CN104047604B - 一种复合截齿及其制造方法 - Google Patents
一种复合截齿及其制造方法 Download PDFInfo
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- CN104047604B CN104047604B CN201410254957.9A CN201410254957A CN104047604B CN 104047604 B CN104047604 B CN 104047604B CN 201410254957 A CN201410254957 A CN 201410254957A CN 104047604 B CN104047604 B CN 104047604B
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- tooth
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- 239000002131 composite materials Substances 0.000 title abstract description 6
- 238000004519 manufacturing process Methods 0.000 title abstract description 5
- 229910045601 alloys Inorganic materials 0.000 claims abstract description 73
- 239000000956 alloys Substances 0.000 claims abstract description 73
- REDXJYDRNCIFBQ-UHFFFAOYSA-N aluminium(3+) Chemical class data:image/svg+xml;base64,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 data:image/svg+xml;base64,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 [Al+3] REDXJYDRNCIFBQ-UHFFFAOYSA-N 0.000 claims abstract description 72
- 229910000679 solders Inorganic materials 0.000 claims abstract description 34
- 239000007788 liquids Substances 0.000 claims abstract description 33
- 238000002360 preparation methods Methods 0.000 claims abstract description 19
- 238000005065 mining Methods 0.000 claims abstract description 12
- 239000000203 mixtures Substances 0.000 claims abstract description 7
- 238000005219 brazing Methods 0.000 claims abstract 2
- 241001081830 Degeneriaceae Species 0.000 claims description 36
- 229910000831 Steel Inorganic materials 0.000 claims description 13
- 239000010959 steel Substances 0.000 claims description 13
- 229910000954 Medium-carbon steel Inorganic materials 0.000 claims description 8
- 229910001339 C alloys Inorganic materials 0.000 claims description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N chromium Chemical compound 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[Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 5
- 229910052804 chromium Inorganic materials 0.000 claims description 5
- 239000011651 chromium Substances 0.000 claims description 5
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N potassium Chemical compound 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[K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 claims description 5
- 229910052700 potassium Inorganic materials 0.000 claims description 5
- 239000011591 potassium Substances 0.000 claims description 5
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 4
- 239000000463 materials Substances 0.000 claims description 4
- 229910001018 Cast iron Inorganic materials 0.000 claims description 3
- 239000011230 binding agents Substances 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 238000005242 forging Methods 0.000 claims description 3
- 238000002309 gasification Methods 0.000 claims description 3
- 238000010791 quenching Methods 0.000 claims description 3
- 230000000171 quenching Effects 0.000 claims description 3
- 238000007711 solidification Methods 0.000 claims description 3
- 239000003570 air Substances 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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[C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052799 carbon Inorganic materials 0.000 claims description 2
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound 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[W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims 1
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Abstract
Description
技术领域
[0001]本发明涉及一种采掘机械用截齿及其制备方法,适用于采煤机、掘进机、挖掘机等采掘机械使用的截齿。
背景技术
[0002]截齿类别很多,有圆柄截齿、刀型截齿、盾构机截齿等。现有的截齿结构包括齿体和硬质合金头两部分,其制造方法有四种:第一种是用圆钢加工成齿体,在齿体的上端面加工出安装硬质合金齿尖的孔,然后用焊机将硬质合金头与齿体焊接在一起。这种方法,生产效率低,且常因焊接不牢而导致硬质合金头脱落。第二种是,用圆钢加工成齿体,在齿体的上端面加工出安装硬质合金齿尖的孔,然后在安装孔内放入焊剂,加热使焊剂熔化后,将硬质合金头压入安装孔内,焊剂冷却凝固后将硬质合金头与齿体固结牢固,同时齿体被进行了正火热处理。这种方法虽然能实现齿尖与齿体的良好焊接,但是,为了防止齿柄与齿体接触部不断裂,只能进行正火处理,齿体硬度一般只要求2 40HRC,因此,抗磨性不高。第三种方法是硬质合金头与安装孔之间采用过盈配合,将合金头压入后再进行焊接。第四种,陈泽发明了一种冷挤缩颈压合截齿体和硬质合金头的工艺方法(201010260319.X),它通过圆柱形的截齿体材料进行冷挤变形,形成截齿体的同时将带有正锥度的硬质合金头自锁固定在截齿体的前端,省去了传统的焊接方法将截齿体和硬质合金头连接牢固的工序。但是,由于截齿体材料既要满足冷挤变形的需要,又要满足高硬度、高抗磨的需要,其材料限制很大。
[0003]上述齿体端部焊接硬质合金头的结构和制备方法有一个共同的缺点:为了防止齿头和齿柄连接不断裂,齿体的硬度一般都控制在45-48之间,导致抗磨性不足。若再提高硬度,则齿头和齿柄连接部容易断裂。
发明内容
[0004]为了解决现有技术的截齿抗磨性和齿柄断裂的矛盾,做到既能提高齿体的抗磨性,同时还能有效防止齿柄断裂,提出了本发明。本发明根据液态模锻和包覆铸造的原理,提供一种采掘机械用截齿及其制备方法。
[0005] —种采掘机械用截齿,由齿尖、齿头和齿柄三部分组成。
[0006]所述的齿尖顶端为圆锥体形,下段为圆柱体;所述的齿头呈锥台形;所述的齿柄为圆柱体,其上段具有螺纹;齿头中央设有一圆柱形的安装孔,齿尖下段的圆柱体安装在安装孔内的上部,齿柄具有螺纹的上段安装在安装孔内的下部;齿尖与齿柄之间由钎焊料熔焊在一起;齿尖、齿头和齿柄牢固地结为一体。
[0007]所述的齿尖用硬质合金制成;所述的齿头用高铬铸铁或高锰钢或低合金钢中的一种抗磨合金制成;所述的齿柄用中碳钢或中碳合金钢制成。
[0008] —种采掘机械用截齿的制备方法,采用液态模锻方法将齿头、齿尖和齿柄紧密结合为一体,包括如下步骤:
[0009]步骤1,齿柄加热至150_300°C,将齿柄具有螺纹的上段垂直安装在金属模具的安装孔内的下部;齿柄上端面粘有厚度为2-3mm的钎焊料;再将齿尖的圆柱段朝下垂直安装在模具的安装孔内的上部,置于钎焊料上;钎焊料为铜基钎焊料,熔点800-900°C;
[0010]步骤2,以高于抗磨合金的液相线温度15〜80°C的浇注温度,向金属模具腔内浇注抗磨合金液,充满金属模具模腔,将齿柄的螺纹及齿尖包裹,并将其间的钎焊料熔化、粘结剂气化;
[0011]步骤3,在抗磨合金液完全凝固前,对抗磨合金液施加50〜150MPa的压强并保压1-5秒;在保压过程中,抗磨合金液发生凝固形成齿头,钎焊料凝固将齿头和硬质合金齿尖焊接在一起,并在凝固收缩力和外加压力的共同作用下,抗磨合金齿头与齿柄螺纹及硬质合金齿尖接触的界面达到良好的结合,实现了齿头、齿柄和硬质合金齿尖三者之间牢固地结合,成为一体;
[0012]步骤4,停止加压后,将制成的截齿从模具内腔中取出,冷却至400°C以下后,重新加热进行整体或局部热处理,提高齿头的抗磨性,最终得到一种采掘机械用截齿。
[0013]本发明的有益效果是:
[0014] 1、结合强度高。利用本发明生产的截齿,硬质合金与齿体间结合牢固,使用中不会出现脱落。
[0015] 2、齿柄不断裂。由于齿柄为强韧性良好的中碳钢,其使用中不会发生断裂。
[0016] 3、齿头抗磨性好。由于齿头选用抗磨合金,其硬度高达51-60HRC,所以抗磨性优异。与现有截齿相比,使用寿命提高50〜200%。
附图说明
[0017]图1复合截齿示意图,
[0018]图2制备复合截齿的示意图。
[0019]图中:
[0020] 1-齿尖,2-钎焊料,3-螺纹,4-齿头,5-齿柄,6_压头,7_上模,8_下摸
具体实施方式
[0021]下面结合附图详细说明一种复合截齿及其制备方法。
[0022]参见图1,本发明提供的一种采掘机械用截齿,由齿尖1、齿头4和齿柄5三部分组成。所述的齿尖I用碳化钨硬质合金制成,其顶端为圆锥体形,下段为圆柱体。所述的齿头4用高铬铸铁或高锰钢或低合金钢中的一种抗磨合金制成,呈锥台形。所述的齿柄5用中碳钢或中碳合金钢制成,为圆柱体;齿柄5的上段具有螺纹3,下段为光面。齿头4中央设有一圆柱形的安装孔,齿尖I下段的圆柱体安装在安装孔内的上部,齿柄5具有螺纹3的上段安装在安装孔内的下部。齿尖I与齿柄5之间由钎焊料2熔焊在一起;齿尖1、齿头4和齿柄5牢固地结为一体。
[0023]参见图2,本发明提供的一种采掘机械用截齿的制备方法,是采用液态模锻方法将齿头、齿尖和齿柄紧密结合为一体。制备截齿使用的模具为压头6、上模7和下模8。压头6、上模7和下模8均为金属模具。上模7为圆柱体,其模腔直径等于齿头4的外径,高度与齿头4相等。下模8中央设有模腔,其直径等于齿柄5的直径,深度等于齿柄5下段的长度。压头6的外径与上模7的模腔内径相匹配,其内腔底部的形状与齿头4的外形相同,顶部与齿尖I顶端的圆锥体的外形相同。
[0024]截齿的制备具体包括如下步骤:
[0025]步骤1,齿柄5加热至150_300°C,将齿柄5下段垂直安装在下模8的模腔内,然后在下模8上放置上模7,将齿柄5具有螺纹3的上段垂直置于上模7模腔中央的下部,齿柄5上端面粘贴厚度为2_3mm的钎焊料2。再将齿尖I的圆柱段朝下垂直安装在上模7的模腔内的上部,置于钎焊料2上。钎焊料2为铜基钎焊料,熔点800-900°C。
[0026]步骤2,以高于抗磨合金的液相线温度15〜80°C的浇注温度,向模具7腔内浇注抗磨合金液,充满上模7模腔,将齿柄5的螺纹3及齿尖I包裹,并将其间的钎焊料2熔化、粘结剂气化。
[0027]步骤3,在抗磨合金液完全凝固前,利用压头6对抗磨合金液施加50〜150MPa的压强并保压1-5秒。在保压过程中,抗磨合金液发生凝固形成齿头4,钎焊料2凝固将齿头4和硬质合金齿尖I焊接在一起;并在凝固收缩力和外加压力的共同作用下,抗磨合金齿头4与齿柄螺纹3及硬质合金齿尖I接触的界面达到良好的结合,实现了齿头4、齿柄5和硬质合金齿尖I三者之间牢固地结合,成为一体。
[0028]步骤4,停止加压后,将制成的截齿从模具内腔中取出,在空气中冷却至400°C以下后,重新加热至齿头材料要求的淬火温度对齿头进行淬火处理,淬火后8小时内加热至回火温度进行回火处理,提高齿头4的抗磨性,最终得到一种采掘机械用截齿。
[0029]在步骤4中,这里的热处理的淬火、回火温度是根据齿头使用的材料来确定,为现有技术相同的处理方法。
[0030] 实施例1
[0031 ]所述的截齿的制备方法中:
[0032]所述的齿头4用高铬铸铁制成;所述的齿柄5用45中碳钢制成。
[0033]在步骤I中,所述的齿柄5加热至150°C,齿柄5上端面粘有厚度为2mm的钎焊料2,所述的钎焊料2熔点800°C。
[0034]在步骤2中,以高于抗磨合金的液相线温度80°C的浇注温度向金属模腔内浇注抗磨合金液。
[0035]在步骤3中,在抗磨合金液完全凝固前,对抗磨合金液施加150MPa的压强并保压I秒。
[0036]在步骤4中,将截齿从模具内腔中取出后冷却至390°C。
[0037] 实施例2
[0038]所述的截齿的制备方法中:
[0039]所述的齿头4用高锰钢制成;所述的齿柄5用42CrMo中碳合金钢制成。
[0040]在步骤I中,所述的齿柄5加热至225°C;齿柄5上端面粘有厚度为2.5_的钎焊料2,所述的钎焊料2熔点900°C。
[0041]在步骤2中,以高于抗磨合金的液相线温度50°C的浇注温度向金属模腔内浇注抗磨合金液。
[0042]在步骤3中,在抗磨合金液完全凝固前,对抗磨合金液施加10MPa的压强并保压1-5秒。
[0043]在步骤4中,将截齿从模具内腔中取出后冷却至200°C。
[0044] 实施例3
[0045]所述的截齿的制备方法中:
[0046]所述的齿头4用35SiMnMo低合金钢制成;所述的齿柄5用中碳钢或中碳调质钢制成。
[0047]在步骤I中,所述的齿柄5加热至150°C;齿柄5上端面粘有厚度为3mm的钎焊料2,所述的钎焊料2熔点800°C。
[0048]在步骤2中,以高于抗磨合金的液相线温度80°C的浇注温度向金属模腔内浇注抗磨合金液。
[0049]在步骤3中,在抗磨合金液完全凝固前,对抗磨合金液4施加50MPa的压强并保压5秒。
[0050]在步骤4中,将截齿从模具内腔中取出后冷却至25°C。
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CN105543770A (zh) * | 2015-12-22 | 2016-05-04 | 湖北鄂瑞孚截齿钻具科技有限公司 | 一种截齿的表面处理工艺 |
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CN106141595A (zh) * | 2016-08-11 | 2016-11-23 | 镇江市宝偃工程机械有限公司 | 截齿的钎焊与热处理一体化工艺方法 |
CN107780933B (zh) * | 2017-09-19 | 2020-02-28 | 江苏师范大学 | 一种能测量截割温度的刀型截齿 |
CN108412491B (zh) * | 2018-01-19 | 2020-03-27 | 湖南泰鼎新材料有限责任公司 | 一种复合截齿 |
CN109732062A (zh) * | 2019-03-07 | 2019-05-10 | 大连理工大学 | 金属型镶铸采煤机截齿 |
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