锻压技术

煤矿坑道钻机用深孔套管精密成形工艺开发

英文标题：Development of precision forming process for deep hole casing used in coal mine tunnel drilling rig

作者：张培彦

分类号：TG314.3

出版年,卷(期):页码：2024,49(10):35-45

摘要：

针对某型号煤矿坑道钻机用深孔套管传统工艺中存在的材料利用率低、零件寿命低、锻件余量大等问题，根据深孔套管的结构特点，开发了一种新的无飞边精密成形工艺。首先，利用Gleeble-1500D热模拟试验机对深孔套管所用材料40Cr合金钢进行了高温压缩实验，得到了不同温度和应变速率下的真实应力-真实应变曲线。然后，将其导入Deform-3D数值模拟软件中，对深孔套管的精密成形过程进行模拟，得到成形过程中冲头载荷及应力场、温度场分布等。最后，根据模拟结果并结合实际生产条件，设计了深孔套管精密成形模具结构并进行了工艺实验验证。数值模拟结果显示，预锻阶段上冲头的载荷峰值为3920 kN，终锻阶段则为6440 kN,模具应力在许用应力范围内。工艺实验得到的深孔套管锻件充填饱满，锻件尺寸一致性较好，无锻造缺陷，金属流线沿锻件轮廓分布，符合设计要求。研究结果表明，提出的深孔套管精密成形工艺是可行的，对该类零件的实际生产具有一定的指导意义。

For the problems of low material utilization, low life of part, and large allowance of forgings in the traditional process of deep hole casing used in a certain model of coal mine tunnel drilling rig, based on the structural characteristics of deep hole casing, a new precision forming process without burrs was developed. Firstly, a high-temperature compression experiment was conducted on 40Cr alloy steel used in deep hole casing by thermal simulation testing machine Gleeble-1500D, and the true stress-true strain curves at different temperatures and strain rates were obtained. Then, they were imported into the numerical simulation software Deform-3D to simulate the precision forming process of deep hole casing, and the punch load, stress field distribution and temperature field distribution during the forming process were obtained. Finally, based on the simulation results and combined with the actual production conditions, a precision forming mold structure for deep hole casing was designed and validated by process experiments. The numerical simulation results show that the peak load of punch during the pre-forging stage is 3920 kN, and it is 6440 kN during the final forging stage. The stress of mold is within the allowable stress range. And the deep hole casing forgings obtained from the process experiment is fully filled, with good dimensional consistency and no forging defects. The metal flow line is distributed along the contour of forgings, which meets the design requirements. The research results indicate that the proposed precision forming process of deep hole casing is feasible and has certain guiding significance for the actual production of such parts.

基金项目：

河南省高等学校重点科研项目(24B430021);河南省高等教育教学改革研究与实践项目(2024SJGLX0737)

作者简介：张培彦（1979-），男，硕士，副教授,E-mail：zpy20230627@163.com

参考文献：

[1]张幼振,刘焱杰,钟自成,等. 煤矿全液压动力头式钻机振动测试与分析[J].煤炭科学技术, 2022, 50(2): 271-279.

Zhang Y Z, Liu Y J, Zhong Z C, et al. Vibration measurement and analysis of full hydraulic power head drilling rig in coal mine [J]. Coal Science and Technology, 2022, 50 (2): 271-279.

[2]石智军,姚克,姚宁平,等. 我国煤矿井下坑道钻探技术装备40年发展与展望[J].煤炭科学技术, 2020, 48(4): 1-34.

Shi Z J, Yao K, Yao N P, et al. 40 years of development and prospect on underground coal mine tunnel drilling technology and equipment in China [J]. Coal Science and Technology, 2020, 48 (4): 1-34.

[3]刘若君. 大功率全液压坑道钻机关键部件故障诊断研究[D].北京：煤炭科学研究总院，2023.

Liu R J. Research on Fault Diagnosis of Key Components of High Power Full Hydraulic Tunnel Drilling Rig [D]. Beijing: China Coal Research Institute, 2023.

[4]刘焱杰. 煤矿坑道动力头式钻机钻进系统振动特性研究[D].北京：煤炭科学研究总院，2022.

Liu Y J. Study on Vibration Characteristics of Drilling System of Power Head Drilling Rig in Coal Mine Tunnel [D]. Beijing: China Coal Research Institute, 2022.

[5]林波，刘祥. 汽车用铝合金深孔件精密锻造成形工艺研究[J].锻压技术, 2023, 48(8):48-56.

Lin B，Liu X. Research on precision forging process for automobile aluminum alloy deep-hole part[J]. Forging & Stamping Technology, 2023, 48(8):48-56.

[6]王姝俨，夏华. 深孔筒套精密成形工艺及模具设计[J].精密成形工程，2016,8(5):147-151.

Wang S Y, Xia H. Deep-hole sleeve precision forming technology and die design[J].Journal of Netshape Forming Engineering，2016,8(5):147-151.

[7]李冰,陈星合,付博文，等.7075铝合金线材连续流变挤压与双级时效热处理研究[J].稀有金属,2023,47(9):1195-1203.

Li B,Chen X H, Fu B W, et al.Continuous rheo-extrusion and double aging heat treatment of 7075 aluminum alloy wire[J].Chinese Journal of Rare Metals，2023,47(9):1195-1203.

[8]罗林丰. 4130钢阀体多向模锻过程晶粒演化及数值模拟研究[D].秦皇岛：燕山大学，2021.

Luo L F. Study on Grain Evolution and Numerical Simulation of 4130 Steel Valve Body in Multi-directional Die Forging Process [D]. Qinhuangdao: Yanshan University, 2021.

[9]刘乐, 石大鹏, 孙晓军, 等.航天用7055高强铝合金热变形行为及热加工图[J]. 特种铸造及有色合金, 2022, 42(5):564-568.

Liu L, Shi D P, Sun X J, et al. Hot deformation behavior and hot working diagram of 7055 high-strength aluminum alloy for aerospace use [J]. Special Casting & Nonferrous Alloy, 2022, 42 (5): 564-568.

[10]马世博, 孙立科, 张双杰, 等.多台阶电机轴镦挤复合成形工艺[J]. 塑性工程学报, 2021, 28 (7): 29-35.

Ma S B,Sun L K,Zhang S J, et al. Upsetting extrusion composite forming process of multi-step electromotor shaft [J]. Journal of Plasticity Engineering, 2021, 28 (7): 29-35.

[11]尚勇, 姜海峰, 李英发，等. 30CrNiMo8钢的热变形行为及热加工图[J]. 金属功能材料，2023，30(4):66-72.

Shang Y, Jiang H F, Li Y F, et al. Hot deformation behavior and hot working diagram of 30CrNiMo8 steel [J]. Metal Functional Materials, 2023, 30 (4): 66-72.

[12]张芳萍, 高毅, 和蕊芳，等. 316L/Q420双金属热变形行为及热加工图[J].塑性工程学报，2023，30 (11):98-105.

Zhang F P, Gao Y, He R F, et al. Thermal deformation behavior and hot processing map of 316L/Q420 bimetal [J]. Journal of Plasticity Engineering, 2023, 30 (11): 98-105.

[13]GB/T 6394—2017, 金属平均晶粒度测定方法[S].

GB/T 6394—2017, Determination of estimating the average grain size of metal[S].

[14]刘乐,殷银银,金宏,等.行星齿轮架中空多向锻造工艺及模具设计[J].制造技术与机床,2022(6):140-146.

Liu L, Yin Y Y, Jin H, et al. Multi direction forging process and die design of hollow planetary carrier [J]. Manufacturing Technology & Machine Tool, 2022(6): 140-146.

[15]徐芳,乐沛雯,李寒松，等.第二代镍基单晶高温合金高温氧化行为及机制研究[J].稀有金属,2023,47(4):493-501.

Xu F, Le P W, Li H S, et al. High-temperature oxidation behavior and mechanism of second-generation nickel-based single crystal superalloy[J]. Chinese Journal of Rare Metals，2023,47(4):493-501.

[16]陈刚,姚远超,贾寓真, 等.30Cr4MoNiV超高强度钢热变形本构方程的构建与优化[J].材料导报, 2022, 36(21):194-200.

Chen G, Yao Y C, Jia Y Z, et al. Construction and optimization of hot deformation constitutive equation of 30Cr4MoNiV ultra-high-strength steel [J]. Materials Reports, 2022, 36 (21): 194-200.

服务与反馈：

【文章下载】【加入收藏】