CN106541060B - A kind of rolling production method of super-large diameter aluminium alloy integral loop - Google Patents
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Abstract
本发明属于环轧成形技术领域,具体涉及一种超大直径铝合金整体环的轧制生产方法。本发明技术方案采用环轧成形技术,通过控制超大规格铝合金环件的轧制变形温度、直径增大速率、径轴向进给速率、径轴向压下量、轧制比、芯辊直径、环轧火次等,实现了超大直径铝合金整体环轧制过程的稳定持续进行,有效控制了环件尺寸精度、椭圆度及径轴向变形量,提高了产品质量一致性和产品合格率,满足了产品的技术指标要求。The invention belongs to the technical field of ring rolling, and in particular relates to a rolling production method of a super large-diameter aluminum alloy integral ring. The technical scheme of the present invention adopts ring rolling forming technology, by controlling the rolling deformation temperature, diameter increase rate, radial and axial feed rate, radial and axial reduction, rolling ratio, and core roll diameter of super-large aluminum alloy rings , ring rolling fire, etc., realized the stable and continuous rolling process of super-large-diameter aluminum alloy overall ring, effectively controlled the dimensional accuracy, ellipticity and radial and axial deformation of ring parts, and improved product quality consistency and product qualification rate , meeting the technical specification requirements of the product.
Description
技术领域technical field
本发明属于环轧成形技术领域,具体涉及一种超大直径铝合金整体环的轧制生产方法。The invention belongs to the technical field of ring rolling, and in particular relates to a rolling production method of a super large-diameter aluminum alloy integral ring.
背景技术Background technique
大型环件被广泛应用于各工业领域,如风电设备的轴承套圈及齿轮环坯、运载火箭的过渡环、压力容器及核反应堆的加强圈等。近年来,随着工业的发展,各行业对大型环件的需求量越来越大、性能要求也越来越高,因此研究大型环件的制造工艺显得尤为重要。Large rings are widely used in various industrial fields, such as bearing rings and gear ring blanks for wind power equipment, transition rings for launch vehicles, pressure vessels and reinforcement rings for nuclear reactors, etc. In recent years, with the development of industry, the demand for large-scale rings in various industries is increasing, and the performance requirements are also getting higher and higher. Therefore, it is particularly important to study the manufacturing process of large-scale rings.
整体环轧制成形属于径向-轴向压缩、切向延伸的锻造过程,包括:直线进给运动、旋转轧制运动、导向运动以及环件自身的转动和直径扩大运动,这使得控制环件轧制成形过程极为复杂。采用该技术生产的特大型环锻件,不仅具有外形尺寸精度高、材料消耗少等特点,并且能有效改善材料内部组织结构及其均匀性,金属纤维沿圆周连续排列,与零件的受力和磨损相适应,内在质量优良、综合性能高。同时整体锻环为整体机加工件,因此大型整体环轧成形件加工后零件的尺寸精度高、质量一致性和稳定性好、可靠性高。Roll forming of the integral ring belongs to the forging process of radial-axial compression and tangential extension, including: linear feed motion, rotary rolling motion, guiding motion, and the rotation and diameter expansion motion of the ring itself, which makes the control ring The roll forming process is extremely complex. The extra-large ring forgings produced by this technology not only have the characteristics of high precision of external dimensions and less material consumption, but also can effectively improve the internal structure and uniformity of the material. The metal fibers are arranged continuously along the circumference, which is incompatible with the stress and wear of the parts. Compatible, with excellent internal quality and high comprehensive performance. At the same time, the integral forged ring is an integral machined part, so the large integral ring rolled forming part has high dimensional accuracy, good quality consistency, good stability, and high reliability.
目前,国内多家单位成功轧制出直径5米级2219铝合金环件,并在航空航天领域得到了广泛地应用,但是直径5米以上的铝合金整体环件在国内还属空白。随着环件尺寸的进一步增大,特别是直径大于8m后,环件的刚性大大减弱,轧制过程中容易产生塑性失稳,使得环轧过程中环件的圆度及尺寸精度很难控制;同时由于大型环件的截面变化大,环轧过程中容易产生折叠、粘辊、表面起皮、多边形等缺陷,从而导致环件轧制过程终止或者产品报废,因此其轧制工艺过程更加复杂,对轧制工艺过程的控制也提出了更高的要求。At present, many domestic units have successfully rolled 2219 aluminum alloy rings with a diameter of 5 meters, and have been widely used in the aerospace field, but aluminum alloy rings with a diameter of more than 5 meters are still blank in China. With the further increase of the size of the ring, especially when the diameter is greater than 8m, the rigidity of the ring is greatly weakened, and plastic instability is prone to occur during the rolling process, making it difficult to control the roundness and dimensional accuracy of the ring during the ring rolling process; At the same time, due to the large cross-section of large rings, defects such as folding, sticking, surface peeling, and polygons are prone to occur during the ring rolling process, resulting in termination of the ring rolling process or product scrap, so the rolling process is more complicated. Higher requirements are also put forward for the control of the rolling process.
因此,精确调控超大直径整体环件的成形工艺过程,实现Φ8-10m环件产品“形状-性能”的协同控制,对提高国内超大直径环件的轧制技术水平有很大促进作用,成为我国在此技术领域内亟需解决的重要技术。Therefore, the precise control of the forming process of super-large-diameter overall rings and the realization of the "shape-performance" collaborative control of Φ8-10m ring products will greatly promote the improvement of the rolling technology level of domestic super-large-diameter rings, and become my country's An important technology that needs to be solved urgently in this technical field.
发明内容Contents of the invention
本发明要解决的技术问题是实现Φ8-10m超大直径铝合金整体环轧制成形,控制环件的圆度和尺寸精度,保证环件轧制过程稳定持续进行,对超大直径铝合金整体环件的“形-性”协同控制,从而满足我国超大直径整体环件的使用要求。The technical problem to be solved by the present invention is to realize the rolling forming of the super large diameter aluminum alloy integral ring of Φ8-10m, control the roundness and dimensional accuracy of the ring, and ensure the stable and continuous rolling process of the ring. The "shape-property" coordinated control can meet the use requirements of super large diameter integral rings in my country.
为了实现这一目的,本发明采取的技术方案是:In order to realize this object, the technical scheme that the present invention takes is:
一种超大直径铝合金整体环的轧制生产方法,包括如下步骤:A rolling production method of an ultra-large-diameter aluminum alloy integral ring, comprising the steps of:
(1)环坯制备:通过自由锻造方法制备所需规格的环坯,进行车加工及超声波探伤检测,保证获得合格的环轧坯料;(1) Ring blank preparation: Prepare ring blanks of required specifications by free forging, and carry out lathe processing and ultrasonic flaw detection to ensure qualified ring rolling blanks;
锻造加工:自由锻方式获得外径为3500~4500mm、内径为3000~3500mm、高度为500~650mm的环坯;Forging process: free forging to obtain ring blanks with an outer diameter of 3500-4500mm, an inner diameter of 3000-3500mm, and a height of 500-650mm;
车加工:对环坯上、下端面及内、外圆面进行车加工,去除表面黑皮及折叠伤,表面粗糙度达到Ra3.2以上,圆度控制在1mm以内;Turning processing: Carry out turning processing on the upper and lower end faces of the ring blank, as well as the inner and outer circular faces, remove the black skin and fold damage on the surface, the surface roughness should reach Ra3.2 or more, and the roundness should be controlled within 1mm;
超声波探伤:对坯料上端面进行100%超声波探伤,按GJB2057标准A级验收,排除超标缺陷;Ultrasonic flaw detection: 100% ultrasonic flaw detection is carried out on the upper end surface of the billet, and it is accepted according to the GJB2057 standard A level, and the defects exceeding the standard are excluded;
(2)环坯加热:将环轧坯料在电炉中进行加热、保温;(2) Ring billet heating: the ring rolling billet is heated and kept warm in an electric furnace;
(3)环轧成形:对环轧坯料进行二火次环轧成形;包括:(3) Ring rolling forming: carry out secondary ring rolling forming on the ring rolling billet; including:
(3.1)转运:将加热后的环轧坯料转运到环轧机上,转运时间小于290s,坯料表面温降控制在40℃以内;(3.1) Transfer: transfer the heated ring rolling billet to the ring rolling mill, the transfer time is less than 290s, and the temperature drop on the billet surface is controlled within 40°C;
(3.2)第一火轧制:采用直径为400~600mm的芯辊对环轧坯料进行辗轧,辗轧至环轧坯料的外径为5000~6000mm、高度为450~600mm,轧制比为1.2~2.0,径轴向压下量之比为2.0~3.0;(3.2) The first fire rolling: use core rolls with a diameter of 400-600mm to roll the ring-rolled billet until the outer diameter of the ring-rolled billet is 5000-6000mm and the height is 450-600mm, and the rolling ratio is 1.2~2.0, the ratio of radial to axial reduction is 2.0~3.0;
轧制过程分咬入阶段、快速轧制阶段、稳定轧制阶段、减速轧制阶段及成形整圆阶段共5个阶段进行:The rolling process is divided into five stages: biting stage, rapid rolling stage, stable rolling stage, deceleration rolling stage and forming full circle stage:
咬入阶段:环轧坯料咬入辊缝,开始建立轧制过程,该阶段只进行径向轧制,轴向轧辊无进给,轴向仅轧制由于径向轧制引起的宽展,咬入阶段轧制厚度值为整个轧制厚度变化量的5%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为3~5mm/s、径向进给速率为0.02~0.06mm/s、轴向进给速率为0~0.02mm/s;Biting stage: the ring rolling billet bites into the roll gap, and the rolling process starts to be established. In this stage, only radial rolling is carried out, and the axial roll has no feed. The rolling thickness value in the initial stage is 5% of the change in the entire rolling thickness; at this stage, the initial diameter increase rate is 1-3mm/s, the final diameter increase rate is 3-5mm/s, and the radial feed rate 0.02~0.06mm/s, axial feed rate 0~0.02mm/s;
快速轧制阶段:轧辊径向进给速度加快,环轧坯料随之快速长大,轴向进给按与径向进给成比例的进给,快速轧制阶段轧制厚度值为整个轧制厚度变化量的15%;在此阶段的直径初增大率为3~5mm/s、直径终增大率为5~12mm/s、径向进给速率为0.06~0.3mm/s、轴向进给速率为0.02~0.15mm/s;Rapid rolling stage: the radial feed speed of the rolls is accelerated, and the ring rolling billet grows rapidly accordingly, the axial feed is fed in proportion to the radial feed, and the rolling thickness value of the rapid rolling stage is 15% of the thickness change; at this stage, the initial diameter increase rate is 3-5mm/s, the final diameter increase rate is 5-12mm/s, the radial feed rate is 0.06-0.3mm/s, the axial The feed rate is 0.02~0.15mm/s;
稳定轧制阶段:控制芯辊与锥辊的进给速度,使其与环轧坯料的直径增长速度相匹配,使轧制过程快速、稳定进行,稳定轧制阶段轧制厚度值为整个轧制厚度变化量的60%;在此阶段的直径初增大率为5~12mm/s、直径终增大率为5~12mm/s、径向进给速率为0.15~0.4mm/s、轴向进给速率为0.04~0.2mm/s;Stable rolling stage: control the feed speed of the core roll and the tapered roll to match the diameter growth rate of the ring rolling billet, so that the rolling process can be carried out quickly and stably. 60% of the thickness change; at this stage, the initial diameter increase rate is 5-12mm/s, the final diameter increase rate is 5-12mm/s, the radial feed rate is 0.15-0.4mm/s, the axial The feed rate is 0.04~0.2mm/s;
减速轧制阶段:径向和轴向进给速度减小,环轧坯料长大速率随之降低,减速轧制阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为5~12mm/s、直径终增大率为1~5mm/s、径向进给速率为0.05~0.4mm/s、轴向进给速率为0.02~0.15mm/s;Deceleration rolling stage: The radial and axial feed speeds decrease, and the growth rate of the ring rolling billet decreases accordingly. The rolling thickness value in the deceleration rolling stage is 10% of the variation of the entire rolling thickness; the diameter at this stage The initial increase rate is 5-12mm/s, the final diameter increase rate is 1-5mm/s, the radial feed rate is 0.05-0.4mm/s, and the axial feed rate is 0.02-0.15mm/s;
成形整圆阶段:仅进行径向轧制,轴向仅轧制由于径向轧制引起的宽展,在仅有径向轧制的过程中进行整圆,同时消除因回弹引起的尺寸误差,成形整圆阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为1~3mm/s、径向进给速率为0.02~0.05mm/s、轴向进给速率为0~0.02mm/s;Forming full circle stage: only radial rolling is carried out, and the widening caused by radial rolling is only rolled in the axial direction, and the full circle is carried out in the process of only radial rolling, and the dimensional error caused by springback is eliminated at the same time , the rolling thickness value in the full-circle forming stage is 10% of the variation of the entire rolling thickness; The feed rate is 0.02-0.05mm/s, and the axial feed rate is 0-0.02mm/s;
(3.3)进行回炉保温2~4h,保温温度为420~460℃;(3.3) Return to the furnace for heat preservation for 2 to 4 hours, and the heat preservation temperature is 420 to 460 °C;
(3.4)第二火轧制:换直径为700~900mm的芯辊对环轧坯料进行辗轧,辗轧至外径为8000~10000mm、高度为400~550mm,轧制比为1.2~1.8,径轴向压下量之比为2.0~3.0;(3.4) Second fire rolling: Change the core roll with a diameter of 700-900mm to roll the ring-rolled billet until the outer diameter is 8000-10000mm, the height is 400-550mm, and the rolling ratio is 1.2-1.8. The ratio of radial to axial reduction is 2.0 to 3.0;
轧制过程同步骤(3.2)相同,分咬入阶段、快速轧制阶段、稳定轧制阶段、减速轧制阶段及成形整圆阶段共5个阶段进行:The rolling process is the same as step (3.2), and it is divided into five stages: biting stage, rapid rolling stage, stable rolling stage, deceleration rolling stage and forming full circle stage:
咬入阶段:环轧坯料咬入辊缝,开始建立轧制过程,该阶段只进行径向轧制,轴向轧辊无进给,轴向仅轧制由于径向轧制引起的宽展,咬入阶段轧制厚度值为整个轧制厚度变化量的5%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为3~8mm/s、径向进给速率为0.02~0.08mm/s、轴向进给速率为0~0.02mm/s;Biting stage: the ring rolling billet bites into the roll gap, and the rolling process starts to be established. In this stage, only radial rolling is carried out, and the axial roll has no feed. The rolling thickness value in the initial stage is 5% of the change in the entire rolling thickness; at this stage, the initial diameter increase rate is 1-3mm/s, the final diameter increase rate is 3-8mm/s, and the radial feed rate 0.02~0.08mm/s, axial feed rate 0~0.02mm/s;
快速轧制阶段:轧辊径向进给速度加快,环轧坯料随之快速长大,轴向进给按与径向进给成比例的进给,快速轧制阶段轧制厚度值为整个轧制厚度变化量的15%;在此阶段的直径初增大率为3~8mm/s、直径终增大率为8~15mm/s、径向进给速率为0.08~0.35mm/s、轴向进给速率为0.04~0.15mm/s;Rapid rolling stage: the radial feed speed of the rolls is accelerated, and the ring rolling billet grows rapidly accordingly, the axial feed is fed in proportion to the radial feed, and the rolling thickness value of the rapid rolling stage is 15% of the thickness change; at this stage, the initial diameter increase rate is 3-8mm/s, the final diameter increase rate is 8-15mm/s, the radial feed rate is 0.08-0.35mm/s, the axial The feed rate is 0.04~0.15mm/s;
稳定轧制阶段:控制芯辊与锥辊的进给速度,使其与环轧坯料的直径增长速度相匹配,使轧制过程快速、稳定进行,稳定轧制阶段轧制厚度值为整个轧制厚度变化量的60%;在此阶段的直径初增大率为8~15mm/s、直径终增大率为8~15mm/s、径向进给速率为0.15~0.5mm/s、轴向进给速率为0.08~0.3mm/s;Stable rolling stage: control the feed speed of the core roll and the tapered roll to match the diameter growth rate of the ring rolling billet, so that the rolling process can be carried out quickly and stably. 60% of the thickness change; at this stage, the initial diameter increase rate is 8-15mm/s, the final diameter increase rate is 8-15mm/s, the radial feed rate is 0.15-0.5mm/s, the axial The feed rate is 0.08~0.3mm/s;
减速轧制阶段:径向和轴向进给速度减小,环轧坯料长大速率随之降低,减速轧制阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为8~15mm/s、直径终增大率为1~5mm/s、径向进给速率为0.05~0.5mm/s、轴向进给速率为0.02~0.2mm/s;Deceleration rolling stage: The radial and axial feed speeds decrease, and the growth rate of the ring rolling billet decreases accordingly. The rolling thickness value in the deceleration rolling stage is 10% of the variation of the entire rolling thickness; the diameter at this stage The initial increase rate is 8-15mm/s, the final diameter increase rate is 1-5mm/s, the radial feed rate is 0.05-0.5mm/s, and the axial feed rate is 0.02-0.2mm/s;
成形整圆阶段:仅进行径向轧制,轴向仅轧制由于径向轧制引起的宽展,在仅有径向轧制的过程中进行整圆,同时消除因回弹引起的尺寸误差,成形整圆阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为1~3mm/s、径向进给速率为0.02~0.05mm/s、轴向进给速率为0~0.02mm/s;Forming full circle stage: only radial rolling is carried out, and the widening caused by radial rolling is only rolled in the axial direction, and the full circle is carried out in the process of only radial rolling, and the dimensional error caused by springback is eliminated at the same time , the rolling thickness value in the full-circle forming stage is 10% of the variation of the entire rolling thickness; The feed rate is 0.02-0.05mm/s, and the axial feed rate is 0-0.02mm/s;
(3.5)环件轧制结束后在封闭环境中进行冷却,冷却过程中控制各个部位冷却速率一致;(3.5) Cool the ring in a closed environment after rolling, and control the cooling rate of each part to be consistent during the cooling process;
(4)尺寸检测:对环轧成形的环件进行尺寸检测,获得满足质量要求的环件。(4) Dimensional inspection: carry out dimension inspection on rings formed by ring rolling to obtain rings that meet quality requirements.
进一步的,如上所述的一种超大直径铝合金整体环的轧制生产方法,步骤(2)中,将环轧坯料放入电炉中,采用随炉升温方式,加热温度为420~460℃,保温时间为12~12.5h。Furthermore, in the above-mentioned method for rolling a super large-diameter aluminum alloy monolithic ring, in step (2), the ring-rolled billet is put into an electric furnace, and the heating temperature is 420-460°C by adopting the heating method with the furnace. The holding time is 12-12.5 hours.
进一步的,如上所述的一种超大直径铝合金整体环的轧制生产方法,步骤(3)中,轧制过程对主轧辊、芯辊、上锥辊、下锥辊、环坯的4个边角部位进行润滑,控制各个部位润滑均匀一致,控制环坯的表面温度在360~460℃。Further, the rolling production method of a super-large-diameter aluminum alloy integral ring as described above, in step (3), the rolling process is for the main roll, the core roll, the upper cone roll, the lower cone roll, and the ring blank. The corner parts are lubricated, the lubrication of each part is controlled uniformly, and the surface temperature of the ring blank is controlled at 360-460 °C.
进一步的,如上所述的一种超大直径铝合金整体环的轧制生产方法,步骤(4)中,对车加工后的环形件进行尺寸检测的质量要求是环形件圆度≤5‰。Further, in the rolling production method of an ultra-large-diameter aluminum alloy integral ring as described above, in step (4), the quality requirement for dimension inspection of the turned ring is that the roundness of the ring is ≤ 5‰.
本发明技术方案采用环轧成形技术,通过控制超大规格铝合金环件的轧制变形温度、直径增大速率、径轴向进给速率、径轴向压下量、轧制比、芯辊直径、环轧火次等,实现了超大直径铝合金整体环轧制过程的稳定持续进行,有效控制了环件尺寸精度、椭圆度及径轴向变形量,提高了产品质量一致性和产品合格率,满足了产品的技术指标要求。The technical scheme of the present invention adopts ring rolling forming technology, by controlling the rolling deformation temperature, diameter increase rate, radial and axial feed rate, radial and axial reduction, rolling ratio, and core roll diameter of super-large aluminum alloy rings , ring rolling fire, etc., realized the stable and continuous rolling process of super-large-diameter aluminum alloy overall ring, effectively controlled the dimensional accuracy, ellipticity and radial and axial deformation of ring parts, and improved product quality consistency and product qualification rate , meeting the technical specification requirements of the product.
具体实施方式Detailed ways
下面结合具体实施例对本发明技术方案进行详细说明。The technical solutions of the present invention will be described in detail below in conjunction with specific embodiments.
本发明一种超大直径铝合金整体环的轧制生产方法,包括如下步骤:A rolling production method of an ultra-large-diameter aluminum alloy integral ring of the present invention comprises the following steps:
(1)环坯制备:通过自由锻造方法制备所需规格的环坯,进行车加工及超声波探伤检测,保证获得合格的环轧坯料;(1) Ring blank preparation: Prepare ring blanks of required specifications by free forging, and carry out lathe processing and ultrasonic flaw detection to ensure qualified ring rolling blanks;
锻造加工:自由锻方式获得外径为3500~4500mm、内径为3000~3500mm、高度为500~650mm的环坯;Forging process: free forging to obtain ring blanks with an outer diameter of 3500-4500mm, an inner diameter of 3000-3500mm, and a height of 500-650mm;
车加工:对环坯上、下端面及内、外圆面进行车加工,去除表面黑皮及折叠伤,表面粗糙度达到Ra3.2以上,圆度控制在1mm以内;Turning processing: Carry out turning processing on the upper and lower end faces of the ring blank, as well as the inner and outer circular faces, remove the black skin and fold damage on the surface, the surface roughness should reach Ra3.2 or more, and the roundness should be controlled within 1mm;
超声波探伤:对坯料上端面进行100%超声波探伤,按GJB2057标准A级验收,排除超标缺陷;Ultrasonic flaw detection: 100% ultrasonic flaw detection is carried out on the upper end surface of the billet, and it is accepted according to the GJB2057 standard A level, and the defects exceeding the standard are excluded;
(2)环坯加热:将环轧坯料在电炉中进行加热、保温;优选的技术方案是将环轧坯料放入电炉中,采用随炉升温方式,加热温度为420~460℃,保温时间为12~12.5h。(2) Ring billet heating: heat and keep the ring rolling billet in an electric furnace; the preferred technical solution is to put the ring rolling billet into the electric furnace, adopt the heating method with the furnace, the heating temperature is 420-460 °C, and the holding time is 12~12.5h.
(3)环轧成形:对环轧坯料进行二火次环轧成形;包括:(3) Ring rolling forming: carry out secondary ring rolling forming on the ring rolling billet; including:
(3.1)转运:将加热后的环轧坯料转运到环轧机上,转运时间小于290s,坯料表面温降控制在40℃以内;(3.1) Transfer: transfer the heated ring rolling billet to the ring rolling mill, the transfer time is less than 290s, and the temperature drop on the billet surface is controlled within 40°C;
(3.2)第一火轧制:采用直径为400~600mm的芯辊对环轧坯料进行辗轧,辗轧至环轧坯料的外径为5000~6000mm、高度为450~600mm,轧制比为1.2~2.0,径轴向压下量之比为2.0~3.0;(3.2) The first fire rolling: use core rolls with a diameter of 400-600mm to roll the ring-rolled billet until the outer diameter of the ring-rolled billet is 5000-6000mm and the height is 450-600mm, and the rolling ratio is 1.2~2.0, the ratio of radial to axial reduction is 2.0~3.0;
轧制过程分咬入阶段、快速轧制阶段、稳定轧制阶段、减速轧制阶段及成形整圆阶段共5个阶段进行:The rolling process is divided into five stages: biting stage, rapid rolling stage, stable rolling stage, deceleration rolling stage and forming full circle stage:
咬入阶段:环轧坯料咬入辊缝,开始建立轧制过程,该阶段只进行径向轧制,轴向轧辊无进给,轴向仅轧制由于径向轧制引起的宽展,咬入阶段轧制厚度值为整个轧制厚度变化量的5%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为3~5mm/s、径向进给速率为0.02~0.06mm/s、轴向进给速率为0~0.02mm/s;Biting stage: the ring rolling billet bites into the roll gap, and the rolling process starts to be established. In this stage, only radial rolling is carried out, and the axial roll has no feed. The rolling thickness value in the initial stage is 5% of the change in the entire rolling thickness; at this stage, the initial diameter increase rate is 1-3mm/s, the final diameter increase rate is 3-5mm/s, and the radial feed rate 0.02~0.06mm/s, axial feed rate 0~0.02mm/s;
快速轧制阶段:轧辊径向进给速度加快,环轧坯料随之快速长大,轴向进给按与径向进给成比例的进给,快速轧制阶段轧制厚度值为整个轧制厚度变化量的15%;在此阶段的直径初增大率为3~5mm/s、直径终增大率为5~12mm/s、径向进给速率为0.06~0.3mm/s、轴向进给速率为0.02~0.15mm/s;Rapid rolling stage: the radial feed speed of the rolls is accelerated, and the ring rolling billet grows rapidly accordingly, the axial feed is fed in proportion to the radial feed, and the rolling thickness value of the rapid rolling stage is 15% of the thickness change; at this stage, the initial diameter increase rate is 3-5mm/s, the final diameter increase rate is 5-12mm/s, the radial feed rate is 0.06-0.3mm/s, the axial The feed rate is 0.02~0.15mm/s;
稳定轧制阶段:控制芯辊与锥辊的进给速度,使其与环轧坯料的直径增长速度相匹配,使轧制过程快速、稳定进行,稳定轧制阶段轧制厚度值为整个轧制厚度变化量的60%;在此阶段的直径初增大率为5~12mm/s、直径终增大率为5~12mm/s、径向进给速率为0.15~0.4mm/s、轴向进给速率为0.04~0.2mm/s;Stable rolling stage: control the feed speed of the core roll and the tapered roll to match the diameter growth rate of the ring rolling billet, so that the rolling process can be carried out quickly and stably. 60% of the thickness change; at this stage, the initial diameter increase rate is 5-12mm/s, the final diameter increase rate is 5-12mm/s, the radial feed rate is 0.15-0.4mm/s, the axial The feed rate is 0.04~0.2mm/s;
减速轧制阶段:径向和轴向进给速度减小,环轧坯料长大速率随之降低,减速轧制阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为5~12mm/s、直径终增大率为1~5mm/s、径向进给速率为0.05~0.4mm/s、轴向进给速率为0.02~0.15mm/s;Deceleration rolling stage: The radial and axial feed speeds decrease, and the growth rate of the ring rolling billet decreases accordingly. The rolling thickness value in the deceleration rolling stage is 10% of the variation of the entire rolling thickness; the diameter at this stage The initial increase rate is 5-12mm/s, the final diameter increase rate is 1-5mm/s, the radial feed rate is 0.05-0.4mm/s, and the axial feed rate is 0.02-0.15mm/s;
成形整圆阶段:仅进行径向轧制,轴向仅轧制由于径向轧制引起的宽展,在仅有径向轧制的过程中进行整圆,同时消除因回弹引起的尺寸误差,成形整圆阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为1~3mm/s、径向进给速率为0.02~0.05mm/s、轴向进给速率为0~0.02mm/s;Forming full circle stage: only radial rolling is carried out, and the widening caused by radial rolling is only rolled in the axial direction, and the full circle is carried out in the process of only radial rolling, and the dimensional error caused by springback is eliminated at the same time , the rolling thickness value in the full-circle forming stage is 10% of the variation of the entire rolling thickness; The feed rate is 0.02-0.05mm/s, and the axial feed rate is 0-0.02mm/s;
(3.3)进行回炉保温2~4h,保温温度为420~460℃;(3.3) Return to the furnace for heat preservation for 2 to 4 hours, and the heat preservation temperature is 420 to 460 °C;
(3.4)第二火轧制:换直径为700~900mm的芯辊对环轧坯料进行辗轧,辗轧至外径为8000~10000mm、高度为400~550mm,轧制比为1.2~1.8,径轴向压下量之比为2.0~3.0;(3.4) Second fire rolling: Change the core roll with a diameter of 700-900mm to roll the ring-rolled billet until the outer diameter is 8000-10000mm, the height is 400-550mm, and the rolling ratio is 1.2-1.8. The ratio of radial to axial reduction is 2.0 to 3.0;
轧制过程同步骤(3.2)相同,分咬入阶段、快速轧制阶段、稳定轧制阶段、减速轧制阶段及成形整圆阶段共5个阶段进行:The rolling process is the same as step (3.2), and it is divided into five stages: biting stage, rapid rolling stage, stable rolling stage, deceleration rolling stage and forming full circle stage:
咬入阶段:环轧坯料咬入辊缝,开始建立轧制过程,该阶段只进行径向轧制,轴向轧辊无进给,轴向仅轧制由于径向轧制引起的宽展,咬入阶段轧制厚度值为整个轧制厚度变化量的5%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为3~8mm/s、径向进给速率为0.02~0.08mm/s、轴向进给速率为0~0.02mm/s;Biting stage: the ring rolling billet bites into the roll gap, and the rolling process starts to be established. In this stage, only radial rolling is carried out, and the axial roll has no feed. The rolling thickness value in the initial stage is 5% of the change in the entire rolling thickness; at this stage, the initial diameter increase rate is 1-3mm/s, the final diameter increase rate is 3-8mm/s, and the radial feed rate 0.02~0.08mm/s, axial feed rate 0~0.02mm/s;
快速轧制阶段:轧辊径向进给速度加快,环轧坯料随之快速长大,轴向进给按与径向进给成比例的进给,快速轧制阶段轧制厚度值为整个轧制厚度变化量的15%;在此阶段的直径初增大率为3~8mm/s、直径终增大率为8~15mm/s、径向进给速率为0.08~0.35mm/s、轴向进给速率为0.04~0.15mm/s;Rapid rolling stage: the radial feed speed of the rolls is accelerated, and the ring rolling billet grows rapidly accordingly, the axial feed is fed in proportion to the radial feed, and the rolling thickness value of the rapid rolling stage is 15% of the thickness change; at this stage, the initial diameter increase rate is 3-8mm/s, the final diameter increase rate is 8-15mm/s, the radial feed rate is 0.08-0.35mm/s, the axial The feed rate is 0.04~0.15mm/s;
稳定轧制阶段:控制芯辊与锥辊的进给速度,使其与环轧坯料的直径增长速度相匹配,使轧制过程快速、稳定进行,稳定轧制阶段轧制厚度值为整个轧制厚度变化量的60%;在此阶段的直径初增大率为8~15mm/s、直径终增大率为8~15mm/s、径向进给速率为0.15~0.5mm/s、轴向进给速率为0.08~0.3mm/s;Stable rolling stage: control the feed speed of the core roll and the tapered roll to match the diameter growth rate of the ring rolling billet, so that the rolling process can be carried out quickly and stably. 60% of the thickness change; at this stage, the initial diameter increase rate is 8-15mm/s, the final diameter increase rate is 8-15mm/s, the radial feed rate is 0.15-0.5mm/s, the axial The feed rate is 0.08~0.3mm/s;
减速轧制阶段:径向和轴向进给速度减小,环轧坯料长大速率随之降低,减速轧制阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为8~15mm/s、直径终增大率为1~5mm/s、径向进给速率为0.05~0.5mm/s、轴向进给速率为0.02~0.2mm/s;Deceleration rolling stage: The radial and axial feed speeds decrease, and the growth rate of the ring rolling billet decreases accordingly. The rolling thickness value in the deceleration rolling stage is 10% of the variation of the entire rolling thickness; the diameter at this stage The initial increase rate is 8-15mm/s, the final diameter increase rate is 1-5mm/s, the radial feed rate is 0.05-0.5mm/s, and the axial feed rate is 0.02-0.2mm/s;
成形整圆阶段:仅进行径向轧制,轴向仅轧制由于径向轧制引起的宽展,在仅有径向轧制的过程中进行整圆,同时消除因回弹引起的尺寸误差,成形整圆阶段轧制厚度值为整个轧制厚度变化量的10%;在此阶段的直径初增大率为1~3mm/s、直径终增大率为1~3mm/s、径向进给速率为0.02~0.05mm/s、轴向进给速率为0~0.02mm/s;Forming full circle stage: only radial rolling is carried out, and the widening caused by radial rolling is only rolled in the axial direction, and the full circle is carried out in the process of only radial rolling, and the dimensional error caused by springback is eliminated at the same time , the rolling thickness value in the full-circle forming stage is 10% of the variation of the entire rolling thickness; The feed rate is 0.02-0.05mm/s, and the axial feed rate is 0-0.02mm/s;
(3.5)环件轧制结束后在封闭环境中进行冷却,冷却过程中控制各个部位冷却速率一致;(3.5) Cool the ring in a closed environment after rolling, and control the cooling rate of each part to be consistent during the cooling process;
优选的技术方案是在步骤(3)中,轧制过程对主轧辊、芯辊、上锥辊、下锥辊、环坯的4个边角部位进行润滑,控制各个部位润滑均匀一致,控制环坯的表面温度在360~460℃。The preferred technical solution is that in step (3), the rolling process lubricates the four corners of the main roll, the core roll, the upper cone roll, the lower cone roll, and the ring blank, and controls the lubrication of each position to be uniform, and the control ring The surface temperature of the blank is 360-460°C.
(4)尺寸检测:对环轧成形的环件进行尺寸检测,获得满足质量要求的环件。具体的对车加工后的环形件进行尺寸检测的质量要求是环形件圆度≤5‰。(4) Dimensional inspection: carry out dimension inspection on rings formed by ring rolling to obtain rings that meet quality requirements. The specific quality requirement for dimensional inspection of ring parts after turning is that the roundness of the ring parts is ≤5‰.
整体轧制过程中要求环件具备一定的整体刚度和圆度,才能保证轧制过程顺利进行。大直径薄壁铝合金圆环的整体刚度很弱,并且随着环件瞬时直径的增大而进一步减小,轧制过程中后段容易产生塑性失稳而丧失整体圆度,导致轧制过程无法继续,或椭圆度超差产生废品。特别是环件的直径越大、质量越重,其轧制过程的稳定性越难控制,对环件轧制工艺的控制要求就越高,因此在保证产品性能的基础上控制环轧过程的稳定性是超大直径铝合金整体环轧制生产的一项关键技术。环成形工艺参数对环锻件轧制过程的顺利进行和最终成形质量有着非常重要的影响,因此必须对环轧成形的各个阶段的工艺参数进行合理的分配和精确的控制。本发明提供的一种超大直径铝合金整体环的轧制生产方法,解决了超大直径铝合金环件轧制过程中的圆度和尺寸的精确控制、轧制缺陷的控制及产品性能的控制,实现了超大直径铝合金整体环的“形-性”的协同控制,满足整体环件使用性能的要求。The overall rolling process requires the ring to have a certain overall rigidity and roundness in order to ensure the smooth progress of the rolling process. The overall rigidity of the large-diameter thin-walled aluminum alloy ring is very weak, and further decreases with the increase of the instantaneous diameter of the ring. During the rolling process, the latter part is prone to plastic instability and loses the overall roundness, resulting in the rolling process. Unable to continue, or the ovality is out of tolerance to produce waste. In particular, the larger the diameter and the heavier the quality of the ring, the more difficult it is to control the stability of the rolling process, and the higher the requirements for the control of the ring rolling process. Therefore, on the basis of ensuring product performance, control the ring rolling process. Stability is a key technology in the rolling production of super large diameter aluminum alloy monolithic rings. Ring forming process parameters have a very important impact on the smooth progress of the ring forging rolling process and the final forming quality, so the process parameters in each stage of ring rolling forming must be reasonably allocated and accurately controlled. The invention provides a rolling production method of a super-large-diameter aluminum alloy integral ring, which solves the problems of precise control of roundness and size, control of rolling defects, and control of product performance during the rolling process of super-large-diameter aluminum alloy rings. The "shape-property" coordinated control of the super-large-diameter aluminum alloy integral ring is realized, and the performance requirements of the integral ring are met.
下面通过实施例具体说明本发明提供的一种超大直径铝合金整体环的轧制生产方法。The rolling production method of a super-large-diameter aluminum alloy monolithic ring provided by the present invention will be specifically described below through examples.
实施例1Example 1
用自由锻造方式制备外径为3965mm、内径为3224mm、高度为575mm的环轧坯料,车加工后经探伤检验合格后,放置于电炉中随炉加热,加热温度为445℃、保温时间12h。A ring rolling billet with an outer diameter of 3965 mm, an inner diameter of 3224 mm and a height of 575 mm was prepared by free forging. After turning and passing the flaw detection inspection, it was placed in an electric furnace and heated with the furnace at a heating temperature of 445 °C and a holding time of 12 hours.
将加热后的环轧坯料转移至环轧机采用Φ500mm芯辊进行第一火环轧,辗环至外径5130mm、高度510mm,然后对其进行回炉保温,保温温度446℃、保温时间2.1h;换Φ800芯辊进行第二火环轧,轧制工艺参数如下表所示,辗环至外径8760mm、内径8379mm、高度470mm,轧制工艺参数如下表所示。Transfer the heated ring rolling billet to the ring rolling mill and use the Φ500mm core roll for the first fire ring rolling. The ring is rolled to an outer diameter of 5130mm and a height of 510mm, and then it is returned to the furnace for heat preservation. The heat preservation temperature is 446°C and the heat preservation time is 2.1h; The Φ800 core roll is used for the second fire ring rolling. The rolling process parameters are shown in the table below. The ring is rolled to an outer diameter of 8760mm, an inner diameter of 8379mm and a height of 470mm. The rolling process parameters are shown in the table below.
经尺寸测量,环件圆度为19mm,小于5‰,符合技术指标要求。After size measurement, the roundness of the ring is 19mm, less than 5‰, which meets the requirements of technical indicators.
实施例2Example 2
将外径为4100mm、内径为3300mm、高度为550mm的环轧坯料进行表面清理和探伤检验后,放置于电炉中随炉加热,加热温度为440℃、保温时间12.2h。The ring rolling billet with an outer diameter of 4100mm, an inner diameter of 3300mm and a height of 550mm is cleaned and inspected for flaws, and then placed in an electric furnace to be heated with the furnace at a heating temperature of 440°C and a holding time of 12.2h.
将加热后的环轧坯料转移至环轧机采用Φ500mm芯辊进行第一火环轧,辗环至外径5800mm、高度500mm,然后对其进行回炉保温,保温温度446℃、保温时间2.1h;换Φ800芯辊进行第二火环轧,轧制工艺如下表所示,辗环至外径9205mm、内径8812mm、高度460mm,轧制工艺参数如下表所示。Transfer the heated ring rolling blank to the ring rolling mill and use the Φ500mm core roll for the first fire ring rolling, rolling the ring to an outer diameter of 5800mm and a height of 500mm, and then return it to the furnace for heat preservation at a heat preservation temperature of 446°C and a heat preservation time of 2.1h; The Φ800 core roll is used for the second fire ring rolling. The rolling process is shown in the table below. The ring is rolled to an outer diameter of 9205mm, an inner diameter of 8812mm and a height of 460mm. The rolling process parameters are shown in the table below.
经尺寸测量,环件圆度为35mm,小于5‰,符合技术指标要求。After size measurement, the roundness of the ring is 35mm, which is less than 5‰, which meets the requirements of technical indicators.
Claims (4)
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