A T-flange forging forming method and system based on tapered roller profile

Abstract

The present invention relates to the field of flange forging technology, and in particular to a T-flange forging forming method and system based on tapered roller profile, comprising: processing raw materials into flange blanks to be ring-rolled and forming, and obtaining a surface image of at least one flange blank; determining whether the surface image is an abnormal area of ​​the flange blank based on geometric feature characterization parameters, and determining the ring rolling mode of the tapered roller profile according to the surface roughness; obtaining an infrared image of the abnormal area of ​​the flange blank corresponding to the T-flange; determining whether the metal flow uniformity ratio of the T-flange is qualified based on texture distribution uniformity, and adjusting the feed speed or rotation speed of the tapered roller based on the difference between a preset texture distribution uniformity and the texture distribution uniformity; determining whether the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is qualified based on the surface waviness, and adjusting the surface roughness threshold according to the ratio. The present invention improves the ring rolling processing accuracy of the tapered roller on the T-flange.

Description

Technical Field

[0001] The present invention relates to the technical field of flange forging, and in particular to a forming method and system for a T-shaped flange forging based on a tapered roller profile. Background Art

[0002] In the field of industrial manufacturing, T-flanges are key components of heavy equipment such as pipeline connections, pressure vessels and wind turbine towers. Their forming quality directly affects the sealing and load-bearing capacity of the overall structure. Traditional T-flange manufacturing mainly relies on free forging and die forging processes, and the blank is formed through upsetting, drawing, punching and other processes. However, there are problems such as low material utilization and large processing allowance. Especially for flanges with special cross-sections, the mold development cost is high and it is difficult to ensure dimensional accuracy. The rolling forming technology based on tapered roller profiles has gradually become the mainstream. This technology achieves high-precision forming of complex cross-sections through continuous local plastic deformation of tapered rollers and rings.

[0003] Chinese patent application publication number CN117983756A discloses a method for determining the size of a wind turbine flange ring blank formed using tapered roller rolling. The method uses the target size of the wind turbine flange ring and the core roller diameter of the tapered roller to determine the range and values ​​of the rolling ratio K0 and the radial-axial deformation distribution ratio tanα0 during the tapered roller rolling phase, thereby determining the rolled blank size. Based on the rolled blank size, the criterion hw is then used to determine whether it meets the requirements for precise forming. The preform size is then determined based on the rolled blank size, the step ring width b1, and the assembly distance L1 between the tapered roller and the outer diameter of the ring. The preform size and core roller diameter are used to determine the range and values ​​of the rolling ratio Kr and the radial-axial deformation distribution ratio tanαr during the bidirectional rolling phase, ultimately determining the initial blank size. This method can reversely deduce the blank size values ​​for each stage of tapered roller rolling based on the relationship between billet size changes during each stage, thereby improving the quality of tapered roller rolling.

[0004] However, the existing technology has the following problems: the metal flow on the surface of the T-flange during the cone roller ring rolling process is not refined, resulting in defects in the T-flange, thereby causing low precision in the cone roller ring rolling of the T-flange. Summary of the Invention

[0005] To this end, the present invention provides a T-flange forging forming method and system based on tapered roller profile, which is used to overcome the problem that the prior art does not perform fine processing on the metal flow on the surface of the T-flange during the tapered roller ring rolling process, resulting in defects in the T-flange, thereby leading to low ring rolling processing accuracy of the T-flange by the tapered roller.

[0006] To achieve the above object, the present invention provides a T-flange forging forming method based on a tapered roller profile, comprising:

[0007] Processing the raw material into a flange blank to be ring-rolled, and acquiring a surface image of at least one of the flange blanks;

[0008] Determining whether the surface image is an abnormal area of ​​the flange blank based on the geometric characteristic characterization parameter of the surface image, and determining whether the tapered roller profiled ring rolling mode is spiral ring rolling or repeated ring rolling according to the surface roughness of the abnormal area of ​​the flange blank;

[0009] 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;

[0010] 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 adjusting 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;

[0011] Under the condition that the metal flow uniformity ratio is determined to be qualified, determining 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, so as to adjust the surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness;

[0012] The remaining flange blank is rolled based on the adjusted rolling parameters of the tapered roller.

[0013] Furthermore, under the condition that the surface image of the flange blank is determined to be obtained, the surface image is determined to be an abnormal area of ​​the flange blank based on a comparison result that a geometric feature characterization parameter of the surface image is greater than a preset geometric feature characterization parameter.

[0014] Furthermore, under the condition that the surface image is determined to be an abnormal area of ​​the flange blank, the ring rolling mode of the tapered roller is determined to be 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.

[0015] Furthermore, under the condition that the surface image is determined to be an abnormal area of ​​the flange blank, the ring rolling mode of the tapered roller is determined to be repeated ring rolling based on the comparison result that the surface roughness of the abnormal area of ​​the flange blank is greater than a surface roughness threshold.

[0016] Furthermore, under the condition of determining the corresponding ring rolling mode, the comparison result based on the texture distribution uniformity of the infrared image is less than or equal to the preset texture distribution uniformity, and it is determined that the metal flow uniformity ratio of the T-flange is unqualified.

[0017] Furthermore, under the condition that the metal flow uniformity ratio of the T-flange is determined to be unqualified, 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, it is determined to reduce the feed speed of the tapered roller by the preset feed speed adjustment coefficient.

[0018] Furthermore, under the condition that the metal flow uniformity ratio of the T-flange is determined to be unqualified, the speed of the tapered roller is increased by a preset 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.

[0019] Furthermore, under the condition that the metal flow uniformity ratio is determined to be qualified, the ring rolling process of the abnormal area of ​​the flange blank with the tapered roller is determined to be unqualified based on the comparison result that the surface waviness of the infrared image is greater than the preset surface waviness.

[0020] Furthermore, under the condition that the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is determined to be unqualified, the process of adjusting the surface roughness threshold includes:

[0021] dividing a predetermined surface waviness by the surface waviness;

[0022] Set a number of adjustment coefficients corresponding to the corresponding ratios;

[0023] reducing a surface roughness threshold based on a number of said adjustment factors;

[0024] A corresponding relationship between the corresponding ratio and the reduction threshold of the surface roughness is set to adjust the surface roughness threshold.

[0025] On the other hand, the present invention also provides a T-flange forging forming system based on a tapered roller profile, comprising:

[0026] A data acquisition module, which is used to obtain a surface image of at least one flange blank and an infrared image of an abnormal area of ​​the flange blank corresponding to the T-flange;

[0027] 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 characteristic characterization parameters of the surface image, and determining whether the tapered roller profiled ring rolling mode is spiral ring rolling or repeated ring rolling according to the surface roughness of the abnormal area of ​​the flange blank;

[0028] a metal flow analysis module, connected to the data acquisition module and the pattern determination module, respectively, for determining whether the metal flow uniformity ratio of the T-flange is qualified based on the texture distribution uniformity of the infrared image, and adjusting the feed speed or rotation speed of the tapered roller according to the difference between a preset texture distribution uniformity and the texture distribution uniformity;

[0029] The ring rolling analysis module is connected to the data acquisition module and the metal flow analysis module respectively, and is used to 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, under the condition that the metal flow uniformity ratio is qualified, so as to determine the adjustment surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness.

[0030] Compared with the prior art, the beneficial effect of the present invention lies in that 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 according to the surface roughness, and then compares the texture distribution uniformity with the preset texture distribution uniformity to determine whether the metal flow uniformity ratio is qualified. If it is unqualified, the tapered roller parameters are adjusted according to the difference between the texture distribution uniformity and the preset texture distribution uniformity. If it is qualified, the ring rolling process is determined according to the surface waviness. If it is unqualified, the surface roughness threshold is adjusted, which improves the product strength, wear resistance and fatigue life, improves production efficiency, improves material utilization, reduces the occurrence of defects such as cracks and burrs in traditional forging, and thus improves the ring rolling processing accuracy of the tapered roller for T-flanges.

[0031] Furthermore, the present invention determines whether there is an abnormal area by calculating the geometric feature characterization parameters of the surface image and comparing them with preset geometric feature characterization parameters. If there is an abnormal area, the rolling mode of the tapered roller is determined based on the comparison result of the surface roughness and the surface roughness threshold, thereby reducing the processing error caused by surface defects, reducing friction resistance, reducing the obstruction of metal flow caused by abnormal areas, improving processing efficiency, and thus improving production efficiency.

[0032] Furthermore, the present invention determines whether the metal flow is uniform by detecting the uniformity of the texture distribution of the infrared image of the T-flange. 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 uniformity of the metal flow, thereby ensuring the quality stability of the T-flange, improving the processing accuracy of the T-flange, reducing the scrap rate caused by uneven metal flow, and improving material utilization.

[0033] Furthermore, the present invention determines whether the ring rolling process of the abnormal area of ​​the flange blank by the tapered roller is qualified by detecting the surface waviness of the infrared image of the T-flange. 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, ensure the stability of the ring rolling process, improve the surface quality of the T-flange, improve production efficiency, and improve the accuracy of T-flange detection, thereby improving the ring rolling processing accuracy of the T-flange by the tapered roller. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1This is a flow chart of a T-flange forging forming method based on a tapered roller profile according to an embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of module connections of a T-flange forging forming system based on a tapered roller profile according to an embodiment of the present invention;

[0036] Figure 3 This is a flow chart for determining whether the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is qualified according to an embodiment of the present invention;

[0037] Figure 4 Schematic diagram of the working process of the method and system for forming T-flange forgings based on a tapered roller profile according to an embodiment of the present invention;

[0038] In the figure, 1, main roller; 2, core roller; 3, tapered roller; 4, auxiliary holding roller; 5, T-flange. DETAILED DESCRIPTION

[0039] In order to make the objects and advantages of the present invention more clearly understood, the present invention is 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.

[0040] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0041] It should be pointed out that the data in this embodiment are obtained by comprehensive analysis and evaluation of the historical test data and the corresponding historical test results of the three months before this test. It can be understood by those skilled in the art that the present invention can determine the above parameters for a single item by selecting the value with the highest proportion as the preset standard parameter based on the data distribution, using weighted summation to use the obtained value as the preset standard parameter, substituting each historical data into a specific formula and using the value obtained by the formula as the preset standard parameter or other selection methods, as long as the present invention can clearly define the different specific situations in the single determination process through the obtained values.

[0042] See also Figure 1 As shown, it is a flow chart of a T-flange forging forming method based on a tapered roller profile according to an embodiment of the present invention.

[0043] The embodiment of the present invention provides a method for forming a T-shaped flange forging based on a tapered roller profile, comprising:

[0044] Step S1, processing raw materials into flange blanks to be ring-rolled, and obtaining a surface image of at least one of the flange blanks;

[0045] Step S2: determining whether the surface image is an abnormal area of ​​the flange blank based on the geometric characteristic parameters of the surface image, and determining whether the tapered roller profiled ring rolling mode is spiral ring rolling or repeated ring rolling according to the surface roughness of the abnormal area of ​​the flange blank;

[0046] 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 an infrared image of the abnormal area of ​​the flange blank corresponding to the T-shaped flange;

[0047] Step S4, 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 adjusting 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;

[0048] Step S5, under the condition that the metal flow uniformity ratio is determined to be qualified, determining 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 adjusting the surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness;

[0049] Step S6: rolling the remaining flange blank based on the adjusted rolling parameters of the tapered roller.

[0050] See also Figure 2 As shown, it is a schematic diagram of the module connection of the T-flange forging forming system based on the tapered roller profile according to an embodiment of the present invention.

[0051] On the other hand, the present invention also provides a T-flange forging forming system based on a tapered roller profile, comprising:

[0052] A data acquisition module, which is used to obtain a surface image of at least one flange blank and an infrared image of an abnormal area of ​​the flange blank corresponding to the T-flange;

[0053] 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 characteristic characterization parameters of the surface image, and determining whether the tapered roller profiled ring rolling mode is spiral ring rolling or repeated ring rolling according to the surface roughness of the abnormal area of ​​the flange blank;

[0054] a metal flow analysis module, connected to the data acquisition module and the pattern determination module, respectively, for determining whether the metal flow uniformity ratio of the T-flange is qualified based on the texture distribution uniformity of the infrared image, and adjusting the feed speed or rotation speed of the tapered roller according to the difference between a preset texture distribution uniformity and the texture distribution uniformity;

[0055] The ring rolling analysis module is connected to the data acquisition module and the metal flow analysis module respectively, and is used to 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, under the condition that the metal flow uniformity ratio is qualified, so as to determine the adjustment surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness.

[0056] In an embodiment of the present invention, the surface image is obtained by taking a photo with an industrial camera, and the infrared image is obtained by taking a photo with an infrared thermal imager. Both the industrial camera and the infrared thermal imager are vertically fixed above the T-shaped flange.

[0057] In the embodiment of the present invention, the rotation speed of the tapered roller is in the range of 2 to 2.5 rad / s, preferably 2.1 rad / s, and the feed speed is in the range of 1.2 to 1.8 mm / s, preferably 1.5 mm / s.

[0058] In the embodiment of the present invention, the groove angle between the special-shaped tapered roller and the flange blank is 69°.

[0059] Specifically, 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 according to the surface roughness, and then compares the texture distribution uniformity with the preset texture distribution uniformity to determine whether the metal flow uniformity ratio is qualified. If it is unqualified, the tapered roller parameters are adjusted according to the difference between the texture distribution uniformity and the preset texture distribution uniformity. If it is qualified, the ring rolling process is determined according to the surface waviness. If it is unqualified, the surface roughness threshold is adjusted, which improves the product strength, wear resistance and fatigue life, improves production efficiency, improves material utilization, and reduces the occurrence of defects such as cracks and burrs in traditional forging, thereby improving the ring rolling processing accuracy of the tapered roller for T-flanges.

[0060] It is understood that the tapered roller can move forward during operation. When the T-shaped flange reaches a predetermined size, the ring rolling machine does not stop working. The tapered roller moves toward the mandrel. After reaching the point, the tapered roller presses down to finally achieve one-step forming.

[0061] Specifically, the embodiment of the present invention determines whether the surface image is an abnormal area of ​​the flange blank based on the comparison result of the geometric feature characterization parameter of the surface image and the preset geometric feature characterization parameter under the condition of determining the acquisition of the surface image of the flange blank;

[0062] 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;

[0063] 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.

[0064] In the embodiment of the present invention, the preset geometric feature characterization parameter value is 0.86, and the preset geometric feature characterization parameter value range is [0.80, 0.90], but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0065] In the embodiment of the present invention, the abnormal area of ​​the flange blank is an area of ​​geometric feature mutation caused by raw material defects, processing defects or uneven heat treatment on the surface of the flange blank.

[0066] During implementation, the geometric feature characterization parameter is the root of the ratio of the edge gradient standard deviation to the edge gradient mean multiplied by the sum of the ratios of the absolute values ​​of the differences between the curvatures of several contour points and the average curvature to the average curvature.

[0067] It is understandable that the abnormal area of ​​the flange blank will increase the friction resistance of the tapered roller ring rolling process and hinder the uniform flow of metal. For the flange blank area that is not the abnormal area of ​​the flange blank, the tapered roller rolls in a unidirectional linear manner.

[0068] Specifically, in an embodiment of the present invention, under the condition that the surface image is determined to be an abnormal area of ​​the flange blank, the ring rolling mode of the tapered roller is determined according to a comparison result of the surface roughness of the abnormal area of ​​the flange blank and a surface roughness threshold;

[0069] When the surface roughness is less than or equal to the surface roughness threshold, the ring rolling mode of the tapered roller is determined to be spiral ring rolling;

[0070] When the surface roughness is greater than the surface roughness threshold, it is determined that the ring rolling mode of the tapered roller is repeated ring rolling.

[0071] In the embodiment of the present invention, the surface roughness threshold is 0.82, and the surface roughness threshold value range is [0.75, 0.85]. However, the above values ​​are not limited thereto, and those skilled in the art may also adjust the values ​​according to actual needs.

[0072] In an embodiment of the present invention, the spiral ring rolling is a rolling method in which the conical roller is continuously fed along a single rotation direction. During the processing, the conical roller maintains constant contact with the blank to form a continuous spiral deformation trajectory; the repeated ring rolling is a rolling method in which the conical roller is rolled multiple times in the abnormal area.

[0073] During implementation, 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 heights divided by the number of sampling points, wherein the profile height is the height of the flange blank surface in a direction perpendicular to the surface, and the sampling points are based on the flat plane of the end face of the flange blank, which is perpendicular to the axis of the flange blank, and all profile height measurements are performed relative to this reference plane.

[0074] Specifically, the present invention determines whether there is an abnormal area by calculating the geometric feature characterization parameters of the surface image and comparing them with the preset geometric feature characterization parameters. If there is an abnormal area, the rolling mode of the tapered roller is determined based on the comparison result of the surface roughness and the surface roughness threshold, thereby reducing the processing error caused by surface defects, reducing friction resistance, reducing the obstruction of metal flow in abnormal areas, improving processing efficiency, and thus improving production efficiency.

[0075] Specifically, in an embodiment of the present invention, under the condition of determining a corresponding ring rolling mode, the flange blank is ring rolled to obtain a T-shaped flange, and an infrared image of an abnormal area of ​​the flange blank corresponding to the T-shaped flange is obtained.

[0076] Specifically, in the embodiment of the present invention, under the condition of determining that the infrared image is obtained, whether the metal flow uniformity ratio of the T-flange is qualified is determined based on the comparison result of the texture distribution uniformity of the infrared image and the preset texture distribution uniformity;

[0077] 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;

[0078] 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.

[0079] In the embodiment of the present invention, the preset texture distribution uniformity value is 1.10, and the preset texture distribution uniformity value range is [0.90, 1.20]. Those skilled in the art may also adjust the value according to actual needs.

[0080] During the implementation process, the texture distribution uniformity is the ratio of the current infrared image contrast to the preset contrast multiplied by the ratio of the current infrared image entropy value to the preset entropy value. The preset contrast and preset entropy value are the average contrast and entropy values ​​of several historical infrared images with qualified metal flow uniformity ratios.

[0081] Specifically, in an embodiment of the present invention, under the condition that it is determined that the metal flow uniformity ratio of the T-shaped flange is unqualified, the feed speed or rotation speed of the tapered roller is adjusted according to the comparison result of the preset texture distribution uniformity and the difference between the texture distribution uniformity and the preset difference;

[0082] When the difference is less than or equal to the preset difference, it is determined to reduce the feed speed of the tapered roller to a corresponding value using a preset feed speed adjustment coefficient of 0.95;

[0083] When the difference is greater than the preset difference, it is determined to increase the speed of the tapered roller to a corresponding value using a preset speed adjustment coefficient of 1.03;

[0084] The difference is a difference between the preset texture distribution uniformity and the texture distribution uniformity.

[0085] In the embodiment of the present invention, the preset difference value is 0.35, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0086] In an 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 rotational speed is the product of the rotational speed and the preset rotational speed adjustment coefficient of 1.03. In order to ensure that the adjusted feed speed and rotational speed meet actual needs, the adjustment range should not be too large, so the adjustment coefficient is set accordingly to control the adjustment range.

[0087] It can be understood that reducing the feed rate can prolong the axial flow time of the metal and reduce local accumulation, while increasing the rotation speed can increase the tangential shear force and promote grain sliding and redistribution.

[0088] Specifically, the present invention determines whether the metal flow is uniform by detecting the uniformity of the texture distribution of the infrared image of the T-flange. 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 uniformity of the metal flow, thereby ensuring the quality stability of the T-flange, improving the processing accuracy of the T-flange, reducing the scrap rate caused by uneven metal flow, and improving material utilization.

[0089] See also Figure 3 As shown, it is a flow chart of determining whether the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is qualified according to an embodiment of the present invention.

[0090] Specifically, under the condition that the metal flow uniformity ratio is determined to be qualified, the embodiment of the present invention determines whether the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is qualified based on the comparison result of the surface waviness of the infrared image and the preset surface waviness;

[0091] When the surface waviness is less than or equal to the preset surface waviness, it is determined that the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is qualified;

[0092] When the surface waviness is greater than the preset surface waviness, it is determined that the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is unqualified.

[0093] In the embodiment of the present invention, the preset surface waviness value is 20, and the preset surface waviness value range is [15, 30]. However, the above values ​​are not limited thereto, and those skilled in the art may also adjust the values ​​according to actual needs.

[0094] In the implementation process, the surface waviness is the average absolute value of the grayscale gradient along the radial direction of the T-flange in the infrared image.

[0095] It can be understood that the grayscale value of the infrared image reflects the surface temperature distribution, and the temperature gradient is related to the frictional heat generated and plastic deformation energy during metal flow, which can indirectly characterize the surface waviness.

[0096] Specifically, the embodiment of the present invention determines the adjustment of the surface roughness threshold value based on the comparison result of the ratio of the preset surface waviness to the surface waviness and the preset ratio under the condition that the ring rolling process of the flange blank by the tapered roller in the abnormal area is determined to be unqualified;

[0097] When the ratio is less than or equal to the preset ratio, it is determined to reduce the surface roughness threshold to a corresponding value using a first preset threshold adjustment coefficient of 0.97;

[0098] When the ratio is greater than the preset ratio, it is determined to reduce the surface roughness threshold to a corresponding value using a second preset threshold adjustment coefficient of 0.93;

[0099] The ratio is the ratio of the preset surface waviness to the surface waviness.

[0100] 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 may also adjust the value according to actual needs.

[0101] In an 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, which is 0.97, and a second preset threshold adjustment coefficient, which is 0.93. In order to ensure that the adjusted surface roughness threshold meets actual needs, the adjustment range should not be too large, so the corresponding adjustment coefficient is set to control the adjustment range.

[0102] It is understandable that lowering the roughness threshold will expand the scope of “abnormal area” determination 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.

[0103] Specifically, the remaining flange blank is rolled according to the adjusted rolling parameters of the tapered roller.

[0104] Specifically, the present invention determines whether the ring rolling process of the abnormal area of ​​the flange blank by the tapered roller is qualified by detecting the surface waviness of the infrared image of the T-flange. 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, ensure the stability of the ring rolling process, improve the surface quality of the T-flange, improve production efficiency, and improve the accuracy of T-flange detection, thereby improving the ring rolling processing accuracy of the T-flange by the tapered roller.

[0105] See also Figure 4 As shown, it is a schematic diagram of the working process of the T-flange forging forming method and system based on the profiled tapered roller according to an embodiment of the present invention.

[0106] The main roller 1 contacts the outer surface of the T-shaped flange 5 and is used to drive the flange blank to plastically deform;

[0107] The core roller 2 is embedded in the inner hole of the T-shaped flange 5 to support the inner hole structure of the flange blank;

[0108] a tapered roller 3, which is arranged at one end of the T-shaped flange 5 away from the main roller 1 and is used to form a cross section of the T-shaped flange 5;

[0109] The auxiliary holding roller 4 is symmetrically arranged at one end of the T-shaped flange close to the tapered roller 3 to constrain the radial runout of the T-shaped flange 5.

[0110] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

Claims

1. A T-flange forging forming method based on tapered roller profile, characterized in that: include: Processing the raw material into a flange blank to be ring-rolled, and acquiring a surface image of at least one of the flange blanks; Determining whether the surface image is an abnormal area of ​​the flange blank based on the geometric characteristic characterization parameter of the surface image, and determining whether the tapered roller profiled ring rolling mode is 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 metal flow uniformity ratio of the T-shaped flange is qualified based on the texture distribution uniformity of the infrared image, and adjusting 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 of the infrared image; Under the condition that the metal flow uniformity ratio is determined to be qualified, determining 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 adjusting the surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness of the infrared image; The remaining flange blank is rolled based on the adjusted rolling parameters of the tapered roller.

2. The method for forming T-flange forgings based on tapered roller profile according to claim 1, characterized in that: Under the condition that the surface image of the flange blank is determined to be obtained, the surface image is determined to be an abnormal area of ​​the flange blank based on a comparison result that a geometric feature characterization parameter of the surface image is greater than a preset geometric feature characterization parameter.

3. The method for forming T-flange forgings based on tapered roller profile according to claim 2, characterized in that: Under the condition that the surface image is determined to be an abnormal area of ​​the flange blank, the ring rolling mode of the tapered roller is determined to be 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 method for forming T-flange forgings based on tapered roller profile according to claim 2, characterized in that: Under the condition that the surface image is determined to be an abnormal area of ​​the flange blank, the ring rolling mode of the tapered roller is determined to be repeated ring rolling based on the comparison result that the surface roughness of the abnormal area of ​​the flange blank is greater than a surface roughness threshold.

5. The method for forming T-flange forgings based on tapered roller profile according to claim 1, characterized in that: Under the condition of determining the corresponding ring rolling mode, the comparison result based on the texture distribution uniformity of the infrared image is less than or equal to the preset texture distribution uniformity, which determines that the metal flow uniformity ratio of the T-flange is unqualified.

6. The method for forming T-flange forgings based on tapered roller profile according to claim 5, characterized in that: Under the condition that the metal flow uniformity ratio of the T-flange is determined to be unqualified, based on the comparison result that the difference between the preset texture distribution uniformity and the texture distribution uniformity of the infrared image is less than or equal to the preset difference, it is determined to reduce the feed speed of the tapered roller by the preset feed speed adjustment coefficient.

7. The method for forming T-flange forgings based on tapered roller profile according to claim 5, characterized in that: Under the condition that the metal flow uniformity ratio of the T-flange is determined to be unqualified, it is determined that the speed of the tapered roller is increased by a preset speed adjustment coefficient based on the comparison result that the difference between the preset texture distribution uniformity and the texture distribution uniformity of the infrared image is greater than the preset difference.

8. The method for forming T-flange forgings based on tapered roller profile according to claim 1, characterized in that: Under the condition that the metal flow uniformity ratio is determined to be qualified, it is determined that the ring rolling process of the abnormal area of ​​the flange blank with the tapered roller is unqualified based on the comparison result that the surface waviness of the infrared image is greater than the preset surface waviness.

9. The method for forming T-flange forgings based on tapered roller profile according to claim 8, characterized in that: Under the condition that the ring rolling process of the tapered roller on the abnormal area of ​​the flange blank is determined to be unqualified, the process of adjusting the surface roughness threshold includes: Dividing the preset surface waviness by the surface waviness of the infrared image; Set a number of adjustment coefficients corresponding to the corresponding ratios; reducing a surface roughness threshold based on a number of said adjustment factors; A corresponding relationship between the corresponding ratio and the reduction threshold of the surface roughness is set to adjust the surface roughness threshold.

10. A T-flange forging forming system based on tapered roller profile, adopting the T-flange forging forming method based on tapered roller profile according to any one of claims 1 to 9, characterized in that: include: A data acquisition module, which is used to obtain a surface image of at least one flange blank and an infrared image of an abnormal area of ​​the flange blank corresponding to the T-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 characteristic characterization parameters of the surface image, and determining whether the tapered roller profiled ring rolling mode is 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 pattern determination module, respectively, for determining whether the metal flow uniformity ratio of the T-flange is qualified based on the texture distribution uniformity of the infrared image, and adjusting the feed speed or rotation speed of the tapered roller according to the difference between a preset texture distribution uniformity and the texture distribution uniformity of the infrared image; The ring rolling analysis module is connected to the data acquisition module and the metal flow analysis module respectively, and is used to 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, under the condition that the metal flow uniformity ratio is qualified, and to determine the adjustment surface roughness threshold according to the ratio of the preset surface waviness to the surface waviness of the infrared image.

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