CN108555468B - Online welding repair process for large straight gear - Google Patents
Online welding repair process for large straight gear Download PDFInfo
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- CN108555468B CN108555468B CN201810378064.3A CN201810378064A CN108555468B CN 108555468 B CN108555468 B CN 108555468B CN 201810378064 A CN201810378064 A CN 201810378064A CN 108555468 B CN108555468 B CN 108555468B
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- 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
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
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- 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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
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Abstract
The invention discloses an on-line welding repair process for a large straight gear, which is characterized by being carried out according to preparation before welding, welding treatment and post-welding treatment, wherein the welding treatment comprises weldment position adjustment, cleaning before welding, flattening at a welding tooth breaking position, heating the weldment, welding a transitional priming layer and welding a surfacing layer; after welding, the tooth-shaped sample plates manufactured firstly are used for comparison, redundant welding seams are cut and flattened by plasma gas planing, then are roughly ground by an angle grinder so as to meet the size of the tooth-shaped sample plates, and finally stress relief operation is carried out. The invention has the advantages that the online welding repair of the gear part to be welded is completed in a narrow space, the straight teeth after overlaying are manually ground to meet the running size, the surface has no welding defects, the quality of the subsequent running period is ensured, the overhaul time is saved, the maintenance cost is reduced, the shutdown loss is reduced, and the guarantee is provided for reasonable production.
Description
Technical Field
The invention belongs to the technical field of gear maintenance, and particularly relates to an on-line welding repair process for broken teeth of a large straight gear on a wheel band rolling mill.
Background
The wheel band rolling mill is used for rolling wheel band flange, its main driving system is formed from main motor, main speed reducer, main driving shaft, bevel gear and large and small spur gears, and can be used for respectively driving main roller vertical shaft and horizontal roller to make them rotate, in which the small spur gear is mounted on the main driving shaft, and its meshed large spur gear is mounted on the horizontal roller shaft, and a pair of mutually-meshed large and small spur gears can be used for matching rotating speed and transferring torque when the wheel band rolling mill is worked. With the increase of the working time of the rim rolling mill, the meshed spur gears operate under the action of load for a long time, and broken teeth locally appear on large spur gears (m is 28, Z is 73), so that the running precision of a shafting is influenced, and large vibration and noise are generated when the rim rolling mill operates. Because the straight gear of the wheel band rolling mill is huge in size and has certain difficulty in disassembly, hoisting and transportation, the straight gear is transported to a factory for repair, the period is long, the procurement period of spare parts required for field replacement is long, and in order to restore the production as soon as possible, the broken teeth need to be welded and repaired from the broken positions on the site. In the prior art, the welding repair application of various gear wear and fracture is common, and a plurality of documents describe the welding repair application, but the welding repair application aiming at the site of broken teeth of a large-sized straight gear is rare.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide an on-line welding repair process for a large straight gear, which is used for completing the operations of heating, welding, heat preservation and the like of a gear part to be welded in a narrow space, wherein the piled straight gear meets the running size through grinding, the surface has no welding defects, and the quality of the subsequent running period is ensured.
In order to achieve the purpose, the invention adopts the following technical scheme:
the on-line welding repair process for the large straight gear is characterized by comprising the following steps of:
step one preparation before welding
1) And (3) field construction conditions: all wheel band rolling mills are powered off, parts around the large straight gear are removed, a semicircle at the upper part of the box body is opened, the large straight gear is exposed, the broken tooth is moved to the horizontal position, the box body around the broken tooth and nearby the broken tooth is cleaned by a cleaning agent, and in addition, no cross-ventilation exists in a welding place and night construction lighting facilities and fire extinguishing equipment are arranged;
2) a heating device: an oxyacetylene bottle, an electric heating belt;
3) welding and auxiliary equipment: the welding equipment comprises a digital control inverse manual direct current welding machine and a digital pulse gas shielded welding machine, and the back chipping adopts a high-power welding machine matched with a plasma air plane; the auxiliary equipment comprises an angle grinder, a file, a hand hammer, a flat shovel, a heat-insulating barrel, a tooth-shaped template, a temperature measuring instrument, a magnifier and heat-insulating cotton;
step two welding process
1) Adjusting the position of a weldment and cleaning before welding: the welding broken teeth are positioned at the upper horizontal position and fixed by the support frames at the two sides of the center of the straight gear, so that the large straight gear is prevented from moving when repair welding is carried out; removing rust, water and grease at the welding broken teeth;
2) flattening the welding broken teeth and heating the weldment: before welding the transition bottoming layer, cutting and flattening the welding broken teeth by using a plasma air plane to enable the welding broken teeth to meet the welding requirement; then heating the welding position by oxygen and acetylene, uniformly preheating the rest part by an electric heating belt, preheating the welding broken tooth position to about 250 ℃, uniformly raising the preheating temperature of the rest part by 40 ℃/h, measuring once every half hour by a thermodetector so as to avoid nonuniform high-temperature heating to cause micro-cracks to be generated in the base metal, and completely covering the preheated area, thereby reducing the local temperature difference stress, improving the internal structure and preventing or reducing the hardened structure;
3) welding a transition bottom layer: during welding, the root of the transition bottom layer is welded by a digital control inverse manual direct current welding machine, welding rods are subjected to arc welding, overlaying along the periphery of the bottom can be widened according to the area of broken teeth to form a square frame shape, then, overlaying is uniformly and symmetrically performed from the center of the square frame to two sides, the welding rods can be conveyed in a straight line or a triangle shape, the arc length is 4-6 mm, welding is performed continuously, and two sides are slightly stopped; after the welding of the transition bottom layer is finished, cleaning the surface by using an angle grinder, and checking whether welding defects exist by using a 3-4 times magnifying lens;
4) welding a surfacing layer: the method is characterized in that digital pulse gas shielded welding is adopted during a large number of overlaying welding of more than two layers, the current is amplified, welding wires can be used for linear or crescent strip conveying, welding is carried out by adopting a medium arc length of 18-25 mm, continuous welding is carried out, two sides are slightly stopped, each layer is carefully checked after welding, the next layer is welded after no defect is confirmed, and continuous welding with no defect is confirmed layer by layer; when the angle of the triangle is close to the apex angle, the welding current is slightly lower than the bottom current, the weld bead is filled, and when in surfacing, the whole outer side surface of the broken tooth corresponds to the shape of the tooth-shaped sample plate of the large-scale straight gear; according to the requirement of a surfacing layer, the diameter of a welding wire is adjusted, the shape of a welded broken tooth is close to the tooth shape of a tooth-shaped sample plate, the grinding amount of the surfacing tooth is reduced, the outer side of the surfacing tooth is close to a tooth-shaped area, the welding size can be properly widened, no undercut is formed on two sides of the surfacing tooth, the surfacing tooth can be directly observed, and the surfacing tooth can be inspected by a 3-4 times magnifier;
three-step post-weld treatment
1) After welding, comparing the tooth-shaped sample plates manufactured firstly, cutting and flattening redundant welding seams by using a plasma gas plane, and roughly grinding the welding seams by using an angle grinder so as to meet the size of the tooth-shaped sample plates;
2) eliminating welding stress, continuously heating the welding seam and the periphery of a weldment to 250-400 ℃ by using oxygen, acetylene and an electric heating device, wrapping asbestos, slowly cooling to room temperature, reducing the hardening degree after welding, and avoiding embrittlement; and finally, precisely grinding the integrally-welded horizontal teeth by using an angle grinder, wherein the integrally-welded horizontal teeth completely correspond to the tooth form of the tooth form sample plate, and the rotation requirement of the integral straight gear is met.
Furthermore, the welding equipment in the first step comprises a HT400D digital control inverse manual direct current welding machine, a Nb-500P digital pulse gas shielded welding machine, and a high-power ZX 5-630 welding machine matched with a plasma gouging LGK-100 MA is adopted for back chipping.
And further, removing water and grease by using oxyacetylene flame during cleaning before welding in the second step, and polishing and derusting by using abrasive cloth or a grinding wheel machine.
Furthermore, the interlayer temperature is always kept to be not lower than 100 ℃ during the welding of the surfacing layer in the second step, the surfacing layer is left outside except the welding part, the rest parts are covered by the asbestos plate and the heat-insulating cotton heat-insulating material, and the electric heating device is used for adjusting the temperature difference, reducing the heat loss and preventing an operator from being radiated by high temperature.
Further, the weldment used in the second step is 35# steel, the welding material is a welding rod, E5015 phi 3.2mm and phi 4.0mm are obtained, and the welding rod is baked at 350-400 ℃ for 2 hours and then is kept at a constant temperature and taken at any time; the welding wire, SWE711 flux-cored wire, has no defect on the surface and phi of 1.2 mm; the gas is carbon dioxide with a purity of 99.8%.
Further, welding rods are used in the process of welding the transition bottoming layer, E5015 phi 3.2mm and phi 4.0mm, the welding current is 120-180A, the arc voltage is 26 +/-1V, and the welding speed is 15 +/-1 cm & min-1The selection of the current is beneficial to the good fusion of the welding layer and the base material,
furthermore, the SWE711 flux-cored wire is used for welding the surfacing layer, the surface is free of defects, the specification phi is 1.2mm, the welding current is 280-360A, the arc voltage is 30 +/-1V, and the welding speed is 25 +/-1 cm-min-1。
Compared with the prior art, the invention has the advantages that the online welding repair of the gear part to be welded is completed in a narrow space, the straight teeth after overlaying are manually ground to meet the operation size, the surface has no welding defects, the quality of the subsequent operation period is ensured, the overhaul time is saved, the maintenance cost is reduced, the shutdown loss is reduced, and the guarantee is provided for reasonable production assembly.
Drawings
The invention is further explained below with reference to the drawings of the embodiments.
FIG. 1 is a partial schematic view of a large spur gear of the present invention;
FIG. 2 is a schematic view of a broken tooth bottom weld of the gear of the present invention;
FIG. 3 is a schematic view of a transition primer layer at a welded tooth breakage of the present invention;
FIG. 4 is a schematic view of a gear tooth breakage forming weld of the present invention;
fig. 5 is a schematic view of a tooth form template of the present invention.
In the figure: 1-large spur gear 2-welding broken tooth position 3-transition bottoming layer 4-surfacing layer 5-tooth-shaped sample plate.
Detailed Description
The present invention is further illustrated by the following specific examples.
Referring to fig. 1, 2, 3, 4 and 5, the on-line welding repair process for the large spur gear is characterized by comprising the following steps:
step one preparation before welding
1) And (3) field construction conditions: all wheel band rolling mills are powered off, parts around the large straight gear 1 are removed, a semicircle at the upper part of the box body is opened, the large straight gear 1 is exposed, the broken teeth are moved to the horizontal position, the box body around the broken teeth and nearby the broken teeth are cleaned by a cleaning agent, and in addition, no cross-ventilation exists in a welding place and night construction lighting facilities and fire extinguishing equipment are arranged;
2) a heating device: an oxyacetylene bottle, an electric heating belt;
3) welding and auxiliary equipment: the welding equipment comprises a digital control inverse manual direct current welding machine and a digital pulse gas shielded welding machine, and the back chipping adopts a high-power welding machine matched with a plasma air plane; the auxiliary equipment comprises an angle grinder, a file, a hand hammer, a flat shovel, a heat-insulating barrel, a tooth-shaped template, a temperature measuring instrument, a magnifier and heat-insulating cotton;
step two welding process
1) Adjusting the position of a weldment and cleaning before welding: the welding broken tooth part 2 is in an upper horizontal position, and two sides of the center of the straight gear are fixed by a support frame, so that the large straight gear 1 is prevented from moving when repair welding is carried out; removing rust, water and grease at the welding broken tooth part 2;
2) flattening the welding broken teeth and heating the weldment: before welding the transition bottoming layer 3, cutting and flattening the welding broken tooth part 2 by using a plasma air plane to enable the welding broken tooth part to meet the welding requirement; then heating the welding position by oxygen and acetylene, uniformly preheating the rest part by an electric heating belt, preheating the welding broken tooth position 2 to about 250 ℃, uniformly raising the preheating temperature of the rest part by 40 ℃/h, measuring once every half hour by a thermodetector so as to avoid nonuniform high-temperature heating to cause micro-cracks to be generated in the base metal, and completely covering the preheated area, thereby reducing the local temperature difference stress, improving the internal structure and preventing or reducing the hardened structure;
3) welding a transition bottom layer: during welding, the root of the transition bottom layer 3 adopts a digital control inverse manual direct current welding machine, welding rods are subjected to arc welding, overlaying welding along the periphery of the bottom can be widened according to the area of broken teeth to form a square frame shape, then, overlaying welding is uniformly and symmetrically carried out from the center of the square frame to two sides, the welding rods can carry out linear or triangular conveying, the arc length is 4-6 mm, welding is carried out continuously, and two sides are slightly stopped; after the transition bottoming layer 3 is welded, cleaning the surface by using an angle grinder, and checking whether a welding defect exists by using a 3-4 times magnifying lens;
4) welding a surfacing layer: the method is characterized in that digital pulse gas shielded welding is adopted during a large number of overlaying welding of more than two layers, the current is amplified, welding wires can be used for linear or crescent strip conveying, welding is carried out by adopting a medium arc length of 18-25 mm, continuous welding is carried out, two sides are slightly stopped, each layer is carefully checked after welding, the next layer is welded after no defect is confirmed, and continuous welding with no defect is confirmed layer by layer; when the triangular vertex angle is approached, the welding current is slightly lower than the bottom layer current, a weld bead is filled, and when surfacing is carried out, the whole outer side surface of a broken tooth corresponds to the shape of the tooth-shaped sample plate 5 of the large-sized straight gear 1; according to the requirement of the surfacing layer 4, the diameter of the welding wire is adjusted, the shape of the welded broken tooth is close to the tooth shape of the tooth-shaped sample plate 5, the grinding amount of the surfacing tooth is reduced, the outer side of the surfacing tooth is close to a tooth-shaped area, the welding size can be properly widened, no undercut is formed on two sides of the surfacing tooth, the surfacing tooth can be directly observed, and the surfacing tooth can also be inspected by a 3-4 times magnifier;
three-step post-weld treatment
1) After welding, comparing by using a tooth-shaped sample plate 5 which is manufactured firstly, cutting and flattening redundant welding seams by using a plasma gas plane, and roughly grinding by using an angle grinder so as to accord with the size of the tooth-shaped sample plate;
2) eliminating welding stress, continuously heating the welding seam and the periphery of a weldment to 250-400 ℃ by using oxygen, acetylene and an electric heating device, wrapping asbestos, slowly cooling to room temperature, reducing the hardening degree after welding, and avoiding embrittlement; and finally, precisely grinding the integrally-welded horizontal teeth by using an angle grinder, wherein the integrally-welded horizontal teeth completely correspond to the tooth form of the tooth form sample plate, and the rotation requirement of the integral straight gear is met.
In the first step, welding equipment comprises a HT400D digital control inverse manual direct current welding machine and a Nb-500P digital pulse gas shielded welding machine, and back chipping adopts a high-power ZX 5-630 welding machine to be matched with a plasma gouging LGK-100 MA.
And in the step two, water and grease are removed by oxyacetylene flame during cleaning before welding, and the rust is removed by polishing by using an abrasive cloth or a grinding wheel machine.
In the second step, the temperature of the interlayer 4 is always kept to be not lower than 100 ℃ during welding, the welding parts are left outside, the rest parts are covered by the asbestos plate and the heat-insulating cotton heat-insulating material, and the electric heating device adjusts the temperature difference, reduces the heat loss and prevents an operator from being radiated by high temperature.
The weldment used in the second step is 35# steel, the welding material is a welding rod, E5015 phi 3.2mm and phi 4.0mm are obtained, and the welding rod is baked for 2 hours at 350-400 ℃ and then is kept at constant temperature and taken at any time; the welding wire, SWE711 flux-cored wire, has no defect on the surface and phi of 1.2 mm; the gas is carbon dioxide with a purity of 99.8%.
Welding rods are used for welding the transition bottoming layer 3, E5015 phi 3.2mm and phi 4.0mm, the welding current is 120-180A, the arc voltage is 26 +/-1V, and the welding speed is 15 +/-1 cm-min-1The selection of the current is beneficial to the good fusion of the welding layer and the base material,
the SWE711 flux-cored wire is used for welding the surfacing layer 4, the surface is free of defects, the specification phi is 1.2mm, the welding current is 280-360A, the arc voltage is 30 +/-1V, and the welding speed is 25 +/-1 cm & min-1。
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention will be covered by the present invention, and therefore, the scope of the present invention should be subject to the protection scope defined by the claims.
Claims (7)
1. The on-line welding repair process for the large straight gear is characterized by comprising the following steps of:
step one preparation before welding
1) And (3) field construction conditions: all wheel band rolling mills are powered off, parts around the large straight gear are removed, a semicircle at the upper part of the box body is opened, the large straight gear is exposed, the broken tooth is moved to the horizontal position, the box body around the broken tooth and nearby the broken tooth is cleaned by a cleaning agent, and in addition, no cross-ventilation exists in a welding place and night construction lighting facilities and fire extinguishing equipment are arranged;
2) a heating device: an oxyacetylene bottle, an electric heating belt;
3) welding and auxiliary equipment: the welding equipment comprises a digital control inverse manual direct current welding machine and a digital pulse gas shielded welding machine, and the back chipping adopts a high-power welding machine matched with a plasma air plane; the auxiliary equipment comprises an angle grinder, a file, a hand hammer, a flat shovel, a heat-insulating barrel, a tooth-shaped template, a temperature measuring instrument, a magnifier and heat-insulating cotton;
step two welding process
1) Adjusting the position of a weldment and cleaning before welding: the welding broken teeth are positioned at the upper horizontal position and fixed by the support frames at the two sides of the center of the straight gear; removing rust, water and grease at the welding broken teeth;
2) flattening the welding broken teeth and heating the weldment: before welding the transition bottoming layer, cutting and flattening the welding broken teeth by using a plasma air plane to enable the welding broken teeth to meet the welding requirement; then heating the welding position by oxygen and acetylene, uniformly preheating the rest part by an electric heating belt, preheating the welding broken tooth position to about 250 ℃, uniformly raising the preheating temperature of the rest part at 40 ℃/h, and measuring once every half hour by a thermodetector;
3) welding a transition bottom layer: during welding, the root of the transition bottom layer is welded by a digital control inverse manual direct current welding machine, welding rods are subjected to arc welding, overlaying along the periphery of the bottom can be widened according to the area of broken teeth to form a square frame shape, then, overlaying is uniformly and symmetrically performed from the center of the square frame to two sides, the welding rods can be conveyed in a straight line or a triangle shape, the arc length is 4-6 mm, welding is performed continuously, and two sides are slightly stopped; after the welding of the transition bottom layer is finished, cleaning the surface by using an angle grinder, and checking whether welding defects exist by using a 3-4 times magnifying lens;
4) welding a surfacing layer: the method is characterized in that digital pulse gas shielded welding is adopted during a large number of overlaying welding of more than two layers, the current is amplified, welding wires can be used for linear or crescent strip conveying, welding is carried out by adopting a medium arc length of 18-25 mm, continuous welding is carried out, two sides are slightly stopped, each layer is carefully checked after welding, the next layer is welded after no defect is confirmed, and continuous welding with no defect is confirmed layer by layer; when the angle of the triangle is close to the apex angle, the welding current is slightly lower than the bottom current, the weld bead is filled, and when in surfacing, the whole outer side surface of the broken tooth corresponds to the shape of the tooth-shaped sample plate of the large-scale straight gear; according to the requirement of a surfacing layer, the diameter of a welding wire is adjusted, the shape of a welded broken tooth is close to the tooth shape of a tooth-shaped sample plate, the outer side of the welded broken tooth is close to a tooth-shaped area, the welding size can be properly widened, no undercut is formed on two sides of the welded broken tooth, the welded broken tooth can be directly observed, and the welded broken tooth can be inspected by using a 3-4 times magnifying lens;
three-step post-weld treatment
1) After welding, comparing the tooth-shaped sample plates manufactured firstly, cutting and flattening redundant welding seams by using a plasma gas plane, and roughly grinding the welding seams by using an angle grinder to meet the size of the tooth-shaped sample plates;
2) eliminating welding stress, continuously heating the welding seam and the periphery of a weldment to 250-400 ℃ by using oxygen, acetylene and an electric heating device, wrapping asbestos, slowly cooling to room temperature, reducing the hardening degree after welding, and avoiding embrittlement; and finally, precisely grinding the integrally-welded horizontal teeth by using an angle grinder, wherein the integrally-welded horizontal teeth completely correspond to the tooth form of the tooth form sample plate.
2. The on-line welding repair process for the large spur gear according to claim 1, wherein the on-line welding repair process comprises the following steps: the welding equipment in the first step comprises a HT400D digital control inversion type manual direct current welding machine and a Nb-500P digital pulse gas shielded welding machine, and the back chipping adopts a high-power ZX 5-630 welding machine to be matched with a plasma gouging LGK-100 MA.
3. The on-line welding repair process for the large spur gear according to claim 1, wherein the on-line welding repair process comprises the following steps: and in the second step, water and grease are removed by oxyacetylene flame during cleaning before welding, and the rust is removed by polishing by using an abrasive cloth or a grinding wheel machine.
4. The on-line welding repair process for the large spur gear according to claim 1, wherein the on-line welding repair process comprises the following steps: and in the second step, the interlayer temperature is always kept to be not lower than 100 ℃ during welding of the surfacing layer, the surfacing layer is left outside except the welding part, the rest parts are covered by a asbestos plate and a heat-insulating cotton heat-insulating material, and the temperature difference is adjusted by an electric heating device.
5. The on-line welding repair process for the large spur gear according to claim 1, wherein the on-line welding repair process comprises the following steps: the weldment used in the second step is 35# steel, the welding material is a welding rod, E5015 phi 3.2mm and phi 4.0mm are obtained, and the welding rod is baked for 2 hours at 350-400 ℃ and then is kept at constant temperature and taken at any time; the welding wire, SWE711 flux-cored wire, has no defect on the surface and phi of 1.2 mm; the gas is carbon dioxide with a purity of 99.8%.
6. The on-line welding repair process for large spur gears according to claim 1, wherein the on-line welding repair process is characterized in thatThe method comprises the following steps: welding rods are used in the process of welding the transition bottoming layer, E5015 phi 3.2mm, phi 4.0mm, welding current is 120-180A, arc voltage is 26 +/-1V, and welding speed is 15 +/-1 cm-min-1And the selection of the current is favorable for the good fusion of the welding layer and the base material.
7. The on-line welding repair process for the large spur gear according to claim 1, wherein the on-line welding repair process comprises the following steps: the SWE711 flux-cored wire is used for welding the surfacing layer, the surface is free of defects, the specification phi is 1.2mm, the welding current is 280-360A, the arc voltage is 30 +/-1V, and the welding speed is 25 +/-1 cm & min-1。
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| JP4416614B2 (en) * | 2004-09-22 | 2010-02-17 | 住友金属工業株式会社 | Welding repair method for gear box for railway vehicles |
| CN100548566C (en) * | 2008-01-30 | 2009-10-14 | 天津烨峤激光技术有限公司 | A kind of renovation technique of main drive gear of producing oxygen air compressor |
| CN104209668B (en) * | 2014-07-28 | 2016-01-20 | 辽宁科技大学 | A kind of involute spur large gear repair method and device thereof |
| CN105149360A (en) * | 2015-06-30 | 2015-12-16 | 江苏永钢集团有限公司 | Method for rapidly repairing bearing hole of on-line gear box |
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