CN102861840B - Three-roll cross rolling forming method for asymmetrical duel-step revolving body parts - Google Patents

Abstract

The invention relates to a three-roll cross rolling forming method for asymmetrical duel-step revolving body parts. The method comprises the following steps of: (1) determining the shape of a blank according to asymmetry degree of parts, and determining the volume distribution ratio according to metal flowing rules so as to determine the size of the blank; (2) according to three-roll cross rolling forming principle and equipment structure and size requirement of the blank and the parts, firstly designing the size and position on the working plane of a secondary roll, and then determining the size of a main roll; (3) according to three-roll cross rolling gripping conditions and roll size, blank size and part size, sequentially designing the rotating speed of the main roll, the feeding speed and rolling time of the main roll; and (4) rolling and forming the parts according to rolling parameters of the step (3). The three-roll cross rolling forming process parameters of the parts can be reasonably determined, the stable rolling forming of the parts can be ensured, the rate of the rolled waste and defective products can be decreased so as to realize low-consumption, high-efficient and high-quality forming manufacturing of mechanical parts such as a duplicate gear, a double-side supporting wheel body and a high-pressure valve body.

Description

A kind of asymmetric double step revolving parts three roller transverse rolling manufacturing process

Technical field

The present invention relates to a kind of asymmetric double step revolving parts three roller transverse rolling manufacturing process.

Background technology

Asymmetric double step revolving parts, as shown in Figure 1, its geometric properties forms a deep trouth for surperficial by length or highly asymmetric up/down steps, and center band aperture or not with holes, is typically applied as duplicate gear, double-side thrust wheel body etc. in engineering machinery.The surperficial deep trouth of this type of part is difficult to by forging direct Accurate Shaping, normally adopt at present open die forging or die forging to be simply shaped, be shaped by machining again, power consumption of polymer processing is high, stock utilization is low, a large amount of not only lost time and destructible part metallic fiber streamlines of machining, cause that production efficiency is low, cost is high, properties of product are poor.

Three roller transverse rollings are to utilize revolution plastic deformation and a kind of plastic working new technology of many steps revolving parts that is shaped, and its principle as shown in Figure 2.Three roll axis are arranged in parallel, and king roller 1 is done initiatively to rotatablely move and do straight-line feed motion simultaneously downwards; Left secondary roll 2, right secondary roll 3 are the fixing dummy roll in axle center, under part drives, do passive rotatablely moving; The part pass that three rollers form of nipping under the rotation of drive roll and radial feed effect, produces continuous rotation and local plastic deformation, and through too much changing shape accumulation, part section profile is full of rolling groove, completes roll forming.In three roller transverse rolling processes, part deformation district is part and the regional area that three rolls contact, and belongs to partial plastic forming, thereby resistance of deformation is little, and equipment needed thereby tonnage is little; In the operation of rolling, in the time that External Shape step profile is full of pass, distortion just finishes, and does not produce overlap, and forming accuracy is high; In addition part groove is shaped through plastic deformation, and its fibre flow and crystal grain distribute, and part performance is high.Therefore, adopt three roller cross rolling process many steps revolving parts that is shaped to there is significant technological and economical advantages.

But, three roller transverse rolling distortion are the complicated dynamic deformation process under a Multi-parameter coupling effect, and due to the geometry asymmetry of asymmetric double step revolving parts, make in the part operation of rolling metal flow and geometrical figuration rule very complicated, affect parameter numerous, need the design rolling technological parameter of Proper Match, effectively controlled rolling process metal flow and motion deformation, otherwise, in rolling, easily produce part and squeeze the defects such as flat, cross section is not fully filled.Owing to not grasping effective milling method, in actual production, often there is various rolling defect, rolling is useless, defect rate is high, causes such part still to be manufactured with traditional forging associating cutting working method at present.

Summary of the invention

The technical problem to be solved in the present invention is: for above-mentioned deficiency, a kind of asymmetric double step revolving parts three roller transverse rolling manufacturing process are provided, by appropriate design rolling technological parameter, realize stable formation of asymmetric double step revolving parts three roller transverse rolling, effectively reduce such part and manufacture the energy and material consumption, improved production efficiency and properties of product.

In order to solve the problems of the technologies described above, the technical solution adopted in the present invention is:

A kind of asymmetric double step revolving parts three roller transverse rolling manufacturing process, is characterized in that: adopt stable formation asymmetric double step revolving parts of three roller transverse rolling methods; Specifically comprise the steps: that (1) is according to accessory size and asymmetric degree, selected suitable blank shape, then determine capacity distribution ratio according to law of metal flow, and then definite blank dimension base; Described blank cross sectional shape is rectangle, frustum type or stepped ramp type; (2) according to three roller transverse rolling Forming Theories and device structure and blank, accessory size requirement, first design secondary rolling face size and position, then determine king roller size; (3) design successively roll forming parameter according to three roller transverse rolling bite conditions and dimension of roller, blank dimension, accessory size, described roll forming parameter comprises king roller rotating speed, king roller feed speed and rolling time; (4) by stable rolling of the roll forming parameter of step (3) described part that is shaped; When rolling, king roller is done initiatively to rotatablely move and do straight-line feed motion simultaneously downwards; Left secondary roll, right secondary roll are the fixing dummy roll in axle center, under blank drives, do passive rotatablely moving; The part pass that three rollers form of nipping under the rotation of drive roll and radial feed effect, produces continuous rotation and local plastic deformation, and through too much changing shape accumulation, blank cross section profile is full of rolling groove, completes roll forming; Step (1) is carried out in the following order:

1) the asymmetric degree K of calculating part _d

If R ₁, R ₂, R ₃, r is respectively part top bar radius, groove radius, get out of a predicament or an embarrassing situation radius and interior pore radius; For solid class part, r=0; B ₁, B ₂, B ₃be respectively part top bar height, groove height and get out of a predicament or an embarrassing situation height, part total height B=B ₁+ B ₂+ B ₃; V _lu, V _ldbe respectively part top bar volume and the volume of getting out of a predicament or an embarrassing situation;

Dissymmetryc coefficient asymmetric degree K _d=| K _l-1|;

Work as K _dwhen <0.1, adopt square-section blank;

As 0.1≤K _d≤ 0.3, adopt frustum type blank;

Work as K _dwhen >0.3, adopt stepped ramp type blank.

2) calculate blank volume V

For the narrow meshed part in center, after three roller transverse rolling distortion, endoporus there will be slight waist drum phenomenon, and therefore blank dimension will design than inner bore of part undersized, while calculating blank volume, inner bore of part size need be adjusted.Blanking inner hole radius r ₀get (0.9～1) r, part wall thickness is less, r ₀value less.For solid parts, there is not above-mentioned phenomenon, i.e. r ₀=r=0;

Therefore required blank volume V=π R ₁ ²b ₁+ π R ₂ ²b ₂+ π R ₃ ²b ₃-π r ₀ ²b;

Inner bore of part radius r is got to r ₀revise, with K _rrepresent the ratio of inner bore of part radius and groove radius,

Taking groove half At The Height as boundary, part is divided into upper and lower two parts, with V _u, V _dpart upper and lower part partial volume after representing respectively to revise, after revising, part upper and lower part volume ratio is:

$K_{\mathrm{ud}}=\frac{V_u}{V_d}=\frac{2B_1(R_1^2-r^2)+B_2(R_2^2-r^2)}{2B_3(R_3^2-r^2)+B_2(R_2^2-r^2)};$

The ratio of part the first half volume and cumulative volume after revising

The ratio K of blank the first half volume and cumulative volume _u'=kK _u, k gets 0.8～1, and asymmetric degree is larger, and correction factor k value is less;

3) determine blank dimension base

Blank height B ₀b equates with part height, B ₀=B=B ₁+ B ₂+ B ₃

1. for Single Size Rectangular Blanks

Blank outer radius $R_0=\sqrt{\frac{V}{\mathrm{\&pi;}{B}_0}+{r_0}^2}$

2. for frustum type blank

Angle between blank outer surface and gyroaxis

Wherein $a=\frac{1}{9}{B}^2+\frac{1}{9}{B_m}^2-\frac{1}{9}B{B}_m,b=\frac{V(B_m-{\mathrm{BK}}_{\mathrm{ud}})}{\mathrm{\&pi;}{B}_m(B-B_m)}-\frac{2V(B_m-{\mathrm{BK}}_{\mathrm{ud}})(B+B_m)}{3\mathrm{\&pi;}{\mathrm{BB}}_m(B-B_m)}-r^2-\frac{V}{\mathrm{\&pi;B}},$

$c=\frac{V^2{(B_m-B_0{K}_{\mathrm{ud}})}^2}{{\mathrm{\&pi;}}^2{B_0}^2{B_m}^2{(B_0-B_m)}^2},B_m=B_1+\frac{B_2}{2};$

Blank small end outer radius $R_0=\frac{V(B_m-{\mathrm{BK}}_{\mathrm{ud}})}{\mathrm{\&pi;}{\mathrm{BB}}_m(B-B_m)\tan \mathrm{\&theta;}}-\frac{1}{3}(B+B_m)\tan \mathrm{\&theta;}$

3. for stepped ramp type blank

Blank small end outer radius $R_0=\sqrt{\frac{{r_0}^2(2B_1+B_2)+\frac{2{\mathrm{VK}}_{\mathrm{ud}}}{\mathrm{\&pi;}}}{2B_1+B_2}}$

Shoulder height B _l=B ₃

Length of bench $L=\frac{-B_L{R}_0+\sqrt{{B_L}^2{R_0}^2-({R_0}^2{B}_0-{r_0}^2{B}_0-\frac{V}{\mathrm{\&pi;}})}}{B_L}.$

By technique scheme, step (2) dimension of roller is determined as follows:

1) determine secondary rolling face size and position

Secondary roll is arranged symmetrically with taking the home roll center of circle and blank circle center line connecting as axis, and when initial rolling, two secondary rolls are close to blank, for good support part, and guarantee rolling motion stabilization, the secondary roll center of circle and the line at blank center and the angle theta of axis ₀be designed to 45 °～60 °;

Two secondary Roller Design are the same, and secondary rolling face radius determines according to device space size conventionally, for prevent part from secondary roll shop building be extruded and two secondary rolling faces between mutually interfere, secondary roll boss radius R _c2meet following requirement:

$\frac{{R_0}^{\&prime;}\sin {\mathrm{\&theta;}}_0-R_2}{1-\sin {\mathrm{\&theta;}}_0}<R_{c2}<\frac{{R_0}^{\&prime;}\sin {\mathrm{\&theta;}}_0}{1-\sin {\mathrm{\&theta;}}_0}+R_3-R_2-L_{\mathrm{cd}}$

Wherein R ₀' be the initial contact radius of blank and roll, for square-section and stepped ramp type blank R ₀'=R ₀, for taper type cross section R ₀'=R ₀+ (B ₁+ B ₂) tan β;

Owing to adopting enclosed pass, secondary roll lower impressions width L _cdshould meet: R ₃-R ₂<L _cd<R ₃-r;

Can determine secondary roll upper impression width L by the physical dimension of part _cu=L _cd+ R ₁-R ₃,

R _c2after determining, can determine secondary roll upper impression radius surface R according to geometrical relationship _c1=R _c2-(R ₁-R ₂), secondary roll lower impressions radius surface R _c3=R _c2-(R ₃-R ₂);

In order to ensure the ring sectional dimension precision that is shaped, according to the ring height B of topping bar ₁, groove height B ₂with the height B of getting out of a predicament or an embarrassing situation ₃can determine secondary roll upper impression height B _c1, boss height B _c2, lower impressions height B _c3for

B _c1＝B ₁+(0.3～0.6mm)，B _c2＝B ₂，B _c3＝B ₃+(0.3～0.6mm)，

Secondary roll upper side wall height B _cu, lower wall height B _cddetermine according to the concrete installation dimension of equipment, consider intensity, its height can not be too small.

2) determine king roller working face size

For ensureing pass correspondence, can determine king roller upper side wall height B _mu=B _cu, king roller lower wall height B _md=B _cd, king roller upper impression height B _m1=B _c1, king roller boss height B _m2=B _c2, king roller lower impressions height B _m3=B _c3, king roller lower impressions width L _md=L _cd, king roller upper impression width L _mu=L _md+ R ₁-R ₃;

In order to prevent that king roller from contacting interference with secondary roll, king roller boss radius R _m2need to meet:

$R_{m2}<\frac{{R_2}^2-R_2{R}_{c2}-\frac{1}{2}{(L_{\mathrm{cd}}+L_{\mathrm{md}}+2R_2-2R_3)}^2-R_{c2}(L_{\mathrm{cd}}+L_{\mathrm{md}}-2R_3)+R_2\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2}{\mathrm{\&theta;}}_0}{R_{c2}+L_{\mathrm{cd}}+L_{\mathrm{md}}+R_2-2R_3-\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2{\mathrm{\&theta;}}_0}}$

According to above formula, bonding apparatus bulk and requirement of strength, can determine R _m2;

And then can determine king roller upper impression radius surface R according to geometrical relationship _m1=R _m2-(R ₁-R ₂), king roller lower impressions radius surface R _m3=R _m2-(R ₃-R ₂).

By technique scheme, step (3) is determined roll forming parameter according to following manner:

1) king roller rotation speed n _m

In order to ensure that the operation of rolling is stable, king roller linear velocity V _mget 1.1～1.3m/s; According to king roller working face radius R _m2, calculating king roller rotating speed is

2) king roller feed speed v

Produced continuous rolling distortion by rolling groove in order to ensure that blank can be nipped, king roller feed speed can not be excessive, designs according to following formula:

$v=(0.3~0.7)\frac{{\mathrm{\&mu;}}^2{n}_m{R_{m2}}^2{R}_{c2}{\cos }^2\mathrm{\&theta;}(2R_{c2}{\cos }^2\mathrm{\&theta;}({R_0}^{\&prime;}+R_{m2})+R_{m2}({R_0}^{\&prime;}+R_{c2}))}{60{R_0}^{\&prime;2}{(R_{c2}{\cos }^2\mathrm{\&theta;}+2R_{m2})}^2}$

In formula, μ is part and roll shop building coefficient of friction;

3) rolling time

Rolling time is made up of drive roll feeding time and rounding time two parts, and the operation of rolling adopts at the uniform velocity feeding, and rolling time T can be defined as T=T ₁+ T ₂;

The drive roll feeding time

Wherein h is rolling total feed amount

$h=({R_0}^{\&prime;}+R_{c2})\cos {\mathrm{\&theta;}}_0+{R_0}^{\&prime;}-R_2-\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2{\mathrm{\&theta;}}_0}$

The rounding time should at least ensure that part rotates one week, gets the rounding time

By technique scheme, in step (4), first roll is installed in rolling equipment, then the blank of handling well is put into rolling equipment, the roll forming parameter definite by step (3) is rolled into required part.

The asymmetric double step revolving parts three roller transverse rolling manufacturing process that the present invention proposes, can determine rational rolling blank, pass and forming parameter, avoid causing metal flow unreasonable distribution and the rolling defect that causes by part asymmetry, thereby realized the low consumption of asymmetric double step revolving parts, efficient, high-performance stable formation manufacture.

Brief description of the drawings:

Below in conjunction with accompanying drawing and each embodiment, the present invention is described in further detail:

Fig. 1 is asymmetric double step revolving parts schematic cross-section of the present invention;

Fig. 2 is the present invention three roller transverse rolling Forming Theory figure (front view);

Fig. 3 is the present invention's three roller transverse rolling schematic diagrams (side view, blank stage);

Fig. 4 is the present invention three roller transverse rolling Forming Theory figure (side view, part is shaped);

In Fig. 2-4, Reference numeral is corresponding as follows: 1-king roller, the left secondary roll of 2-, the right secondary roll of 3-, 4-part blank, 5-part;

Fig. 5 is square-section of the present invention blank schematic cross-section;

Fig. 6 is frustum type of the present invention cross section blank schematic cross-section;

Fig. 7 is stepped ramp type of the present invention cross section blank schematic cross-section;

Fig. 8 is the structural representation of king roller of the present invention;

Fig. 9 is the structural representation of the secondary roll of the present invention;

Figure 10 be rolling of the present invention initial with the finish time each roll and part position contrast schematic diagram (left part is divided into rolling initial time, and right part is divided into rolling finish time).

Detailed description of the invention

According to asymmetric double step revolving parts three roller transverse rolling manufacturing process of the invention process,, by appropriate design rolling technological parameter, realize asymmetric double step revolving parts three roller transverse rolling stable formations, specifically comprise following key step:

(1) determine blank shape and size

For asymmetric double step revolving parts, if the upper and lower step dimension difference of part is more greatly that asymmetry is remarkable, while adopting cylindrical shape blank rolling, metal may occur that one end is not fully filled and the phenomenon of other end metal accumulation in filling pass process, finally causes obtaining the part of required physical dimension.Therefore, first need to determine rational blank shape and size.

1) the asymmetric degree K of calculating part _d

As shown in Figure 1, establish R ₁, R ₂, R ₃, r is respectively the radius of topping bar, the groove radius of formation of parts, get out of a predicament or an embarrassing situation radius and interior pore radius (for solid class part, r=0), B ₁, B ₂, B ₃be respectively ring top bar height, groove height and get out of a predicament or an embarrassing situation height, part total height B=B ₁+ B ₂+ B ₃; V _lu, V _ldbeing respectively part tops bar and gets out of a predicament or an embarrassing situation volume.(wherein, in Fig. 1 the little person of step volume for topping bar).

Dissymmetryc coefficient asymmetric degree K _d=| K _l-1|, K _dlarger, asymmetry is more remarkable, is more difficult to be shaped.

Work as K _dwhen <0.1, adopt square-section blank; (as Fig. 5);

As 0.1≤K _d≤ 0.3, adopt frustum type blank; (as Fig. 6);

Work as K _dwhen >0.3, adopt stepped ramp type blank.(as Fig. 7).

2) calculate blank volume V

For the narrow meshed part in center, after three roller transverse rolling distortion, endoporus there will be slight waist drum phenomenon, and therefore blank dimension will design than inner bore of part undersized, while calculating blank volume, inner bore of part size need be adjusted.General blanking inner hole radius r ₀get (0.9～1) r, part wall thickness is less, r ₀value less; For solid parts, there is not above-mentioned phenomenon, i.e. r ₀=r=0.

Therefore required blank volume V=π R ₁ ²b ₁+ π R ₂ ²b ₂+ π R ₃ ²b ₃-π r ₀ ²b

Inner bore of part radius r is got to r ₀revise, with K _rrepresent the ratio of inner bore of part radius and groove radius,

Taking groove half At The Height as boundary, part is divided into upper and lower two parts, with V _u, V _dpart upper and lower part partial volume after representing respectively to revise, after revising, part upper and lower part volume ratio is

$K_{\mathrm{ud}}=\frac{V_u}{V_d}=\frac{2B_1(R_1^2-r^2)+B_2(R_2^2-r^2)}{2B_3(R_3^2-r^2)+B_2(R_2^2-r^2)}$

After correction, the ratio of part the first half volume and cumulative volume

The ratio K of blank the first half volume and cumulative volume _u'=kK _u, k generally gets 0.8～1, and asymmetric degree is larger, and correction factor k value is less.

3) determine blank dimension

Blank height B ₀b equates with part height, as shown in Figure 1, and B ₀=B=B ₁+ B ₂+ B ₃

1. for cylindrical shape blank, as shown in Figure 5:

Blank outer radius $R_0=\sqrt{\frac{V}{\mathrm{\&pi;}{B}_0}+{r_0}^2}$

2. for frustum type blank, as shown in Figure 6:

Angle between blank outer surface and gyroaxis

Wherein $a=\frac{1}{9}{B}^2+\frac{1}{9}{B_m}^2-\frac{1}{9}B{B}_m,b=\frac{V(B_m-{\mathrm{BK}}_{\mathrm{ud}})}{\mathrm{\&pi;}{B}_m(B-B_m)}-\frac{2V(B_m-{\mathrm{BK}}_{\mathrm{ud}})(B+B_m)}{3\mathrm{\&pi;}{\mathrm{BB}}_m(B-B_m)}-r^2-\frac{V}{\mathrm{\&pi;B}},$

$c=\frac{V^2{(B_m-B_0{K}_{\mathrm{ud}})}^2}{{\mathrm{\&pi;}}^2{B_0}^2{B_m}^2{(B_0-B_m)}^2},B_m=B_1+\frac{B_2}{2};$

Blank small end outer radius $R_0=\frac{V(B_m-{\mathrm{BK}}_{\mathrm{ud}})}{\mathrm{\&pi;}{\mathrm{BB}}_m(B-B_m)\tan \mathrm{\&theta;}}-\frac{1}{3}(B+B_m)\tan \mathrm{\&theta;};$

3. for stepped ramp type blank, as shown in Figure 7:

Blank small end outer radius $R_0=\sqrt{\frac{{r_0}^2(2B_1+B_2)+\frac{2{\mathrm{VK}}_{\mathrm{ud}}}{\mathrm{\&pi;}}}{2B_1+B_2}};$

Shoulder height B _l=B ₃;

Length of bench $L=\frac{-B_L{R}_0+\sqrt{{B_L}^2{R_0}^2-({R_0}^2{B}_0-{r_0}^2{B}_0-\frac{V}{\mathrm{\&pi;}})}}{B_L};$

(2) determine rolling groove structure and size processing roll

As Fig. 2-4,10 3 roller transverse rolling passes are made up of king roller 1 and two secondary rolls 2 and 3; For prevent blank 4 in the operation of rolling because axial metal flow produces sunken end face, rolling groove is all designed to enclosed pass; King roller 1 and two secondary rolls 2 and 3 working face die cavity corresponding with part section shape (as shown in Figure 4), dimension of roller design is as follows:

1) determine secondary rolling face size and position

Secondary roll is arranged symmetrically with taking the home roll center of circle and blank circle center line connecting as axis, and when initial rolling, two secondary rolls are close to blank 4, for good support part, and guarantee rolling motion stabilization, the secondary roll center of circle and the line at blank 4 centers and the angle theta of axis ₀can be designed to 45 °～60 ° (as Figure 10 left-half rolling zero hour);

Two secondary rolls 2 and 3 are designed to the same, and as shown in Figure 9, secondary rolling face radius determines according to device space size conventionally, for prevent part from secondary roll shop building be extruded and two secondary rolling faces between mutually interfere, secondary roll boss radius R _c2meet following requirement:

$\frac{{R_0}^{\&prime;}\sin {\mathrm{\&theta;}}_0-R_2}{1-\sin {\mathrm{\&theta;}}_0}<R_{c2}<\frac{{R_0}^{\&prime;}\sin {\mathrm{\&theta;}}_0}{1-\sin {\mathrm{\&theta;}}_0}+R_3-R_2-L_{\mathrm{cd}}$

Wherein R ₀' be the initial contact radius of blank and roll, for cylindrical in cross-section and stepped ramp type blank R ₀'=R ₀, for taper type cross section R ₀'=R ₀+ (B ₁+ B ₂) tan β; L _cdfor secondary roll lower impressions width;

Owing to adopting enclosed pass, secondary roll lower impressions width L _cdshould meet: R ₃-R ₂<L _cd<R ₃-r

Can determine secondary roll upper impression width L by the physical dimension of part _cu=L _cd+ R ₁-R ₃,

R _c2after determining, can determine secondary roll upper impression radius surface R according to geometrical relationship _c1=R _c2-(R ₁-R ₂), secondary roll lower impressions radius surface R _c3=R _c2-(R ₃-R ₂);

In order to ensure the annular part section dimensional accuracy that is shaped, according to the part height B of topping bar ₁, groove height B ₂with the height B of getting out of a predicament or an embarrassing situation ₃can determine secondary roll upper impression height B _c1, boss height B _c2, lower impressions height B _c3for

B _c1＝B ₁+(0.3～0.6mm)，B _c2＝B ₂，B _c3＝B ₃+(0.3～0.6mm)，

Secondary roll upper side wall height B _cu, lower wall height B _cdcan determine according to the concrete installation dimension of equipment, consider intensity, its height can not be too small.

2) determine king roller working face size

As shown in Figure 8, for ensureing pass correspondence, can determine king roller upper side wall height B _mu=B _cu, king roller lower wall height B _md=B _cd, king roller upper impression height B _m1=B _c1, king roller boss height B _m2=B _c2, king roller lower impressions height B _m3=B _c3, king roller lower impressions width L _md=L _cd, king roller upper impression width L _mu=L _md+ R ₁-R ₃

In order to prevent that king roller from contacting interference with secondary roll, king roller boss radius R _m2need to meet:

$R_{m2}<\frac{{R_2}^2-R_2{R}_{c2}-\frac{1}{2}{(L_{\mathrm{cd}}+L_{\mathrm{md}}+2R_2-2R_3)}^2-R_{c2}(L_{\mathrm{cd}}+L_{\mathrm{md}}-2R_3)+R_2\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2}{\mathrm{\&theta;}}_0}{R_{c2}+L_{\mathrm{cd}}+L_{\mathrm{md}}+R_2-2R_3-\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2{\mathrm{\&theta;}}_0}}$

According to above formula, bonding apparatus bulk and requirement of strength, can determine R _m2;

And then can determine king roller upper impression radius surface R according to geometrical relationship _m1=R _m2-(R ₁-R ₂), king roller lower impressions radius surface R _m3=R _m2-(R ₃-R ₂)

(3) determine roll forming parameter

Roll forming parameter comprises king roller rotating speed, king roller feed speed and rolling time, can determine by following:

1) king roller rotation speed n _m

In order to ensure that the operation of rolling is stable, king roller linear velocity V _mconventionally get 1.1～1.3m/s; According to king roller working face radius R _m2, can calculate king roller rotating speed and be

2) king roller feed speed v

Produced continuous rolling distortion by rolling groove in order to ensure that blank can be nipped, king roller feed speed conventionally can not be excessive, can design according to following formula:

$v=(0.3~0.7)\frac{{\mathrm{\&mu;}}^2{n}_m{R_{m2}}^2{R}_{c2}{\cos }^2\mathrm{\&theta;}(2R_{c2}{\cos }^2\mathrm{\&theta;}({R_0}^{\&prime;}+R_{m2})+R_{m2}({R_0}^{\&prime;}+R_{c2}))}{60{R_0}^{\&prime;2}{(R_{c2}{\cos }^2\mathrm{\&theta;}+2R_{m2})}^2}$

In formula, μ is part and roll shop building coefficient of friction;

3) rolling time

Rolling time is made up of drive roll feeding time and rounding time two parts, and the operation of rolling adopts at the uniform velocity feeding, and rolling time T can be defined as T=T ₁+ T ₂;

Wherein, the feeding time

H is rolling total feed amount,

$h=({R_0}^{\&prime;}+R_{c2})\cos {\mathrm{\&theta;}}_0+{R_0}^{\&prime;}-R_2-\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2{\mathrm{\&theta;}}_0}$

The rounding time should at least ensure that part rotates one week, generally gets

The rounding time $T_2=(1~4)\frac{2\mathrm{\&pi;}{R}_2}{V_m}$

(4) roll forming: roll is installed in rolling equipment, the blank of handling well is put into rolling equipment, be rolled into required part by the rolling forming parameter; King roller 1 is done initiatively to rotatablely move and do straight-line feed motion simultaneously downwards; Left secondary roll 2, right secondary roll 3 are the fixing dummy roll in axle center, under part drives, do passive rotatablely moving; The part pass that three rollers form of nipping under the rotation of drive roll and radial feed effect, produces continuous rotation and local plastic deformation, and through too much changing shape accumulation, part section profile is full of rolling groove, completes roll forming.

Taking duplicate gear shown in Fig. 1 as specific embodiment, this manufacturing process is described below:

Require the part of the roll forming radius R of topping bar ₁, groove radius R ₂, the radius R of getting out of a predicament or an embarrassing situation ₃be respectively 95mm, 80mm, 105mm and 25mm with inside radius r, the part height B of topping bar ₁, groove height B ₂with the height B of getting out of a predicament or an embarrassing situation ₃be respectively 15mm, 28mm, 13mm, its three rollers transverse rolling manufacturing process comprises following content:

(1) determine blank shape and size base

1) the asymmetric degree K of calculating part _d=0.345>0.3, therefore should adopt stepped ramp type blank, and its cross sectional shape as shown in Figure 7.

2) get blanking inner hole radius r ₀=0.92r=23mm, required blank volume V=1345468.74mm after revising ³, part the first half volume ratio K overall with part after revising _u'=0.959, get correction factor k=0.95, the ratio K of blank the first half volume and cumulative volume _u=0.465.

3) blank total height B ₀=B=56mm, blank small end outer radius R ₀=86.00mm, shoulder height B _l=B ₃=13mm, length of bench L=13.51mm.

By designed blank dimension, by bar section (concrete material be Q345 steel) from room temperature homogeneous heating to high-ductility, the heat distortion temperature (1150～1250 DEG C) of low resistance, then hot bar section is carried out forging and making rolling blank through forcing press;

(2) determine rolling groove structure and size processing roll

1) secondary rolling face size and position

As Figure 10, by the secondary roll center of circle and the line at blank center and the angle theta of axis ₀be designed to 60 °; According to secondary rolling face size design method, design secondary roll structure as shown in Figure 9, secondary roll boss face diameter R _c2, upper impression radius surface R _c1, lower impressions radius surface R _c3be respectively 100mm, 85mm, 75mm, upper and lower die cavity width L _cuand L _cdbe respectively 50mm and 60mm, upper impression height B _c1, boss height B _c2, lower impressions height B _c3, upper side wall height B _cu, lower wall height B _cdbe respectively 15.5mm, 28mm, 13.5mm, 20mm, 20mm.

2) king roller working face size

According to king roller working face size design method, design king roller structure as shown in Figure 8, king roller boss face diameter R _m2, upper impression radius surface R _m1, lower impressions radius surface R _m3be respectively 300mm, 285mm, 275mm, upper and lower die cavity width L _muand L _mdbe respectively 50mm and 60mm, upper impression height B _m1, boss height B _m2, lower impressions height B _m3, upper side wall height B _mu, lower wall height B _mdbe respectively 15.5mm, 28mm, 13.5mm, 20mm, 20mm.

(3) determine roll forming parameter

1) king roller rotation speed n _m

Home roll linear velocity V _mget 1.257m/s, determine king roller rotation speed n according to king roller Design of Rotation formula _mfor 40r/min.

2) king roller feed speed v

Determine that according to king roller Design of Rotation formula king roller feed speed is 1.5mm/s.

3) rolling time T

Rolling total feed amount h is 18.68mm, the feeding time

The rounding time $T_2=2.5\frac{2\mathrm{\&pi;}{R}_2}{V_m\&times;{10}^3}=1s$

Rolling time T can be defined as T=T ₁+ T ₂=13.45s.

(4) roll forming: roll is installed in rolling equipment, the ring blank processing is put into rolling equipment, be rolled into duplicate gear shown in Fig. 1 by the rolling parameter.

The part three roller transverse rolling roll forming techniques such as double-side thrust wheel body, smash valve body of other material and dimensions are identical with above-mentioned example, at this particularize embodiment not.

Claims (4)

1. asymmetric double step revolving parts three roller transverse rolling manufacturing process, is characterized in that: adopt stable formation asymmetric double step revolving parts of three roller transverse rolling methods; Specifically comprise the steps: that (1) is according to accessory size and asymmetric degree, selected suitable blank shape, then determine capacity distribution ratio according to law of metal flow, and then definite blank dimension base; Described blank cross sectional shape is rectangle, frustum type or stepped ramp type; (2) according to three roller transverse rolling Forming Theories and device structure and blank, accessory size requirement, first design secondary rolling face size and position, then determine king roller size; (3) design successively roll forming parameter according to three roller transverse rolling bite conditions and dimension of roller, blank dimension, accessory size, described roll forming parameter comprises king roller rotating speed, king roller feed speed and rolling time; (4) by stable rolling of the roll forming parameter of step (3) described part that is shaped; When rolling, king roller is done initiatively to rotatablely move and do straight-line feed motion simultaneously downwards; Left secondary roll, right secondary roll are the fixing dummy roll in axle center, under blank drives, do passive rotatablely moving; The part pass that three rollers form of nipping under the rotation of drive roll and radial feed effect, produces continuous rotation and local plastic deformation, and through too much changing shape accumulation, blank cross section profile is full of rolling groove, completes roll forming;

Step (1) is carried out in the following order:

1) the asymmetric degree K of calculating part _d

If R ₁, R ₂, R ₃, r is respectively part top bar radius, groove radius, get out of a predicament or an embarrassing situation radius and interior pore radius; For solid class part, r=0; B ₁, B ₂, B ₃be respectively part top bar height, groove height and get out of a predicament or an embarrassing situation height, part total height B=B ₁+ B ₂+ B ₃; V _lu, V _ldbe respectively part top bar volume and the volume of getting out of a predicament or an embarrassing situation;

Dissymmetryc coefficient asymmetric degree K _d=| K _l-1|;

Work as K _dwhen <0.1, adopt square-section blank;

As 0.1≤K _d≤ 0.3, adopt frustum type blank;

Work as K _dwhen >0.3, adopt stepped ramp type blank;

2) calculate blank volume V

For the narrow meshed part in center, after three roller transverse rolling distortion, endoporus there will be slight waist drum phenomenon, and therefore blank dimension will design than inner bore of part undersized, while calculating blank volume, inner bore of part size need be adjusted; Blanking inner hole radius r ₀get (0.9～1) r, part wall thickness is less, r ₀value less; For solid parts, there is not above-mentioned phenomenon, i.e. r ₀=r=0;

Therefore required blank volume V=π R ₁ ²b ₁+ π R ₂ ²b ₂+ π R ₃ ²b ₃-π r ₀ ²b;

Inner bore of part radius r is got to r ₀revise, with K _rrepresent the ratio of inner bore of part radius and groove radius,

Taking groove half At The Height as boundary, part is divided into upper and lower two parts, with V _u, V _dpart upper and lower part partial volume after representing respectively to revise, after revising, part upper and lower part volume ratio is:

$K_{\mathrm{ud}}=\frac{V_u}{V_d}=\frac{2B_1(R_1^2-r^2)+B_2(R_2^2-r^2)}{2B_3(R_3^2-r^2)+B_2(R_2^2-r^2)};$

The ratio of part the first half volume and cumulative volume after revising

The ratio K of blank the first half volume and cumulative volume _u'=kK _u, k gets 0.8～1, and asymmetric degree is larger, and correction factor k value is less;

3) determine blank dimension base

Blank height B ₀b equates with part height, B ₀=B=B ₁+ B ₂+ B ₃

1. for Single Size Rectangular Blanks

Blank outer radius $R_0=\sqrt{\frac{V}{\mathrm{\&pi;}{B}_0}+{r_0}^2}$

2. for frustum type blank

Angle between blank outer surface and gyroaxis

Wherein $a=\frac{1}{9}{B}^2+\frac{1}{9}{B_m}^2-\frac{1}{9}B{B}_m,b=\frac{V(B_m-{\mathrm{BK}}_{\mathrm{ud}})}{\mathrm{\&pi;}{B}_m(B-B_m)}-\frac{2V(B_m-{\mathrm{BK}}_{\mathrm{ud}})(B+B_m)}{3\mathrm{\&pi;}{\mathrm{BB}}_m(B-B_m)}-r^2-\frac{V}{\mathrm{\&pi;B}},$

$c=\frac{V^2{(B_m-B_0{K}_{\mathrm{ud}})}^2}{{\mathrm{\&pi;}}^2{B_0}^2{B_m}^2{(B_0-B_m)}^2},B_m=B_1+\frac{B_2}{2};$

Blank small end outer radius $R_0=\frac{V(B_m-{\mathrm{BK}}_{\mathrm{ud}})}{\mathrm{\&pi;}{\mathrm{BB}}_m(B-B_m)\tan \mathrm{\&theta;}}-\frac{1}{3}(B+B_m)\tan \mathrm{\&theta;}$

3. for stepped ramp type blank

Blank small end outer radius $R_0=\sqrt{\frac{{r_0}^2(2B_1+B_2)+\frac{2{\mathrm{VK}}_{\mathrm{ud}}}{\mathrm{\&pi;}}}{2B_1+B_2}}$

Shoulder height B _l=B ₃

Length of bench $L=\frac{-B_L{R}_0+\sqrt{{B_L}^2{R_0}^2-({R_0}^2{B}_0-{r_0}^2{B}_0-\frac{V}{\mathrm{\&pi;}})}}{B_L}.$

2. manufacturing process according to claim 1, is characterized in that: step (2) dimension of roller is determined as follows:

1) determine secondary rolling face size and position

Secondary roll is arranged symmetrically with taking the home roll center of circle and blank circle center line connecting as axis, and when initial rolling, two secondary rolls are close to blank, for good support part, and guarantee rolling motion stabilization, the secondary roll center of circle and the line at blank center and the angle theta of axis ₀be designed to 45 °～60 °;

Two secondary Roller Design are the same, and secondary rolling face radius determines according to device space size conventionally, for prevent part from secondary roll shop building be extruded and two secondary rolling faces between mutually interfere, secondary roll boss radius R _c2meet following requirement:

$\frac{{R_0}^{\&prime;}\sin {\mathrm{\&theta;}}_0-R_2}{1-\sin {\mathrm{\&theta;}}_0}<R_{c2}<\frac{{R_0}^{\&prime;}\sin {\mathrm{\&theta;}}_0}{1-\sin {\mathrm{\&theta;}}_0}+R_3-R_2-L_{\mathrm{cd}}$

Wherein R ₀' be the initial contact radius of blank and roll, for square-section and stepped ramp type blank R ₀'=R ₀, for taper type cross section R ₀'=R ₀+ (B ₁+ B ₂) tan β;

Owing to adopting enclosed pass, secondary roll lower impressions width L _cdshould meet: R ₃-R ₂<L _cd<R ₃-r;

Can determine secondary roll upper impression width L by the physical dimension of part _cu=L _cd+ R ₁-R ₃,

R _c2after determining, can determine secondary roll upper impression radius surface R according to geometrical relationship _c1=R _c2-(R ₁-R ₂), secondary roll lower impressions radius surface R _c3=R _c2-(R ₃-R ₂);

In order to ensure the ring sectional dimension precision that is shaped, according to the ring height B of topping bar ₁, groove height B ₂with the height B of getting out of a predicament or an embarrassing situation ₃can determine secondary roll upper impression height B _c1, boss height B _c2, lower impressions height B _c3for

B _c1＝B ₁+(0.3～0.6mm)，B _c2＝B ₂，B _c3＝B ₃+(0.3～0.6mm)，

Secondary roll upper side wall height B _cu, lower wall height B _cddetermine according to the concrete installation dimension of equipment, consider intensity, its height can not be too small;

2) determine king roller working face size

For ensureing pass correspondence, can determine king roller upper side wall height B _mu=B _cu, king roller lower wall height B _md=B _cd, king roller upper impression height B _m1=B _c1, king roller boss height B _m2=B _c2, king roller lower impressions height B _m3=B _c3, king roller lower impressions width L _md=L _cd, king roller upper impression width L _mu=L _md+ R ₁-R ₃;

In order to prevent that king roller from contacting interference with secondary roll, king roller boss radius R _m2need to meet:

$R_{m2}<\frac{{R_2}^2-R_2{R}_{c2}-\frac{1}{2}{(L_{\mathrm{cd}}+L_{\mathrm{md}}+2R_2-2R_3)}^2-R_{c2}(L_{\mathrm{cd}}+L_{\mathrm{md}}-2R_3)+R_2\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2}{\mathrm{\&theta;}}_0}{R_{c2}+L_{\mathrm{cd}}+L_{\mathrm{md}}+R_2-2R_3-\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2{\mathrm{\&theta;}}_0}}$

According to above formula, bonding apparatus bulk and requirement of strength, can determine R _m2;

And then can determine king roller upper impression radius surface R according to geometrical relationship _m1=R _m2-(R ₁-R ₂), king roller lower impressions radius surface R _m3=R _m2-(R ₃-R ₂).

3. manufacturing process according to claim 2, is characterized in that: step (3) is determined roll forming parameter according to following manner:

1) king roller rotation speed n _m

In order to ensure that the operation of rolling is stable, king roller linear velocity V _mget 1.1～1.3m/s; According to king roller working face radius R _m2, calculating king roller rotating speed is

2) king roller feed speed v

Produced continuous rolling distortion by rolling groove in order to ensure that blank can be nipped, king roller feed speed can not be excessive, designs according to following formula:

$v=(0.3~0.7)\frac{{\mathrm{\&mu;}}^2{n}_m{R_{m2}}^2{R}_{c2}{\cos }^2\mathrm{\&theta;}(2R_{c2}{\cos }^2\mathrm{\&theta;}({R_0}^{\&prime;}+R_{m2})+R_{m2}({R_0}^{\&prime;}+R_{c2}))}{60{R_0}^{\&prime;2}{(R_{c2}{\cos }^2\mathrm{\&theta;}+2R_{m2})}^2}$

In formula, μ is part and roll shop building coefficient of friction;

3) rolling time

Rolling time is made up of drive roll feeding time and rounding time two parts, and the operation of rolling adopts at the uniform velocity feeding, and rolling time T can be defined as T=T ₁+ T ₂;

The drive roll feeding time

Wherein h is rolling total feed amount

$h=({R_0}^{\&prime;}+R_{c2})\cos {\mathrm{\&theta;}}_0+{R_0}^{\&prime;}-R_2-\sqrt{{(R_2+R_{c2})}^2-{({R_0}^{\&prime;}+R_{c2})}^2{\sin }^2{\mathrm{\&theta;}}_0}$

The rounding time should at least ensure that part rotates one week, gets the rounding time

4. according to the manufacturing process described in claim 1 or 2 or 3, it is characterized in that: in step (4), first roll is installed in rolling equipment, then the blank of handling well is put into rolling equipment, the roll forming parameter definite by step (3) is rolled into required part.