
Conclusion:
1. the main difference between comparative example 1 and example 1 is that the upsetting process is different, the test result of comparative example 2 has a lower grain size and more defects than the test result of example 1, and the mechanical properties are reduced.
2. The uniformity of the crystal structure of comparative example 2 was poor and the crystal structure was locally organized to agglomerate. The forging obtained in comparative example 2 detected a plurality of ultrasonic echo signals, indicating that forging defects exist in the tissue.
The technical features of the above-described embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above-described embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The above examples illustrate only a few embodiments of the invention, which are described in detail and are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (8)
1. A process for roll forming a flange of a housing, comprising the steps of:
s1, blanking;
step S2, heating: heating and preserving heat of the plate blank;
step S3, upsetting and pulling: the blank is subjected to primary drawing, the forging ratio of the primary drawing is 3.6 at the lowest, then primary upsetting is carried out, the forging ratio of the primary upsetting is 1.6 at the lowest, then the blank is subjected to secondary drawing, the forging ratio of the secondary drawing is 1.6 at the lowest, then the blank is subjected to eight directions, the blank is subjected to secondary upsetting, the forging ratio of the secondary upsetting is 1.8 at the lowest, and finally the outer edge of the blank is rounded;
step S4, punching:
step S5, spinning: taking the center of the wall thickness as a reference, pressing one side (L1) of the outer edge firstly, pressing one side (L2) of the inner edge afterwards, pressing down the same amount (L1) and (L2), and turning over the blank to perform the same spinning action;
step S6, returning to the furnace and heating: heating and preserving the blank in a furnace;
step S7, ring rolling: the special-shaped main roller and the special-shaped core roller are used for ring rolling, the initial rolling stage is a blank rounding stage a, the shaping stage b is carried out at a speed increasing speed, and the rolling curve is an exponential function Wherein x is the radial rolling amount and y is the axial rolling amount. And after the shape of the forging piece is completely formed, the forging piece enters a direct growth stage, the feeding speed of the core roller is reduced, and finally the forging piece enters a shaping stage c.
2. A process for roll forming a flange of a housing according to claim 1, characterized in that:
in the step S2, the heating temperature of the plate blank is 1230 ℃, and the heat preservation time is 3-4 hours.
3. A process for roll forming a flange of a housing according to claim 1, characterized in that:
in step S3, the total forging ratio of the billet is 8.6 or more.
4. A process for roll forming a flange of a housing according to claim 1, characterized in that: in step S5, the deformation amount of the spinning is 36%.
5. A process for roll forming a flange of a housing according to claim 1, characterized in that: in step S6, the blank was heated to 1230℃for a holding time of 1.5h.
6. A process for roll forming a flange of a housing according to claim 1, characterized in that: in the step S7, the blank rounding stage, the roller feeding speed is set to be 0.8mm/S, and the feeding speed is rapidly increased to 2mm/S after the blank rotates 3-5 circles.
7. A process for roll forming a flange of a housing according to claim 1, characterized in that: in the forming stage b, in step S7, the shape of the forging piece is completely formed, the feeding speed of the core roller is reduced to 1mm/S, and then the direct growing stage is entered.
8. A process for roll forming a flange of a housing according to claim 1, characterized in that: in step S7, when the diameter of the forging piece is 100mm different from the finished product, the feeding speed of the core roller is reduced to 0.6mm/S, and the forging piece enters a shaping stage.
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| CN202311229055.5A CN117161277A (en) | 2023-09-21 | 2023-09-21 | Rolling forming process for shell flange |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117600371A (en) * | 2024-01-17 | 2024-02-27 | 山西金正达金属制品有限公司 | Forging process of long-neck flange |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117600371A (en) * | 2024-01-17 | 2024-02-27 | 山西金正达金属制品有限公司 | Forging process of long-neck flange |
| CN117600371B (en) * | 2024-01-17 | 2024-04-09 | 山西金正达金属制品有限公司 | Forging process of long-neck flange |
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