Preparation method of wind power spline housing forge piece blank
By using die forging and vertical ring rolling forming processes, combined with tempered steel and precise heat treatment, the problems of high raw material consumption and high cost in spline sleeve forging manufacturing have been solved, achieving efficient and low-cost preparation of spline sleeve forging blanks and improving the mechanical properties of forgings.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHANDONG IRAETA HEAVY IND
- Filing Date
- 2025-12-31
- Publication Date
- 2026-04-17
AI Technical Summary
Existing methods for manufacturing spline sleeve forgings suffer from high raw material consumption, high costs, and low efficiency, especially when manufacturing irregularly shaped blanks.
The process of preparing spline sleeve forging blanks is optimized by adopting a process of die forging and vertical ring rolling forming, combined with tempered steel and precise heat treatment steps, including multiple deformation, die preheating, vertical ring rolling forming, pre-heat treatment and performance heat treatment.
It significantly reduces raw material consumption and production costs, improves the mechanical properties of spline sleeve forgings, and enhances the internal quality of forgings by conformal rolling of fiber flow.
Smart Images
Figure CN121869985A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of wind turbine gearbox component manufacturing technology, specifically relating to a method for preparing a forged blank of a spline sleeve for wind power. Background Technology
[0002] Spline sleeve forgings are core components for mechanical transmission, manufactured through forging processes. They are a key part of "spline connections" and are widely used in wind power, automobiles, machine tools, and construction machinery. Their core function is to achieve precise connection and power transmission between two components through the "spline structure," combining high strength, high centering accuracy, and high transmission efficiency.
[0003] Existing methods for manufacturing spline sleeve forgings generally employ rectangular ring rolling. However, rectangular ring rolling has drawbacks such as high material consumption, high cost, and low efficiency.
[0004] Its main defects are as follows: 1. Due to the relatively complex shape of spline sleeves for wind power, the existing rectangular rolling process consumes a lot of raw materials. 2. Due to the complex shape of the spline sleeve for wind power, and the high performance requirements of customers, an additional normalizing treatment is needed to ensure the final performance heat treatment. Therefore, the energy consumption required for subsequent heat treatment of the rectangular rolled ring, as well as the processing time and tool consumption, will also increase accordingly, resulting in a significant increase in production costs.
[0005] Patent CN114289675A discloses a manufacturing method for a gear ring forging for a wind turbine gearbox, which adopts a forging mode of ordinary free forging + ordinary rolling ring. However, the above method has the following problems: (1) the raw material consumption is high after the mold is produced; (2) the above method can only manufacture rectangular products, while the cost is relatively high and the consumption of raw materials and energy is large when manufacturing irregular blanks.
[0006] Therefore, it is necessary to develop a new process for preparing spline sleeve forging blanks for wind power applications and optimize the existing spline sleeve forging manufacturing process to avoid the aforementioned defects. Summary of the Invention
[0007] To address the technical problems of high raw material consumption and high cost in the existing preparation of irregular spline sleeve forging blanks, this invention provides a method for preparing spline sleeve forging blanks for wind power applications, thereby solving the above problems.
[0008] The technical solution of this invention is as follows: A method for preparing a forged blank of a spline sleeve for wind power includes the following steps: (1) The raw material is sawn and cut into blanks to obtain billets; (2) Heating and holding the billet at the desired temperature; (3) The heated billet is subjected to multiple material changes and die forging is performed to obtain a forged billet; (4) The forging billet is returned to the furnace for reheating and heat preservation. After exiting the furnace, the forging billet is rolled into a ring shape using a vertical rolling die to obtain a forging billet for a spline sleeve for wind power. (5) Perform preliminary heat treatment on the spline sleeve forging blank; (6) After preheating the spline sleeve forging blank, the forging blank is preliminarily machined by lathe. (7) Perform performance heat treatment on the spline sleeve forging blank.
[0009] Furthermore, in step (1), the raw material is quenched and tempered steel, which comprises the following components by weight percentage: C: 0.38~0.45%, Si: 0.17~0.35%, Mn: 0.60~0.90%, P≤0.015%, S≤0.010%, Cr: 0.90~1.20%, Mo: 0.15~0.30%, Cu≤0.20%.
[0010] Furthermore, the quenched and tempered steel is 42CrMo4.
[0011] Furthermore, the heating temperature in step (2) is 1230±20℃, and the holding time is determined based on the diameter of the billet, wherein the holding time is 2.0mm / min~3.0mm / min. A heating furnace is used for heating and holding.
[0012] Furthermore, the heating temperature in step (4) is 1230℃±30℃, and the heat preservation time is 1 / 3 to 1 / 2 of the heat preservation time in step (2).
[0013] Furthermore, the mold mentioned in step (3) is an upper and lower bowl-shaped mold, which ensures that the blank is deformed to the required size during the forming process; The preparation steps of the forging blank in step (3) are as follows: (3.1) Preheat the upper and lower molds to 300℃±5℃; (3.2) After heating, the billet is removed from the furnace and changed multiple times until the size of the billet meets the requirements for mold entry; (3.3) Place the billet after the material change into the upper and lower molds for upsetting. When the upsetting reaches the predetermined height, demold. (3.4) After demolding, the precast blank is rolled into a round shape; (3.5) Put it into the mold again to ensure that all parts of the blank are formed; (3.6) After demolding, punch holes in the precast blank.
[0014] Furthermore, in step (4), the die ring rolling forming includes the following steps: (4.1) Assemble the vertical ring rolling die on the vertical ring rolling machine, and preheat the vertical ring rolling die to 300℃±5℃; (4.2) Place the reheated forging billet on a vertical ring rolling mill; (4.3) The forging billet is rolled into a ring using the vertical rolling die.
[0015] Furthermore, step (5) of the preparatory heat treatment of the spline sleeve forging blank includes the following steps: (5.1) The forged blank of the spline sleeve for wind power after being formed by ring rolling with a mold is loaded into a heat treatment furnace; (5.2) The forging blank of the spline sleeve for wind power is heated to 900℃~930℃ at a heating rate of ≤120℃ / h, and the holding time is determined based on the wall thickness of the forging blank of the spline sleeve for wind power and the holding time is 30mm / h~50mm / h. (5.3) Take the heat-insulated spline sleeve forging blank out of the furnace, air cool it, and when the surface temperature drops to 350℃±5℃, put it back into the furnace; (5.4) The forged blank of the spline sleeve for wind power is heated to 690℃~720℃ at a heating rate of ≤80℃ / h, and the holding time is determined based on the wall thickness of the forged blank of the spline sleeve for wind power and the holding time is 30mm / h~50mm / h. (5.5) The heat-insulated spline sleeve forging blank for wind power is taken out of the furnace and air-cooled.
[0016] Furthermore, step (7) of the performance heat treatment of the spline sleeve forging blank includes the following steps: (7.1) The forging blank for wind power spline sleeve after normalizing is preliminarily machined by lathe and then loaded into heat treatment furnace; (7.2) The wind power spline sleeve forging blank is heated to 600℃~650℃ at a heating rate of ≤120℃ / h and then heated to 860℃~880℃ at a heating rate of ≤120℃ / h and held at that temperature. The holding time is determined based on the wall thickness of the wind power spline sleeve forging blank and the holding time is 30mm / h~50mm / h. (7.3) After the heat preservation, the forged blank of the spline sleeve for wind power is taken out of the furnace and water-cooled. When the surface temperature drops to 230℃±10℃, it is returned to the furnace. (7.4) The forging blank of the spline sleeve for wind power is heated to 350°C at a heating rate of ≤80°C / h, and the holding time is determined based on the wall thickness of the forging blank of the spline sleeve for wind power and the holding time is 30mm / h~50mm / h. (7.5) Take the heat-insulated spline sleeve forging blank out of the furnace and air cool it.
[0017] Furthermore, after obtaining the blank of the spline sleeve forging for wind power, further processing can be carried out to obtain the spline sleeve forging for wind power, including the following steps: (A) The forged spline sleeve for wind power is subjected to quenching and tempering and then rough machining. The surface roughness of the forged spline sleeve for wind power after quenching and tempering is ≤ Ra6.3μm. (B) Perform ultrasonic testing on the wind power spline sleeve forgings after quenching and tempering and rough machining; (C) Perform precision machining on the spline sleeve forgings for wind power that have passed ultrasonic testing.
[0018] (D) Inspect and test the finished forgings to ensure they meet the technical requirements.
[0019] The beneficial effects of this invention are as follows: (1) The method for preparing the forging blank of the spline sleeve for wind power provided by the present invention adopts die forging blank and vertical rolling die ring rolling to make the forging blank of the spline sleeve for wind power, which can make the forging blank of the spline sleeve for wind power conform to the shape and greatly reduce the overall consumption of raw materials.
[0020] (2) The method for preparing the forging blank of spline sleeve for wind power provided by the present invention reduces the consumption of raw materials, and at the same time reduces the radial and axial rolling forces of the hydraulic press, loading and unloading machine and the ring rolling machine required for blank preparation, thereby greatly reducing the production cost.
[0021] (3) The method for preparing the spline sleeve forging blank for wind power provided by the present invention produces a spline sleeve forging with a smaller cross section and lighter weight through the die ring rolling forming process. The energy consumption is lower during subsequent heat treatment, and the consumption of tools and time during processing is also reduced.
[0022] (4) The method for preparing the spline sleeve forging blank for wind power provided by the present invention, the spline sleeve forging for wind power produced by the die ring rolling forming process, the internal forging fiber is a conformal rolling fiber flow direction, which can effectively improve the mechanical properties of the spline sleeve forging for wind power. Attached Figure Description
[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0024] Figure 1 This is a schematic diagram of the structure of a forging die used in step (3) of the present invention.
[0025] Figure 2 This is a forging schematic diagram of the forging blank of the spline sleeve for wind power according to the present invention.
[0026] In the figure, 1-ring base plate one; 2-ring partition plate; 3-ring base plate two; 4-forging blank; 5-core roller; 6-upper mold; 7-lower mold; 8-blank. Detailed Implementation
[0027] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this invention.
[0028] Example 1 A method for preparing a forged blank of a spline sleeve for wind power includes the following steps: (1) Based on the calculated weight of 600kg and the specifications of φ600mm circle and 270mm length, the 42CrMo4 quenched and tempered steel is sawn to obtain the billet; the 42CrMo4 quenched and tempered steel includes the following components by weight percentage: C: 0.42%; Si: 0.25%; Mn: 0.69%; P: 0.014%; S: 0.001%; Ni: 0.11%; Cr: 1.13%; Mo: 0.16%; Cu: 0.023%.
[0029] (2) Heat the billet to a preset temperature (1230℃) and keep it at 1230℃ for 3 hours; (3) The heated billet undergoes four upsetting and drawing processes, and adopts the following methods: Figure 1 The mold shown is used for die forging to produce a forged billet; the details are as follows: (3.1) Preheat the upper mold 6 and the lower mold 7 to 300℃±5℃; (3.2) After heating, the billet is removed from the furnace and changed multiple times until the size of the billet meets the requirements for mold entry; (3.3) Place the billet after the material change into the upper mold 6 and the lower mold 7 for upsetting. When the upsetting reaches the predetermined height, demold. (3.4) After demolding, the precast blank is rolled into a round shape; (3.5) Put it into the mold again to ensure that all parts of the blank are formed; (3.6) After demolding, punch holes in the precast blank.
[0030] (4) The forging billet is reheated in the furnace at a preset temperature (1230℃) and held for 3 hours. After exiting the furnace, the forging billet is rolled into a ring using a vertical rolling die to obtain a forging blank for a spline sleeve for wind power. The vertical rolling die is as follows: Figure 2 As shown, the vertical ring rolling mold consists of an annular base plate 1, an annular partition plate 2, and an annular base plate 3 arranged sequentially. The vertical ring rolling mold is assembled on a vertical ring rolling machine, and the space enclosed by the core roller 5 of the vertical ring rolling machine and the vertical ring rolling mold matches the dimensions of the spline sleeve for wind power applications. Annular base plate 1, annular partition plate 2, and annular base plate 3 are all individually formed and then fixedly connected and assembled after forming. The specific method is as follows: (4.1) Assemble a vertical ring rolling die on the vertical ring rolling machine and preheat the vertical ring rolling die to 300°C; (4.2) Remove the reheated forging billet from the furnace and place it on a vertical ring rolling mill; (4.3) The forging billet is rolled into a ring using a vertical rolling die.
[0031] (5) Perform preliminary heat treatment on the forged spline sleeve blank for wind power, and the specific method is as follows: (5.1) The forged blank of the spline sleeve for wind power after being formed by ring rolling with a mold is loaded into a heat treatment furnace; (5.2) The forging blank of the spline sleeve for wind power is heated to 900℃~930℃ at a heating rate of ≤120℃ / h, and the holding time is determined based on the wall thickness of the forging blank of the spline sleeve for wind power and the holding time is 40mm / h. (5.3) Take the heat-insulated spline sleeve forging blank out of the furnace, air cool it, and when the surface temperature drops to 350℃±5℃, put it back into the furnace; (5.4) The wind power spline sleeve forging blank is heated to 690℃~720℃ at a heating rate of ≤80℃ / h, and the holding time is determined based on the wall thickness of the wind power spline sleeve forging blank and the holding time is 40mm / h. (5.5) The heat-insulated spline sleeve forging blank for wind power is taken out of the furnace and air-cooled.
[0032] (6) After normalizing the forging blank of the spline sleeve for wind power, the forging blank is initially machined by lathe. (7) The performance heat treatment of the spline sleeve forging blank for wind power is carried out. The specific steps are as follows: (7.1) The forged blank of the spline sleeve for wind power after normalizing and rough machining is loaded into the heat treatment furnace; (7.2) The wind power spline sleeve forging blank is heated to 600℃~650℃ for 1 hour at a heating rate of ≤120℃ / h, and then heated to 860℃~880℃ at a heating rate of ≤120℃ / h and held at that temperature. The holding time is determined based on the wall thickness of the wind power spline sleeve forging blank and the holding time is 40mm / h. (7.3) After the heat preservation, the forged blank of the spline sleeve for wind power is taken out of the furnace and water-cooled. When the surface temperature drops to 230℃±10℃, it is returned to the furnace. (7.4) The forged blank of the spline sleeve for wind power is heated to 350°C at a heating rate of ≤80°C / h, and the holding time is determined based on the wall thickness of the forged blank of the spline sleeve for wind power and the holding time is 40mm / h. (7.5) Take the heat-insulated spline sleeve forging blank out of the furnace and air cool it.
[0033] After weighing, the weight difference between the blank obtained in step (3) and the forged wind power spline sleeve blank obtained in step (5) is 300 kg. In the past, to meet the performance requirements, rectangular blanks required a series of processing steps such as rough turning before tempering, which resulted in significant electricity costs and tool wear. This invention saves on these operations.
[0034] Example 2 The method for preparing spline sleeve forgings using the wind power spline sleeve forging blank prepared in Example 1 includes the following specific steps: (1) The forged spline sleeve for wind power is subjected to quenching and tempering and then rough machining. The surface roughness of the forged spline sleeve for wind power after quenching and tempering is ≤ Ra6.3μm. (2) Ultrasonic testing was performed on the wind power spline sleeve forgings after quenching and tempering and rough machining; (3) Perform precision machining on the spline sleeve forgings for wind power that have passed ultrasonic testing; (4) The finished forgings are inspected and tested to ensure that they meet the technical requirements.
[0035] Although the present invention has been described in detail with reference to the accompanying drawings and preferred embodiments, the present invention is not limited thereto. Various equivalent modifications or substitutions can be made to the embodiments of the present invention by those skilled in the art without departing from the spirit and essence of the invention, and such modifications or substitutions should all be within the scope of the present invention. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should also be covered within the protection scope of the present invention.
Claims
1. A method for preparing a forged blank of a spline sleeve for wind power, characterized in that, Includes the following steps: (1) The raw material is sawn and cut into blanks to obtain billets; (2) Heating and holding the billet at the desired temperature; (3) The heated billet is subjected to multiple material changes and die forging is performed to obtain a forged billet; (4) The forging billet is returned to the furnace for reheating and heat preservation. After exiting the furnace, the forging billet is rolled into a ring shape using a vertical rolling die to obtain a forging billet for a spline sleeve for wind power. (5) Perform preliminary heat treatment on the forged blank of spline sleeve for wind power; (6) After the forging blank of the spline sleeve for wind power is preheated, the forging blank is preliminarily cut by lathe. (7) Perform performance heat treatment on the spline sleeve forging blank.
2. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, In step (1), the raw material is quenched and tempered steel, which comprises the following components by weight percentage: C: 0.38~0.45%, Si: 0.17~0.35%, Mn: 0.60~0.90%, P≤0.015%, S≤0.010%, Cr: 0.90~1.20%, Mo: 0.15~0.30%, Cu≤0.20%.
3. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 2, characterized in that, The quenched and tempered steel used is 42CrMo4.
4. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, The heating temperature in step (2) is 1230±20℃, and the holding time is determined based on the diameter of the billet, which is 2.0mm / min~3.0mm / min.
5. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, The heating temperature in step (4) is 1230℃±30℃, and the heat preservation time is 1 / 3 to 1 / 2 of the heat preservation time in step (2).
6. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, The mold mentioned in step (3) is a double-bowl mold, which ensures that the blank is deformed to the required size during the forming process; The preparation steps of the forging blank in step (3) are as follows: (3.1) Preheat the upper and lower molds to 300℃±5℃; (3.2) After heating, the billet is removed from the furnace and changed multiple times until the size of the billet meets the requirements for mold entry; (3.3) Place the billet after the material change into the upper and lower molds for upsetting. When the upsetting reaches the predetermined height, demold. (3.4) After demolding, the precast blank is rolled into a round shape; (3.5) Put it into the mold again to ensure that all parts of the blank are formed; (3.6) After demolding, punch holes in the precast blank.
7. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, In step (4), the die ring rolling forming includes the following steps: (4.1) Assemble the vertical ring rolling die on the vertical ring rolling machine, and preheat the vertical ring rolling die to 300℃±5℃; (4.2) Place the reheated forging billet on a vertical ring rolling mill; (4.3) The forging billet is rolled into a ring using the vertical rolling die.
8. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, Step (5) The preparatory heat treatment of the spline sleeve forging blank includes the following steps: (5.1) The forged blank of the spline sleeve for wind power after being formed by ring rolling with a mold is loaded into a heat treatment furnace; (5.2) The forging blank of the spline sleeve for wind power is heated to 900℃~930℃ at a heating rate of ≤120℃ / h, and the holding time is determined based on the wall thickness of the forging blank of the spline sleeve for wind power and the holding time is 30mm / h~50mm / h. (5.3) Take the heat-insulated spline sleeve forging for wind power out of the furnace, air cool it, and when the surface temperature drops to 350℃±5℃, put it back into the furnace; (5.4) The spline sleeve forging for wind power is heated to 690℃~720℃ at a heating rate of ≤80℃ / h, and the holding time is determined based on the wall thickness of the forging blank for wind power and the holding time is 30mm / h~50mm / h. (5.5) The heat-insulated spline sleeve forging blank for wind power is taken out of the furnace and air-cooled.
9. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, Step (7) The performance heat treatment of the spline sleeve forging blank includes the following steps: (7.1) The forging blank for wind power spline sleeve after normalizing is preliminarily machined by lathe and then loaded into heat treatment furnace; (7.2) The wind power spline sleeve forging blank is heated to 600℃~650℃ at a heating rate of ≤120℃ / h and then heated to 860℃~880℃ at a heating rate of ≤120℃ / h and held at that temperature. The holding time is determined based on the wall thickness of the wind power spline sleeve forging blank and the holding time is 30mm / h~50mm / h. (7.3) After the heat preservation, the forged blank of the spline sleeve for wind power is taken out of the furnace and water-cooled. When the surface temperature drops to 230℃±10℃, it is returned to the furnace. (7.4) The forging blank of the spline sleeve for wind power is heated to 350°C at a heating rate of ≤80°C / h, and the holding time is determined based on the wall thickness of the forging blank of the spline sleeve for wind power and the holding time is 30mm / h~50mm / h. (7.5) Take the heat-insulated spline sleeve forging blank out of the furnace and air cool it.
10. The method for preparing a forged blank of a spline sleeve for wind power as described in claim 1, characterized in that, After obtaining the blank of the spline sleeve forging for wind power, further processing can be carried out to obtain the spline sleeve forging for wind power, including the following steps: (A) The forged spline sleeve for wind power is subjected to quenching and tempering and then rough machining. The surface roughness of the forged spline sleeve for wind power after quenching and tempering is ≤ Ra6.3μm. (B) Perform ultrasonic testing on the wind power spline sleeve forgings after quenching and tempering and rough machining; (C) Perform precision machining on the spline sleeve forgings for wind power that have passed ultrasonic testing; (D) Inspect and test the finished forgings to ensure they meet the technical requirements.