CN118558739A - Three-roller oblique rolling forming method for equal-wall-thickness hollow shaft parts based on core rod control - Google Patents
Three-roller oblique rolling forming method for equal-wall-thickness hollow shaft parts based on core rod control Download PDFInfo
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- CN118558739A CN118558739A CN202410829312.7A CN202410829312A CN118558739A CN 118558739 A CN118558739 A CN 118558739A CN 202410829312 A CN202410829312 A CN 202410829312A CN 118558739 A CN118558739 A CN 118558739A
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Abstract
The invention discloses a three-roller oblique rolling forming method of hollow shaft parts with equal wall thickness based on core rod control, which is characterized in that rollers of a three-roller oblique rolling machine are set to be drum-shaped, and the shapes of the rollers are optimized so that the rollers are in line contact with rolled parts at any time under a rectangular coordinate system of the rollers in the rolling process; the method has the advantages that the shape of the roller is optimally designed, so that the roller and a rolled piece are in line contact at any moment under a rectangular coordinate system of the roller in the rolling process, the finishing times and finishing time of the roller to the surface of a rolled piece forming area in the rolling process are increased, the spiral mark defect on the surface of the rolled piece is effectively reduced, the mechanical property of hollow shaft pieces is ensured, the machining allowance of subsequent machining is reduced, and the waste of materials is reduced.
Description
Technical Field
The invention relates to the technical field of oblique rolling forming of hollow shafts, in particular to a three-roller oblique rolling forming method of a hollow shaft part with equal wall thickness based on core rod control.
Background
Because the hollow axle not only can meet the strength requirement of the axle, but also can greatly reduce the unsprung weight of the train and improve the running stability and safety of the motor train unit, the hollow axle is generally adopted by the train axle. At present, for manufacturing and processing of hollow axles, some hollow axles are drilled after being rolled by adopting a solid axle blank, and the method has the advantages of simple process, larger material waste and larger subsequent cold processing amount; the hollow blank is directly rolled into the hollow shaft through oblique rolling, and compared with the method, the method has remarkable material-saving and energy-saving effects, but in the oblique rolling process, spiral marks are inevitably generated on the surface of the hollow shaft, the spiral marks reduce the mechanical property of the hollow shaft, and meanwhile, the machining allowance of subsequent machining is increased, so that materials are wasted.
Disclosure of Invention
The invention aims to solve the technical problem of providing a mandrel control-based three-roller oblique rolling forming method for a hollow shaft class piece with equal wall thickness, which can effectively control spiral mark defects on the surface of a rolled piece.
The technical scheme adopted for solving the technical problems is as follows: a three-roller oblique rolling forming method of a hollow shaft part with equal wall thickness based on core rod control comprises the following specific steps:
(1) The rollers of the three-roller inclined rolling mill are drum-shaped, namely, the rollers comprise a front cone section, a cylindrical section and a rear cone section which are sequentially arranged;
(2) The relation of the working bus of the roller is set as follows:
So that the roller and the rolled piece are in line contact at any moment under the rectangular coordinate system of the roller in the rolling process, wherein: r is the roll radius of a section I-I of a roll, which is perpendicular to the axis of the rolled piece and is cut by the intersection point of the axis of the rolled piece and the axis of the roll, R 0 is the outer radius of the section of the rolled piece corresponding to the section I-I, x is the distance from the section x-x to the section I-I of the roll, the section x-x is the section of the roll, which is perpendicular to the axis of the rolled piece and is parallel to the section I-I, beta is the roll deflection angle of the roll axis relative to the axis of the rolled piece, L 1 is the length of a front cone section of the roll, L 2 is the length of a cylindrical section of the roll, L 3 is the length of a rear cone section of the roll, alpha 1 is the forming angle of the front cone section of the roll, alpha 3 is the forming angle of the rear cone section of the roll, and y is the roll radius of the section x-x on the roll;
(3) When the tube blank rolled piece is rolled, the control roller rotates around the axis of the control roller and moves radially towards the direction close to the tube blank rolled piece to roll the reducing section of the tube blank rolled piece, meanwhile, the four-jaw chuck clamps the tube blank rolled piece to move axially at a constant speed, the mandrel with the conical head is inserted into the tube blank rolled piece and controls the mandrel to move axially, the moving direction of the mandrel is opposite to the moving direction of the tube blank rolled piece, and the gap between the conical surface of the front conical section of the roller and the conical surface of the mandrel is kept unchanged in the reducing rolling process;
(4) After the rolling of the reducing section is finished, the roller is kept to be radial, the four-jaw chuck clamps the tube blank rolled piece to continuously move at a uniform speed along the same axial direction at the same speed, and meanwhile, the mandrel is controlled to stop moving axially so as to roll the tube blank rolled piece in a straight shaft section;
(5) After the straight shaft section rolling is finished, the four-jaw chuck clamps the tube blank rolled piece to continuously move along the same axial direction at a constant speed, the roller moves radially in the direction away from the tube blank rolled piece to roll the tube blank rolled piece in the diameter-increasing section, meanwhile, the axial movement of the core rod is controlled, the moving direction of the core rod is the same as the moving direction of the tube blank rolled piece, and the gap between the conical surface of the front conical section of the roller and the conical surface of the core rod is kept unchanged in the diameter-increasing rolling process until the diameter-increasing section rolling is finished, so that a rolled piece finished product is obtained.
Further, in the step (3), the radial moving speed of the roller is set to V r, the axial moving speed of the mandrel bar is set to V x, and V r=Vxtanα1, so that the gap between the conical surface of the front cone section of the roller and the conical surface of the mandrel bar is kept unchanged during the reducing rolling process.
Further, in the steps (4) and (5), the axial moving speed of the tube blank rolled piece is equal to the axial moving speed of the tube blank rolled piece in the step (3), and in the step (5), the radial moving speed of the roller is equal to the radial moving speed of the roller in the step (3), and v r is set; the axial moving speed of the core rod in the step (5) is equal to that of the core rod in the step (3), V x and V r=Vxtanα1 are adopted, so that the gap between the conical surface of the front cone section of the roller and the conical surface of the core rod is kept unchanged in the diameter-increasing rolling process.
Further, the conical surface angle of the head part of the core rod is smaller than or equal to the forming angle alpha 1 of the front conical section of the roller, and the maximum diameter of the head part of the core rod is smaller than the initial inner diameter of the tube blank rolled piece.
Compared with the prior art, the method has the advantages that the shape of the roller is optimally designed, so that the roller and a rolled piece are in line contact at any moment under a rectangular coordinate system of the roller in the rolling process, the finishing times and finishing time of the roller to the surface of a rolled piece forming area in the rolling process are increased, the spiral mark defect on the surface of the rolled piece is effectively reduced, the mechanical property of hollow shaft pieces is ensured, the processing allowance of subsequent machining is reduced, and the waste of materials is reduced. In addition, in the reducing and increasing rolling process, the clearance between the conical surface of the front conical section of the roller and the conical surface of the core rod is kept unchanged all the time by controlling the radial moving speed of the roller and the axial moving speed of the core rod, so that the wall thickness of the hollow shaft part obtained by rolling is uniform and equal, and the precise forming of the inner surface and the outer surface of the hollow shaft part with the same wall thickness is facilitated.
Drawings
FIG. 1 is a schematic view of the fit of a roll, a rolled piece, a four-jaw chuck and a mandrel in the rolling process of the present invention;
FIG. 2 is a schematic view of the structure of the roll of the present invention;
FIG. 3 is a schematic view of the core rod of the present invention;
FIG. 4 is a view showing a projection of a roll and a rolled piece in the rolling process according to the present invention;
FIG. 5 is a left side view of section I-I of FIG. 4;
FIG. 6 is a schematic view showing a rolled state of a reducing section of a tube blank rolled piece according to the present invention;
FIG. 7 is a schematic view of the rolling state of the straight shaft section of the tube blank rolling stock of the present invention;
FIG. 8 is a schematic view showing a rolled state of a diameter-increasing section of a tube blank rolled piece according to the present invention;
FIG. 9 is a right side projection of the roll in contact with the product at various stages of rolling in accordance with the present invention;
FIG. 10 is a view showing the effect of a rolled product obtained by conventional disc roll rolling;
Fig. 11 is a graph showing the effect of rolling a rolled product obtained by the optimized roll rolling of the present invention.
Detailed Description
The invention is described in further detail below with reference to the embodiments of the drawings.
As shown in the figure, the three-roller oblique rolling forming method of the hollow shaft parts with equal wall thickness based on the control of the core rod comprises the following specific steps:
(1) The roller 1 of the three-roller oblique rolling mill is drum-shaped, namely comprises a front cone section 11, a cylindrical section 12 and a rear cone section 13 which are sequentially arranged;
(2) The relation of the working bus of the roller 1 is set as follows:
So that the roller 1 and the rolled piece are in line contact at any moment under the rectangular coordinate system of the roller in the rolling process, specifically: the method comprises the steps of (1) perpendicularly cutting a section I-I on a roller 1 through an intersection point of the axis of the rolled piece and the axis of the roller, cutting a parallel section x-x on the roller 1 at a distance x from the section I-I, wherein projections of the intersection points of the two sections and the axis of the roller in left views are O I and O x respectively, and the axis of the rolled piece is O, as shown in FIG. 5, the section of the roller can be approximately round in the left view due to a small (+ -10 DEG) deflection angle of the roller, but the center of the section x-x is moved from O I to O x in the left view due to the existence of the deflection angle of the roller; thus, in the above relation, R is the roll radius at section I-I on the roll, R 0 is the outer radius of the section of the rolled piece corresponding to section I-I, x is the distance from section x-x to section I-I on roll 1, β is the roll deflection angle of the roll axis relative to the axis of the rolled piece, L 1 is the length of the roll front cone 11, L 2 is the length of the roll cylinder 12, L 3 is the length of the roll rear cone 13, α 1 is the forming angle of the roll front cone 11, α 3 is the forming angle of the roll rear cone 13, and y is the roll radius at section x-x on the roll;
(3) When the tube blank rolled piece 2 is put into a three-roller inclined rolling mill, the roller 1 is controlled to rotate around the axis of the roller 1, the rotating speed of the roller 1 is kept unchanged in the whole rolling process, the roller 1 radially moves towards the direction close to the tube blank rolled piece 2 at the speed of V r to roll the reducing section of the tube blank rolled piece 2, meanwhile, the four-jaw chuck 3 clamps the tube blank rolled piece 2 to axially move at a uniform speed, the mandrel 4 with the conical head part is inserted into the tube blank rolled piece 2, the conical surface angle theta of the head part of the mandrel 4 is smaller than or equal to the forming angle alpha 1 of the front cone section 11 of the roller, the maximum diameter d m of the head part of the mandrel 4 is smaller than the initial inner diameter of the tube blank rolled piece 2, the mandrel 4 is controlled to axially move at the speed of V x, the moving direction of the mandrel 4 is opposite to the moving direction of the tube blank rolled piece 2, and V r=Vxtanα1 is kept unchanged in the reducing rolling process, as shown in fig. 6;
(4) After the reducing section rolling is finished, the roller 1 is kept to be radially motionless, the four-jaw chuck 3 clamps the tube blank rolled piece 2 to continuously move at the same speed along the same axial direction at a uniform speed, and meanwhile, the mandrel 4 is controlled to stop moving axially so as to perform straight-axis section rolling on the tube blank rolled piece 2, as shown in fig. 7;
(5) After the straight shaft section rolling is finished, the four-jaw chuck 3 clamps the tube blank rolling piece to continuously move at a constant speed along the same axial direction, the roller 1 moves radially to the direction away from the tube blank rolling piece 2 at a speed of V r to roll the tube blank rolling piece 2 in the diameter-increasing section, meanwhile, the core rod 4 is controlled to move axially at a speed of V x, the moving direction of the core rod 4 is the same as the moving direction of the tube blank rolling piece 2, and V r=Vxtanα1 is adopted to ensure that the gap between the conical surface of the front cone section 11 of the roller and the conical surface of the core rod 4 is kept unchanged in the diameter-increasing rolling process, as shown in fig. 8, until the diameter-increasing section rolling is finished, and the rolled piece finished product is obtained.
The specific deduction process of the relation of the working bus of the roller in the invention is as follows:
Since the three-roll skew hollow axle has different roll surface areas in contact with the rolled piece in different rolling stages, a right side projection of the contact of the roll 1 with the rolled piece in different rolling stages is shown in fig. 9. In order to reasonably design the working bus of the roller in each stage, the working bus of the roller in different rolling stages is designed as follows:
(1) Radius of any point on working bus of roller during rolling of rolled piece in ascending diameter
Along the axis of the product, a section x 1-x1 perpendicular to the axis of the product is taken at a distance L 1x from the section I-I on the front cone section 11 of the roll 1, and the axial center O x1 of the roll on the section x 1-x1 is projected in right view as shown in fig. 9 (a), from which it is possible to obtain:
（1）
Wherein: o x1O1 is the distance from the axis O x1 of the roller at the section x 1-x1 to the axis O 1 of the rolled piece; OO x1 is the distance from the axis O x1 of the roll at section x 1-x1 to the axis O of the roll when no deflection occurs (i.e., at section I-I); r x1 is the ideal roll radius at section x 1-x1; r 1 is the outer radius of the product at section x 1-x1; r 0 is the radius of the forming zone of the rolled piece; beta is the roll deflection angle of the roll axis relative to the axis of the rolled piece, and alpha 1 is the forming angle of the roll front cone segment 11.
From formula (1), to maintain the roll 1 in line contact with the rolled material in roll rectangular coordinate system during roll reducing rolling, the ideal roll radius R x1 at section x 1-x1 is:
（2）
Namely: （3）
wherein: r is the roll radius at section I-I.
(2) Radius of any point on working bus of roller during rolling of straight shaft section of rolled piece
Along the axis of the product, a section x 2-x2 perpendicular to the axis of the product is taken at a distance L 2x from the section I-I on the cylindrical section 12 of the roll 1, and the axial center O x2 of the roll is projected on the section x 2-x2 in the right-hand view as shown in fig. 9 (b), from which it is possible to obtain:
（4）
Wherein: o x2O1 is the distance from the axis O x2 of the roller at the section x 2-x2 to the axis O 1 of the rolled piece; OO x2 is the distance from the roll axis O x2 at section x 2-x2 to the roll axis O when the roll is undeflected (i.e., at section I-I), and R x2 is the ideal roll radius at section x 2-x2.
As can be seen from the formula (4), to keep the roll 1 in line contact with the rolled piece in the roll rectangular coordinate system during the roll straight axis rolling, the ideal roll radius R x2 at the section x 2-x2 is:
（5）
Namely: （6）
(3) Radius of any point on working bus of roller during reducing rolling of rolled piece
Along the axis of the product, a section x 3-x3 perpendicular to the axis of the product is taken at a distance L 3x from the section I-I on the rear cone section 13 of the roll 1, and the axial center O x3 of the roll is projected on the section x 3-x3 in a right-hand view as shown in fig. 9 (c), from which it is possible to obtain:
（7）
Wherein: o x3O1 is the distance from the axis O x3 of the roller at the section x 3-x3 to the axis O 1 of the rolled piece; OO x3 is the distance from the axis O x3 of the roll at section x 3-x3 to the axis O of the roll when no deflection occurs (i.e., at section I-I), R x3 is the ideal roll radius at section x 3-x3; r 3 is the outer radius of the product at section x 3-x3; l 2 is the length of the cylindrical section 12 of the roll and a 3 is the forming angle of the rear cone section of the roll.
As can be seen from the formula (7), to keep the roll 1 in line contact with the rolled material in the roll rectangular coordinate system during the roll up-rolling, the ideal roll radius R x3 at the section x 3-x3 is:
（8）
Namely: （9）
The combined type (3), the formula (6) and the formula (9) can be obtained, so that the relation formula of the roll working bus which is in line contact with the rolled piece at any moment under a roll rectangular coordinate system in the whole rolling process is as follows:
。
The experimental verification of the rolling effect of hollow shaft rolling by adopting the optimized roller is carried out on the method, and the method specifically comprises the following steps:
The optimized drum-shaped roller and the conventional disc-shaped roller are respectively adopted in a three-roller oblique rolling mill for oblique rolling and forming of the tube blank with the same specification, and the same technological parameters (namely, the roller rotating speed, the tube blank axial moving speed and the roller radial moving speed) are adopted in the rolling process, so that the surface forming quality pair of rolled pieces obtained by rolling is shown in figures 10 and 11. As can be seen, the surface of the rolled product obtained by the optimized crown roll is significantly smoother than the surface of the rolled product obtained by the conventional disc roll, the maximum height R z = 1.25 of the surface profile of the rolled product obtained by the optimized crown roll according to the present invention under the same process parameters, the maximum height R z = 2.97 of the surface profile of the rolled product obtained by the conventional disc roll, the maximum height R z of the surface profile of the rolled product is an evaluation index of the spiral mark of the surface of the rolled product, the deviation of the actual profile line of the rolled product from the theoretical profile line is the profile deviation of the rolled product, denoted by d, and the maximum height R z of the surface profile of the rolled product is: r z=dmax－dmin, wherein: d max is the maximum profile deviation and d min is the minimum profile deviation. Therefore, the optimized drum-shaped roller rolling hollow shaft piece can effectively control the spiral mark defect on the surface of the rolled piece. In addition, the wall thickness of hollow shaft parts and the like can be well enabled by the method.
The protection scope of the present invention includes, but is not limited to, the above embodiments, the protection scope of which is subject to the claims, and any substitutions, modifications, and improvements made by those skilled in the art are within the protection scope of the present invention.
Claims (4)
1. A three-roller oblique rolling forming method of a hollow shaft part with equal wall thickness based on core rod control is characterized by comprising the following specific steps:
(1) The rollers of the three-roller inclined rolling mill are drum-shaped, namely, the rollers comprise a front cone section, a cylindrical section and a rear cone section which are sequentially arranged;
(2) The relation formula of the set roll working bus is as follows:
So that the roller and the rolled piece are in line contact at any moment under the rectangular coordinate system of the roller in the rolling process, wherein: r is the roll radius of a section I-I of a roll, which is perpendicular to the axis of the rolled piece and is cut by the intersection point of the axis of the rolled piece and the axis of the roll, R 0 is the outer radius of the section of the rolled piece corresponding to the section I-I, x is the distance from the section x-x to the section I-I of the roll, the section x-x is the section of the roll, which is perpendicular to the axis of the rolled piece and is parallel to the section I-I, beta is the roll deflection angle of the roll axis relative to the axis of the rolled piece, L 1 is the length of a front cone section of the roll, L 2 is the length of a cylindrical section of the roll, L 3 is the length of a rear cone section of the roll, alpha 1 is the forming angle of the front cone section of the roll, alpha 3 is the forming angle of the rear cone section of the roll, and y is the roll radius of the section x-x on the roll;
(3) When the tube blank rolled piece is rolled, the control roller rotates around the axis of the control roller and moves radially towards the direction close to the tube blank rolled piece to roll the reducing section of the tube blank rolled piece, meanwhile, the four-jaw chuck clamps the tube blank rolled piece to move axially at a constant speed, the mandrel with the conical head is inserted into the tube blank rolled piece and controls the mandrel to move axially, the moving direction of the mandrel is opposite to the moving direction of the tube blank rolled piece, and the gap between the conical surface of the front conical section of the roller and the conical surface of the mandrel is kept unchanged in the reducing rolling process;
(4) After the rolling of the reducing section is finished, the roller is kept to be radial, the four-jaw chuck clamps the tube blank rolled piece to continuously move at a uniform speed along the same axial direction at the same speed, and meanwhile, the mandrel is controlled to stop moving axially so as to roll the tube blank rolled piece in a straight shaft section;
(5) After the straight shaft section rolling is finished, the four-jaw chuck clamps the tube blank rolled piece to continuously move along the same axial direction at a constant speed, the roller moves radially in the direction away from the tube blank rolled piece to roll the tube blank rolled piece in the diameter-increasing section, meanwhile, the axial movement of the core rod is controlled, the moving direction of the core rod is the same as the moving direction of the tube blank rolled piece, and the gap between the conical surface of the front conical section of the roller and the conical surface of the core rod is kept unchanged in the diameter-increasing rolling process until the diameter-increasing section rolling is finished, so that a rolled piece finished product is obtained.
2. The three-roller skew rolling forming method of the hollow shaft type piece with the same wall thickness based on the control of the core rod, which is characterized by comprising the following steps of: in the step (3), the radial moving speed of the roller is set to be V r, the axial moving speed of the mandrel is set to be V x and V r=Vxtanα1, so that the gap between the conical surface of the front cone section of the roller and the conical surface of the mandrel is kept unchanged in the reducing rolling process.
3. The three-roller skew rolling forming method of the hollow shaft type piece with the same wall thickness based on the control of the core rod as claimed in claim 2, wherein the method comprises the following steps: in the steps (4) and (5), the axial moving speed of the tube blank rolled piece is equal to that of the tube blank rolled piece in the step (3), and in the step (5), the radial moving speed of the roller is equal to that of the roller in the step (3) and is v r; the axial moving speed of the core rod in the step (5) is equal to that of the core rod in the step (3), V x and V r=Vxtanα1 are adopted, so that the gap between the conical surface of the front cone section of the roller and the conical surface of the core rod is kept unchanged in the diameter-increasing rolling process.
4. The three-roller skew rolling forming method of the hollow shaft type piece with the same wall thickness based on the control of the core rod, which is characterized by comprising the following steps of: the angle of the conical surface of the head part of the core rod is smaller than or equal to the forming angle alpha 1 of the front conical section of the roller, and the maximum diameter of the head part of the core rod is smaller than the initial inner diameter of the tube blank rolled piece.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410829312.7A CN118558739A (en) | 2024-06-25 | 2024-06-25 | Three-roller oblique rolling forming method for equal-wall-thickness hollow shaft parts based on core rod control |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410829312.7A CN118558739A (en) | 2024-06-25 | 2024-06-25 | Three-roller oblique rolling forming method for equal-wall-thickness hollow shaft parts based on core rod control |
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| CN118558739A true CN118558739A (en) | 2024-08-30 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202410829312.7A Pending CN118558739A (en) | 2024-06-25 | 2024-06-25 | Three-roller oblique rolling forming method for equal-wall-thickness hollow shaft parts based on core rod control |
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