CN112935708A - Manufacturing process of ultra-large wheel belt forge piece - Google Patents
Manufacturing process of ultra-large wheel belt forge piece Download PDFInfo
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Abstract
本申请公开了一种超大型轮带锻件制造工艺，包括下述步骤：对板坯进行热处理；将板坯按照预设置尺寸进行切割制得单元坯料；对单元坯料进行铣削加工及清洗打磨，使粗糙度及清洁度达到预设置阈值；将单元坯料按照预设置顺序在堆垛平台上进行堆垛制得堆垛坯；将堆垛坯整体装入真空室进行真空电子束封焊制得封焊坯；对封焊坯进行锻造开坯；采用径‑轴向轧制将封焊坯轧制成型，以制得超大型轮带锻件。本申请公开的方法提供了一种降低原材料用量、提高毛坯表面质量的工艺成型方法，能够制造出成分偏析小、组织均匀、流线完整，综合成本较低的超大型轮带锻件。
The present application discloses a manufacturing process for a super-large tire forging, which includes the following steps: heat-treating a slab; cutting the slab according to a preset size to obtain a unit blank; milling, cleaning and grinding the unit blank to make The roughness and cleanliness reach the preset threshold; stack the unit blanks on the stacking platform according to the preset sequence to obtain the stacking blank; put the stacking blank into the vacuum chamber as a whole for vacuum electron beam sealing and welding to obtain the sealing welding billet; forging and opening the sealing and welding billet; adopting radial-axial rolling to roll the sealing and welding billet to form super-large tire forgings. The method disclosed in the present application provides a process forming method for reducing the amount of raw materials and improving the surface quality of the blank, which can manufacture super-large tire forgings with small component segregation, uniform structure, complete streamline and low comprehensive cost.
Description
Technical Field
The invention belongs to the technical field of manufacturing of ultra-large type forged pieces, and particularly relates to a manufacturing process of ultra-large type wheel belt forged pieces.
Background
The ultra-large forging is a key part in the fields of nuclear power, thermal power, hydropower, ships, engineering machinery manufacturing and the like, and the ultra-large forging is manufactured by using steel ingots with ultra-large sizes made of various materials. However, the conventional manufacturing process of the oversized die-cast steel ingot generally has the following problems: (1) the manufacturing process of the oversized die-cast steel ingot is complex and usually needs to be customized independently; (2) the problems of segregation, looseness, uneven element distribution and the like generally occur in the manufacturing process of the oversized die-cast steel ingot due to different cooling speeds of all parts and the like; (3) the oversized die-cast steel ingot has low material utilization rate in the manufacturing process, and about 20-35% of materials at a water gap, a riser and the like need to be cut off.
In addition, the production capacity and the technological level of the ultra-large forging piece are also one of the important marks for measuring the development level of the heavy industry and the self-sufficient capacity of the important key equipment in one country. At present, the manufacture of wheel band forgings mainly comprises two modes of free forging and roll forming. The following problems generally exist in the conventional free forging process for manufacturing the wheel band forged piece: (1) limited by equipment factors such as the opening size of an oil press and the like, the diameter of a forged piece adopting a free forging process is generally less than or equal to 7500 mm; (2) the free forging process has many forging fire times, and the internal structure of the forged piece is poor in homogenization; (3) the surface quality of the forged piece is poor, more machining allowance needs to be reserved, and the machining efficiency is low; (4) the free forging process has long manufacturing period and higher comprehensive production cost.
Therefore, a new manufacturing process of the ultra-large wheel band forging needs to be developed at present, so as to solve the above problems in the manufacturing process of the existing ultra-large steel ingot and the ultra-large wheel band forging and avoid the above defects.
Disclosure of Invention
It is an object of the present invention to provide a process for manufacturing very large wheel band forgings which solves or alleviates at least one or more of the technical problems of the prior art, or which at least provides a useful alternative. According to the manufacturing process of the ultra-large wheel belt forging piece, provided by the embodiment of the invention, on one hand, the problems of internal defects and the like in the existing manufacturing process of ultra-large steel ingots can be effectively improved; on the other hand, the defects of the existing free forging process for manufacturing the ultra-large wheel band forging can be effectively overcome, the rolling forming process for reducing the consumption of raw materials and improving the surface quality of a blank is provided, and the ultra-large wheel band forging with small component segregation, uniform tissue, complete streamline and lower comprehensive cost is manufactured.
In order to achieve the purpose, the embodiment of the invention provides a manufacturing process of an ultra-large wheel belt forging, which comprises the following steps:
(1) carrying out heat treatment on the plate blank to eliminate the structural stress of the plate blank;
(2) cutting the plate blank according to a preset size to prepare a unit blank;
(3) milling the unit blanks to enable the roughness of the unit blanks to reach a preset roughness threshold, and cleaning and grinding the milled unit blanks to enable the cleanliness of the unit blanks to reach a preset cleanliness threshold;
(4) stacking the treated unit blanks on a stacking platform according to a preset sequence to obtain stacking blanks;
(5) putting the whole stacking blank into a vacuum chamber for vacuum electron beam sealing welding to prepare a sealing welding blank;
(6) forging and cogging the seal welding blank, wherein the forging and cogging at least comprises one or more of upsetting, drawing, punching and reaming;
(7) and rolling and forming the seal welding blank by radial-axial rolling to obtain the ultra-large wheel belt forging.
Preferably, the temperature of the heat treatment in step (1) is 500 ℃ to 700 ℃.
Preferably, the milling in the step (3) comprises milling the upper surface and the lower surface of the unit blank, and the milling removal amount is 2-5mm, so that the roughness of the upper surface and the lower surface of the unit blank reaches Ra3.2-12.5; and/or
And milling four sides of the unit blank to enable the roughness of the four sides of the unit blank to reach Ra6.3-25.
Preferably, the cleaning and polishing in the step (3) includes cleaning and polishing the upper surface and the lower surface of the unit blank, so that the cleanness of the upper surface and the lower surface of the unit blank reaches RFU (RFU) less than or equal to 20.0.
Preferably, the vacuum electron beam sealing in step (5) adopts multi-stage sealing, wherein the multi-stage sealing at least comprises one-stage unit blank vacuum sealing and two-stage truncated cone blank vacuum sealing.
Further, the air pressure of the vacuum chamber in the primary unit blank vacuum seal welding is not more than 10-2Pa, welding voltage of 80-100KV, welding current of 100-150mA, welding speed of 150-300mm/min, and furnace temperature of 1150-1250 ℃.
Further, the air pressure of the vacuum chamber in the vacuum sealing welding of the secondary truncated cone blank is not more than 10-2Pa, welding voltage of 80-100KV, welding current of 100-150mA, platform rotation speed of 0.025-0.05 r/min, and secondary coneThe vacuum sealing welding of the bench blank adopts a gas heating furnace, and the furnace temperature is 1150-1250 ℃.
Preferably, the manufacturing process of the ultra-large wheel band forging further comprises the following steps:
(8) carrying out post-forging heat treatment on the ultra-large wheel band forging, wherein the post-forging heat treatment at least comprises one or more of normalizing and tempering;
(9) carrying out rough machining on the ultra-large wheel belt forge piece subjected to heat treatment after forging;
(10) performing performance heat treatment on the rough machined ultra-large wheel belt forging, wherein the performance heat treatment at least comprises one or more of quenching and tempering;
(11) and performing finish machining on the ultra-large wheel belt forging after the performance heat treatment.
Further, the normalizing temperature in the step (8) is 860-900 ℃, and the tempering temperature is 500-550 ℃; and/or
The surface roughness of the ultra-large wheel belt forging piece after rough machining in the step (9) is Ra6.3-12.5; and/or
The quenching temperature in the step (10) is 860 ℃ and 890 ℃, and the tempering temperature is 540 ℃ and 580 ℃.
Further, the manufacturing process of the ultra-large wheel band forging piece further comprises the following steps between the step (10) and the step (11):
ultrasonic detection, wherein the ultrasonic detection is used for detecting whether the internal quality of the ultra-large wheel belt forging has defects;
and sampling and detecting, wherein the sampling and detecting at least comprises one of sample decomposition and physical and chemical detection.
After having adopted above-mentioned technical scheme, the beneficial effect that this application was gained is:
(1) according to the manufacturing process of the ultra-large wheel belt forging, disclosed by the embodiment of the invention, the plate blank is cut into a plurality of unit blanks with smaller volumes, the unit blanks are used as elements of metal construction, the unit blanks are subjected to milling, cleaning and polishing, then the unit blanks are made into stacking blanks, and the stacking blanks are subjected to integral sealing welding by adopting a vacuum electron beam sealing welding process, so that ultra-large steel ingots can be manufactured. The metal construction molding technology is adopted to replace the traditional die-cast steel ingot, so that the prepared steel ingot with the oversized dimension realizes homogenization, densification and purification. Meanwhile, the manufacturing process of the ultra-large wheel band forging disclosed by the embodiment of the invention adopts a radial-axial rolling process to replace the traditional free forging process to manufacture the ultra-large wheel band forging. Compared with the traditional free forging process, the method disclosed by the embodiment of the invention has the characteristics of energy conservation, high efficiency, high material utilization rate and the like, and the ultra-large wheel band forge piece subjected to radial-axial rolling has compact internal structure, fine grains and complete streamline, and can effectively improve the strength, the wear resistance, the fatigue life and the like of the forge piece.
(2) The manufacturing process of the ultra-large wheel band forging disclosed by the embodiment of the invention adopts a multi-stage sealing and welding method, can make full use of the limit capacity of the existing processing equipment to manufacture the forging with the weight exceeding hundreds of tons, and can more effectively ensure the quality of the ultra-large wheel band forging by adopting multi-stage sealing and welding.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.
In the drawings:
FIG. 1 is a schematic flow chart illustrating a process for manufacturing a very large wheel band forging according to an embodiment of the present invention.
Detailed Description
In the following, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments may be modified in various different ways, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
First, the technical concept of the technical solution disclosed in the present invention will be explained. At present, two problems commonly exist in the production of ultra-large forgings, namely, the manufacturing process of ultra-large steel ingots and the forming process of ultra-large forgings. The traditional manufacturing process of the oversized steel ingot has the following problems: the manufacturing process is complex and needs to be customized independently; the problems of segregation, looseness, uneven element distribution and the like generally occur in the manufacturing process due to different cooling speeds of all parts and the like; and the material utilization rate is low, and about 20% -35% of materials at a water gap, a riser and the like need to be cut off. The problems commonly existing in the process of manufacturing the wheel band forging by adopting the traditional free forging process are as follows: the diameter of a forged piece is generally smaller than 7500mm under the limitation of equipment factors such as the opening size of an oil press and the like; the forging fire is more, and the internal structure of the forging is poor in homogenization; the surface quality of the forged piece is poor, more machining allowance needs to be reserved, and the machining efficiency is low; and the manufacturing period is long, and the comprehensive production cost is high.
In view of the above problems in the prior art, the present invention provides a novel manufacturing process for ultra-large wheel band forgings. The invention is described below with reference to the accompanying drawings.
The specific scheme is as follows:
FIG. 1 is a flow diagram illustrating one embodiment of a process for manufacturing a very large wheel band forging. As shown in fig. 1, the embodiment provides a manufacturing process of an ultra-large wheel band forging, which includes the following steps:
(1) carrying out heat treatment on the plate blank to eliminate the structural stress of the plate blank;
(2) cutting the plate blank according to a preset size to prepare a unit blank;
(3) milling the unit blanks to enable the roughness of the unit blanks to reach a preset roughness threshold, and cleaning and polishing the milled unit blanks to enable the cleanliness of the unit blanks to reach the preset cleanliness threshold;
(4) stacking the treated unit blanks on a stacking platform according to a preset sequence to obtain stacking blanks;
(5) putting the whole stacking blank into a vacuum chamber for vacuum electron beam sealing welding to prepare a sealing welding blank;
(6) forging and cogging the seal-welded blank, wherein the forging and cogging at least comprises one or more of upsetting, drawing, punching and reaming;
(7) and rolling and forming the seal welding blank by radial-axial rolling to obtain the ultra-large wheel belt forging.
In the manufacturing process of the ultra-large wheel band forging piece, the structural stress of the plate blank is eliminated through the step (1), so that the sealing and welding quality of the plate blank in the subsequent steps can be guaranteed. And then cutting the plate blank into unit blanks, and milling, cleaning and polishing the cut unit blanks to ensure that the roughness and the cleanliness of the unit blanks reach the standards, so that the quality of the seal-welded blanks in the subsequent steps can be ensured. And stacking the unit blanks according to a preset sequence to prepare a stacked blank, and integrally filling the stacked blank into a vacuum chamber by adopting a vacuum electron beam sealing and welding technology to seal and weld to prepare the steel ingot with the super-large size.
Compared with the traditional die casting process, the process for manufacturing the oversized steel ingot by adopting the metal construction blank process has the following advantages:
(1) and the homogenization manufacturing of large-size metal devices is realized. A plurality of metal blanks with smaller volumes are used as construction elements, the component uniformity of the metal blanks is far better than that of a large metal blank integrally cast in the prior art due to high solidification speed, and large-size metal devices constructed on the basis do not have obvious macrosegregation.
(2) Realizing the densification manufacturing of large-size metal devices. A plurality of metal blanks with smaller volumes are used as construction elements, and because the solidification speed is high, the simultaneous solidification can be almost realized, and the concentrated shrinkage cavities in the blanks are less loose. After deformation, heat preservation and multidirectional forging of the welding interface, the compactness is higher than that of a forging piece made of a traditional integral casting blank.
(3) Realizing the purification manufacture of large-size metal devices. A plurality of metal blanks with smaller volumes are used as construction elements, and the preparation cost and difficulty are low, so that the purification of the elements can be realized by adopting various flexible refining methods, and the purity of large-size metal devices constructed on the basis is higher than that of forgings made of traditional integral casting blanks.
(4) Realizing low-cost manufacture of large-size metal devices. The metal blank with small volume can be prepared by adopting large production means such as continuous casting and the like, and the manufacturing cost is far lower than that of a die casting means which is required to be adopted for preparing the metal blank with large volume, so the manufacturing cost can be greatly reduced. In addition, the continuous casting billet is used as a construction element, the loss of a riser and a nozzle of the traditional steel ingot is avoided, and the material utilization rate can be effectively improved.
Meanwhile, the manufacturing process of the ultra-large wheel band forging of the embodiment adopts a radial-axial rolling process to replace the traditional free forging process to manufacture the ultra-large wheel band forging. At present, the manufacturing process of the wheel band forging is mainly divided into two processes of free forging and roll forming. It is difficult to manufacture a monolithic annular forging with a diameter greater than 7000mm due to the free forging process subject to the space constraints of the forging apparatus. The ring rolling process (ring rolling) is an internationally recognized near-net-shape forming advanced manufacturing process, is suitable for forming ring, disc and cylinder forgings, and has the characteristics of energy conservation, high efficiency and high material utilization rate compared with the traditional free forging process, and the rolled product has compact internal structure, fine grains and complete streamline, and has very important significance for improving the strength, the wear resistance and the fatigue life of a workpiece. The ring rolling process has two forms of radial rolling and radial-axial rolling, the radial rolling is mainly suitable for rolling small ring parts such as pipeline flanges, and the radial-axial rolling process is mostly adopted for large wheel band forgings. Compared with radial rolling, the radial-axial rolling process has the advantages that end face rollers are added, the cross section is compressed in the radial direction and the axial direction in the rolling process, the rolling process is more stable, the end face of the formed forge piece is smoother, and the rolling ratio of the forge piece is relatively larger.
Compared with the traditional free forging process, the radial-axial rolling process for manufacturing the ultra-large wheel band forging piece has the following advantages:
(1) the size of the forging is not limited by the size, and the diameter of the maximum wheel belt forging can reach 16 meters at present.
(2) The rolling of the wheel band forging is generally finished within 20 minutes, and due to the fact that the wheel band forging is uniformly deformed, the rolling time is short, and the internal structure is well homogenized.
(3) The forging has good surface quality and small machining allowance.
(4) Short manufacturing period and low comprehensive cost.
In this example, the temperature of the heat treatment in step (1) was 500 ℃ to 700 ℃.
In this embodiment, the milling in step (3) includes milling the upper and lower surfaces of the unit blank, and the milling removal amount is 2-5mm, so that the roughness of the upper and lower surfaces of the unit blank reaches ra 3.2-12.5. And (4) cleaning and polishing in the step (3) comprises cleaning and polishing the upper surface and the lower surface of the unit blank so that the cleanness of the upper surface and the lower surface of the unit blank reaches RFU (radio frequency unit) less than or equal to 20.0. For the unit blank, the upper surface and the lower surface of the blank are key surfaces, and the roughness and the cleanliness of the upper surface and the lower surface have great influence on the quality of the subsequent sealing and welding blank.
And further, milling four sides of the unit blank to enable the roughness of the four sides of the unit blank to reach Ra6.3-25.
In this embodiment, the vacuum electron beam sealing in step (5) adopts multi-stage sealing, wherein the multi-stage sealing at least includes one-stage unit blank vacuum sealing and two-stage truncated cone blank vacuum sealing. By adopting the multistage seal welding method, the limit capacity of the existing processing equipment can be fully utilized, the forged piece with the weight exceeding hundreds of tons can be manufactured, and the quality of the ultra-large wheel belt forged piece can be more effectively ensured by adopting the multistage seal welding.
Further, the air pressure of the vacuum chamber in the primary unit blank vacuum seal welding is not more than 10-2Pa, welding voltage of 80-100KV, welding current of 100-150mA, and welding speed of 150-300 mm/min. And putting the seal welding blank into a gas heating furnace, wherein the furnace temperature is 1150-1250 ℃. And (3) forging the seal welding blank in three directions, molding the seal welding blank into a circular truncated cone blank in a mold, and then processing the circular truncated cone blank by a circular truncated cone blank machine.
Further, the air pressure of the vacuum chamber in the vacuum sealing welding of the secondary truncated cone blank is not more than 10-2Pa, welding voltage of 80-100KV, welding current of 100-150mA, and platform rotation speed of 0.025-0.05 r/min. And (3) placing the secondary cone frustum blank into a gas heating furnace, wherein the furnace temperature is 1150-1250 ℃.
In this embodiment, the manufacturing process of the ultra-large wheel band forging further includes the following steps:
(8) carrying out post-forging heat treatment on the ultra-large wheel band forging, wherein the post-forging heat treatment at least comprises one or more of normalizing and tempering;
(9) carrying out rough machining on the ultra-large wheel belt forged piece subjected to heat treatment after forging;
(10) performing performance heat treatment on the roughly machined ultra-large wheel band forging, wherein the performance heat treatment at least comprises one or more of quenching and tempering;
(11) and (5) carrying out finish machining on the ultra-large wheel belt forging with the performance subjected to heat treatment.
After forging, the ultra-large wheel belt forging is subjected to heat treatment, so that grains can be refined, stress can be eliminated, and preparation is provided for subsequent performance heat treatment.
The performance heat treatment comprises the items of stretching, impacting, hardness and the like, so that the manufactured ultra-large wheel belt forging can meet various performance requirements.
In this embodiment, the normalizing temperature in step (8) is 860 ℃ and 900 ℃, and the tempering temperature is 500 ℃ and 550 ℃.
In the embodiment, the surface roughness of the ultra-large wheel band forging after rough machining in the step (9) is Ra6.3-12.5.
In this embodiment, the quenching temperature in step (10) is 860-890 ℃, and the tempering temperature is 540-580 ℃.
In this embodiment, the manufacturing process of the ultra-large wheel band forging further includes the following steps between step (10) and step (11):
ultrasonic detection, wherein the ultrasonic detection is used for detecting whether the internal quality of the ultra-large wheel belt forging has defects;
and sampling and detecting, wherein the sampling and detecting at least comprises one of decomposing a sample and physical and chemical detection.
Ultrasonic detection is an important process in the manufacturing process of the ultra-large wheel belt forging, and can be used for detecting whether the internal quality of the forging is flawless or not and whether preset standard requirements can be met or not.
In order to facilitate understanding of the embodiment of the present invention, the following further describes an example manufacturing process of the ultra-large wheel band forging according to the embodiment of the present invention:
embodiment mode 1
Taking the manufacturing of the ultra-large type wheel belt forging as an example, the material of the forging is 28Mn 6. The diameter of the wheel band forging reaches 7388mm, the wall thickness is 542.5mm, the height is 1438mm, the weight of the forging stock exceeds 160 tons, if the wheel band forging is manufactured by adopting the traditional die casting steel ingot, the weight of the steel ingot exceeds 250 tons, and the defects of steel ingot component segregation, internal shrinkage cavity, inclusion and the like can cause adverse effects on the hardness, uniformity and service life of the forging. And if the free forging process is adopted for manufacturing, the size of the wheel band forging reaches or even exceeds the manufacturing limit of a domestic free forging press, so the manufacturing difficulty is extremely high.
Therefore, in the embodiment, the ultra-large wheel band forging is manufactured by combining the metal construction forming process and the forging and rolling process.
The method for manufacturing the ultra-large wheel belt forging comprises the following steps:
(1) heat treatment of the plate blank: after the plate blank is qualified by the reinspection, in order to eliminate the internal stress of the plate blank and ensure the sealing and welding quality, stress-removing heat treatment is firstly carried out, and the heating temperature is 500-700 ℃. Preferably, the heat treatment temperature is 650 ℃. + -. 10 ℃.
(2) Sawing the plate blank: and cutting the plate blank according to the preset size to obtain a plurality of unit blanks. Preferably, the slab is sawed into unit blanks of dimensions (length x width x height) 2000x1710x300mm, for a total of 26 blocks.
(3) Milling: 6 surfaces of the unit blank are milled. Preferably, the unit blank is dimensioned (length x width x height) to 2180x1690x293mm to achieve a roughness of ra6.3 on its upper and lower surfaces and a roughness of ra12.5 on the remaining four sides.
(4) Cleaning and polishing: and cleaning and polishing the upper surface and the lower surface of the unit blank. Preferably, the cleanness of the upper surface and the lower surface of the stainless steel plate is RFU less than or equal to 20.0.
(5) Assembling: and assembling the treated unit blanks on a stacking platform according to a preset sequence, wherein the time for integrally loading the unit blanks into a vacuum chamber is less than or equal to 12 hours.
(6) Vacuum sealing and welding of the primary unit blank: the air pressure of the vacuum chamber in the first-stage unit blank vacuum seal welding is not more than 10- 2Pa, welding voltage of 80-100KV, welding current of 100-150mA, and welding speed of 150-300 mm/min. Preferably, the vacuum chamber has a pressure of 10 deg.C or less-2Pa, welding voltage100KV, welding current 120mA, and welding speed 200 mm/min.
(7) Heating: and putting the seal welding blank into a gas heating furnace, wherein the furnace temperature is 1150-1250 ℃. Preferably, the furnace temperature is 1250 ± 20 ℃.
(8) Building and forming: and (3) forging the seal welding blank in three directions, molding the seal welding blank into a circular truncated cone blank in a mold, and then processing the circular truncated cone blank by a circular truncated cone blank machine.
(9) Sealing and welding the second-stage truncated cone blank: the air pressure of the vacuum chamber in the secondary truncated cone blank vacuum seal welding is not more than 10- 2Pa, welding voltage of 80-100KV, welding current of 100-150mA, and platform rotation speed of 0.025-0.05 r/min. Preferably, the vacuum chamber pressure 10-2Pa, welding voltage of 100KV, welding current of 120mA, and platform rotation speed of 0.03352 r/min.
(10) Heating: and (3) placing the secondary cone frustum blank into a gas heating furnace, wherein the furnace temperature is 1150-1250 ℃. Preferably, the furnace temperature is set to 1250 ℃ ± 20 ℃.
(11) Forging and cogging: the seal welding blank is processed by three-dimensional forging, upsetting, punching, chambering and the like. Preferably, the cogging size is φ 5000/φ 3000/1610 mm.
(12) Rolling and forming: and (3) rolling and forming the seal welding blank by using a 16-meter ultra-strong radial-axial numerical control ring rolling machine and adopting a radial-axial rolling process to prepare the ultra-large wheel belt forging. Preferably, the blank size of the final belt forging is phi 7455/phi 6225/1510 mm.
(13) Heat treatment after forging: adopting a normalizing and tempering heat treatment process, wherein the normalizing temperature is 870-.
(14) Rough machining: the rough machining requires that the surface of the forged piece is not allowed to have defects such as cracks, folds and the like, and the surface roughness reaches Ra6.3-12.5.
(15) Performance heat treatment: is a heat treatment performed to meet preset performance requirements, including at least one of tensile, impact, hardness, and the like. The quenching temperature in the performance heat treatment is 860-890 ℃, and the tempering temperature is 540-580 ℃.
(16) Semi-finishing: the semi-finishing requires that the forging piece has visible light on four sides and the roughness reaches Ra6.3.
(17) Ultrasonic detection: and (4) according to EN10228-3, checking whether the internal quality of the forged piece is defect-free and can meet the specification requirements.
(18) Sampling: at least one of decomposition of the sample and physical and chemical detection is included.
(19) Finish machining: the ultra-large wheel belt forging piece meets the requirements of drawings.
(20) And (6) packaging.
Through multiple tests, the nondestructive testing and the mechanical property of the ultra-large wheel belt forging manufactured by the method disclosed by the embodiment can meet the requirements of technical specifications.
While the invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and are not to be considered limiting of the invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically defined otherwise.
In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; the connection can be mechanical connection, electrical connection or communication; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise expressly stated or limited, "above" or "below" a first feature means that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact with each other via another feature therebetween. Also, the first feature being "on," "square," and "over" the second feature includes the first feature being directly above and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly above and obliquely above the second feature, or simply meaning that the first feature is at a lesser level than the second feature.
The above disclosure provides many different embodiments, or examples, for implementing different features of the invention. The components and arrangements of the specific examples are described above to simplify the present disclosure. Of course, they are merely examples and are not intended to limit the present invention. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples, such repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. In addition, the present invention provides examples of various specific processes and materials, but one of ordinary skill in the art may recognize applications of other processes and/or uses of other materials.
Claims (10)
1. The manufacturing process of the ultra-large wheel belt forging is characterized by comprising the following steps:
(1) carrying out heat treatment on the plate blank to eliminate the structural stress of the plate blank;
(2) cutting the plate blank according to a preset size to prepare a unit blank;
(3) milling the unit blanks to enable the roughness of the unit blanks to reach a preset roughness threshold, and cleaning and grinding the milled unit blanks to enable the cleanliness of the unit blanks to reach a preset cleanliness threshold;
(4) stacking the treated unit blanks on a stacking platform according to a preset sequence to obtain stacking blanks;
(5) putting the whole stacking blank into a vacuum chamber for vacuum electron beam sealing welding to prepare a sealing welding blank;
(6) forging and cogging the seal welding blank, wherein the forging and cogging at least comprises one or more of upsetting, drawing, punching and reaming;
(7) and rolling and forming the seal welding blank by radial-axial rolling to obtain the ultra-large wheel belt forging.
2. The manufacturing process of the ultra-large wheel band forging piece according to claim 1, characterized in that:
the temperature of the heat treatment in the step (1) is 500-700 ℃.
3. The manufacturing process of the ultra-large wheel band forging piece according to claim 1, characterized in that:
the milling in the step (3) comprises the step of milling the upper surface and the lower surface of the unit blank, wherein the milling removal amount is 2-5mm, so that the roughness of the upper surface and the lower surface of the unit blank reaches Ra3.2-12.5; and/or
And milling four sides of the unit blank to enable the roughness of the four sides of the unit blank to reach Ra6.3-25.
4. The manufacturing process of the ultra-large wheel band forging piece according to claim 1, characterized in that:
and (3) cleaning and polishing the upper surface and the lower surface of the unit blank, so that the cleanness of the upper surface and the lower surface of the unit blank reaches RFU (radio frequency unit) less than or equal to 20.0.
5. The manufacturing process of the ultra-large wheel band forging piece according to claim 1, characterized in that:
and (5) adopting multi-stage sealing welding for the vacuum electron beam sealing welding, wherein the multi-stage sealing welding at least comprises one-stage unit blank vacuum sealing welding and two-stage cone frustum blank vacuum sealing welding.
6. The manufacturing process of the ultra-large wheel band forging piece according to claim 5, wherein the manufacturing process comprises the following steps:
the air pressure of the vacuum chamber in the primary unit blank vacuum sealing welding is not more than 10-2Pa, welding voltage of 80-100KV, welding current of 100-150mA, welding speed of 150-300mm/min, and furnace temperature of 1150-1250 ℃.
7. The manufacturing process of the ultra-large wheel band forging piece according to claim 5, wherein the manufacturing process comprises the following steps:
the air pressure of the vacuum chamber in the secondary truncated cone blank vacuum seal welding is not more than 10-2Pa, welding voltage of 80-100KV, welding current of 100-150mA, platform rotation speed of 0.025-0.05 r/min, gas heating furnace for vacuum sealing and welding of the secondary cone frustum blank, and furnace temperature of 1150-1250 ℃.
8. The very large wheel band forging manufacturing process of claim 1, further comprising the steps of:
(8) carrying out post-forging heat treatment on the ultra-large wheel band forging, wherein the post-forging heat treatment at least comprises one or more of normalizing and tempering;
(9) carrying out rough machining on the ultra-large wheel belt forge piece subjected to heat treatment after forging;
(10) performing performance heat treatment on the rough machined ultra-large wheel belt forging, wherein the performance heat treatment at least comprises one or more of quenching and tempering;
(11) and performing finish machining on the ultra-large wheel belt forging after the performance heat treatment.
9. The manufacturing process of the ultra-large wheel band forging piece according to claim 8, wherein the manufacturing process comprises the following steps:
the normalizing temperature in the step (8) is 860 ℃ and 900 ℃, and the tempering temperature is 500 ℃ and 550 ℃; and/or
The surface roughness of the ultra-large wheel belt forging piece after rough machining in the step (9) is Ra6.3-12.5; and/or
The quenching temperature in the step (10) is 860 ℃ and 890 ℃, and the tempering temperature is 540 ℃ and 580 ℃.
10. The oversized wheel band forging manufacturing process according to claim 8, wherein the method further comprises the following steps between the step (10) and the step (11):
ultrasonic detection, wherein the ultrasonic detection is used for detecting whether the internal quality of the ultra-large wheel belt forging has defects;
and sampling and detecting, wherein the sampling and detecting at least comprises one of sample decomposition and physical and chemical detection.
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| CN202011465378 | 2020-12-14 | ||
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| CN114210893A (en) * | 2021-12-09 | 2022-03-22 | 山西太钢不锈钢股份有限公司 | Method for manufacturing large-diameter stainless steel round pipe blank |
| CN114505652A (en) * | 2022-03-04 | 2022-05-17 | 伊莱特能源装备股份有限公司 | Method for preventing surface cracking of austenitic stainless steel forging in manufacturing process |
| CN114603314A (en) * | 2022-02-21 | 2022-06-10 | 伊莱特能源装备股份有限公司 | Manufacturing process of support ring forge piece of ten-thousand-ton-level aluminum extrusion machine |
| CN116786739A (en) * | 2023-05-24 | 2023-09-22 | 伊莱特能源装备股份有限公司 | Rolling forming process of ultra-large-specification and ultra-large-wall-thickness cylinder |
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| CN116786739A (en) * | 2023-05-24 | 2023-09-22 | 伊莱特能源装备股份有限公司 | Rolling forming process of ultra-large-specification and ultra-large-wall-thickness cylinder |
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