RU2825737C9 - Device for production of shaped shells by spinning-rolling processing - Google Patents

Abstract

FIELD: metal forming.

SUBSTANCE: invention relates to devices for spinning-rolling processing of shaped shells. Device comprises three-roller head with rollers, adapter connected with machine spindle and mandrel. Mandrel has section with shaped working surface. Rollers have different radii of curvature of the working surface and are installed with different radial and axial displacements relative to the profile section of the mandrel. On the base, fastening posts are uniformly mounted along the perimeter by means of a threaded connection, on which a puller, a workpiece and a clamp are installed.

EFFECT: as a result, it is possible to obtain shaped shells with high dimensional accuracy and quality of the processed surface, and also to increase wear resistance of working surfaces of rollers and mandrel and efficiency of shells manufacturing.

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Description

The invention relates to the field of metal forming, namely to the production of profile shells of a curvilinear or conical shape on devices related to pressing and rolling machines, which represents a complex technical problem caused by large shaping efforts and friction forces, leading to a decrease in the accuracy and quality of the processed surface, as well as to a decrease in productivity.

There are devices described in the book by M.A. Greditor “Pressing works and rotary extrusion”, Moscow, Mashinostroenie publishing house, 1971, pp. 192-199, Fig. 109 “a”, “b”, Fig. 110, 111, 112.

Fig. 111, 112 pp. 196, 197 show devices with a three-roller head, in which three rollers are fixed, the head has the ability to move axially, the rollers - radially. An ejector is located inside the mandrel.

These devices are used to roll out shells from blanks with a wall thickness of up to 14 mm made of steel, up to 28 mm thick made of aluminum steel and up to 1000 mm long.

The disadvantage of this device is the lack of removal of the workpiece by a puller, and not only by an ejector, the lack of the ability to remove workpieces by rollers and the impossibility of forming a profile surface of workpieces.

The closest in technical essence and achievable technical result is the device described in the Russian Federation patent No. 2527541 C1, 2013, published 10.09.2014, Bulletin No. 25.

The device includes a three-roller head with rollers, a mandrel, an adapter connected by mounting seats to the machine spindle and the mandrel, a puller, the opening of which is made with a diameter greater than the diameter of the mandrel, while the rollers are made of a triangular or trapezoidal profile with apexes rounded by radius and are installed with axial and radial offsets between themselves equal to 0.1÷0.7 of the depth of the deformed layer of the workpiece.

This device was adopted by the authors as a prototype.

As can be seen from this technical solution, the process of shaping is carried out by rollers on a cylindrical mandrel (Fig. 1, Fig. 2, Fig. 3, Fig. 4) with a working cylindrical surface.

The working surfaces of the rollers are made triangular or trapezoidal in shape, which is due to the formation of cylindrical shells on a mandrel with a cylindrical working surface.

The choice of axial and radial displacement of the rollers between themselves in the prototype is determined in relation to the formation of cylindrical blanks.

The profiles of the working surfaces of the rollers - triangular and trapezoidal - are also specified in relation to the formation of cylindrical blanks.

When processing blanks on rolling machines, high forces and friction forces cause wear on the working surfaces of the rollers and mandrels, which reduces the dimensional accuracy and quality of the processed surface of the blank, and also reduces the productivity of manufacturing shells due to downtime of the rolling machine when replacing worn tools.

The main drawback of the technical solution adopted as a prototype is the impossibility of using this device in the manufacture of profile shells.

The objective of this technical solution, adopted as a prototype, was to develop a device that would increase the stability of the forming process, improve the accuracy and quality of the machined surface of thin-walled cylindrical shells of great length by reducing the vibration of rollers, mandrels, workpieces and other parts and assemblies.

Common features with the device proposed by the authors are the presence of a three-roller head with rollers installed with axial and radial offsets, an adapter connected by seats to the machine spindle and a mandrel, which is attached to the adapter by a clamping ring, a puller, the opening of which is made with a diameter larger than the diameter of the mandrel, and installed above the clamping ring of the mandrel, a clamp and fasteners.

Unlike the prototype, in the device proposed by the authors for the pressing and rolling processing of profile shells, the mandrel contains a section with a profile working surface, the rollers are made with different radii of the working surface and are installed with different radial and axial offsets relative to the profile section of the mandrel, on the base, uniformly along the perimeter, mounting posts are mounted by means of a threaded connection, on which a puller, a workpiece with an end ledge and a clamp are installed, fixed with nuts.

In particular cases, that is, in specific forms of implementation, the invention is characterized by the following features:

- the first roller installed in the direction of axial feed is one with a large radius of the working surface and with a large radial and axial offset, and subsequent rollers are installed with smaller radii and smaller radial and axial offsets;

- a wear-resistant fluorine-containing coating is applied to the working surfaces of the rollers and the mandrel in the form of a solution of the surfactant "Efren-K" in an organic solvent and a synthetic dye of the triphenylmethane series with a percentage ratio of components - mass: fluorine-containing substance and dye (0.5-0.9)%, (0.01-0.1)%, respectively;

- the working surfaces of the rollers, mandrels and the outer surface of the workpieces are provided with a protective anti-corrosion composition based on a fluorine-containing substance of the universal modifier "UM" and industrial oil with a percentage ratio of components - mass: (10÷25)%, (90÷75)%, respectively;

- the clamping hole is made with a diameter smaller than the diameter of the end ledge of the workpiece by (1÷5)%;

- a sleeve is installed between the end of the workpiece and the puller, the length of which is selected depending on the length of the workpiece overhang above the section with the profile surface of the mandrel;

- a support sleeve is placed between the puller and the pressure ring, the length of which is selected depending on the length of the workpiece overhang above the section with the profile surface of the mandrel;

- the mandrel is provided with a profile and cylindrical sections, the rollers have triangular or trapezoidal working surfaces and are installed relative to the cylindrical part of the mandrel with various radial and axial offsets, and the end clamp is made with an inner surface profile corresponding to the profile of the outer surface of the workpiece.

This is what allows us to conclude that there is a cause-and-effect relationship between the set of essential features of the declared technical solution and the technical result achieved.

The specified features, distinctive from the prototype and to which the requested scope of legal protection applies, are sufficient in all cases.

The objective of the proposed invention is to develop a device for the pressing and rolling processing of profile shells, which makes it possible to increase the accuracy of geometric dimensions, the quality of the processed surface, as well as the wear resistance of the working surfaces of the rollers and mandrel and the productivity of shell manufacturing.

The specified technical result in the implementation of the invention is achieved in that in the known device, including a three-roller head with rollers installed with axial and radial offsets, an adapter connected by mounting seats to the machine spindle and the mandrel, which is attached to the adapter by a clamping ring, a puller made with an opening, the diameter of which is larger than the diameter of the mandrel and installed above the clamping ring of the mandrel, a clamp and fastening elements, the feature is that the mandrel contains a section with a profile working surface, the rollers are made with different radii of the working surface and are installed with different radial and axial offsets relative to the profile section of the mandrel, on the base, uniformly along the perimeter, fastening posts are mounted by means of a threaded connection, on which the puller, the workpiece with an end ledge and the clamp are installed, fixed with nuts.

The new set of operations, as well as the presence of connections between them, allow, in particular, due to:

- the presence of a section with a profile working surface on the mandrel ensures the possibility of forming profile shells of a curvilinear, conical or any other complex shape;

- the production of rollers with different radii of the working surface increases the accuracy and quality of the processed surface of the workpieces as a result of the division of deformation between the rollers, i.e. the division of a continuous deformation zone into separate zones of different areas, which ensures a smooth increase in deformation along the profile section of the mandrel, and the elimination of corrugations, shrinkage and metal build-up in front of the rollers;

- installation of rollers with different radial and axial offsets relative to the profile part of the mandrel to increase the accuracy and quality of the processed surface of the workpieces as a result of dividing the deformation between the rollers, i.e. dividing the continuous deformation zone into separate zones of different areas, which ensures a smooth increase in deformation along the profile section of the mandrel, and the elimination of corrugations, shrinkage and metal build-up in front of the rollers;

- uniform installation along the perimeter of the base of the mounting posts using a threaded connection to ensure uniform distribution of the clamping forces of the workpiece on its end ledge with a clamp;

- installation on the mounting posts of the puller, the workpiece with the end ledge and the clamp, fixed with nuts, ensure reliable fastening of the workpiece on the mandrel.

The features characterizing the invention in specific forms of execution allow, in particular, due to:

- installation of a roller with a large radius of the working surface and with a large radial and axial offset as the first in the direction of axial feed, and subsequent rollers with smaller radii and smaller radial and axial offsets, to increase the accuracy and quality of the machined surface of the workpieces as a result of separating the deformations between the rollers, which ensures a smooth increase in deformation along the profile section of the mandrel, and the elimination of corrugations, shrinkage, and metal build-up in front of the rollers;

- applying a wear-resistant fluorine-containing coating to the working surfaces of the rollers and the mandrel in the form of a solution of the surfactant "Efren-K" in an organic solvent and a synthetic dye of the triphenylmethane series with a percentage ratio of components - masses: fluorine-containing substance and dye (0.5 ÷ 0.9)%, (0.01 ÷ 0.1)%, respectively, to ensure color visualization of the quality of the coating, contact zones and wear of the working surfaces, reduce the setup time and increase the wear resistance of the working surfaces and the productivity of shell manufacturing, these percentage ratios are optimal, determined experimentally, at values of the fluorine-containing substance content of less than 0.5% and dye less than 0.01%, respectively, the wear resistance of the working surfaces of the rollers and the mandrel decreases and the color visualization of the coating decreases, and at values of the fluorine-containing substance content of more than 0.9% and dye more than 0.1%, the cost of shell manufacturing increases;

- supplying the working surfaces of the rollers, mandrel and outer surface of the workpiece with a protective anti-corrosion composition based on a fluorine-containing substance of the universal modifier "UM" and industrial oil with a percentage ratio of components - masses: (10 ÷ 25)%, (90 ÷ 75)%, respectively, to reduce the friction force, increase wear resistance and anti-corrosion resistance of the working surfaces of the deforming tool - rollers and mandrel, and to increase the surface purity of the processed workpieces, these percentage ratios are optimal, determined experimentally, with values of the modifier "UM" less than 10% wear and corrosion increase, and with values more than 25% the cost of manufacturing shells increases;

- performing a clamp with a hole with a diameter smaller than the diameter of the end stop of the workpiece by (1÷5)% ensures the reliability of fastening the workpiece, this value is optimal, determined experimentally, with values of the diameter of the clamp hole less than 1% of the diameter of the end stop of the workpiece or more than 5%, the reliability of fixing the workpiece in the device decreases due to a decrease in the contact area of the clamp and the end ledge of the workpiece;

- installations between the end of the workpiece and the sleeve puller, the length of which is set depending on the length of the workpiece overhang above the section with the profile surface of the mandrel, expand the technical capabilities of the device, ensuring the possibility of forming a section with a profile surface in several passes;

- installation between the puller and the clamping ring of a support sleeve, the length of which is set depending on the length of the workpiece overhang above the section with the profile surface of the mandrel, expand the technical capabilities of the device, ensuring the possibility of forming a section with a profile surface in several passes;

- production of a mandrel with a profile and cylindrical section; use one mandrel to obtain a profile and cylindrical section of the workpiece and, as a result, increase the productivity of shell manufacturing and expand the technical capabilities of the device;

- the production of rollers with triangular or trapezoidal working surfaces ensures the formation of a cylindrical section of the workpiece on a cylindrical section of the mandrel, since this profile of the working surfaces of the rollers is optimal for processing cylindrical surfaces with high precision and quality of the processed surface of the workpieces;

- installation of rollers with triangular or trapezoidal working surfaces with different radial and axial displacements to divide the deformation between the rollers and ensure high dimensional accuracy and quality of the processed surface;

- performing end clamping with the profile of the inner working surface corresponding to the profile of the outer surface of the workpiece, to ensure reliable fastening of the workpiece on the profile section of the mandrel.

The features that distinguish the proposed technical solution from the prototype are not identified in other technical solutions and are not known from the state of the art during the patent research process, which allows us to conclude that the invention meets the criterion of “novelty”.

Having studied the state of the art during a patent search for all types of information available in the countries of the former USSR and foreign countries, it was discovered that the proposed technical solution does not clearly follow from the state of the art known today, therefore, it can be concluded that it meets the criterion of “inventive step”.

The essence of the invention lies in the fact that in the device for pressing and rolling processing of profile shells, including a three-roller head with rollers installed with axial and radial offsets, an adapter connected by seats to the machine spindle and a mandrel, which is attached to the adapter by a clamping ring, a puller made with an opening, the diameter of which is larger than the diameter of the mandrel and installed above the clamping ring of the mandrel, a clamp and fastening elements, in contrast to the prototype, according to the invention, in it the mandrel contains a section with a profile working surface, the rollers are made with different radii of the working surface and are installed with different radial and axial offsets relative to the profile section of the mandrel, on the base, uniformly along the perimeter, fastening posts are mounted by means of a threaded connection, on which the puller, the workpiece with an end ledge and the clamp are installed, fixed with nuts.

The essence of the invention is explained by drawings, where Fig. 1 shows a device for pressing and rolling processing of profile shells, in which the workpiece 1 is mounted on a mandrel 5, attached to an adapter 6 by a clamping ring 7.

Rollers 2, 3 and 4 are shown at the beginning and end of the formation of the profile section of the workpiece.

Adapter 6 is connected by means of mounting seats to mandrel 5 and spindle 8 of the pressing and rolling machine.

The mounting posts 11 are fastened to the base 6 by a threaded connection.

On the mounting posts 11, a puller 9, a workpiece 1 with an end ledge and a clamp 10 are installed, fixed with nuts 12.

D _op (mm) - diameter of the mandrel 5.

D _np (mm) - diameter of the clamp hole 10.

D _yс (mm) - diameter of the end ledge of the workpiece 1.

L _zg (mm) – the length of the projection of the workpiece 1 over the profile section of the mandrel 5.

F (mm/min) - axial feed.

n (min ^-1 ) - rotation speed.

Fig. 2, view A from Fig. 1, shows a three-roller head 13 with rollers 2, 3 and 4, a mandrel 5 and a workpiece 1.

R _p (t/s) - radial forces,

n (min ^-1 ) - rotation speed.

Fig. 3 shows a diagram of the formation of a profile section of workpiece 1 by rollers 2, 3 and 4 with working surface sections R ₂ (mm), R ₃ (mm) and R ₄ (mm) on the profile section of mandrel 5.

Δ ₁ (mm), Δ ₂ (mm) and Δ ₃ (mm) are the radial displacements of rollers 2, 3 and 4 relative to the profile section of mandrel 5.

L _2.3 (mm) and L _3.4 (mm) - axial displacements of rollers 2, 3 and 4 relative to the profile section of mandrel 5.

S ₂ (mm ² ) – area of the deformation zone of roller 2.

S ₃ (mm ² ) – area of the deformation zone of roller 3.

S ₄ (mm ² ) – area of the deformation zone of roller 4.

B, C, G and D - working surfaces of rollers 2, 3 and 4 and mandrel 5.

E - outer surface of workpiece 1.

Fig. 4 shows a variant of the device in which a sleeve 14 of length L _вт (mm) is installed between the end of the workpiece 1 and the puller 9, which is set depending on the length of the projection L _зг (mm) of the workpiece 1 above the profile surface of the mandrel 5.

Fig. 5 shows a variant of the device in which a support sleeve 15 of length L _вт (mm) is installed between the puller 9 and the clamping ring 7, which is set depending on the length of the workpiece projection L _зг (mm) above the profile section of the mandrel 5.

Fig. 6 shows a variant of the device in which the mandrel 5 is made with profile and cylindrical surfaces, the rollers 17, 18 and 19 are made with triangular or trapezoidal working surfaces and are installed relative to the cylindrical section of the mandrel 5 with various radial and axial offsets, the end clamp 20 is made with a profile of the inner working surface corresponding to the profile of the outer surface of the workpiece 16.

Fig. 7 shows a diagram of the formation of a cylindrical section of a workpiece 16 on a cylindrical section of a mandrel 5 by rollers 17, 18 and 19 with radial displacements Δ ₁₇ (mm), Δ ₁₈ (mm) and Δ ₁₉ (mm) and axial displacements L _17.18 (mm) and L _18.19 (mm) and areas of deformation zones of rollers 17, 18 and 19 on the cylindrical part of the workpiece 16: S ₁₇ (mm ² ), S ₁₈ (mm ² ), S ₁₉ (mm ² ), respectively.

3, Ж, И and К - working surfaces of rollers 17, 18, 19 and mandrel 5.

L - outer surface of workpiece 16.

The above device works as follows.

The workpiece 1 is installed on the mandrel 5 with the end with the end ledge on the puller 9 and the workpiece is fixed on the end ledge by means of the clamp 10 and nuts 12 on the fastening posts 11 (Fig. 1).

The working surfaces B, V, G and D of rollers 2, 3, 4 and mandrel 5 are coated with a wear-resistant fluorine-containing coating in the form of a solution of the surfactant “Efren-K” in an organic solvent and a synthetic dye of the triphenylmethane series.

The working surfaces B, V, G and D of rollers 2, 3, 4 and mandrel 5 and the outer surface E of workpiece 1 are provided with a protective anti-corrosion composition based on a fluorine-containing substance of the universal modifier “UM” and industrial oil.

According to the CNC program of the machine, the rotation of the spindle 8 and the device fixed on it is switched on, and the profile section of the workpiece 1 (Fig. 1, 2, 3) is formed by rollers 2, 3, 4 made with different radii of the working surface, installed in the three-roller head 13 (Fig. 2) with different radial and axial offsets relative to the profile section of the mandrel 5.

When forming a profile section of workpiece 1, roller 2 with a working surface radius of R ₂ (mm) is installed first in the direction of axial feed with a radial offset of Δ ₂ (mm) and an axial offset of L _2.3 (mm).

Roller 3 with a working surface radius of R ₃ (mm) is installed second in the direction of axial feed with a radial offset of Δ ₃ (mm) and an axial offset of L _3.4 (mm).

Roller 4 with a working surface radius of R ₄ (mm) is installed third in the direction of axial feed with a radial offset of Δ ₄ (mm) and an axial offset of L _3.4 (mm) (Fig. 3).

R ₂ >R ₃ >R ₄ , Δ ₂ >Δ ₃ >Δ ₄ , L _2.3 >L _3.4 .

The length of the projection L ₃₂ (mm) is set based on the equality of the volumes of the sections of the workpiece 1 before and after the formation of the profile section.

After the formation of the profile section according to the CNC machine program is completed, the rotation of the machine spindle and the device and the rollers return to their original position.

Nuts 12 are unscrewed from mounting posts 11 and clamp 10 is removed from posts 11.

Then the rollers from the initial position approach the working surfaces under the puller 9 and, when moving in the direction F of the axial feed of the puller 9, remove the workpiece 1 from the mandrel 5.

In a particular case (Fig. 1), the hole of the clamp 10 is made with a diameter D _pr (mm) smaller than the diameter D _yc (mm) of the end ledge of the workpiece 1 by (1÷5)%.

Also, in a particular case (Fig. 4), a sleeve 14 of length L _in (mm) is installed between the end of the workpiece 1 and the puller 9, or (Fig. 5) a sleeve 15 of length L _in (mm) is installed between the puller 9 and the clamping ring 7, the lengths of which are set depending on the length of the projection L _{in of} the workpiece 1 over the profile section of the mandrel 5.

In a particular case (Fig. 6, 7), a device is used in which the mandrel 5 is provided with profile and cylindrical sections, the rollers 17, 18 and 19 have triangular or trapezoidal working surfaces and are installed relative to the cylindrical part of the mandrel 5 with different radial Δ ₁₇ (mm), Δ ₁₈ (mm), Δ ₁₉ and axial L _17,18 , L _18,19 offsets.

Δ ₁₇ >Δ ₁₈ >Δ ₁₉ , L _17.18 >L _18.19 .

One mandrel 5 is used.

At the beginning, the profile section of the workpiece 16 is formed on the profile section of the mandrel 5 (Fig. 1).

Then, a cylindrical section of the workpiece 16 is formed on the cylindrical section of the mandrel 5 (Fig. 6, 7).

Example.

A workpiece 1 made of steel 10 with a diameter of 150 mm and a wall thickness of 5.0 mm and an end ledge diameter D _yc (mm) = 155 mm is installed on a mandrel 5 with a profile curvilinear section (Fig. 1).

Workpiece 1 is fixed on the end ledge with clamp 10 with an opening D _p = 150.5 mm.

(1÷5)% - according to the invention formula.

The profile section of the workpiece 1 is formed by rollers 2, 3 and 4 on the mandrel 5, fixed in the adapter 6, connected to the spindle of the pressing and rolling machine model DV-450, RL 60/75 or SKhP-10.

Rollers 2, 3 and 4 are made with working surface radii:

R ₂ = 140 mm, R ₃ = 120 mm, R ₄ = 10 mm and are installed with radial offsets:

Δ ₂ = 4.0 mm, Δ ₃ = 3 mm, Δ ₄ = 2.5 mm and axial displacements:

L _2.3 =7.0 mm, L _3.4 =3.0 mm.

The first roller installed in the direction of axial feed F is roller 2, the second is roller 3, and the third is roller 4.

R ₂ >R ₃ >P ₄ , Δ ₂ >Δ ₃ >Δ ₄ , L _2.3 >L _3.4 .

A device for pressing and rolling processing of profile shells, in accordance with the invention, provides the possibility of manufacturing profile shells with high precision of geometric dimensions, with high quality of the processed surface, and also makes it possible to increase the wear resistance of the working surfaces of the rollers and mandrel and the productivity of shell manufacturing.

The invention can be used in the production of various shells with a profile surface made of steel and aluminum alloys.

The stated positive effect has been confirmed by testing the device during the production of shells with a profiled surface.

Claims (7)

1. A device for producing profile shells by pressing and rolling processing, comprising a mandrel made with a section with a profile working surface, a head with rollers made with different radii of the working surface and installed with different radial offsets relative to the profile section of the mandrel, and a workpiece clamp having a ledge, characterized in that it is provided with an adapter made with the possibility of connecting a seat to the spindle of the pressing and rolling machine, a pressure ring by means of which the mandrel is attached to the adapter, a puller made with an opening with a diameter exceeding the diameter of the mandrel and installed above the pressure ring, and mounting posts uniformly mounted along the perimeter on the adapter by means of a threaded connection, on which the puller and the clamp are installed, fixed with nuts, the head is made with three rollers with working surface radii R ₂ , R ₃ and R ₄ , which are installed with a radial offset relative to the profile section of the mandrel, respectively, Δ ₂ , Δ ₃ and Δ ₄ , wherein R ₂ > R ₃ > R ₄ , Δ ₂ > Δ ₃ > Δ ₄ , the first roller installed in the direction of axial feed is one with a working surface radius of R ₂ , the second roller installed is one with a working surface radius of R ₃ and with an axial offset of L _2.3 , and the third roller is one with a working surface radius of R ₄ and with an axial offset of L _3.4 , wherein the rollers are installed with different axial offsets, which decrease in the direction opposite to the axial feed, L _2.3 > L _3.4 . 2. The device according to item 1, characterized in that a wear-resistant fluorine-containing coating is applied to the working surfaces of the rollers and the mandrel in the form of a solution of the surfactant "Efren-K" in an organic solvent and a synthetic dye of the triphenylmethane series with the following ratio of components, wt.%: surfactant 0.5-0.9, synthetic dye 0.01-0.1. 3. The device according to item 1, characterized in that the working surfaces of the rollers, the mandrel and the outer surface of the workpiece are provided with a protective anti-corrosion composition based on a fluorine-containing substance of the universal modifier "UM" and industrial oil with a component ratio, wt.%: 10-25 and 90-75, respectively. 4. The device according to item 1, characterized in that the clamp is made with an opening, the diameter of which is smaller than the diameter of the end ledge of the workpiece by 1-5%. 5. The device according to item 1, characterized in that a sleeve is installed between the end of the workpiece and the puller, the length of which is selected depending on the length of the workpiece projection above the section with the profile surface of the mandrel. 6. The device according to item 1, characterized in that a support sleeve is placed between the puller and the pressure ring, the length of which is selected depending on the length of the workpiece projection above the section with the profile surface of the mandrel. 7. A device according to any one of paragraphs 1-3, characterized in that the mandrel is provided with profile and cylindrical sections, the rollers have triangular or trapezoidal working surfaces and are installed relative to the cylindrical part of the mandrel with various radial and axial offsets, and the end clamp is made with an inner surface profile corresponding to the profile of the outer surface of the workpiece.

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