CN111119915B - High-strength TBM (tunnel boring machine) center knife box and preparation method thereof - Google Patents
High-strength TBM (tunnel boring machine) center knife box and preparation method thereof Download PDFInfo
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- CN111119915B CN111119915B CN201911300442.7A CN201911300442A CN111119915B CN 111119915 B CN111119915 B CN 111119915B CN 201911300442 A CN201911300442 A CN 201911300442A CN 111119915 B CN111119915 B CN 111119915B
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D9/00—Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
- E21D9/06—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining
- E21D9/08—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining with additional boring or cutting means other than the conventional cutting edge of the shield
- E21D9/087—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining with additional boring or cutting means other than the conventional cutting edge of the shield with a rotary drilling-head cutting simultaneously the whole cross-section, i.e. full-face machines
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/26—Methods of annealing
- C21D1/30—Stress-relieving
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- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
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- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
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- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
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Abstract
The invention provides a high-strength TBM (tunnel boring machine) center knife box and a preparation method thereof. The inner cutter box is subjected to quenching and tempering and hardening treatment, and is connected in a welding mode by adopting the inner cutter box and the outer cutter box, the inner cutter box and the outer cutter box are formed by adopting a forging process, and the inner cutter box is made of low-carbon medium alloy structural steel to reduce the welding stress concentration and the cracking deformation of the inner cutter box and the outer cutter box; the surface hardening treatment of the inner cutter box can improve the strength and fatigue performance of the bearing part, and the stress relief annealing treatment of the inner cutter box and the outer cutter box can effectively reduce the distribution of residual stress in the forging forming process and the welding stress concentration points of the inner cutter box and the outer cutter box.
Description
Technical Field
The invention relates to the field of TBM materials, in particular to a high-strength TBM center cutter box and a preparation method thereof.
Background
A hard rock tunnel boring machine (also called TBM) mainly achieves the purpose of breaking rock by means of extruding rock through disc-shaped hobbing cutters, wherein the TBM is called a king of engineering machinery, the hobbing cutters are called teeth of the TBM, and a cutter box is a teethridge and bears alternating load during rock breaking. Along with the increase of the rock strength, the efficiency of crushing the rock by the hob is gradually reduced, and the abnormal abrasion and replacement frequency of the hob box are increased. Because the hobbing cutter case welds on the blade disc, when crackle and the phenomenon of ftractureing need be changed, waste time and energy and seriously influence the construction progress, reduce tunnelling efficiency and then increase tunnel construction cost. The traditional tool box adopts a forging form, the process route is completed by adopting processes such as forging, rough machining, flaw detection, quenching and tempering, welding and the like, and failure means such as crushing deformation, tool box welding cracking and the like easily occur due to insufficient strength of the tool box under an extremely hard rock working condition (the existing tool box is mainly made of medium-carbon low alloy steel or medium-carbon medium alloy steel such as 30CrNiMo, 30Cr2Ni2Mo and the like). In order to solve the problems, the invention provides a novel material for a TBM (tunnel boring machine) knife box and a preparation method thereof, which solve the problems of low strength, easiness in crushing, cracking and the like of the existing knife box.
Disclosure of Invention
The invention provides a high-strength TBM (tunnel boring machine) center cutter box and a preparation method thereof, and solves the problems of low strength, easiness in crushing, cracking and the like of the existing cutter box.
The technical scheme for realizing the invention is as follows:
the utility model provides a central sword case of high strength TBM, includes outer sword case and interior sword case, and the outer sword case adopts low alloy structure steel material, and the alloy structure steel material in the interior sword case adopted the low carbon, and the interior sword case of interior outer sword case adopts the welded mode to combine together.
The low-alloy structural steel material adopted by the outer cutter box comprises the following components in percentage by weight: c: 0.11-0.18%, Si: 0.2-0.5%, Mn: 0.38-0.58%, V: 0.07-0.12%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The low-carbon medium alloy structural steel material adopted by the inner cutter box comprises the following components in percentage by weight: c: 0.11-0.17%, Si: 0.2-0.4%, Mn: 0.38-0.58%, Cr: 1.45-1.75%, Ni: 4.5-5.2%, W: 0.9-1.3%, V: 0.08-0.10%, Ti: 0.03 to 0.06%, Nb: 0.01-0.02%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron. The addition of the forming elements of the strong carbides of the trace elements Nb, V and Ti can ensure that the steel can be dispersed and precipitated through carbon and nitride particles (the size is less than 5 nm) of the steel and solid solution of Nb, V and Ti to refine grains when the carbon equivalent is low, greatly improve the strength and toughness of the steel, particularly the low-temperature toughness (the effect on TBM equipment in high-altitude and high-cold areas is outstanding), ensure that the steel has good weldability, and provide a powerful guarantee for the welding process of the inner and outer cutter boxes.
The invention selects the inner cutter box material as low-carbon medium alloy steel, the carbon content of which is close to that of the outer cutter box material, and the problems of welding cracking, large welding deformation, residual stress concentration after welding and the like in the welding process of the inner cutter box and the outer cutter box are avoided.
The inner tool box is made of low-carbon medium alloy steel, the strength and toughness are good after quenching and tempering, the hardenability is good due to the addition of alloy elements, medium-frequency quenching is carried out on the bearing area of the inner tool box, the depth of a hardened layer is controlled to be 10-25mm, the strength of the bearing part of the inner tool box is greatly improved, and direct damage to the tool box caused by high rock strength under extreme working conditions is reduced.
The preparation method of the high-strength TBM center knife box comprises the following steps:
(a) forging and forming the outer cutter box and the inner cutter box; the forging adopts a near-net-shape closed die forging process, the high-temperature and high-pressure rapid forming is realized, the feeding amount is accurate, the continuity of metal fibers is kept, the controllable plastic flow direction is obtained, a fine and uniform grain structure is obtained, the structure segregation is reduced, the mechanical property of the forging is improved, the material utilization rate is high, and the cost is saved;
the method comprises the following specific steps: preheating the mold for 300-2 h; setting forging parameters (including forging speed and blank parameters); forging and pressing are started, in the basic forming stage, the male die moves downwards by delta H1; in the groove filling stage, the male die moves downwards by delta H2; in the longitudinal burr forming stage, the male die moves downwards by delta H3;
(b) stress relief annealing treatment is carried out on the outer cutter box in the step (a);
(c) hardening and tempering the inner cutter box in the step (a);
(d) and (4) welding the outer cutter box and the inner cutter box, and then performing stress relief annealing treatment.
The stress relief annealing treatment in the step (b) comprises the following specific processes: the stress relief treatment is carried out in an atmosphere protection furnace, the furnace temperature is 190 +/-10 ℃, and the treatment time is 90-120 min.
Detecting, positioning and evaluating cracks, inclusions and the like on the surface layer and the core part of the inner cutter box by using an ultrasonic flaw detector, determining whether technical indexes are met, and hardening and tempering the inner cutter box meeting the technical indexes; the specific process of quenching and tempering in the step (c) is as follows: heating the inner knife box in a heat treatment furnace from room temperature to 520-minus-plus 580 ℃ at the speed of 100-150 ℃/h, preserving heat for 40min at the temperature of 520-minus-plus 580 ℃, heating the inner knife box to 850 +/-10 ℃ at the speed of 80-100 ℃/h, preserving heat for 1h at the temperature of 850 +/-10 ℃, finally quenching in an oil quenching mode, and tempering the inner knife box at the high temperature of 510 +/-10 ℃ in the heat treatment furnace for 3h, wherein the surface hardness is more than or equal to 33HRC after tempering.
The hardening treatment in the step (c) comprises the following specific processes: the bearing part of the inner cutter box is subjected to surface quenching in a medium-frequency quenching mode, the depth of a hardening layer is 10-25mm, the strength of the bearing part of the inner cutter box is greatly improved, the fatigue performance of the material of the cutter box is improved, the direct damage to the cutter box caused by the high rock strength under the extreme working condition is reduced, then a hardened layer is built up on the bearing part, and the strength of the bearing part of the inner cutter box is improved. In order to prevent the inner cutter box from further failure and improve the strength of the bearing part of the inner cutter box, the bearing part of the inner cutter box is subjected to wear-resistant layer surfacing or vacuum ion coating, ions are injected into the surface in a vacuum environment, N, Cr ions are injected, carbides, nitrides and the like are precipitated on the surface, the surface hardness is increased, the surface strength is improved, the material strength and the fatigue resistance are improved, and the service life under extreme working conditions is prolonged.
The hardened layer is a wear-resistant layer or a plasma cladding layer, wherein the wear-resistant layer is a high-carbon high-chromium surfacing coating, the thickness of the wear-resistant layer is 3-6mm, the plasma cladding is a metal ceramic composite cladding layer, and the thickness of the plasma cladding layer is 3-4 mm.
After welding, detecting, positioning and evaluating cracks, inclusions and the like of the assembly welding seam by using an ultrasonic flaw detector, and performing stress relief annealing treatment after confirming that technical indexes are met; the specific process of the welding treatment comprises the following steps: preheating the outer knife box and the inner knife box at the temperature of 200-250 ℃, controlling the current to be 310A and the voltage to be 27-34V for welding, and adopting the American imported low-carbon alloy flux-cored wire for welding at present; the stress relief annealing treatment comprises the following specific processes: stress relief treatment is carried out in an atmosphere protection furnace, the furnace temperature is 200 +/-10 ℃, and the treatment time is 90-120 min.
Carrying out finish turning on the inner cutter box subjected to the stress relief annealing treatment in the step (d), wherein the excircle tolerance of the machining precision is 0.01-0.02mm, and the roughness is 1.6; the aim is to remove a decarburized layer on the surface of the cutter box after heat treatment due to oxidation. The invention adopts the stress relief annealing treatment on the tempered inner cutter box to eliminate the residual stress and stress concentration phenomenon generated by the material structure after heat treatment, and carries out the stress relief annealing on the welding part of the inner cutter box and the outer cutter box to eliminate the stress concentration point and the nonuniform structure phenomenon of the welding part.
The invention has the beneficial effects that:
(1) the inner and outer cutter boxes are connected in a welding mode, the inner and outer cutter boxes are formed by adopting a forging process, and the inner cutter box is made of low-carbon medium alloy structural steel so as to reduce the welding stress concentration and cracking deformation of the inner and outer cutter boxes. The inner cutter box is developed and designed into low-carbon medium-alloy structural steel, trace alloy elements such as Nb, V and Ti are added, crystal grains are refined on the basis of reducing the carbon content, the toughness of alloy steel is improved, the dispersion strengthening effect of carbon and nitride is formed, the strength of parts is improved, and the low-carbon medium-alloy structural steel has good strength and toughness;
(2) the surface hardening treatment of the inner cutter box can improve the strength and fatigue performance of the bearing part and prolong the service life;
(3) the stress relief annealing treatment of the inner and outer cutter boxes can effectively reduce the distribution of residual stress in the forging forming process and the welding stress concentration points of the inner and outer cutter boxes.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a front view of a knife box of the present invention;
fig. 2 is a top view of the knife box of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments of the present invention, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
Example 1
The utility model provides a high strength TBM center sword case, includes outer sword case 101 and interior sword case 102, and outer sword case 101 adopts low alloy structure steel material, and interior sword case 102 adopts alloy structure steel material in the low carbon.
The low-alloy structural steel material adopted by the outer cutter box 101 comprises the following components in percentage by weight: c: 0.11%, Si: 0.2%, Mn: 0.38%, V: 0.07%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The low-carbon medium-alloy structural steel material adopted by the inner cutter box 102 comprises the following components in percentage by weight: c: 0.11%, Si: 0.2%, Mn: 0.38%, Cr: 1.45%, Ni: 4.5%, W: 0.9%, V: 0.08%, Ti: 0.03%, Nb: 0.01%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The preparation method of the high-strength TBM center knife box comprises the following steps:
(a) forging and forming the outer cutter box 101 and the inner cutter box 102;
(b) stress relief annealing treatment is carried out on the outer cutter box 101 in the step (a); the stress relief annealing treatment comprises the following specific processes: performing stress relief treatment in an atmosphere protection furnace at 180 ℃ for 120 min;
(c) detecting the surface layer and the core part of the inner cutter box 102 by using an ultrasonic flaw detector, confirming whether the technical indexes are met, and hardening and tempering the inner cutter box 102 meeting the technical indexes;
the specific process of the quenching and tempering treatment comprises the following steps: heating the inner knife box 102 in a heat treatment furnace at a speed of 110 ℃/h from room temperature to 520 ℃, preserving heat at the temperature of 580 ℃ for 40min at the temperature of 520-;
the concrete process of the hardening treatment is as follows: carrying out surface quenching on the bearing part 104 of the inner cutter box 102 in a medium-frequency quenching mode, wherein the depth of a hardening layer is 10mm, and then carrying out surfacing welding on the bearing part 104 to form a hardened layer 105; the hardened layer 105 is a plasma cladding layer, the plasma cladding layer is a metal ceramic composite cladding layer, and the thickness of the plasma cladding layer is 3 mm;
(d) welding the outer cutter box 101 and the inner cutter box 102, assembling and welding a welding seam 103 by ultrasonic flaw detection after welding, and performing stress-relief annealing treatment after confirming that the technical indexes are met; the specific process of the welding treatment comprises the following steps: preheating the outer cutter box 101 and the inner cutter box 102 at 200 ℃, and controlling the current to be 220A and the voltage to be 27V for welding; after welding, performing stress relief annealing treatment, wherein the stress relief annealing treatment comprises the following specific processes: and (3) performing stress relief treatment in an atmosphere protection furnace, wherein the temperature of the treatment furnace is 190 ℃, and the treatment time is 90 min.
And (d) carrying out finish turning on the inner cutter box 102 subjected to the stress relief annealing treatment in the step (d), wherein the machining precision excircle tolerance is 0.01mm, and the roughness is 1.6, so that a decarburized layer on the surface of the cutter box subjected to the heat treatment, which is caused by oxidation, is removed.
Example 2
The utility model provides a high strength TBM center sword case, includes outer sword case 101 and interior sword case 102, and outer sword case 101 adopts low alloy structure steel material, and interior sword case 102 adopts alloy structure steel material in the low carbon.
The low-alloy structural steel material adopted by the outer cutter box 101 comprises the following components in percentage by weight: c: 0.14%, Si: 0.3%, Mn: 0.40%, V: 0.09%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The low-carbon medium-alloy structural steel material adopted by the inner cutter box 102 comprises the following components in percentage by weight: c: 0.13%, Si: 0.3%, Mn: 0.42%, Cr: 1.50%, Ni: 4.8%, W: 1.2%, V: 0.09%, Ti: 0.04%, Nb: 0.015%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The preparation method of the high-strength TBM center knife box comprises the following steps:
(a) forging and forming the outer cutter box 101 and the inner cutter box 102;
(b) stress relief annealing treatment is carried out on the outer cutter box 101 in the step (a); the stress relief annealing treatment comprises the following specific processes: performing stress relief treatment in an atmosphere protection furnace at the furnace temperature of 190 ℃ for 100 min;
(c) detecting the surface layer and the core part of the inner cutter box 102 by using an ultrasonic flaw detector, confirming whether the technical indexes are met, and hardening and tempering the inner cutter box 102 meeting the technical indexes;
the specific process of the quenching and tempering treatment comprises the following steps: heating the inner knife box 102 in a heat treatment furnace at a speed of 140 ℃/h from room temperature to 530 ℃, preserving heat at 530 ℃ for 40min, heating the inner knife box 102 at a speed of 95 ℃/h to 845 ℃, preserving heat at 845 ℃ for 1h, finally quenching in an oil quenching mode, wherein the surface hardness after quenching is more than or equal to 48HRC, and finally tempering the inner knife box 102 in the heat treatment furnace at a high temperature of 515 ℃, preserving heat for 3h, and the surface hardness after tempering is more than or equal to 33 HRC;
the concrete process of the hardening treatment is as follows: carrying out surface quenching on the bearing part 104 of the inner cutter box 102 in a medium-frequency quenching mode, wherein the depth of a hardening layer is 15mm, and then carrying out surfacing welding on the bearing part 104 to form a hardened layer 105; the hardened layer 105 is a plasma cladding layer, the plasma cladding layer is a metal ceramic composite cladding layer, and the thickness of the plasma cladding layer is 4 mm;
(d) welding the outer cutter box 101 and the inner cutter box 102, assembling and welding a welding seam 103 by ultrasonic flaw detection after welding, and performing stress-relief annealing treatment after confirming that the technical indexes are met; the specific process of the welding treatment comprises the following steps: preheating the outer cutter box 101 and the inner cutter box 102 at 210 ℃, controlling the current to be 240A, and welding under the voltage of 34V, wherein the welding is carried out by adopting a low-carbon alloy flux-cored wire imported from America at present; after welding, performing stress relief annealing treatment, wherein the stress relief annealing treatment comprises the following specific processes: the stress relief treatment is carried out in an atmosphere protection furnace, the furnace temperature is 195 ℃, and the treatment time is 95 min.
And (d) carrying out finish turning on the inner cutter box 102 subjected to the stress relief annealing treatment in the step (d) so as to remove a decarburized layer on the surface of the cutter box after the heat treatment due to oxidation.
Example 3
The utility model provides a high strength TBM center sword case, includes outer sword case 101 and interior sword case 102, and outer sword case 101 adopts low alloy structure steel material, and interior sword case 102 adopts alloy structure steel material in the low carbon.
The low-alloy structural steel material adopted by the outer cutter box 101 comprises the following components in percentage by weight: c: 0.16%, Si: 0.4%, Mn: 0.45%, V: 0.10%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The low-carbon medium-alloy structural steel material adopted by the inner cutter box 102 comprises the following components in percentage by weight: c: 0.16%, Si: 0.35%, Mn: 0.42%, Cr: 1.55%, Ni: 5.0%, W: 1.2%, V: 0.09%, Ti: 0.05%, Nb: 0.02%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The preparation method of the high-strength TBM center knife box comprises the following steps:
(a) forging and forming the outer cutter box 101 and the inner cutter box 102;
(b) stress relief annealing treatment is carried out on the outer cutter box 101 in the step (a); the stress relief annealing treatment comprises the following specific processes: performing stress relief treatment in an atmosphere protection furnace at 200 ℃ for 110 min;
(c) detecting the surface layer and the core part of the inner cutter box 102 by using an ultrasonic flaw detector, confirming whether the technical indexes are met, and hardening and tempering the inner cutter box 102 meeting the technical indexes;
the specific process of the quenching and tempering treatment comprises the following steps: heating the inner knife box 102 in a heat treatment furnace at a speed of 100 ℃/h from room temperature to 540 ℃, preserving heat at 540 ℃ for 40min, heating the inner knife box 102 at a speed of 80 ℃/h to 850 ℃, preserving heat at 850 ℃ for 1h, finally quenching in an oil quenching mode, wherein the surface hardness after quenching is more than or equal to 48HRC, and finally tempering the inner knife box 102 in the heat treatment furnace at a high temperature of 520 ℃, preserving heat for 3h, and the surface hardness after tempering is more than or equal to 33 HRC;
the concrete process of the hardening treatment is as follows: carrying out surface quenching on the bearing part 104 of the inner cutter box 102 in a medium-frequency quenching mode, wherein the depth of a hardening layer is 20mm, and then carrying out surfacing welding on the bearing part 104 to form a hardened layer 105; the hardened layer 105 is a wear-resistant layer, the wear-resistant layer is a high-carbon high-chromium surfacing coating, and the thickness of the wear-resistant layer is 5 mm;
(d) welding the outer cutter box 101 and the inner cutter box 102, assembling and welding a welding seam 103 by ultrasonic flaw detection after welding, and performing stress-relief annealing treatment after confirming that the technical indexes are met; the specific process of the welding treatment comprises the following steps: preheating the outer cutter box 101 and the inner cutter box 102 at 220 ℃, controlling the current to be 260A and the voltage to be 34V for welding, and adopting a low-carbon alloy flux-cored wire imported from America to weld at present; after welding, performing stress relief annealing treatment, wherein the stress relief annealing treatment comprises the following specific processes: and (3) performing stress relief treatment in an atmosphere protection furnace, wherein the furnace temperature is 200 ℃, and the treatment time is 100 min.
And (d) carrying out finish turning on the inner cutter box 102 subjected to the stress relief annealing treatment in the step (d), wherein the machining precision excircle tolerance is 0.02mm, and the roughness is 1.6, so that a decarburized layer on the surface of the cutter box subjected to the heat treatment, which is caused by oxidation, is removed.
Example 4
The utility model provides a high strength TBM center knife case, includes outer knife case 101 and interior knife case 102, and outer knife case 101 adopts structural steel material, and interior knife case 102 adopts alloy structural steel material in the low carbon.
The structural steel material adopted by the outer knife box 101 comprises the following components in percentage by weight: c: 0.18%, Si: 0.5%, Mn: 0.58%, V: 0.12%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The low-carbon medium-alloy structural steel material adopted by the inner cutter box 102 comprises the following components in percentage by weight: c: 0.17%, Si: 0.4%, Mn: 0.58%, Cr: 1.75%, Ni: 5.2%, W: 1.3%, V: 0.10%, Ti: 0.06%, Nb: 0.02%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The preparation method of the high-strength TBM center knife box comprises the following steps:
(a) forging and forming the outer cutter box 101 and the inner cutter box 102;
(b) stress relief annealing treatment is carried out on the outer cutter box 101 in the step (a); the stress relief annealing treatment comprises the following specific processes: performing stress relief treatment in an atmosphere protection furnace at 185 ℃ for 120 min;
(c) detecting the surface layer and the core part of the inner cutter box 102 by using an ultrasonic flaw detector, confirming whether the technical indexes are met, and hardening and tempering the inner cutter box 102 meeting the technical indexes;
the specific process of the quenching and tempering treatment comprises the following steps: heating the inner knife box 102 in a heat treatment furnace at a speed of 130 ℃/h from room temperature to 570 ℃, preserving heat at 570 ℃ for 40min, heating the inner knife box 102 at a speed of 90 ℃/h to 855 ℃, preserving heat at 855 ℃ for 1h, finally quenching in an oil quenching mode, wherein the surface hardness after quenching is more than or equal to 48HRC, and finally tempering the inner knife box 102 in the heat treatment furnace at a high temperature of 505 ℃ for 3h, wherein the surface hardness after tempering is more than or equal to 33 HRC;
the concrete process of the hardening treatment is as follows: carrying out surface quenching on the bearing part 104 of the inner cutter box 102 in a medium-frequency quenching mode, wherein the depth of a hardening layer is 25mm, and then carrying out surfacing welding on the bearing part 104 to form a hardened layer 105; the hardened layer 105 is a wear-resistant layer, the wear-resistant layer is a high-carbon high-chromium surfacing coating, and the thickness of the wear-resistant layer is 6 mm;
(d) welding the outer cutter box 101 and the inner cutter box 102, assembling and welding a welding seam 103 by ultrasonic flaw detection after welding, and performing stress-relief annealing treatment after confirming that the technical indexes are met; the specific process of the welding treatment comprises the following steps: preheating the outer cutter box 101 and the inner cutter box 102 at 230 ℃, controlling the current to be 280A and the voltage to be 30V for welding, and adopting a low-carbon alloy flux-cored wire imported from America to weld at present; after welding, performing stress relief annealing treatment, wherein the stress relief annealing treatment comprises the following specific processes: and (3) performing stress relief treatment in an atmosphere protection furnace, wherein the furnace temperature is 205 ℃, and the treatment time is 110 min.
And (d) carrying out finish turning on the inner cutter box 102 subjected to the stress relief annealing treatment in the step (d), wherein the machining precision excircle tolerance is 0.01mm, and the roughness is 1.6, so that a decarburized layer on the surface of the cutter box subjected to the heat treatment, which is caused by oxidation, is removed.
Example 5
The utility model provides a high strength TBM center knife case, includes outer knife case 101 and interior knife case 102, and outer knife case 101 adopts structural steel material, and interior knife case 102 adopts alloy structural steel material in the low carbon.
The structural steel material adopted by the outer knife box 101 comprises the following components in percentage by weight: c: 0.13%, Si: 0.4%, Mn: 0.45%, V: 0.09%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The low-carbon medium-alloy structural steel material adopted by the inner cutter box 102 comprises the following components in percentage by weight: c: 0.14%, Si: 0.35%, Mn: 0.46%, Cr: 1.65%, Ni: 4.9%, W: 1.2%, V: 0.08%, Ti: 0.05%, Nb: 0.01%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
The preparation method of the high-strength TBM center knife box comprises the following steps:
(a) forging and forming the outer cutter box 101 and the inner cutter box 102; the specific forging process is a near-net-shape closed die forging process, high-temperature and high-pressure rapid forming is realized, the feeding amount is accurate, the continuity of metal fibers is kept, the controllable plastic flow direction is obtained, a fine and uniform grain structure is obtained, the structure segregation is reduced, the mechanical property of the forge piece is improved, the material utilization rate is high, and the cost is saved;
(b) stress relief annealing treatment is carried out on the outer cutter box 101 in the step (a); the stress relief annealing treatment comprises the following specific processes: performing stress relief treatment in an atmosphere protection furnace at the furnace temperature of 195 ℃ for 120 min;
(c) detecting the surface layer and the core part of the inner cutter box 102 by using an ultrasonic flaw detector, confirming whether the technical indexes are met, and hardening and tempering the inner cutter box 102 meeting the technical indexes;
the specific process of the quenching and tempering treatment comprises the following steps: heating the inner knife box 102 in a heat treatment furnace at the speed of 150 ℃/h from room temperature to 580 ℃, preserving heat at 580 ℃ for 40min, heating the inner knife box 102 at the speed of 100 ℃/h to 860 ℃, preserving heat at 860 ℃ for 1h, finally quenching in an oil quenching mode, wherein the surface hardness after quenching is more than or equal to 48HRC, and finally tempering the inner knife box 102 in the heat treatment furnace at the high temperature of 510 ℃, preserving heat for 3h, and the surface hardness after tempering is more than or equal to 33 HRC;
the concrete process of the hardening treatment is as follows: carrying out surface quenching on the bearing part 104 of the inner cutter box 102 in a medium-frequency quenching mode, wherein the depth of a hardening layer is 25mm, and then carrying out surfacing welding on the bearing part 104 to form a hardened layer 105; the hardened layer 105 is a wear-resistant layer or a plasma cladding layer, the thickness of the wear-resistant layer is 6mm, and the thickness of the plasma cladding layer is 4 mm;
(d) welding the outer cutter box 101 and the inner cutter box 102, assembling and welding a welding seam 103 by ultrasonic flaw detection after welding, and performing stress-relief annealing treatment after confirming that the technical indexes are met; the specific process of the welding treatment comprises the following steps: preheating the outer cutter box 101 and the inner cutter box 102 at 250 ℃, controlling the current to be 310A and the voltage to be 34V for welding, and adopting a low-carbon alloy flux-cored wire imported from America to weld at present; after welding, performing stress relief annealing treatment, wherein the stress relief annealing treatment comprises the following specific processes: and (3) performing stress relief treatment in an atmosphere protection furnace, wherein the furnace temperature is 210 ℃, and the treatment time is 120 min.
And (d) carrying out finish turning on the inner cutter box 102 subjected to the stress relief annealing treatment in the step (d), wherein the machining precision excircle tolerance is 0.01-0.02mm, and the roughness is 1.6, so that a decarburized layer on the surface of the cutter box subjected to the heat treatment, which is caused by oxidation, is removed.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (9)
1. The utility model provides a central sword case of high strength TBM which characterized in that: the cutter comprises an outer cutter box (101) and an inner cutter box (102), wherein the outer cutter box (101) is made of a low-alloy structural steel material, and the inner cutter box (102) is made of a low-carbon medium-alloy structural steel material;
the preparation method of the high-strength TBM center knife box comprises the following steps:
(a) the outer cutter box (101) and the inner cutter box (102) are forged and formed;
(b) stress relief annealing treatment is carried out on the outer cutter box (101) in the step (a);
(c) hardening and tempering the inner knife box (102) in the step (a);
(d) and (3) welding the outer cutter box (101) and the inner cutter box (102), and performing stress relief annealing treatment after welding.
2. The high-strength TBM center knife box according to claim 1, characterized in that the low-alloy structural steel material adopted by the outer knife box (101) comprises the following components in percentage by weight: c: 0.11-0.18%, Si: 0.2-0.5%, Mn: 0.38-0.58%, V: 0.07-0.12%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
3. The high-strength TBM center knife box according to claim 1, characterized in that the low-carbon medium-alloy structural steel material adopted by the inner knife box (102) comprises the following components in percentage by weight: c: 0.11-0.17%, Si: 0.2-0.4%, Mn: 0.38-0.58%, Cr: 1.45-1.75%, Ni: 4.5-5.2%, W: 0.9-1.3%, V: 0.08-0.10%, Ti: 0.03 to 0.06%, Nb: 0.01-0.02%, S: less than or equal to 0.02 percent, P: less than or equal to 0.02 percent, and the balance being iron.
4. The high-strength TBM center knife box according to claim 1, wherein the stress relief annealing treatment in the step (b) comprises the following specific processes: the stress relief treatment is carried out in an atmosphere protection furnace, the furnace temperature is 190 +/-10 ℃, and the treatment time is 90-120 min.
5. The high-strength TBM center blade box according to claim 1, wherein the surface layer and the core part of the inner blade box (102) are detected by an ultrasonic flaw detector to confirm whether technical indexes are met, and the inner blade box (102) meeting the technical indexes is subjected to hardening and tempering treatment; the specific process of quenching and tempering in the step (c) is as follows: heating the inner knife box (102) in a heat treatment furnace from room temperature to 520-580 ℃ at the speed of 100-150 ℃/h, preserving heat at 520-580 ℃ for 40min, heating the inner knife box (102) to 850 +/-10 ℃ at the speed of 80-100 ℃/h, preserving heat at 850 +/-10 ℃ for 1h, finally quenching in an oil quenching mode, and tempering the inner knife box (102) at the high temperature of 510 +/-10 ℃ in the heat treatment furnace for 3h, wherein the surface hardness after quenching is more than or equal to 48 HRC.
6. The high-strength TBM center knife box according to claim 1, wherein the hardening treatment in the step (c) is carried out by the following specific process: carrying out surface quenching on a bearing part (104) of the inner cutter box (102) in a medium-frequency quenching mode, wherein the depth of a hardening layer is 10-25mm, and then carrying out surfacing hardening layer (105) on the bearing part (104).
7. The high-strength TBM center knife box according to claim 6, characterized in that the hardened layer (105) is a wear-resistant layer or a plasma cladding layer, the thickness of the wear-resistant layer is 3-6mm, and the thickness of the plasma cladding layer is 3-4 mm.
8. The high-strength TBM center knife box according to claim 1, characterized in that after welding in step (d), an ultrasonic flaw detection assembly welding seam (103) is used for performing stress relief annealing treatment after the technical index is met; the specific process of the welding treatment comprises the following steps: preheating the outer knife box (101) and the inner knife box (102) at the temperature of 200-250 ℃, controlling the current to be 220-310A, and welding at the voltage of 27-34V; the stress relief annealing treatment comprises the following specific processes: stress relief treatment is carried out in an atmosphere protection furnace, the furnace temperature is 200 +/-10 ℃, and the treatment time is 90-120 min.
9. The high strength TBM center knife box of any one of claims 2-8, wherein: and (d) carrying out finish turning on the inner cutter box (102) subjected to the stress relief annealing treatment in the step (d), wherein the machining precision excircle tolerance is 0.01-0.02mm, and the roughness is 1.6.
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