φ200悬臂式精轧机油膜—滚子组合轴承开发研究
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摘要
现代高速线材精轧机为满足线材产品的大量需求，不断向高速化方向发展，其代表轧机有八十年代从德国DEMAG公司引进的侧交15°/75°型φ200悬臂式精轧机。然而，φ200悬臂式精轧机从试生产至今，频繁发生油膜轴承短寿烧损事故，造成年经济损失达一百多万元，严重困扰生产。
用间接测定轧制力和直接测定油膜轴承润滑油温度的方案对φ200悬臂式精轧机进行现场实测轧制力和油温，查明导致油膜轴承短寿烧损问题的原因。
利用机构学和动力学理论，分析φ200悬臂式精轧机辊系的动态行为。针对实验查明的油膜轴承短寿烧损原因共给出五种解决方案，分别为自位式、拉杆式、斜铁式、偏心套式和油膜—滚子组合轴承式。概述每种方案的理论依据并给出改造示意图，经过认真综合、比较，最后确定选用油膜—滚子组合轴承方案。
建立油膜—滚子组合轴承载荷特性的匹配原理。在φ200悬臂式精轧机最恶劣工况条件下，用ANSYS有限元法软件模拟计算辊轴辊颈在油膜轴承宽度方向上的偏斜量，并用滚动轴承载荷三维分布的边界元法专用程序3—DECBBEM及相关前后处理程序计算滚子轴承的压扁量。利用计算结果给出油膜—滚子组合轴承方案中油膜轴承与滚子轴承中心线的偏心距。
针对φ200悬臂式精轧机现有辊系结构，开发设计油膜—滚子组合轴承。确定改造方案的具体结构，即对每个改造件都给出改造说明和改造后的结构简图。
油膜—滚子组合轴承，不仅防止原油膜轴承在重载下的油膜破坏，还显著强化轴承的承载能力，可解决单一油膜轴承烧损短寿问题，具有重要的学术意义和工程实用价值。
In order to meet the great need of providing wire products, modern high-speed wire mills will develop to be of higher working speed. The typical kind of mills is lateral intersection 15°/75°φ200 cantilever finishing mill. However, from its pilot to now, there are frequent occurrences of the shortened longevity and burning damage accidents of oil film bearing of φ 200 cantilever finishing mill. The result is more than one million of economic losses every year and hardship of production.
A new scheme of indirectly measuring rolling force and directly measuring temperature of lubricating oil is used to measure the magnitude of rolling force and temperature of lubricating oil. All these measurements above are to study the reasons of shortened longevity and burning damage accidents of oil film bearing.
With the theory of mechanism and dynamics, the dynamic behavior of roll system of φ 200 cantilever finishing mill has been analyzed. According to these reasons, five projects which can solve the problem has been presented: self-aligning, puller, lean-iron, eccentric-cover and oil film-roller bearing. The paper gives the references and drawing of each project. After the comparison of synthetic function among the five projects, oil film-roller bearing project has been chosen.
The theoretical modal of oil film-roller bearing's load was set up. With the worst working conditions, the FEM software ANSYS was used to calculate the deflection of roll shaft in the width direction of oil film bearing as well as the software program 3-DECBBEM and corresponding supporting programs are used to calculate the press flat of the roller bearing in the width direction of roller bearing. The result will be used to determine excursion between center line of oil film bearing and roller bearing.
Oil film-roller bearing is designed and produced in accordance with the existing construct of roll system of φ 200 cantilever finishing mill. Then, part of detailed structure of oil film-roller bearing will be determined. The paper will give the declaration and drawing of each component reformed.
Oil film-roller bearing can not only prevent film's destruction when oil film bearing is on heavy load, but also extremely reinforce capacity load bearing of oil film bearing. It can solve the problem of shortened longevity and burning damage accidents of oil film bearing. Above all, this will have important academic significance and value of engineering utilitarian.
用间接测定轧制力和直接测定油膜轴承润滑油温度的方案对φ200悬臂式精轧机进行现场实测轧制力和油温，查明导致油膜轴承短寿烧损问题的原因。
利用机构学和动力学理论，分析φ200悬臂式精轧机辊系的动态行为。针对实验查明的油膜轴承短寿烧损原因共给出五种解决方案，分别为自位式、拉杆式、斜铁式、偏心套式和油膜—滚子组合轴承式。概述每种方案的理论依据并给出改造示意图，经过认真综合、比较，最后确定选用油膜—滚子组合轴承方案。
建立油膜—滚子组合轴承载荷特性的匹配原理。在φ200悬臂式精轧机最恶劣工况条件下，用ANSYS有限元法软件模拟计算辊轴辊颈在油膜轴承宽度方向上的偏斜量，并用滚动轴承载荷三维分布的边界元法专用程序3—DECBBEM及相关前后处理程序计算滚子轴承的压扁量。利用计算结果给出油膜—滚子组合轴承方案中油膜轴承与滚子轴承中心线的偏心距。
针对φ200悬臂式精轧机现有辊系结构，开发设计油膜—滚子组合轴承。确定改造方案的具体结构，即对每个改造件都给出改造说明和改造后的结构简图。
油膜—滚子组合轴承，不仅防止原油膜轴承在重载下的油膜破坏，还显著强化轴承的承载能力，可解决单一油膜轴承烧损短寿问题，具有重要的学术意义和工程实用价值。
In order to meet the great need of providing wire products, modern high-speed wire mills will develop to be of higher working speed. The typical kind of mills is lateral intersection 15°/75°φ200 cantilever finishing mill. However, from its pilot to now, there are frequent occurrences of the shortened longevity and burning damage accidents of oil film bearing of φ 200 cantilever finishing mill. The result is more than one million of economic losses every year and hardship of production.
A new scheme of indirectly measuring rolling force and directly measuring temperature of lubricating oil is used to measure the magnitude of rolling force and temperature of lubricating oil. All these measurements above are to study the reasons of shortened longevity and burning damage accidents of oil film bearing.
With the theory of mechanism and dynamics, the dynamic behavior of roll system of φ 200 cantilever finishing mill has been analyzed. According to these reasons, five projects which can solve the problem has been presented: self-aligning, puller, lean-iron, eccentric-cover and oil film-roller bearing. The paper gives the references and drawing of each project. After the comparison of synthetic function among the five projects, oil film-roller bearing project has been chosen.
The theoretical modal of oil film-roller bearing's load was set up. With the worst working conditions, the FEM software ANSYS was used to calculate the deflection of roll shaft in the width direction of oil film bearing as well as the software program 3-DECBBEM and corresponding supporting programs are used to calculate the press flat of the roller bearing in the width direction of roller bearing. The result will be used to determine excursion between center line of oil film bearing and roller bearing.
Oil film-roller bearing is designed and produced in accordance with the existing construct of roll system of φ 200 cantilever finishing mill. Then, part of detailed structure of oil film-roller bearing will be determined. The paper will give the declaration and drawing of each component reformed.
Oil film-roller bearing can not only prevent film's destruction when oil film bearing is on heavy load, but also extremely reinforce capacity load bearing of oil film bearing. It can solve the problem of shortened longevity and burning damage accidents of oil film bearing. Above all, this will have important academic significance and value of engineering utilitarian.
引文
1 陈汉騄．高速线材精轧机的最新发展．北京：冶金工业出版社，2001：1-2
2 郭溪泉，李树青．现代大型连轧机油膜轴承．北京：机械工业出版社，2000：1-2
3 郭溪泉．轧机油膜轴承计算进步与创新探讨．太原重型机械学院学报，2000，增刊：5-8
4 申福昌．当今轧机油膜轴承的技术现状．太原重型机械学院学报，1998，(1)：13-15
5 曲庆文，朱均．薄膜润滑的等效粘度模拟计算．机械科学与技术，1996，(15)：25-28
6 中国机械工程学会，第一机械工业部．机修手册-滑动轴承．北京：机械工业出版社，1976：1-2
7 杨建奎，孟心斋．液体静压支承静态性能新表达式与应用．洛阳工学院学报，2001，(1)：11-14
8 [英]RJ．威尔逊．滑动轴承设计手册．尚礼 译．北京：机械工业出版社，1989：142-144
9 胡雄海，汪久根，章维明．污染对滑动轴承性能的影响．农业机械学报，2001，32(6)：21-23
10 郭大威，徐桢基，顾敦清，等．滑动轴承的失效分析．北京：机械工业出版社，1985：18-53
11 成西平．高速线材轧机油膜轴承．北京：冶金工业出版社，2001：916-920
12 Venner C H, Napel W E Ten, Bosma R.Advanced Multilevel Solution of The EHL Line Contact Problem. ASME Journal of Tribology, 1998,112(3): 23-26
13 McIvor J D C, Fenner D N. Finite Element Analysis of Dynamically Loaded Flexible Journal Bearing: A Fast Newton-Raphson Method. ASME Journal of Tribology, 1989,111(4): 17-23
14 Cameron A. Basic Lubrication Theory. New York: John Wiley&Sons, 1981: 35-50
15 李长城．高速线材轧机φ500mm粗轧机组测试与研究．钢铁，2002，(3)：7-12
16 杨沛然．流体润滑数值分析．北京：国防工业出版社，1998：20-52
17 [美]S．铁摩辛柯，J．盖尔．材料力学．北京：科学出版社，1978：122-123
18 Courant, R.,Variational Method for Solutions of Problems of Equilibrium and Vibrations. Bull.Am. Math. Soc. 1943, (49): 1-23
19 Turner, M.J., Clough, R.W., Martin H.C., Topp L.C. Stiffness and Deflection Analysis of Complex Structures J.Aero. Sci. 1956, (23): 805-823
20 Clough, R.W. The Finite Element Method in Plane Stress Analysis. Proc. 2nd
ASME Conference on Electronic Computation, Pittsburgh, Pa., Sept. 1960.41-48
21 王勖成，劭敏．有限单元法基本原理和数值方法．北京：清华大学出版社，1997：1-2
22 谢贻权，何福保．弹性和塑性力学中的有限单元法．北京：机械工业出版社，1981：1-2
23 李人宪．有限元法基础．北京：国防工业出版社，2002：3-4
24 夸克工作室．有限元分析基础篇ANSYS与Mathematica．北京：清华大学出版社，2002：2-4
25 T．A．Harris．滚动轴承分析．罗继伟 译．1997：321-350
26 A.B.Jones. Analysis of Stresses and Deflections.new Departure Engineering Date, Bsistol. Cone, 1946, (6): 135-152
27 [英]F．T．E威尔．轴承系统—理论与实践．西安交大零件教研室译．北京：机械工业出版社，1983：125-136
28 Ozen, M., McKenzie, M., Generalized Chock and Bearing Analysis Procedure, 4th International ANSYS Conference and Exhibition 1989. PA, USA Publ by ANSYS,1989,(4):47-54
29 Yuanke, L., Guangwei, C., Jun, Y., Qigui, Z., Caiyun, Z., 3-D Finite Element Analysis of Rolling Mill Bearings, America Society of Mechanical Engineers, Design Engineering Division DE v19 pt1 Sep 17-21 1989 1989 New York, NY, USA Publ by ASME, 1989,19(1): 417-421
30 W.W. CHENG. Experimental and Numerical Study of Multi-body Contact System with Roller Bearing - Part Ⅱ: Semi-Finite Element Analysis and Optical Design of Housing, 2000, 36(1): 166-172
31 Filetu, E.G. Rumbarger, J.H. A General Method for Predicting The Influence of Structural Support on Rolling Element: Bearing Performance. Jour. Of Lubr. Tech, 1970,92(1): 121-128
32 Bardlein,J. The Stressing of Rolling Bearings in Elastic Housings. FAG Ball and Roller Bearing Eng. 1973,12(1):4-9
33 Marciniec A., Torstenfelt B. Load Distribution in Flexibly Supported Three-row Roller Slew Bearing. Trib. Trans,2000, (37) :757-769
34 Chen,W., Zhu,F. and Luo,J. Computational Finite Element Analysis and Optimal Design for Multi-body Contact System. Compter Meth. In Appl. Mech. And Eng, 1988,(71):31-39
35 Ozen,M., Mckenzie M.R. Stress Analysis of Rolling Element Bearings Using The Finite Element Method. SAE Paper 881234.1988:423-462
36 Mckenzie M.R., Ozen, M. The Effect of Housing Clearance on The Life of Cylindrical Roller Bearings. Lubr. Eng, 1988,44(9):810-815
37 罗继伟．用有限元法分析轴承座弹性变形对圆柱滚子轴承载荷分布的影
响．洛阳轴承研究所技术报告，1993，(3)：13-18
38 M.A.Honeygosky, T.A.Garcia,J.A.Butine. Finite Element Analysis of A Work Roll Chock and Roller Bearing Assembly. Iron and Steel Engineer. 1993: 43-49
39 A.B.Jones, T.A.Harris. Analysis of A Rolling Element Idler Gear Bearings Having A Deformable Outer Race Structure. ASME J. Basic Eng, 1963,(6): 273-278
40 T.A.Harris, J.L.Broschard. Analysis of An Improved Planetary Gear Transmission Bearing. ASME J.Basic Eng, 1964,(9):457-462
41 胡于进，李元科．边界元法在滚动轴承载荷分布计算中的应用．轴承，1994，(6)：5-8
42 束学道，陈占福，申光宪等．轧机轴承负荷特性数值解析．重型机械，1999(1)：31-34
43 Shu Xuedao,etc, Computation of Three-dimensional Distribution of Contact Pressure on Roller Bearing by BEM. Proceeding of the Eighth China-Japan Symposium on BEM, 1998:210-215
44 束学道，郭景峰，申光宪．轧机轴承负荷特性边界元并行解法．计算力学研究与进展，2000，(3)：255-258
45 申光宪，兰兴昌．多列滚子轴承三维接触压力分布的数值解析．计算结构力学及其应用，1990，7(3)：9-16
46 C.A.Brebbia T. Anderson. The Boundary Element Method Applied to Two-dimensional Contact Problem with Friction, Boundary Element methods, ed. by, Springer-Verlag, Berlin. 1981: 153-164
47 C.A.Brebbia et al. Boundary Element Method Techniques. NY:Springer—Verlag. 1984: 213-240
48 Andersson T. The Boundary Element Method Applied 2-D Contact Problems with Friction. BEM. Brebbia(Ed).SV. Berlin. 1982. 45-52
49 Liu Shubin. Improvement of BEM Applied to Contact Problems and Its Application in 3-D Problems. BEM Du Qinghua(Ed).PERGAMON Press. 1986:71-78
50 Shen Guangxian.et al.Elasto-plastic Contact Analysis by BEM.BEM M.Tanaka.et al(Ed).ESP. 1993：153-158
51 Xiao Hong.et al.Three Dimensional Elasto-plastic Contact Boundary Element Analysis for Rolling with Consideration of Friction. Chinese Journal of Mechanicl Engineering, 1998,1 (11): 35-40
52 Shen Guangxian.et al.The BEM to Contact Problems in 3-D Elasticity with Friction. The 4-th China-Japan Symposium on BEM.Beijing. 1991：61-68
53 兰兴昌．三维弹性接触问题的边界元法．[燕山大学工学硕士论文]．1988：57-80
54 Brebbia C A. The Boundary Element Method for Engineering. Pentech Press,London. 1978:9-16
55 Brebbia C A.,Telles J C F, Wroble L C.Boundary Element Technique. Theory and Application in Engineering. 1984: 153-162
56 束学道等．轧机轴承载体特性板单元边界元法模拟．重庆建筑大学学报增刊，2000，(12)：35-40
57 束学道．铝箔轧机二维微尺度可控辊系理论与实验研究．[燕山大学工学博士论文]．2000：32-51
2 郭溪泉，李树青．现代大型连轧机油膜轴承．北京：机械工业出版社，2000：1-2
3 郭溪泉．轧机油膜轴承计算进步与创新探讨．太原重型机械学院学报，2000，增刊：5-8
4 申福昌．当今轧机油膜轴承的技术现状．太原重型机械学院学报，1998，(1)：13-15
5 曲庆文，朱均．薄膜润滑的等效粘度模拟计算．机械科学与技术，1996，(15)：25-28
6 中国机械工程学会，第一机械工业部．机修手册-滑动轴承．北京：机械工业出版社，1976：1-2
7 杨建奎，孟心斋．液体静压支承静态性能新表达式与应用．洛阳工学院学报，2001，(1)：11-14
8 [英]RJ．威尔逊．滑动轴承设计手册．尚礼 译．北京：机械工业出版社，1989：142-144
9 胡雄海，汪久根，章维明．污染对滑动轴承性能的影响．农业机械学报，2001，32(6)：21-23
10 郭大威，徐桢基，顾敦清，等．滑动轴承的失效分析．北京：机械工业出版社，1985：18-53
11 成西平．高速线材轧机油膜轴承．北京：冶金工业出版社，2001：916-920
12 Venner C H, Napel W E Ten, Bosma R.Advanced Multilevel Solution of The EHL Line Contact Problem. ASME Journal of Tribology, 1998,112(3): 23-26
13 McIvor J D C, Fenner D N. Finite Element Analysis of Dynamically Loaded Flexible Journal Bearing: A Fast Newton-Raphson Method. ASME Journal of Tribology, 1989,111(4): 17-23
14 Cameron A. Basic Lubrication Theory. New York: John Wiley&Sons, 1981: 35-50
15 李长城．高速线材轧机φ500mm粗轧机组测试与研究．钢铁，2002，(3)：7-12
16 杨沛然．流体润滑数值分析．北京：国防工业出版社，1998：20-52
17 [美]S．铁摩辛柯，J．盖尔．材料力学．北京：科学出版社，1978：122-123
18 Courant, R.,Variational Method for Solutions of Problems of Equilibrium and Vibrations. Bull.Am. Math. Soc. 1943, (49): 1-23
19 Turner, M.J., Clough, R.W., Martin H.C., Topp L.C. Stiffness and Deflection Analysis of Complex Structures J.Aero. Sci. 1956, (23): 805-823
20 Clough, R.W. The Finite Element Method in Plane Stress Analysis. Proc. 2nd
ASME Conference on Electronic Computation, Pittsburgh, Pa., Sept. 1960.41-48
21 王勖成，劭敏．有限单元法基本原理和数值方法．北京：清华大学出版社，1997：1-2
22 谢贻权，何福保．弹性和塑性力学中的有限单元法．北京：机械工业出版社，1981：1-2
23 李人宪．有限元法基础．北京：国防工业出版社，2002：3-4
24 夸克工作室．有限元分析基础篇ANSYS与Mathematica．北京：清华大学出版社，2002：2-4
25 T．A．Harris．滚动轴承分析．罗继伟 译．1997：321-350
26 A.B.Jones. Analysis of Stresses and Deflections.new Departure Engineering Date, Bsistol. Cone, 1946, (6): 135-152
27 [英]F．T．E威尔．轴承系统—理论与实践．西安交大零件教研室译．北京：机械工业出版社，1983：125-136
28 Ozen, M., McKenzie, M., Generalized Chock and Bearing Analysis Procedure, 4th International ANSYS Conference and Exhibition 1989. PA, USA Publ by ANSYS,1989,(4):47-54
29 Yuanke, L., Guangwei, C., Jun, Y., Qigui, Z., Caiyun, Z., 3-D Finite Element Analysis of Rolling Mill Bearings, America Society of Mechanical Engineers, Design Engineering Division DE v19 pt1 Sep 17-21 1989 1989 New York, NY, USA Publ by ASME, 1989,19(1): 417-421
30 W.W. CHENG. Experimental and Numerical Study of Multi-body Contact System with Roller Bearing - Part Ⅱ: Semi-Finite Element Analysis and Optical Design of Housing, 2000, 36(1): 166-172
31 Filetu, E.G. Rumbarger, J.H. A General Method for Predicting The Influence of Structural Support on Rolling Element: Bearing Performance. Jour. Of Lubr. Tech, 1970,92(1): 121-128
32 Bardlein,J. The Stressing of Rolling Bearings in Elastic Housings. FAG Ball and Roller Bearing Eng. 1973,12(1):4-9
33 Marciniec A., Torstenfelt B. Load Distribution in Flexibly Supported Three-row Roller Slew Bearing. Trib. Trans,2000, (37) :757-769
34 Chen,W., Zhu,F. and Luo,J. Computational Finite Element Analysis and Optimal Design for Multi-body Contact System. Compter Meth. In Appl. Mech. And Eng, 1988,(71):31-39
35 Ozen,M., Mckenzie M.R. Stress Analysis of Rolling Element Bearings Using The Finite Element Method. SAE Paper 881234.1988:423-462
36 Mckenzie M.R., Ozen, M. The Effect of Housing Clearance on The Life of Cylindrical Roller Bearings. Lubr. Eng, 1988,44(9):810-815
37 罗继伟．用有限元法分析轴承座弹性变形对圆柱滚子轴承载荷分布的影
响．洛阳轴承研究所技术报告，1993，(3)：13-18
38 M.A.Honeygosky, T.A.Garcia,J.A.Butine. Finite Element Analysis of A Work Roll Chock and Roller Bearing Assembly. Iron and Steel Engineer. 1993: 43-49
39 A.B.Jones, T.A.Harris. Analysis of A Rolling Element Idler Gear Bearings Having A Deformable Outer Race Structure. ASME J. Basic Eng, 1963,(6): 273-278
40 T.A.Harris, J.L.Broschard. Analysis of An Improved Planetary Gear Transmission Bearing. ASME J.Basic Eng, 1964,(9):457-462
41 胡于进，李元科．边界元法在滚动轴承载荷分布计算中的应用．轴承，1994，(6)：5-8
42 束学道，陈占福，申光宪等．轧机轴承负荷特性数值解析．重型机械，1999(1)：31-34
43 Shu Xuedao,etc, Computation of Three-dimensional Distribution of Contact Pressure on Roller Bearing by BEM. Proceeding of the Eighth China-Japan Symposium on BEM, 1998:210-215
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