CN109890987A - 用于制造具有改进的抗白蚀裂纹(wec)形成的坚固性的滚动轴承环的方法 - Google Patents
用于制造具有改进的抗白蚀裂纹(wec)形成的坚固性的滚动轴承环的方法 Download PDFInfo
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Abstract
本发明涉及一种用于制造具有改进的抗白蚀裂纹(WEC)形成的坚固性的滚动轴承环的方法,其中,将由含有0.4~0.55%的C和0.5~2.0%的Cr的亚共析调质钢制成的滚动轴承构件以感应方式加热以形成硬化的边缘层,然后淬火,并然后回火。
Description
技术领域
本发明涉及一种用于制造具有改进的抗白蚀裂纹(WEC)形成的坚固性的滚动轴承环的方法。
背景技术
滚动轴承用于及其不同的应用中,例如汽车领域或工业设备或工业机器等。这种滚动轴承的载荷除了常规载荷(即由滚动体对轴承环的碾辊以及与此相关的赫兹压力或者说赫兹接触)以外通常还包括附加载荷,其例如可以是强的混合摩擦或电气电或动电或类似情况。特别是,当存在这种附加载荷时,在应用中有时会出现所谓的白蚀裂纹(WEC)形式的对这种滚动轴承或滚动轴承构件的损坏。这些白蚀裂纹首先表现为涉及的滚动轴承组件的材料中的组织变化。组织变化发生在支承表面即受负载的面的下方。在进一步的过程中,微裂纹可以在外部负载的影响下形成并扩散到表面。然后,微裂纹以轴向裂纹或剥落的形式产生WEC的典型损坏,优选地在受负载的构件的滚道区域中,例如滚动轴承的内环或外环的滚道区域中。在极端情况下,随着损坏的不断进行,可能导致滚动轴承环的撕裂或断裂,从而导致轴承过早失效。
导致形成这种WEC的损坏机制尚未最终明了。然而,据信附加载荷导致从润滑轴承的润滑剂体系释放氢。该氢可能在滚动轴承材料(即钢)的组织中导致马氏体和/或贝氏体结构转变成具有强制溶解碳或溶解碳化物结构的非晶或纳米晶铁素体。
由EP 2 123 779 A1已知由具有0.4~0.8重量%之间的碳含量的完全硬化钢制造受机械负载的轴承构件。然而,完全硬化依赖于例如提高可硬化性的合金元素的含量地限于某一特定横截面。此外,如果该构件在硬化后在芯中要具有高韧性,则该技术不可用。
由EP 2 573 195 A1已知一种用于制造滚动轴承构件的方法,其中,滚动轴承构件在100~200℃之间的温度加热5~120分钟的时间,在此事件期间,滚动轴承构件在滚道区域中与化学添加剂发生接触,以构成局部表面变化的滚道边缘层。作为这样的化学添加剂,可以使用水含量最高达500ppm的防腐剂油或变速器油。然而,只有在操作期间没有磨损时,这种表面改性才是有效对抗WEC形成的。因此,这些构件的使用只能是有限的,特别是在污染环境中的应用中和/或具有高混合摩擦份额的应用中。
WO 2015/199 599 A1描述了一种具有感应硬化和随后的回火步骤的对金属组件进行表面硬化的方法。
这种情况类似于在滚道面即受载荷的构件区域上施加特殊涂层或构造出发蓝层的情形。它们可能在被磨损掉时失去其功能。
发明内容
因此,本发明基于如下问题:提供一种方法,该方法能够制造具有改善的抗白蚀裂纹形成的坚固性的滚动轴承环。
为了解决这个问题,根据本发明规定了一种方法,其特征在于,将由含有0.4~0.55%的C和0.5~2.0%的Cr的亚共析调质钢制成的滚动轴承环以感应方式加热以构造出硬化的边缘层,然后淬火,并然后回火。
一方面,根据本发明的方法规定使用特殊的起始材料,即亚共析调质钢,另一方面,规定执行限定的硬化和温度处理步骤,这导致构造出硬化的边缘层。
作为钢,根据本发明使用一种亚共析调质钢,其具有0.4~0.55%的碳含量和0.5~2.0%的铬含量。然后,这种亚共析调质钢在感应硬化过程中仅在边缘侧硬化,从而构造出感应硬化的边缘层。在硬化状态下,这种亚共析调质钢在硬化的边缘层区域中不含未溶解的碳化物。在感应加热之后,进行滚动轴承构件的淬火(硬化),然后进行回火步骤。通过回火形成最小的回火碳化物(Fe2C),其尺寸明显小于1微米。
由于感应式边缘层硬化,边缘层中产生很高的残余压应力,这产生对被认为是形成WEC的原因的氢的某种阻挡效应。这意味着尽管产生了附加载荷并由此可能导致形成氢,但是它不能扩散到组织中,这就是为什么这样制造的滚动轴承环已经被证明针对WEC的形成非常坚固的原因。由感应式硬化产生的高残余压应力的另一个优点是它们过度补偿在碾辊时产生的拉伸应变场,从而还抑制了这些区域中氢的吸附。由于高残余压应力,最终显著降低了绝对氢浓度并因此降低了碾辊体积中的有害影响。
加热可以在待硬化的面上或在进给过程中均匀地进行。对于进给过程,控制加热所需的电功率,使得在到达已经硬化的区域时不会发生其再加热,淬火同样可以在进给中通过喷淋进行。
根据本发明的滚动轴承环的硬化边缘层下方的组织与常规的完全硬化的滚动轴承钢(例如来自100Cr6系列)相比不是由片状马氏体组成,而是由板条状马氏体组成。该组织结合了硬化且坚固的边缘层确保了符合或达到滚动轴承构件的所需机械性能。
由于仅进行发生速度可以比完全硬化快得多的感应式边缘层硬化,因此显著简化了制造。而且,不需要如现有技术中提出的施加特殊涂层或产生表面改性的滚道面等,这就是滚动轴承构件可以很简单且快速地制造的原因。
根据本发明的一个特别合适的改进方案,所用的调质钢可以具有0.5~1.0%的Ni含量。因此,亚共析调质钢表现出限定的相对高的Ni含量。该Ni含量导致韧性提高,并且因此导致可达到的机械性能的进一步改善。同时,通过提高Ni含量,可以稍微降低C含量,而这是附加有利的,因为如上所述,在硬化状态下不存在未溶解的碳化物。
特别优选使用基于50CrMo4的调质钢,其具有在0.5~1.0%之间的Ni含量。与已知的其C含量在0.46~0.54%之间的50CrMo4调质钢相比,由于所述Ni含量,C含量略低。这意味着优选使用以下组成的调质钢(数据以%表示):
在一种具体的实施例中,根据本发明,优选使用具有以下组成的调质钢(数据以%表示):
以及由铁和痕量元素组成的余量。
按照根据本发明方法的一种有利的改进方案,可以规定的是,进行感应式加热使得构造出至少0.2mm厚度至最高8mm厚度的硬化边缘层。当然,边界层的厚度依赖于滚动轴承环的尺寸。在这种情况下,感应式边缘层硬化特别是对于较大的横截面或者较大的构件并因此以较大的边缘层硬化深度优选在预调质钢上进行,但也可以从正常退火组织或GKZ状态进行硬化(GKZ=球状渗碳体上的退火)。
感应式加热以8~11kHz的频率,特别是9~10kHz的频率进行3~10秒,特别是4~7秒的持续时间。特别优选在9.9kHz下硬化5秒。
感应式硬化导致在硬化的边缘区域中构造出高残余压应力。根据本发明,硬化进行的方式应当使得在硬化的边缘区域中产生至少300MPa或明显更高的残余压应力。随着残余压应力的增加,边缘层对氢扩散的阻挡效果提高。
导致形成回火碳化物的回火应在120~160℃的温度下、特别是在130~150℃的温度下进行1~4小时、特别是2~3小时的持续时间。特别优选地,回火在140℃的温度下进行2小时。回火之前的淬火在合适的淬火液体中进行。
除了方法本身之外,本发明还涉及一种滚动轴承环,其根据本发明的方法制造。滚动轴承环由一种含有0.4~0.55%的C和0.5~2.0%的Cr的亚共析调质钢组成,其具有通过感应式硬化形成的硬化的边缘层。
在本发明的改进方案中,滚动轴承环可以由基于50CrMo4的调质钢制成,该调质钢具有0.5~1.0%的Ni含量,该调质钢可以优选具有以下组成(数据以%表示):
以及由铁和痕量元素组成的余量。
具体实施方式
分别制造六个分别由两个推力垫圈组成的推力轴承。
第一批六个推力轴承由市售的100Cr6钢制成,具有以下制造路线:锻造-调质-车削-马氏体硬化-淬火-回火-磨削-珩磨。
以根据本发明的方式,由具有以下组成的亚共析调质钢制造第二批六个轴承:
以及由铁和痕量元素组成的余量(数据以%表示)。
该基于50CrMo4改性的亚共析调质钢的制造路线如下:锻造-GKZ退火-车削-感应式边缘层硬化-回火-磨削-珩磨。
感应式硬化以9.9kHz的频率进行,加热时间为5秒。淬火在可以商品名“Aquatenside-BW”购得的淬火浴中在室温下进行。回火在140℃下进行2小时。
轴承分别由两个推力轴承垫圈组成,其具有95mm的外直径和60mm的内直径。滚动体是陶瓷圆柱滚子,其具有11mm的长度和11mm的直径。滚动体在保持架中引导。
寿命试验根据DIN51819-1的规定执行,但转速为750转/分钟,负荷为60kN(2075MPa),并且存在特殊的产生WEC的油。研究了各两个相同类型的滚动轴承,即各两个根据本发明的由改性50CrMo4制成的轴承或者各两个由先前使用的100Cr6制成的轴承。
获得的结果显示在下表中。
在标准化运行试验中对每个轴承确定了到失效为止的使用寿命,即直到轴承由于运转原因而不再能够使用的时间,无论是检测到了宏观损坏,还是检测到了WEC。
显然,通过使用根据本发明的含Ni的亚共析调质钢结合根据本发明的制造路线或者特别是感应式边缘层硬化,与由100Cr6制成的马氏体推力轴承垫圈相比,可以实现使用寿命的显著改善。结果是使用寿命提高了因数2以上,这是由平均使用寿命的比较得出的。在由100Cr6制成的轴承的情况下,在所有6个轴承上确定的平均使用寿命为43h,而在根据本发明的轴承的情况下,平均使用寿命为98小时,大于两倍。
所采用的比较研究表明,根据本发明的方法或者根据本发明的滚动轴承构件表现出抗WEC形成的坚固性的明显改善。
这也表现在图中所示的测量值的威布尔(Weibull)表示中。沿横坐标绘制的是寿命,即到失效为止的运转时间,沿着纵坐标绘制所谓的不可靠性值,其以百分比给出失效概率Hi,分别用对数表示。威布尔分布代表一般分布。
累积频率Hi按如下确定:
Hi=(i-0.3):(n+0.4)
其中:
i=失效的序数(这里为1……6)
n=样品的数目(这里为6)
表示为方块的测量值(■)给出由100Cr6生产的滚动轴承或推力垫圈的值。菱形符号(◆)表示根据本发明的滚动轴承构件或推力垫圈的测量值。还分别显示了拟合直线。
Claims (9)
1.用于制造具有改进的抗白蚀裂纹(WEC)形成的坚固性的滚动轴承环的方法,其中,将由含有0.4~0.55%的C和0.5~2.0%的Cr的亚共析调质钢制成的滚动轴承环以感应方式加热以构造出硬化的边缘层,然后淬火,并然后回火,其特征在于,加热以8~11kHz、特别是9~10kHz的频率进行3~10秒、特别是4~7秒的持续时间。
2.根据权利要求1所述的方法,其特征在于,使用的调质钢具有0.5~1.0%的Ni含量。
3.根据权利要求2所述的方法,其特征在于,使用基于50CrMo4的具有在0.5~1.0%之间的Ni含量的调质钢。
4.根据权利要求3所述的方法,其特征在于,使用具有以下组成的调质钢(数据以%表示):
以及由铁和痕量元素组成的余量。
5.根据以上权利要求中任一项所述的方法,其特征在于,进行感应式加热使得构造出至少0.2mm厚度至最高8mm厚度的硬化的边缘层。
6.根据以上权利要求中任一项所述的方法,其特征在于,进行加热使得在硬化的边缘区域中产生至少300MPa的残余压应力。
7.根据以上权利要求中任一项所述的方法,其特征在于,回火在120~180℃的温度下、特别是在130~150℃的温度下进行1~4小时、特别是2~3小时的持续时间。
8.滚动轴承环,所述滚动轴承环根据以上权利要求中任一项所述的方法来制造,所述滚动轴承环由含有0.4~0.55%的C和0.5~2.0%的Cr的亚共析调质钢组成,并具有通过感应式硬化构造出的硬化的边缘层。
9.根据权利要求9所述的滚动轴承环,其特征在于,所述调质钢是具有0.5~1.0%之间的Ni含量的基于50CrMo4的钢,并优选具有以下组成(数据以%表示):
以及由铁和痕量元素组成的余量。
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