Rolling mill and rolling process for large-thickness-ratio thin-wall right-angle inner stepped ring

Abstract

A kind of big height-thickness ratio thin-walled right-angle inner step ring rolling forming roller system and rolling process, belong to the technical field of rolling forming, solve the technical problems of blank making difficulty and filling shortage in the rolling of step ring blank and rectangular ring blank, the solution is: according to the forming stage of big height-thickness ratio thin-walled right-angle inner step ring, corresponding rolling roller system is set respectively: rolling-expanding stage roller system: including 1# main roller, 1# core roller and two 1# cone rollers;Rolling forming stage roller system: including 2# main roller, 1# core roller, 1# cone roller and 2# cone roller;Closed die forging forming roller system: including 3# main roller, 2# core roller and two 1# cone rollers;On this basis, big height-thickness ratio thin-walled right-angle inner step ring rolling process is disclosed.The present application adopts simple multi-process, multi-mold process method, especially suitable for preparing big height-thickness ratio thin-walled right-angle inner step ring, easy to operate, reduce production cost.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of rolling forming, and particularly relates to a large height-thickness ratio thin-wall right-angle inner step ring rolling forming roller system and a rolling process. BACKGROUND

[0002] Large rings are widely used in the industrial fields of wind power, shipbuilding, aerospace, etc. as basic components of heavy equipment, and the high-quality production of large rings is one of the important standards of the national industrial level. Generally, the manufacturing of large rings adopts ring rolling forming, that is, the wall thickness of the ring is thinned and the diameter is expanded through the rotation and feeding of the rollers on the rolling equipment, and the ring after rolling has the advantages of good quality, high efficiency and low cost.

[0003] With the rapid development of new energy and industrialization, the demand for large special-shaped rings with complex cross sections increases, and higher requirements for the forming quality and performance of the special-shaped rings are put forward. However, the current large special-shaped rings are faced with problems such as unstable rolling, complex material flow, low coordination between the ring and the roller, and process parameters, which result in the inability to guarantee the forming quality of the products. Therefore, it is urgent to conduct in-depth research on the stability control and shape control of the rolling forming process of large special-shaped rings, and then obtain a new process method for high-quality forming of special-shaped rings. SUMMARY

[0004] The main purpose of the present application is to overcome the deficiencies in the prior art and solve the technical problems of difficult blanking and insufficient filling in direct step ring blank rolling and rectangular ring blank rolling (the difference between the volumes of the large and small hole rings of the large height-thickness ratio thin-wall right-angle inner step ring leads to a large amount of axial metal flow of the rectangular ring blank, resulting in uneven rolling deformation and defects such as insufficient filling), and the present application provides a large height-thickness ratio thin-wall right-angle inner step ring rolling forming roller system and a rolling process.

[0005] The present application is implemented by the following technical solutions:

[0006] The large height-thickness ratio thin-wall right-angle inner step ring rolling forming roller system comprises a large hole ring and a small hole ring, the large hole ring is located above the small hole ring, a right-angle inner step is formed between the inner wall of the large hole ring and the upper end surface of the small hole ring, and the large hole ring and the small hole ring are integrally rolled and formed.

[0007] The initial shape and size of the ring blank are as follows: the outer circular surface radius is R0, the inner circular surface radius is r0, the initial wall thickness is H0, and the initial height is B0.

[0008] The shape and size of the large height-thickness ratio thin-wall right-angle inner step ring after rolling forming of the ring blank are as follows: the height of the large height-thickness ratio thin-wall right-angle inner step ring is B; the outer circular surface radius of the large hole ring is R, the inner circular surface radius of the large hole ring is r b , and the wall thickness of the large hole ring is H bThe height of the inner wall of the large hole ring is B b The radius of the inner circular surface of the small hole ring is r s The wall thickness of the small hole ring is H b +H s The height of the inner wall of the small hole ring is B s ;

[0009] According to the forming stage of the large high-thin ratio thin-walled right-angle inner stepped ring piece, corresponding rolling roller systems are respectively arranged:

[0010] The rolling expansion stage roller system includes a 1# main roller, a 1# core roller and two 1# cone rollers, the 1# core roller is a cylindrical roller, and the two 1# cone rollers are both conical rollers; the middle part of the side wall of the 1# main roller is provided with a first annular groove, the width of the first annular groove is not less than B0, and the depth of the first annular groove is not less than H b +H s ; the initial wall thickness H0 of the annular blank is not less than the depth of the first annular groove, the annular blank is located in the first annular groove, and the outer circular surface of the annular blank is pressed by the first annular groove of the 1# main roller, the inner circular surface of the annular blank is pressed by the 1# core roller, and the two 1# cone rollers are symmetrically arranged, and the generatrix of the 1# cone roller presses the upper and lower end surfaces of the annular blank respectively;

[0011] The rolling forming stage roller system includes a 2# main roller, a 1# core roller, a 1# cone roller and a 2# cone roller, the 2# main roller is arranged as a cylindrical roller, the 2# main roller presses the outer circular surface of the annular blank, the 1# core roller presses the inner circular surface of the annular blank, the 1# cone roller and the 2# cone roller are symmetrically arranged, and the generatrix of the 1# cone roller and the generatrix of the 2# cone roller press the upper and lower end surfaces of the annular blank respectively; the 2# cone roller is a conical roller, and a second annular groove with a rectangular cross section is arranged at the tail of the 2# cone roller, the width of the second annular groove is not less than the wall thickness H b of the large hole ring, and the depth of the second annular groove is not less than the height B b of the inner wall of the large hole ring;

[0012] The closed die forging forming roller system includes a 3# main roller, a 2# core roller and two 1# cone rollers, the middle part of the side wall of the 3# main roller is provided with a third annular groove, the width of the third annular groove is B, and the depth of the third annular groove is H b ; the lower part of the side wall of the 2# core roller is provided with a fourth annular groove, the width of the fourth annular groove is B s , the depth of the fourth annular groove is H s , the outer wall of the 3# main roller is tangent to the outer wall of the 2# core roller, and the lower side wall of the fourth annular groove is flush with the lower side wall of the third annular groove.

[0013] The rolling process for preparing the large high-thin ratio thin-walled right-angle inner stepped ring piece by using the rolling forming roller system as described above includes the following steps:

[0014] S1, ring blank rolling expansion forming: first, the first ring groove of the 1# main roller compresses the outer circular surface of the ring blank, the 1# core roller compresses the inner circular surface of the ring blank, the two 1# taper rollers are symmetrically arranged, and the generatrices of the 1# taper rollers compress the upper and lower end surfaces of the ring blank respectively; then, the 1# core roller feeds in the radial direction, and the ring blank is rolled and expanded to form a ring blank, and when the outer circular surface radius of the ring blank is 0.8R, the 1# core roller stops radial feeding;

[0015] S2, rolling forming right angle inner step hole: first, the ring blank after rolling expansion forming in step S1 is taken down, the rolling expansion stage roller system in step S1 is replaced by a rolling forming stage roller system, and the wall thickness of the ring blank after rolling expansion forming near the edge is H b The position is located below the second ring groove; then, the 1# core roller and the 2# main roller stop radial movement, the 2# taper roller axially feeds to the side of the 1# taper roller, and the axial feeding amount of the 2# taper roller is B b A right angle inner step hole is rolled and formed on the upper end surface of the ring blank;

[0016] S3, closed die forging forming large height-thickness ratio thin-walled right angle inner step ring product: first, the ring blank after rolling forming right angle inner step hole in step S2 is taken down, the rolling forming stage roller system in step S2 is replaced by a closed die forging forming roller system, and the outer circular surface of the right angle inner step hole ring blank is located in the third ring groove, and the inner circular surface of the right angle inner step hole ring blank is located in the fourth ring groove; then, the 2# core roller feeds in the radial direction to the 3# main roller, until the third ring groove and the fourth ring groove are closed, and at the same time, the two 1# taper rollers are adjusted to move towards each other along the axial direction until the spacing between the generatrices is B, and a large height-thickness ratio thin-walled right angle inner step ring is prepared.

[0017] Further, in the step S3, the volume ratio of the large hole ring to the small hole ring of the prepared large height-thickness ratio thin-walled right angle inner step ring is 3:7.

[0018] The beneficial effects of the present application are that the complex process method of traditional rolling forming large size thin-walled inner right angle step hole ring is improved to a simple multi-process, multi-mold process method, which is especially suitable for preparing a large height-thickness ratio thin-walled right angle inner step ring, and is convenient to operate and reduces production cost. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 It is a longitudinal section schematic diagram of the initial state of the ring blank;

[0020] Figure 2 It is a longitudinal section schematic diagram of the large height-thickness ratio thin-walled right angle inner step ring product;

[0021] Figure 3 It is a rolling process flow chart of the large height-thickness ratio thin-walled right angle inner step ring.

[0022] In the diagram, 1 is the No. 1 main roller, 2 is the No. 1 core roller, 3 is the No. 1 conical roller, 4 is the first annular groove, 5 is the No. 2 main roller, 6 is the No. 2 conical roller, 7 is the second annular groove, 8 is the No. 3 main roller, 9 is the No. 2 core roller, 10 is the third annular groove, and 11 is the fourth annular groove. Detailed Implementation

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0024] A rolling forming roll system for thin-walled right-angled inner step rings with high height-to-thickness ratio, the thin-walled right-angled inner step rings with high height-to-thickness ratio include a large hole ring and a small hole ring, the large hole ring is located above the small hole ring, a right-angled inner step is formed between the inner wall of the large hole ring and the upper end face of the small hole ring, the large hole ring and the small hole ring are integrally rolled and formed;

[0025] Determine the shape and dimensions of the ring blank: Based on the principle of constant volume, the volume of the blank ring should be equal to the volume of the thin-walled right-angled inner step ring with a large height-to-thickness ratio. Figure 1 As shown, the initial shape and dimensions of the annular blank are: outer circle radius R0 = 984 mm, inner circle radius r0 = 682 mm, initial wall thickness H0 = 322 mm, and initial height B0 = 380 mm.

[0026] Calculate the volume and cross-sectional area of ​​a thin-walled right-angled inner stepped ring with a large height-to-thickness ratio:

[0027] like Figure 2 As shown, the volume V of the ring is calculated using the following formula:

[0028] V = π[B] b (R 2 -r b 2 )+B s (R 2 -r s 2 )];

[0029] The cross-sectional area S of the ring is calculated using the following formula:

[0030] S = H b B+H s B s ;

[0031] Assume the shape and dimensions of the high-height-to-thickness ratio thin-walled right-angled inner stepped ring after rolling the annular billet are as follows: the height of the high-height-to-thickness ratio thin-walled right-angled inner stepped ring is B = 388 mm; the radius of the outer circle of the large hole ring is R = 1943 mm; and the radius of the inner circle of the large hole ring is r. b =1859mm, the wall thickness of the large-hole ring is H b =84mm, that is, R=r b +Hb The height of the inner wall of the large hole ring is B b = 190 mm; the radius of the inner circular surface of the small hole ring is r s = 1751 mm, the wall thickness of the small hole ring is H b + H s = 192 mm, the height of the inner wall of the small hole ring is B s = 198 mm, that is, B = B b + B s ; the volume ratio of the large hole ring to the small hole ring is 3:7, if the large high-thin straight-angle inner stepped ring is directly formed from the rectangular cross-section ring, the metal volume flow is large, and it is not easy to form;

[0032] According to the forming stage of the large high-thin straight-angle inner stepped ring, corresponding rolling roller systems are respectively arranged:

[0033] The rolling-expanding stage roller system comprises a 1# main roller 1, a 1# core roller 2 and two 1# taper rollers 3, the 1# core roller 2 is a cylindrical roller, the two 1# taper rollers 3 are both conical rollers, the 1# core roller 2 and the two 1# taper rollers 3 play the role of clamping and supporting, so there is no special requirement for the shape and size; the middle part of the side wall of the 1# main roller 1 is provided with a first annular groove 4, the width of the first annular groove 4 is not less than B0, and the depth of the first annular groove 4 is not less than H b + H s ; the initial wall thickness H0 of the annular blank is not less than the depth of the first annular groove 4, the annular blank is located in the first annular groove 4, and the outer circular surface of the annular blank is pressed by the first annular groove 4 of the 1# main roller 1, the inner circular surface of the annular blank is pressed by the 1# core roller 2, and the two 1# taper rollers 3 are symmetrically arranged, and the generatrix of the 1# taper roller 3 respectively presses the upper and lower end surfaces of the annular blank;

[0034] The rolling-forming stage roller system comprises a 2# main roller 5, a 1# core roller 2, a 1# taper roller 3 and a 2# taper roller 6, the 2# main roller 5 is arranged as a cylindrical roller, the 2# main roller 5 presses the outer circular surface of the annular blank, the 1# core roller 2 presses the inner circular surface of the annular blank, the 1# taper roller 3 and the 2# taper roller 6 are symmetrically arranged, and the generatrix of the 1# taper roller 3 and the generatrix of the 2# taper roller 6 respectively press the upper and lower end surfaces of the annular blank; the 2# taper roller 6 is a conical roller, and a second annular groove 7 with a rectangular cross-section is arranged at the tail of the 2# taper roller 6, the width of the second annular groove 7 is not less than the wall thickness H b of the large hole ring, and the depth of the second annular groove 7 is not less than the height B b of the inner wall of the large hole ring;

[0035] The closed die forging forming roller system comprises a 3# main roller 8, a 2# core roller 9 and two 1# taper rollers 3, the middle part of the side wall of the 3# main roller 8 is provided with a third annular groove 10, the width of the third annular groove 10 is B, and the depth of the third annular groove 10 is H bThe lower part of the sidewall of the 2# core roller 9 is provided with a fourth annular groove 11, the width of the fourth annular groove 11 is B s , the depth of the fourth annular groove 11 is H s , the outer wall of the 3# main roller 8 is tangent to the outer wall of the 2# core roller 9, and the lower sidewall of the fourth annular groove 11 is flush with the lower sidewall of the third annular groove 10.

[0036] As shown in Figure 3 , the rolling process for preparing a large height-thickness ratio thin-walled right-angle inner step ring piece by using the rolling forming roller system as described above comprises the following steps:

[0037] S1, ring blank rolling expansion forming: first, the first annular groove 4 of the 1# main roller 1 compresses the outer circular surface of the ring blank, the 1# core roller 2 compresses the inner circular surface of the ring blank, and the two 1# taper rollers 3 are symmetrically arranged, and the generatrices of the 1# taper rollers 3 compress the upper and lower end surfaces of the ring blank respectively; then, the 1# core roller 2 feeds in the radial direction to perform rolling expansion forming on the ring blank, and when the radius of the outer circular surface of the ring blank is 0.8R, the 1# core roller 2 stops radial feeding;

[0038] S2, rolling forming right-angle inner step hole: first, the ring blank after rolling expansion forming in step S1 is taken down, the rolling expansion stage roller system in step S1 is replaced by a rolling forming stage roller system, and the wall thickness of the ring blank after rolling expansion forming near the edge is located below the second annular groove 7 at the position of H b ; then, the 1# core roller 2 and the 2# main roller 5 stop radial movement, the 2# taper roller 6 axially feeds to one side of the 1# taper roller 3, and the axial feeding amount of the 2# taper roller 6 is B b , a right-angle inner step hole is rolled and formed on the upper end surface of the ring blank;

[0039] S3, closed die forging forming large height-thickness ratio thin-walled right-angle inner step ring piece: first, the ring blank after rolling forming right-angle inner step hole in step S2 is taken down, the rolling forming stage roller system in step S2 is replaced by a closed die forging forming roller system, and the outer circular surface of the right-angle inner step hole ring blank is located in the third annular groove 10, and the inner circular surface of the right-angle inner step hole ring blank is located in the fourth annular groove 11; then, the 2# core roller 9 feeds in the radial direction to the 3# main roller 8 direction until the third annular groove 10 and the fourth annular groove 11 are combined, and at the same time, the two 1# taper rollers 3 are adjusted to move towards each other along the axial direction until the spacing between the generatrices is B, and a large height-thickness ratio thin-walled right-angle inner step ring piece is prepared.

[0040] The rolling process parameters are selected according to the common knowledge in the art, in the specific embodiment,

[0041] The angular velocity of the main roller is set to 2 rad / s, and the feeding speed of the core roller is set to 0.3 mm / s;

[0042] The friction coefficient of the main roller is set to 0.8, the friction coefficient of the core roller is set to 0.4, and the friction coefficient of the taper roller is set to 0.1.

[0043] The initial temperature of the mold is 150 DEG C, and the initial temperature of the ring is 1240 DEG C.

[0044] The above is only a specific embodiment of the present application, but the protection scope of the present application is not limited to this, any person skilled in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A large height-thickness ratio thin-walled right-angle inner step ring rolling forming roller system, the large height-thickness ratio thin-walled right-angle inner step ring comprises a large hole ring and a small hole ring, the large hole ring is located above the small hole ring, a right-angle inner step is formed between the inner wall of the large hole ring and the upper end surface of the small hole ring, and the large hole ring and the small hole ring are integrally rolled and formed. The initial shape and size of the annular blank are as follows: the outer circular surface radius is R0, the inner circular surface radius is r0, the initial wall thickness is H0, and the initial height is B0. The shape and size of the large-height-thin-wall right-angle inner step ring formed after the annular blank is rolled are as follows: the height of the large-height-thin-wall right-angle inner step ring is B; the outer circular surface radius of the large-hole ring is R, the inner circular surface radius of the large-hole ring is r b , the wall thickness of the large-hole ring is H b , the height of the inner wall of the large-hole ring is B b ; the inner circular surface radius of the small-hole ring is r s , the wall thickness of the small-hole ring is H b + H s , and the height of the inner wall of the small-hole ring is B s ​ characterized in that According to the forming stages of the large height-thickness ratio thin-walled right-angle inner step ring, corresponding rolling roller systems are respectively arranged: The roller system of the rolling and expanding stage comprises a 1# main roller (1), a 1# core roller (2) and two 1# taper rollers (3), the 1# core roller (2) is a cylindrical roller, and the two 1# taper rollers (3) are both conical rollers; a first annular groove (4) is arranged in the middle of the side wall of the 1# main roller (1), the width of the first annular groove (4) is not less than B0, and the depth of the first annular groove (4) is not less than H b +H s The initial wall thickness H0 of the annular blank is not less than the depth of the first annular groove (4), the annular blank is located in the first annular groove (4), and the outer cylindrical surface of the annular blank is pressed by the first annular groove (4) of the 1# main roller (1), the inner cylindrical surface of the annular blank is pressed by the 1# core roller (2), the two 1# taper rollers (3) are symmetrically arranged, and the generatrix of the 1# taper roller (3) presses the upper and lower end surfaces of the annular blank, respectively. The rolling forming stage roller system comprises a 2# main roller (5), a 1# core roller (2), a 1# taper roller (3) and a 2# taper roller (6), the 2# main roller (5) is arranged as a cylindrical roller, the 2# main roller (5) is arranged to press the outer circumferential surface of the annular blank, the 1# core roller (2) is arranged to press the inner circumferential surface of the annular blank, the 1# taper roller (3) and the 2# taper roller (6) are symmetrically arranged, and the generatrix of the 1# taper roller (3) and the generatrix of the 2# taper roller (6) are arranged to press the upper end surface and the lower end surface of the annular blank respectively; the 2# taper roller (6) is a conical roller, a second annular groove (7) with a rectangular cross section is arranged at the tail of the 2# taper roller (6), the width of the second annular groove (7) is not less than the wall thickness H of the large-hole ring b , and the depth of the second annular groove (7) is not less than the height B of the inner wall of the large-hole ring b . The closed die forging forming roller system comprises a 3# main roller (8), a 2# core roller (9) and two 1# taper rollers (3), the middle part of the side wall of the 3# main roller (8) is provided with a third annular groove (10), the width of the third annular groove (10) is B, and the depth of the third annular groove (10) is H b The lower part of the side wall of the 2# core roller (9) is provided with a fourth annular groove (11), the width of the fourth annular groove (11) is B s , the depth of the fourth annular groove (11) is H s The outer wall of the 3# main roller (8) is tangent to the outer wall of the 2# core roller (9), and the lower side wall of the fourth annular groove (11) is flush with the lower side wall of the third annular groove (10).

2. Rolling process using a roll forming roll train as claimed in claim 1, characterized in that The method comprises the following steps: S1, annular blank rolling expansion forming: first, the first annular groove (4) of the 1# main roller (1) compresses the outer circular surface of the annular blank, the 1# core roller (2) compresses the inner circular surface of the annular blank, the two 1# taper rollers (3) are symmetrically arranged, and the generatrices of the 1# taper rollers (3) compress the upper and lower end surfaces of the annular blank; then, the 1# core roller (2) feeds in the radial direction to roll and expand the annular blank until the outer circular surface radius of the annular blank is 0.8R, and the 1# core roller (2) stops radial feeding; S2, a right-angle inner stepped hole is formed by rolling: first, the annular blank after the rolling expansion forming in step S1 is removed, the rolling expansion stage roll system in step S1 is replaced by a rolling forming stage roll system, and the wall thickness of the annular blank after the rolling expansion forming near the edge is H b The position is located below the second annular groove (7); then, the 1# core roller (2) and the 2# main roller (5) stop moving radially, the 2# taper roller (6) is axially fed to the side of the 1# taper roller (3), and the axial feeding amount of the 2# taper roller (6) is B b A right-angle inner stepped hole is formed by rolling on the upper end face of the annular blank; S3, closed die forging forming of the large height-thickness ratio thin-walled right-angle inner step ring product: first, the annular blank after the rolling forming of the right-angle inner step hole in step S2 is taken out, the roller system in step S2 is replaced with a closed die forging forming roller system, the outer circular surface of the right-angle inner step hole annular blank is located in the third annular groove (10), and the inner circular surface of the right-angle inner step hole annular blank is located in the fourth annular groove (11); then, the 2# core roller (9) feeds in the radial direction to the 3# main roller (8), until the third annular groove (10) and the fourth annular groove (11) are closed, and at the same time, the two 1# taper rollers (3) move towards each other along the axis direction until the spacing between the generatrices is B, and the large height-thickness ratio thin-walled right-angle inner step ring is prepared.

3. The rolling process according to claim 2, characterized in that In the step S3, the volume ratio of the large hole ring to the small hole ring of the prepared large height-thickness ratio thin-walled right-angle inner step ring is 3:7.

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