CN211938423U - Ultrasonic and induction current mixed auxiliary wedge-shaped cavity profile rolling line - Google Patents
Ultrasonic and induction current mixed auxiliary wedge-shaped cavity profile rolling line Download PDFInfo
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- CN211938423U CN211938423U CN202020126628.7U CN202020126628U CN211938423U CN 211938423 U CN211938423 U CN 211938423U CN 202020126628 U CN202020126628 U CN 202020126628U CN 211938423 U CN211938423 U CN 211938423U
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Abstract
The utility model relates to a wedge chamber section bar rolling technical field especially relates to an ultrasonic wave and induced-current mix supplementary wedge chamber section bar roll line. The horizontal calibration roller comprises a left horizontal calibration roller, a pre-rolling roller, a left ultrasonic vibration roller, a heating coil, an upper roller, a lower flat roller, a right ultrasonic vibration roller, a right height calibration roller and a right horizontal calibration carrier roller which are sequentially arranged along a rolling line, wherein the left horizontal calibration roller and the right horizontal calibration roller are composed of a left roller and a right roller which are horizontally arranged, the right height calibration roller is composed of an upper roller and a lower roller which are vertically arranged, the left ultrasonic vibration roller and the right ultrasonic vibration roller are composed of an upper roller and a lower roller which are vertically arranged, and the upper roller and the lower flat roller are vertically arranged; the ultrasonic vibration module is connected with the left ultrasonic vibration roller and the right ultrasonic vibration roller and drives the left ultrasonic vibration roller and the right ultrasonic vibration roller to vibrate ultrasonically; the heating coil is connected with an induction current source. The processing and forming performance is improved, the processing and forming difficulty is reduced, the size precision and the smoothness of the section are improved, and the processing energy consumption is reduced.
Description
Technical Field
The utility model relates to a wedge chamber section bar rolling technical field especially relates to an ultrasonic wave and induced-current mix supplementary wedge chamber section bar roll line.
Background
The selectable preparation processes of the thin-neck wedge-shaped cavity section made of the metal material mainly comprise a cold/warm/hot extrusion forming process, a cold/warm/hot drawing forming process, a milling process and a wire cut electrical discharge machining process. Common metal material thin neck wedge cavity section bars are mainly prepared from metal materials with low yield strength and low deformation resistance, such as aluminum alloy, copper alloy and low-carbon steel. The thin neck wedge-shaped cavity section is mainly prepared by adopting a cold/warm/hot extrusion forming process or a cold/warm/hot drawing forming process. However, if the metal material thin neck wedge-shaped cavity with higher yield strength, deformation resistance and hardness and lower forming strain limit is prepared, the defects that the die necking part is worn quickly to cause high cost and the transition fillet radius of the finished section is generally larger exist. For metal thin-neck wedge-shaped cavity profiles with higher yield strength and hardness and lower forming strain limit, such as medium/high carbon steel thin-neck wedge-shaped cavity profiles, the milling process and the wire electrical discharge machining process can be selected for machining. However, the common disadvantage of these two processes is that the fiber flow lines of the metal blank are cut off, weakening the overall strength of the formed profile. In addition, in the milling process, the diameter of the milling cutter bar must be smaller than the width of the short side opening of the thin-neck wedge-shaped cavity, and the thin cutter bar reduces the overall rigidity of the cutter in the milling process, so that the processing speed and the stability of the processing process are reduced, and the processing precision is reduced. Moreover, for the section bar with the narrow neck part of the narrow-neck wedge-shaped cavity body with the excessively small position width and height, the section bar can hardly be processed by a milling process. The disadvantage of wire cut electrical discharge machining is that the total length of the profile is limited by the height of the machining equipment, resulting in a limitation of the total length of the profile. In addition, because the formed surface is subjected to electrochemical corrosion to form a surface oxide layer, the surface is rough and loose, and subsequent grinding and polishing treatment is required to reduce the surface roughness so as to improve the size and shape precision. Given the complex geometry of the narrow necked wedge cavity, this process significantly increases the difficulty of improving surface quality. Compared with the first three processes, the linear cutting processing speed is the slowest, and the cost-effectiveness ratio is the lowest. In the process of processing the metal thin-neck wedge-shaped cavity profile with higher yield strength and hardness and lower forming limit, the process has the advantages of low yield, over-quick abrasion of production tools/dies and serious waste of raw materials and energy. Therefore, how to prepare the thin-neck wedge-shaped cavity profile from the medium/high carbon steel strip with high yield strength and hardness by high processing efficiency on the premise of ensuring the dimensional accuracy, geometric accuracy and surface roughness of the thin-neck wedge-shaped cavity profile becomes a difficult problem in the field of plastic processing.
The induced current is applied in the plastic forming process of the metal material, so that the metal has an electro-plastic effect, a skin effect, and a fusion repair and crack arrest effect on tiny holes and microcracks. This can reduce the deformation resistance of the metal material in the forming process, and improve the forming limit, thereby improving the formability and the machinability of the metal blank. The above advantages make the induced current widely used in the field of metal rolling and rapidly developed. The difference between induction heating and pulse current is that the former can prominently heat the whole of a certain depth of the shallow surface layer of the section bar, and prominently heat the whole of the shallow surface layer metal to raise the temperature and soften, while the latter can independently find and determine the positions of the cavities and microcracks in the conducting metal shallow surface layer metal, and form eddy current to rapidly heat the cavities and microcracks and extrude the metal due to thermal expansion. The heating mode can be preferentially selected according to metals with different mechanical properties and microstructures.
The ultrasonic-assisted metal plastic forming process has two significant advantages: firstly, the ultrasonic action metal material has an ultrasonic softening effect with good instantaneity, can reduce the deformation resistance and the yield strength of the metal material in the forming process in real time, has insignificant heating and temperature rise and thermal deformation, and has the advantages of lower thermal effect and thermal load of the metal; secondly, the vibration can cause the reduction of the contact friction coefficient of the metal surface, the ultrasonic vibration has a particularly outstanding effect on reducing the friction coefficient of the metal contact surface, the application of the ultrasonic vibration in the plastic deformation process of the metal is beneficial to improving the finish quality of the metal surface of the formed part, the requirement that the surface finish is improved by further grinding and polishing after the part is formed is reduced, the environmental pollution and the production cost caused by grinding and polishing are reduced, and the production efficiency is improved. Therefore, the ultrasonic vibration is introduced into the electrically-assisted rolling process, and the ceramic roller with balanced hardness and toughness is adopted, so that the method becomes a very feasible solution to the problems of reducing the contact friction coefficient between the roller and the strip material, inhibiting the electrothermal effect from causing remarkable heating-softening behaviors of the roller and the profile and the like on the premise of not applying a fluid/liquid with lubricating and cooling functions in the electrified rolling process.
SUMMERY OF THE UTILITY MODEL
In order to overcome the defects of the prior art, the utility model provides an ultrasonic wave and induction current mixed auxiliary wedge-shaped cavity profile rolling line. Firstly, the processing method can reduce the deformation resistance of the metal blank section material strip in the rolling forming process of the metal blank section material strip, improve the forming limit and the process processing forming performance of the metal blank section material strip and reduce the rolling process processing forming difficulty of the metal blank section material strip; and secondly, the friction coefficient between the contact performance of the roller and the strip in the rolling process under the lubrication state of no/little lubricating liquid can be reduced, so that the large heat accumulation temperature rise and heating temperature rise amplitude, the severe abrasion degree of the surface of the section, the obvious heat load and thermal deformation of the roller and the section, which are caused by the higher friction coefficient, are reduced, the geometric and dimensional precision of the formed section strip after the rolling and rolling forming and the smoothness of the surface appearance are obviously improved, and the required processing energy consumption is reduced. And thirdly, realizing accurate regulation and control of the thin neck structure of the wedge-shaped cavity profile after the profile is formed by rolling and the precision grade of the wedge-shaped cavity parameter of the profile through the optimization design of the geometric parameters of the roller represented by the geometric dimension of the protruding ring belt on the special-shaped roller and the parameters of the rolling process. The utility model provides a processing method possesses the ability that realizes above-mentioned promotion rolling forming process ability and shaping back part quality promotion.
In order to achieve the above purpose, the utility model adopts the following technical scheme:
the ultrasonic and induction current mixed auxiliary wedge-shaped cavity profile rolling line is sequentially provided with a left horizontal calibration roller, a pre-rolling roller, a left ultrasonic vibration roller, a heating coil, an upper roller, a lower flat roller, a right ultrasonic vibration roller, a right height calibration roller and a right horizontal calibration carrier roller along the rolling line, wherein the left and right horizontal calibration rollers consist of a left roller and a right roller which are arranged in the horizontal direction; the ultrasonic vibration module is connected with the left ultrasonic vibration roller and the right ultrasonic vibration roller and drives the left ultrasonic vibration roller and the right ultrasonic vibration roller to vibrate ultrasonically; the heating coil is connected with an induction current source.
The left horizontal calibration roller is installed on a left horizontal calibration roller base, the pre-rolling roller is installed on a pre-rolling roller base, the left ultrasonic vibration roller is installed on a left ultrasonic vibration roller base, the right ultrasonic vibration roller is installed on a right ultrasonic vibration roller base, the right height calibration roller is installed on a right height calibration roller base, and the right horizontal calibration roller is installed on a right horizontal calibration roller base.
The left and right rollers of the left horizontal calibration roller are in elastic contact with the left and right sides of the blank section strip material, and the shapes of the left and right rollers correspond to the surfaces of the left and right sides of the blank section strip material; the left and right rollers of the right horizontal calibration roller set are in elastic contact with the left and right sides of the roll-formed section, and the shapes of the left and right rollers correspond to the surfaces of the left and right sides of the wedge-shaped groove section strip; the left and right rollers of the left horizontal calibration roller set and the right horizontal calibration roller set are cylindrical rollers.
The shapes of the upper roller and the lower roller of the pre-rolling roller are arranged in a profiling way with the shapes of the upper surface and the lower surface of the blank section strip; the shapes of the upper and lower rollers of the right height calibration roller and the shapes of the upper and lower surfaces of the rolled section are arranged in a copying way.
The upper and lower rollers of the left and right height calibration rollers are in elastic contact with the upper and lower surfaces of the blank section strip; the surface of an upper roller of the pre-rolling roller is similar to M shape, and a lower roller of the pre-rolling roller is a cylindrical roller; the upper roller and the lower roller of the right height calibration roller are cylindrical rollers.
The left ultrasonic vibration roller comprises two upper rollers and a lower roller which are arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller; the right ultrasonic vibration roller comprises two upper rollers and a lower roller which are arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller.
The roll surface of the upper roll and the lower roll of the roll set is provided with an annular belt, the width of the annular belt corresponds to the width of the narrow neck of the wedge-shaped groove profile, and the thickness of the annular belt corresponds to the depth of the wedge-shaped groove profile.
The rollers of the left horizontal calibration roller, the pre-rolling roller, the left ultrasonic vibration roller, the upper roller, the lower flat roller, the right ultrasonic vibration roller, the right height calibration roller and the right horizontal calibration carrier roller are ceramic rollers.
The inner contour of the inner cavity of the heating coil is arranged in a shape of the outline of the blank section material.
The rollers are all ceramic rollers.
Compared with the prior art, the beneficial effects of the utility model are that:
1. the C-like cross section shape of the strip to be rolled before rolling is matched, and the annular protruding roller is preferentially arranged, so that the wedge-shaped cavity hollow section with the cross section being narrow at the top and wide at the bottom and having the thin neck structure can be accurately, simply and quickly processed after rolling by the roller, the amplitude and the precision of the height and the width of the thin neck can be ensured, the design and the processing difficulty of production tools and processes can be reduced, raw materials can be saved, the production cost and the forming difficulty can be reduced, and the production efficiency can be improved.
2. In the rolling and rolling deformation process of a blank section strip material, the comprehensive effects of electric eddy current repairing and healing, ultrasonic softening and antifriction effects of cavities and microcracks generated by large deformation corresponding to electric heating effect, electro-plastic effect and induction current can be realized, the deformation resistance, yield strength and hardness in the rolling process of the strip material can be reduced in real time, the forming limit of the strip material is obviously improved on the premise of not changing the metal type, heat treatment state and stress hardening level of the blank section strip material, the plastic deformation capability of the strip material is improved, the processing and forming performance of the strip material is further improved, the processing and forming speed and the processing adaptability of the same rolling device to different metal materials, particularly high-carbon steel strip materials with large yield strength and low limit strain are improved, and the service life and the working life length of a roller are increased.
3. The induction current is utilized to flow through the strip to cause a heat effect, overcome an energy barrier, improve the diffusion capacity of metal atoms, facilitate the recovery and recrystallization of induction metal, facilitate the refinement of metal grains, realize the fine grain strengthening of the microstructure of the formed thin-neck wedge-shaped cavity section bar and improve the comprehensive mechanical property of the rolled finished section bar. Meanwhile, due to the thermal history of the strip material electric heating, the residual stress is favorably reduced, and the warping and deformation degree of the formed section bar are reduced; when induced current flows through the blank section material strip and the blank section material strip is vibrated by ultrasonic waves, the heat effect, the electro-plasticity and the ultrasonic softening effect are comprehensively acted on the blank section material strip in the rolling process, so that the plasticity of a metal material is improved, the deformation resistance of a workpiece is reduced, and the energy consumption caused by the plastic deformation is reduced; the current density of the surface layer of the steel strip is improved by using the skin effect of induced current, so that the heating area of the metal strip is mainly concentrated in the area with larger surface strain, and the energy utilization efficiency is improved; and repairing and healing the microcrack formed by the strain damage of the strain area by using the eddy current effect of the induced current.
4. The process of roll forming the thin-neck wedge-shaped cavity belongs to a plastic forming process without liquid/fluid lubrication and heat dissipation. Because of the absence of liquid/fluid, the method has the advantages of preventing corrosion and stabilizing the contact resistance of the roller and the blank section strip. However, this also causes the problems of increased friction coefficient of the contact surface between the rolling and blank section strips, severe heat generation during the rolling process, significant thermal load and deformation of the rolls, and severe wear loss of the surfaces of the rolls and the tapered cavities of the neck after forming. In order to solve the problem, the ultrasonic vibration applying method is adopted, the friction coefficient of the contact surface between the roller and the blank section strip material under the conditions of no lubrication and no heat dissipation liquid/fluid is reduced, the functions of reducing the friction heat productivity, reducing the heat accumulation speed of the roller surface, the heat load degree and the heat deformation level are realized, and the purpose of reducing the overhigh wear loss speed caused by temperature rise is further realized. The advantages can improve the processing performance of rolling the metal blank section material with larger hardness, yield strength and deformation resistance, and also can ensure that the surface of a rolled workpiece has cleaner quality, the energy required by processing and forming is lower, and the processing and forming efficiency can be obviously improved.
5. When the blank section strip is initially introduced during rolling, the rollers need to have a larger contact friction coefficient with the contact surface of the blank section strip, namely, higher-amplitude friction force is beneficial to bringing the blank section strip into the space between the upper roller and the lower roller for rolling. Thus, the ultrasonic vibrations are not applied at the initial moment of rolling, but are applied at an optimum amplitude, frequency and power to maximize the ultrasonic softening effect and the effectiveness of the ultrasonic vibrations on the contact coefficient of friction, when the blank-section strip has been introduced into the rolls, and the process of rolling the blank-section strip has been operating normally.
Drawings
FIG. 1 is a schematic diagram of the structure and a process flow diagram of the present invention.
Figure 2 is the cross section schematic diagram of the wedge-shaped cavity section bar of the invention.
Fig. 3 is a sectional view taken along the line a of fig. 1.
Fig. 4 is a sectional view taken along line B of fig. 1.
Fig. 5 is a schematic diagram of cross-sectional structural parameters of the profile blank strip of fig. 4, the specific structural parameters including α 1: demoulding angles of blank section strip materials; h 1: the height of the blank; w1 width of blank section strip; r 1: a top fillet radius.
Fig. 6 is a cross-sectional view taken along line C of fig. 1.
FIG. 7 is a cross-sectional structural parameter schematic of the blank section strip of FIG. 6, where α 2 is the strip draft angle after the blank section strip has been pre-rolled; h2 is the minor height of the blank section strip; h3 is the total height of the blank section bar material; w2 is the inner width of the blank section strip; w2 is the strip out width of the blank.
Fig. 8 is a cross-sectional view taken along line D of fig. 1.
Fig. 9 is a cross-sectional view taken along line E of fig. 1.
Fig. 10 is a sectional view taken along direction F of fig. 1.
Fig. 11 is a sectional view taken along line G of fig. 1.
Fig. 12 is a sectional view taken along line H of fig. 1.
In the figure: 1-induction current source 2-blank section bar 3-left horizontal calibration roller 4-pre-rolling roller 5-left ultrasonic vibration roller 6-heating coil 7-upper roller 8-right ultrasonic vibration roller 9-right height calibration roller 10-right horizontal calibration roller 11-left horizontal calibration roller base 12-pre-rolling roller base 13-left ultrasonic vibration roller base 14-left ultrasonic vibration module 15-lower flat roller 16-right ultrasonic vibration module 17-right ultrasonic vibration roller base 18-right height calibration roller base 19-right horizontal calibration roller base
Detailed Description
The following description of the embodiments of the present invention will be made with reference to the accompanying drawings:
as shown in fig. 1, the ultrasonic and induction current mixed auxiliary wedge-shaped cavity profile rolling line is sequentially provided with a left horizontal calibration roller 3, a pre-rolling roller 4, a left ultrasonic vibration roller 5, a heating coil 6, an upper roller 7, a lower flat roller 15, a right ultrasonic vibration roller 8, a right height calibration roller 9 and a right horizontal calibration carrier roller 10 along the rolling line. The left and right horizontal calibration rollers consist of a left roller and a right roller which are arranged in the horizontal direction, the left and right height calibration rollers consist of an upper roller and a lower roller which are arranged in the vertical direction, the left and right ultrasonic vibration rollers consist of an upper roller and a lower roller which are arranged in the vertical direction, and the upper roller 7 and the lower flat roller 15 are arranged in the vertical direction; the ultrasonic vibration module is connected with the left ultrasonic vibration roller and the right ultrasonic vibration roller and drives the left ultrasonic vibration roller and the right ultrasonic vibration roller to vibrate ultrasonically; the heating coil 6 is connected to the induction current source 1.
Two ultrasonic vibration modules are including controlling two sets ofly, left side group includes left ultrasonic vibration roll 5, left ultrasonic vibration module 14 and left ultrasonic vibration roll base 13, right side group includes right ultrasonic vibration roll 8, right ultrasonic vibration module 16 and right ultrasonic vibration roll base 17, arrange respectively that the business turn over position forms ultrasonic vibration group around thin neck wedge chamber section bar roll forming separately, the realization is to applying ultrasonic excitation to the thin neck wedge chamber section bar in-process of rolling, realize the ultrasonic softening and reduce the effect of metal section bar surface friction coefficient, and the concrete details of the mounting means of whole rolling in-process ultrasonic vibration module are as follows:
(a) the left ultrasonic vibration roller 5 is positioned at the inlet stage of rolling the thin-neck wedge-shaped cavity profile blank section bar material 2, and the two rollers are respectively arranged up and down and respectively in profiling contact with the upper surface and the lower surface of the blank section bar material 2 in a preferred matching state. The upper roller and the upper surface of the blank section strip material 2 are in a shape of a profile modeling, and are in profile modeling contact with the upper surface of the blank section strip material 2; the lower surface of the lower roller and the blank section strip material 2 is in a shape of a profile, and the lower surface of the blank section strip material 2 is a plane, so that the space of the lower roller is a cylindrical flat roller. The upper and lower rollers and the blank section strip material 2 are in a transition fit adaptive state of a surface elastic deformation contact state, and a preferred fit state. The ultrasonic vibration module 14 is positioned on the left ultrasonic roller base 13, and the generated ultrasonic vibration can be applied to the blank section strip material by driving the upper roller and the lower roller, so that the friction state between the contact surfaces of the blank section strip material 2 and the upper flat roller 7 and the lower flat roller 15 is improved, the friction coefficient of the contact roller surface in the rolling forming process of the blank section strip material 2 is reduced, and the effects of reducing the energy required by forming and the friction heating degree are achieved.
(b) The right ultrasonic vibration roller 9 is positioned at an outlet section of the blank section material 2 of the thin-neck wedge-shaped cavity section after the final rolling forming, the rollers are arranged up and down and respectively contacted with the upper surface and the lower surface of the blank section material 2 in a profiling way, and the matching state is selected preferably. The upper roller and the upper surface of the blank section strip material 2 are in a shape of a profile, and are in profile contact with the upper surface of the blank section strip material 2, and the preferred matching state is selected; the lower surface of the lower roller and the blank section strip material 2 is in a shape of a profile, and the lower surface of the blank section strip material 2 is a plane, so that the space of the lower roller is a cylindrical flat roller. The upper and lower rollers and the blank section strip material 2 are in a transition fit adaptive state of a surface elastic deformation contact state, and a preferred fit state. The right ultrasonic vibration module 16 is fixed on the right ultrasonic roller base 17, and the generated ultrasonic vibration can be applied to the blank section material strip 2 by driving the upper and lower rollers, so that the friction state between the blank section material strip 2 and the contact surface is improved, the friction coefficient in the rolling forming process of the blank section material strip 2 is reduced, and the purpose of reducing the energy required by forming and the friction heating degree is achieved.
The left and right ultrasonic roller groups excite the profile blank section strip material 2 to inject ultrasonic vibration energy, and reduce the contact friction coefficient between the contact surfaces of the upper roller 7, the lower flat roller 15 and the blank section strip material 2, so as to alleviate/reduce a series of common problems in the roll forming process caused by high contact friction coefficient, such as high heating value of the profile and the rollers, too fast surface abrasion of the profile and the rollers, high surface roughness of the formed blank section strip material and the like.
The left horizontal calibration roll 3 is fixed on the left horizontal calibration roll base 12, the left horizontal calibration roll 3 and the left horizontal calibration roll base 12 are arranged in the stage before the blank section strip 2 is preformed by rolling, the right horizontal calibration roll 11 is fixed on the right horizontal calibration roll base 20, and the right horizontal calibration roll 10 and the right horizontal calibration roll base 19 are respectively arranged in the stage of the outlet after the blank section strip 2 is formed by final rolling and is calibrated in height. Two groups of horizontal calibration rollers and horizontal calibration roller bases are arranged before and after the thin-neck wedge-shaped cavity profile is rolled, so that the horizontal positioning and calibration accuracy coordination and guarantee of the blank profile strip 2 to the upper flat roller 7 and the lower flat roller 15 are realized, the pre-rolling before the final rolling is realized, the final rolling difficulty is reduced, and the rolling accuracy is improved.
In order to realize the determination of the positioning and calibration precision of the horizontal direction of the strip 2 of the blank section and the thin-neck wedge-shaped cavity section fed to the rolling pair, the left horizontal calibration roller 3 and the right horizontal calibration roller 11 are installed in the following modes in the whole rolling process:
the left horizontal calibration roller 3 is located at the entrance section before pre-roll forming of the blank profile strip 2 of the rolled thin-neck wedge-shaped cavity profile, and the two rollers are respectively arranged left and right relative to the blank profile strip 2 and are respectively in surface contact with the left and right side surfaces of the blank profile strip 2. The left roller and the left surface of the blank section strip 2 are in a shape of a profile modeling, and are in profile modeling contact with the left surface of the blank section strip 2, and the preferred matching state is selected; the right roller and the right surface of the blank section material 2 present a profile modeling shape, and contacts with the right surface of the blank section material 2, and the preferred matching state is selected. Because the left and right surfaces of the blank section bar 2 are both planes, the space shapes of the left and right rollers are cylindrical flat rollers. The left and right rollers and the left and right side surfaces of the blank section strip 2 are in a transition fit adaptive state with a preferred elastic deformation state in a surface contact state, and the elastic force generated by the contact with the side surface of the blank section strip 2 can be applied to the blank section strip 2, so that support is provided for ensuring the horizontal positioning precision of the blank section strip 2 between the upper flat roller 7 and the lower flat roller 15.
The right horizontal calibration roller 11 is positioned at an outlet section of the blank section bar strip material 2 of the rolling thin-neck wedge-shaped cavity section bar, and the two rollers are respectively arranged on the left and right sides, are respectively contacted with the left and right side surfaces of the blank section bar strip material 2 and are in a preferred matching state. The left roller and the left surface of the blank section strip material 2 are in a shape of a profile modeling and are contacted with the left surface of the blank section strip material 2; the right roller and the right side surface of the blank section material strip 2 are in a shape of a profile, and are in contact with the right side surface of the blank section material strip 2, and the state of preferred matching is selected. Because the left side surface and the right side surface of the blank section bar material 2 are both planes, the space shapes of the left roller and the right roller are cylindrical flat rollers. The contact states of the left and right rollers and the left and right side surfaces of the blank section strip 2 are transition fit adaptation states with surface elastic deformation, and the elastic force generated by the contact with the side surface of the blank section strip 2 can be applied to the blank section strip 2 in a preferred fit state, so that support and guarantee are provided for guaranteeing the horizontal positioning accuracy of the blank section strip 2 between the upper flat roller 7 and the lower flat roller 15.
The left horizontal calibration roller 3 and the right horizontal calibration roller 10 ensure the positioning and calibration precision of the running horizontal direction of the blank section material 2, and reduce the running horizontal movement error of the blank section material 2 and the thin-neck wedge-shaped cavity section, thereby relieving a series of problems such as overlarge rolling shape deviation, unstable running process, over-poor dimensional precision and the like caused by the higher horizontal error of the blank section material 2 and the thin-neck wedge-shaped cavity section material in the rolling forming process.
The pre-rolling roller 4 is fixed on the pre-rolling roller base 12, the pre-rolling roller 4 and the pre-rolling roller base 12 are arranged at an inlet section before the blank section strip is applied with the ultrasonic vibration, the right height calibration roller 9 is fixed on the right height calibration roller base 18, and the right height calibration roller 9 and the right height calibration roller base 18 are respectively arranged at an outlet section after the blank section strip is applied with the ultrasonic vibration. Two groups of rollers and roller bases are arranged before and after the thin-neck wedge-shaped cavity profile is subjected to ultrasonic vibration, so that coordination and guarantee of height positioning and calibration accuracy of the blank profile strip 2 introduced into the upper roller 7 and the lower flat roller 15 are achieved.
The positioning and calibration precision in the height direction of the blank section bar 2 supplied by the pair roller rolling is determined, and the installation modes of the pre-rolling roller 4 and the right height calibration roller 10 in the whole rolling process are as follows:
the pre-rolling rollers 4 are located at the inlet section of the blank section strip 2 to which ultrasonic vibration excitation is applied, and the two rollers are respectively arranged up and down relative to the blank section strip and are respectively contacted with the upper surface and the lower surface of the blank section strip 2. The upper roller and the upper surface of the blank section strip material 2 are in a shape of a profile, and are in contact with the upper surface of the blank section strip material 2; the lower roller and the lower surface of the blank section material strip 2 are in a shape of a profile and are in contact with the lower surface of the blank section material strip 2. Because the upper surface of the blank section bar material 2 is in a shape close to C, the space shape of the upper roller is a special-shaped roller similar to M. The lower surface of the blank strip 2 is a flat roller, so the space shape of the lower roller is a cylindrical shape. The upper and lower rollers and the upper and lower surfaces of the blank section strip 2 are in surface contact, and are in elastic deformation state, and in a preferred transition fit adaptation state, the elastic force generated by the surface contact with the blank section strip 2 can be applied to the blank section strip 2, so that support is provided for ensuring the positioning precision of the blank section strip 2 in the height direction between the upper roller 7 and the lower flat roller 15.
The right height calibration roller 10 is located at the exit section of the blank section strip 2 after being ultrasonically excited, and the two rollers are arranged up and down respectively and are in contact with the upper and lower surfaces of the blank section strip 2. The upper roller and the upper surface of the blank section strip material 2 are in a shape of a profile, and are in contact with the upper surface of the blank section strip material 2; the lower roller and the lower surface of the blank section material strip 2 are in a shape of a profile and are in contact with the lower surface of the blank section material strip 2. Because the upper surface and the lower surface of the blank section bar material 2 are both planes, the space shapes of the upper roller and the lower roller are cylindrical flat rollers. The upper and lower rollers are in surface elastic deformation and in a preferred transition fit adaptation state with the upper and lower surfaces of the blank section strip 2, and the elastic force generated by the contact with the upper and lower surfaces of the blank section strip 2 can be applied to the blank section strip 2, so that support is provided for ensuring the positioning precision of the blank section strip 2 in the height direction between the upper roller 7 and the lower flat roller 15.
The pre-rolling roller 4 and the right height calibration roller 10 ensure the positioning and calibration precision of the running height direction of the blank section strip material 2, and reduce the height motion error of the feeding running of the blank section strip material 2, thereby alleviating a series of problems such as overlarge rolling shape error, unstable rolling running process, and ultra-poor dimensional precision of a thin-neck wedge-shaped cavity after forming caused by the high positioning error of the blank section strip material 2 in the rolling forming process of the upper roller 7 and the lower flat roller 15.
The arrangement positions are based on the fact that rolling of the thin-neck wedge-shaped cavity section bar can be finished in a qualified mode, and the front, back, left and right arrangement of the relative positions of the devices is not fixed uniquely.
The utility model discloses in, induction power supply 1's electric current homoenergetic is so that the blank section bar strip 2 by rolling produces induced-current and forms the return circuit. And only one set of induction coils 6 is connected to the induction power supply 1 during rolling. In the rolling process, the upper roll group and the lower roll group rotate and do not generate displacement change, and the section blank section material 2 is driven by the relative rotation of the upper roll 7 and the lower flat roll 15 to run from the front of the upper roll 7 and the lower flat roll 15 to the back of the rolls for forming.
The utility model discloses a work flow as follows: the section blank section material 2 to be rolled is placed between the left horizontal calibration roller 3 and the pre-rolling roller 4 which enter the guide rollers arranged in pairs, and the section blank section material 2 runs from the front of the rollers to the back of the rollers under the driving of the relative rotation of the paired roller sets. The induction coil is contacted with a profile blank profile material 2 to be rolled, a power supply is switched on, the upper roller 7 and the lower flat roller 15 are started to enable the profile blank profile material 2 to move from left to right in the horizontal direction, the profile blank profile material 2 is rolled and formed, bulges on the left side and the right side of the cross section of the blank profile material are rolled and deformed by the rollers, strain towards the middle is generated, a profile with a hollow thin neck wedge-shaped cavity structure with a narrow upper cross section and a wide lower cross section is formed, the width and the height of a thin neck after the thin neck wedge-shaped cavity profile is formed are accurately controlled due to the self width of a raised ring belt on the upper roller 7, and the height of the thin neck wedge-shaped cavity can also be accurately controlled with the help of the optimized geometric shape of the cross section of the profile blank profile material 2. The serious consequence that the size error of the workpiece is overlarge due to the matching interference between the workpiece and the electrode can be avoided. The left ultrasonic roller 6 is in elastic contact with the upper surface and the lower surface of the blank section material 2, and the right ultrasonic roller 8 is in elastic contact with the upper surface and the lower surface of the blank section material 2. Ultrasonic vibration is applied differently in the initial stage of rolling, and after the rolling blank section strip material 2 is introduced into the upper roller 7 and the lower flat roller 15 for rolling forming for a period of time, the ultrasonic vibration is applied, so that the problem that the introduction of the blank section strip material 2 is difficult caused by the fact that the friction coefficient of the contact surface between the guide roller and the blank section strip material 2 is reduced by applying the ultrasonic vibration in the initial stage is avoided.
The working rolling roller for rolling the profile blank profile strip material 2 can be a ceramic roller. Preferably the fracture strength, bending strength, hardness, toughness and ultimate strain are sufficient to meet the ceramic work rolls used in the production of rolling mills. The ceramic roller is selected as the working roller of the rolling mill, so that the insulating property of the roller can be ensured, the heat energy and the electro-plasticity generated when induced current passes through the roller can be avoided, the defect that the softening of the metal roller is obvious due to obvious temperature rise is overcome, the ceramic roller has stable mechanical property due to the lower production temperature, the abrasion rate of the roller is reduced, and the electric energy is saved.
Fig. 2 is a schematic diagram of a cross-sectional geometry of a specific formed narrow-neck wedge-shaped cavity profile shown in an embodiment, the cross-sectional geometry of the formed profile includes not only a hollow wedge-shaped cavity shape, but also a width and a height of a narrow-neck structure, and specific parameters need to be obtained with a certain level of precision through forming control. In the figure L represents the inner width, D the outer width and H the profile height. Due to the small width value of the thin neck in the thin neck structure, the traditional milling processing of the wedge-shaped cavity hollow section is difficult to implement.
Fig. 3 is a schematic sectional view of a left horizontal calibration roll a-a according to an embodiment, which shows functional links of horizontal positioning and calibration of a blank profile strip profile to be rolled before a link of final roll forming of a thin-necked wedge-shaped cavity profile, including cross-sectional shapes of the blank profile strip to be roll formed and the left horizontal calibration roll, and schematic diagrams of mutual matching, corresponding to the section a-a in the general flow diagram of fig. 1.
Fig. 5 is a schematic diagram of the cross-sectional structural parameters of the blank profile before pre-rolling, which includes specific structural parameters α 1: demoulding angles of blank section strip materials; h 1: the height of the blank; w1 width of blank section strip; r 1: a top fillet radius.
FIG. 7 is a schematic diagram of the cross-sectional structural parameters of a strip of a blank section after pre-rolling and before final rolling, and a schematic diagram of the cross-sectional structural parameters of a strip of a blank section after pre-rolling and before final rolling (α 2: strip draft angle after pre-rolling of a blank section; h 2: minor height of strip of a blank section; h 3: total height of strip of a blank section; w 2: inner width of strip of a blank section; w 3: outer width of strip of a blank section), where α 2 is strip draft angle after pre-rolling of a blank section; h2 is the minor height of the blank section strip; h3 is the total height of the blank section bar material; w2 is the inner width of the blank belt material; w2 is the strip out width of the blank. The magnitude of the demoulding angle is designed preferentially, and the process that the upper roller rolls into the blank section material strip and breaks away from the blank section material strip is smoothened.
FIG. 9 is a schematic cross-sectional view E-E of a blank section prior to entering an induction heating coil, specifically including an insulation layer, a profiling induction heating coil, and a blank section strip. Corresponding to the schematic E-E cross-section before the final rolling in fig. 1. As can be seen, after roll forming, a hollow structure with a wedge-shaped cavity and a thin neck structure are formed.
The utility model provides a processing method which can firstly reduce the deformation resistance of the section bar strip in the rolling forming process of the metal blank section bar strip, improve the forming limit and the process forming performance of the metal blank section bar strip and reduce the rolling process forming difficulty of the metal blank section bar strip; and secondly, the friction coefficient between the contact performance of the roller and the strip in the rolling process under the lubrication state of no/little lubricating liquid can be reduced, so that the large heat accumulation temperature rise and heating temperature rise amplitude, the severe abrasion degree of the surface of the section, the obvious heat load and thermal deformation of the roller and the section, which are caused by the higher friction coefficient, are reduced, the geometric and dimensional precision of the formed section strip after the rolling and rolling forming and the smoothness of the surface appearance are obviously improved, and the required processing energy consumption is reduced. And thirdly, realizing accurate regulation and control of the thin neck structure of the wedge-shaped cavity profile after the profile is formed by rolling and the precision grade of the wedge-shaped cavity parameter of the profile through the optimization design of the geometric parameters of the roller represented by the geometric dimension of the protruding ring belt on the special-shaped roller and the parameters of the rolling process. The utility model provides a processing method possesses the ability that realizes above-mentioned promotion rolling forming process ability and shaping back part quality promotion.
Under the assistance of induced current and ultrasonic vibration dual energy excitation with preferred characteristic parameters, the width size of the thin neck part is regulated and controlled by adopting an initial blank section material with a C-like cross section shape which is optimally designed, and a roller with a protruding ring belt is adopted to regulate and control and realize regulation and calibration of related size and precision. The method comprises the steps of realizing the regulation and the precision calibration of the height of the thin neck and quickly preparing the wedge-shaped cavity section with a smooth integral surface and a local structure of the thin neck by the optimization of the geometric shape of the initial cross section of the blank section strip (2) and related structural dimension parameters and the optimization of the center distance of a pair of rollers formed in the rolling process and the geometric dimension parameters of the protruding section strip.
The utility model discloses mainly be with the initial blank section bar area material through preferred cross section geometry, under the excitation is united with induced-current technique and the dual energy preferred parameter of ultrasonic wave in the thin neck wedge chamber forming process of rolling, designed on this basis can show the shaping quality that promotes thin neck wedge chamber section bar, cost-effective ratio and the workable ability of roll processing forming technique, can show and promote roll forming back section bar finish, reduce the frictional heating intensification range in the production process, reduce the heat load and the thermal strain level of relevant roll and section bar.
The utility model discloses mainly to hardness, intensity on the high side and the shaping limit on the low side metal blank section bar area material, can promote the induced-current and the dual supplementary rolling processing method of ultrasonic wave of its processing nature, formability and usability. In order to make section bar formability and processing cost more than higher, workable formability better, geometry and size precision are higher after the shaping, whole mechanical properties is more stable, even and optimization, and the grain size is more tiny, the thin neck wedge chamber section bar that residual stress is littleer, the utility model provides a use induction-current and ultrasonic vibration to roll the in-process jointly, carry out the rolling production of thin neck wedge chamber section bar.
The utility model discloses the technical problem that will solve is: the method aims at providing a process for roll forming a thin-neck wedge-shaped cavity sectional material which is made of metal and has higher plastic roll forming processing difficulty, can reduce the processing difficulty, improve the processing performance and cost ratio of metal materials, improve the quality of the geometric precision and the dimensional precision of a formed part and the forming processing efficiency, inhibit the temperature rise of the sectional material, improve the surface smoothness after forming, reduce the defects of larger heat load, larger thermal deformation, serious abrasion and the like of a roller and the sectional material caused by higher friction coefficient in the roll forming process, improve the production efficiency and roll-form the thin-neck wedge-shaped cavity sectional material with high dimensional precision.
The utility model discloses an induced-current excitation is realized through following technical scheme: a method for rolling and forming a wedge-shaped cavity profile special-shaped roller with a thin neck structure by ultrasonic wave and induction current mixed assistance is characterized in that a mounting mode of a blank profile strip comprises the steps that an induction current source forms a closed loop through a heating coil which is profiled with the blank profile strip, and the integral heating of a profile shallow surface layer with controllable heating depth in the rolling process of the thin neck wedge-shaped cavity profile is realized by utilizing the skin effect of the induction current and regulating and controlling the current frequency; by utilizing the electro-plasticity of the metal material and matching with the extrusion of the section bar in the rolling process to repair the strain damage and the pressing healing of the cavities and the microcracks, the deformation resistance of the metal with higher yield strength is reduced, the initiation-expansion of the cavities and the microcracks on the shallow surface layer of the section bar caused by the overlarge strain is timely inhibited and repaired, the plastic forming performance of the wedge-shaped cavity section bar with the thin-neck structure of the metal difficult to be plastically processed is improved, and the forming efficiency, the energy utilization efficiency, the finish quality of the finished surface and the quality of the finished product of the rolling process are obviously improved.
The above, only be the concrete implementation of the preferred embodiment of the present invention, but the protection scope of the present invention is not limited thereto, and any person skilled in the art is in the technical scope of the present invention, according to the technical solution of the present invention and the utility model, the concept of which is equivalent to replace or change, should be covered within the protection scope of the present invention.
Claims (9)
1. The ultrasonic and induction current mixed auxiliary wedge-shaped cavity profile rolling line is characterized in that a left horizontal calibration roller, a pre-rolling roller, a left ultrasonic vibration roller, a heating coil, an upper roller, a lower flat roller, a right ultrasonic vibration roller, a right height calibration roller and a right horizontal calibration carrier roller are sequentially arranged along the rolling line, the left horizontal calibration roller and the right horizontal calibration roller are composed of a left roller and a right roller which are arranged in the horizontal direction, the pre-rolling roller and the right height calibration roller are composed of an upper roller and a lower roller which are arranged in the vertical direction, the left ultrasonic vibration roller and the right ultrasonic vibration roller are composed of an upper roller and a lower roller which are arranged in the vertical direction, and the upper roller and the lower flat roller; the ultrasonic vibration module is connected with the left ultrasonic vibration roller and the right ultrasonic vibration roller and drives the left ultrasonic vibration roller and the right ultrasonic vibration roller to vibrate ultrasonically; the heating coil is connected with an induction current source.
2. The ultrasonic and induction current hybrid assisted wedge cavity profile mill pass line of claim 1, wherein the left horizontal calibration roll is mounted on a left horizontal calibration roll base, the pre-rolling roll is mounted on the pre-rolling roll base, the left ultrasonic vibrating roll is mounted on the left ultrasonic vibrating roll base, the right ultrasonic vibrating roll is mounted on the right ultrasonic vibrating roll base, the right height calibration roll is mounted on the right height calibration roll base, and the right horizontal calibration idler is mounted on the right horizontal calibration idler base.
3. The ultrasonic and induction current hybrid assisted wedge cavity profile mill pass line of claim 1, wherein the left and right rolls of the left horizontal alignment roll set are in resilient contact with the left and right sides of the blank profile strip, and the left and right rolls of the right horizontal alignment roll set are in resilient contact with the left and right sides of the roll formed profile; the left and right rollers of the left horizontal calibration roller set and the right horizontal calibration roller set are cylindrical rollers.
4. The ultrasonic and induction current hybrid assisted wedge cavity profile mill pass line of claim 1, wherein the pre-rolling roll upper and lower roll shapes are contoured to the upper and lower surface shapes of the blank profile strip; the shapes of the upper and lower rollers of the right height calibration roller and the shapes of the upper and lower surfaces of the rolled section are arranged in a copying way.
5. The ultrasonic and induction current hybrid assisted wedge cavity profile mill pass line of claim 4, wherein the left and right height calibration rolls upper and lower rolls are in elastic contact with upper and lower surfaces of the blank profile strip; the surface of an upper roller of the pre-rolling roller is similar to M shape, and a lower roller of the pre-rolling roller is a cylindrical roller; the upper roller and the lower roller of the right height calibration roller are cylindrical rollers.
6. The ultrasonic and induction current hybrid assisted wedge cavity profile mill pass line of claim 1, wherein the left ultrasonic vibration roll comprises two upper rolls and one lower roll arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller; the right ultrasonic vibration roller comprises two upper rollers and a lower roller which are arranged up and down; the shape of the two upper rollers is arranged in a shape copying way with the shape of the upper surface of the blank strip material, and the lower roller is a cylindrical flat roller.
7. The ultrasonic and induction current hybrid assisted wedge cavity profile rolling line of claim 1, wherein the roll surfaces of the upper and lower rolls of the roll set are provided with an annulus, the width of the annulus corresponds to the width of the narrow neck of the wedge groove profile, and the thickness of the annulus corresponds to the depth of the wedge groove profile.
8. The ultrasonic and induction current hybrid auxiliary wedge cavity profile rolling line of claim 1, wherein the rolls of said left horizontal calibration roll, pre-rolling roll, left ultrasonic vibration roll, upper roll, lower flat roll, right ultrasonic vibration roll, right height calibration roll, right horizontal calibration idler are ceramic rolls.
9. The ultrasonic and induction current hybrid assisted wedge cavity profile roll line of claim 1, wherein the inner contour of the cavity inside the heater coil follows the outline of the green section strip and the exterior of the heater coil is provided with insulation.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111136102A (en) * | 2020-01-20 | 2020-05-12 | 中冶焦耐(大连)工程技术有限公司 | Ultrasonic and induction current mixed auxiliary wedge-shaped cavity profile rolling line and rolling process |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111136102A (en) * | 2020-01-20 | 2020-05-12 | 中冶焦耐(大连)工程技术有限公司 | Ultrasonic and induction current mixed auxiliary wedge-shaped cavity profile rolling line and rolling process |
| CN111136102B (en) * | 2020-01-20 | 2024-10-01 | 中冶焦耐(大连)工程技术有限公司 | Ultrasonic and induced current mixed auxiliary wedge-shaped cavity profile rolling process |
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