CN106119768B - 一种卡瓦的加工方法 - Google Patents

一种卡瓦的加工方法 Download PDF

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CN106119768B
CN106119768B CN201610434575.3A CN201610434575A CN106119768B CN 106119768 B CN106119768 B CN 106119768B CN 201610434575 A CN201610434575 A CN 201610434575A CN 106119768 B CN106119768 B CN 106119768B
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王观礼
张亚昌
伍玉娇
张超
梁柔
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Guizhou Gaofeng Petroleum Machinery Co Ltd
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Abstract

本发明公开了一种卡瓦的加工方法。采用高峰2号钢加工卡瓦;加工工序包括:投料→粗加工→精加工接近成型→铣槽留筋倒毛刺并确保各倒角及工作面粗糙度符图要求→渗碳确保渗碳层深度不大于设计要求的下限0.8mm→正火确保不发生氧化和脱碳(渗碳出炉转入中温盐炉浸入后立即取出空冷300℃以下再入盐炉保温后硝盐浴淬火并去应力回火)→淬火确保不发生变形,回火后清洗并干燥后喷砂、抛光→QPQ处理或软氮化处理→去筋再倒毛刺→磷化待装配。本发明明显提高了卡瓦基体的韧性,缺口冲击功提高30J。确保了卡瓦基体硬度不低于36HRC(36‑40),有效防止了卡瓦抱死,35CrMo失效件分析基体硬度只有28‑30HRC。经过QPQ处理或软氮化表面处理后防止了表面咬伤,使用寿命提高了30%。

Description

一种卡瓦的加工方法
技术领域
本发明涉及一种卡瓦的加工方法,属于金属材料及热处理技术领域。
背景技术
卡瓦是机械式随钻震击器的核心部件,主要作用是调节震击器的上、下震击力。在机械式随钻震击器中卡瓦与卡瓦心轴组成锁紧机构,卡瓦与卡瓦心轴之间为滑动连接,滑动过程中产生机械摩擦。机械式随钻震击器在上击、复位、下击时卡瓦要承受拉、压、弯综合交变应力作用。卡瓦在工作时一旦发生脆断或卡瓦与卡瓦心轴之间发生抱死,即视为卡瓦失效。因此对卡瓦的加工要求是:卡瓦表面硬度应尽可能高些,提高卡瓦表面的耐磨性;卡瓦基体应具有较高的柔韧性同时确保基体具有足够的硬度防止抱死。
一直以来,现有卡瓦都是采用35CrMo加工成型,并经渗碳淬火中温回火制成。用35CrMo加工的卡瓦经渗碳淬火500℃回火后表面硬度为47HRC、缺口冲击功为49J。工作过程中经常会出现卡瓦失效现象。如果35CrMo渗碳淬火580℃回火相同时间,其表面硬度则会降至40HRC,就没有使用价值了。
因此,需要另外寻找一套卡瓦的加工方法以提高卡瓦的总体性能。
发明内容
本发明的目的,提供一种卡瓦的加工方法,达到零件表面获得足够硬度和耐磨性,基体获得较高韧性。利用高峰2号钢表现出来的热处理特性:具有较高的回火稳定性能够确保在表面获得足够硬度和耐磨性同时,使基体获得较高韧性。利用渗碳层深度对零件整体韧性的影响规律,解决机械式随钻震击器核心部零件卡瓦存在的问题:或者硬度过高韧性不足发生脆断、或者硬度过低弹性不足发生咬伤、抱死,以解决现有技术的不足。
本发明的技术方案
为解决上述技术问题,本发明通过以下技术方案实现:
一种卡瓦的加工方法,采用高峰2号钢加工卡瓦;加工工序包括粗加工→精加工(包括拉槽留筋并倒毛刺)→热处理包括渗碳、正火、淬火并去应力回火、抛光、QPQ或软氮化)→去筋再倒毛刺→磷化;所述精加工是将卡瓦加工至接近成型尺寸,并抛光及倒毛刺同时保留零件上的工艺筋;所述热处理工序是对渗碳炉排气使炉温降至装炉温度后将精加工后的卡瓦装入渗碳炉,再将炉温升至900~920℃保温2-3小时之后散渗1-2小时停止加热,使卡瓦随炉降温至860℃出炉;出炉后迅速将卡瓦转入中温盐浴炉挂盐后空冷至300℃以下;空冷后再转入中温盐浴炉升温至880℃保温20-30分钟再空冷,空冷后再转入淬火炉升温至800℃-830℃保温20分钟左右,将卡瓦淬火转入160度硝盐浴炉等温淬火10分左右,再将温度升至200℃左右保温1-2小时进行去应力回火;最后再对卡瓦进行QPQ处理或软氮化处理后出炉空冷。
前述加工方法中,所述渗碳层深度不大于0.8mm。
前述加工方法中,所述QPQ处理是一种盐浴复合处理技术,具体是先对卡瓦工作面进行一次抛光处理后,再在盐浴中作一次氧化处理。
前述加工方法中,所述高峰2号钢是一种低碳多元微合金化多用途高强韧性结构钢,采用以下质量份材料炼制而成:碳(C)0.22~0.31、硅(Si)0.15~0.30、锰(Mn)0.45~0.85、铬(Cr)1.10~1.40、钼(Mo)0.45~0.75、镍(Ni)≤0.25、铜(Cu)≤0.25、硫(S)≤0.005、磷(P)≤0.015、钒(V)0.02~0.10、钛(Ti)≤0.01、铌(Nb)0.02~0.05、硼(B)0.001~0.003,余量为铁。
与现有技术相比,本发明制造卡瓦的钢材是我单位特定的高峰2号钢,用我单位特定的钢通过上述热处理工艺制成的卡瓦,明显提高了卡瓦基体的韧性,缺口冲击功提高30J。确保了卡瓦基体硬度不低于36HRC(36-40),有效防止了卡瓦抱死, 35CrMo失效件分析基体硬度只有28-30HRC。经过QPQ处理或软氮化表面处理后防止了表面咬伤,使用寿命提高了30%。
附图说明
图1是高峰2号钢制作机械式随钻卡瓦热处理工艺曲线示意图;
图2是35CrMo渗碳试样冲击功随回火温度变化的曲线示意图;图A是无缺口冲击功曲线图,图B是缺口冲击功曲线图。
图3是35CrMo渗碳试样表面硬度随回火温度变化的曲线示意图;
图4是高峰2号钢渗碳试样抗拉强度随回火温度变化的曲线示意图;
图5是高峰2号钢渗碳0.9mm,830℃盐浴加热保温18min淬硝盐200℃经90min 不同温度回火后开缺口与无缺口冲击试样冲击功及硬度随回火温度的变化。从图5可见,高峰2号钢在550度以上回火的冲击功提高明显,而表面硬度的变化很小,充分说明其回火稳定性高的优势也十分明显。
具体实施方式
以下结合附图及实施例,对本发明具体的实施方式、结构、特征及其效果,详细说明如下。
一种卡瓦的加工方法,采用高峰2号钢加工卡瓦;加工工序包括粗加工→精加工(包括拉槽留筋并倒毛刺)→热处理(包括渗碳、正火、淬火并去应力回火、抛光、QPQ或软氮化)→去筋再倒毛刺→磷化;所述精加工是将卡瓦加工至接近成型尺寸,并保留零件上的工艺筋和倒毛刺;所述热处理工序是对渗碳炉滴入保护气排气到渗碳温度启开炉盖装炉后将精加工后的卡瓦装入渗碳炉,再将炉温升温同时排气至900~920℃保温2-3小时之后再扩散渗1-2小时停止加热,使卡瓦随炉降温至860℃出炉;再将卡瓦转入中温盐浴炉挂盐后空冷至300℃以下;空冷后再转入中温盐浴炉升温至880℃保温20-30分钟再空冷,空冷后再转入淬火炉升温至800-830℃保温20分钟左右,将卡瓦淬火转入硝盐浴炉等温淬火10分左右,再将温度升至200℃左右保温1-2小时进行去应力回火;最后再对卡瓦进行QPQ处理或软氮化处理后出炉空冷。
前述加工方法中,所述渗碳层深度不大于0.8mm。
前述加工方法中,所述QPQ处理是一种盐浴复合处理技术,具体是先对卡瓦工作面进行一次抛光处理后,再在盐浴中作一次氧化处理。
前述加工方法中,所述高峰2号钢是一种低碳多元微合金化多用途高强韧性结构钢,采用以下质量份数材料炼制而成:碳(C)0.22~0.31、硅(Si)0.15~0.30、锰(Mn)0.45~0.85、铬(Cr)1.10~1.40、钼(Mo)0.45~0.75、镍(Ni)≤0.25、铜(Cu)≤0.25、硫(S)≤0.005、磷(P)≤0.015、钒(V)0.02~0.10、钛(Ti)≤0.01、铌(Nb)0.02~0.05、硼(B)0.001~0.003,余量为铁。
实施例
本例的加工工序如下:包括投料→粗加工→精加工接近成型→铣槽留筋倒毛刺并确保各倒角及工作面粗糙度符图要求→渗碳确保渗碳层深度不大于设计要求的下限0.8mm→正火确保不发生氧化和脱碳(渗碳出炉转入中温盐炉浸入后立即取出空冷300℃以下再入盐炉保温后硝盐浴淬火并去应力回火)→淬火确保不发生变形硝盐浴淬火并去应力回火),回火后清洗烘干并内外喷砂及抛光→QPQ处理或软氮化处理→去筋再倒毛刺→磷化待装配。
本发明与现有技术的比较实验曲线图如下:
图1是高峰2号钢制作机械式随钻卡瓦热处理工艺曲线示意图;
图2是现有技术所用35CrMo材料渗碳试样的冲击功与温度变化曲线图;
图3是现有技术所用35CrMo材料渗碳试样的表面硬度与温度变化曲线图;图3中曲线A是35CrMo 冲击试样920℃渗碳0.8mm出炉转浸860℃盐浴后空冷+880℃ 20min空冷+830℃淬硝盐经不同温度回火水冷时的曲线,曲线B是35CrMo 无缺口冲击试样920℃渗碳0.8mm出炉转浸860℃盐浴后空冷+886℃ 20min空冷+830℃ 20min淬硝盐经不同温度回火水冷时的曲线。
图4是本发明所用高峰2号钢材料渗碳试样的抗拉强度与温度变化的关系图,试验条件是退火态+830℃ 18min淬硝盐不同温度回火水冷;
图5是高峰2号钢渗碳0.8mm,830℃盐浴加热保温18min淬硝盐200℃经90min 不同温度回火后开缺口与无缺口冲击试样冲击功及硬度随回火温度的变化。从图5可见,高峰2号钢在550度以上回火的冲击功提高明显,而表面硬度的变化很小,充分说明其回火稳定性高的优势也十分明显。

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1.一种卡瓦的加工方法,其特征在于:采用高峰2号钢加工卡瓦;加工工序包括粗加工→精加工→热处理→去筋再倒毛刺→磷化;所述精加工是将卡瓦加工至接近成型尺寸,并抛光及倒毛刺同时保留零件上的工艺筋;所述热处理工序包括渗碳、正火、淬火并去应力回火、抛光、QPQ或软氮化;热处理工序是对渗碳炉预先排气并使炉温到900-920℃开启炉盖将精加工后的卡瓦装入渗碳炉,再将炉温升温至900~920℃同时排气,强渗2-3小时再扩散渗1-2小时之后停止加热,使卡瓦随炉降温至860℃出炉;出炉同时将卡瓦转入中温盐浴炉挂盐后空冷至300℃以下;空冷后再转入中温盐浴炉升温至880℃保温20-30分钟再空冷,空冷后再转入淬火炉升温至800℃-830℃保温20分钟,将卡瓦淬入160℃硝盐浴炉等温淬火10分,再将温度升至200℃保温1-2小时进行去应力回火;最后再对卡瓦进行QPQ处理或软氮化处理后出炉空冷;QPQ处理是一种盐浴复合处理技术,具体是先对卡瓦工作面进行一次抛光处理后,再在盐浴中作一次氧化处理;所述渗碳层深度不大于0.8mm;所述高峰2号钢是一种低碳多元微合金化多用途高强韧性结构钢,采用以下质量份数材料炼制而成:碳(C)0.22~0.31、硅(Si)0.15~0.30、锰(Mn)0.45~0.85、铬(Cr)1.10~1.40、钼(Mo)0.45~0.75、镍(Ni)≤0.25、铜(Cu)≤0.25、硫(S)≤0.005、磷(P)≤0.015、钒(V)0.02~0.10、钛(Ti)≤0.01、铌(Nb)0.02~0.05、硼(B)0.001~0.003,余量为铁。
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