High-speed roller chamfer cold heading equipment and process

Abstract

The present application relates to a kind of high-iron roller chamfer cold heading equipment and process, specific steps are as follows, raw material is cut off by high-speed circular saw machine, forms section, requires end face smooth without burr, length error 0.02mm;Section is transported by conveying line, truss machine hand is placed into double-end chamfering machine gripper, positioning is accurate, then double-end chamfering machine servo control feeding, automatically turn section to form chamfer;Chamfer angle is 10-13 °;352226 × 5 roller is processed using cold heading machine cold heading.Processing advantages are that raw material is cut off by high-speed circular saw machine, end face is smooth without burr, length error 0.02mm;Chamfer angle is 10-13 °, section is not in the gap between mould extrusion forming process, air is not sealed into chamfer and mould, will not cause mould chamfer place to blow and damage, and quality problem.

Description

Technical Field

[0001] This invention relates to the field of roller manufacturing, specifically to a cold heading equipment and process for chamfering high-speed rail rollers. Background Technology

[0002] Cold heading of rollers involves high-speed, high-pressure extrusion of raw materials, resulting in rollers with high fiber density and superior performance. This process is generally required for railway roller hub bearings. However, due to the relatively large size of railway rollers (approximately 25mm in diameter and 50mm in length), cold heading is generally difficult. This is mainly because burrs are easily generated during the cutting of the raw material, resulting in uneven cut surfaces and potential defects during the cold heading extrusion process, which can damage the die. Directly machining rollers using a cold heading machine leads to a low yield rate, significant quality risks, and requires specialized equipment for flaw detection, resulting in higher production costs. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention proposes a cold heading equipment and process for chamfering high-speed rail rollers. The process is ingenious, easy to operate, reduces mold damage, and improves product qualification rate.

[0004] The equipment and process for cold heading and chamfering of high-speed rail rollers are as follows:

[0005] 1) The raw materials are cut into sections by a high-speed circular saw, requiring smooth, burr-free end faces and a length error of 0.02mm;

[0006] 2) The material segment is conveyed by the conveyor line, and the gantry robot arm picks it up and places it into the gripper of the double-head chamfering machine. The positioning is accurate, and then the double-head chamfering machine is fed by servo control and automatically turns the material segment to form a chamfer.

[0007] 3) Based on the configuration analysis of the mold and forming process, the chamfer angle is 10-13° to ensure that no air is trapped in the gap between the chamfer and the mold during the extrusion forming process of the material segment, so as not to cause air blockage damage at the chamfer of the mold and quality problems.

[0008] 4) The 352226×5 rollers were cold-forged using a cold-forging machine. The blank dimensions were: length 47.8±0.02mm, outer diameter φ24.75±0.02mm, taper 2°20′±0.05mm, displacement ≤0.08mm. The appearance was free of cracks and other obvious scratches. The chamfers and rings were uniform. The pickling inspection showed no cracks, folds, padding marks, or tearing defects. The fiber structure was fine and dense. Ultrasonic, magnetic particle, and eddy current flaw detection showed no defects. The crushing load, wear resistance, and corrosion resistance of the rollers were improved by about 30%.

[0009] The high-speed circular saw mentioned is the S-70 high-speed metal circular saw, manufactured by Hangzhou Jingweite Machine Tool Co., Ltd.

[0010] The double-head chamfering machine is the DJJ-60CNC double-head chamfering machine.

[0011] The cold heading machine mentioned is the AS-32-2 cold heading machine, manufactured by Asahi Sunac Corporation of Japan.

[0012] The advantages of this invention are that the raw material is cut with a smooth, burr-free end face by a high-speed circular saw, with a length error of 0.02mm; the chamfer angle is preferably 10-13°; during the extrusion molding process of the material segment, no air will be trapped in the gap between the chamfer and the mold, thus avoiding air entrapment damage at the chamfer of the mold and quality problems. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the roller chamfer of the present invention.

[0014] Figure 2 This is a simplified schematic diagram of the cold heading mold of the present invention. Detailed Implementation

[0015] The following explanation is provided in conjunction with the accompanying drawings.

[0016] The equipment and process for cold heading and chamfering of high-speed rail rollers are as follows:

[0017] Process flow: Raw material bar sawing - automatic chamfering - cold heading.

[0018] 1. The raw materials are cut by a high-speed circular saw, with smooth, burr-free end faces and a length error of 0.02mm.

[0019] 2. The material segment is conveyed by the conveyor line, and the gantry robot arm picks it up and places it into the gripper of the double-head chamfering machine. The positioning is accurate, and then the double-head chamfering machine is fed by servo control and automatically turns the material segment to form a chamfer.

[0020] 3. For example Figure 1 The chamfer angle should be 10-13° based on the configuration analysis of the mold and the forming process. Otherwise, during the extrusion forming process of the material segment, air will be trapped in the gap between the chamfer and the mold. An unsuitable angle will cause air to trap and damage the chamfer of the mold, as well as quality problems.

[0021] 4. Cold heading of 352226×5 rollers: blank dimensions: length 47.8±0.02mm, outer diameter φ24.75±0.02mm, taper 2°20′±0.05mm, displacement ≤0.08mm. The appearance is free of cracks and other obvious scratches; chamfers and rings are uniform. Acid pickling inspection revealed no hidden defects such as cracks, folds, padding marks, or tearing. The fiber structure is fine and dense; ultrasonic, magnetic particle, and eddy current testing showed no defects. The roller's crushing load, wear resistance, and corrosion resistance are improved by approximately 30%.

[0022] like Figure 2 The cold heading mold includes an upper ejector pin 1, an upper mold core 2, a lower ejector pin 3, and a lower mold core 4. The material segment is placed into the upper mold core. The chamfer angle of the material segment should be 10-13° for optimal results. During the material segment placement process, air can be discharged through the chamfer angle design, which will not cause air trapping problems due to the gap between the chamfer and the mold. The mold will not be damaged during cold heading, thus improving the cold heading effect of the roller.

Claims

1. Process for cold heading of high-iron roller chamfers, characterized in that, The specific steps are as follows, 1) raw materials are cut by a high-speed circular saw machine to form a section, the end surface is required to be smooth and free of burrs, and the length error is 0.02mm; 2) the section is conveyed by a conveying line, a truss machine hand clamps and places it into the clamping jaw of a double-end chamfering machine, accurate positioning is performed, then the double-end chamfering machine is servo-controlled to feed, and the section is automatically turned to form a chamfer; 3) the chamfer angle is 10-13° according to mold and forming process configuration analysis, to ensure that the section does not cause air to be sealed into the gap between the chamfer and the mold during the extrusion molding process, and does not cause damage and quality problems due to air trapping at the chamfer of the mold; 4) a cold header is used to cold header 352226x5 rollers, the blank size length is 47.8±0.02mm, the outer diameter size is φ24.75±0.02mm, the taper is 2°20'±0.05mm, the displacement is ≤0.08mm, the appearance is free of cracks and other obvious damage, the chamfer and ring belt are uniform, pickling inspection is free of cracks, folding, cushion injury, and strain defects; the fiber organization is fine, ultrasonic, magnetic powder and eddy current flaw detection are free of defects, the roller crushing load, wear resistance and corrosion resistance are improved by about 30%.

2. High speed roller chamfer cold heading equipment and process according to claim 1, characterized in that, The high-speed circular saw machine is a high-speed metal circular saw machine S-70.

3. The high speed roller chamfer cold heading equipment and process according to claim 1, characterized in that, The double-end chamfering machine is a double-end chamfering machine DJJ-60CNC.

4. The high speed roller chamfer cold heading equipment and process according to claim 1, characterized in that, The cold header is a cold header AS-32-2.

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