大型风电轴承套圈滚道轧制数值模拟与实验

风电轴承是风电装备的关键零件,而套圈作为轴承的核心组件,对轴承服役寿命以及主机运行可靠性至关重要。环件径轴向轧制是制造各种大型无缝轴承套圈、回转支承、法兰环件的先进回转塑性成形工艺。目前,风电装备中应用的各种球轴承,其套圈滚道均是通过切削加工成形,材料浪费多,加工效率低,且滚道金属流线分布差,削弱了套圈的力学性能。文章以典型的大型双滚道风电轴承套圈为对象,开展其滚道轧制成形数值模拟和实验研究。通过环件轧制工艺理论分析,提出了主要工艺参数设计方法;建立套圈径轴向轧制热力耦合有限元模型,通过模拟分析,对轧制进给规程进行优化;根据模拟结果,开展了轧制实验,成功轧制成形出合格的双滚道轴承套圈。该文研究实现了大型风电轴承套圈滚道直接轧制成形,为风电以及其他领域用大型轴承套圈、回转支承环件节能节材的先进制造,提供了有效的工艺理论指导。

Numerical simulation and experimental study on raceway rolling of large wind power bearing ring

Wind power bearing is the key part of wind power devices.As the crucial component of bearing,the bearing ring plays a decisive role in the life and the reliability of the devices.Radial axial ring rolling is an advanced rotary plastic forming technology for manufacturing large seamless bearing rings,slewing bearings and flange rings.Currently,the bearing ring raceways of many typical ball bearings used in wind power devices are processed by cutting,which has large material consumption and low productivity.Moreover,the poor distribution of metal flow line weakens the mechanical properties.Focusing on the typical large double-raceway wind power bearing ring,this paper carried out a numerical and experimental study on raceway rolling.The design methods of the main forming parameters were proposed through theoretical analysis of ring rolling at first.Then a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring was established,and the feeding procedure of the rolling process was optimized by simulation analysis.Finally,the rolling experiment was performed and the qualified bearing ring was successfully rolled based on the simulation result.The research in this paper achieved the direct forming of raceway of large wind power bearing ring by rolling,which could provide an effective technological and theoretical instruction for processing the large bearing rings and slewing bearings in wind power and other fields with savings of material and energy.