CN106064286A - The broken teeth bracing means of a kind of huge gear and method for repairing and mending - Google Patents
The broken teeth bracing means of a kind of huge gear and method for repairing and mending Download PDFInfo
- Publication number
- CN106064286A CN106064286A CN201610660507.9A CN201610660507A CN106064286A CN 106064286 A CN106064286 A CN 106064286A CN 201610660507 A CN201610660507 A CN 201610660507A CN 106064286 A CN106064286 A CN 106064286A
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- China
- Prior art keywords
- gear
- boring
- metal bar
- broken teeth
- repairing
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
Abstract
The broken teeth bracing means of a kind of huge gear and method for repairing and mending, this method for repairing and mending comprises the following steps: (1) polishes；(2) detection；(3) boring: the uniform at least three that is drilled with of each tooth root repair surface at gear is holed；(4) reinforce: metal bar interference respectively is squeezed in each boring described in step (3), as the reinforcement of reparation gear internal, and metal bar and gear are welded into one；(5) welding；(6) restore.Present invention additionally comprises the broken teeth bracing means of a kind of huge gear.One aspect of the present invention can be greatly increased the tooth face hardness of gear and by force intensity, and then the service life of raising gear, and functional reliability is high；On the other hand, simple to operate, repair speed fast, it is not necessary to carry out post weld heat treatment, and then the heavy losses that equipment causes because of shutdown will not be stopped over for a long time, and be greatly saved cost, be effectively improved economic benefit and social benefit.
Description
Technical field
The present invention relates to maintenance of equipment field, the broken teeth bracing means of a kind of huge gear and method for repairing and mending.
Background technology
Huge gear is mainly used in water conservancy and hydropower, mine, metallurgy and machinery industry, and their feature is that diameter is big, load
Greatly, force-bearing situation is complicated, and lubrication state is poor, work under bad environment, often due to bond abrasion and fatigue equivalent and be greatly shortened
Its service life.Some gears only because of flank of tooth sharpening or due to the fracture of indivedual teeth, fall tooth and result in scrapping of whole part, significantly
The utilization rate of reduction equipment and work efficiency, if processing by steel scrap after scrapping, can have a greatly reduced quality, not only causing the wave of material
Take, also lose a large number of expense.For example with the gear of large-scale ball crusher, diameter 4m, weight 5.8 tons, there are 196 teeth.
When after its abrasion or fracture failure, it is 500 yuan/t by steel scrap salvage value, totally 2900 yuan.If repaired, recover to use function
After, its price is 12000 yuan/t, altogether value 69600 yuan, and both differ 24 times.
Therefore for the huge gear that this value is high, more complicated, rupturing suddenly in operation, it is if able to quickly repair
Multiple, and reach use technology requirement, it will it is greatly saved operating cost, and will not stop over what equipment caused because of shutdown for a long time
Heavy losses, have bigger economic benefit and social benefit.
Summary of the invention
It is an object of the invention to overcome the above-mentioned deficiency of prior art to provide a kind of rehabilitation cost low, repair fireballing
The broken teeth bracing means of huge gear and method for repairing and mending, the gear after reparation can continue to use, and ensures certain use
Life-span.
The technical scheme is that
The broken teeth method for repairing and mending of a kind of huge gear of the present invention, comprises the following steps:
(1) polishing: polish gear to be repaired, removes surface impurity, removes impaired wound surface, until metal is exposed on surface
Gloss；
(2) detection: each tooth bar of gear being carried out internal carrying out flaw detection, if detecting on tooth bar defective, removing, it is ensured that
Each tooth bar does not has internal flaw, makes wound surface expose metallic luster；
(3) boring: the uniform at least three that is drilled with of each tooth root repair surface at gear is holed；
(4) reinforce: metal bar interference respectively is squeezed in each boring described in step (3), as repairing adding of gear internal
Strong muscle, and metal bar and gear are welded into one；
(5) welding: broken teeth is integrally welded with metal bar, and it is qualified to detecting to carry out carrying out flaw detection；Wherein, broken teeth can be
The tooth of fracture on this gear, it is also possible to be another set of gear old tooth spare part in damaged condition；
(6) restore: profiling polishing and cooperation processing on the flank of tooth repaired, reach original standard size.
Further, in step (3), described each tooth root repair surface at gear is uniform is drilled with 4-10 boring.
Further, a diameter of 10-15mm of described boring, the degree of depth is 55-65mm.
Further, in step (4), a length of 110-130mm of described metal bar, a diameter of 10-15mm.
Further, described metal bar is stainless steel bar.
Further, in step (4), the top of described boring offers the groove being easy to form weld seam between metal bar.
Further, in step (5), the mode of described welding uses cold surface welding, and the surplus of welding is higher than the height of former tooth bar.
Further, the welding manner of argon arc welding is used to carry out bottoming welding.
Further, the Ni-based wlding of Ultra-low carbon selected by welding material.
The broken teeth bracing means of a kind of huge gear of the present invention, each tooth root repair surface at described gear is laid with
At least three is holed, and is provided with metal bar in boring, metal bar with hole interference fit integrally welded, the length of metal bar is big
In the degree of depth of boring, the metal bar beyond boring is integrally welded with the broken teeth of gear.
Further, each tooth root repair surface of described gear is provided with 4-10 boring.
Further, 2 times of a length of drilling depth of described metal bar.
Further, a diameter of 10-15mm of described boring, the degree of depth is 55-65mm；The a length of 110-of described metal bar
130mm, a diameter of 10-15mm.
Further, the top of described boring offers the groove being easy to form weld seam between metal bar.
Further, described metal bar tilts fixing, and the angle between metal bar and gear repair surface is 60 ~ 85 °.
Beneficial effects of the present invention:
(1) by using metal bar to carry out bar planting, the tooth face hardness of gear can be greatly increased and by force intensity, and then improve gear
Service life, functional reliability is high；
(2) simple to operate, repair speed fast, it is not necessary to carry out post weld heat treatment, and then the equipment that will not stop over for a long time is because shutting down
And the heavy losses caused；
(3) process by steel scrap after need not scrap, be i.e. not required to buy new gear and be replaced, be greatly saved cost, be effectively improved
Economic benefit and social benefit.
Accompanying drawing explanation
Fig. 1 is the structural representation after embodiment of the present invention bar planting.
Detailed description of the invention
Below with reference to Figure of description and specific embodiment, the present invention is described in further details.
As shown in Figure 1: the broken teeth bracing means of a kind of huge gear, each tooth root repair surface 11 at gear 1 is all laid
Having at least three to hole, be provided with stainless steel bar 2 in boring, stainless steel bar 2 and boring interference fit are the most integrally welded, rustless steel
The length of rod 2 is more than the degree of depth of boring, and the stainless steel bar 2 beyond boring is integrally welded with the broken teeth of gear 1.
The present invention, by squeezing in boring by stainless steel bar 2 interference, is used as repairing the reinforcement within gear 1, simulation
Reinforcing bar in armored concrete, and welding auxiliary is fixing, then weld, significantly identical with stainless steel bar 2 for the broken teeth of gear 1
Add the tooth face hardness of gear 1 and by force intensity, and then the service life of raising gear, cost-effective.
The present invention will be specifically described by an embodiment below.
Inventor, when gear wheel large and small to coal pulverizer carries out flank of tooth inspection, has a broken teeth in finding denticle wheel case, for
Promptly and accurately find the particular location of broken teeth, by the degras that cleaning denticle wheel case inner product is full, and check little roller axle one by one
Tooth, finds that immediately below little gear wheel, rupture completely in a tooth acting in accordance with YIN YANG changes in four seasons portion, broken teeth length about 510mm.For emergency repair, intend utilizing thing
Money warehouse is another set of collapses the old spare part of little gear wheel that tooth damages, and this spare part has a tooth along facewidth direction defect, can be as promptly repairing
Multiple spare part is replaced damaging little gear wheel.
1, situation is repaired:
The little gear wheel of coal pulverizer don't lose efficacy by block, needs repair process, resizing about (maximum: long * height * width) 420*60*50 millimeter.
This gear material is 37SiMn2MoV, for the senior quenched and tempered steel of middle carbon, bears the tune of heavy load for manufacturing heavy in section
Matter part and surface hardening part, such as the gear shaft class etc. of heavy-duty machinery.
2, selection of Welding:
Owing to 37SiMn2MoV material is in the case of interlayer temperature is more than 1200 DEG C, martensite steel can be quickly converted to, and have
Strong hot cracking tendency, weld seam is easily generated fire check near the zone of influence.Need to make weld preheating according to normal welding reparation
Processing, be required for carrying out post weld heat treatment after per pass weld seam welding, it is big to repair difficulty, complex process, repair time length and
After reparation, delayed crack is difficult to predict, therefore, all block region recovery matrixes that entirely collapse all use cold surface welding form reparation.
3, welding equipment:
Arc spraying cold welding machine: arc spraying cold-welding technique is a physical and chemical process, is based on the wlding in gaseous environment
Occur that the infiltration phenomenon that metal ionization spray regime and moment high arc temperature occur makes metal ionization thing be formed to anode transfer
New metallurgical bonding layer and set up, be particularly suitable for abuse and casting flaw sloppy heat Bead weld repair.Employing electric arc sprays
Penetrate cold-welding technique and carry out sloppy heat welding, on material selects, select the Ni-based wlding of Ultra-low carbon content, can be true under sloppy heat technique
Protect metallurgical binding, because the control of interlayer temperature and the selection of welding material, it can be ensured that do not produce martensitic structure and ensure weldering
Connect quality.
4, welding material selects:
Select the Ni-based wlding of Ultra-low carbon, the trade mark: A1002, Z408.
Use above two welding material (and using bottom argon arc welding to weld), it is ensured that its heart portion has preferably extension
Property, outside has stronger cracking resistance, can obtain preferable occlusal surface under the pressure of work surface.
5, concrete method for repairing and mending:
(1) gear 1 to be repaired is polished, remove surface impurity, remove impaired wound surface, until metal light is exposed on surface
Pool；
(2) each tooth bar 12 to gear 1 carries out internal carrying out flaw detection, such as, use dye penetrant inspection agent to carry out dye penetrant inspection, if
Detect on tooth bar defective, remove, it is ensured that each tooth bar 12 does not has internal flaw, makes wound surface expose metallic luster, if finding
New defect, in the lump repair process；Such as, the present embodiment, after to the polishing detection of other flank of tooth, in addition to this collapses tooth, is also sent out
Existing another tooth bar adjacent also has crackle at root, needs thoroughly to remove in the lump and process；
(3) at two gear root magnetic drills, 8 a diameter of 12mm of each uniform brill damaged, the degree of depth is the boring of 60mm；
(4) carrying out bar planting with stainless steel bar 2 in each boring described in step 3, the bar planting degree of depth is 60mm, takes interference of holing
Coordinate, offer groove in drill tip, it is simple to form weld seam with bar planting, after welding, make stainless steel bar 2 firmly be linked as with base material
Integrally；Wherein, a length of 120mm of stainless steel bar 2, a diameter of 12mm, stainless steel bar 2 and base material have certain after being welded and fixed
Tilting, the angle between itself and gear repair surface 11 is preferably in 80 °.Why stainless steel bar 2 is designed to incline by the present embodiment
Oblique, it being because the involute that is shaped as of gear surface, stainless steel bar tilts certain angle, it is possible to make stainless steel bar bear more
The power in polyaxial direction, stress is more reasonable.
(5) after bar planting, take arc spraying cold welding machine to carry out cold surface welding, make parent metal weld with stainless steel bar 2,
Guarantee firmly to be connected as a single entity, and qualified through dye penetrant inspection detection；
(6), after all REPAIR WELDING, carry out roughing through polishing welding seams appearance, it is ensured that after carrying out flaw detection is qualified, then determine programming
Parameter, uses the three-dimension numerical controlled lathe of Large CNC to carry out polish；
(7) use resin reverse mould manual partial polishing chamfer machining complex to qualified.
(8), after all REPAIR WELDING and completion of processing, tooth face hardness and defect detecting test after REPAIR WELDING and processing are checked and accepted,
I.e. tooth face hardness HRC is 32-36；Interlayer and finished pigmented defect detecting test result: qualified.All repairs complete, and input makes
With.
By the method for repairing and mending of the present embodiment, on the one hand can be greatly increased the tooth face hardness of gear 1 and by force intensity, enter
And improving the service life of gear, functional reliability is high；On the other hand, this method for repairing and mending is simple to operate, repairs speed soon, is not required to
Post weld heat treatment to be carried out, and then the heavy losses that equipment causes because of shutdown will not be stopped over for a long time；Furthermore, it is not necessary that scrap
Press steel scrap afterwards to process, be i.e. not required to buy new gear and be replaced, be greatly saved cost, be effectively improved economic benefit and society's effect
Benefit.
Claims (10)
1. the broken teeth method for repairing and mending of a huge gear, it is characterised in that comprise the following steps:
(1) polishing: polish gear to be repaired, removes surface impurity, removes impaired wound surface, until metal is exposed on surface
Gloss；
(2) detection: each tooth bar of gear being carried out internal carrying out flaw detection, if detecting on tooth bar defective, removing, it is ensured that
Each tooth bar does not has internal flaw, makes wound surface expose metallic luster；
(3) boring: the uniform at least three that is drilled with of each tooth root repair surface at gear is holed；
(4) reinforce: metal bar interference respectively is squeezed in each boring described in step (3), as repairing adding of gear internal
Strong muscle, and metal bar and gear are welded into one；
(5) welding: broken teeth is integrally welded with metal bar, and it is qualified to detecting to carry out carrying out flaw detection；
(6) restore: profiling polishing and cooperation processing on the flank of tooth repaired, reach original standard size.
The broken teeth method for repairing and mending of the hugest gear, it is characterised in that in step (3), described at gear
Each tooth root repair surface uniform be drilled with 4-10 boring；Or a diameter of 10-15mm of described boring, the degree of depth is 55-65mm.
The broken teeth method for repairing and mending of huge gear the most according to claim 1 or claim 2, it is characterised in that in step (4), described gold
Belong to a length of 110-130mm, a diameter of 10-15mm of rod；Or described metal bar is stainless steel bar.
The broken teeth method for repairing and mending of huge gear the most according to claim 1 or claim 2, it is characterised in that in step (4), described brill
The top in hole offers the groove being easy to form weld seam between metal bar.
The broken teeth method for repairing and mending of huge gear the most according to claim 1 or claim 2, it is characterised in that in step (5), described weldering
The mode connect uses cold surface welding, and the surplus of welding is higher than the height of former tooth bar；Or the welding manner using argon arc welding carries out beating
Back welding connects；Or the Ni-based wlding of Ultra-low carbon selected by welding material.
6. the broken teeth bracing means of a huge gear, it is characterised in that each tooth root repair surface at described gear is all laid
Having at least three to hole, be provided with metal bar in boring, metal bar and boring interference fit are the most integrally welded, the length of metal bar
More than the degree of depth of boring, the metal bar beyond boring is integrally welded with the broken teeth of gear.
The broken teeth bracing means of the hugest gear, it is characterised in that each tooth root of described gear is repaiied
Coverlay is provided with 4-10 boring.
8. according to the broken teeth bracing means of gear huge described in claim 6 or 7, it is characterised in that the length of described metal bar
For drilling depth 2 times；Or a diameter of 10-15mm of described boring, the degree of depth is 55-65mm；Described metal bar a length of
110-130mm, a diameter of 10-15mm.
9. according to the broken teeth bracing means of gear huge described in claim 6 or 7, it is characterised in that the top of described boring is opened
It is provided with the groove being easy to form weld seam between metal bar.
10. according to the broken teeth bracing means of gear huge described in claim 6 or 7, it is characterised in that described metal bar tilts solid
Fixed, the angle between metal bar and gear repair surface is 60 ~ 85 °.
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| CN201610660507.9A CN106064286B (en) | 2016-08-12 | 2016-08-12 | A kind of the broken teeth bracing means and method for repairing and mending of huge gear |
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| CN201610660507.9A CN106064286B (en) | 2016-08-12 | 2016-08-12 | A kind of the broken teeth bracing means and method for repairing and mending of huge gear |
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108547767A (en) * | 2018-05-28 | 2018-09-18 | 山西东睦华晟粉末冶金有限公司 | A kind of combined type cycloid rotor and preparation method thereof |
| CN108555468A (en) * | 2018-04-25 | 2018-09-21 | 安徽马钢设备检修有限公司 | A kind of online welding and restoring process of large size spur gear |
| CN109551167A (en) * | 2018-11-26 | 2019-04-02 | 阳泉煤业集团华越机械有限公司煤机装备研究院 | A kind tooth reproduces gear restorative procedure |
| CN110735908A (en) * | 2019-10-29 | 2020-01-31 | 中交烟台环保疏浚有限公司 | Method for repairing broken gear |
| CN112589373A (en) * | 2020-12-04 | 2021-04-02 | 南京劲拓海洋工程装备有限公司 | Drilling platform gear shaft repairing method |
| CN112872706A (en) * | 2021-01-13 | 2021-06-01 | 武汉彤烨科技有限公司 | Rotary kiln riding wheel and wheel belt damage repairing method |
| CN112958996A (en) * | 2021-02-09 | 2021-06-15 | 北京建工土木工程有限公司 | Repairing method of gear ring for shield machine |
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108555468A (en) * | 2018-04-25 | 2018-09-21 | 安徽马钢设备检修有限公司 | A kind of online welding and restoring process of large size spur gear |
| CN108547767A (en) * | 2018-05-28 | 2018-09-18 | 山西东睦华晟粉末冶金有限公司 | A kind of combined type cycloid rotor and preparation method thereof |
| CN109551167A (en) * | 2018-11-26 | 2019-04-02 | 阳泉煤业集团华越机械有限公司煤机装备研究院 | A kind tooth reproduces gear restorative procedure |
| CN110735908A (en) * | 2019-10-29 | 2020-01-31 | 中交烟台环保疏浚有限公司 | Method for repairing broken gear |
| CN112589373A (en) * | 2020-12-04 | 2021-04-02 | 南京劲拓海洋工程装备有限公司 | Drilling platform gear shaft repairing method |
| CN112872706A (en) * | 2021-01-13 | 2021-06-01 | 武汉彤烨科技有限公司 | Rotary kiln riding wheel and wheel belt damage repairing method |
| CN112958996A (en) * | 2021-02-09 | 2021-06-15 | 北京建工土木工程有限公司 | Repairing method of gear ring for shield machine |
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| CN106064286B (en) | 2018-11-30 |
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