L形截面风电偏航轴承锻件近净轧制工艺数值模拟与优化

Numerical Simulation and Optimization of Near-Net Rolling Process for Wind Turbine Yaw Bearing Forgings with L-Shaped Section

为解决L形截面风电偏航轴承锻件近净轧制受力与变形不均匀,台阶径向宽度较大而轴向深度较浅,成形困难等问题,通过数值模拟和异形芯辊轧制试验对锻件成形效果进行分析,发现成形过程中坯料台阶高度方向的金属填充不满,金属存在折叠堆积的情况,修改锻件及坯料的尺寸后仍难以完全改善成形效果,因此提出异形锥辊近净轧制成形方案,通过试验验证了该方案的可行性,并分析了坯料尺寸对成形效果的影响,结果表明增大坯料的壁厚有利于改善锻件的最终成形效果。

In order to solve the problems of uneven forces and deformation during near-net rolling of wind turbine yaw bearing forgings with L-shaped section,large radial width and shallow axial depth of step,and difficult forming,the forming effect of the forgings is analyzed through numerical simulation and special-shaped mandrel rolling experiments.It is found that the metal in height direction of blank step is not filled during forming process,and the metal is folded and stacked.Even after modifying the dimensions of the forgings and blank,it is still difficult to improve the forming effect completely.Therefore,a near-net rolling forming scheme using special-shaped conical roller is proposed.The feasibility of the scheme is verified through experiments,and the influence of blank dimensions on forming effect is analyzed.The results show that increasing the wall thickness of blank is beneficial to improve the final forming effect of the forgings.