The processing technology of steel cap under electrification railway contact net metal die forging porcelain insulator
technical field
The present invention relates to the processing technology of steel cap under electrification railway contact net metal die forging porcelain insulator.
background technology
Electrification railway contact net porcelain insulator steel cap comprises steel cap and lower steel cap, and Fig. 1 shows the structure of lower steel cap, and lower steel cap comprises cylindrical part 5, ear 6 and the connecting bottom board between cylindrical part and ear.In ear, have through hole 7, cylindrical part has corrugated inwall 4.The steel cap of existing casting, because of its inner unavoidable defectiveness, causes the actual effective dimensions of some steel cap to be less than design load, does not reach the requirements such as intensity.
summary of the invention
The technical problem to be solved in the present invention is to provide the processing technology of steel cap under a kind of electrification railway contact net metal die forging porcelain insulator.
In order to solve the problems of the technologies described above, technical scheme of the present invention is:
A processing technology for steel cap under electrification railway contact net metal die forging porcelain insulator, order is processing according to the following steps:
1) Q235B bar is placed on the unpowered horizontal feed Roller conveyor of longitudinal extension, Roller conveyor the place ahead is provided with rear grip mechanism and the front clamp mechanism of passing for bar, rear grip mechanism and front clamp mechanism all can and unclamp under two kinds of active states of bar at clamping bar and switch, front clamp mechanism the place ahead is provided with Direct Action Type travel switch, the saw blade of electric circular saw is between front clamp mechanism and Direct Action Type travel switch, the fore-and-aft distance of saw blade and Direct Action Type travel switch is cutting length, and front clamp mechanism is near saw blade, rear grip mechanism clamps bar and proceeds to when bar front end touches Direct Action Type travel switch, front clamp mechanism clamps bar, rear grip mechanism unclamps bar and retreats reset, saw blade circumgyration incision bar, complete cutting action one time, then, rear grip mechanism clamps bar, bar unclamps in front clamp mechanism, rear grip mechanism drives bar to proceed to when bar front end touches Direct Action Type travel switch, front clamp mechanism clamps bar, rear grip mechanism unclamps bar and retreats reset, saw blade circumgyration incision bar, complete cutting action next time, so move in circles, complete blank blanking operation, billet size Φ 70mm * 125mm,
2) coating ceramic tapetum fibrosum on every blank periphery, the coated ceramic fiber blanket gross thickness in blank middle part is 10mm, and the coated ceramic fiber blanket gross thickness in blank both ends is 5mm, and the height at blank middle part is 2/3 of blank whole height;
3) blank of many coating ceramic tapetum fibrosums is deposited in heating furnace and is heated, heating furnace programming rate is 5 ℃/min, when furnace temperature rises to 800 ℃, be incubated 5min, then programming rate is adjusted into 8 ℃/min and continues to heat up, and is incubated 25min when furnace temperature rises to 1180 ℃; With heating furnace, beginning forging die is heated to 900 ℃; With heating furnace, finisher is heated to 600 ℃;
4) blank of the coating ceramic tapetum fibrosum of heating is carried out to jumping-up and form intermediate blank, remove the ceramic fiber blanket in intermediate blank;
5) wire brush extending along intermediate blank short transverse is around intermediate blank revolution to get rid of the oxide skin on intermediate blank periphery, and this operation completes in incubator, and the intermediate blank temperature of taking out from incubator is at least 1150 ℃;
6) intermediate blank forms beginning forging after forging through beginning, initial forging temperature is 1120 ℃, beginning forging die comprises begin forging counterdie and conical punch, the cylindrical part corresponding part that begins to forge on counterdie has conical die cavity, and conical punch and conical die cavity forge the cylindrical part of the circular cone tubular that outer end is large, root is little jointly; Beginning forging forms finish-forging part after finish-forging, final forging temperature is 700 ℃, finisher comprises finish-forging counterdie and cylindrical punch, finish-forging counterdie has the center hole that internal diameter is identical with the cylindrical part root external diameter of circular cone tubular, beginning forging is placed in the center hole of finish-forging counterdie, the descending cylindrical part of circular cone tubular that makes of cylindrical punch is passed to be forged into isometrical cylindrical part cylindraceous in center hole;
7) finish-forging part is dropped in gutter channel immediately, water outlet cool drying when finish-forging part temperature drops to 100 ℃, then removes finish-forging part surface scale with abrasive brush;
8) processing through hole and cylindrical part inwall;
9) forging after machining is carried out to blasting treatment, then hot water wash and heated-air drying, be then placed in fluxing agent 40s, the forging of pulling out put into temperature and maintain the oven dry hole oven dry of 130 ℃, checks degree of drying, until fully dry every 30s; Dry forging is immersed in thermal plating bath zinc liquid zinc-plated, zinc liquid temperature maintains 450 ℃, galvanizing time is 50-55s, in whole galvanizing process, the motion mode of forging is: the axis of forging is consistent with vertical direction all the time, in the descending immersion zinc of forging liquid, in zinc liquid, forging is around its axis revolution 4-5 circle, then at the rotating zinc liquid that rises from simultaneously, again forging is turned upside down, follow in descending immersion zinc liquid, in zinc liquid, forging is around its axis revolution 4-5 circle, then at the rotating zinc liquid that rises from simultaneously, zinc-plated complete; Zinc-plated complete forging purges cooling with 35 ℃ of clean compressed airs.
The processing technology of steel cap under above-mentioned electrification railway contact net metal die forging porcelain insulator, in step 9), fluxing agent temperature maintains 70 ℃, and the component comprising in every liter of fluxing agent is: propylene glycol 5g/L, Zinc vitriol 12g/L, zinc chloride 50g/L, glycerine 5g/L, six hydration nickel sulfate 3g/L, potassium chloride 50g/L, sodium nitrate 2g/L, boric acid 10g/L, hypo 30g/L, ethanol 6g/L, ammonium chloride 40g/L, dimethyl sulfoxide (DMSO) 4g/L, sulfonate 5g/L, all the other are water.
The processing technology of steel cap under above-mentioned electrification railway contact net metal die forging porcelain insulator, helping in depositing process in step 9) need add hydrogen peroxide and ammonium carbonate so that the ferrous salt in fluxing agent is transformed into molysite deposition in fluxing agent.
The processing technology of steel cap under above-mentioned electrification railway contact net metal die forging porcelain insulator, in step 9), in zinc liquid, the percentage by weight of each component is respectively: aluminium 0.13 %, lead 0.25%, nickel 0.25%, copper 0.9%, magnesium 0.07 %, antimony 0.25%, bismuth 0.25%, tin 0.19 %, cadmium 0.003 %, surplus are zinc.
The processing technology of steel cap under above-mentioned electrification railway contact net metal die forging porcelain insulator, in the zincincation of step 9), in zinc liquid, the percentage by weight of iron should be controlled at below 0.04%.
The processing technology of steel cap under above-mentioned electrification railway contact net metal die forging porcelain insulator, in step 5), wire brush comprises brush body and is welded on the bristle in brush body, and brush body is extended along intermediate blank short transverse, and the material of bristle is 4Cr14Ni14W2Si3MoMn stainless refractory steel; The following Technology for Heating Processing of bristle process: bristle is incubated 80min at 1000 ℃, then immerses in saline slot and quenches.
First complete the blank cutting of Φ 70mm * 125mm, coating ceramic tapetum fibrosum retarding heat loss on blank, jumping-up after blank heating, after jumping-up, with wire brush, the oxide skin on intermediate blank periphery is got rid of to improve forging quality, then die forging, first cylindrical part is swaged into circular cone tubular, and then be swaged into isometrical cylindric, forging quality is good, and forging efficiency is high, and then finish-forging part chilling removes finish-forging part surface scale with abrasive brush, then process through hole and cylindrical part inwall, surface treatment again, then carries out zinc-platedly, completes the processing of lower steel cap.
accompanying drawing explanation
Fig. 1 is the structural representation of lower steel cap.
In figure: 4 corrugated inwalls, 5 cylindrical part, 6 ears, 7 through holes.
Embodiment
A processing technology for steel cap under electrification railway contact net metal die forging porcelain insulator, order is processing according to the following steps:
1) by material, be that Q235B bar cuts into the blank that is of a size of Φ 70mm * 125mm.
Preferred cutting method is: Q235B bar is placed on the unpowered horizontal feed Roller conveyor of longitudinal extension, Roller conveyor the place ahead is provided with rear grip mechanism and the front clamp mechanism of passing for bar, rear grip mechanism and front clamp mechanism all can and unclamp under two kinds of active states of bar at clamping bar and switch, and front clamp mechanism the place ahead is provided with Direct Action Type travel switch.The saw blade of electric circular saw is between front clamp mechanism and Direct Action Type travel switch, the fore-and-aft distance of saw blade and Direct Action Type travel switch is cutting length, longitudinal direction is that fore-and-aft direction is also the length direction of bar, and front clamp mechanism is near saw blade, and while guaranteeing blanking, bar is stable.Technology for blanking process is: rear grip mechanism clamps bar and proceeds to when bar front end touches Direct Action Type travel switch, and front clamp mechanism clamps bar, and rear grip mechanism unclamps bar and retreats reset, and saw blade circumgyration incision bar completes cutting action one time.Then, rear grip mechanism clamps bar, bar unclamps in front clamp mechanism, rear grip mechanism drives bar to proceed to when bar front end touches Direct Action Type travel switch, and front clamp mechanism clamps bar, and rear grip mechanism unclamps bar and retreats reset, saw blade circumgyration incision bar, complete cutting action next time, so move in circles, complete blank blanking operation.Billet size Φ 70mm * 125mm.
2) coating ceramic tapetum fibrosum on every blank periphery, the coated ceramic fiber blanket gross thickness in blank middle part is 10mm, and the coated ceramic fiber blanket gross thickness in blank both ends is 5mm, and the height at blank middle part is 2/3 of blank whole height.On every blank periphery, coating ceramic tapetum fibrosum can slow down scattering and disappearing of blank heat, plays insulation effect.In addition, the coated ceramic fiber blanket in blank middle part, compared with coated thick in two ends, makes the temperature at blank middle part higher than the temperature at two ends, in the middle part of jumping-up operation can easily obtain, is the intermediate blank of even cydariform, and slowed down intermediate blank face checking, improved qualification rate and the quality of forging.Heating and jumping-up for blank are shown in step 3) and step 4).
3) blank of many coating ceramic tapetum fibrosums is deposited in heating furnace and is heated, heating furnace programming rate is 5 ℃/min, when furnace temperature rises to 800 ℃, be incubated 5min, then programming rate is adjusted into 8 ℃/min and continues to heat up, and is incubated 25min when furnace temperature rises to 1180 ℃.This mode of heating stage by stage reduces or has avoided the appearance of blank surface crackle, has also improved firing rate simultaneously.With heating furnace, beginning forging die is heated to 900 ℃; With heating furnace, finisher is heated to 600 ℃.To beginning forging die and finisher heating, when forging, avoided the chilling of blank and forging die contact portion, improve forging quality.
4) blank of the coating ceramic tapetum fibrosum of heating is carried out to jumping-up and form intermediate blank, remove the ceramic fiber blanket in intermediate blank.
5) wire brush extending along intermediate blank short transverse is around intermediate blank revolution to get rid of the oxide skin on intermediate blank periphery, and this operation completes in incubator, and the intermediate blank temperature of taking out from incubator is at least 1150 ℃.Scale removal, obtains better forging quality.
6) intermediate blank forms beginning forging after forging through beginning, initial forging temperature is 1120 ℃, beginning forging die comprises begin forging counterdie and conical punch, the cylindrical part corresponding part that begins to forge on counterdie has conical die cavity, and conical punch and conical die cavity forge the cylindrical part of the circular cone tubular that outer end is large, root is little jointly.Beginning forging forms finish-forging part after finish-forging, final forging temperature is 700 ℃, finisher comprises finish-forging counterdie and cylindrical punch, finish-forging counterdie has the center hole that internal diameter is identical with the cylindrical part root external diameter of circular cone tubular, beginning forging is placed in the center hole of finish-forging counterdie, the cylindrical part root that is circular cone tubular is placed in the center hole of finish-forging counterdie, the outer end of cylindrical part is positioned at finish-forging counterdie top, and the descending cylindrical part of circular cone tubular that makes of cylindrical punch is passed to be forged into isometrical cylindrical part cylindraceous in center hole.This forging has stage by stage reduced forging difficulty, has improved the efficiency and the forging quality that forge.
7) finish-forging part is dropped in gutter channel immediately, forging is carried out to chilling, destroyed oxide skin and the combination of finish-forging part, water outlet cool drying when finish-forging part temperature drops to 100 ℃, then removes finish-forging part surface scale with abrasive brush.
8) processing through hole and cylindrical part inwall.
9) forging after machining is carried out to blasting treatment, then hot water wash and heated-air drying.Then be placed in fluxing agent 40s, the forging of pulling out put into temperature and maintain the oven dry hole oven dry of 130 ℃, every 30s, check degree of drying, until fully dry.By zinc-plated in dry forging immersion thermal plating bath zinc liquid, zinc liquid temperature maintains 450 ℃, and galvanizing time is 50-55s.In whole galvanizing process, zinc-plated forging moves always, to obtain evenly and the good zinc coat of associativity.Concrete motion mode is: the axis of forging is consistent with vertical direction all the time, in the descending immersion zinc of forging liquid, in zinc liquid, forging is around its axis revolution 4-5 circle, then at the rotating zinc liquid that rises from simultaneously, forging is turned upside down again, follow in descending immersion zinc liquid, in zinc liquid, forging is around its axis revolution 4-5 circle, then at the rotating zinc liquid that rises from simultaneously, zinc-plated complete.Zinc-plated complete forging purges cooling with 35 ℃ of clean compressed airs.The revolution of forging makes forging surface can fully contact with zinc liquid, and zinc liquid is produced to slight agitaion.The galvanized layer thickness that the spiral emersion of forging can make forging evenly and smooth surface.
Before zincincation, need to help depositing process, be beneficial to zinc-platedly, introduce a kind of fluxing agent below.In step 9), fluxing agent temperature maintains 70 ℃, and the component comprising in every liter of fluxing agent is: propylene glycol 5g/L, Zinc vitriol 12g/L, zinc chloride 50g/L, glycerine 5g/L, six hydration nickel sulfate 3g/L, potassium chloride 50g/L, sodium nitrate 2g/L, boric acid 10g/L, hypo 30g/L, ethanol 6g/L, ammonium chloride 40g/L, dimethyl sulfoxide (DMSO) 4g/L, sulfonate 5g/L, all the other are water.This kind of fluxing agent has extremely strong activation, clean effective to forging surface, can avoid forging surface to be again oxidized, and helps plating effective, improved wettability and adhesiveness between forging surface and zinc liquid.
Along with helping the carrying out of depositing process, the ferrous salt of fluxing agent increases gradually, when ferrous salt content is larger, impact is helped to plating effect, helping in depositing process in step 9), need in fluxing agent, add hydrogen peroxide and ammonium carbonate so that the ferrous salt in fluxing agent is transformed into molysite deposition, reduce the content of ferrous salt in fluxing agent.
Introduce a kind of zinc liquid below, in step 9), in zinc liquid, the percentage by weight of each component is respectively: aluminium 0.13 %, lead 0.25%, nickel 0.25%, copper 0.9%, magnesium 0.07 %, antimony 0.25%, bismuth 0.25%, tin 0.19 %, cadmium 0.003 %, surplus are zinc.The aluminium of certain content can improve the stickiness of zinc liquid, increases the thickness of forging Zinc coat, also can improve purity and the adhesiveness of zinc liquid.The lead of certain content makes Several Thiourea Derivatives on Zinc Plate Surface attractive in appearance.The nickel of certain content can improve the adhesiveness of zinc coat.The copper of certain content and magnesium can improve the corrosion resistance of zinc coat.The antimony of certain content, bismuth and tin can improve the density and hardness of zinc coat.The cadmium of certain content makes zinc coat have good toughness.
In the zincincation of step 9), in zinc liquid, the percentage by weight of iron should be controlled at below 0.04%, and iron can reduce the content of aluminium in zinc liquid, and the stickiness of zinc liquid also just reduces, and adhering reduction causes the reduction of galvanizing quality and the prolongation of zinc-plated time.
In step 5), wire brush comprises brush body and is welded on the bristle in brush body, and brush body is extended along intermediate blank short transverse, and the material of bristle is 4Cr14Ni14W2Si3MoMn stainless refractory steel; The following Technology for Heating Processing of bristle process: bristle is incubated 80min at 1000 ℃, then immerses in saline slot and quenches.Bristle after Overheating Treatment not only has the heat-resisting characteristic of not repairing, and hardness and resistance to wear are also improved.