Method of manufacturing an alloy structural steel swivel faucet bail fitting

Abstract

The application provides a manufacturing method of an alloy structural steel rotating faucet handle ring joint, which comprises the following steps: upsetting and elongating a round steel, forging a blank in multiple passes to form three stepped shafts by pre-forging, and forging and upsetting the middle part of two steps in multiple passes to form an intermediate shuttle-shaped shaft. The two end steps are forged into flat squares with the required process and are punched at an angle. Then, the middle 1000mm position is heated and a bending reinforcement is welded to ensure the distance between the center lines of the two ends. Finally, polishing, flaw detection and load test are performed. The method effectively improves the size tolerance of the forged piece, solves the problem of long process time, reduces the weight of the product blank, and improves the production quality of the product.

Description

Technical Field

[0001] This invention relates to the field of manufacturing top drive oil drilling rig components, and in particular to a method for manufacturing an alloy structural steel rotary swivel lifting ring connector. Background Technology

[0002] Oil drilling equipment includes the "nodding" pumping unit commonly seen in pictures and videos, as well as rotary drilling rigs. Rotary drilling rigs use a turntable to rotate a square rod for drilling. When a longer drill pipe is needed, the turntable stops rotating; after adding the new drill pipe, it restarts rotation. However, when encountering complex rock formations, the lack of sufficient rotational inertia upon restarting can cause stuck drill pipe. Therefore, top-drive drilling systems were developed, using a power swivel on the drill string to rotate the drill string and circulate drilling fluid, significantly reducing stuck drill pipe and improving worker safety and efficiency. The swivel, a roughly inverted V-shaped lifting ring, is a relatively large component of top-drive oil drilling rigs. With the development of the oil drilling industry, the demand for top-drive oil drilling rig components in my country has increased significantly. However, due to the complex manufacturing process, high molding difficulty, high mechanical performance requirements, and limitations on large-scale production of the rotary swivel lifting ring connector, a method for manufacturing alloy structural steel rotary swivel lifting ring connectors is desired. Summary of the Invention

[0003] The purpose of this invention is to provide a manufacturing method for a rotating faucet lifting ring connector made of alloy structural steel, so as to solve the problems existing in the prior art, effectively improve the problems of dimensional deviation of forgings and long product production cycle, reduce the weight of product blanks, improve product production quality, optimize the forging process of rotating faucet lifting ring connector, reduce production costs, improve production efficiency, and fill the technical gap.

[0004] To achieve the above objectives, the present invention provides the following solution: a method for manufacturing a rotating faucet lifting ring connector made of alloy structural steel, comprising the following steps:

[0005] Material preparation: Select alloy structural steel billets, choose the diameter of round steel according to process requirements, and saw them to the required length;

[0006] Heating: The sawn blanks are heated to a temperature of 1180-1200℃, with a heating rate controlled at 100-120℃ / h, and held for 2-3 hours;

[0007] Upsetting, drawing, and initial forming of the rod and insert box: The heated billet undergoes multiple upsetting and drawing processes, with a forging ratio of approximately 2 during the forging process. First, the billet is upset using forging equipment at a pressing rate of 40mm / s. The billet is monitored in real-time during the upsetting process to prevent folding. If folding occurs, it is immediately repaired. During the drawing process, the billet is first forged into a square shape using forging equipment, and then upset and rounded. The subsequent upsetting and drawing process is repeated with the first upsetting and drawing. Finally, the diameter range of the billet after drawing is determined based on the dimensions of the faucet connector insert box, ensuring that the billet diameter is greater than or equal to 120% of the final product's surface area. The two ends are flattened to form the insert box, and the middle section forms the rod. Forging is performed to ensure that the two ends of the insert box and the rod form an angle consistent with the dimensions required in the drawing.

[0008] Bending and Welding Tie Rods: Heat the middle section of the angled blank 1000mm from the center. Then fix the center point of the blank and apply force to bring the two ends of the insert box inward. Stop bringing them together when the distance between the center lines of the two insert boxes is equal to the design distance on the drawing. Then weld tie rods according to the center point distance requirements.

[0009] Heat treatment: The forgings after welding tie rods undergo preliminary heat treatment and final heat treatment according to process requirements. Preliminary heat treatment includes normalizing + tempering; final heat treatment: quenching and tempering (quenching + high-temperature tempering).

[0010] Grinding: Grind the surface of the heat-treated forging to the required dimensions in the drawing, and finally shape it;

[0011] Load test: Perform a load test of 1.5 times the rated load on the molded part.

[0012] Preferably, in the blanking step, the surface of the selected alloy structural steel billet is subjected to flaw detection and visual inspection to remove uneven and defective parts.

[0013] Preferably, in the upsetting, drawing, and preliminary forming steps of the rod and insert box, the billet after the last drawing is pressed and forged into a dumbbell shape, with the weight of the blank at both ends being 2.1-2.3 times the weight of the finished end. Then, the rod is rounded, and the middle 1000mm section of the rod is forged into a shuttle shape to form a variable diameter rod, while the rest of the rod has a uniform diameter. During the forging process, the pulling speed of the shaft is controlled at 2.5-4.5m / min, and the deformation amount of each pass forming the intermediate step shaft is controlled at 35%-40%, with the pulling speed controlled at 2.5-4.5m / min.

[0014] Preferably, in the upsetting, drawing and preliminary forming steps of the rod and the insert box, the end of the blank that has been pressed and slammed is formed into a flat square shape, and the transition part between the rod and the insert box is rounded (R500).

[0015] Preferably, in the upsetting, drawing, and preliminary forming steps of the rod and insert box, the process of forging the insert box at both ends to form an angle is as follows: during the forging process, the manipulator clamps one end of the insert box, the rod is fixed using a hoisting device, the forging equipment designs the angle of the other end of the insert box to obtain an angle consistent with the dimensions required in the drawing, and the other end repeats the process.

[0016] Preferably, in the bending and welding of the tie rod, the middle 1000mm section of the angled billet is heated. During the heating process, the temperature is kept at 1000±10℃ and the holding time is 1-2 hours to ensure the forging temperature of the middle 1000mm section, ensuring that the deformation of the middle section during the bending process meets the product requirements, while preventing the section from overheating due to excessive time.

[0017] Preferably, during the bending and welding of the tie rods, the oxide scale at the welding location of the bent forging is ground off to reveal the metallic luster; before welding, there should be no water, oil, rust, or other impurities in or around the welding area. Preheating is required before welding, with a preheating temperature ≥150℃. The tie rod length is set according to the centerline dimensions of the box body as required by the drawings, ensuring the center point distance. After welding, the forging is immediately placed in an insulation pit for post-weld heat treatment.

[0018] Preferably, during the grinding step, the surface quality of the forging is inspected, and defects are ground out. However, no more than three defects may be ground, and they must not be located on the same cross-section. The depth must not exceed 4% of the cross-sectional dimension, and the deepest point must not exceed 3 mm. The width must not be less than 6 times the depth. The length must extend at least 3 mm from the outermost point of the defect. The grinding depth at arc-shaped connections must not exceed 1 mm. The grinding should be smooth, and defects must not be continuous.

[0019] Preferably, in the load test procedure, the ground forging is subjected to a load test of 1.5 times the rated load, and the load is gradually increased to the specified value at levels of 25%, 50%, 75%, and 100%, and then unloaded after holding the load for no less than 5 minutes. After the test, a functional check is performed, and there should be no functional impairment: for example, no deformation or damage should be found in any part. A comprehensive non-destructive test is performed on the lifting ring 24 hours after the test.

[0020] The present invention achieves the following technical effects compared to the prior art:

[0021] First, the present invention sets the initial dimensions of the forging by pressing and rolling, which can greatly reduce the waste of raw materials and create a good forging surface quality for subsequent processing.

[0022] Second, high forging ratio forging can fully break the as-cast structure of steel ingots, refine the grains, and ensure the internal structure and performance requirements of forgings;

[0023] Third, by heating and heat preservation in the middle 1000mm, the dimensions and internal structure of the most critical part of the rotating faucet lifting ring joint can be effectively guaranteed by comprehensively considering the deformation resistance of the forging, the direction of metal flow, and the degree of metal deformation, thus ensuring product quality. Attached Figure Description

[0024] Figure 1 A frontal view of the rotating faucet's lifting ring connector;

[0025] Figure 2 Side view of the rotating faucet's lifting ring connector;

[0026] Figure 3 Schematic diagram of forging the lifting ring joint for a rotary faucet;

[0027] Figure 4 A schematic diagram showing the angled insertion of the lifting ring connector of the rotating faucet into both ends of the housing. Detailed Implementation

[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0029] like Figures 3 to 4 As shown in the figure, this embodiment provides a method for manufacturing a rotating faucet lifting ring connector made of alloy structural steel, including the following steps:

[0030] Material preparation: Select alloy structural steel billets, perform flaw detection and visual inspection on the surface of the billets, and remove uneven and defective parts. The purpose of flaw detection is to ensure the quality of raw materials and provide a guarantee for subsequent forging. Select the diameter of round steel according to process requirements and saw it to the required length.

[0031] Heating: The blank after cutting is heated to a temperature of 1180-1200℃, the heating rate is controlled at 100-120℃ / h, and the temperature is held for 2-3 hours;

[0032] Upsetting and drawing: The heated billet undergoes multiple upsetting and drawing processes, with a forging ratio of approximately 2 during the forging process. First, the billet is upset using forging equipment at a pressing rate of 40 mm / s. The billet is monitored in real-time during the upsetting process to prevent folding. If folding occurs, it is immediately repaired. During the drawing process, the billet is first forged into a square shape using forging equipment, and then upset and rounded. The subsequent upsetting and drawing processes are repeated with the first upsetting and drawing. Finally, the diameter range of the billet after drawing is determined based on the dimensions of the faucet connector housing, ensuring that the billet diameter is greater than 120% of the final product's surface area.

[0033] Forging and stamping: The handle of the rotating faucet is forged and rounded. To reduce the deformation resistance of the bent section, the middle 1000mm section of the handle is forged into a spindle shape, with dimensions 1.18-1.25 times that required by the drawing. The remaining handle is forged to dimensions 1.11-1.15 times that required by the drawing.

[0034] Insert box forming: The end of the blank that has been pressed and slammed is formed into a flat square shape. The dimensions after forging are 1.15-1.23 times the dimensions in the drawing. The transition part between the rod and the insert box is rounded (R500).

[0035] Angle setting: The two ends of the blank that has been initially formed by inserting the box body are forged to an angle. During the forging process, the manipulator clamps one end of the insert body, and the rod is fixed by the hoisting equipment. The forging equipment designs the angle of the other end of the insert body to obtain an angle that is consistent with the size requirements of the drawing. The other end is processed by repeating the same process.

[0036] Bending: Heat the middle 1000mm section of the angled billet, ensuring the temperature is 1000±10℃ and holding for 1-2 hours to maintain the forging temperature of the middle 1000mm section. This ensures the deformation during bending meets product requirements while preventing overheating. Then, fix the midpoint of the billet and apply force to bring the two ends of the insert body inwards. Stop bringing them together when the distance between the center lines of the two insert bodies equals the design distance on the drawing.

[0037] Welding tie rods: After bending, grind off the oxide scale at the welding location of the forging to expose the metallic luster; before welding, the welding area and its surroundings must be free of water, oil, rust, and other impurities. Preheating is required before welding, with a preheating temperature ≥150℃. The tie rod length should be set according to the centerline dimensions of the box body as required by the drawings, ensuring the center point distance. After welding, the forging should be immediately placed in an insulation pit for post-weld heat treatment.

[0038] Heat treatment: After welding the tie rods, the forgings undergo preliminary heat treatment according to process requirements. Preliminary heat treatment includes normalizing and tempering; and final heat treatment: quenching and tempering (quenching + high-temperature tempering). When loading the furnace, the rotating faucet lifting ring joints must be leveled, with stable and effective support in the middle and at both ends to prevent slippage and deformation. Special attention should be paid to leveling the ends to avoid twisting deformation. Pads should be placed at the tray tie rod positions; empty pads and missing pads are not allowed, and at least three pads should be used. When two or more rotating faucet lifting ring joints are heat-treated in the same furnace, ensure that the distance between the rods of adjacent lifting ring joints is greater than 200mm to ensure uniform heating.

[0039] Grinding: Grind the surface of the heat-treated forging to the dimensions required in the drawing. Simultaneously inspect the surface quality of the forging, eliminating any defects by grinding. No more than three defects should be ground, and they must not be located on the same cross-section. The grinding depth must not exceed 4% of the cross-sectional dimension, with a maximum depth of 3mm; the width must be at least 6 times the depth; in addition to the length of the defect itself, the grinding depth must extend at least 3mm beyond the defect's perimeter. The grinding depth at curved joints must not exceed 1mm. Grinding should result in a smooth transition, and defects must not be continuous.

[0040] Load test: After grinding, the forging is subjected to a load test of 1.5 times the rated load. The load is gradually increased to the specified value at 25%, 50%, 75%, and 100%, and then held for at least 5 minutes before unloading. After the test, a functional check is performed, and there should be no functional impairment: such as no deformation or damage in any part. A comprehensive non-destructive test is performed on the lifting ring 24 hours after the test. Example

[0041] Specific drawings are as follows Figure 1 As shown, the material grade is 34CrNi1Mo;

[0042] like Figure 1 As shown, a forging method for a rotating water head lifting ring joint includes the following steps:

[0043] Step 1: First, cut the material according to the process calculations. The material size is Φ350*1655. Use a grinding wheel to eliminate obvious surface defects to prevent them from becoming crack sources during subsequent forging. Use ultrasonic testing to inspect the internal structure of the round steel to ensure that the raw material has no linear or single-point defects. Defects exceeding Φ2 are generally not allowed.

[0044] Step 2: Heat the flaw-tested billet to a temperature of 1180-1200℃, with a heating rate of 100-120℃ / h, and hold for 2 hours.

[0045] Step 3: First, upset the alloy steel. The specific steps are as follows: upset from Φ350*1655 to Φ495×830 and elongate → 450×785mm octagonal → octagonal 420×900mm upset → octagonal 595×450mm elongate → 450×785mm octagonal → octagonal 420×900mm upset → octagonal 595×450mm → roll to Φ350×1655.

[0046] Step 4: Leave Φ350*390 at each end of the blank as the insertion box body, and forge the center circle of the rod to Φ185. Forge it into a 1000mm long shuttle shape with an end size of Φ150. The rest of the rod is Φ150.

[0047] Step 5: Shape the end of the blank after pressing and slamming into a flat square shape. The dimensions after forging are 640*340*120. The transition part between the rod and the insertion box is rounded (R500).

[0048] Step 6: Forge the two ends of the blank that has been initially formed into the insert box into an angle. During the forging process, the manipulator clamps one end of the insert box, and the rod is fixed by the hoisting equipment. The forging equipment designs the angle of the other end of the insert box to obtain an angle that is consistent with the size requirements of the drawing. Repeat the process on the other end.

[0049] Step 7: Heat the middle section of the angled billet, 1000mm from the center. During heating, ensure the temperature is 1000±10℃ and hold for 1.5 hours to maintain the forging temperature at the middle 1000mm. This ensures the deformation during bending meets product requirements while preventing overheating. Then, fix the center point of the billet and bring the two ends of the insert box closer together. Stop bringing them together when the distance between the center lines of the two insert boxes equals the design distance (897mm±1mm).

[0050] Step 7: Grind off the oxide scale at the welding location of the bent forging to reveal the metallic luster; before welding, the welding area and its surroundings must be free of water, oil, rust, and other impurities. Preheating is required before welding, with a preheating temperature ≥150℃. Set the tie rod length (897mm±1) according to the centerline dimensions of the box body as required by the drawings, ensuring the center point distance. After welding, the forging should be immediately placed in an insulation pit for post-weld heat treatment.

[0051] Step 8: After welding the tie rods, the forgings undergo preliminary heat treatment according to process requirements. Preliminary heat treatment includes normalizing and tempering; and final heat treatment: quenching and tempering (quenching + high-temperature tempering). When loading the furnace, the rotating water tap lifting ring joint must be leveled, with stable and effective support in the middle and at both ends to prevent slippage and deformation. Pay particular attention to leveling the ends to avoid twisting deformation. Pads should be placed at the tie rod positions on the pallet; empty pads and omissions are not allowed, and at least three pads should be used. The distance between the workpiece rods should be greater than 200mm to ensure uniform heating.

[0052] Step 9: Grind the surface of the heat-treated forging to the dimensions required in the drawing. Simultaneously check the surface quality of the forging, eliminating any defects by grinding. No more than three defects should be ground, and they must not be located on the same cross-section. The grinding depth must not exceed 4% of the cross-sectional dimension, with a maximum depth of 3mm; the width must be no less than 6 times the depth; and the length should extend at least 3mm beyond the defects at both ends. The grinding depth at arc-shaped connections must not exceed 1mm. Grinding should be smooth, and defects must not be continuous.

[0053] Step 10: Perform a 1.5 times rated load test on the ground forging. Apply the test load in increments of 25%, 50%, 75%, and 100% until the specified value is reached, then hold the load for at least 5 minutes before unloading. After the test, perform a functional check; there should be no functional impairment, such as deformation or damage to any part. Perform a comprehensive non-destructive testing on the lifting ring 24 hours after the test.

[0054] To verify the mechanical properties of the 34CrNi1Mo rotary faucet lifting ring connector provided by the forging method of the present invention, the inventors took a 200mm sample from the end of the product of the embodiment and conducted mechanical property testing. The mechanical property test data are shown in Table 1.

[0055] Table 1 Product Sampling Test Data

[0056]

Claims

1. A method for manufacturing a rotating faucet lifting ring connector made of alloy structural steel, characterized in that, Includes the following steps: Material preparation: Select alloy structural steel billets, choose the diameter of round steel according to the process size requirements, and saw it to the required length; Heating: The sawn blanks are heated to a temperature of 1180-1200℃, with a heating rate controlled at 100-120℃ / h, and held for 2-3 hours; Upsetting, drawing, and preliminary forming of the shank and insert body: The heated billet undergoes multiple upsetting and drawing processes, with a forging ratio of 2 during forging. First, the billet is upset using forging equipment at a pressing rate of 40mm / s. The billet is monitored in real time during the upsetting process to prevent folding; if folding occurs, it is repaired. During the drawing process, the billet is forged into a square shape using forging equipment, and then the square is upset and rounded. The subsequent upsetting and drawing processes are repeated with the first upsetting and drawing. Finally, the diameter range of the billet after drawing is determined according to the dimensions of the faucet connector insert body, ensuring that the billet diameter is greater than or equal to 120% of the final product surface area. Both ends are flattened to form the insert body. The middle section is the rod. Forging is performed so that the two end inserts and the rod form an angle consistent with the dimensions required in the drawing. The forging conditions for the inserts and the rod are as follows: the blank after the last drawing is pressed and forged into a dumbbell shape. The weight of the blank at both ends is 2.1-2.3 times the weight of the finished end. Then the rod is rounded. The 1000mm long section in the middle of the rod is forged into a shuttle shape to form a variable diameter rod. The diameter of the rest of the rod is the same. During the forging process, the pulling speed of the shaft is controlled at 2.5-4.5m / min. The deformation of each pass forming the middle step shaft is controlled at 35%-40%, and the pulling speed is controlled at 2.5-4.5m / min. Bending and welding tie rods: Heat and keep warm the middle rod part of the billet 1000mm after the angle is made. Then fix the middle point of the billet and apply force to make the two ends of the insertion box body move inward. Stop moving inward when the distance between the center lines of the two ends of the insertion box body is equal to the design distance on the drawing. Then weld tie rods according to the center point distance requirements. Heat treatment: The forgings after welding tie rods are subjected to preliminary heat treatment and final heat treatment according to process requirements. Preliminary heat treatment includes normalizing and tempering, and final heat treatment includes quenching and high-temperature tempering. Grinding: Grind the surface of the heat-treated forging to the required dimensions in the drawing, and finally shape it; Load test: Perform a load test of 1.5 times the rated load on the molded part.

2. The manufacturing method of the alloy structural steel rotary faucet lifting ring joint according to claim 1, characterized in that, During the material preparation process, the surface of the selected alloy structural steel billet is subjected to flaw detection and visual inspection to remove uneven and defective parts.

3. The method for manufacturing the alloy structural steel rotary faucet lifting ring joint according to claim 1, characterized in that, In the upsetting, drawing, and preliminary forming steps of the rod and the insert box, the end of the blank that has been pressed and slammed is formed into a flat square shape, and the transition part between the rod and the insert box is rounded.

4. The manufacturing method of the alloy structural steel rotary faucet lifting ring joint according to claim 1, characterized in that, In the upsetting, drawing, and preliminary forming steps of the rod and insert box, the process of forging the insert box at both ends to form an angle is as follows: During the forging process, the manipulator clamps one end of the insert box, the rod is fixed using hoisting equipment, and the forging equipment designs the angle of the other end of the insert box to obtain an angle consistent with the dimensions required in the drawing. The other end is then subjected to the same process.

5. The method for manufacturing the alloy structural steel rotary faucet lifting ring joint according to claim 1, characterized in that, During the bending and welding of the tie rods, the heating temperature at 1000mm of the middle rod section of the blank after the angle is set is 1000±10℃, and the holding time is 1-2 hours.

6. The method for manufacturing the alloy structural steel rotary faucet lifting ring joint according to claim 5, characterized in that, During the bending and welding of the tie rods, the oxide scale at the welding position of the bent forging is ground off to reveal the metallic luster. Before welding, there should be no water, oil, or rust in or around the welding area. Preheating should be performed before welding, with a preheating temperature ≥150℃. The tie rod length should be set according to the center line dimension requirements of the box body in the drawing to ensure the center point distance. After welding, the forging should be immediately placed in the heat preservation pit for post-weld heat treatment.

7. The manufacturing method of the alloy structural steel rotary faucet lifting ring joint according to claim 1, characterized in that, During the grinding process, inspect the surface quality of the forging, grind away any defects, and grind away no more than three defects that are located on the same cross section. The depth of the grinding should not exceed 4% of the cross section size and should not exceed 3 mm. The width should not be less than 6 times the depth. The length should extend at least 3 mm from the outermost point of the defect. The grinding depth at the arc connection should not exceed 1 mm. The grinding should be smooth and the defects should not be continuous.

8. The method for manufacturing the alloy structural steel rotary faucet lifting ring joint according to claim 1, characterized in that, In the load test procedure, the load is gradually increased to the specified value at levels of 25%, 50%, 75%, and 100%, and then unloaded after holding the load for no less than 5 minutes. After the test, the function is checked. The qualified product should not have any functional impairment. 24 hours after the test, the rotating faucet lifting ring joint is subjected to overall non-destructive testing.

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