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我國首臺(tái)套盾構(gòu)機(jī)用超大直徑主軸承研制成功

2022-12-15 08:50:57 來源：中國科學(xué)院金屬研究所 閱讀量：12016 評(píng)論

導(dǎo)讀：近期，由中國科學(xué)院金屬研究所李殿中研究員、李依依院士團(tuán)隊(duì)牽頭攻關(guān)的超大型盾構(gòu)機(jī)用直徑8米主軸承研制成功。

　　【農(nóng)機(jī)網(wǎng) 科技創(chuàng)新】近期，由中國科學(xué)院金屬研究所李殿中研究員、李依依院士團(tuán)隊(duì)牽頭攻關(guān)的超大型盾構(gòu)機(jī)用直徑8米主軸承研制成功。該主軸承重達(dá)41噸，是目前我國制造的首臺(tái)套直徑最大、單重最大的盾構(gòu)機(jī)用主軸承。該主軸承將安裝在直徑16米級(jí)的超大型盾構(gòu)機(jī)上，用于隧道工程挖掘。該主軸承的研制成功，標(biāo)志著我國已掌握盾構(gòu)機(jī)主軸承的自主設(shè)計(jì)、材料制備、精密加工、安裝調(diào)試和檢測評(píng)價(jià)等集成技術(shù)。經(jīng)國家軸承質(zhì)量檢驗(yàn)檢測中心檢測和專家組評(píng)審，認(rèn)為該主軸承各項(xiàng)技術(shù)性能指標(biāo)與進(jìn)口同類主軸承相當(dāng)，滿足超大型盾構(gòu)機(jī)裝機(jī)應(yīng)用需求。
 
　　盾構(gòu)機(jī)是國民經(jīng)濟(jì)建設(shè)的重大裝備，承載著穿山越嶺、過江跨海的重任。我國已實(shí)現(xiàn)了盾構(gòu)機(jī)的國產(chǎn)化，但其核心部件——主軸承卻依賴進(jìn)口，亟需打通自主可控制造的“最后一公里”。
 
　　主軸承是盾構(gòu)機(jī)刀盤驅(qū)動(dòng)系統(tǒng)的核心關(guān)鍵部件，盾構(gòu)機(jī)掘進(jìn)過程中，主軸承“手持”刀盤旋轉(zhuǎn)切削掌子面并為刀盤提供旋轉(zhuǎn)支撐。直徑8米的主軸承在運(yùn)轉(zhuǎn)過程中承載的最大軸向力達(dá)到10萬千牛(1千牛約等于0.1噸物體的重力，一頭成年亞洲象的體重按4噸算的話，這相當(dāng)于軸向受到2500頭亞洲象重力的作用)、徑向力達(dá)1萬千牛、傾覆力矩達(dá)10萬千牛·米。為保證主軸承的高承載能力和高可靠性，特別要求制造主軸承的軸承鋼要高純凈、高均質(zhì)、高強(qiáng)韌、高耐磨，同時(shí)對(duì)主軸承成套設(shè)計(jì)、加工精度、潤滑脂等都提出了很高的要求。而大型盾構(gòu)機(jī)在掘進(jìn)過程中，只能前進(jìn)，不能倒退，主軸承一旦失效，會(huì)造成嚴(yán)重?fù)p失。
 
　　中國科學(xué)院于2020年啟動(dòng)了“高端軸承自主可控制造”戰(zhàn)略性先導(dǎo)科技專項(xiàng)，中國科學(xué)院金屬研究所、中國科學(xué)院蘭州化學(xué)物理研究所等7家院內(nèi)科研單位組成建制化團(tuán)隊(duì)，聯(lián)合中國交通建設(shè)集團(tuán)有限公司的中交天和機(jī)械設(shè)備制造有限公司、洛陽新強(qiáng)聯(lián)回轉(zhuǎn)支承股份有限公司等20余家單位進(jìn)行協(xié)同攻關(guān)，先后解決了主軸承材料制備、精密加工、成套設(shè)計(jì)中的12項(xiàng)核心關(guān)鍵技術(shù)問題，開發(fā)出直徑3米級(jí)到8米級(jí)的盾構(gòu)機(jī)主軸承共10套。在沈陽市政府的大力推動(dòng)與支持下，直徑3米的主軸承已在沈陽地鐵工程中成功應(yīng)用。
 
　　此前，我國盾構(gòu)機(jī)用超大直徑主軸承制造久而未決的主要原因在于：制造軸承的材料和大型滾子的加工精度不過關(guān)，全流程技術(shù)鏈條不貫通。攻關(guān)團(tuán)隊(duì)認(rèn)為，要制造高純凈、高均質(zhì)、高強(qiáng)韌、高耐磨的軸承鋼材料，一定要從源頭解決材料制造的問題，他們將目光瞄準(zhǔn)了稀土軸承鋼。已有大量研究表明，鋼中添加微量稀土能夠顯著提高鋼的韌塑性、耐磨性、耐熱性、耐蝕性等。然而，稀土鋼在工業(yè)化生產(chǎn)時(shí)遭遇兩大難題：一是工藝不順行，存在澆口嚴(yán)重堵塞的問題；二是稀土在鋼中添加后，鋼的性能劇烈波動(dòng)，存在穩(wěn)定性不好的問題。這兩大難題一直未能有效解決，導(dǎo)致我國稀土鋼的研究與應(yīng)用由熱變冷。
 
　　為發(fā)揮我國稀土資源優(yōu)勢，解決軸承領(lǐng)域的重大需求，中國科學(xué)院金屬研究所團(tuán)隊(duì)歷經(jīng)十多年的研究，發(fā)現(xiàn)稀土鋼性能波動(dòng)、澆口堵塞問題的根源在于氧含量。經(jīng)過大量的實(shí)驗(yàn)、計(jì)算和表征，他們揭示了稀土在鋼中的主要作用機(jī)制，開發(fā)出“低氧稀土鋼”關(guān)鍵技術(shù)。該團(tuán)隊(duì)通過控制氧含量，制備出性能優(yōu)越、穩(wěn)定性好的低氧稀土鋼，研制出的稀土軸承鋼拉壓疲勞壽命提高40多倍，滾動(dòng)接觸疲勞壽命提升40%，相關(guān)基礎(chǔ)研究成果于今年發(fā)表在國際著名期刊《自然材料》(Nature Materials)上。同時(shí)，有效解決了稀土軸承鋼工業(yè)生產(chǎn)時(shí)遭遇的澆口嚴(yán)重堵塞的問題及加入稀土性能不穩(wěn)定的問題，牽頭制訂了多項(xiàng)稀土鋼標(biāo)準(zhǔn)。目前由相關(guān)合作企業(yè)生產(chǎn)的稀土軸承鋼綜合力學(xué)性能優(yōu)異，好于進(jìn)口產(chǎn)品。
 
　　該團(tuán)隊(duì)在攻關(guān)過程中，盾構(gòu)機(jī)主軸承技術(shù)總師胡小強(qiáng)研究員帶隊(duì)深入生產(chǎn)一線，聯(lián)合骨干企業(yè)成功攻克了主軸承高精度加工和精度保持性難題。研制中發(fā)現(xiàn)，我國進(jìn)口設(shè)備由于受國外技術(shù)限制，大型滾子加工精度只能達(dá)到二級(jí)(如：直徑規(guī)值≤2.5微米，表面粗糙度：滾動(dòng)表面≤0.16微米、端面≤0.25微米、圓角≤2.5微米)，尚不能實(shí)現(xiàn)一級(jí)精度加工(如：直徑規(guī)值≤1.0微米，表面粗糙度：滾動(dòng)表面≤0.1微米、端面≤0.125微米、圓角≤1.25微米)。該團(tuán)隊(duì)聯(lián)合企業(yè)集智攻關(guān)，研制出直徑100毫米以上的一級(jí)滾子，使我國軸承行業(yè)突破了一級(jí)大型滾子精密加工技術(shù)。與洛陽新強(qiáng)聯(lián)股份有限公司密切合作，實(shí)現(xiàn)了盾構(gòu)機(jī)主軸承加工制造、裝配調(diào)試、檢測評(píng)價(jià)等全流程自主可控，同時(shí)帶動(dòng)了相關(guān)國產(chǎn)裝備的研制。
 
　　盾構(gòu)機(jī)用超大直徑主軸承的研制成功，為我國高端基礎(chǔ)零部件攻關(guān)提供了良好的范式，是“貫通技術(shù)鏈、打造創(chuàng)新鏈、對(duì)接產(chǎn)業(yè)鏈”的積極實(shí)踐，是發(fā)揮新型舉國體制優(yōu)勢，開展“政、產(chǎn)、學(xué)、研、用”協(xié)同創(chuàng)新的生動(dòng)體現(xiàn)。
 
自研超大型盾構(gòu)機(jī)用直徑8米主軸承
 
成功應(yīng)用于沈陽地鐵工程的自研直徑3米盾構(gòu)機(jī)主軸承
 
自研的直徑8米主軸承驗(yàn)收會(huì)(于2022年9月30日召開)
 

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