WO2018028168A1 - 一种轴承套圈精密锻件的加工方法 - Google Patents

一种轴承套圈精密锻件的加工方法 Download PDF

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WO2018028168A1
WO2018028168A1 PCT/CN2017/074226 CN2017074226W WO2018028168A1 WO 2018028168 A1 WO2018028168 A1 WO 2018028168A1 CN 2017074226 W CN2017074226 W CN 2017074226W WO 2018028168 A1 WO2018028168 A1 WO 2018028168A1
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heating
ring
forging
processing
bearing ring
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PCT/CN2017/074226
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English (en)
French (fr)
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李雷
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上海电机学院
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Publication of WO2018028168A1 publication Critical patent/WO2018028168A1/zh
Priority to US15/989,803 priority Critical patent/US10632524B2/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/04—Making machine elements ball-races or sliding bearing races
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H1/00—Making articles shaped as bodies of revolution
    • B21H1/06—Making articles shaped as bodies of revolution rings of restricted axial length
    • B21H1/12—Making articles shaped as bodies of revolution rings of restricted axial length rings for ball or roller bearings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/003—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass bearings

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  • the invention relates to the field of forging, in particular to a method for processing a precision forging of a bearing ring.
  • the bearing is one of the most important basic components in all mechanical motion mechanisms. It is used to transmit power, support the rotating body, and ensure the accuracy of rotation. It is the key component to keep the machine running normally. Bearings are widely used in all walks of life, and the normal operation of engines, motors, transmission systems, etc. in aircraft, rockets, ships, automobiles, trains, etc., needs to be achieved through bearings.
  • the bearing is generally composed of an inner ring, an outer ring, a ball and a cage, and the inner ring has a raceway on the outer circular surface and the inner ring inner surface. On the one hand, the raceway provides a track for ball movement and on the other hand constrains the direction of movement of the ball.
  • Bearings are used in high-temperature, high-temperature, variable-load, friction and vibration environments, and are prone to fatigue damage.
  • China has achieved certain results in the development of long-life bearings, but there are still large gaps with the United States, Germany, Sweden, Japan and other countries, some key bearings, such as high-speed railway bearings, aviation bearings, passengers Car bearings and the like are largely dependent on joint ventures or imported from abroad.
  • Several foreign bearing companies, such as Sweden's SKF, the United States TIMKEN, Germany's FAG, ZF and Japan's NSK and NTN and other multinational companies have monopolized the high-end bearing market.
  • the bearing looks simple in appearance, it has high machining precision and strict performance requirements. It is one of the most technically demanding parts of all mechanical parts.
  • These high-precision, long-life high-end bearing processing methods belong to the core technical secrets of foreign companies. It is difficult to know that they can only be based on self-sufficiency innovation.
  • the bearing ring forgings are generally formed by ring rolling method (referred to as circling).
  • the traditional production process is: “saw cutting and feeding ⁇ upsetting ⁇ heating ⁇ punching blind holes ⁇ punching through holes ⁇ one fire or multiple fires circling ⁇ ordinary Bearing ring ⁇ ... ⁇ turning the raceway”.
  • the process of “cutting and cutting ⁇ upsetting ⁇ heating ⁇ blind hole ⁇ punching through hole” in the process is to provide the ring blank for the subsequent entanglement process. It is called the ring blank process.
  • the ellipsis in the process refers to the possible heat treatment, pickling or shot peening. For some metals or alloys with high temperature strength and poor plasticity, it is generally impossible to roll and form a fire.
  • the hoisting is formed, and the raceway cannot be rolled out, and the raceway needs to be processed by the turning process after the end of rolling.
  • the conventional bearing forging production process has the following disadvantages:
  • the forging blank is easy to be eccentric, stretched and pulled, and the like, and the machining allowance is large, and it is difficult to achieve precision forming;
  • the invention proposes a short-flow circling process of a bearing ring precision forging which can realize a fire rolling forming and the raceway can also be simultaneously formed, and the process is also applicable to a metal bearing sleeve with good plasticity and low deformation resistance. Looping of precision forgings.
  • the object of the present invention is to provide a method for processing a precision forging of a bearing ring, which is used to overcome the shortcomings of the conventional bearing forming process and obtain a precision forging of the bearing ring.
  • a processing method for a bearing ring precision forging comprising the following processing flow:
  • the machining method in the step (1) is turning processing, and the ring blank can be processed by turning on a common lathe, or the ring blank can be processed by using a numerically controlled lathe, thereby shortening the process flow and obtaining a ring blank with high precision and consistency.
  • Overcoming the traditional blanking process "cutting and cutting ⁇ upsetting ⁇ heating ⁇ punching blind holes ⁇ punching through holes" has a long process flow, low precision of the processed ring blank, large dimensional dispersion, easy eccentricity during punching, and shrinkage Shortcomings such as cracking;
  • the center of the chamfered annular blank has a circular hole
  • the annular blank has a width B and a height H
  • the invention uses the chamfered annular blank to reduce the contact area between the blank and the roll, reduce the filling resistance, thereby reducing the tonnage requirement of the equipment, and more importantly, avoiding the burrs and pits by gradually deforming the chamfer. The formation of defects.
  • the heating method in the step (2) is a protective atmosphere heating, a vacuum heating, an electromagnetic induction rapid heating, and a ring blank surface coating protective layer heating method, or no heating. If ordinary heating methods are used, such as resistance heating, gas heating, heavy oil heating, etc., due to oxidation, thick oxide scale is generated on the surface of the metal blank, and the metal is seriously burnt. On the other hand, the blank of the same furnace is forged. Different order, which leads to different heating time of different billets, resulting in different degrees of burning, affecting the accuracy and consistency of the billet. Therefore, in order to obtain high-precision forgings, it is necessary to use less or no oxidation heating or Not heated.
  • the heating step is performed immediately before the end of the ring rolling step, and the forging temperature can be accurately controlled.
  • the heating process is performed before the punching process, and the punching die is cooled by water while punching, which inevitably cools the heated billet, so that it is difficult to control the forging temperature by the conventional process, and the present invention overcomes
  • the conventional ring rolling process has difficulty in controlling the forging temperature.
  • direct ring rolling can be performed without heating.
  • the hoisting forming in the step (3) is completed by using a circling machine, and the bearing ring raceway is simultaneously rolled out during the hoisting process to realize integral forming of the raceway and the ferrule; since the steps of the present invention are adopted (1) and (2), for a material having a low temperature plasticity and a high deformation resistance, a fire forming can be achieved.
  • the machining method is used to make the blank, which not only ensures the required precision of the ring blank, but also greatly
  • the process shortens the process, saves the processes of upsetting, punching, punching blind holes, etc., avoids the eccentricity problem of the center hole of the ring blank, and eliminates the defects such as shrinkage and cracking generated during the punching process;
  • the invention adopts the chamfered annular blank, which reduces the contact area between the blank and the roll, reduces the filling resistance, thereby reducing the tonnage requirement of the equipment, and more importantly, avoiding the burrs by the gradual deformation of the chamfer.
  • the heating method is protection atmosphere heating, vacuum heating, electromagnetic induction rapid heating and ring blank surface coating protective layer heating method, which solves the problem that the conventional heating method has poor precision due to different oxidation and heating time, and improves forgings. Precision.
  • the heating step is performed immediately before the ring rolling process, and immediately after the heating is performed, the forging temperature can be accurately controlled, and the disadvantage that the conventional ring rolling process is difficult to control the forging temperature is overcome.
  • the forging temperature can be accurately controlled, and the rolling path of the forging is integrally formed with the rolling, thereby ensuring the continuity and integrity of the forging flow line.
  • FIG. 1 is a schematic view showing a processing flow of a precision forging of a bearing ring according to the present invention
  • FIG. 2 is a numerical value diagram of a ring-shaped annular blank proposed by the present invention.
  • Figure 3 is a numerical value diagram of a ring blank having a chamfered angle proposed by the present invention.
  • a processing method for a precision forging of a bearing ring proposed by the present invention includes the following processing flow, and referring to FIG. 1:
  • the machining method in the step (1) is turning processing, and the ring blank can be processed by turning on a common lathe, and the ring blank can also be processed by using a numerically controlled lathe;
  • the heating mode in the step (2) is a protective atmosphere heating, a vacuum heating, an electromagnetic induction rapid heating, and a ring layer surface coating protective layer heating method, or without heating, directly circling at room temperature;
  • the hoisting forming in the step (3) is completed by using a ringing machine, and the bearing ring raceway is simultaneously rolled out during the hoisting process to realize integral forming of the raceway and the ferrule;
  • Example 1 Preparation of a bearing inner ring precision forging, a high-temperature bearing steel, the original process requires two fire forming, the raceway is processed by turning after the forging is formed, the original process uses gas heating, the surface oxide scale is serious, and the processing Forgings processing allowance of 3.5mm.
  • the annular blank with chamfering is first processed by a numerically controlled lathe, heated by nitrogen protection, and circumscribed by a D51-300 type circling machine to realize a fire forming, the raceway is circumscribed
  • the deformation is integrally formed without any burrs and pit defects, and the machining allowance is 1.0 mm;
  • Example 2 Preparation of a bearing outer ring precision forging, a high-temperature bearing steel. Due to its large diameter, the original process requires three-fire forming.
  • the raceway is processed by turning after the forging is formed. The original process uses gas heating and oxidation. The skin is thicker and the machining allowance for the forged parts is 4mm.
  • the heat entanglement process of the invention is adopted, and the annular blank with chamfering is processed by a numerically controlled lathe, and the nitrogen is protected and heated, and the ring is tying by a D51-300 type ringing machine to realize a fire forming, and the raceway is integrally formed with the circumscribed deformation. Processing allowance 1.5mm;
  • Example 3 Preparation of a bearing inner ring forging, using carburized bearing steel G20CrMo, the original process requires two fire forming, gas heating, processing allowance 3mm.
  • the short-flow circling process of the invention firstly, the circular blank with rounded corners is processed by a numerically controlled lathe, without heating, circling at room temperature, and the URWA160 type cold ring tying machine is used to realize the precision forming of the raceway with the circling.
  • the machining allowance is 0.1mm.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Rolling Contact Bearings (AREA)
  • Forging (AREA)

Abstract

一种轴承套圈精密锻件的加工方法，包括以下加工工艺流程：(1)采用机械加工方式制备带倒角的环形坯；(2)少氧化加热或无氧化加热或者不加热；(3)环轧成形；步骤(1)中的机械加工方式为车削加工；步骤(2)中的加热方式为保护气氛加热、真空加热、电磁感应快速加热和环坯表面涂覆保护层加热方式；步骤(3)中的环轧成形采用环轧机完成，且轴承套圈滚道在环轧过程中同时轧出，实现滚道与套圈锻件的一体成形。

Description

一种轴承套圈精密锻件的加工方法 技术领域
本发明涉及锻造领域，特别是一种轴承套圈精密锻件的加工方法。
背景技术
轴承是所有机械运动机构中的最重要的基础部件之一，它用于传递动力、支撑旋转体，保证回转精度，是保持机械正常运转的关键部件。轴承广泛应用于各行各业，飞机、火箭、船舶、汽车、火车等领域的发动机、电机、传动系统等的正常运转，都需要通过轴承来实现。轴承一般由内、外套圈、滚珠和保持架组成，内圈外圆面、外圈内圆面上有滚道。滚道一方面提供滚珠运动的轨道，另一方面约束滚珠的运动方向。
轴承在高速、高温、变载、摩擦和振动等严苛的环境中服役，易于产生疲劳破坏。近年来，我国在长寿命轴承研制方面已取得了一定的成果，但与美国、德国、瑞典、日本等国家尚存在较大的差距，一些关键轴承，例如，高速铁路轴承、航空轴承、乘用车轴承等在很大程度上依赖于合资公司，或者从国外进口。国外数家轴承公司，例如瑞典SKF、美国TIMKEN，德国FAG、ZF和日本NSK和NTN等跨国公司已经垄断了高端轴承市场。轴承虽然看起来外形简单，但加工精度高，性能要求严苛，是所有机械零部件中技术含量最高、加工难度最大的零部件之一。这些高精度、长寿命高端轴承的加工方法属于国外企业核心技术秘密，我们很难得知，只能立足于自足创新。
轴承套圈锻件一般采用环形轧制法(简称环扎)成形，传统生产工艺流程为：“锯切下料→镦粗→加热→冲盲孔→冲通孔→一火或多火次环扎→普通 轴承套圈→…→车削加工滚道”。工艺流程中的“锯切下料→镦粗→加热→冲盲孔→冲通孔”等工序的目的是为后续环扎工序提供环形坯，可称为制环坯工序。工艺流程中省略号是指可能的热处理、酸洗或喷丸等工序。对于一些高温强度高、塑性差的金属或合金，一般一火无法轧制成形，需要多火次环扎成形，并且滚道无法轧出，需要通过轧制结束后的车削工序来加工滚道。传统轴承锻件生产工艺存在如下缺点：
(1)锯切下料时，由于锯条的弯曲、摆动、偏转，造成坯料精度很低，不同坯料之间的尺寸离散性非常大，一致性低；
(2)锻坯冲孔时易偏心、拉缩和拉裂等缺陷，加工余量大，难以实现精密成形；
(3)加热工序在冲孔工序前，冲孔模具需要用冷却水连续冷却，冷却水不可避免地流到坯料上，造成坯料内外表面形成大的温度梯度，坯料内部产生较大的内应力；
(4)实际锻造温度的不可控性，由于加热工序在冲孔工序前，离环扎工序较远，同时还有冷却水冷却，造成了实际轧制温度与加热温度相差较大，这就使得实际锻造温度难以控制，难以准确知道实际锻造温度值，因为加热后的坯料经过冲孔工序和水冷后，其温度有了很大幅度的变化；
(5)易产生凹坑和高毛边缺陷，有时毛边会划伤套圈表面，或毛边被压入套圈表面而造成压痕；
(6)生产流程长，最后一火变形量小，导致晶粒粗大；
(7)滚道难以轧出，需要通过后续机加工车出，这就切断了锻造流线，造成流线露头，这就破坏了零件的表面完整性，使得轴承极易产生应力腐蚀，降低疲劳性能。
鉴此传统环扎工艺的以上缺点，要想得到高精度、疲劳寿命高的轴承 套圈锻件，必须保证锻造流线的完整性，得到完整分布的锻造流线，这就要求滚道必须在环扎的同时成形，不能采用轧出平环后再车滚道的加工办法。另一方面，为了提高疲劳寿命，必须锻件确保晶粒度小，提高轧制变形量能够细化晶粒，如果采用多火次成形，则由于最后一火次变形量小而导致晶粒粗大。鉴此，为了保证大变形量，这就需要轴承套圈锻件能够一火成形。然而，对于一些关键轴承，其高温强度大、塑性低，难以实现一火成形，滚道无法在环扎同时成形。这就需要一种能够一火轧制成形、并且滚道也同时成形的环扎工艺。本发明即提出了一种能够实现一火轧制成形，并且滚道也能同时成形的轴承套圈精密锻件的短流程环扎工艺，该工艺同样适用于塑性好、变形抗力低的金属轴承套圈精密锻件的环扎。
发明内容
本发明的目的是提供一种轴承套圈精密锻件的加工方法，用于克服传统轴承成形的工艺缺点，获得轴承套圈精密锻件。
本发明为解决其技术问题所采用的技术方案是，
一种轴承套圈精密锻件的加工方法，包括以下加工工艺流程：
(1)采用机械加工方式制备带倒角的环形坯；
(2)少氧化加热或无氧化加热或者不加热；
(3)环扎成形；
进一步的，步骤(1)中的机械加工方式为车削加工，可采用普通车床车削加工环形坯，也可采用数控车床加工环形坯，从而缩短工艺流程，得到精度高、一致性好的环形坯，克服传统制坯工序“锯切下料→镦粗→加热→冲盲孔→冲通孔”工艺流程长、所加工的环形坯精度低、尺寸离散性大、冲孔时易偏心、拉缩和拉裂等缺点；
进一步的，所述带倒角的环形坯中心有圆孔，设环形坯宽度为B，高度为H，宽度值和高度值的最小值为A＝min(B,H)，若所倒角为圆角，则圆角半径取值范围为0.1A～0.5A，若所倒角为斜角，则斜角边长L1＝(0.1～0.5)B，L2＝(0.1～0.5)H。采用发明的带倒角的环形坯，减少了坯料与轧辊的接触面积，降低了充型阻力，从而降低设备吨位需求，更重要的是，通过倒角的逐渐变形，避免了毛边和凹坑等缺陷的形成。
进一步的，步骤(2)中的加热方式为保护气氛加热、真空加热、电磁感应快速加热和环坯表面涂覆保护层加热方式，或者不加热。如果采用普通加热方式，例如电阻加热、燃气加热、重油加热等方式，由于氧化作用，在金属坯料表面产生较厚的氧化皮，金属产生严重的烧损，另一方面，由于同一炉的坯料锻造先后顺序不同，这就导致了不同坯料的加热时间长短不同，从而导致烧损程度不同，影响坯料精度和一致性，因此，要想得到高精度的锻件，必须采用少氧化或者无氧化的加热方式或者不加热。此外，在本发明中，加热工序在环轧工序前，加热结束立即轧制，从而可准确控制锻造温度。而在传统环轧工艺中，加热工序在冲孔工序前，在冲孔的同时要用水冷却冲孔模具，不可避免地冷却了已加热过的坯料，故传统工艺难以控制锻造温度，本发明克服了传统环轧工艺难以控制锻造温度的缺点。此外，对于塑性好、变形抗力低的金属，可不加热直接环轧。
进一步的，步骤(3)中的环扎成形采用环扎机完成，且轴承套圈滚道在环扎过程中同时轧出，实现滚道与套圈的一体成形；由于采用了本发明的步骤(1)和(2)，对于高温塑性低、变形抗力高的材料，能够实现一火成型。
本发明的优点在于，
(1)采用机械加工方式制坯，既确保了环形坯达到所需精度，又大幅 度缩短了工艺流程，省却了镦粗、冲孔、冲盲孔等工序，避免了环形坯中心孔的偏心问题，杜绝了冲孔过程中产生的拉缩和拉裂等缺陷；
(2)采用发明的带倒角的环形坯，减少了坯料与轧辊的接触面积，降低了充型阻力，从而降低设备吨位需求，更重要的是，通过倒角的逐渐变形，避免了毛边和凹坑等缺陷的形成，并实现了锻件的一火精密成形。
(3)加热方式为保护气氛加热、真空加热、电磁感应快速加热和环坯表面涂覆保护层加热方式，解决了传统加热方式由于氧化作用与加热时间不同导致的精度差的问题，提高了锻件的精度。
(4)在本发明中，加热工序在环轧工序前，加热结束立即轧制，可准确控制锻造温度，克服了传统环轧工艺难以控制锻造温度的缺点。
(5)由于采用了带到角的环形坯、锻造温度可准确控制，实现了锻件的滚道随轧制一体成型，从而保证了锻造流线的连续性和完整性。
附图说明
图1是本发明提出一种轴承套圈精密锻件的加工流程示意图；
图2是本发明提出的带倒圆角的环形坯的参数数值图；
图3是本发明提出的带倒斜角的环形坯的参数数值图；
具体实施方式
为了使本发明实现的技术手段、创作特征、达成目的与功效易于明白 了解，下面结合图示与具体实施例，进一步阐述本发明。
如图1至图3所示，本发明提出的一种轴承套圈精密锻件的加工方法，包括以下加工工艺流程，参照图1：
(1)采用机械加工方式制备带倒角的环形坯；
(2)少氧化加热或无氧化加热或者不加热；
(3)环扎成形；
进一步的，步骤(1)中的机械加工方式为车削加工，可采用普通车床车削加工环形坯，也可采用数控车床加工环形坯；
参照图2与图3，进一步的，所述带倒角的环形坯中心有圆孔，设环形坯宽度为B，高度为H，宽度值和高度值的最小值为A＝min(B,H)，若所倒角为圆角，则圆角半径取值范围为0.1A～0.5A，若所倒角为斜角，则斜角边长L1＝(0.1～0.5)B，L2＝(0.1～0.5)H；
进一步的，步骤(2)中的加热方式为保护气氛加热、真空加热、电磁感应快速加热和环坯表面涂覆保护层加热方式，或者不加热，直接在室温下环扎；
进一步的，步骤(3)中的环扎成形采用环扎机完成，且轴承套圈滚道在环扎过程中同时轧出，实现滚道与套圈的一体成形；
实施实例一：制备一种轴承内圈精密锻件，一种高温轴承钢，原工艺需要两火成形，滚道在锻件成形后采用车削方式加工，原工艺采用燃气加热，表面氧化皮严重，所加工锻件加工余量3.5mm。采用本发明的热环扎工艺，首先采用数控车床加工带倒角的环形坯，采用氮气保护方式加热，采用D51-300型环扎机进行环扎，实现了一火成形，滚道随环扎变形一体成形，没有任何毛边和凹坑缺陷出现，加工余量1.0mm；
实施实例二：制备一种轴承外圈精密锻件，一种高温轴承钢，由于其直径较大，原工艺需要三火成形，滚道在锻件成形后采用车削方式加工，原工艺采用燃气加热，氧化皮较厚，所加工锻件加工余量4mm。采用本发明热环扎工艺，采用数控车床加工带倒角的环形坯，氮气保护加热，采用D51-300型环扎机进行环扎，实现了一火成形，滚道随环扎变形一体成形，加工余量1.5mm；
实施实例三：制备一种轴承内圈锻件，采用渗碳轴承钢G20CrMo，原工艺需要两火成形，燃气加热，加工余量3mm。采用本发明短流程环扎工艺，首先采用数控车床加工带倒圆角的环形坯，不加热，在室温下环扎，采用URWA160型冷环扎机，实现了滚道随环扎一体精密成形，加工余量0.1mm。
以上显示和描述了本发明的基本原理、主要特征和本发明的优点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等同物界定。

Claims (5)

  1. 一种轴承套圈精密锻件的加工方法，其特征在于：包括以下加工工艺流程：
    (1)采用机械加工方式制备带倒角的环形坯；
    (2)少氧化加热或无氧化加热或者不加热；
    (3)环扎成形。
  2. 根据权利要求1所述的一种轴承套圈精密锻件的加工方法，其特征在于：步骤(1)中的机械加工方式为车削加工。
  3. 根据权利要求1或2所述的一种轴承套圈精密锻件的加工方法，其特征在于：所述带倒角的环形坯中心有圆孔，设环形坯宽度为B，高度为H，宽度值和高度值的最小值为A＝min(B,H)，若所倒角为圆角，则圆角半径取值范围为0.1A～0.5A，若所倒角为斜角，则斜角边长L1＝(0.1～0.5)B，L2＝(0.1～0.5)H。
  4. 根据权利要求1所述的一种轴承套圈精密锻件的加工方法，其特征在于：步骤(2)中的加热方式为保护气氛加热、真空加热、电磁感应快速加热和环坯表面涂覆保护层加热方式，或者不加热。
  5. 根据权利要求1所述的一种轴承套圈精密锻件的加工方法，其特征在于：步骤(3)中的环扎成形采用环扎机完成，且轴承套圈滚道在环扎过程中同时轧出，实现滚道与套圈锻件的一体成形。
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