A large aluminum bronze cage and its forming method

Abstract

The present invention relates to the technical field of cage forming, and particularly to a large-sized aluminum bronze cage and a forming method thereof, including: sequentially heating and upsetting a blank ring produced by centrifugal casting; determining an upsetting accuracy adjustment method according to the upsetting pressures of several fan-shaped areas during the upsetting of the blank ring, including adjusting the rotation and extraction method of the primary blank formed after upsetting, or determining whether to spray a heat-conducting liquid on the primary blank; performing pre-horseframe hole expansion; determining a stress deviation correction method according to the vibration intensity of the primary blank, including adjusting the contact surface length between the ring rolling mill and the primary blank, or performing a ring rolling accuracy treatment method; performing actual horseframe hole expansion to form a secondary blank; sequentially performing pre-drilling of round holes, milling machine processing, and slitting to form a finished cage. The present invention realizes the improvement of the forming processing accuracy and the processing efficiency of the cage.

Description

Technical Field

[0001] The present invention relates to the technical field of cage forming, and particularly relates to a large aluminum bronze cage and a forming method thereof. Background Art

[0002] In the prior art, traditional cage manufacturing mostly adopts the process of forging ingots to produce billets, which has problems such as low material utilization rate and long processing cycle. Especially for cages with complex groove structures, the conventional milling processing efficiency is low, and the processing time for a single groove reaches 15 - 20 minutes. Moreover, the tool wears severely during the processing, resulting in difficulties in ensuring machining accuracy and surface quality, as well as problems such as many casting defects and uneven structure, which seriously affect the performance and service life of the cage.

[0003] Chinese Patent Publication No.: CN101487497B discloses a rotary bearing integral cage and its production process, including the following steps: a) cutting the raw material steel; b) surface grinding; c) punching round holes; d) grinding the punched round holes; e) rough rolling, in this step, non - equiangular rolling structure is used for rolling, the non - equiangular rolling structure includes an active roller and two passive rollers, and the distance between the contact points of the two passive rollers with the integral cage of the bearing is less than or equal to 2 times the center distance of adjacent two round holes; f) welding; g) finish rolling. It can be seen that the rotary bearing integral cage and its production process have problems such as a decline in production quality due to the stress generated during the truncation of the blank or the stress caused by the long axis direction of the upset blank contacting air cooling, and a decline in ring rolling stability and thus a decline in production efficiency due to the uneven internal and external stresses of the blank that are not detected during the front - end operation. Summary of the Invention

[0004] Therefore, the present invention provides a large aluminum bronze cage and a forming method thereof to overcome the problems in the prior art, such as a decline in production quality due to the stress generated during the truncation of the blank or the stress caused by the long axis direction of the upset blank contacting air cooling, and a decline in ring rolling stability and thus a decline in production efficiency due to the uneven internal and external stresses of the blank that are not detected during the front - end operation.

[0005] To achieve the above object, the present invention provides a large aluminum bronze cage and a forming method thereof, including:

[0006] heating and upsetting the blank ring produced by centrifugal casting in sequence to form a primary blank;

[0007] determining the upsetting accuracy adjustment method according to the upsetting pressures of several fan - shaped regions during the upsetting of the blank ring, including adjusting the translation extraction method of the primary blank formed after upsetting to a rotary extraction method, or determining whether to spray a heat - conducting liquid on the primary blank according to the change amount of the thickness of the primary blank;

[0008] Use a ring rolling machine to perform pre-expansion of the first-stage blank according to the rolling curve;

[0009] Determine the stress deviation correction method according to the vibration intensity of the first-stage blank during the pre-expansion of the first-stage blank, including adjusting the contact surface length between the ring rolling machine and the first-stage blank, or performing ring rolling accuracy processing according to the slip amount of the contact surface;

[0010] Control the ring rolling machine to perform actual expansion of the first-stage blank according to the corresponding stress deviation correction to form a second-stage blank;

[0011] Perform pre-drilling of round holes, milling machine processing, and slitting on the second-stage blank in sequence to form a finished cage.

[0012] Furthermore, heating and upsetting the blank ring produced by the centrifugal casting method in sequence to form a first-stage blank, including:

[0013] Heat the blank ring according to a preset temperature;

[0014] Place the heated blank ring between the upper anvil and the lower anvil in the upsetting machine, and the upper anvil presses down the blank ring to the required height to output the first-stage blank.

[0015] Furthermore, the method for determining the upsetting accuracy adjustment method includes:

[0016] Obtain the upsetting pressures in several fan-shaped areas at several initial pressing moments during the pressing process of the upper anvil respectively;

[0017] Calculate the average upsetting pressure of each fan-shaped area according to the upsetting pressures in each fan-shaped area respectively, and calculate the standard deviation of the upsetting pressure according to the average upsetting pressure of each area;

[0018] Compare the standard deviation of the upsetting pressure with a preset first standard deviation and a preset second standard deviation respectively, where,

[0019] If the standard deviation of the upsetting pressure is greater than or equal to the preset first standard deviation, it is determined that the upsetting stress of the blank ring does not meet the requirements;

[0020] If the standard deviation of the upsetting pressure is greater than or equal to the preset second standard deviation, rotate the fan-shaped area with the smallest average upsetting pressure to the outlet direction after upsetting, and increase the temperature of the upper anvil on the side away from the outlet and extend the removal time of the lower anvil when taking out;

[0021] Wherein, the average upsetting pressure of each area is the average of the upsetting pressures in a single fan-shaped area; the preset first standard deviation is less than the preset second standard deviation;

[0022] The temperature of the upper anvil on the side away from the discharge port is positively correlated with the standard deviation of the upsetting pressure; the removal duration of the lower anvil is positively correlated with the standard deviation of the upsetting pressure.

[0023] Furthermore, the determining of the upsetting accuracy adjustment method further includes:

[0024] If the standard deviation of the upsetting pressure is greater than or equal to the preset first standard deviation and less than the preset second standard deviation, it is preliminarily determined that the air cooling stress does not meet the requirements, and the change amount of half of the thickness of the vertical section of the primary blank during upsetting is obtained;

[0025] If the change amount of the half thickness is greater than the preset change amount, it is secondarily determined that the air cooling stress does not meet the requirements, and a heat-conducting liquid is sprayed on the surface of the primary blank.

[0026] Furthermore, the half thickness is the thickness between the long axis of the vertical section of the primary blank and the lower anvil; the change amount of the half thickness is the difference between the half thickness at a unit downward pressing moment and the half thickness at the next unit downward pressing moment.

[0027] Furthermore, the determining of the stress deviation correction method includes:

[0028] Obtain the vibration intensity of the secondary blank during the ring rolling of the skew rolling mill;

[0029] Compare the vibration intensity with the preset first vibration intensity and the preset second vibration intensity respectively;

[0030] If the vibration intensity is greater than or equal to the preset first vibration intensity, it is determined that the internal and external stress uniformity of the primary blank does not meet the requirements;

[0031] If the vibration intensity is greater than or equal to the preset second vibration intensity, increase the contact surface length between the ring rolling mill and the primary blank to the vibration surface wavelength of the primary blank,

[0032] Wherein, the preset first vibration intensity is less than the preset second vibration intensity.

[0033] Furthermore, the determining of the stress deviation correction method further includes:

[0034] If the vibration intensity is greater than or equal to the preset first vibration intensity and less than the preset second vibration intensity, it is preliminarily determined that the ring rolling stability does not meet the requirements, and the slip amount of the contact surface within the unit ring rolling duration is obtained;

[0035] If the sliding amount is greater than or equal to the preset sliding amount, it is determined for the second time that the ring rolling stability does not meet the requirements, and the position where the sliding amount reaches the preset sliding amount is marked on the primary blank as the sliding mark point, and the ring rolling accuracy processing method is carried out after the sliding mark point runs one week;

[0036] Wherein, the sliding amount of the contact surface is the displacement amount between the central position of the contact surface of the primary blank at the start time of the unit ring rolling duration and the central position of the contact surface of the ring rolling machine at the end time of the unit ring rolling duration.

[0037] Further, the ring rolling accuracy processing method is to increase the ring rolling pressure when the ring rolling contacts the sliding mark point after the sliding mark point runs one week, and at the same time increase the feeding speed of the primary blank;

[0038] The ring rolling pressure is positively correlated with the sliding amount, and the feeding speed is positively correlated with the sliding amount.

[0039] Further, the secondary blank is successively subjected to pre-drilling circular holes, milling machine processing, and slitting to form a finished cage, including:

[0040] Calculating the diameter of the center line connecting the rolling grooves according to the angular intervals of several required rolling grooves;

[0041] Pre-drilling circular holes on the secondary blank according to the diameter of the center line connecting the rolling grooves according to the pitch circle;

[0042] Processing the pre-drilled secondary blank on a milling machine according to the dimensions of the required rolling grooves and performing equal-length slitting to form the finished cage.

[0043] The present invention also provides a large-sized aluminum bronze cage, including:

[0044] A cage body for isolating bearing rolling elements,

[0045] On the cage body, several rolling grooves for restricting the movement direction of the bearing rolling elements are further provided, and a first positioning boss and a second positioning boss for fixing the cage body are respectively arranged on the inner circumferential surface and the outer circumferential surface of the cage body;

[0046] Wherein, the component of the cage body is CuAL 10 Fe5Ni5 alloy.

[0047] Compared with the prior art, the beneficial effects of the present invention are as follows. In the method of the present invention, for the blank obtained by centrifugal casting, during the centrifugal casting process, centrifugal casting does not require risers, which improves the metal utilization rate. By utilizing the surface characteristics of the ring-shaped blank, the core and gating system can be omitted, thus saving man-hours and materials. Under the action of centrifugal force, the casting solidifies directionally from the outside to the inside, and gases and slag move towards the inner cavity of the casting and are discharged due to their lower density. Therefore, there are very few shrinkage cavities, porosity, gas holes, slag inclusions and other defects in the casting, thereby improving the mechanical properties and physical properties, and efficiently filling the mold at the same time; subsequently, the blank ring obtained by centrifugal casting is heated and ring-rolled, which not only saves the loss of punching in the forging process, reduces the surplus and thus saves the input of raw materials, but also reduces a heating process while ensuring the performance, making the process more simplified; the final product is processed through processes such as ring-rolling, heat treatment, drilling, and slitting of the blank after hole expansion. Since there are a large number of grooves on the cage product for maintaining the running track of the bearing rolling elements, these grooves are usually machined by milling during the processing. The method of the present invention uses pre-drilling for processing and finally performs finish milling on a milling machine. Compared with the overall milling method, the efficiency of the processing technology is improved while ensuring the accuracy; during the upsetting process after heating, since heating the blank causes changes in the stress of the blank, resulting in inconsistent extrusion stresses at each position of the upper anvil during the upsetting process, which leads to uneven deformation of the blank, or due to the long-axis circumferential plane of the blank expanding outwards and contacting the air and cooling during upsetting, resulting in stress differences between the surface and the interior of the long-axis side of the blank, and the metal fluidity on the surface of the long-axis side decreases. By adjusting the taking-out method and spraying heat-conducting liquid, the stress distribution, deformation uniformity and metal fluidity of the blank are improved; due to the undetected stress changes in the blank after heating, when the blank contacts different stress regions during the cage hole-expanding stage, vibration occurs during ring-rolling, resulting in an unstable ring-rolling state, which affects the overall quality and accuracy of the cage. By determining the stress deviation correction method, absorbing the vibration energy and reducing the uneven ring-shaped processing caused by slippage, the surface accuracy of the ring-shaped structure of the cage is improved.

[0048] Further, in the method of the present invention, by setting a primary heat treatment for the blank ring, the internal temperature of the blank is ensured to be uniform to maintain a thermally stable state, and the deformation ability of the blank is increased, thereby optimizing the subsequent upsetting and hole-expanding processes and increasing the forming efficiency.

[0049] Furthermore, in the method of the present invention, by setting a preset first standard deviation and a preset second standard deviation, since the shear stress during sawing causes uneven stress on the sawing surface, which in turn leads to uneven stress distribution in each fan-shaped area during upsetting. The unevenly distributed blank produces minute deformations, affecting the production accuracy. By rotating the fan-shaped area with the minimum stress to the direction of the outlet, and increasing the temperature of the upper anvil on the side away from the outlet and prolonging the removal time of the lower anvil, the internal stress of the blank is balanced, ensuring the stability and accuracy of subsequent processing, and reducing the height difference of the upset blank caused by the premature encounter of the area with large stress with cold air, thus improving the production accuracy.

[0050] Furthermore, in the method of the present invention, by setting a preset change amount, during the upsetting deformation of the blank, since the low-temperature air outside the anvil with a temperature difference contacts the surface on the long-axis side, the metal flow rate on the long-axis side decreases, resulting in a decrease in the upsetting efficiency. When the internal metal is squeezed, due to the decrease in the surface metal flow rate, the extrusion stress on the internal metal increases, easily generating metal cracks and affecting the overall performance of the blank. By spraying a heat-conducting liquid on the surface of the primary blank, using the rapid heat conduction of the heat-conducting liquid to balance the temperature difference between the surface and the interior of the blank, it can also improve the fluidity of the surface metal and reduce the extrusion stress of the internal metal, thereby reducing the generation of metal cracks and the problem of uneven internal and external stresses, and improving the overall performance of the blank.

[0051] Furthermore, in the method of the present invention, by setting a preset first vibration intensity and a preset second vibration intensity, since continuous sawing, heating, and extrusion result in uneven internal and external stresses of the blank, and this unevenness cannot be observed, during the ring rolling process, the vibration intensity at the contact surface between the ring rolling machine and the blank increases, leading to unstable ring rolling and affecting the machining accuracy and surface quality of the cage. By increasing the contact surface length between the ring rolling machine and the blank to the vibration surface wavelength of the blank, the vibration energy is absorbed, reducing the relative vibration between the ring rolling machine and the blank, increasing the stability of ring rolling, and improving the machining accuracy and surface quality of the cage.

[0052] Furthermore, in the method of the present invention, by setting a preset slip amount, due to the vibration caused by uneven stress and the slip at the contact surface between the ring rolling machine and the blank when the ring rolling machine contacts different areas with different stresses, this slip will cause uneven machining of the ring structure, affecting the overall quality and accuracy of the cage. By marking the starting position where the slip amount does not meet the requirements on the blank, and performing ring rolling accuracy processing on the marked starting position during the next week of ring rolling, the correction of uneven machining of the ring structure is achieved, improving the overall quality and accuracy of the cage.

[0053] Furthermore, the method of the present invention also provides a positioning reference for subsequent milling machine processing by setting pre-drilled round holes, reducing the positioning error during milling machine processing and improving the processing accuracy; the pre-drilled round holes can also reduce the cutting amount during milling machine processing and improve the processing efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Figure 1 It is the overall flowchart of the large aluminum bronze cage and its forming method in the embodiment of the present invention;

[0055] Figure 2 It is the structural schematic diagram of the finished cage of the large aluminum bronze cage and its forming method in the embodiment of the present invention;

[0056] Figure 3 It is the schematic cross-sectional view of the secondary blank of the large aluminum bronze cage and its forming method in the embodiment of the present invention;

[0057] Figure 4 It is the schematic diagram of the upsetting structure of the large aluminum bronze cage and its forming method in the embodiment of the present invention;

[0058] Figure 5 It is the structural schematic diagram of the blank ring of the large aluminum bronze cage and its forming method in the embodiment of the present invention;

[0059] Explanation of the reference numerals in the drawings: 1 - cage body, 2 - rolling groove, 3 - first positioning boss, 4 - second positioning boss, 5 - blank ring, 6 - upper anvil, 7 - lower anvil. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0060] In order to make the purpose and advantages of the present invention clearer, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0061] The preferred embodiments of the present invention will be described below with reference to the drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0062] It should be noted that in the description of the present invention, the terms indicating the direction or positional relationship such as "upper", "lower", "left", "right", "inner", "outer", etc. are based on the direction or positional relationship shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0063] In addition, it should be noted that in the description of the present invention, unless otherwise clearly specified and defined, the terms "installation", "connection", and "coupling" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the communication inside two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0064] Please refer to Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 and Figure 5 shown in the figures, which are respectively the overall flowchart of the large aluminum bronze cage and its forming method in the embodiment of the present invention, the structure schematic diagram of the finished cage, the cross-sectional schematic diagram of the secondary blank, the upsetting structure schematic diagram, and the blank ring structure schematic diagram. An embodiment of a forming method for a large aluminum bronze cage of the present invention includes:

[0065] Step S1, heating and upsetting the blank ring 5 produced by centrifugal casting in sequence to form a primary blank;

[0066] Step S2, determining the upsetting accuracy adjustment method according to the upsetting pressures of several fan-shaped areas during the upsetting process of the blank ring, including adjusting the translation extraction method of the primary blank formed after upsetting to a rotational extraction method, or determining whether to spray a heat-conducting liquid on the primary blank according to the change amount of the thickness of the primary blank;

[0067] Step S3, using a ring rolling machine to perform pre-horseframe hole expansion on the primary blank according to a rolling curve;

[0068] Step S4, determining the stress deviation correction method according to the vibration intensity of the primary blank during the pre-horseframe hole expansion process, including adjusting the contact surface length between the ring rolling machine and the primary blank, or performing a ring rolling accuracy processing method according to the slip amount of the contact surface;

[0069] Step S5, controlling the ring rolling machine to perform actual horseframe hole expansion on the primary blank according to the corresponding stress deviation correction to form a secondary blank;

[0070] Step S6, performing pre-drilling round holes, milling machine processing, and slitting on the secondary blank in sequence to form a finished cage.

[0071] Specifically, the diameter of the secondary blank is larger than that of the primary blank, and the thickness of the secondary blank is smaller than that of the primary blank.

[0072] Specifically, in Step S1, the device for heating the blank ring 5 is a forging heating furnace, and the device for upsetting the blank ring 5 is an upsetting machine;

[0073] The equipment for centrifugal casting is a centrifugal casting machine. Among them, when the centrifugal casting machine performs centrifugal casting under the condition that the height of the blank ring 5 is 305 mm and the cross-sectional diameter is 120 mm, the general value range of the centrifugal rotation speed is [800 rpm, 1000 rpm], and the preferred embodiment of the centrifugal rotation speed is 900 rpm;

[0074] In step S3, the rolling curve is the plastic deformation path of parameters such as the diameter, length, and volume of the primary blank;

[0075] In step S6, the equipment for pre-drilling round holes in the secondary blank is a drilling machine, and the equipment for slitting is a slitting machine;

[0076] Among them, the aperture tolerance of the pre-drilled round hole is ±0.02 mm, the positioning accuracy is less than or equal to 0.05 mm, and the general value range of the drill speed of the drilling machine is [800 rpm, 1200 rpm],

[0077] The general value range of the cutting speed for milling machine processing includes [80 m / min, 150 m / min],

[0078] The edge roughness of the slitting tool of the slitting machine is less than or equal to 0.4 μm, the general value range of the slitting gap is [0.02 mm, 0.05 mm], and the stamping tonnage is greater than or equal to 20 kN.

[0079] In implementation, in the method of the present invention, for the blank produced by centrifugal casting, during the centrifugal casting process, the centrifugal casting does not require risers, which improves the metal utilization rate. By utilizing the surface characteristics of the ring-shaped blank, the core and gating system can be omitted, thus saving man-hours and materials. Under the action of centrifugal force, the casting undergoes directional solidification from the outside to the inside, and gases and slag move towards the inner cavity of the casting and are discharged due to their lower density. Therefore, there are very few shrinkage cavities, porosity, gas holes, slag inclusions and other defects inside the casting, thereby improving the mechanical properties and physical properties, and efficiently filling the mold at the same time; subsequently, the blank ring 5 produced by centrifugal casting is heated and ring-rolled, which not only saves the loss of punching in the forging process, reduces the allowance and thus saves the input of raw materials, but also reduces a heating process while ensuring the performance, making the process more simplified; the final product is processed through processes such as ring-rolling, heat treatment, drilling, and slitting of the blank after hole expansion. Since there are a very large number of grooves on the cage product for maintaining the running track of the bearing rolling elements, these grooves are usually machined by milling during the processing. The method of the present invention uses a pre-drilling processing method and finally performs finish milling on a milling machine. Compared with the overall milling processing method, the efficiency of the processing technology is improved while ensuring the accuracy; during the upsetting process after heating, due to the change in the stress of the blank caused by heating the blank, the extrusion stresses at various positions of the upper anvil 6 are inconsistent during the upsetting process, resulting in uneven deformation of the blank, or due to the outward expansion of the circumferential plane of the long axis of the blank when upsetting and contacting the air and encountering a change in cold stress, resulting in a difference in stress between the surface and the inside of one side of the long axis of the blank, and the metal fluidity on one side of the surface of the long axis is reduced. By adjusting the taking-out method and spraying heat-conducting liquid, the stress distribution, deformation uniformity and metal fluidity of the blank are improved; due to the undetected stress change of the blank after heating, when the blank contacts different stress regions during the horse-frame hole expansion stage, vibration occurs during ring-rolling, resulting in an unstable ring-rolling state, affecting the overall quality and accuracy of the cage. By determining the stress deviation correction method, absorbing the vibration energy and reducing the uneven circular processing caused by slip, the surface accuracy of the circular structure of the cage is improved.

[0080] Specifically, heating and upsetting the blank ring 5 produced by the centrifugal casting method in sequence to form a primary blank includes:

[0081] Heating the blank ring 5 according to a preset temperature;

[0082] Putting the heated blank ring 5 between the upper anvil 6 and the lower anvil 7 in an upsetting machine, and the upper anvil 6 presses down the blank ring 5 to the required height to output the primary blank.

[0083] Specifically, under the condition that the height of the blank ring 5 is 305 mm and the cross-sectional diameter is 120 mm, the general value range of the preset temperature is [935 °C, 955 °C], and the preferred embodiment of the preset temperature is 945 °C.

[0084] Those skilled in the art can understand that 945 °C is the preferred embodiment under the condition that the length of the blank ring 5 is 305 mm and the cross-sectional diameter is 120 mm. Those skilled in the art can make adaptive adjustments to the preset change amount according to the changes in the actual application environment.

[0085] In implementation, the method of the present invention ensures uniform temperature inside the blank by setting a primary heat treatment for the blank ring 5 to maintain a thermally stable state, increases the deformation ability of the blank, thereby optimizing the subsequent upsetting and hole expanding processes, and increases the forming efficiency.

[0086] Specifically, the method for determining the upsetting accuracy adjustment method includes:

[0087] Respectively obtain several upsetting pressures in each sector area at several starting pressing moments during the downward pressing of the upper anvil 6;

[0088] Respectively calculate the zonal average upsetting pressure in each sector area according to several upsetting pressures in each sector area, and calculate the standard deviation of the upsetting pressure according to the zonal average upsetting pressure;

[0089] Compare the standard deviation of the upsetting pressure with a preset first standard deviation and a preset second standard deviation respectively, where

[0090] If the standard deviation of the upsetting pressure is greater than or equal to the preset first standard deviation, it is determined that the upsetting stress of the blank ring 5 does not meet the requirements;

[0091] If the standard deviation of the upsetting pressure is greater than or equal to the preset second standard deviation, after upsetting, rotate the sector area with the smallest zonal average upsetting pressure to the outlet direction, and increase the temperature of the upper anvil 6 on the side away from the outlet and extend the removal time of the lower anvil 7 when taking out;

[0092] Wherein, the zonal average upsetting pressure is the average value of several upsetting pressures within a single sector area; the preset first standard deviation is less than the preset second standard deviation;

[0093] The temperature of the upper anvil 6 on the side away from the outlet is positively correlated with the standard deviation of the upsetting pressure; the removal time of the lower anvil 7 is positively correlated with the standard deviation of the upsetting pressure.

[0094] Specifically, the shape of the upper anvil 6 is circular, and the lower surface of the upper anvil 6 is divided into several fan-shaped regions with the same shape and equal area. An equal amount of piezoelectric sensors are evenly distributed in each fan-shaped region;

[0095] The number of piezoelectric sensors provided is positively correlated with the diameter of the lower surface of the upper anvil 6;

[0096] The arrangement of the piezoelectric sensors within a single fan-shaped region is such that in the direction from the center of the upper anvil 6 to the edge of the fan-shaped region, the number of piezoelectric sensors per unit fan-shaped area increases.

[0097] Specifically, under the condition that the height of the blank ring 5 is 305 mm and the cross-sectional diameter is 120 mm, the general value range of the preset first standard deviation is [0.0055, 0.01], and the general value range of the preset second standard deviation is [0.014, 0.05].

[0098] Preferably, the preferred embodiment of the preset first standard deviation is 0.007, and the preferred embodiment of the preset second standard deviation is 0.02.

[0099] Those skilled in the art can understand that 0.007 and 0.02 are the preferred embodiments under the condition that the length of the blank ring 5 is 305 mm and the cross-sectional diameter is 120 mm. Those skilled in the art can make adaptive adjustments to the preset variation according to the changes in the actual application environment.

[0100] In implementation, when the difference between the upsetting pressure standard deviation and the preset second standard deviation is within 0.001, the temperature of the upper anvil 6 increases by 10 °C, and the removal duration of the lower anvil 7 increases by 4 s. When the difference between the upsetting pressure standard deviation and the preset second standard deviation exceeds 0.001, for every 0.001 exceeded, the temperature of the upper anvil 6 increases by 8 °C, and the removal duration of the lower anvil 7 increases by 3 s. For example, when the difference between the upsetting pressure standard deviation and the preset second standard deviation is 0.003, the current temperature of the upper anvil 6 is 600 °C, and the removal duration of the lower anvil 7 is 30 s. The temperature of the upper anvil 6 increases to 600 °C + 10 °C + 8 °C + 8 °C = 626 °C, and the removal duration of the lower anvil 7 increases to 30 s + 4 s + 3 s + 3 s = 40 s.

[0101] Specifically, the temperature of the upper anvil 6 on the side far from the discharge port is positively correlated with the upsetting pressure standard deviation; the removal duration of the lower anvil 7 is positively correlated with the upsetting pressure standard deviation.

[0102] In implementation, the method of the present invention sets a preset first standard deviation and a preset second standard deviation. Due to the shear stress during sawing, the stress on the sawing surface is uneven, which further leads to uneven stress distribution in each fan-shaped area during upsetting. The billet with uneven distribution generates slight deformation, affecting the production accuracy. By rotating the fan-shaped area with the minimum stress to the direction of the take-out port, increasing the temperature of the upper anvil 6 on the side far from the take-out port, and extending the removal time of the lower anvil 7, the internal stress of the billet is balanced, ensuring the stability and accuracy of subsequent processing, reducing the height difference of the upset billet caused by the premature encounter of cold air in the area with large stress, and achieving the improvement of production accuracy.

[0103] Specifically, the determination of the upsetting accuracy adjustment method further includes:

[0104] If the upsetting pressure standard deviation is greater than or equal to the preset first standard deviation and less than the preset second standard deviation, it is preliminarily determined that the air cooling stress does not meet the requirements, and the change amount of half of the thickness of the vertical section of the primary billet during upsetting is obtained;

[0105] If the change amount of half of the thickness is greater than the preset change amount, it is secondarily determined that the air cooling stress does not meet the requirements, and a heat-conducting liquid is sprayed on the surface of the primary billet.

[0106] Specifically, under the condition that the height of the billet ring 5 is 305 mm and the cross-sectional diameter is 120 mm, the general value range of the preset change amount is [0.4 mm, 0.8 mm], and the preferred embodiment of the preset change amount is 0.5 mm.

[0107] Those skilled in the art can understand that 0.5 mm is the preferred embodiment under the condition that the length of the billet ring 5 is 305 mm and the cross-sectional diameter is 120 mm. Those skilled in the art can make adaptive adjustments to the preset change amount according to the changes in the actual application environment.

[0108] Specifically, a liquid spraying port for spraying a heat-conducting liquid is provided on the inner wall of the upsetting machine; a rotating motor is provided below the lower anvil 7 to drive the lower anvil 7 to rotate.

[0109] Specifically, examples of the heat-conducting liquid include heat-conducting oil and water-ethylene glycol solution, and the preferred embodiment of the heat-conducting liquid is heat-conducting oil.

[0110] Specifically, the half of the thickness is the thickness between the major axis of the vertical section of the primary billet and the lower anvil 7; the change amount of half of the thickness is the difference between the half of the thickness at a unit pressing moment and the half of the thickness at the next unit pressing moment.

[0111] In implementation, in the method of the present invention, by setting a preset change amount, during the upsetting deformation of the blank, since the low-temperature air outside the anvil with a temperature difference contacts the surface on one side of the long axis, the metal flow rate on one side of the long axis is reduced, thereby reducing the upsetting efficiency. Since the internal metal is under extrusion, due to the reduction of the surface metal flow rate, the extrusion stress on the internal metal increases, and metal cracks are likely to occur, affecting the overall performance of the blank. By spraying a heat-conducting liquid on the surface of the primary blank, using the rapid heat conduction of the heat-conducting liquid, the temperature difference between the surface and the interior of the blank is balanced, the fluidity of the surface metal is improved, the extrusion stress on the internal metal is reduced, thereby reducing the generation of metal cracks and the problem of uneven internal and external stresses, and improving the overall performance of the blank.

[0112] Specifically, the method for determining the stress deviation correction includes:

[0113] Obtaining the vibration intensity of the secondary blank during the process of expanding the hole by the mandrel;

[0114] Comparing the vibration intensity with a preset first vibration intensity and a preset second vibration intensity respectively;

[0115] If the vibration intensity is greater than or equal to the preset first vibration intensity, it is determined that the internal and external stress uniformity of the primary blank does not meet the requirements;

[0116] If the vibration intensity is greater than or equal to the preset second vibration intensity, increase the contact surface length between the ring rolling mill and the primary blank to the vibration surface wavelength of the primary blank,

[0117] Wherein, the preset first vibration intensity is less than the preset second vibration intensity.

[0118] Specifically, the vibration intensity of the secondary blank is collected by a displacement sensor. The present invention does not limit the setting position of the displacement sensor, as long as it can detect the vibration intensity of the secondary blank.

[0119] Specifically, the method of increasing the contact surface length between the ring rolling mill and the primary blank to the vibration surface wavelength of the primary blank is to increase the pressure between the hole expanding mandrel and the pressure applicator of the ring rolling mill.

[0120] Specifically, under the condition that the outer diameter of the ring of the primary blank is 6287 mm, the inner diameter is 6045 mm, and the height is 75 mm, the general value range of the preset first vibration intensity is , and the general value range of the preset second vibration intensity is .

[0121] Preferably, the preferred embodiment of the preset first vibration intensity is , and the preferred embodiment of the preset second vibration intensity is .

[0122] Those skilled in the art can understand that and For a preferred embodiment under the conditions that the outer diameter of the ring blank of the first-stage blank is 6287 mm, the inner diameter is 6045 mm, and the height is 75 mm, those skilled in the art can make adaptive adjustments to the preset change amount according to the changes in the actual application environment.

[0123] In implementation, in the method of the present invention, by setting a preset first vibration intensity and a preset second vibration intensity, due to continuous sawing, heating, and extrusion, the internal and external stresses of the blank are unbalanced. This imbalance cannot be observed, resulting in an increase in the vibration intensity of the contact surface between the ring rolling machine and the blank during the ring rolling process, leading to unstable ring rolling and affecting the machining accuracy and surface quality of the cage. By increasing the contact surface length between the ring rolling machine and the blank to the vibration surface wavelength of the blank, the vibration energy is absorbed, the relative vibration between the ring rolling machine and the blank is reduced, the stability of ring rolling is increased, and the machining accuracy and surface quality of the cage are improved.

[0124] Specifically, the method for determining the stress deviation correction further includes:

[0125] If the vibration intensity is greater than or equal to the preset first vibration intensity and less than the preset second vibration intensity, it is preliminarily determined that the ring rolling stability does not meet the requirements, and the slip amount of the contact surface within the unit ring rolling duration is obtained;

[0126] If the slip amount is greater than or equal to the preset slip amount, it is secondarily determined that the ring rolling stability does not meet the requirements, and the position where the slip amount reaches the preset slip amount is marked on the first-stage blank as a slip marking point, and a ring rolling accuracy processing method is performed on the slip marking point after the slip marking point runs one week;

[0127] Wherein, the slip amount of the contact surface is the displacement amount between the central position of the contact surface of the first-stage blank at the start time of the unit ring rolling duration and the central position of the contact surface of the ring rolling machine at the end time of the unit ring rolling duration.

[0128] Specifically, the ring rolling accuracy processing method is to increase the ring rolling pressure when the ring rolling contacts the slip marking point after the slip marking point runs one week, and at the same time increase the feed speed of the first-stage blank;

[0129] The ring rolling pressure is positively correlated with the slip amount, and the feed speed is positively correlated with the slip amount.

[0130] Specifically, under the condition that the outer diameter of the ring of the primary blank is 6287 mm, the inner diameter is 6045 mm, and the height is 75 mm, the general value range of the preset slip amount is [6 mm, 14 mm], and the preferred embodiment of the preset slip amount is 8 mm.

[0131] Those skilled in the art can understand that 8 mm is the preferred embodiment under the condition that the outer diameter of the ring of the primary blank is 6287 mm, the inner diameter is 6045 mm, and the height is 75 mm. Those skilled in the art can make adaptive adjustments to the preset change amount according to the changes in the actual application environment.

[0132] In implementation, for every 1 mm increase in the difference between the slip amount and the preset slip amount, when the ring rolling contacts the slip marking point after the slip marking point runs one week, the ring rolling pressure increases to 1.05 times the original, and the feeding speed of the primary blank increases to 1.02 times the original.

[0133] In implementation, the method of the present invention also sets a preset slip amount. Due to the vibration caused by unbalanced stress and the slip occurring at the contact surface between the ring rolling machine and the blank when the ring rolling machine contacts different stresses in different regions, this slip will cause uneven processing of the ring structure, affecting the overall quality and accuracy of the cage. By marking the starting position where the slip amount does not meet the requirements on the blank and performing ring rolling accuracy processing on the marked starting position in the next week of ring rolling process, the correction of uneven processing of the ring structure is realized, and the overall quality and accuracy of the cage are improved.

[0134] Specifically, the secondary blank is successively pre-drilled with round holes, processed by a milling machine, and slit to form a finished cage, including:

[0135] Calculating the diameter of the center connection line of the rolling grooves 2 according to the angular intervals of a plurality of required rolling grooves 2;

[0136] Pre-drilling round holes on the secondary blank according to the diameter of the center connection line of the rolling grooves 2 according to the pitch circle;

[0137] Processing the pre-drilled secondary blank on a milling machine according to the dimensions of the required rolling grooves 2 and performing equal-length slitting to form the finished cage.

[0138] In implementation, the method of the present invention also sets pre-drilled round holes, which provides a positioning reference for subsequent milling machine processing, reduces the positioning error during milling machine processing, and improves the processing accuracy; the pre-drilled round holes can also reduce the cutting amount during milling machine processing and improve the processing efficiency.

[0139] The present invention also provides an embodiment of a large-sized aluminum bronze cage, including:

[0140] A cage body for isolating bearing rolling elements,

[0141] A plurality of rolling grooves for restricting the movement direction of the bearing rolling elements are further provided on the cage body, and a first positioning boss and a second positioning boss for fixing the cage body are respectively provided on the inner circumferential surface and the outer circumferential surface of the cage body;

[0142] Among them, the component of the cage body is CuAL 10 Fe5Ni5 alloy.

[0143] Specifically, the component ratio of CuAL 10 Fe5Ni5 alloy is that the mass content of copper is 78%, the mass content of aluminum is 10%, the mass content of nickel is 5%, the mass content of iron is 4%, and the total mass content of manganese, silicon, zinc, magnesium, lead and tin is 2%.

[0144] So far, the technical solution of the present invention has been described in conjunction with the preferred embodiments shown in the drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the protection scope of the present invention.

Claims

1. A forming method for a large aluminum bronze cage, characterized in that, Including: heating and upsetting a blank ring produced by a centrifugal casting method in sequence to form a primary blank; determining an upsetting accuracy adjustment method according to the upsetting pressures of several fan-shaped areas during the upsetting process of the blank ring, including adjusting the translation removal method of the primary blank formed after upsetting to a rotational removal method, or determining whether to spray a heat-conducting liquid on the primary blank according to the change amount of the thickness of the primary blank; using a ring rolling mill to perform pre-roll-expansion on the primary blank according to a rolling curve; determining a stress deviation correction method according to the vibration intensity of the primary blank during the pre-roll-expansion process, including adjusting the contact surface length between the ring rolling mill and the primary blank, or performing a ring rolling accuracy treatment method according to the slip amount of the contact surface; controlling the ring rolling mill to perform actual roll-expansion on the primary blank according to the corresponding stress deviation correction to form a secondary blank; performing pre-drilling of round holes, milling, and slitting on the secondary blank in sequence to form a finished cage; wherein, heating and upsetting the blank ring produced by the centrifugal casting method in sequence to form a primary blank includes: heating the blank ring according to a preset temperature; placing the heated blank ring between an upper anvil and a lower anvil in an upsetting machine, and pressing down the upper anvil on the blank ring to a required height to output the primary blank; the determining of the upsetting accuracy adjustment method includes: respectively obtaining the upsetting pressures in several fan-shaped areas at several initial pressing-down moments during the pressing-down process of the upper anvil; respectively calculating the partition average upsetting pressure of each fan-shaped area according to the several upsetting pressures in each fan-shaped area, and calculating the standard deviation of the upsetting pressure according to the partition average upsetting pressure; comparing the standard deviation of the upsetting pressure with a preset first standard deviation and a preset second standard deviation respectively, wherein, if the standard deviation of the upsetting pressure is greater than or equal to the preset first standard deviation, it is determined that the upsetting stress of the blank ring does not meet the requirements; if the standard deviation of the upsetting pressure is greater than or equal to the preset second standard deviation, after upsetting, rotate the fan-shaped area with the smallest partition average upsetting pressure to the direction of the extraction port, and increase the temperature of the upper anvil on the side away from the extraction port and extend the moving-out time of the lower anvil during extraction; wherein, the partition average upsetting pressure is the average value of the several upsetting pressures within a single fan-shaped area; the preset first standard deviation is less than the preset second standard deviation; the temperature of the upper anvil on the side away from the extraction port is positively correlated with the standard deviation of the upsetting pressure; the moving-out time of the lower anvil is positively correlated with the standard deviation of the upsetting pressure; the determining of the upsetting accuracy adjustment method further includes: if the standard deviation of the upsetting pressure is greater than or equal to the preset first standard deviation and less than the preset second standard deviation, it is preliminarily determined that the air-cooling stress does not meet the requirements, and the change amount of half of the thickness of the vertical section of the primary blank during the upsetting process is obtained; if the change amount of the half thickness is greater than the preset change amount, it is secondarily determined that the air-cooling stress does not meet the requirements, and a heat-conducting liquid is sprayed on the surface of the primary blank; the determining of the stress deviation correction method includes: Obtain the vibration intensity of the secondary blank during the process of expanding the hole of the horse frame; Compare the vibration intensity with a preset first vibration intensity and a preset second vibration intensity respectively; If the vibration intensity is greater than or equal to the preset first vibration intensity, it is determined that the internal and external stress uniformity of the primary blank does not meet the requirements; If the vibration intensity is greater than or equal to the preset second vibration intensity, increase the contact surface length between the ring rolling machine and the primary blank to the vibration surface wavelength of the primary blank, wherein, the preset first vibration intensity is less than the preset second vibration intensity; The determination of the stress deviation correction method further includes: If the vibration intensity is greater than or equal to the preset first vibration intensity and less than the preset second vibration intensity, it is preliminarily determined that the ring rolling stability does not meet the requirements, and obtain the slip amount of the contact surface within the unit ring rolling time; If the slip amount is greater than or equal to the preset slip amount, it is secondarily determined that the ring rolling stability does not meet the requirements, and mark the position where the slip amount reaches the preset slip amount on the primary blank as the slip marking point, and perform the ring rolling accuracy processing method on the slip marking point after the slip marking point runs one week; wherein, the slip amount of the contact surface is the displacement between the center position of the contact surface of the primary blank at the start moment of the unit ring rolling time and the center position of the contact surface of the ring rolling machine at the end moment of the unit ring rolling time; The ring rolling accuracy processing method is to increase the ring rolling pressure when the ring rolling contacts the slip marking point after the slip marking point runs one week, and at the same time increase the feed speed of the primary blank; The ring rolling pressure is positively correlated with the slip amount, and the feed speed is positively correlated with the slip amount.

2. The method for forming a large aluminum bronze cage according to claim 1, characterized in that The half thickness is the thickness between the long axis of the vertical section of the primary blank and the lower anvil; the change amount of the half thickness is the difference between the half thickness at the moment of unit downward pressure and the half thickness at the next moment of unit downward pressure.

3. The forming method of the large-sized aluminum bronze cage according to claim 1, characterized in that, The secondary blank is successively pre-drilled with round holes, processed by a milling machine, and slit to form a finished cage, including: Calculate the diameter of the center line connecting the rolling grooves according to the angular intervals of several required rolling grooves; Pre-drill round holes on the secondary blank according to the diameter of the center line connecting the rolling grooves according to the pitch circle; Process the pre-drilled secondary blank on a milling machine according to the dimensions of the required rolling grooves and perform equal-length slitting to form the finished cage.

4. A large aluminum bronze cage manufactured by the large aluminum bronze cage forming method according to any one of claims 1-3, characterized in that, Including: A cage body for isolating bearing rolling elements, On the cage body, there are also provided several rolling grooves for restricting the movement direction of the bearing rolling elements, and a first positioning boss and a second positioning boss respectively arranged on the inner circumferential surface and the outer circumferential surface of the cage body for fixing the cage body; Among them, the component of the cage body is CuAL 10 Fe5Ni5 alloy.

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