CN118558739A - A three-roller cross-rolling forming method for hollow shafts of equal wall thickness based on mandrel control - Google Patents
A three-roller cross-rolling forming method for hollow shafts of equal wall thickness based on mandrel control Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B17/00—Tube-rolling by rollers of which the axes are arranged essentially perpendicular to the axis of the work, e.g. "axial" tube-rolling
- B21B17/02—Tube-rolling by rollers of which the axes are arranged essentially perpendicular to the axis of the work, e.g. "axial" tube-rolling with mandrel, i.e. the mandrel rod contacts the rolled tube over the rod length
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B25/00—Mandrels for metal tube rolling mills, e.g. mandrels of the types used in the methods covered by group B21B17/00; Accessories or auxiliary means therefor ; Construction of, or alloys for, mandrels or plugs
- B21B25/02—Guides, supports, or abutments for mandrels, e.g. carriages or steadiers; Adjusting devices for mandrels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
- B21B27/02—Shape or construction of rolls
- B21B27/024—Rolls for bars, rods, rounds, tubes, wire or the like
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Abstract
Description
技术领域Technical Field
本发明涉及空心轴的斜轧成形技术领域,尤其涉及一种基于芯棒控制的等壁厚空心轴类件三辊斜轧成形方法。The invention relates to the technical field of cross-rolling forming of hollow shafts, and in particular to a three-roll cross-rolling forming method for hollow shafts of equal wall thickness based on mandrel control.
背景技术Background Art
由于空心车轴不仅能满足车轴的强度要求,还能大大减小列车的簧下重量,提高动车组运行的平稳性和安全性,因此,列车轴普遍采用空心车轴。目前,对于空心车轴的制造加工,有的采用实心轴坯轧制后钻出内孔,这种方法虽然工艺简单,但材料浪费较大,后续冷加工量较大;也有的是将空心毛坯直接通过斜轧轧制成空心轴,该方法相较于前述方法节材节能效果显著,但是在斜轧的过程中,空心轴表面不可避免的会产生螺旋痕,而螺旋痕会降低空心轴的力学性能,同时还会增加后续机加工的加工余量,浪费材料。Since hollow axles can not only meet the strength requirements of axles, but also greatly reduce the unsprung weight of trains, and improve the stability and safety of EMU operation, hollow axles are generally used in train axles. At present, for the manufacturing and processing of hollow axles, some adopt solid axle billets for rolling and then drill the inner hole. Although this method has a simple process, it wastes a lot of materials and requires a large amount of subsequent cold processing; some directly roll the hollow billets into hollow axles through oblique rolling. Compared with the above methods, this method has significant material and energy saving effects. However, during the oblique rolling process, spiral marks will inevitably appear on the surface of the hollow shaft, which will reduce the mechanical properties of the hollow shaft, and at the same time increase the processing allowance of subsequent machining, wasting materials.
发明内容Summary of the invention
本发明所要解决的技术问题是提供一种可有效控制轧件表面的螺旋痕缺陷的基于芯棒控制的等壁厚空心轴类件三辊斜轧成形方法。The technical problem to be solved by the present invention is to provide a three-roller oblique rolling forming method for equal-wall-thickness hollow shaft-like parts based on mandrel control, which can effectively control the spiral mark defects on the surface of the rolled parts.
本发明解决上述技术问题所采用的技术方案为:一种基于芯棒控制的等壁厚空心轴类件三辊斜轧成形方法,包括以下具体步骤:The technical solution adopted by the present invention to solve the above technical problems is: a three-roller cross-rolling forming method for hollow shaft parts of equal wall thickness based on mandrel control, comprising the following specific steps:
(1)、设置三辊斜轧机的轧辊为鼓形,即包括依次设置的前锥段、圆柱段和后锥段;(1) The rollers of the three-roller cross-rolling mill are drum-shaped, i.e., they include a front cone section, a cylindrical section and a rear cone section arranged in sequence;
(2)、设定轧辊的工作母线的关系式为:(2) The relationship between the working generatrix of the roller is set as:
以使得轧制过程中在轧辊直角坐标系下任意时刻轧辊与轧件均为线接触,其中:R为轧辊上垂直轧件轴线并经轧件轴线与轧辊轴线的交点所截取剖面I-I处的轧辊半径,r0为剖面I-I处所对应的轧件截面的外半径,x为轧辊上的剖面x-x到剖面I-I的距离,剖面x-x为轧辊上垂直于轧件轴线且与剖面I-I相平行的剖面,β为轧辊轴线相对轧件轴线的轧辊偏转角,L1为轧辊前锥段的长度,L2为轧辊圆柱段的长度,L3为轧辊后锥段的长度,α1为轧辊前锥段的成形角,α3为轧辊后锥段的成形角,y为轧辊上剖面x-x处的轧辊半径; so that the roller and the workpiece are in line contact at any time in the roller rectangular coordinate system during the rolling process, wherein: R is the roller radius at section II on the roller perpendicular to the workpiece axis and intercepted through the intersection of the workpiece axis and the roller axis, r0 is the outer radius of the workpiece cross section corresponding to section II, x is the distance from section xx on the roller to section II, section xx is a section on the roller perpendicular to the workpiece axis and parallel to section II, β is the roller deflection angle of the roller axis relative to the workpiece axis, L1 is the length of the front cone section of the roller, L2 is the length of the cylindrical section of the roller, L3 is the length of the rear cone section of the roller, α1 is the forming angle of the front cone section of the roller, α3 is the forming angle of the rear cone section of the roller, and y is the roller radius at section xx on the roller;
(3)、将管坯轧件放入三辊斜轧机中,轧制时,控制轧辊绕自身轴线旋转,并向靠近管坯轧件的方向径向移动对管坯轧件进行减径段的轧制,同时四爪卡盘夹持管坯轧件轴向匀速移动,头部为锥形的芯棒插入管坯轧件中,并控制芯棒轴向移动,芯棒的移动方向与管坯轧件的移动方向相反,且使轧辊前锥段的锥面与芯棒的锥面之间的间隙在减径轧制过程中保持不变;(3) The tube billet is placed in a three-roller cross-rolling mill. During rolling, the rollers are controlled to rotate around their own axes and move radially toward the tube billet to roll the tube billet in the reduced diameter section. At the same time, the four-claw chuck clamps the tube billet and moves axially at a uniform speed. A mandrel with a conical head is inserted into the tube billet and the mandrel is controlled to move axially. The moving direction of the mandrel is opposite to that of the tube billet, and the gap between the conical surface of the front conical section of the roller and the conical surface of the mandrel remains unchanged during the diameter-reducing rolling process.
(4)、减径段轧制完成后,保持轧辊径向不动,四爪卡盘夹持管坯轧件以相同的速度继续沿同向轴向匀速移动,同时控制芯棒停止轴向移动,以对管坯轧件进行直轴段轧制;(4) After the diameter reduction section is rolled, the rollers are kept stationary in the radial direction, and the four-jaw chuck clamps the tube billet and continues to move at a uniform speed along the same axial direction at the same speed. At the same time, the mandrel is controlled to stop axial movement to roll the tube billet in a straight axial section;
(5)、直轴段轧制完成后,四爪卡盘夹持管坯轧件以相同的速度继续沿同向轴向匀速移动,轧辊向远离管坯轧件的方向径向移动对管坯轧件进行升径段的轧制,同时控制芯棒轴向移动,芯棒的移动方向与管坯轧件的移动方向相同,且使轧辊前锥段的锥面与芯棒的锥面之间的间隙在升径轧制过程中保持不变,直至升径段轧制完成,得到轧件成品。(5) After the straight shaft section is rolled, the four-jaw chuck clamps the tube billet and continues to move at a uniform speed along the same axial direction at the same speed. The roller moves radially away from the tube billet to roll the tube billet in the diameter-increasing section. At the same time, the mandrel is controlled to move axially in the same direction as the tube billet. The gap between the conical surface of the front conical section of the roller and the conical surface of the mandrel remains unchanged during the diameter-increasing rolling process until the diameter-increasing section is rolled to obtain the finished product.
进一步地,所述的步骤(3)中,设定轧辊的径向移动速度大小为vr,芯棒的轴向移动速度大小为vx,且Vr=Vxtanα 1,以使轧辊前锥段的锥面与芯棒的锥面之间的间隙在减径轧制过程中保持不变。Furthermore, in step (3), the radial moving speed of the roller is set to v r , the axial moving speed of the mandrel is set to v x , and V r =V x tan α 1 , so that the gap between the conical surface of the front conical section of the roller and the conical surface of the mandrel remains unchanged during the diameter reducing rolling process.
进一步地,所述的步骤(4)、(5)中,管坯轧件的轴向移动速度与步骤(3)中的管坯轧件的轴向移动速度相等,所述的步骤(5)中,轧辊的径向移动速度大小与步骤(3)中的轧辊的径向移动速度大小相等,为vr;所述的步骤(5)中的芯棒的轴向移动速度大小与步骤(3)中的芯棒的轴向移动速度大小相等,为vx,且Vr=Vxtanα 1,以使轧辊前锥段的锥面与芯棒的锥面之间的间隙在升径轧制过程中保持不变。Furthermore, in the steps (4) and (5), the axial movement speed of the tube billet is equal to the axial movement speed of the tube billet in the step (3); in the step (5), the radial movement speed of the roller is equal to the radial movement speed of the roller in the step (3), which is v r ; the axial movement speed of the mandrel in the step (5) is equal to the axial movement speed of the mandrel in the step (3), which is v x , and V r =V x tan α 1 , so that the gap between the conical surface of the front conical section of the roller and the conical surface of the mandrel remains unchanged during the diameter-increasing rolling process.
进一步地,芯棒的头部的锥面角度小于等于轧辊前锥段的成形角α1,芯棒的头部的最大直径小于管坯轧件的初始内径。Furthermore, the cone angle of the mandrel head is less than or equal to the forming angle α 1 of the front cone section of the roll, and the maximum diameter of the mandrel head is less than the initial inner diameter of the tube blank.
与现有技术相比,本发明的优点是本方法优化设计了轧辊的形状,使得轧制过程中在轧辊直角坐标系下任意时刻轧辊与轧件均为线接触,增加了轧制过程中轧辊对轧件成形区表面的精整次数和精整时间,有效降低了轧件表面的螺旋痕缺陷,保证了空心轴类件的力学性能,同时也减小了后续机加工的加工余量,减少了材料的浪费。此外,在减径和升径轧制过程中,通过控制轧辊的径向移动速度和芯棒的轴向移动速度,使得轧辊前锥段的锥面与芯棒的锥面之间的间隙始终保持不变,使轧制得到的空心轴类件的壁厚均匀且相等,有利于等壁厚空心轴类件内外表面的精确成形。Compared with the prior art, the advantage of the present invention is that the method optimizes the shape of the roller, so that the roller and the workpiece are in line contact at any time in the roller rectangular coordinate system during the rolling process, increasing the number of times and time for the roller to finish the surface of the forming area of the workpiece during the rolling process, effectively reducing the spiral mark defects on the surface of the workpiece, ensuring the mechanical properties of hollow shaft parts, while also reducing the processing allowance of subsequent machining and reducing material waste. In addition, during the diameter reduction and diameter increase rolling process, by controlling the radial movement speed of the roller and the axial movement speed of the mandrel, the gap between the conical surface of the front cone section of the roller and the conical surface of the mandrel remains unchanged, so that the wall thickness of the hollow shaft parts obtained by rolling is uniform and equal, which is conducive to the precise forming of the inner and outer surfaces of hollow shaft parts with equal wall thickness.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明轧制过程中轧辊、轧件、四爪卡盘以及芯棒的配合示意图;FIG1 is a schematic diagram of the coordination of the rolls, the workpiece, the four-jaw chuck and the mandrel in the rolling process of the present invention;
图2为本发明的轧辊的结构示意图;FIG2 is a schematic structural diagram of a roller according to the present invention;
图3为本发明的芯棒的结构示意图;FIG3 is a schematic structural diagram of a mandrel of the present invention;
图4为本发明轧制过程中轧辊与轧件的投影对比图;FIG4 is a projection comparison diagram of the roll and the workpiece during the rolling process of the present invention;
图5为图4中剖面I-I的左视图;Fig. 5 is a left side view of the section I-I in Fig. 4;
图6为本发明的管坯轧件的减径段的轧制状态示意图;FIG6 is a schematic diagram of the rolling state of the reduced diameter section of the tube blank rolled piece of the present invention;
图7为本发明的管坯轧件的直轴段的轧制状态示意图;FIG7 is a schematic diagram of the rolling state of the straight shaft section of the tube blank rolled piece of the present invention;
图8为本发明的管坯轧件的升径段的轧制状态示意图;FIG8 is a schematic diagram of the rolling state of the pipe blank rolled piece of the present invention at the diameter increasing section;
图9为本发明的不同轧制阶段轧辊与轧件接触的右视投影图;FIG9 is a right side projection diagram of the contact between the roller and the workpiece at different rolling stages of the present invention;
图10为通过常规的盘形轧辊轧制得到的轧件效果图;FIG10 is a diagram showing the effect of a rolled piece obtained by conventional disc roller rolling;
图11为通过本发明优化后的轧辊轧制得到的轧件效果图。FIG. 11 is a diagram showing the effect of a rolled piece obtained by rolling with the optimized rollers of the present invention.
具体实施方式DETAILED DESCRIPTION
以下结合附图实施例对本发明作进一步详细描述。The present invention is further described in detail below with reference to the accompanying drawings.
如图所示,一种基于芯棒控制的等壁厚空心轴类件三辊斜轧成形方法,包括以下具体步骤:As shown in the figure, a three-roller cross-rolling forming method for hollow shaft parts of equal wall thickness based on mandrel control includes the following specific steps:
(1)、设置三辊斜轧机的轧辊1为鼓形,即包括依次设置的前锥段11、圆柱段12和后锥段13;(1) The roller 1 of the three-roller cross-rolling mill is drum-shaped, that is, it includes a front cone section 11, a cylindrical section 12 and a rear cone section 13 arranged in sequence;
(2)、设定轧辊1的工作母线的关系式为:(2) The relationship between the working generatrix of roller 1 is set as:
以使得轧制过程中在轧辊直角坐标系下任意时刻轧辊1与轧件均为线接触,具体为:在轧辊1上垂直轧件轴线并经轧件轴线与轧辊轴线的交点截取剖面I-I,在轧辊1上离剖面I-I距离x处截取平行的剖面x-x,如图4所示,两个剖面与轧辊轴线的交点在左视图的投影分别为OI和O x ,轧件的轴心为O,如图5所示,由于轧辊偏转角一般很小(±10°),轧辊截面在左视图可近似为圆,但因轧辊偏转角的存在,在左视图中剖面x-x的圆心从OI点移至O x 点;因此,上述关系式中,R为轧辊上剖面I-I处的轧辊半径,r0为在剖面I-I处所对应的轧件截面的外半径,x为轧辊1上的剖面x-x到剖面I-I的距离,β为轧辊轴线相对轧件轴线的轧辊偏转角,L1为轧辊前锥段11的长度,L2为轧辊圆柱段12的长度,L3为轧辊后锥段13的长度,α1为轧辊前锥段11的成形角,α3为轧辊后锥段13的成形角,y为轧辊上剖面x-x处的轧辊半径; So that during the rolling process, at any time in the rectangular coordinate system of the roll, the roll 1 and the workpiece are in line contact. Specifically, a section II is cut on the roll 1 perpendicular to the axis of the workpiece and through the intersection of the axis of the workpiece and the axis of the roll, and a parallel section xx is cut on the roll 1 at a distance x from section II, as shown in Figure 4. The projections of the intersections of the two sections with the axis of the roll are O I and O x respectively in the left view, and the axis center of the workpiece is O. As shown in Figure 5, since the roll deflection angle is generally very small (±10°), the roll cross section can be approximated as a circle in the left view, but due to the existence of the roll deflection angle, the center of section xx moves from point O I to point O x in the left view; therefore, in the above relationship, R is the roll radius at section II on the roll, r0 is the outer radius of the workpiece cross section corresponding to section II, x is the distance from section xx on the roll 1 to section II, β is the roll deflection angle of the roll axis relative to the workpiece axis, and L L1 is the length of the front cone section 11 of the roller, L2 is the length of the cylindrical section 12 of the roller, L3 is the length of the rear cone section 13 of the roller, α1 is the forming angle of the front cone section 11 of the roller, α3 is the forming angle of the rear cone section 13 of the roller, and y is the roller radius at the section xx on the roller;
(3)、将管坯轧件2放入三辊斜轧机中,轧制时,控制轧辊1绕自身轴线旋转,且在整个轧制过程中轧辊1的转速保持不变,轧辊1向靠近管坯轧件2的方向以速度大小为vr径向移动对管坯轧件2进行减径段的轧制,同时四爪卡盘3夹持管坯轧件2轴向匀速移动,头部为锥形的芯棒4插入管坯轧件2中,且芯棒4的头部的锥面角度θ小于等于轧辊前锥段11的成形角α1,芯棒4的头部的最大直径dm小于管坯轧件2的初始内径,控制芯棒4以速度大小为vx轴向移动,芯棒4的移动方向与管坯轧件2的移动方向相反,且Vr=Vxtanα 1,以使轧辊前锥段11的锥面与芯棒4的锥面之间的间隙在减径轧制过程中保持不变,如图6所示;(3) Put the tube blank 2 into the three-roller cross-rolling mill. During rolling, the roller 1 is controlled to rotate around its own axis, and the speed of the roller 1 remains unchanged during the entire rolling process. The roller 1 moves radially at a speed v r in the direction close to the tube blank 2 to roll the tube blank 2 in the diameter-reducing section. At the same time, the four-jaw chuck 3 clamps the tube blank 2 and moves axially at a uniform speed. The mandrel 4 with a conical head is inserted into the tube blank 2, and the cone angle θ of the head of the mandrel 4 is less than or equal to the forming angle α 1 of the front cone section 11 of the roller. The maximum diameter d m of the head of the mandrel 4 is less than the initial inner diameter of the tube blank 2. The mandrel 4 is controlled to move axially at a speed v x . The moving direction of the mandrel 4 is opposite to that of the tube blank 2, and V r =V x tan α 1 , so that the gap between the cone surface of the front cone section 11 of the roller and the cone surface of the mandrel 4 remains unchanged during the diameter-reducing rolling process, as shown in FIG6 ;
(4)、减径段轧制完成后,保持轧辊1径向不动,四爪卡盘3夹持管坯轧件2继续以相同的速度沿同向轴向匀速移动,同时控制芯棒4停止轴向移动,以对管坯轧件2进行直轴段轧制,如图7所示;(4) After the rolling of the diameter-reducing section is completed, the roller 1 is kept radially stationary, and the four-jaw chuck 3 clamps the tube billet 2 and continues to move at a uniform speed along the same axial direction, while the mandrel 4 is controlled to stop axial movement, so as to perform straight-axis section rolling on the tube billet 2, as shown in FIG7 ;
(5)、直轴段轧制完成后,四爪卡盘3夹持管坯轧件以相同的速度继续沿同向轴向匀速移动,轧辊1向远离管坯轧件2的方向以速度大小为vr径向移动对管坯轧件2进行升径段的轧制,同时控制芯棒4以速度大小为vx轴向移动,芯棒4的移动方向与管坯轧件2的移动方向相同,且Vr=Vxtanα 1,以使轧辊前锥段11的锥面与芯棒4的锥面之间的间隙在升径轧制过程中保持不变,如图8所示,直至升径段轧制完成,得到轧件成品。(5) After the straight-axis section is rolled, the four-jaw chuck 3 clamps the tube billet and continues to move at a uniform speed along the same axial direction at the same speed. The roller 1 moves radially at a speed v r in a direction away from the tube billet 2 to roll the tube billet 2 in the diameter-increasing section. At the same time, the mandrel 4 is controlled to move axially at a speed v x . The moving direction of the mandrel 4 is the same as that of the tube billet 2, and V r =V x tan α 1 , so that the gap between the conical surface of the front conical section 11 of the roller and the conical surface of the mandrel 4 remains unchanged during the diameter-increasing rolling process, as shown in FIG8 , until the diameter-increasing section rolling is completed to obtain a finished rolled product.
本发明中轧辊工作母线的关系式的具体推导过程如下:The specific derivation process of the relationship formula of the roller working generatrix in the present invention is as follows:
由于三辊斜轧空心车轴在不同轧制阶段与轧件接触的轧辊辊面区域不同,不同轧制阶段轧辊1与轧件接触的右视投影图如图9所示。为了合理设计每个阶段轧辊工作母线,对不同轧制阶段轧辊工作母线的设计过程如下:Since the roll surface area of the three-roller oblique rolled hollow axle in contact with the workpiece is different at different rolling stages, the right-view projection diagram of the roll 1 in contact with the workpiece at different rolling stages is shown in Figure 9. In order to reasonably design the roll working generatrix at each stage, the design process of the roll working generatrix at different rolling stages is as follows:
(1)、轧件升径轧制时轧辊工作母线上任一点的半径(1) The radius of any point on the roller working generatrix during the rolling of the rolled piece
沿轧件轴线,在轧辊1的前锥段11上距剖面I-I距离L1x取垂直于轧件轴线的剖面x 1-x 1,在剖面x 1-x 1上轧辊的轴心Ox1在右视图投影如图9中的(a)所示,由图(a)可得:Along the axis of the workpiece, a section x1 - x1 perpendicular to the axis of the workpiece is taken at a distance L1x from the section II on the front cone section 11 of the roll 1. The axis Ox1 of the roll on the section x1 - x1 is projected in the right view as shown in (a) of FIG9. From FIG(a), we can get:
(1) (1)
式中:O x1 O 1为剖面x 1-x 1处轧辊的轴心Ox1到轧件轴心O1的距离;OO x1为剖面x 1-x 1处轧辊的轴心Ox1到轧辊无偏转时(即剖面I-I处)轴心O的距离;R x1为剖面x 1-x 1处的理想轧辊半径;r 1为剖面x 1-x 1处的轧件外半径;r 0为轧件成形区半径;β为轧辊轴线相对轧件轴线的轧辊偏转角,α 1为轧辊前锥段11的成形角。In the formula: O x 1 O 1 is the distance from the axis O x1 of the roller at section x 1 - x 1 to the axis O 1 of the workpiece; OO x 1 is the distance from the axis O x1 of the roller at section x 1 - x 1 to the axis O when the roller is not deflected (i.e., at section II); R x 1 is the ideal roller radius at section x 1 - x 1 ; r 1 is the outer radius of the workpiece at section x 1 - x 1 ; r 0 is the radius of the forming area of the workpiece; β is the roller deflection angle of the roller axis relative to the workpiece axis, and α 1 is the forming angle of the front cone section 11 of the roller.
由式(1)可知,要保持在轧辊减径轧制时在轧辊直角坐标系下轧辊1与轧件线接触,剖面x 1-x 1处的理想轧辊半径R x1为:From formula (1), it can be seen that in order to maintain the linear contact between roller 1 and the workpiece in the roller rectangular coordinate system during roller reducing rolling, the ideal roller radius R x 1 at the section x 1 - x 1 is:
(2) (2)
即: (3)Right now: (3)
式中:R为剖面I-I处的轧辊半径。Where: R is the roller radius at section II.
(2)、轧件直轴段轧制时轧辊工作母线上任一点的半径(2) The radius of any point on the roller working generatrix when rolling the straight shaft section of the rolled piece
沿轧件轴线,在轧辊1的圆柱段12上距剖面I-I距离L2x取垂直于轧件轴线的剖面x 2-x 2,在剖面x 2-x 2上轧辊的轴心Ox2在右视图投影如图9中的(b)所示,由图(b)可得:Along the axis of the workpiece, a section x2 - x2 perpendicular to the axis of the workpiece is taken at a distance L2x from the section II on the cylindrical section 12 of the roll 1. The axis Ox2 of the roll on the section x2 - x2 is projected in the right view as shown in (b) of Figure 9. From Figure (b), we can get:
(4) (4)
式中:O x2 O 1为剖面x 2-x 2处轧辊的轴心Ox2到轧件轴心O1的距离;OO x2为剖面x 2-x 2处轧辊的轴心Ox2到轧辊无偏转时(即剖面I-I处)轴心O的距离,R x2为剖面x 2-x 2处的理想轧辊半径。In the formula: O x 2 O 1 is the distance from the axis O x2 of the roller at section x 2 - x 2 to the axis O 1 of the workpiece; OO x 2 is the distance from the axis O x2 of the roller at section x 2 - x 2 to the axis O when the roller is not deflected (i.e. at section II); R x 2 is the ideal roller radius at section x 2 - x 2 .
由式(4)可知,要保持在轧辊直轴轧制时在轧辊直角坐标系下轧辊1与轧件线接触,剖面x 2-x 2处的理想轧辊半径R x2为:From formula (4), it can be seen that in order to keep the roller 1 in linear contact with the workpiece in the roller rectangular coordinate system during roller straight axis rolling, the ideal roller radius R x 2 at the section x 2 - x 2 is:
(5) (5)
即: (6)Right now: (6)
(3)、轧件减径轧制时轧辊工作母线上任一点的半径(3) The radius of any point on the roller working generatrix during the rolling of the workpiece
沿轧件轴线,在轧辊1的后锥段13上距剖面I-I距离L3x取垂直于轧件轴线的剖面x 3-x 3,在剖面x 3-x 3上轧辊的轴心Ox3在右视图投影如图9中的(c)所示,由图(c)可得:Along the axis of the workpiece, a section x3 - x3 perpendicular to the axis of the workpiece is taken at a distance L3x from the section II on the rear cone section 13 of the roller 1. The axis Ox3 of the roller on the section x3 - x3 is projected in the right view as shown in (c) of Figure 9. From Figure (c), it can be obtained that:
(7) (7)
式中:O x3 O 1为剖面x 3-x 3处轧辊的轴心Ox3到轧件轴心O1的距离;OO x3为剖面x 3-x 3处轧辊的轴心Ox3到轧辊无偏转时(即剖面I-I处)轴心O的距离,R x3为剖面x 3-x 3处的理想轧辊半径;r 3为剖面x 3-x 3处的轧件外半径;L2为轧辊圆柱段12的长度,α 3为轧辊后锥段的成形角。In the formula: O x 3 O 1 is the distance from the axis O x3 of the rolling mill at section x 3 - x 3 to the axis O 1 of the workpiece; OO x 3 is the distance from the axis O x3 of the rolling mill at section x 3 - x 3 to the axis O when the rolling mill is not deflected (i.e., at section II); R x 3 is the ideal roller radius at section x 3 - x 3 ; r 3 is the outer radius of the workpiece at section x 3 - x 3 ; L 2 is the length of the cylindrical section 12 of the rolling mill; α 3 is the forming angle of the rear cone section of the rolling mill.
由式(7)可知,要保持在轧辊升径轧制时在轧辊直角坐标系下轧辊1与轧件线接触,剖面x 3-x 3处的理想轧辊半径R x3为:From formula (7), it can be seen that in order to keep the roll 1 in linear contact with the workpiece in the roll rectangular coordinate system during the roll diameter increase rolling, the ideal roll radius R x 3 at the section x 3 - x 3 is:
(8) (8)
即: (9)Right now: (9)
联立式(3)、式(6)、式(9)可得,要使得整个轧制过程中在轧辊直角坐标系下任意时刻轧辊1与轧件均为线接触的轧辊工作母线的关系式如下:By combining equations (3), (6) and (9), we can get the following relationship between the roller working generatrix that ensures that the roller 1 and the workpiece are in linear contact at any time in the roller rectangular coordinate system during the entire rolling process:
。 .
对本方法采用优化后的轧辊进行空心轴轧制的轧制效果进行实验验证,具体为:The rolling effect of hollow shaft rolling using the optimized rollers in this method was experimentally verified, specifically:
分别在三辊斜轧机中采用本发明优化后的鼓形轧辊和常规的盘形轧辊对同等规格的管坯斜轧成形,且在轧制过程中采用相同的工艺参数(即:轧辊转速、管坯轴向移动速度和轧辊径向移动速度),轧制得到的轧件表面成形质量对比如图10、11所示。可见,通过优化后的鼓形轧辊轧制得到的轧件表面明显比常规的盘形轧辊轧制得到的轧件表面更加光滑,在上述相同工艺参数下通过本发明优化后的鼓形轧辊轧制得到的轧件表面轮廓最大高度Rz=1.25,而通过常规的盘形轧辊轧制得到的轧件表面轮廓最大高度Rz=2.97,轧件表面轮廓最大高度Rz为轧件表面螺旋痕的评价指标,轧件实际轮廓线与理论轮廓线的偏差为轧件的轮廓偏差,用d来表示,轧件表面轮廓最大高度Rz为:Rz=dmax-dmin,式中:dmax为最大轮廓偏差,dmin为最小轮廓偏差。由此说明通过本发明优化后的鼓形轧辊轧制空心轴类件能有效控制轧件表面的螺旋痕缺陷。此外,通过本方法能很好地使空心轴类件等壁厚。The optimized drum roll of the present invention and the conventional disc roll are respectively used in a three-roller cross-rolling mill to cross-roll the tube billets of the same specifications, and the same process parameters (i.e., roll speed, tube billet axial movement speed and roll radial movement speed) are used in the rolling process. The surface forming quality comparison of the rolled product is shown in Figures 10 and 11. It can be seen that the surface of the rolled product obtained by the optimized drum roller rolling is obviously smoother than that obtained by the conventional disc roller rolling. Under the same process parameters, the maximum height Rz of the rolled product surface profile obtained by the optimized drum roller rolling of the present invention is 1.25, while the maximum height Rz of the rolled product surface profile obtained by the conventional disc roller rolling is 2.97. The maximum height Rz of the rolled product surface profile is an evaluation index of the spiral mark on the rolled product surface. The deviation between the actual contour line of the rolled product and the theoretical contour line is the contour deviation of the rolled product, which is represented by d . The maximum height Rz of the rolled product surface profile is: Rz = dmax - dmin , where dmax is the maximum contour deviation and dmin is the minimum contour deviation. This shows that the spiral mark defect on the surface of the rolled product can be effectively controlled by rolling hollow shaft parts with the optimized drum roller of the present invention. In addition, the wall thickness of hollow shaft parts can be well made equal by this method.
本发明的保护范围包括但不限于以上实施方式,其保护范围以权利要求书为准,任何对本技术做出的本领域的技术人员容易想到的替换、变形、改进均落入本发明的保护范围。The protection scope of the present invention includes but is not limited to the above embodiments, and its protection scope is subject to the claims. Any replacement, deformation, and improvement of the technology that can be easily thought of by technicians in this field shall fall within the protection scope of the present invention.
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