T-shaped flange forge piece forming method and system based on cone roller special shape

Abstract

The invention relates to the technical field of flange forging, in particular to a T-shaped flange forge piece forming method and system based on the special shape of a conical roller, and the method comprises the steps that a raw material is machined into a flange blank to be subjected to ring rolling forming, and a surface image of at least one flange blank is obtained; determining whether the surface image is an abnormal region of the flange blank based on the geometric feature characterization parameter, and determining a ring rolling mode of the special shape of the conical roller according to the surface roughness; acquiring an infrared image of a flange blank abnormal area corresponding to the T-shaped flange; based on the texture distribution uniformity, whether the metal flow uniformity proportion of the T-shaped flange is qualified or not is determined, and the feeding speed or the rotating speed of an adjusting cone roller is determined according to the difference value between the preset texture distribution uniformity and the texture distribution uniformity; and whether the ring rolling process of the abnormal area of the flange blank by the conical roller is qualified or not is determined based on the surface waviness, the surface roughness threshold value is determined and adjusted according to the ratio, and the ring rolling machining precision of the conical roller on the T-shaped flange is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of flange forging, and particularly relates to a forming method and system for T-shaped flange forgings based on the special shape of conical rollers. Background Art

[0002] In the field of industrial manufacturing, as a key component of heavy equipment such as pipeline connections, pressure vessels, and wind power tower frames, the forming quality of T-shaped flanges directly affects the sealing performance and load-bearing capacity of the overall structure. Traditional T-shaped flange manufacturing mainly relies on free forging and die forging processes, and the blank is formed through processes such as upsetting, drawing, and punching. However, there are problems such as low material utilization rate and large machining allowance. Especially for flanges with special-shaped cross-sections, the mold development cost is high and it is difficult to ensure dimensional accuracy. The rolling forming technology based on the special shape of conical rollers has gradually become the mainstream. This technology realizes high-precision forming of complex cross-sections through the continuous local plastic deformation of conical roller wheels and ring parts.

[0003] Chinese Patent Application Publication No.: CN117983756A discloses a method for determining the blank size of special-shaped conical roller rolling forming of wind power flange rings. It determines the range and values of the rolling ratio K0 and the radial-axial deformation amount distribution ratio tanα0 in the special-shaped conical roller rolling stage through the target forming blank size of the wind power flange ring and the core roller diameter of the special-shaped conical roller, and then determines the rolling blank size. Then, it determines whether the criterion hw meets the requirements of precise forming according to the rolling blank size. Then, it determines the preform size according to the rolling blank size in combination with the step ring width b1 of the forming blank and the assembly distance L1 between the special-shaped conical roller and the outer diameter of the ring part, and determines the range and values of the rolling ratio Kr and the radial-axial deformation amount distribution ratio tanαr in the two-way rolling stage of the preform through the preform size and the core roller diameter, and finally determines the initial blank size. This invention can sequentially reverse-derive the blank size values in each stage according to the relationship between the blank size changes in each stage of special-shaped conical roller rolling, improving the rolling quality of special-shaped conical rollers.

[0004] However, the following problems exist in the prior art: There is no refined treatment of the metal flow on the surface of the T-shaped flange during the conical roller ring rolling process, resulting in defects in the T-shaped flange, thus leading to the problem of low ring rolling processing accuracy of the conical roller for the T-shaped flange. Summary of the Invention

[0005] Therefore, the present invention provides a forming method and system for T-shaped flange forgings based on the special shape of conical rollers to overcome the problem that the prior art does not have refined treatment of the metal flow on the surface of the T-shaped flange during the conical roller ring rolling process, resulting in defects in the T-shaped flange, thus leading to low ring rolling processing accuracy of the conical roller for the T-shaped flange.

[0006] To achieve the above object, the present invention provides a forming method for T-shaped flange forgings based on the special shape of conical rollers, including: Process the raw materials into flange blanks to be ring-rolled, and obtain surface images of at least one of the flange blanks; Determine whether the surface image is an abnormal area of the flange blank based on the geometric feature characterization parameters of the surface image, and determine the ring-rolling mode of the tapered roller in the form of spiral ring-rolling or repeated ring-rolling according to the surface roughness of the abnormal area of the flange blank; Under the condition of determining the corresponding ring-rolling mode, ring-roll the flange blank to obtain a T-shaped flange, and obtain an infrared image of the abnormal area of the flange blank corresponding to the T-shaped flange; Determine whether the proportion of uniform metal flow of the T-shaped flange is qualified based on the texture distribution uniformity of the infrared image, and determine to adjust the feed speed or rotation speed of the tapered roller according to the difference between the preset texture distribution uniformity and the texture distribution uniformity; Under the condition of determining that the proportion of uniform metal flow is qualified, determine whether the ring-rolling process of the tapered roller on the abnormal area of the flange blank is qualified based on the surface waviness of the infrared image, and determine to adjust the surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness; Ring-roll the remaining flange blanks based on the ring-rolling parameters of the adjusted tapered roller.

[0007] Further, under the condition of obtaining the surface image of the flange blank, determine that the surface image is an abnormal area of the flange blank based on the comparison result that the geometric feature characterization parameters of the surface image are greater than the preset geometric feature characterization parameters.

[0008] Further, under the condition of determining that the surface image is an abnormal area of the flange blank, determine that the ring-rolling mode of the tapered roller is spiral ring-rolling based on the comparison result that the surface roughness of the abnormal area of the flange blank is less than or equal to the surface roughness threshold.

[0009] Further, under the condition of determining that the surface image is an abnormal area of the flange blank, determine that the ring-rolling mode of the tapered roller is repeated ring-rolling based on the comparison result that the surface roughness of the abnormal area of the flange blank is greater than the surface roughness threshold.

[0010] Further, under the condition of determining the corresponding ring-rolling mode, determine that the proportion of uniform metal flow of the T-shaped flange is unqualified based on the comparison result that the texture distribution uniformity of the infrared image is less than or equal to the preset texture distribution uniformity.

[0011] Further, under the condition of determining that the proportion of uniform metal flow of the T-shaped flange is unqualified, determine to reduce the feed speed of the tapered roller with a preset feed speed adjustment coefficient based on the comparison result that the difference between the preset texture distribution uniformity and the texture distribution uniformity is less than or equal to the preset difference.

[0012] Further, under the condition that the qualified ratio of the uniform metal flow of the T-shaped flange is unqualified, the rotation speed of the taper roller is increased with a preset rotation speed adjustment coefficient based on the comparison result that the difference between the preset texture distribution uniformity and the texture distribution uniformity is greater than the preset difference.

[0013] Further, under the condition that the qualified ratio of the uniform metal flow is qualified, it is determined that the ring rolling process of the taper roller on the abnormal area of the flange blank is unqualified based on the comparison result that the surface waviness of the infrared image is greater than the preset surface waviness.

[0014] Further, under the condition that the ring rolling process of the taper roller on the abnormal area of the flange blank is unqualified, the process of adjusting the surface roughness threshold includes: Dividing the preset surface waviness by the surface waviness; Setting a number of adjustment coefficients corresponding to the respective ratios; Reducing the surface roughness threshold based on a number of the adjustment coefficients; Setting the corresponding relationship between the respective ratios and the reduced surface roughness threshold to adjust the surface roughness threshold.

[0015] On the other hand, the present invention also provides a T-shaped flange forging forming system based on the taper roller special shape, including: A data acquisition module, which is used to acquire the surface image of at least one flange blank and the infrared image of the abnormal area of the flange blank corresponding to the T-shaped flange; A mode determination module, which is connected to the data acquisition module, and is used to determine whether the surface image is an abnormal area of the flange blank based on the geometric feature characterization parameter of the surface image, and to determine the ring rolling mode of the taper roller special shape as spiral ring rolling or repeated ring rolling according to the surface roughness of the abnormal area of the flange blank; A metal flow analysis module, which is respectively connected to the data acquisition module and the mode determination module, and is used to determine whether the qualified ratio of the uniform metal flow of the T-shaped flange is qualified based on the texture distribution uniformity of the infrared image, and to determine to adjust the feed speed or rotation speed of the taper roller according to the difference between the preset texture distribution uniformity and the texture distribution uniformity; A ring rolling analysis module, which is respectively connected to the data acquisition module and the metal flow analysis module, and is used to determine whether the ring rolling process of the taper roller on the abnormal area of the flange blank is qualified based on the surface waviness of the infrared image under the condition that the qualified ratio of the uniform metal flow is qualified, and to determine to adjust the surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows. The present invention judges the abnormal area of the flange blank by comparing the geometric feature characterization parameters with the preset geometric feature characterization parameters, determines the ring rolling mode of the tapered roller with special shape according to the surface roughness, and then compares the texture distribution uniformity with the preset texture distribution uniformity to determine whether the proportion of uniform metal flow is qualified. When it is unqualified, the tapered roller parameters are adjusted according to the difference between the texture distribution uniformity and the preset texture distribution uniformity. When it is qualified, it is determined whether the ring rolling process is qualified according to the surface waviness. When it is unqualified, the surface roughness threshold is adjusted, improving the product strength, wear resistance and fatigue life, enhancing the production efficiency, increasing the material utilization rate, reducing the occurrence of defects such as cracks and burrs in traditional forging, and thus improving the ring rolling processing accuracy of the tapered roller for the T-shaped flange.

[0017] Furthermore, the present invention calculates the geometric feature characterization parameters of the surface image and compares them with the preset geometric feature characterization parameters to judge whether there is an abnormal area. If there is an abnormal area, the ring rolling mode of the tapered roller is determined according to the comparison result between the surface roughness and the surface roughness threshold, reducing the processing error caused by surface defects, reducing the friction resistance, reducing the obstruction of the abnormal area to the metal flow, improving the processing efficiency, and thus enhancing the production efficiency.

[0018] Furthermore, the present invention detects the texture distribution uniformity of the infrared image of the T-shaped flange to judge whether the metal flow is uniform. For unqualified cases, the feed speed or rotation speed of the tapered roller is adjusted according to the difference between the texture distribution uniformity and the preset value to optimize the metal flow uniformity, ensuring the quality stability of the T-shaped flange, enhancing the processing accuracy of the T-shaped flange, reducing the reject rate caused by uneven metal flow, and increasing the material utilization rate.

[0019] Furthermore, the present invention detects the surface waviness of the infrared image of the T-shaped flange to judge whether the ring rolling process of the tapered roller for the abnormal area of the flange blank is qualified. For unqualified cases, the surface roughness threshold is dynamically adjusted according to the ratio of the preset surface waviness to the actual surface waviness to optimize the ring rolling process, ensuring the stability of the ring rolling process, enhancing the surface quality of the T-shaped flange, enhancing the production efficiency, improving the accuracy of detecting the T-shaped flange, and thus improving the ring rolling processing accuracy of the tapered roller for the T-shaped flange. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a flowchart of the method for forming a T-shaped flange forging based on the special shape of the tapered roller in an embodiment of the present invention; Figure 2 It is a schematic diagram of the module connection of the system for forming a T-shaped flange forging based on the special shape of the tapered roller in an embodiment of the present invention; Figure 3 It is a flowchart of determining whether the ring rolling process of the tapered roller for the abnormal area of the flange blank is qualified in an embodiment of the present invention; Figure 4 This is a schematic diagram of the working process of the T-shaped flange forging forming method and system based on the special-shaped taper roller according to an embodiment of the present invention; In the figure, 1 is the main roller; 2 is the core roller; 3 is the taper roller; 4 is the auxiliary holding roller; 5 is the T-shaped flange. Specific embodiments

[0021] 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.

[0022] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principle of the present invention and do not limit the protection scope of the present invention.

[0023] It should be noted that the data in this embodiment are all obtained through comprehensive analysis and evaluation of the historical detection data and corresponding historical detection results in the three months before this detection by the present invention. Those skilled in the art can understand that the determination method of the present invention for the above single parameter can be to select the value with the highest proportion according to the data distribution as the preset standard parameter, use weighted summation to take the obtained value as the preset standard parameter, substitute each historical data into a specific formula and take the value obtained by using this formula as the preset standard parameter or other selection methods, as long as it meets the requirement that the present invention can clearly define different specific situations in the single-item determination process through the obtained values.

[0024] Please refer to Figure 1 As shown, it is a flowchart of the T-shaped flange forging forming method based on the special-shaped taper roller according to an embodiment of the present invention.

[0025] The T-shaped flange forging forming method based on the special-shaped taper roller according to an embodiment of the present invention includes: Step S1, processing the raw material into a flange blank to be ring-rolled and obtaining the surface image of at least one said flange blank; Step S2, determining whether the surface image is an abnormal area of the flange blank based on the geometric feature characterization parameters of the surface image, and determining the ring-rolling mode of the special-shaped taper roller as spiral ring-rolling or repeated ring-rolling according to the surface roughness of the abnormal area of the flange blank; Step S3, under the condition of determining the corresponding ring-rolling mode, ring-rolling the flange blank to obtain a T-shaped flange and obtaining the infrared image of the abnormal area of the flange blank corresponding to the T-shaped flange; Step S4, determine whether the metal flow uniformity ratio of the T-shaped flange is qualified based on the texture distribution uniformity of the infrared image, and determine the feed speed or rotation speed of the adjusting taper roller according to the difference between the preset texture distribution uniformity and the texture distribution uniformity; Step S5, under the condition that the metal flow uniformity ratio is determined to be qualified, determine whether the ring rolling process of the taper roller on the abnormal area of the flange blank is qualified based on the surface waviness of the infrared image, and determine the adjusted surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness; Step S6, perform ring rolling on the remaining flange blanks based on the ring rolling parameters of the adjusted taper roller.

[0026] Please refer to Figure 2 As shown, it is a schematic diagram of the module connection of the T-shaped flange forging forming system based on the special-shaped taper roller according to the embodiment of the present invention.

[0027] On the other hand, the present invention also provides a T-shaped flange forging forming system based on the special-shaped taper roller, including: A data acquisition module for acquiring the surface image of at least one flange blank and the infrared image of the abnormal area of the flange blank corresponding to the T-shaped flange; A mode determination module connected to the data acquisition module for determining whether the surface image is an abnormal area of the flange blank based on the geometric feature characterization parameters of the surface image, and determining the ring rolling mode of the special-shaped taper roller as spiral ring rolling or repeated ring rolling according to the surface roughness of the abnormal area of the flange blank; A metal flow analysis module connected to the data acquisition module and the mode determination module respectively for determining whether the metal flow uniformity ratio of the T-shaped flange is qualified based on the texture distribution uniformity of the infrared image, and determining the feed speed or rotation speed of the adjusting taper roller according to the difference between the preset texture distribution uniformity and the texture distribution uniformity; A ring rolling analysis module connected to the data acquisition module and the metal flow analysis module respectively for determining whether the ring rolling process of the taper roller on the abnormal area of the flange blank is qualified under the condition that the metal flow uniformity ratio is determined to be qualified, and determining the adjusted surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness.

[0028] In the embodiment of the present invention, the surface image is obtained by shooting with an industrial camera, the infrared image is obtained by shooting with an infrared thermal imager, and the industrial camera and the infrared thermal imager are both vertically fixed above the T-shaped flange. In the embodiment of the present invention, the rotation speed range of the taper roller is 2 - 2.5 rad / s, preferably 2.1 rad / s, and the feed speed range is 1.2 - 1.8 mm / s, preferably 1.5 mm / s.

[0029] In the embodiment of the present invention, the angle between the special-shaped taper roller and the groove of the flange blank is 69°.

[0030] Specifically, the present invention determines the abnormal area of the flange blank by comparing the geometric feature characterization parameters with the preset geometric feature characterization parameters, determines the ring rolling mode of the special-shaped taper roller according to the surface roughness, then compares the texture distribution uniformity with the preset texture distribution uniformity to determine whether the proportion of uniform metal flow is qualified. When it is unqualified, the taper roller parameters are adjusted according to the difference between the texture distribution uniformity and the preset texture distribution uniformity. When it is qualified, it is determined whether the ring rolling process is qualified according to the surface waviness. When it is unqualified, the surface roughness threshold is adjusted, which improves the product strength, wear resistance and fatigue life, improves the production efficiency, increases the material utilization rate, and reduces the occurrence of defects such as cracks and burrs in traditional forging, thereby improving the ring rolling processing accuracy of the taper roller for the T-shaped flange.

[0031] It can be understood that the taper roller can move forward during the working process. When the T-shaped flange reaches a predetermined size for the first time, the ring rolling machine does not stop working. The taper roller moves towards the mandrel direction. After moving to the designated position, the taper roller presses down. Finally, one-time forming is achieved.

[0032] Specifically, in the embodiment of the present invention, under the condition of determining to obtain the surface image of the flange blank, it is determined whether the surface image is an abnormal area of the flange blank according to the comparison result between the geometric feature characterization parameters of the surface image and the preset geometric feature characterization parameters; When the geometric feature characterization parameter is less than or equal to the preset geometric feature characterization parameter, it is determined that the surface image is not an abnormal area of the flange blank; When the geometric feature characterization parameter is greater than the preset geometric feature characterization parameter, it is determined that the surface image is an abnormal area of the flange blank.

[0033] In the embodiment of the present invention, the value of the preset geometric feature characterization parameter is 0.86, and the value range of the preset geometric feature characterization parameter is [0.80, 0.90]. However, the above values are not limited to this, and those skilled in the art can also adjust the values according to actual needs.

[0034] In the embodiment of the present invention, the abnormal area of the flange blank is a geometric feature mutation area on the surface of the flange blank caused by raw material defects, processing defects or uneven heat treatment.

[0035] During the implementation process, the geometric feature characterization parameter is the radical result of the ratio of the standard deviation of the edge gradient to the mean value of the edge gradient multiplied by the sum of the absolute values of the differences between the curvatures of several contour points and the ratio of the mean curvature.

[0036] It is understandable that the abnormal area of the flange blank will increase the friction resistance during the conical roller ring rolling process, hinder the uniform flow of metal. For the flange blank area that is not the abnormal area of the flange blank, the conical roller rolls in a unidirectional straight line manner.

[0037] Specifically, under the condition that the present invention embodiment determines that the surface image is the abnormal area of the flange blank, it determines the ring rolling mode of the conical roller according to the comparison result between the surface roughness of the abnormal area of the flange blank and the surface roughness threshold value; When the surface roughness is less than or equal to the surface roughness threshold value, it is determined that the ring rolling mode of the conical roller is spiral ring rolling; When the surface roughness is greater than the surface roughness threshold value, it is determined that the ring rolling mode of the conical roller is repeated ring rolling.

[0038] In the embodiment of the present invention, the surface roughness threshold value is taken as 0.82, and the value range of the surface roughness threshold value is [0.75, 0.85]. However, the above values are not limited to this, and those skilled in the art can also adjust the values according to actual needs.

[0039] In the embodiment of the present invention, the spiral ring rolling is a rolling method in which the conical roller continuously feeds along a single rotation direction. During the processing, the conical roller and the blank keep constant contact to form a continuous spiral deformation track; the repeated ring rolling is that the conical roller rolls multiple times in the abnormal area.

[0040] During the implementation process, the surface roughness is the result of the sum of the differences between the profile heights of several surface profile sampling points and the average profile height divided by the number of sampling points. Among them, the profile height is the height of the flange blank surface in the direction perpendicular to the surface, and the sampling points are based on the flat plane of the flange blank end face. This reference plane is perpendicular to the axis of the flange blank, and all profile height measurements are carried out relative to this reference plane.

[0041] Specifically, the present invention calculates the geometric feature characterization parameters of the surface image and compares them with the preset geometric feature characterization parameters to judge whether there is an abnormal area. If there is an abnormal area, it determines the ring rolling mode of the conical roller according to the comparison result between the surface roughness and the surface roughness threshold value, reduces the processing error caused by surface defects, reduces the friction resistance, reduces the obstruction of the abnormal area to the metal flow, improves the processing efficiency, and thus improves the production efficiency.

[0042] Specifically, under the condition of determining the corresponding ring rolling mode, the present invention embodiment performs ring rolling on the flange blank to obtain a T-shaped flange, and acquires the infrared image of the abnormal area of the flange blank corresponding to the T-shaped flange.

[0043] Specifically, under the condition that the infrared image is determined in the embodiment of the present invention, it is determined whether the metal flow uniformity ratio of the T-shaped flange is qualified according to the comparison result between the texture distribution uniformity of the infrared image and the preset texture distribution uniformity; When the texture distribution uniformity is less than or equal to the preset texture distribution uniformity, it is determined that the metal flow uniformity ratio of the T-shaped flange is unqualified; When the texture distribution uniformity is greater than the preset texture distribution uniformity, it is determined that the metal flow uniformity ratio of the T-shaped flange is qualified.

[0044] In the embodiment of the present invention, the value of the preset texture distribution uniformity is 1.10, and the value range of the preset texture distribution uniformity is [0.90, 1.20]. Those skilled in the art can also adjust this value according to actual needs.

[0045] During the implementation process, the texture distribution uniformity is the result of multiplying the ratio of the current infrared image contrast to the preset contrast by the ratio of the current infrared image entropy value to the preset entropy value. The preset contrast and the preset entropy value are the average contrast value and the average entropy value of several historical infrared images with qualified metal flow uniformity ratios.

[0046] Specifically, under the condition that it is determined that the metal flow uniformity ratio of the T-shaped flange is unqualified in the embodiment of the present invention, the feed speed or rotation speed of the adjusting taper roller is determined according to the comparison result between the difference between the preset texture distribution uniformity and the texture distribution uniformity and the preset difference; When the difference is less than or equal to the preset difference, it is determined to reduce the feed speed of the taper roller to the corresponding value with a preset feed speed adjustment coefficient of 0.95; When the difference is greater than the preset difference, it is determined to increase the rotation speed of the taper roller to the corresponding value with a preset rotation speed adjustment coefficient of 1.03; The difference is the difference between the preset texture distribution uniformity and the texture distribution uniformity.

[0047] In the embodiment of the present invention, the value of the preset difference is 0.35, but the above value is not limited to this. Those skilled in the art can also adjust this value according to actual needs.

[0048] In the embodiment of the present invention, the reduced feed speed is the product of the feed speed and the preset feed speed adjustment coefficient of 0.95; the increased rotation speed is the product of the rotation speed and the preset rotation speed adjustment coefficient of 1.03. To ensure that the adjusted feed speed and rotation speed meet the actual requirements, the adjustment range should not be too large. Therefore, the adjustment coefficient is correspondingly set to control the adjustment range.

[0049] It is understandable that the feed rate is reduced to extend the axial metal flow time, reduce local accumulation, and the rotational speed is increased to increase the tangential shear force, promoting grain slip and redistribution.

[0050] Specifically, the present invention determines whether the metal flow is uniform by detecting the uniformity of the infrared image texture distribution of the T-shaped flange. For unqualified cases, according to the difference between the texture distribution uniformity and the preset value, the feed rate or rotational speed of the taper roller is adjusted to optimize the metal flow uniformity, ensuring the quality stability of the T-shaped flange, improving the processing accuracy of the T-shaped flange, reducing the rejection rate caused by uneven metal flow, and increasing the material utilization rate.

[0051] Please refer to Figure 3 as shown, which is a flowchart for the present invention embodiment to determine whether the ring rolling process of the taper roller on the abnormal area of the flange blank is qualified.

[0052] Specifically, in the present invention embodiment, under the condition that the qualified ratio of the uniform metal flow is determined, it is determined whether the ring rolling process of the taper roller on the abnormal area of the flange blank is qualified according to the comparison result between the surface waviness of the infrared image and the preset surface waviness; When the surface waviness is less than or equal to the preset surface waviness, it is determined that the ring rolling process of the taper roller on the abnormal area of the flange blank is qualified; When the surface waviness is greater than the preset surface waviness, it is determined that the ring rolling process of the taper roller on the abnormal area of the flange blank is unqualified.

[0053] In the present invention embodiment, the preset surface waviness value is 20, and the preset surface waviness value range is [15, 30], but the above values are not limited to this, and those skilled in the art can also adjust the values according to actual needs.

[0054] During the implementation process, the surface waviness is the average value of the absolute value of the gray level gradient along the radial direction of the T-shaped flange in the infrared image.

[0055] It is understandable that the gray level value of the infrared image reflects the surface temperature distribution, and the temperature gradient is related to the frictional heat generation and plastic deformation energy during metal flow, and can indirectly characterize the surface waviness.

[0056] Specifically, in the present invention embodiment, under the condition that the ring rolling process of the taper roller on the abnormal area of the flange blank is determined to be unqualified, the surface roughness threshold is determined according to the comparison result between the ratio of the preset surface waviness to the surface waviness and the preset ratio; When the ratio is less than or equal to the preset ratio, it is determined that the surface roughness threshold is reduced to the corresponding value with the first preset threshold adjustment coefficient of 0.97; When the ratio is greater than the preset ratio, it is determined that the surface roughness threshold is reduced to the corresponding value by the second preset threshold adjustment coefficient of 0.93. The ratio is the ratio of the preset surface waviness to the surface waviness.

[0057] In the embodiment of the present invention, the preset ratio is 0.23, but the above value is not limited thereto, and those skilled in the art can also adjust the value according to actual needs.

[0058] In the embodiment of the present invention, the reduced surface roughness threshold is the product of the surface roughness threshold and the preset threshold adjustment coefficient. The preset threshold adjustment coefficient includes a first preset threshold adjustment coefficient with a value of 0.97 and a second preset threshold adjustment coefficient with a value of 0.93. To ensure that the adjusted surface roughness threshold meets the actual requirements and the adjustment range is not too large, the adjustment coefficient is correspondingly set to control the adjustment range.

[0059] It can be understood that reducing the roughness threshold can expand the determination range of the "abnormal area" so as to trigger the repeated ring rolling mode for more high-risk areas to enhance the local rolling strength and thus improve the surface flatness.

[0060] Specifically, the remaining flange blank is ring rolled according to the ring rolling parameters of the adjusted taper roll.

[0061] Specifically, the present invention detects the surface waviness of the infrared image of the T-shaped flange, judges whether the ring rolling process of the abnormal area of the flange blank by the taper roll is qualified. For unqualified situations, the surface roughness threshold is dynamically adjusted according to the ratio of the preset surface waviness to the actual surface waviness to optimize the ring rolling process, ensuring the stability of the ring rolling process, improving the surface quality of the T-shaped flange, enhancing the production efficiency, improving the accuracy of the detection of the T-shaped flange, and thus improving the ring rolling processing accuracy of the taper roll for the T-shaped flange.

[0062] Please refer to Figure 4 As shown, it is a schematic diagram of the working process of the method and system for forming a T-shaped flange forging based on the special shape of the taper roll in the embodiment of the present invention.

[0063] The main roll 1, which contacts the outer surface of the T-shaped flange 5 and is used to drive the plastic deformation of the flange blank; The core roll 2, which is embedded in the inner hole of the T-shaped flange 5 and is used to support the inner hole structure of the flange blank; The taper roll 3, which is arranged at one end of the T-shaped flange 5 far from the main roll 1 and is used to form the cross section of the T-shaped flange 5; The auxiliary holding roll 4, which is symmetrically arranged at one end of the T-shaped flange close to the taper roll 3 and is used to restrain the radial runout of the T-shaped flange 5.

[0064] So far, the technical solution of the present invention has been described in conjunction with the preferred embodiments shown in the accompanying 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 T-shaped flange forgings based on the special shape of taper rollers, characterized in that, Including: Processing raw materials into flange blanks to be ring-rolled, and obtaining surface images of at least one of the flange blanks; Determining whether the surface image is an abnormal area of the flange blank based on geometric feature characterization parameters of the surface image, and determining the ring-rolling mode of the tapered roller with abnormal shape as spiral ring-rolling or repeated ring-rolling according to the surface roughness of the abnormal area of the flange blank; Under the condition of determining the corresponding ring-rolling mode, ring-rolling the flange blank to obtain a T-shaped flange, and obtaining an infrared image of the abnormal area of the flange blank corresponding to the T-shaped flange; Determining whether the qualified proportion of uniform metal flow of the T-shaped flange is qualified based on the texture distribution uniformity of the infrared image, and determining to adjust the feed speed or rotation speed of the tapered roller according to the difference between the preset texture distribution uniformity and the texture distribution uniformity; Under the condition of determining that the qualified proportion of uniform metal flow is qualified, determining whether the ring-rolling process of the tapered roller for the abnormal area of the flange blank is qualified based on the surface waviness of the infrared image, and determining to adjust the surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness; Performing ring-rolling on the remaining flange blanks based on the ring-rolling parameters of the adjusted tapered roller.

2. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 1, characterized in that, Under the condition of determining to obtain the surface image of the flange blank, determining that the surface image is an abnormal area of the flange blank based on the comparison result that the geometric feature characterization parameter of the surface image is greater than the preset geometric feature characterization parameter.

3. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 2, characterized in that, Under the condition of determining that the surface image is an abnormal area of the flange blank, determining that the ring-rolling mode of the tapered roller is spiral ring-rolling based on the comparison result that the surface roughness of the abnormal area of the flange blank is less than or equal to the surface roughness threshold.

4. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 2, wherein, Under the condition of determining that the surface image is an abnormal area of the flange blank, determining that the ring-rolling mode of the tapered roller is repeated ring-rolling based on the comparison result that the surface roughness of the abnormal area of the flange blank is greater than the surface roughness threshold.

5. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 1, wherein, Under the condition of determining the corresponding ring-rolling mode, determining that the qualified proportion of uniform metal flow of the T-shaped flange is unqualified based on the comparison result that the texture distribution uniformity of the infrared image is less than or equal to the preset texture distribution uniformity.

6. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 5, wherein, Under the condition of determining that the qualified proportion of uniform metal flow of the T-shaped flange is unqualified, determining to reduce the feed speed of the tapered roller with a preset feed speed adjustment coefficient based on the comparison result that the difference between the preset texture distribution uniformity and the texture distribution uniformity is less than or equal to the preset difference.

7. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 5, characterized in that Under the condition of determining that the qualified proportion of uniform metal flow of the T-shaped flange is unqualified, determining to increase the rotation speed of the tapered roller with a preset rotation speed adjustment coefficient based on the comparison result that the difference between the preset texture distribution uniformity and the texture distribution uniformity is greater than the preset difference.

8. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 1, characterized in that, Under the condition of determining that the qualified proportion of uniform metal flow is qualified, determining that the ring-rolling process of the tapered roller for the abnormal area of the flange blank is unqualified based on the comparison result that the surface waviness of the infrared image is greater than the preset surface waviness.

9. The forming method of the T-shaped flange forging based on the special-shaped taper roller according to claim 8, characterized in that, Under the condition of determining that the ring-rolling process of the tapered roller for the abnormal area of the flange blank is unqualified, the process of adjusting the surface roughness threshold includes: Dividing the preset surface waviness by the surface waviness; Setting a number of adjustment coefficients corresponding to the respective ratios; Reducing the surface roughness threshold based on the number of adjustment coefficients; Set the corresponding relationship between the ratio and the surface roughness threshold reduction to adjust the surface roughness threshold.

10. A forming system for T-shaped flange forgings based on the special shape of tapered rolls, which adopts the forming method for T-shaped flange forgings based on the special shape of tapered rolls according to any one of claims 1-9, characterized in that It includes: A data acquisition module for obtaining the surface image of at least one flange blank and the infrared image of the abnormal area of the flange blank corresponding to the T-shaped flange; A mode determination module connected to the data acquisition module for determining whether the surface image is an abnormal area of the flange blank based on the geometric feature characterization parameters of the surface image, and determining the ring rolling mode of the conical roller special-shaped as spiral ring rolling or repeated ring rolling according to the surface roughness of the abnormal area of the flange blank; A metal flow analysis module connected to the data acquisition module and the mode determination module respectively for determining whether the metal flow uniform ratio of the T-shaped flange is qualified based on the texture distribution uniformity of the infrared image, and determining to adjust the feed speed or rotation speed of the conical roller according to the difference between the preset texture distribution uniformity and the texture distribution uniformity; A ring rolling analysis module connected to the data acquisition module and the metal flow analysis module respectively for determining whether the ring rolling process of the conical roller on the abnormal area of the flange blank is qualified based on the surface waviness of the infrared image under the condition that the metal flow uniform ratio is determined to be qualified, and determining to adjust the surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness.

Images