大规格齿圈环锻件热致变形整形方法研究

Research on shaping methods for thermal deformation of large size ring gear forgings

大规格齿圈等环锻件作为风电、核电、水电及工程机械等重型装备的关键零部件,其制造精度直接影响了我国高端装备的服役性能和核心竞争力。大规格环锻件在热处理完成后,由于内外部因素释放了大量残余应力,导致环锻件发生变形,降低了尺寸精度。针对这一现象,基于功能定理和主应力法对齿圈等环锻件的变形状态进行分析,计算获得了齿圈环锻件整形所需的整形力。利用有限元分析软件对齿圈环锻件进行整形仿真分析,获得整形后的齿圈变形量。基于理论分析结论,设计了齿圈环锻件整圆机,搭建整形试验平台,分别对直径φ1000 mm,φ3500 mm的齿圈进行整形试验。试验结果表明,齿圈环锻件尺寸误差由原来的1.73 mm、3.24mm降低至0.37 mm、0.67 mm,该整形理论与整形方案可以有效地降低齿圈环锻件的尺寸误差。

The manufacturing precision directly affects the service performance and core competitiveness of high-end equipment in China and after the manufacture of large size ring gear forgings,the internal stress of the material is released due to internal and external factors,which results in the deformation of the ring gear and reduces the dimensional accuracy.Aiming at this phenomenon,the deformation state of ring gear was analyzed based on function theorem and principal stress method,and the reshaping force required for ring gear shaping was calculated.Finite element software was carried out to simulate and analyze the shaping of ring gear,and the deformation of ring gear after shaping was obtained.Based on the self-developed ring gear rounding machine,the ring gear shaping test platform was built,and the ring gear with diameters of 1000 mm and 3500 mm were shaped.The experimental results showed that the dimension error of ring gear reduces from 1.73 mm to 3.24 mm and 0.37 mm to 0.67 mm respectively.The results of the present work implied the shaping theory and shaping scheme can effectively reduce the dimension error of gear ring.