CN103331585A - Method for manufacturing isothermal quenching spheroidal graphite cast iron large-scale heavy-load gear - Google Patents
Method for manufacturing isothermal quenching spheroidal graphite cast iron large-scale heavy-load gear Download PDFInfo
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- CN103331585A CN103331585A CN2013102762306A CN201310276230A CN103331585A CN 103331585 A CN103331585 A CN 103331585A CN 2013102762306 A CN2013102762306 A CN 2013102762306A CN 201310276230 A CN201310276230 A CN 201310276230A CN 103331585 A CN103331585 A CN 103331585A
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Abstract
The invention relates to a method for manufacturing an isothermal quenching spheroidal graphite cast iron large-scale heavy-load gear in the field of metal materials. The method sequentially comprises the following steps of casting a gear blank, carrying out ferritiszation annealing processing on the blank, roughly and finely machining the blank, carrying out isothermal quenching processing, grinding teeth and carrying out shot peening strengthening. The gear blank comprises, by weight, 3.5-3.7% of C, 2.4-2.6% of Si, 0.2-0.3% of Mn, 0.7-0.8% of Cu, 1.5-1.8% of Ni, not more than 0.03% of P, not more than 0.02% of S, 0.035-0.045% of Mg, 0.01-0.03% of Re, and the balance Fe. According to the method for manufacturing the gear, the overall hardenability of the large-scale heavy-load gear is improved by reasonably controlling the components of Cu and Ni in the gear blank, the structure of a casting swage die is improved, the casting defects of castings are reduced, the mechanical performance of the gear is improved, and the service life of the gear is prolonged.
Description
Technical field
The present invention relates to metal material field, particularly a kind of manufacture method of austempering ductile iron large heavy-load gear.
Background technology
In the prior art, the driven gear of railway locomotive traction and other large heavy-load gear generally adopt steel alloys casting blanks such as 42CrMo, 42MnMoV to form through technology manufacturings such as machining, modified, surface hardenings, its complex process, need large-sized forging equipment and metal pattern, the manufacturing cost height, and the hard-faced quenching degree of blank is poor, makes the overall mechanical properties of large gear poor, easily produce surface pitting in the use, wear no resistance, service life problem such as weak point, noise height.
Summary of the invention
The present invention is directed to the problem that prior art exists, a kind of manufacture method of austempering ductile iron large heavy-load gear is provided, to reduce the gear manufacturing cost, improve the comprehensive mechanical performance of gear and use the casting life.
The object of the present invention is achieved like this, a kind of manufacture method of austempering ductile iron large heavy-load gear, in turn include the following steps: the gear blank is cast, blank is carried out ferritizing annealing processing, roughing and fine finishining blank, means of isothermal quenching, roll flute, shot peening strengthening processing, the mass percent composition of described gear blank is: C 3.5～3.7%, Si2.4～2.6%, Mn0.2～0.3%, Cu0.7～0.8%, Ni1.5～1.8%, P≤0.03%, S≤0.02%, Mg0.035～0.045%, Re0.01～0.03%, all the other are Fe.
The beneficial effect of gear manufacture method of the present invention is: in the gear blank, rationally control phosphorus content, increase carbon equivalent, separate out the graphite of some, make sphere diameter tiny, roundness is good, is conducive to the nodularization of graphite, can also prevent that too much free cementite from appearring in as cast condition, make iron liquid mold-filling capacity good, shrinkage porosite is little and concentrated, the easy feeding of shrinkage cavity, and contain graphite in the gear tissue, can be in gear operation uses, play lubricated and cushioning effect, adding the matrix third constellations difficult to understand body has the work hardening effect, so can also improve wearability and the pitting resistance of gear; Moreover reasonably add suitable Cu and Ni in the gear composition, and can put forward the conductivity of heat and the quenching degree that add in the heat treatment of gear blank, can improve the mechanical performance of large gear finished product integral body, prolong the service life of gear.Simultaneously, the weight of spheroidal graphite cast-iron gear finished product of the present invention is than the steel alloy gear material of available technology adopting 42CrMo, 42MnMoV, weight saving 10%, and reduce the gear manufacturing cost.
For casting is met the requirements with hot metal composition, described casting adopts the special-purpose pig iron of spheroidal graphite cast-iron and steel scrap to be smelted into base iron in smelting temperature is 1470 ℃～1520 ℃ intermediate frequency furnace with molten iron, the composition of base iron is: C 3.5～3.8%, Si1.0～1.2%, Mn0.2～0.3%, Cu0.7～0.8%, Ni1.5～1.8%, P≤0.03%, S≤0.02%, Mg0.035～0.045%, Re0.01～0.03%, all the other are Fe, add low rare-earth nodularizer and ferrosilicon inovulant then and carry out spheroidising and inoculation, the consumption of low rare-earth nodularizer is 1.2～1.5% of base iron quality, and the consumption of ferrosilicon inovulant is base iron quality 1.0～1.2%, and final hot metal composition is met the requirements.Because magnesium iron is through nodularization and inoculation, temperature is fallen 50～100 ℃ approximately, casting flaws such as slag inclusion, pore when casting in order to reduce, must guarantee higher tapping temperature, if but the too high nodulizer of temperature can oxidization burning loss and causes abnormal nodularizing, therefore with smelting temperature control at 1470 ℃～1520 ℃.
For improving the casting quality of gear blank, the pattern of described casting blank comprises mo(u)ld top half, medium-sized and mo(u)ld bottom half, the cavity inner wall of described pattern is nested with graphite chilling block, and described pattern top is provided with the formula ingate core that drenches with rain, and the sprue gate is along circumferentially equally distributed six to eight.Because the light specific gravity of graphite chilling block, fire resistance is good, and thermal conductivity factor is big, therefore the nested graphite chilling block in position that needs Quench at foundry goods, can effectively prevent the shrinkage cavity of foundry goods, defective such as loose, make thick and large casting whole fine and close, improve casting hardness, surface smoothness and wearability.
For improving the mechanical performance of gear, described ferritizing annealing temperature is 890 ℃～920 ℃, high-temperature holding time is 2～3 hours, stove is chilled to 740 ℃-760 ℃ insulations 4 hours, to realize pearlitic ferriteization, improve inside and outside uniformity and the uniformity of blank overall mechanical properties, last stove is chilled to 600 ℃ and comes out of the stove.
For further improving the overall mechanical properties of gear, described austempering temperature is 260 ℃～280 ℃, and temperature retention time is 2～3 hours.
Description of drawings
Fig. 1 is the manufacturing approach craft flow chart of austempering ductile iron large heavy-load gear.
Fig. 2 is the structural representation of gear casting pattern.
Wherein, 1 mo(u)ld top half; 2 is medium-sized; 3 mo(u)ld bottom halves; 4 graphite chilling blocks; The 5 formula ingate cores that drench with rain.
The specific embodiment
The manufacture method step of austempering ductile iron large heavy-load gear of the present invention is as follows, adopts the mixture of Q10 or Q15 and steel scrap to be smelted into base iron in 1470 ℃～1520 ℃ intermediate frequency furnace, the composition C 3.5% of base iron, Si1.2 %, Mn0.2%, Cu0.7%, Ni1.5%, P0.03%, S0.02%, Mg0.045%, Re0.01%, all the other are Fe, add the low rare-earth nodularizer of base iron quality 1.2% and 1.0% ferrosilicon inovulant then and carry out spheroidising and inoculation, alloy element component is C 3.5% in the final molten iron, Si2.4%, Mn0.2%, Cu0.7%, Ni1.5%, P0.03%, S0.02%, Mg0.045%, Re0.01%, all the other are Fe; Adopt casting pattern as shown in Figure 2 to carry out the casting of gear blank then, for improving the performance of foundry goods casting, pattern comprise mo(u)ld top half 1, medium-sized 2 and the cavity inner wall of mo(u)ld bottom half 4, pattern be nested with graphite chilling block 4, the pattern top is provided with the formula ingate core 5 that drenches with rain, the sprue gate is along circumferentially equally distributed six to eight, the gear blank external diameter φ 1120 after the cast molding, and height is 240, thickest is 150, and casting weight reaches 960 kilograms; Then blank being carried out ferritizing annealing processing, roughing and fine finishining blank, means of isothermal quenching, roll flute and shot peening strengthening handles, wherein, the control of ferritizing annealing temperature is at 910 ℃ ± 10 ℃, temperature retention time is 2 hours, and stove is chilled to 740 ℃, is incubated after 4 hours, stove is chilled to 600 ℃ and comes out of the stove again, austempering temperature is 277 ℃ ± 3 ℃, and temperature retention time is 2 hours, and the camber value of bead is 0.58～0.58mm.
Mechanical performance such as the table 1 of gear finished product.
Difference from Example 1 is that the mass content of base iron is: C 3.8%, Si1.1 %, Mn0.2%, Cu0.7%, Ni1.5%, P0.03%, S0.02%, Mg0.045%, Re0.01%, the consumption of low rare-earth nodularizer is 1.4% of base iron quality, the consumption of ferrosilicon inovulant is 1.2% of base iron quality, the composition of gear foundry goods is C 3.7%, Si2.6%, Mn0.3%, Cu0.8%, Ni1.8%, P0.03%, S0.02%, Mg0.035, %, Re0.03%, the ferritizing annealing temperature is controlled at 900 ℃ ± 10 ℃, and temperature retention time is 3 hours, stove is chilled to 760 ℃, is incubated after 4 hours, and stove is chilled to 600 ℃ and comes out of the stove again, austempering temperature is 263 ℃ ± 3 ℃, and temperature retention time is 3 hours.
Mechanical performance such as the table 2 of gear finished product.
Embodiment 3
Difference from Example 1 is that the mass content of base iron is: C 3.6%, Si1.2 %, Mn0.2%, Cu0.7%, Ni1.5%, P0.03%, S0.02%, Mg0.045%, Re0.01%, the consumption of low rare-earth nodularizer is 1.5% of base iron quality, the consumption of ferrosilicon inovulant is 1.2% of base iron quality, the composition of gear foundry goods is C 3.6%, Si2.5%, Mn0.25%, Cu0.75%, Ni1.7%, P0.03%, S0.01%, Mg0.038, %, Re0.02%, the ferritizing annealing temperature is controlled at 905 ℃ ± 10 ℃, and high-temperature holding time is 2.5 hours, stove is chilled to 750 ℃, is incubated 4 hours, and stove is chilled to 600 and comes out of the stove again, austempering temperature is 270 ℃ ± 3 ℃, temperature retention time is 2.5 hours, gear blank external diameter φ 782, and height is 150, thickest is 80, and casting weight reaches 260 kilograms.
The gear that method of the present invention is made, little, the dense structure of casting flaw, the quenching degree of foundry goods integral body is good, obviously improves the mechanical performance of large heavy-load gear, and reach more than the twice service life of improving gear, and reduce the gear manufacturing cost.
The present invention is not limited to above-described embodiment; those skilled in the art is according to disclosed technology contents; do not need performing creative labour just can make some replacements and distortion to some technical characterictics wherein, these replacements and distortion are all in the scope of protection of the invention.
Claims (5)
1. the manufacture method of an austempering ductile iron large heavy-load gear, it is characterized in that, in turn include the following steps: the gear blank is cast, blank is carried out ferritizing annealing processing, roughing and fine finishining blank, means of isothermal quenching, roll flute and shot peening strengthening processing, the mass percent composition of described gear blank is: C 3.5～3.7%, Si2.4～2.6%, Mn0.2～0.3%, Cu0.7～0.8%, Ni1.5～1.8%, P≤0.03%, S≤0.02%, Mg0.035～0.045%, Re0.01～0.03%, all the other are Fe.
2. the manufacture method of austempering ductile iron large heavy-load gear according to claim 1, it is characterized in that, described casting adopts the special-purpose pig iron of spheroidal graphite cast-iron and steel scrap to be smelted into base iron in smelting temperature is 1470 ℃～1520 ℃ intermediate frequency furnace with molten iron, the composition of base iron is: C 3.5～3.8%, Si1.0～1.2%, Mn0.2～0.3%, Cu0.7～0.8%, Ni1.5～1.8%, P≤0.03%, S≤0.02%, Mg0.035～0.045%, Re0.01～0.03%, all the other are Fe, add low rare-earth nodularizer and ferrosilicon inovulant then and carry out spheroidising and inoculation, and the consumption of low rare-earth nodularizer is 1.2～1.5% of base iron quality, the consumption of ferrosilicon inovulant is base iron quality 1.0～1.2%, and final hot metal composition is met the requirements.
3. the manufacture method of austempering ductile iron large heavy-load gear according to claim 1, it is characterized in that, the pattern of described casting blank comprises mo(u)ld top half, medium-sized and mo(u)ld bottom half, the cavity inner wall of described pattern is nested with graphite chilling block, described pattern top is provided with the formula ingate core that drenches with rain, and the sprue gate is along circumferentially equally distributed six to eight.
4. the manufacture method of austempering ductile iron large heavy-load gear according to claim 1, it is characterized in that described ferritizing annealing temperature is 890 ℃～920 ℃, high-temperature holding time is 2～3 hours, stove is chilled to 740 ℃-760 ℃ insulations 4 hours, and stove is chilled to 600 ℃ and comes out of the stove then.
5. the manufacture method of austempering ductile iron large heavy-load gear according to claim 1 is characterized in that, described austempering temperature is 260 ℃～280 ℃, and temperature retention time is 2～3 hours.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104338909A (en) * | 2014-09-28 | 2015-02-11 | 福建丰力机械科技有限公司 | Wheel hub casting molding process |
| CN104480273A (en) * | 2014-11-17 | 2015-04-01 | 芜湖福司精密模具有限公司 | Method for improving processing properties of diesel engine connecting rod casting |
| CN106002114A (en) * | 2016-05-25 | 2016-10-12 | 镇江市经纬工程机械有限公司 | Gear machining method |
| CN106119682A (en) * | 2016-08-18 | 2016-11-16 | 江阴联华铸造有限公司 | A kind of automobile gear wearable ductile iron part and preparation method thereof |
| CN109877550A (en) * | 2019-02-22 | 2019-06-14 | 西安理工大学 | A kind of low-noise, self-lubricated medium and small modulus cylindrical gear and preparation method |
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| JPH04129621A (en) * | 1990-09-14 | 1992-04-30 | Mazda Motor Corp | Manufacture of gear member |
| CN1936368A (en) * | 2006-10-17 | 2007-03-28 | 武汉理工大学 | Automobile rear-bridge spiral conic gear of manganese-copper alloy autenite-bainite nodular iron and its preparing method |
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2013
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| JPH04129621A (en) * | 1990-09-14 | 1992-04-30 | Mazda Motor Corp | Manufacture of gear member |
| CN1936368A (en) * | 2006-10-17 | 2007-03-28 | 武汉理工大学 | Automobile rear-bridge spiral conic gear of manganese-copper alloy autenite-bainite nodular iron and its preparing method |
| CN101713454A (en) * | 2009-12-18 | 2010-05-26 | 吉林圆方机械集团有限公司 | Method for manufacturing driving/driven spiral bevel gear of heavy-duty commercial vehicle by using copper-niobium high-strength austempered ductile iron |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104338909A (en) * | 2014-09-28 | 2015-02-11 | 福建丰力机械科技有限公司 | Wheel hub casting molding process |
| CN104480273A (en) * | 2014-11-17 | 2015-04-01 | 芜湖福司精密模具有限公司 | Method for improving processing properties of diesel engine connecting rod casting |
| CN106002114A (en) * | 2016-05-25 | 2016-10-12 | 镇江市经纬工程机械有限公司 | Gear machining method |
| CN106119682A (en) * | 2016-08-18 | 2016-11-16 | 江阴联华铸造有限公司 | A kind of automobile gear wearable ductile iron part and preparation method thereof |
| CN109877550A (en) * | 2019-02-22 | 2019-06-14 | 西安理工大学 | A kind of low-noise, self-lubricated medium and small modulus cylindrical gear and preparation method |
| CN109877550B (en) * | 2019-02-22 | 2020-10-27 | 西安理工大学 | Low-noise self-lubricating medium-and-small-modulus cylindrical gear and preparation method thereof |
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Application publication date: 20131002 |