Enveloping, shearing, rolling and additive forming equipment and method for large composite roller

Abstract

The invention provides large composite roller envelope shearing rolling additive forming equipment and method, and relates to the technical field of dissimilar metal additive manufacturing, and the equipment comprises an additive manufacturing unit, a temperature control unit, an envelope shearing rolling unit, an online heat treatment unit, a surface cleaning unit, a carrier roller frame, a rolling displacement unit and an arc-shaped frame exiting unit. According to the method, the N enveloping rollers are arranged, the rolling technology and additive manufacturing are combined, a grain structure is refined through multi-pass enveloping shearing rolling, internal defects are closed, and the compactness, strength and toughness of a repairing layer are remarkably improved. The method is suitable for various heat sources such as laser and electric arc and powder / filiform coating materials, is high in compatibility and low in transformation cost, can effectively realize three-dimensional precise forming of special-shaped roller surfaces such as conical surfaces or stepped surfaces, prolongs the service life of the roller, reduces the production cost, and has important application value in the field of high-performance repair of large composite rollers.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of heterogeneous metal additive manufacturing, in particular to a large composite roll envelope shearing rolling additive forming equipment and method. BACKGROUND

[0002] As a core component of rolling mill, the performance of the roll directly determines the quality of the plate and the production cost. Under the trend of high strength of steel, the requirements for wear resistance, fatigue resistance and precision of high-end plate rolls are increasing, but the roll is prone to failure and scrap due to high temperature and high pressure during service. A large number of rolls are replaced every year due to the expiration of the service life, and the cost of manufacturing new rolls is high and the cycle is long. Additive repair technology can restore the geometric size and performance of the roll, prolong the service life by 1-10 times, and significantly reduce the cost of rolling steel. At the same time, the repair process saves more than 30% energy compared with the manufacturing of new rolls, which meets the green transformation demand of the metallurgical industry.

[0003] The existing roll repair technologies such as surfacing, thermal spraying and laser cladding all have significant bottlenecks: surfacing is prone to produce coarse columnar crystals and segregation, resulting in loose repair layer, inclusions and stress corrosion; the residual stress control of surface strengthening technology (such as induction quenching) is difficult; new additive technologies such as spray forming can improve wear resistance, but the compactness of the deposited layer is insufficient and industrialization is limited, and the electric arc wire composite rolling equipment is only suitable for simple shaft parts. The core problem is that the existing equipment lacks multi-degree-of-freedom coordination capability, and cannot realize accurate repair of special-shaped sections such as conical and stepped rolls, and the bonding strength and fatigue performance of the repair layer are lagging behind the level of imported new rolls.

[0004] Therefore, it is urgent to develop a dynamic envelope tracking technology for gradually changing curvature special-shaped roll surface to ensure the uniformity of the thickness of the repair layer, break coarse dendrites and eliminate pores in the semi-solid molten pool stage through coupling rolling compaction and high-frequency shearing, and adjust the microstructure and performance through online local induction heating, to systematically solve the problems of large composite roll additive repair, metallurgical defect control, gradient functional manufacturing and stress regulation, and promote the upgrade of large composite roll remanufacturing to high performance and full section adaptation. SUMMARY

[0005] In order to solve the above-mentioned problems of the prior art, the purpose of the present application is to provide a large composite roll envelope shearing rolling additive forming equipment and method, which introduces rolling into the additive process by adding N envelope rolls. Envelope shearing rolling can significantly refine the grain structure of the material, improve the strength and toughness, close the pores and cracks inside the material, and improve the density to make up for the shortcomings of additive manufacturing.

[0006] Specifically, the application provides a large composite roller envelope shearing rolling additive forming equipment, which comprises an additive manufacturing unit, a temperature control unit, an envelope shearing rolling unit, an online heat treatment unit, a surface cleaning unit, a roller support, a rolling displacement unit and an arc-shaped frame exit unit; the additive manufacturing unit is arranged on the upper side of a roller to be repaired, the envelope shearing rolling unit is arranged on the first side of a workbench, the temperature control unit is arranged adjacent to the envelope shearing rolling unit, the online heat treatment unit is arranged on the second side of the workbench, and the surface cleaning unit is arranged adjacent to the online heat treatment unit; the additive manufacturing unit comprises an X-direction displacement assembly, a Y-direction displacement assembly, a Z-direction displacement assembly and an additive assembly; the additive assembly moves in the X direction, the Y direction or the Z direction through the X-direction displacement assembly, the Y-direction displacement assembly or the Z-direction displacement assembly; the envelope shearing rolling unit comprises an arc-shaped frame, a sliding rail, a position limiter and N envelope shearing rolling assemblies distributed in the circumferential direction; the envelope shearing rolling assemblies are installed on the sliding rail, are guided by rollers and are fixed in position by the position limiter; the envelope shearing rolling assembly comprises a rolling mechanism, a deflection changing mechanism, a rolling changing mechanism and a position changing mechanism; the rolling mechanism is provided with an envelope roller, the deflection angle α between the envelope roller and the roller to be repaired is adjusted by the deflection changing mechanism, the rolling angle β between the envelope roller and the roller to be repaired is adjusted by the rolling changing mechanism, and the distance between the envelope roller and the roller to be repaired is adjusted by the position changing mechanism.

[0007] The distance between the envelope rollers of the N envelope shearing rolling assemblies distributed in the circumferential direction and the roller to be repaired gradually decreases in turn.

[0008] ;

[0009] ;

[0010] wherein, is the reduction of the n-th pass of cladding metal; is the distance between the n-1-th envelope roller and the roller to be repaired; is the distance between the i-th envelope roller and the roller to be repaired; is the distance between the n-th envelope roller and the roller to be repaired, i.e. the target thickness of the cladding metal, is the thickness of the initial cladding metal;

[0011] The cladding metal is rolled for n passes, and the roller profile of each pass partially covers the target shape, and the multiple passes are superimposed to form a complete profile.

[0012] Preferably, the distances between the envelope rollers of the N envelope shearing rolling assemblies distributed in the circumferential direction can be adjusted and arranged at equal intervals or variable intervals.

[0013] Preferably, the distance between the i-th and the i+1-th envelope rollers is adjusted by sliding the rollers of the envelope shearing rolling assembly on the slide rails to adjust the central angle γ between the i-th and the i+1-th envelope rollers, thereby adjusting the distance between the adjacent envelope rollers.

[0014] Preferably, the temperature control unit comprises an induction heating module and a first temperature measuring module; and the in-line heat treatment unit comprises a heating module, a cooling module and a second temperature measuring module.

[0015] Preferably, when the envelope roller and the repaired roller have a rolling angle, the distance between the i-th envelope roller and the repaired roller is calculated according to the following formula:

[0016] ;

[0017] wherein, is the distance between the i-th envelope roller and the repaired roller, and are the maximum distance and the minimum distance between the envelope roller and the repaired roller when rolling, respectively.

[0018] Preferably, the deflection angle between the envelope roller and the repaired roller is α, and |α|≤30°; the rolling angle between the envelope roller and the repaired roller is β, and |β|≤30°; the deflection angle and the rolling angle between the envelope roller and the repaired roller are determined according to the following formulas, respectively:

[0019] ;

[0020] ;

[0021] wherein, is the contact line width of the envelope roller after deflection and the cladding metal; is the cladding metal width, i.e. the contact line width of the envelope roller and the cladding metal when the envelope roller is not deflected; is the length of the envelope roller.

[0022] Preferably, the forming limit load of the large roller additive rolling is determined according to the peak stress and the dynamic contact area, and the theoretical calculation model of the rolling force is shown in the following formula:

[0023] ;

[0024] wherein, F is the rolling force, in N; is the average unit pressure, in MPa; and S is the contact area, in mm².

[0025] The average unit pressure is calculated according to the following formula:

[0026] ;​

[0027] wherein, and are the deformation resistances of the coating material at the material inlet and outlet, respectively, which are related to the temperature T and the strain rate and are calculated using the Arrhenius constitutive equation;

[0028] the contact arc length The solving formula is:

[0029] ;

[0030] wherein, R is the radius of the roller to be repaired; r is the radius of the envelope roller; is the envelope thickness before shear rolling, is the additive thickness after envelope shear rolling;

[0031] The solving formula of the contact area S is:

[0032] ;

[0033] wherein, b is the single-pass additive width;

[0034] The average strain rate of micro-casting is which is expressed as:

[0035] ;

[0036] wherein, is the angular velocity of the micro-roller, in rad / s; is the angular velocity of the roller to be repaired, in rad / s.

[0037] Preferably, the outer surface of the intermediate configuration section of the envelope roller has a spatial configuration.

[0038] Preferably, the rolling displacement unit is arranged at the bottom of the arc-shaped frame, and the axial position adjustment of the envelope roller is realized by driving the arc-shaped frame to move horizontally on the slide rail through the lead screw in the rolling displacement unit.

[0039] In another aspect, the present application provides a large composite roller envelope shear rolling additive forming method, which is realized based on the large composite roller envelope shear rolling additive forming equipment described above, and the method comprises the following steps:

[0040] S1, preparation before rolling: pull the arc-shaped frame to make the arc-shaped frame exit the rolling area, move the roller to be repaired into the repair area, then push the arc-shaped frame back to the rolling area and fix the position; adjust the position of the envelope shear rolling assembly on the slide rail of the envelope shear rolling unit and fix it with the stopper; adjust the rolling displacement unit and the additive manufacturing unit so that they are located in the same repair plane;

[0041] S2, additive manufacturing: the cladding metal is melted into liquid metal droplets under the action of a heat source, and is cladded on the surface of the roller to be repaired;

[0042] S3, pre-rolling heating: the first temperature measuring module detects the temperature of the cladded metal in real time, and the induction heating module heats the cladded metal to reach a temperature T1;

[0043] S4, envelope rolling: the deflection changing mechanism and the rolling changing mechanism in the envelope shearing rolling assembly are adjusted to make the envelope rollers have different deflection angles and rolling angles, so as to realize envelope shearing rolling; the distance between the envelope rollers and the roller to be repaired is adjusted by the position changing mechanism, and the distance between the N envelope rollers and the roller to be repaired shows a decreasing trend;

[0044] S5, online heat treatment: the second temperature measuring module monitors the temperature T2 of the metal after rolling in real time, if the temperature is lower than the target rolling temperature, the heating module is heated by induction heating; if the temperature is higher than the target rolling temperature, the cooling module is cooled by the cooling medium sprayed by the nozzle;

[0045] S6, surface cleaning: the laser beam irradiates the surface of the workpiece to break and fall off the welding slag;

[0046] S7, continuous near-net-shape forming: steps S1-S6 are repeated, and cladding is continued on the preset path to complete near-net-shape forming, and the Z-direction displacement assembly is adjusted during the cladding process to keep the preset height between the welding gun and the cladded metal, so that the large composite roller envelope shearing rolling additive forming equipment adds and repairs the roller to be repaired in the radial direction, and the height of each layer of cladded metal is , and the height of the repaired P circle is ;

[0047] S8, roller exit: after the roller repair is completed, the arc-shaped frame is pulled out, and the repaired roller to be repaired is moved out.

[0048] Compared with the prior art, the beneficial effects of the present application are as follows:

[0049] (1) Compared with the traditional roller additive forming equipment, the large composite roller envelope shearing rolling additive forming equipment adds N envelope rollers, innovatively introduces rolling into the additive process, and can significantly refine the grain structure of the material, improve the strength and toughness, and close the pores and cracks in the material, thereby improving the density.

[0050] (2) The large composite roll envelope shearing rolling additive forming equipment of the application, compared with the traditional roll additive forming equipment, makes the cladding metal gradually approach the target shape in the rolling process through the envelope roll with different deflection angles and rolling angles, and the roll profile of each pass partially covers the final shape, and the complete profile is finally formed by superposition. Unlike the traditional one-time forming, the envelope rolling reduces the material stress concentration and improves the forming precision through multiple passes and small deformation.

[0051] (3) The large composite roll envelope shearing rolling additive forming equipment and method of the application, compared with the traditional roll additive forming, performs heat treatment online through N heating modules and cooling modules, thereby refining the grains or forming the strengthening phase, improving the hardness and strength of the material, adjusting the organizational structure, improving the toughness and impact resistance of the material, softening the material, improving the machining performance such as cutting and stamping, improving the wear resistance and service life of the material, and eliminating the residual stress inside the material to prevent deformation and cracking.

[0052] (4) The heat source of the additive unit of the large composite roll envelope shearing rolling additive forming equipment of the application can be laser, electric arc, etc., and the cladding metal can be powder or wire, so there are more optional schemes for the heat source, the cost of the old equipment transformation is lower, and the coupling application of multiple devices is compatible. BRIEF DESCRIPTION OF DRAWINGS

[0053] Figure 1 It is a whole structure schematic diagram of a large composite roll envelope shearing rolling additive forming equipment of the application;

[0054] Figure 2 It is a three-dimensional structure schematic diagram of a large composite roll envelope shearing rolling additive forming equipment of the application;

[0055] Figure 3 It is a three-dimensional structure schematic diagram of an additive manufacturing unit of the application;

[0056] Figure 4 It is a three-dimensional structure schematic diagram of an envelope shearing rolling unit of the application;

[0057] Figure 5 It is a structure schematic diagram of an envelope shearing rolling unit of the application;

[0058] Figure 6 It is a structure schematic diagram of an envelope shearing rolling assembly of the application;

[0059] Figure 7 It is a distribution schematic diagram of an envelope roll and a heat treatment module of the application;

[0060] Figure 8 It is a distance schematic diagram between envelope rolls of the application;

[0061] Figure 9 A schematic diagram of the distance between the envelope roller of the present application and the roller to be repaired;

[0062] Figure 10 A schematic diagram of the deflection angle of the present application;

[0063] Figure 11 A schematic diagram of the rolling angle of the present application;

[0064] Figure 12 A schematic diagram of the calculation of the additive envelope shear rolling load of the roller of the present application;

[0065] Figure 13 A schematic diagram of the roller to be repaired, the envelope roller and the deformation zone of the present application.

[0066] Main reference signs:

[0067] 1, additive manufacturing unit; 101, X-direction displacement assembly; 102, Y-direction displacement assembly; 103, Z-direction displacement assembly; 104, additive assembly; 2, temperature control unit; 3, envelope shear rolling unit; 301, arc-shaped frame; 302, slide rail; 303, envelope shear rolling assembly; 3031, position changing mechanism; 3032, deflection changing mechanism; 3033, rolling changing mechanism; 3034, rolling mechanism; 30341, envelope roller; 304, position limiter; 4, roller support frame; 5, online heat treatment unit; 501, heating module; 502, cooling module; 6, surface cleaning unit; 7, roller to be repaired; 8, rolling displacement unit; 9, arc-shaped frame exit unit. DETAILED DESCRIPTION

[0068] Hereinafter, embodiments of the present application will be described with reference to the accompanying drawings.

[0069] To solve the above-mentioned problems of the prior art, the present application aims to provide a large composite roller envelope shear rolling additive forming equipment and method.

[0070] Specifically, the present application provides a large composite roller envelope shear rolling additive forming equipment, such as Figures 1 to 13As shown, it comprises an additive manufacturing unit 1, a temperature control unit 2, an envelope shearing rolling unit 3, a roller support 4, an online heat treatment unit 5, a surface cleaning unit 6, a rolling displacement unit 8 and an arc-shaped support exit unit 9. The additive manufacturing unit 1 is arranged on the upper side of the roller to be repaired 7, the envelope shearing rolling unit 3 is arranged on the first side of the workbench, the temperature control unit 2 is arranged adjacent to the envelope shearing rolling unit 3, the online heat treatment unit 5 is arranged on the second side of the workbench, and the surface cleaning unit 6 is arranged adjacent to the online heat treatment unit 5. The temperature control unit 2 comprises an induction heating module and a first temperature measuring module; the online heat treatment unit 5 comprises a heating module, a cooling module and a second temperature measuring module. The additive manufacturing unit comprises an X-direction displacement assembly 101, a Y-direction displacement assembly 102, a Z-direction displacement assembly 103 and an additive assembly 104. The additive assembly 104 moves in the X-direction, Y-direction or Z-direction through the X-direction displacement assembly 101, Y-direction displacement assembly 102 or Z-direction displacement assembly 103 respectively. The envelope shearing rolling unit 3 comprises an arc-shaped support 301, a slide rail 302, a position limiter 304 and N envelope shearing rolling assemblies 303 distributed in the circumferential direction. The envelope shearing rolling assembly 303 is installed on the slide rail 302, guided by the rollers and fixed in position by the position limiter 304. The envelope shearing rolling assembly 303 comprises a rolling mechanism 3034, a deflection changing mechanism 3032, a rolling changing mechanism 3033 and a position changing mechanism 3031. The rolling mechanism 3034 is provided with an envelope roller 30341 and auxiliary structures such as a connecting plate, the deflection angle a between the envelope roller 30341 and the roller to be repaired 7 is adjusted by the deflection changing mechanism 3032, the rolling angle β between the envelope roller 30341 and the roller to be repaired 7 is adjusted by the rolling changing mechanism 3033, and the distance between the envelope roller 30341 and the roller to be repaired 7 is adjusted by the position changing mechanism 3031.

[0071] In the specific working process, the deflection angle a between the envelope roller 30341 and the roller to be repaired 7 is adjusted by the direct drive motor in the deflection changing mechanism 3032 to drive the lower rolling mechanism 3034 to rotate. The rolling angle β between the envelope roller 30341 and the roller to be repaired 7 is synchronously rotated by the two direct drive motors on the fixed plate to drive the lower roller to rotate and realize the rolling angle adjustment, and the distance between the envelope shearing roller and the roller to be repaired is adjusted by the servo motor driving the electric cylinder and positioning under the surrounding guide rod.

[0072] The envelope refers to the deformation profile of the metal gradually approaches the target shape during rolling, and the roll profile of each pass partially covers the final shape, and the final superposition forms the complete profile. Unlike traditional one-step forming, the envelope rolling reduces material stress concentration and improves forming accuracy through multiple passes and small deformation. In the present application, the clad metal is rolled through n passes, and the roll profile of each pass partially covers the target shape, and multiple passes are superimposed to form the complete profile.

[0073] The distance between the envelope roll of the N envelope shearing rolling assembly distributed in the circumferential direction and the repaired roll gradually decreases.

[0074]

[0075]

[0076] wherein, is the reduction of the clad metal in the nth pass; is the distance between the n-1th envelope roll and the repaired roll; is the distance between the ith envelope roll and the repaired roll; is the distance between the n th envelope roll and the repaired roll, i.e. the target thickness of the clad metal, is the thickness of the initial clad metal.

[0077] When the envelope roll and the repaired roll have a rolling angle, the distance between the ith envelope roll and the repaired roll is calculated by the formula:

[0078]

[0079] wherein, is the distance between the ith envelope roll and the repaired roll, and are the maximum distance and the minimum distance between the envelope roll and the repaired roll during rolling, respectively.

[0080] In a specific embodiment, the distance between the envelope rolls in the envelope shearing rolling assembly can be adjusted and arranged in a certain pattern. The distance between the N envelope rolls 30341 of the envelope shearing rolling assembly distributed in the circumferential direction can be adjusted and arranged at equal intervals or variable intervals. Generally, the roll diameter of the envelope roll 30341 gradually decreases. The circumferential angle γ between the ith and i+1th envelope rolls is adjusted by sliding the rollers of the envelope shearing rolling assembly on the slide rail 302, thereby adjusting the distance between adjacent envelope rolls. As shown in Figure 8 Fig. 1, γ1 is the circumferential angle between the 1st and 2nd envelope rolls, and γ2 is the circumferential angle between the 2nd and 3rd envelope rolls. n-1 ​​​The central angle between the n-1th and n th envelope roll.

[0081] In a specific embodiment, the distance between the envelope roll 30341 of the N envelope shear rolling assembly 303 distributed along the circumferential direction and the repaired roll 7 gradually decreases in turn.

[0082] In a specific embodiment, the additive manufacturing unit 1 comprises an X-direction displacement assembly 101, a Y-direction displacement assembly 102, a Z-direction displacement assembly 103, and an additive assembly 104; the temperature control unit 2 comprises an induction heating module and a first temperature measurement module; the online heat treatment unit 5 comprises a heating module 501, a cooling module 502, and a second temperature measurement module.

[0083] In a specific embodiment, the deflection angle between the envelope roll and the repaired roll is α, and |α|≤30°. The rolling angle between the envelope roll and the repaired roll is β, and |β|≤30°. The deflection angle and the rolling angle between the envelope roll and the repaired roll are determined according to the following formula respectively:

[0084] ;

[0085] ;

[0086] wherein is the contact line width of the envelope roll after deflection and the cladding metal; is the cladding metal width, i.e. the contact line width of the envelope roll and the cladding metal before deflection; is the length of the envelope roll; α is the deflection angle between the envelope roll and the repaired roll; β is the rolling angle between the envelope roll and the repaired roll.

[0087] In a specific embodiment, in the large roll additive envelope shear rolling process, the intervention position is closely related to the temperature distribution, and the forming limit load of the large roll additive rolling is determined according to the peak stress and the dynamic contact area. The theoretical calculation model of the rolling force is shown in the following formula:

[0088] ;

[0089] wherein F is the rolling force, in N, is the average unit pressure, in MPa; S is the contact area, in mm².

[0090] Average unit pressure The solving formula is:

[0091] ;

[0092] wherein and respectively, are the deformation resistances of the coating material at the material inlet and outlet, respectively, and the temperature T and strain rate Correspondingly, the Arrhenius constitutive equation can be used for calculation.

[0093] Contact arc length The solving formula is:

[0094] ;

[0095] Wherein, R is the radius of the roller to be repaired; r is the radius of the envelope roller; is the envelope thickness before shearing rolling, is the additive thickness after shearing rolling.

[0096] The solving formula of the contact area S is:

[0097] ;

[0098] Wherein, b is the single-pass additive width.

[0099] Micro-casting average strain rate is expressed as:

[0100] ;

[0101] Wherein, is the angular velocity of the micro-roller, in rad / s; is the angular velocity of the roller to be repaired, in rad / s.

[0102] In one specific embodiment, the outer surface of the intermediate configuration section of the envelope roller 30341 has a spatial configuration, and the curve of the spatial configuration is one or more of a smooth curve, a sine curve, a cosine curve, a circular arc, a triangular curve, a corrugated curve, or a spline curve.

[0103] In one specific embodiment, the rolling displacement unit 8 is arranged at the bottom of the arc-shaped frame, and the axial position adjustment of the envelope roller 30341 is realized by driving the arc-shaped frame to move horizontally on the slide rail through the lead screw in the rolling displacement unit 8. During the rolling process, the to-be-repaired roller can be rotated by the support of the roller frame and the driving of the power source; the axial position adjustment of the envelope roller is realized by driving the arc-shaped frame to move horizontally on the linear slide rail under the guide action of the slide block through the lead screw in the rolling displacement unit 8 at the bottom of the arc-shaped frame; the arc-shaped frame is withdrawn from the rolling area through the slide block and the linear slide rail in the arc-shaped frame withdrawal unit 9 so as to place the to-be-repaired roller and withdraw the roller after the repair is completed.

[0104] In another aspect, the present application provides a large composite roller envelope shearing rolling additive forming method, which is realized based on the large composite roller envelope shearing rolling additive forming equipment described above. The large composite roller envelope shearing rolling additive forming method will be described in detail below in combination with specific embodiments. In one specific embodiment, the method comprises the following steps:

[0105] S1, preparation before rolling: pull the arc-shaped frame out of the rolling area, move the to-be-repaired roller into the repair area, push the arc-shaped frame back to the rolling area, and fix the position of the arc-shaped frame with the guide rail clamp; adjust the position of the envelope shearing rolling assembly on the slide rail of the envelope shearing rolling unit and fix it with the limit stop; adjust the rolling displacement unit and the additive manufacturing unit so that they are located in the same repair plane.

[0106] S2, additive manufacturing: the cladding metal is melted into liquid metal droplets under the action of a heat source, and is cladded on the surface of the to-be-repaired roller.

[0107] S3, pre-rolling heating: the first temperature measuring module detects the temperature of the cladded metal in real time, and the induction heating module heats the cladded metal to a temperature T1.

[0108] S4, envelope rolling: adjust the deflection changing mechanism and the rolling changing mechanism in the envelope shearing rolling assembly so that the roller has different deflection angles and rolling angles, and realize envelope shearing rolling; adjust the distance between the envelope roller and the to-be-repaired roller through the position changing mechanism, and make the distance between the N envelope rollers and the to-be-repaired roller show a decreasing trend.

[0109] S5, online heat treatment: the second temperature measuring module monitors the metal temperature T2 after rolling in real time, if the temperature is lower than the target rolling temperature, the heating module heats up through induction heating; if the temperature is higher than the target rolling temperature, the cooling module cools down by spraying cooling medium through the nozzle.

[0110] S6, surface cleaning: in this embodiment, the high-energy-density laser beam is used to irradiate the workpiece surface weld slag to make it break off.

[0111] S7, continuous and stable near-net forming: repeat steps S1-S6, continue to cladding on the preset path, adjust the Z-direction displacement assembly, and keep the height between the welding gun and the cladded metal at a preset height. The welding gun needs to be raised every time a circle is repaired to keep the height between the welding gun and the cladded metal repair position at a preset height. The height of each layer of cladded metal in the radial direction during additive repair of the to-be-repaired roller is , and the height after repairing P circles is The distance between the envelope roller and the repaired roller after the P-ring is adjusted, the cladding position is changed by the additive movement unit on the gantry, and the envelope shearing roller position is changed by the transverse movement of the arc-shaped frame. There is a 30%-50% overlap rate between the adjacent cladding metals in the axial direction of the repaired roller. Each time the transverse movement covers 30%-50% of the original repair area.

[0112] S8, roller exit: after the roller repair is completed, the arc-shaped frame is pulled out by the guide rail clamp, and the repaired roller after the repair is moved out.

[0113] The above-described embodiments are only to describe the preferred embodiments of the present application, and are not to limit the scope of the present application. Without departing from the design spirit of the present application, various modifications and improvements to the technical solutions of the present application made by those skilled in the art shall fall within the protection scope determined by the claims of the present application.

Claims

1. A large-scale composite roll enveloping shear rolling additive manufacturing equipment, characterized by: It includes an additive manufacturing unit, a temperature control unit, an envelope shear rolling unit, an online heat treatment unit, a surface cleaning unit, a roller stand, a rolling displacement unit and an arc stand exit unit; the additive manufacturing unit is arranged on the upper side of the roll to be repaired, the envelope shear rolling unit is arranged on the first side of the workbench, the temperature control unit is arranged adjacent to the envelope shear rolling unit, the online heat treatment unit is arranged on the second side of the workbench, and the surface cleaning unit is arranged adjacent to the online heat treatment unit; the additive manufacturing unit includes an X-direction displacement component, a Y-direction displacement component, a Z-direction displacement component and an additive component; the additive component is respectively moved by the X-direction displacement component, the Y-direction displacement component or the Z-direction displacement component Movement in the X, Y or Z direction; the enveloping shear rolling unit includes an arc frame, a slide rail, a limiter and N enveloping shear rolling assemblies distributed along the circumferential direction; the enveloping shear rolling assembly is mounted on the slide rail, guided by rollers and fixed in position by the limiter; the enveloping shear rolling assembly includes a rolling mechanism, a deflection changing mechanism, a rolling changing mechanism and a position changing mechanism; the rolling mechanism is provided with an enveloping roller, the deflection angle α between the enveloping roller and the roller to be repaired is adjusted by the deflection changing mechanism; the rolling angle β between the enveloping roller and the roller to be repaired is adjusted by the rolling changing mechanism, and the distance between the enveloping roller and the roller to be repaired is adjusted by the position changing mechanism; The distances between the enveloping rolls of the N circumferentially distributed enveloping shear rolling assemblies and the rolls to be repaired are gradually reduced: ； ； in, is the metal reduction of the nth cladding layer; is the distance between the n-1th enveloping roll and the roll to be repaired; is the distance between the i-th enveloping roll and the roll to be repaired; is the distance between the nth enveloping roll and the roll to be repaired, i.e. the target thickness of the cladding metal, is the thickness of the initial cladding metal; The cladding metal is rolled in n passes, with the roll profile of each pass partially covering the target shape, and multiple passes are superimposed to form a complete profile.

2. The large-scale composite roll enveloping shearing rolling additive molding equipment according to claim 1 is characterized in that: The distances between the envelope rollers of the N envelope shear rolling assemblies distributed along the circumferential direction can be adjusted and arranged with equal spacing or variable spacing.

3. The large-scale composite roll enveloping shearing rolling additive molding equipment according to claim 2, characterized in that: The center angle γ between the i-th and i+1-th enveloping rollers is adjusted by sliding the rollers of the enveloping shear rolling assembly on the slide rails, thereby adjusting the distance between adjacent enveloping rollers.

4. The large-scale composite roll enveloping shearing rolling additive molding equipment according to claim 1, characterized in that: The temperature control unit includes an induction heating module and a first temperature measuring module; the online heat treatment unit includes a heating module, a cooling module and a second temperature measuring module.

5. The large-scale composite roll enveloping shearing and rolling additive manufacturing equipment according to claim 1, characterized in that: When there is a rolling angle between the enveloping roll and the roll to be repaired, the distance between the i-th enveloping roll and the roll to be repaired is The calculation formula is: ； in, is the distance between the i-th enveloping roll and the roll to be repaired, and They are the maximum and minimum distances between the enveloping roll and the roll to be repaired during rolling.

6. The large-scale composite roll enveloping shearing and rolling additive manufacturing equipment according to claim 5, characterized in that: The deflection angle between the enveloping roll and the roll to be repaired is α, |α|≤30°; the rolling angle between the enveloping roll and the roll to be repaired is β, |β|≤30°; the deflection angle and rolling angle between the enveloping roll and the roll to be repaired are determined according to the following formulas: ； ； in, is the contact line width between the envelope roller and the cladding metal after deflection; The width of the cladding metal is the width of the contact line between the two when the envelope roll is not deflected; is the length of the enveloping roll.

7. The large-scale composite roll enveloping shearing rolling additive molding equipment according to claim 1, characterized in that: The forming limit load of large-scale roller additive rolling is determined based on the peak stress and dynamic contact area. The theoretical calculation model of rolling force is shown in the following formula: ； Where, F is the rolling force, unit is N; is the average unit pressure, in MPa; S is the contact area, in mm²; Average unit pressure The solution formula is: ； in, and are respectively the deformation resistance of the cladding material at the material inlet and outlet, and the temperature T and strain rate Correlation, calculated using the Arrhenius constitutive equation; Contact arc length The solution formula is: ； Where R is the radius of the roll to be repaired; r is the radius of the envelope roll; is the thickness before envelope shear rolling, is the thickness of the material after envelope shear rolling; The formula for calculating the contact area S is: ； Wherein, b is the width of single-pass additive manufacturing; Average strain rate of micro casting and rolling Expressed as: ； in, is the angular velocity of the micro roller, in rad / s; is the angular velocity of the roller to be repaired, in rad / s.

8. The large-scale composite roll enveloping shearing rolling additive molding equipment according to claim 1, characterized in that: The outer surface of the middle profiled section of the envelope roll has a spatial profile.

9. The large-scale composite roll enveloping shearing and rolling additive manufacturing equipment according to claim 1, characterized in that: The rolling displacement unit is arranged at the bottom of the arc frame, and the arc frame is driven by the screw rod in the rolling displacement unit to move horizontally on the slide rail to achieve the axial position adjustment of the enveloping roller.

10. A large-scale composite roll enveloping shearing and rolling additive forming method, the method being implemented based on the large-scale composite roll enveloping shearing and rolling additive forming equipment according to any one of claims 1 to 9, characterized in that: The method comprises the following steps: S1. Preparation before rolling: Pull the arc frame out of the rolling area, move the roll to be repaired into the repair area, and then push the arc frame back into the rolling area and fix the position; adjust the position of the envelope shear rolling assembly through the slide rail on the envelope shear rolling unit and fix it with a limiter; adjust the rolling displacement unit and the additive manufacturing unit so that they are located on the same repair plane; S2, additive manufacturing: the cladding metal is melted into liquid metal droplets under the action of heat source and clad on the surface of the roller to be repaired; S3, pre-rolling heating: the first temperature measurement module detects the temperature of the cladding metal in real time, and the induction heating module heats the cladding metal to reach temperature T1; S4. Envelope rolling: Adjust the deflection change mechanism and rolling change mechanism in the envelope shear rolling assembly so that the envelope roll has different deflection angles and rolling angles to achieve envelope shear rolling; adjust the distance between the envelope roll and the roll to be repaired by the position change mechanism, and make the distance between the N envelope rolls and the roll to be repaired tend to decrease; S5, online heat treatment: The second temperature measurement module monitors the metal temperature T2 after rolling in real time. If the temperature is lower than the target rolling temperature, the heating module increases the temperature through induction heating; if the temperature is higher than the target rolling temperature, the cooling module sprays cooling medium through the nozzle to cool down; S6. Surface cleaning: Use laser beam to irradiate welding slag on the workpiece surface to break and fall off the welding slag; S7, continuous near-net forming: repeat steps S1-S6, continue cladding on the preset path, complete near-net forming, adjust the Z-direction displacement component during the cladding process to keep the preset height between the welding gun and the cladding metal, and when additively repairing the roller to be repaired, the height of each layer of cladding metal in the radial direction is , repair the height of P circle ; S8. Roller withdrawal: After the roll repair is completed, the curved frame is pulled out, and the roll to be repaired is moved out.

Images