A high-precision turning method for rail UF rolls
By redefining the X-axis and Z-axis references of UF rolls and combining template inspection and turning procedures, the problems of unstable roll diameter and distorted roll profile in UF roll turning were solved, achieving high-precision roll turning and improving the quality of rail products and the stability of rolling conditions.
Patent Information
- Application Number
- CN202310632596.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2023-05-31
- Publication Date
- 2025-08-01
- Estimated Expiration
- 2043-05-31
AI Technical Summary
In existing UF roll turning methods, the roll diameter control is unstable, which leads to the inability of the rolling line to adjust automatically, serious impact on roll calibration, unstable rolling conditions, asymmetrical rail web dimensions, and misalignment of the die centerline, resulting in overall die distortion, affecting rail quality and rolling quantity.
The X-axis and Z-axis references for UF roll turning are redefined. The relative positions of the rail head arc surface, the inner side of the rail bottom, and the lower jaw slope of the rail head are checked by template to ensure that the roll die is consistent in the Z-axis direction. The roll diameter and die position are precisely controlled by the turning program and the tipping program.
It improves the machining accuracy and stability of UF roll profiles, ensures the stability of rail product quality, avoids profile distortion, and enhances the accuracy of rolling conditions.
Smart Images
Figure CN116571770B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a high-precision turning method for a rail UF roll, belonging to the technical field of rail rolling methods. Background Art
[0002] The modern railway development is towards high speed and heavy load. As an important component of the railway, the quality of the rail directly affects the running safety and stability of the train. Therefore, higher requirements are put forward for the dimensional accuracy of the rail. The rail UF roll pass as the last process in the rail rolling process plays a crucial role in controlling the finished rail dimensions.
[0003] The rail UF roll pass is composed of the passes of the upper and lower rolls. The upper and lower roll passes are symmetric up and down. In order to avoid serious downward buckling of the rail after exiting the UF pass, downward pressure is usually applied, so the roll diameters are usually inconsistent. At present, the main problems existing in the turning of the UF roll are as follows: the control of the roll diameter is unstable, which affects the calibration of the roll, resulting in the inability to automatically adjust the rolling line to a proper position, and ultimately affecting the rail rolling state; the control accuracy of the rail web size of the roll is poor, resulting in asymmetry of the rail web of the finished rail, and even the rail web size being unqualified, affecting the quality of the rail product and the rolling volume of the roll; there is a misalignment between the center lines of the upper and lower roll passes, resulting in distortion of the overall pass and affecting the adjustment of the rail dimensions.
[0004] Therefore, it is necessary to redesign the turning method of the UF roll. Through innovation in the method, eliminate or improve the problems that occur in the turning process of the above UF roll: improve the accuracy of the UF roll diameter, stabilize the roll calibration process, and ensure the rolling state of the rail after exiting the UF pass; eliminate the pass turning deviation caused by the elastic deformation of the turning tool holder and ensure the dimensional accuracy of the pass; solve the deviation problem between the center lines of the upper and lower roll passes and avoid distortion of the UF roll pass. Summary of the Invention
[0005] The object of the present invention is to provide a high-precision turning method for the UF roll of the rail. According to the groove profile of the UF roll and the structural characteristics of the UF roll system, the X-axis reference and Z-axis reference during the turning of the UF roll are redefined. By redefining the Z-axis reference, the groove profiles of the upper and lower UF rolls are made consistent in the Z-axis direction, avoiding the distortion of the groove profile after the UF roll is put into use. By redefining the X-axis reference, the accuracy of the roll diameter turning of the UF roll is ensured; through the turning program and tip-picking program of the UF roll, as well as the templates for inspecting the relative positions of the rail head arc surface and the inner side surface of the rail bottom, and the templates for inspecting the relative positions between the inner side surface of the rail bottom and the inclined surface of the rail head jaw, the relative positions among the rail head arc surface, the inner side surface of the rail bottom, and the inclined surface of the rail head jaw are accurately controlled; the turning precision of the groove profile of the UF roll is greatly improved, the stability of the groove profile of the UF roll is enhanced, which plays an important role in the stable control of the quality of the rail product, and effectively solves the above problems existing in the background technology.
[0006] The technical solution of the present invention is: a high-precision turning method for the UF roll of the rail, comprising the following steps:
[0007] (1) Measure the original roll diameters of the two UF rolls to be turned, select the roll with the larger roll diameter as the lower roll, and the roll with the smaller roll diameter as the upper roll;
[0008] (2) Determine the set value △d of the roll diameter difference, and determine the turning order of the rail roll according to the set value;
[0009] (3) Redefine the X-axis reference and Z-axis reference during the turning of the UF roll. When turning the UF roll, take the vertical contact surface between the roll shaft and the thrust bearing bush of the roll box as the Z-axis reference. According to the groove profile drawing, the horizontal distance from the vertical contact surface between the roll shaft and the thrust bearing bush of the roll box to the center point of the arc of the roll waist is f. Adjust the tool along the Z-axis by a stroke of f, bring the tool into contact with the roll ring of the UF roll, and control the gap between the tool and the roll ring with a feeler gauge, and use this as the turning reference for the X-axis;
[0010] (4) Execute the turning program of the UF roll to turn the roll, and use template 1 to inspect the relative positions of the rail head arc surface and the inner side surface of the rail bottom until both the rail head arc surface and the inner side surface of the rail bottom are in close contact with template 1;
[0011] (5) Execute the tip-picking program to turn the position of the rail head jaw of the roll groove profile, and use template 2 to inspect the relative positions between the inner side surface of the rail bottom and the inclined surface of the rail head jaw until both the inner side surface of the rail bottom and the inclined surface of the rail head jaw are in close contact with the template;
[0012] (6) Align the turning tool with the position where the turning tool of the UF roll shaft contacts the cylindrical roller bearing in the roll box. Use a feeler gauge to control the gap between the turning tool and the roll shaft, and record the numerical value shown on the X-axis of the lathe at this time as a. The diameter of the roll shaft at this position is a fixed value e. Then align the turning tool with the center point of the arc of the roll waist of the roll, use a feeler gauge to control the gap between the turning tool and the roll shaft, and record the numerical value shown on the X-axis of the lathe at this time as b. The accurate diameter after turning the roll is 2*|a - b| + e;
[0013] (7) The required diameter of the other roll is the diameter of the previous roll ±△d. Turn the other roll according to steps (3)-(5), and measure the actual diameter of this roll according to step (6) until the diameter requirement is met.
[0014] In step (2) above, when the roll diameter difference is greater than the set value, turn the roll with the smaller roll diameter first. When the roll diameter difference is less than or equal to the set value, turn the roll with the larger roll diameter first.
[0015] The standard for controlling the gap with the feeler gauge is that a 0.01 mm feeler gauge cannot be inserted.
[0016] In step (1) above, measure the original roll diameters of the two UF rolls to be turned with an outside caliper.
[0017] The beneficial effects of the present invention are as follows: According to the pass profile of the UF roll and the structural characteristics of the UF roll system, the X-axis reference and Z-axis reference during the turning of the UF roll are redefined. By redefining the Z-axis reference, the pass profiles of the upper and lower UF rolls are kept consistent in the Z-axis direction, avoiding the distortion of the pass profile after the UF roll is put into operation. By redefining the X-axis reference, the accuracy of the roll diameter turning of the UF roll is ensured; through the turning program and tip-picking program of the UF roll, as well as the templates for inspecting the relative positions of the rail head arc surface and the rail bottom inner side surface and the templates for inspecting the relative positions between the rail bottom inner side surface and the rail head lower jaw inclined surface, the relative positions among the rail head arc surface, the rail bottom inner side surface, and the rail head lower jaw inclined surface are accurately controlled; the turning accuracy of the pass profile of the UF roll is greatly improved, the stability of the pass profile of the UF roll is enhanced, and it plays an important role in the stability control of the quality of the rail product. Brief Description of the Drawings
[0018] Figure 1 It is a structural diagram of the UF roll of the present invention;
[0019] Figure 2 It is a schematic diagram of turning the pass profile in the turning program of the UF roll of the present invention;
[0020] Figure 3 It is a schematic diagram of turning the pass profile in the tip-picking program of the present invention;
[0021] Figure 4 It is a schematic diagram of the first template for inspecting the relative positions of the rail head arc surface and the rail bottom inner side surface of the present invention;
[0022] Figure 5 Schematic diagram of the second template for inspecting the relative position between the inner side of the rail base and the inclined surface of the lower jaw of the rail head in the present invention;
[0023] In the figure: UF roll shaft 1, UF roll ring 2, vertical contact surface AB between the roll shaft and the thrust bearing of the roll box, contact surface CD between the UF roll shaft and the cylindrical roller bearing in the roll box, rail head arc surface GT, inner side surface GD of the rail base, inclined surface XE of the lower jaw of the rail head, center point H of the arc of the roll waist. Specific implementation manner
[0024] In order to make the purpose, technical solution and advantages of the invention implementation cases clearer, the following will combine the accompanying drawings in the implementation cases to clearly and completely describe the technical solutions in the invention implementation cases. Obviously, the described implementation cases are a small part of the implementation cases of the present invention, rather than all the implementation cases. Based on the implementation cases in the present invention, all other implementation cases obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present invention.
[0025] A high-precision turning method for the UF roll of a rail includes the following steps:
[0026] (1) Measure the original roll diameters of two UF rolls to be turned, select the roll with the larger roll diameter as the lower roll, and the roll with the smaller roll diameter as the upper roll;
[0027] (2) Determine the set value △d of the roll diameter difference, and determine the roll turning order according to the set value;
[0028] (3) Redefine the X-axis reference and Z-axis reference when turning the UF roll. When turning the UF roll, use the vertical contact surface between the roll shaft and the thrust bearing of the roll box as the Z-axis reference. According to the pass drawing, the horizontal distance from the vertical contact surface between the roll shaft and the thrust bearing of the roll box to the center point of the arc of the roll waist is f. Adjust the tool along the Z-axis by a stroke of f, make the tool contact the roll ring of the UF roll, and control the gap between the tool and the roll ring with a feeler gauge, which is used as the turning reference for the X-axis;
[0029] (4) Execute the UF roll turning program to turn the roll, and use the first template to inspect the relative position between the rail head arc surface and the inner side surface of the rail base until both the rail head arc surface and the inner side surface of the rail base are closely fitted to the first template; [[ID=ID=27]]
[0030] (5) Execute the tip turning program to turn the position of the lower jaw of the roll pass rail head, and use the second template to inspect the relative position between the inner side surface of the rail base and the inclined surface of the lower jaw of the rail head until both the inner side surface of the rail base and the inclined surface of the lower jaw of the rail head are closely fitted to the template;
[0031] (6) Align the turning tool with the position where the turning tool of the UF roll shaft contacts the cylindrical roller bearing in the roll box. Use a feeler gauge to control the gap between the turning tool and the roll shaft, and record the value displayed on the X-axis of the lathe at this time as a. The diameter of the roll shaft at this position is a fixed value e. Then, align the turning tool with the center point of the arc of the roll waist, use a feeler gauge to control the gap between the turning tool and the roll shaft, and record the value displayed on the X-axis of the lathe at this time as b. The accurate diameter of the roll after turning is 2*|a - b| + e;
[0032] (7) The required diameter of the other roll is the diameter of the previous roll ±△d. Turn the other roll according to steps (3)-(5), and measure the actual diameter of this roll according to step (6) until the diameter requirement is met.
[0033] In step (2) above, when the roll diameter difference is greater than the set value, first turn the roll with the smaller roll diameter. When the roll diameter difference is less than or equal to the set value, first turn the roll with the larger roll diameter.
[0034] The standard for controlling the gap with the feeler gauge is that a 0.01 mm feeler gauge cannot be inserted.
[0035] In step (1) above, measure the original roll diameters of the two UF rolls to be turned with an outside caliper.
[0036] In practical applications, the present invention includes two roll turning programs, namely the UF roll turning program and the tip turning program. It also includes two process inspection templates. Template 1 is a template for inspecting the relative position of the rail head arc surface and the inner side surface of the rail bottom, and template 2 is a template for inspecting the relative position between the inner side surface of the rail bottom and the inclined surface of the rail head lower jaw. Operate according to the following steps:
[0037] (1) Measure the original roll diameters of the two UF roll rings 2 to be turned with an outside caliper. Set the larger roll diameter as D1 and the smaller roll diameter as D2. Select the roll with the D1 roll diameter as the lower roll and the roll with the D2 roll diameter as the upper roll.
[0038] (2) Determine the required roll diameter difference △d. When D1 - D2 > △d, first turn the roll with the smaller roll diameter (D2). When D1 - D2 ≤ △d, first turn the roll with the larger roll diameter (D1).
[0039] (3) When turning the UF roll, use the vertical contact surface AB of the UF roll shaft 1 and the thrust bearing of the roll box as the Z-axis reference. According to the pass drawing, the horizontal distance from the vertical contact surface AB of the UF roll shaft 1 and the thrust bearing of the roll box to the center point H of the arc of the roll waist is f. Adjust the turning tool along the Z-axis by a stroke of f, bring the turning tool into contact with the UF roll ring 2, and use a feeler gauge to measure the gap between the turning tool and the roll ring, ensuring that a 0.01 mm feeler gauge cannot be inserted. This is used as the turning reference for the X-axis.
[0040] (4) Execute the UF roll turning program to turn the roll, and use Template 1 to check the relative positions of the rail head arc surface and the inner side surface of the rail bottom until both the rail head arc surface and the inner side surface of the rail bottom are in close contact with the template.
[0041] (5) Execute the tip turning program to turn the position of the roll pass rail head lower jaw, and use Template 2 to check the relative positions of the inner side surface of the rail bottom and the inclined surface of the rail head lower jaw until both the inner side surface of the rail bottom and the inclined surface of the rail head lower jaw are in close contact with the template.
[0042] (6) Align the turning tool with the CD surface at the position where the UF roll shaft 1 contacts the cylindrical roller bearing in the roll box. At this time, use a feeler gauge to measure the gap between the turning tool and the UF roll shaft 1, ensure that a 0.01 mm feeler gauge cannot be inserted, record the numerical value displayed on the lathe X-axis at this time as a, the diameter of the roll shaft at this position is a fixed value e, then align the turning tool with the center point H of the roll waist arc, use a feeler gauge to measure the gap between the turning tool and the UF roll shaft 1, ensure that a 0.01 mm feeler gauge cannot be inserted, record the numerical value displayed on the lathe X-axis at this time as b, and the accurate diameter d1 of the roll after turning = 2 * |a - b| + e.
[0043] (7) The required diameter d2 of the other roll = d1 ± △d. Turn the other roll according to steps (3) - (5), and measure the actual diameter of the roll according to step (6) until the diameter requirement of d2 is met.
[0044] Example:
[0045] First, determine the required roll diameter difference △d. Assume that according to the rolling process requirements, the roll diameter difference △d = 10 mm is set.
[0046] (1) Measure the original roll diameters of the two UF roll rings 2 to be turned by an outside caliper. The large roll diameter D1 = 1200 mm and the small roll diameter is D2 = 1180 mm. Select the roll with a roll diameter of D1 = 1200 mm as the lower roll and the roll with a roll diameter of D2 = 1180 mm as the upper roll.
[0047] (2) Since D1 - D2 = 1200 - 1180 = 20 mm > △d = 10 mm, first turn the roll with a roll diameter of D2 = 1180 mm.
[0048] (3) When turning the UF roll with D2 = 1180 mm, use the vertical contact surface AB of the UF roll shaft 1 and the thrust bearing of the roll box as the Z-axis reference. According to the pass drawing, the horizontal distance from the vertical contact surface AB of the UF roll shaft 1 and the thrust bearing of the roll box to the center point H of the roll waist arc is 673 mm. Adjust the turning tool along the Z-axis by a stroke of 673 mm, then contact the turning tool with the UF roll ring 2, and use a feeler gauge to measure the gap between the turning tool and the roll ring, ensure that a 0.01 mm feeler gauge cannot be inserted, and use this as the turning reference for the X-axis.
[0049] (4) Execute the UF roll turning program to turn the roll, and use Template 1 to check the relative positions of the rail head arc surface and the inner side surface of the rail bottom until both the rail head arc surface and the inner side surface of the rail bottom are closely fitted to the template.
[0050] (5) Execute the tip turning program to turn the position of the rail head lower jaw of the roll groove, and use Template 2 to check the relative positions of the inner side surface of the rail bottom and the inclined surface of the rail head lower jaw until both the inner side surface of the rail bottom and the inclined surface of the rail head lower jaw are closely fitted to the template.
[0051] (6) Align the turning tool with the CD surface at the position where the UF roll shaft 1 contacts the cylindrical roller bearing in the roll box. At this time, use a feeler gauge to measure the gap between the turning tool and the UF roll shaft 1, ensuring that a 0.01 mm feeler gauge cannot be inserted. Record the value displayed on the lathe X-axis at this time as 495 mm. The diameter of the roll shaft at this position is a fixed value e = 380 mm. Then align the turning tool with the center point H of the roll waist arc, use a feeler gauge to measure the gap between the turning tool and the UF roll shaft 1, ensuring that a 0.01 mm feeler gauge cannot be inserted. Record the value displayed on the lathe X-axis at this time as b = 100 mm. The accurate diameter d1 after roll turning is 2 * |a - b| + e = 2 * (495 - 100) + 380 = 1170 mm.
[0052] (7) The required diameter d2 of the other roll is d2 = d1 ± △d = 1170 + 10 = 1180 mm. Turn the other roll according to steps (3) - (5), and measure the actual diameter of the roll according to step (6) until the diameter requirement of d2 is met.
Claims
1. A high-precision turning method for a rail UF roll, characterized in that It includes the following steps: (1) Measure the original roll diameters of two UF rolls to be turned, select the roll with the larger diameter as the lower roll, and the roll with the smaller diameter as the upper roll; (2) Determine the set value △d of the roll diameter difference, and determine the roll turning sequence according to the set value; (3) Redefine the X-axis reference and Z-axis reference during the turning of the UF roll. When turning the UF roll, use the vertical contact surface between the roll shaft and the thrust bearing of the roll box as the Z-axis reference. According to the pass drawing, the horizontal distance from the vertical contact surface between the roll shaft and the thrust bearing of the roll box to the center point of the roll waist arc is f. Adjust the travel of the turning tool along the Z-axis by f, bring the turning tool into contact with the roll ring of the UF roll, and use a feeler gauge to control the gap between the turning tool and the roll ring, which is used as the turning reference for the X-axis; (4) Execute the UF roll turning program to turn the roll, and use Template 1 to check the relative positions of the rail head arc surface and the inner side surface of the rail bottom until both the rail head arc surface and the inner side surface of the rail bottom are closely fitted to Template 1; (5) Execute the tip turning program to turn the position of the rail head lower jaw of the roll pass, and use Template 2 to check the relative positions of the inner side surface of the rail bottom and the inclined surface of the rail head lower jaw until both the inner side surface of the rail bottom and the inclined surface of the rail head lower jaw are closely fitted to the template; (6) Align the turning tool with the position where the roll shaft of the UF roll contacts the cylindrical roller bearing in the roll box, use a feeler gauge to control the gap between the turning tool and the roll shaft, record the numerical value displayed on the X-axis of the lathe at this time as a, the diameter of the roll shaft at this position is a fixed value e, then align the turning tool with the center point of the roll waist arc of the roll, use a feeler gauge to control the gap between the turning tool and the roll shaft, record the numerical value displayed on the X-axis of the lathe at this time as b, and the accurate diameter after the roll is turned is 2*|a - b| + e; (7) The required diameter of the other roll is the diameter of the previous roll ±△d. Turn the other roll according to steps (3)-(5), and measure the actual diameter of this roll according to step (6) until the diameter requirement is met; In step (2) above, when the roll diameter difference is greater than the set value, turn the roll with the smaller diameter first; when the roll diameter difference is less than or equal to the set value, turn the roll with the larger diameter first.
2. The high-precision turning method of a rail UF roll according to claim 1, characterized in that: The standard for controlling the gap with the feeler gauge is that a 0.01 mm feeler gauge cannot be inserted.
3. A high-precision turning method for a rail UF roll according to claim 1, characterized in that: In step (1) above, measure the original roll diameters of two UF rolls to be turned with an outside caliper.
Citation Information
Patent Citations
Precision roll turning lathe and automatic tool changer therefor
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