CN104313299B - Large gear ring heat treatment deformation multiple spot stress compensation device and equalising means thereof - Google Patents
Large gear ring heat treatment deformation multiple spot stress compensation device and equalising means thereof Download PDFInfo
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Abstract
The invention discloses a kind of large gear ring heat treatment deformation multiple spot stress compensation device and equalising means thereof, this supplementary device comprises base, interior hydro-cylinder, outer hydro-cylinder, internal stress compensation block and external stress compensation block, described base comprises two disks be set up in parallel up and down, interior hydraulic cylinder is fixedly connected with top disk, and its piston rod is connected with internal stress compensation block; Described outer hydro-cylinder is fixedly connected with below disk, and its piston rod is connected with external stress compensation block; Its equalising means, comprises the steps: that (1) sets up large gear ring model, and it is discrete to carry out finite element model; (2) carry out limitting unit's emulation; (3) carry out the Contrary compensation of stress, then emulate; (4) deflection step (3) obtained and large gear ring model contrast; (5) multiple spot stress compensation device is exported to by finally compensating stress.The present invention can effectively prevent large gear ring to be out of shape in heat treatment process, thus improves the production qualification rate of large gear ring.
Description
Technical field
The present invention relates to a kind of heat treatment deformation compensation technique, particularly relate to a kind of based on the distortion in finite element simulation prediction thermal treatment and the stress that causes, there is provided a kind of large gear ring heat treatment deformation multiple spot adjustable stress compensation device, and the method utilizing this device to compensate.
Background technology
Based on large gear ring, the gearbox drive of parts has in fields such as navigation, mining industry, new forms of energy the effect that can not be substituted.Along with naval vessel, wind-power electricity generation, heavy construction equipment field fast development, need large gear ring improve intensity, transmission accuracy, efficiency, meet heavy duty, at a high speed, the long lifetime, high reliability demand.Due to features such as large gear ring diameter are comparatively large, thin-walled, section structure shape are more complicated, the distortion in processing causes precise decreasing and even problems of crack to be not only the technical quality problems that manufacturer pays special attention to always.The distortion of large gear ring is directly connected to the control of the important quality index such as the strength of gear teeth, precision.
For the gear ring of carburizing and quenching, particularly large gear ring, its deflection is very large and be difficult to strict control, brings serious impact to the following process of large gear ring and use.Larger distortion not only makes stock removal increase, and causes processing and manufacturing cost to improve.More seriously, and uneven due to what be out of shape, in grinding process, occur that the surplus of grinding is different, the cementation zone on one side larger for stock removal is easy to all to grind off, reduce supporting capacity, even cause the premature failure of large gear ring, ultimate life also can decline greatly.Manufacture, the tooling cost of large gear ring are high, and particularly the material of precise part, tooling cost can reach more than 1,000,000 yuan, and its distortion can not be effectively controlled, can give produce, application bring great impact.Need aborning to make setting tooling and the roll flute processing request in later stage is also high for this problem enterprise, have a strong impact on the production cycle of enterprise.Accurate gear ring occurs that larger distortion causes product defective, and rework cost is high, can not deliver goods on schedule to the higher penalty cost of manufacturing enterprise.After large gear ring is delivered for use, cause distortion, cracking causes the work efficiency drop of wheel casing, the life-span greatly reduces, as wind power generation speed-increasing gearbox is arranged on tens meters of high-altitudes, safeguard and change cost higher, geared parts in large ship lost efficacy and causes ship power system impaired, caused serious consequence.
The unrelieved stress that the distortion of large gear ring produces when machining primarily of workpiece, the thermal stresses produced in heat treatment process and the acting in conjunction such as structural stress and workpiece deformation induced by gravity and produce, its influence factor comprises gear ring geometrical shape, starting material and metallurgical quality, forging and mach unrelieved stress, charging method and the aspects such as thermal treatment process and equipment, and controlling distortion is very complicated.The main method controlling large gear ring distortion at present both at home and abroad has gear ring optimization of Heat Treatment Process, and frock is fixing waits measure.Optimization of Heat Treatment Process improves the homogeneity of gear upper, middle and lower position cooling, and make structural transformation be tending towards synchronous, the cooling rate improving end face and stage casing is uneven, can receive obvious effect.
Adopt frock fixing means to carry out large gear ring Deformation control and be mainly divided into two kinds of methods, namely compensation method and pressure are quenched method.Compensation method pair cross-section large gear ring in irregular shape adopts the compensating part such as cushion block or sleeve, makes gear ring sectional uniform, play heating speed of cooling evenly, reduce heat treated thermal stresses effect, in actual production, have certain application.The pressure method of quenching is that the frock generally adopted fixes controlling distortion method, adopts lacing wire fixture or chuck special to carry out clamping to large gear ring, heat-treats subsequently, the relatively heat treated distortion of effective control.
Although aforesaid method can obtain some effects, in practical application, also has a lot of problem.Such as optimization thermal treatment process lacks the systematic Study to processing condition, and its technology stability can not ensure; Although pressure is quenched and can be solved plane warping and endoporus roundness deformation problem, do not improve teeth portion problem on deformation, the impact of the method on the distortion in gear ring thermal treatment process and unrelieved stress also lacks theoretical analysis; Although compensation method has certain application aborning, by the impact of large gear ring geometric parameter complexity, this method also mainly relies on experience at present; Frock fixing means also lacks further investigation to the effect of distortion and unrelieved stress in ring gear machining.At present, mainly rely on practical experience in above large gear ring deformation-controlling measures application, also lack computer-aided analysis and carry out Process Aided Design and Deformation Prediction, can not regulate according to the particular case of gear ring simultaneously.
Summary of the invention
For prior art above shortcomings, the object of the invention is to how to solve large gear ring thermal treatment yielding, and after distortion, be difficult to the problem of carrying out repairing, a kind of large gear ring heat treatment deformation multiple spot stress compensation device and equalising means thereof are provided.
In order to solve the problems of the technologies described above, the technical solution used in the present invention is such: a kind of large gear ring heat treatment deformation multiple spot stress compensation device, it is characterized in that: comprise base, interior hydro-cylinder, outer hydro-cylinder, internal stress compensation block and external stress compensation block, described base comprises two disks be set up in parallel up and down, two disks are fixed together, and the axial line of two disks overlaps, wherein, the diameter of top disk is less than the diameter of below disk; Described interior hydraulic cylinder and outer hydraulic cylinder are multiple, wherein, interior hydraulic cylinder is uniformly distributed around top disk outer rim and is fixedly connected with top disk for one week, and the axis of its piston rod is consistent with the radial direction of top disk, and described internal stress compensation block is connected with the piston rod of interior hydro-cylinder; Described outer hydro-cylinder is fixedly connected with the outer rim of below disk, and the position of outer hydro-cylinder is corresponding with the position of interior hydro-cylinder, and the axis of its piston rod is consistent with the radial direction of below disk, and described external stress compensation block is connected with the piston rod of outer hydro-cylinder.
Further, the outside of described internal stress compensation block and the inner side of external stress compensation block all curved, and when the piston rod of interior hydro-cylinder is consistent with the length difference that the piston rod of outer hydro-cylinder stretches out, the outside of internal stress compensation block is positioned at circumferentially same, and the inner side of external stress compensation block is positioned at circumferentially same.
Utilize above-mentioned large gear ring heat treatment deformation multiple spot stress compensation device to carry out an equalising means for large gear ring heat treatment deformation multiple spot stress compensation, it is characterized in that: comprise the steps:
(1) set up large gear ring model, and it is discrete to carry out finite element model according to large gear ring model; Meanwhile, the processing condition in large gear ring heat treatment process are input to finite element model;
(2) according to the processing condition of input, large gear ring heat treatment process finite element simulation is carried out in conjunction with large gear ring model, the deflection after the thermal treatment of prediction large gear ring completes and the stress position and the size that cause distortion;
(3) stress position obtained according to (2) and size, carry out the Contrary compensation of stress to finite element model, then the thermal treatment of large-scale simulation gear ring complete after deflection and cause the stress of distortion;
(4) deflection step (3) obtained and large gear ring model contrast, if deflection is in tolerance zone, then this stress is as finally compensating stress; If be out of shape overproof, then utilize step (3) to obtain cumulative stress step (2) acquisition stress again to compensate the heat treated deflection of post-simulation large gear ring and cause the stress of distortion, re-start step (3), until the tolerance of distortion allows, using the stress of accumulation as finally compensating stress;
(5) Controlling System is utilized to export to the interior hydro-cylinder of multiple spot stress compensation device and outer hydro-cylinder, to control large gear ring heat treatment deformation the final compensation stress that step (4) obtains.
Further, described final compensation stress is the set of the stress of some continuous distribution.
Further, described Controlling System is equivalent to along the equally distributed several compensating action power of large gear ring circumference by finally compensating stress, then carry out applying outside thrust or inside pulling force, to realize the compensation to large gear ring stress in the position of each compensating action power by controlling multiple spot stress compensation device.
Further, the control method of described Controlling System is, finally to compensate maximum stress place in stress for starting point, correspond to a stress compensation point, then according to stress compensation number, gear ring is divided into several sections, every section is equivalent to a compensating action force compensating to corresponding stress compensation point, and wherein, hydraulic cylinder provides from the gear ring thrust outside from center, and outer hydraulic cylinder provides the pulling force from export-oriented center.
Further, in compensation process, finite element model is according to the standard of gear ring and require to be optimized the processing condition of input, then the processing condition of the optimum obtained is exported.
Further, the processing condition of described optimum comprise thermal treatment temp, heat-treatment medium, carbo-nitriding technique stove atmosphere, the time in each stage, stress compensation position and its size.
Compared with prior art, tool of the present invention has the following advantages:
(1) large gear ring of different size can regulate by adjusting hydrauliccylinder piston position and changing inside and outside stress compensation block, adapts to different products, has saved cost.
(2) adopt multiple spot stress compensation to control large gear ring heat treatment deformation, make gear ring in heat treatment process, effectively can control the distortion in large gear ring heat treatment process, improve the quality of products, thus improve production qualification rate.
(3) present method and device can provide the inside pulling force of inner ring outward thrust and outer ring as required to gear ring heat treatment deformation process, the stress compensation value needed can utilize hydro-cylinder to regulate as required, and the back-up block needed for device, hydro-cylinder quantity and position all can change as required.
(4) utilize computer forecast large gear ring heat treatment deformation amount and cause combined stress numerical value, the position of distortion, and carry out repeatedly cumulative calculation, approach, improve efficiency and accuracy, reduce cost.
Accompanying drawing explanation
Fig. 1 is the vertical view of device of the present invention;
Fig. 2 is the side-view of Fig. 1;
Fig. 3 is the schema of this law equalising means.
In figure: 1-base, 2-interior hydro-cylinder, 3-outer hydro-cylinder, 4-internal stress compensation block, 5-external stress compensation block.
Embodiment
Below in conjunction with drawings and Examples, the invention will be further described.
Embodiment: see Fig. 1, Fig. 2, a kind of large gear ring heat treatment deformation multiple spot stress compensation device, comprises base 1, interior hydro-cylinder 2, outer hydro-cylinder 3, internal stress compensation block 4 and external stress compensation block 5.Described base 1 comprises two disks be set up in parallel up and down, and two disks are fixed together, and the axial line of two disks overlaps, and wherein, the diameter of top disk is less than the diameter of below disk.Described interior hydraulic cylinder and outer hydraulic cylinder are multiple.Wherein, interior hydraulic cylinder is uniformly distributed around top disk outer rim and is fixedly connected with top disk for one week, and the axis of its piston rod is consistent with the radial direction of top disk, and described internal stress compensation block 4 is connected with the piston rod (stretching out one end of cylinder body) of interior hydro-cylinder 2.Described outer hydro-cylinder 3 is fixedly connected with the outer rim of below disk, and the position of outer hydro-cylinder 3 is corresponding with the position of interior hydro-cylinder 2, the axis of its piston rod is consistent with the radial direction of below disk, and described external stress compensation block 5 is connected with the piston rod (stretching out one end of cylinder body) of outer hydro-cylinder 3.
The outside of described internal stress compensation block 4 and the inner side of external stress compensation block 5 all curved, and when the piston rod of interior hydro-cylinder 2 is consistent with the length difference that the piston rod of outer hydro-cylinder 3 stretches out, the outside of internal stress compensation block 4 is positioned at circumferentially same, and the inner side of external stress compensation block 5 is positioned at circumferentially same.
During concrete enforcement, described interior hydro-cylinder 2 and outer hydro-cylinder 3 control by computer (or industrial computer), by the extrusion of the piston rod of each interior hydro-cylinder 2 of computer control and outer hydro-cylinder 3, thus the compensation realized crushed element, adaptive deformation compensation can be carried out according to different heat treatment environment like this, thus the stability of gear ring can be ensured better.
See Fig. 3, a kind ofly utilize above-mentioned large gear ring heat treatment deformation multiple spot stress compensation device to carry out the equalising means of large gear ring heat treatment deformation multiple spot stress, comprise the steps:
(1) set up large gear ring model, and it is discrete to carry out finite element model according to large gear ring model; Meanwhile, the processing condition in large gear ring heat treatment process are input to finite element model.
(2) according to the processing condition of input, large gear ring heat treatment process finite element simulation is carried out in conjunction with large gear ring model, the deflection after the thermal treatment of prediction large gear ring completes and the stress position and the size that cause distortion.
(3) stress position obtained according to (2) and size, carry out the Contrary compensation of stress to finite element model, then the thermal treatment of large-scale simulation gear ring complete after deflection and cause the stress of distortion.
(4) deflection step (3) obtained and large gear ring model contrast, if deflection is in tolerance zone, then this stress is as finally compensating stress; If be out of shape overproof, then utilize step (3) to obtain cumulative stress step (2) acquisition stress again to compensate the heat treated deflection of post-simulation large gear ring and cause the stress of distortion, re-start step (3), until the tolerance of distortion allows, using the stress of accumulation as finally compensating stress; Described final compensation stress is the set of the stress of some continuous distribution.Described Controlling System is equivalent to along the equally distributed several compensating action power of large gear ring circumference by finally compensating stress, then carry out applying outside thrust or inside pulling force, to realize the compensation to large gear ring stress in the position of each compensating action power by controlling multiple spot stress compensation device.
The control method of described Controlling System is, finally to compensate maximum stress place in stress for starting point, correspond to a stress compensation point, then according to stress compensation number, gear ring is divided into several sections, every section is equivalent to a compensating action force compensating to corresponding stress compensation point, wherein interior hydraulic cylinder provides from the gear ring thrust outside from center, and outer hydraulic cylinder provides the pulling force from export-oriented center.Wherein, each inside and outside hydro-cylinder independently controls, and carries out regulable control according to required stress compensation value by the pressure controlled valve above Controlling System regulator solution cylinder pressure or surplus valve.
(5) Controlling System is utilized to export to the interior hydro-cylinder of multiple spot stress compensation device and outer hydro-cylinder, to control large gear ring heat treatment deformation the final compensation stress that step (4) obtains.
In compensation process, according to the standard of gear ring and requirement (as hardness, tissue distribution etc.), the processing condition to input are optimized (optimizing thermal treatment temp, heat-treatment medium (regulating the speed of cooling of the coefficient of heat transfer and material with this), carbo-nitriding technique stove atmosphere, reason time in each stage) finite element model, then the processing condition of the optimum obtained are exported.The processing condition of described optimum comprise thermal treatment temp, heat-treatment medium (regulating the speed of cooling of the coefficient of heat transfer and material with this), carbo-nitriding technique stove atmosphere, the time in each stage, stress compensation position and its size.
Finally it should be noted that, above embodiment is only in order to illustrate technical scheme of the present invention but not restriction technologies scheme, those of ordinary skill in the art is to be understood that, those are modified to technical scheme of the present invention or equivalent replacement, and do not depart from aim and the scope of the technical program, all should be encompassed in the middle of right of the present invention.
Claims (8)
1. a large gear ring heat treatment deformation multiple spot stress compensation device, it is characterized in that: comprise base, interior hydro-cylinder, outer hydro-cylinder, internal stress compensation block and external stress compensation block, described base comprises two disks be set up in parallel up and down, two disks are fixed together, and the axial line of two disks overlaps, wherein, the diameter of top disk is less than the diameter of below disk; Described interior hydraulic cylinder and outer hydraulic cylinder are multiple, wherein, interior hydraulic cylinder is uniformly distributed around top disk outer rim and is fixedly connected with top disk for one week, and the axis of its piston rod is consistent with the radial direction of top disk, and described internal stress compensation block is connected with the piston rod of interior hydro-cylinder; Described outer hydro-cylinder is fixedly connected with the outer rim of below disk, and the position of outer hydro-cylinder is corresponding with the position of interior hydro-cylinder, and the axis of its piston rod is consistent with the radial direction of below disk, and described external stress compensation block is connected with the piston rod of outer hydro-cylinder.
2. large gear ring heat treatment deformation multiple spot stress compensation device according to claim 1, it is characterized in that: the outside of described internal stress compensation block and the inner side of external stress compensation block all curved, and when the piston rod of interior hydro-cylinder is consistent with the length difference that the piston rod of outer hydro-cylinder stretches out, the outside of internal stress compensation block is positioned at circumferentially same, and the inner side of external stress compensation block is positioned at circumferentially same.
3. utilize large gear ring heat treatment deformation multiple spot stress compensation device as claimed in claim 1 or 2 to carry out an equalising means for large gear ring heat treatment deformation multiple spot stress compensation, it is characterized in that: comprise the steps:
(1) set up large gear ring model, and it is discrete to carry out finite element model according to large gear ring model; Meanwhile, the processing condition in large gear ring heat treatment process are input to finite element model;
(2) according to the processing condition of input, large gear ring heat treatment process finite element simulation is carried out in conjunction with large gear ring model, the deflection after the thermal treatment of prediction large gear ring completes and the stress position and the size that cause distortion;
(3) stress position obtained according to (2) and size, carry out the Contrary compensation of stress to finite element model, then the thermal treatment of large-scale simulation gear ring complete after deflection and cause the stress of distortion;
(4) deflection step (3) obtained and large gear ring model contrast, if deflection is in tolerance zone, then this stress is as finally compensating stress; If be out of shape overproof, then utilize step (3) to obtain cumulative stress step (2) acquisition stress again to compensate the heat treated deflection of post-simulation large gear ring and cause the stress of distortion, re-start step (3), until the tolerance of distortion allows, using the stress of accumulation as finally compensating stress;
(5) Controlling System is utilized to export to the interior hydro-cylinder of multiple spot stress compensation device and outer hydro-cylinder, to control large gear ring heat treatment deformation the final compensation stress that step (4) obtains.
4. utilize large gear ring heat treatment deformation multiple spot stress compensation device to carry out the equalising means of large gear ring heat treatment deformation multiple spot stress compensation according to claim 3, it is characterized in that: described final compensation stress is the set of the stress of some continuous distribution.
5. utilize large gear ring heat treatment deformation multiple spot stress compensation device to carry out the equalising means of large gear ring heat treatment deformation multiple spot stress compensation according to claim 4, it is characterized in that: described Controlling System is equivalent to along the equally distributed several compensating action power of large gear ring circumference by finally compensating stress, then carry out applying outside thrust or inside pulling force, to realize the compensation to large gear ring stress in the position of each compensating action power by controlling multiple spot stress compensation device.
6. utilize large gear ring heat treatment deformation multiple spot stress compensation device to carry out the equalising means of large gear ring heat treatment deformation multiple spot stress compensation according to claim 5, it is characterized in that: the control method of described Controlling System is, finally to compensate maximum stress place in stress for starting point, correspond to a stress compensation point, then according to stress compensation number, gear ring is divided into several sections, every section is equivalent to a compensating action force compensating to corresponding stress compensation point, wherein interior hydraulic cylinder provides from the gear ring thrust outside from center, outer hydraulic cylinder provides the pulling force from export-oriented center.
7. utilize large gear ring heat treatment deformation multiple spot stress compensation device to carry out the equalising means of large gear ring heat treatment deformation multiple spot stress compensation according to claim 6, it is characterized in that: in compensation process, finite element model is according to the standard of gear ring and require to be optimized the processing condition of input, then the processing condition of the optimum obtained is exported.
8. utilize large gear ring heat treatment deformation multiple spot stress compensation device to carry out the equalising means of large gear ring heat treatment deformation multiple spot stress compensation according to claim 7, it is characterized in that: the processing condition of described optimum comprise thermal treatment temp, heat-treatment medium, carbo-nitriding technique stove atmosphere, the time in each stage, stress compensation position and its size.
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| CN107169166B (en) * | 2017-04-17 | 2020-02-25 | 燕山大学 | Large gear ring mobile induction heating calculation method based on ANSYS simulation platform |
| CN108103273A (en) * | 2017-11-10 | 2018-06-01 | 武汉船用机械有限责任公司 | A kind of compensation method of laser quenching deformation and the processing method of sliding slot |
| CN108265170A (en) * | 2018-01-12 | 2018-07-10 | 中国航发哈尔滨东安发动机有限公司 | The method for promoting profile accuracy after internal spline is heat-treated |
| CN108247304A (en) * | 2018-01-12 | 2018-07-06 | 中国航发哈尔滨东安发动机有限公司 | The method for promoting teeth directional precision after internal spline is heat-treated |
| CN108950170B (en) * | 2018-07-12 | 2020-04-24 | 中南大学 | Automobile reducer gear carburizing and quenching deformation control method and application |
| CN112380750A (en) * | 2020-11-18 | 2021-02-19 | 内蒙古第一机械集团股份有限公司 | Stress coupling simulation method for continuous heat treatment and machining |
| CN113512637A (en) * | 2021-07-13 | 2021-10-19 | 内蒙古北方重型汽车股份有限公司 | Anti-deformation device for rear tailstock and using method thereof |
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| CN204138729U (en) * | 2014-10-28 | 2015-02-04 | 重庆理工大学 | Large gear ring heat treatment deformation multiple spot stress compensation device |
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