CN111618277A - Manufacturing method of easily-detachable, easily-machined and repairable high-wear-resistance ceramic alloy composite grinding roller - Google Patents
Manufacturing method of easily-detachable, easily-machined and repairable high-wear-resistance ceramic alloy composite grinding roller Download PDFInfo
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- CN111618277A CN111618277A CN202010321798.5A CN202010321798A CN111618277A CN 111618277 A CN111618277 A CN 111618277A CN 202010321798 A CN202010321798 A CN 202010321798A CN 111618277 A CN111618277 A CN 111618277A
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- 239000002131 composite material Substances 0.000 title claims abstract description 46
- 229910002110 ceramic alloy Inorganic materials 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 239000000919 ceramic Substances 0.000 claims abstract description 113
- 229910052751 metal Inorganic materials 0.000 claims abstract description 69
- 239000002184 metal Substances 0.000 claims abstract description 69
- 238000000034 method Methods 0.000 claims abstract description 34
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 32
- 239000000956 alloy Substances 0.000 claims abstract description 20
- 238000005266 casting Methods 0.000 claims abstract description 19
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 18
- 239000000463 material Substances 0.000 claims abstract description 18
- 229910000975 Carbon steel Inorganic materials 0.000 claims abstract description 15
- 239000010962 carbon steel Substances 0.000 claims abstract description 15
- 229910052742 iron Inorganic materials 0.000 claims abstract description 15
- 238000003754 machining Methods 0.000 claims abstract description 11
- 244000035744 Hura crepitans Species 0.000 claims abstract description 7
- 239000002245 particle Substances 0.000 claims description 56
- 239000000203 mixture Substances 0.000 claims description 26
- 238000001035 drying Methods 0.000 claims description 18
- 229910001018 Cast iron Inorganic materials 0.000 claims description 15
- 229910052804 chromium Inorganic materials 0.000 claims description 15
- 239000011651 chromium Substances 0.000 claims description 15
- 239000000843 powder Substances 0.000 claims description 13
- 229910000617 Mangalloy Inorganic materials 0.000 claims description 12
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 12
- 238000002156 mixing Methods 0.000 claims description 12
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 12
- 229910001209 Low-carbon steel Inorganic materials 0.000 claims description 10
- 229910000954 Medium-carbon steel Inorganic materials 0.000 claims description 10
- 239000007788 liquid Substances 0.000 claims description 9
- 229920005989 resin Polymers 0.000 claims description 9
- 239000011347 resin Substances 0.000 claims description 9
- 238000003466 welding Methods 0.000 claims description 9
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 8
- 238000001465 metallisation Methods 0.000 claims description 8
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 8
- 239000007769 metal material Substances 0.000 claims description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- 238000003723 Smelting Methods 0.000 claims description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 6
- 239000011230 binding agent Substances 0.000 claims description 6
- 238000005056 compaction Methods 0.000 claims description 6
- 238000005553 drilling Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- 238000011068 loading method Methods 0.000 claims description 6
- 238000003825 pressing Methods 0.000 claims description 6
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 6
- 229910001141 Ductile iron Inorganic materials 0.000 claims description 5
- 229910002065 alloy metal Inorganic materials 0.000 claims description 5
- 230000000149 penetrating effect Effects 0.000 claims description 5
- 229910052580 B4C Inorganic materials 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 4
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 claims description 4
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 claims description 4
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 4
- 235000019353 potassium silicate Nutrition 0.000 claims description 4
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 4
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 4
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 4
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 2
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 2
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 239000005011 phenolic resin Substances 0.000 claims description 2
- 229920001568 phenolic resin Polymers 0.000 claims description 2
- 239000008279 sol Substances 0.000 claims description 2
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 claims 1
- 238000005299 abrasion Methods 0.000 abstract description 7
- 238000004080 punching Methods 0.000 abstract description 4
- 239000003245 coal Substances 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 230000008595 infiltration Effects 0.000 description 4
- 238000001764 infiltration Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 230000007547 defect Effects 0.000 description 3
- 230000002035 prolonged effect Effects 0.000 description 3
- 239000004568 cement Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000005272 metallurgy Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C4/00—Crushing or disintegrating by roller mills
- B02C4/28—Details
- B02C4/30—Shape or construction of rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/04—Casting by dipping
-
- 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
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Food Science & Technology (AREA)
- Crushing And Grinding (AREA)
Abstract
The invention discloses a method for manufacturing a high-wear-resistance ceramic alloy composite grinding roller, which is easy to disassemble and process and can be repaired, and the method comprises the following steps: fixing the ceramic prefabricated part on the surface of a casting cavity of a roller skin lining plate, placing a sand box on a vibration platform, and pouring two materials of wear-resistant alloy molten metal and carbon steel molten metal in sequence; the small end of the roll skin lining plate with the key groove is sequentially assembled in the small end of the roll core with the clamping groove, 1 roll skin lining plate is installed every time, flat iron is knocked into the key groove of the contact surface of the upper ends of the roll core and the roll skin lining plate to be locked and fixed, then the pin shaft is inserted into the semicircular groove of the side surface of the roll skin lining plate, and the two lining plates are pressed and fixed with the pin shaft when the adjacent roll skin lining plates are installed. According to the invention, the roll skin lining plate and the roll core are internally fixed by a large number of key grooves, clamping grooves and the like, so that a bolt structure on the end face of the roll skin lining plate is replaced, and machining steps such as punching are reduced; the working surface of the grinding roller is formed by the abrasion-resistant alloy and the metal ceramic composite material in a staggered mode, is honeycomb-shaped and has double abrasion-resistant performance.
Description
Technical Field
The invention relates to a manufacturing method of a high-wear-resistance ceramic alloy composite grinding roller which is easy to disassemble and process and can be repaired, and the high-wear-resistance ceramic alloy composite grinding roller can be suitable for grinding rollers in the industries of thermal power generation, cement, metallurgy, mines and the like.
Background
In industries such as electric power, cement, metallurgy, mine and the like, the grinding roller is widely used in a powder making system and is used as a main wear-resistant part, and the wear resistance of the grinding roller directly influences the operation rate of powder making, the quality of pulverized coal, the consumption of the grinding roller and the production cost. Any grinding roller material is abraded seriously under the working condition of pulverizing, so that the coal powder efficiency of the coal mill is reduced after the grinding roller is abraded by serious pits and grooves, and the output of the coal mill is insufficient.
Most of grinding rollers used in the existing thermal power plant are integrally cast by high-chromium cast iron, so that the cost is high and the grinding processing is difficult. The service life of the grinding roller can be prolonged by repeatedly overlaying the wear-resistant alloy layer on the grinding roller after operation and abrasion, but the times are limited, the cost is high, the phenomenon that the overlaying layer falls off is easy to occur, meanwhile, the frequent shutdown maintenance of a power plant causes great economic loss, and the service life is generally 6000-plus 8000 hours.
In order to prolong the service life of the grinding roller, the metal ceramic composite grinding roller is gradually adopted in the current power plant, and the service life can reach 2-3 times of that of a surfacing material. The mature structural forms of the metal ceramic composite grinding roller comprise two types, namely one-time casting molding and secondary casting molding. The one-time casting molding process is formed by pouring a high-chromium cast iron material into a ceramic core plate once, so that the service life of the grinding roller is prolonged, the worn waste grinding roller cannot be used after surfacing, the waste grinding roller cannot be directly recycled, a large amount of carbon planing and labor cost are required, the use frequency of a furnace lining material of the intermediate frequency furnace is seriously influenced, and the maintenance cost of the intermediate frequency furnace is increased. The composite grinding roller is prepared by a secondary casting molding process, firstly, the ceramic grid body is cast by high-chromium cast iron to prepare the metal ceramic composite wear-resistant part, then, the nodular cast iron is cast for the second time on the metal ceramic composite wear-resistant part to prepare the composite grinding roller, the cost of the high-chromium cast iron integrally cast grinding roller is reduced, the used grinding roller cannot be used by overlaying welding, and the used grinding roller is high in use cost after being returned to a furnace again. For users, although the use of the metal ceramic grinding roller can realize 2-3 times of the original surfacing material, the defect that the two processes have the defects that the surfacing cannot be reused in the later period is overcome, and the problem that the purchasing of the metal ceramic composite grinding roller again needs a large amount of capital cost becomes an important reason that the product cannot be popularized widely.
The metal ceramic composite grinding roller with the detachable structure is fixed on the roller core through the end face bolt structure, the roller shell lining plate with the wear-resistant layer can be repaired through detaching and replacing the roller shell lining plate on the surface of the roller core after being worn, but the roller shell lining plate is not easy to process, so that the roller shell lining plate is poor in matching quality with the roller core, vibration is easy to generate during work, and the roller shell lining plate is even broken to cause the grinding roller to be scrapped. Meanwhile, the structure needs machining steps such as punching and the like, and the production cost is increased.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to solve the defects in the prior art and provides a manufacturing method of a high-wear-resistance ceramic alloy composite grinding roller which is easy to disassemble and process and can be repaired, a roller shell lining plate and a roller core are fixed in a large number of key grooves, clamping grooves and the like, a bolt structure on the end face of the roller shell lining plate is replaced, and machining steps such as punching and the like are reduced; the working surface of the grinding roller is formed by the abrasion-resistant alloy and the metal ceramic composite material in a staggered mode, is honeycomb-shaped and has double abrasion-resistant performance.
The technical scheme is as follows: the invention relates to a manufacturing method of a high-wear-resistance ceramic alloy composite grinding roller which is easy to disassemble and process and can be repaired, which comprises the following steps:
(1) carrying out surface metallization pretreatment on ceramic particles with the particle size of 10-30 meshes;
(2) uniformly mixing the pretreated ceramic particles with a binder according to a certain proportion, wherein the addition amount of the binder is 1-8% of the mass of the ceramic particles;
(3) adding a certain proportion of ceramic powder into the mixture obtained in the step (2) and uniformly mixing to obtain a particle mixture, wherein the particle size of the ceramic powder is 200-500 meshes, and the adding amount is 1-10% of the mass of the mixture;
(4) uniformly loading the particle mixture obtained in the step (3) into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 50-200 ℃ for 24-72 hours, and demoulding after drying out of the oven to obtain a ceramic prefabricated member;
(5) fixing the ceramic prefabricated part in the step (4) on the surface of the casting mold cavity of the roll skin lining plate, placing a sand box on a vibration platform, and pouring two materials of wear-resistant alloy metal liquid and carbon steel metal liquid in sequence, wherein the ceramic prefabricated part is preferentially infiltrated by the wear-resistant alloy metal liquid, and the carbon steel is metallurgically bonded with the wear-resistant alloy to obtain a metal ceramic roll skin lining plate which is respectively provided with three layers of a ceramic prefabricated part/wear-resistant alloy/carbon steel from the vertical downward working surface;
(6) carrying out heat treatment on the metal ceramic roller skin lining plate obtained in the step (5) to ensure that the working surface hardness of the metal ceramic roller skin lining plate reaches 58-62 HRC;
(7) machining the metal ceramic roller skin lining plate obtained in the step (6), drilling a threaded hole on the upper end surface of the reference lining plate, and forming key grooves on the upper end surfaces of other lining plates;
(8) smelting a parent metal material to form molten metal, pouring the molten metal into a casting mold cavity to obtain a roller core of the grinding roller, sequentially assembling the small head of the roller shell lining plate provided with the key groove in the step (7) into the small head of the roller core provided with the clamping groove, knocking flat iron into the key groove on the contact surface of the upper ends of the roller core and the roller shell lining plate to be locked and fixed when 1 roller shell lining plate is installed, inserting a pin shaft into a semicircular groove on the side surface of the roller shell lining plate, and pressing and fixing the pin shaft by the two lining plates when the adjacent roller shell lining plates are installed; assembling the big head of the reference roller skin lining plate at the corresponding position of the roller core with a threaded hole, fixing the reference roller skin lining plate on the surface of the roller core by using a spherical bolt plug, penetrating a pin shaft through a through hole of the roller core and inserting into a hole between contact surfaces of the side surfaces of the two lining plates, covering a resin gasket on the spherical bolt plug and the pin shaft and fully welding to obtain the easily detachable, easily processed, repairable and high-wear-resistant ceramic alloy composite grinding roller compounded by the metal ceramic roller skin lining plate and the roller core.
Further, the ceramic particle metallization pretreatment is to coat the surface of the ceramic particle with copper powder, titanium powder, nickel powder or a mixture of any two of the copper powder, the titanium powder and the nickel powder.
Further, the ceramic particles are one or a combination of any several of alumina, zirconia, silicon carbide, titanium carbide, tungsten carbide and titanium nitride.
Further, the binder is one or a combination of any more of silica sol, water glass, aluminum sol, sodium carbonate, polyvinyl alcohol and phenolic resin.
Further, the ceramic powder is one or a combination of any several of boron carbide, silicon carbide and yttrium oxide.
Further, the wear-resistant alloy molten metal is high-chromium cast iron or high-manganese steel.
Further, the carbon steel molten metal is low-carbon steel or medium-carbon steel.
Further, the parent metal material is one of nodular cast iron, low-carbon steel or medium-carbon steel.
Furthermore, the surface of the ceramic prefabricated part is in a honeycomb shape or a grid shape, the thickness of the prefabricated part is 10-50mm, and the surface of the ceramic prefabricated part is a plane or a curved surface.
Furthermore, the shape of the key groove is trapezoidal or rectangular, and the distance between the key groove at the roller skin and the center of the grinding roller is slightly larger than the distance between the key groove at the roller core and the center of the grinding roller.
Has the advantages that: the invention has the following beneficial effects:
(1) the processing surface of the roller shell lining plate is made of common cast steel materials, the processing is easy, the inner arc mounting surface adopts a groove-shaped structure, the polishing area can be reduced when the inner arc mounting surface is assembled with a roller core, and the production cost is reduced;
(2) the roll skin lining plate and the roll core are fixed in a key groove, a clamping groove and the like in a large number, the roll skin lining plate is fixed on the roll core through bending stress generated by deformation of knocked-in flat iron, a bolt structure of the end face of the roll skin lining plate is replaced, machining steps such as punching and the like are reduced, meanwhile, even if the end face of a grinding roll is abraded, a spherical plug in a hole, a pin shaft and the flat iron in the key groove cannot be abraded, and meanwhile, the pin shaft can enable the roll skin lining plate to be fixed on the surface of the roll core after being abraded to generate cracks, so that the safety and reliability of;
(3) the roller core is made of common metal materials, so that the hardness is low, the processing is easy, and the machining cost is greatly reduced;
(4) after the grinding roller is worn later, the roller core does not need to be replaced, the welding seam can be polished, the resin gasket is taken out, the roller shell lining plate which is seriously worn is removed, and a new roller shell lining plate is installed, so that the repairability of the ceramic grinding roller can be realized, and the purchase cost of the grinding roller is greatly reduced;
(5) the working surface of the grinding roller is formed by the abrasion-resistant alloy, the carbon steel and the metal ceramic composite material in a staggered mode, is honeycomb-shaped, has double abrasion-resistant performance, and the service life of the high-chromium cast iron grinding roller is prolonged to more than 2 times.
Drawings
FIG. 1 is a top view of a composite grinding roll in accordance with the present invention;
FIG. 2 is a schematic perspective view of the composite grinding roller of the present invention;
FIG. 3 is a cross-sectional view of the composite grinding roll of the present invention;
FIG. 4 is a partial cross-sectional view A-A of the composite grinding roll of the present invention;
FIG. 5 is a partial sectional view B-B of the composite grinding roll of the present invention;
FIG. 6 is a partial cross-sectional view C-C of the composite grinding roll of the present invention;
FIG. 7 is a schematic structural view of a honeycomb ceramic preform according to the present invention;
FIG. 8 is a cross-sectional view of the structure of FIG. 7;
FIG. 9 is a schematic structural view of the perforated roll skin liner of the present invention;
FIG. 10 is a schematic view of a roll skin liner with a keyway arrangement in accordance with the present invention;
FIG. 11 is a cross-sectional view of the structure of FIG. 10;
FIG. 12 is a cross-sectional view of the alternate construction of FIG. 10;
FIG. 13 is a schematic view of the construction of the roll core of the present invention.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
Example 1
(1) Carrying out surface metallization pretreatment on the alumina particles with the particle size of 10-30 meshes, and coating iron powder on the surfaces of the alumina particles;
(2) uniformly mixing the pretreated alumina particles with silica sol according to a certain proportion, wherein the addition amount of the silica sol is 1 percent of the mass of the alumina particles;
(3) adding boron carbide powder with a certain proportion into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle size of the boron carbide powder is 200-500 meshes, and the adding amount is 1% of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 50 ℃ for 24 hours, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part;
(5) fixing the ceramic prefabricated part in the step (4) on the surface of the casting mold cavity of the roller skin lining plate, and placing a sand box on a vibration platform, so that the infiltration effect of the wear-resistant alloy molten iron is better, and the combination with ceramic particles is firmer; sequentially pouring two materials, namely molten metal of high-chromium cast iron and molten metal of medium carbon steel, wherein the high-chromium cast iron preferentially infiltrates the ceramic preform, and the medium carbon steel is metallurgically bonded with the high-chromium cast iron to obtain a metal ceramic roller skin lining plate which is respectively provided with three layers of a ceramic preform/high-chromium cast iron/medium carbon steel from the vertical downward direction of a working surface;
(6) carrying out heat treatment on the roller skin lining plate to ensure that the surface hardness of the roller skin lining plate reaches 58-62 HRC;
(7) machining the metal ceramic roller skin lining plate obtained in the step (6), drilling a threaded hole on the upper end surface of the reference lining plate, and forming key grooves on the upper end surfaces of other lining plates;
(8) smelting ductile cast iron to form molten metal, pouring the molten metal into a casting mold cavity to obtain a roller core of the grinding roller, sequentially assembling the small head of the roller shell lining plate provided with the key groove in the step (7) on the small head of the roller core provided with a clamping groove structure, knocking flat iron into the key groove on the contact surface of the upper ends of the roller core and the roller shell lining plate to be locked and fixed when 1 roller shell lining plate is installed, inserting a pin shaft into a semicircular groove on the side surface of the roller shell lining plate, and pressing and fixing the pin shaft by the two lining plates when the adjacent roller shell lining plates are installed; assembling the big head of the reference roller skin lining plate at the corresponding position of the roller core with a threaded hole, fixing the reference roller skin lining plate on the surface of the roller core by using a spherical bolt plug, inserting a pin shaft into a hole between the side contact surfaces of the two lining plates after penetrating through the through hole of the roller core, covering a resin gasket on the spherical bolt plug and the pin shaft and fully welding to obtain the easily detachable, easily processed and repairable high-wear-resistance ceramic alloy composite grinding roller compounded by the metal ceramic roller skin lining plate and the roller core.
Example 2
(1) Performing surface metallization pretreatment on zirconia particles with the particle size of 10-30 meshes, and coating nickel powder on the surfaces of the zirconia particles;
(2) uniformly mixing the pretreated zirconia particles with water glass according to a certain proportion, wherein the adding amount of the water glass is 3 percent of the mass of the zirconia particles;
(3) adding a certain proportion of silicon carbide powder into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle size of the silicon carbide powder is 200-500 meshes, and the adding amount is 4% of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 100 ℃ for 36 hours, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part;
(5) fixing the ceramic prefabricated part in the step (4) on the surface of the casting mold cavity of the roller skin lining plate, and placing a sand box on a vibration platform, so that the infiltration effect of the wear-resistant alloy molten iron is better, and the combination with ceramic particles is firmer; sequentially pouring two materials, namely high manganese steel molten metal and low carbon steel molten metal, wherein the high manganese steel is preferentially infiltrated into the ceramic prefabricated part, and the low carbon steel is metallurgically bonded with the high manganese steel to obtain a metal ceramic roller skin lining plate which is respectively provided with three layers of ceramic prefabricated part/high manganese steel/low carbon steel from the vertical downward direction of a working surface;
(6) carrying out heat treatment on the roller skin lining plate to ensure that the surface hardness of the roller skin lining plate reaches 58-62 HRC;
(7) machining the metal ceramic roller skin lining plate obtained in the step (6), drilling a threaded hole on the upper end surface of the reference lining plate, and forming key grooves on the upper end surfaces of other lining plates;
(8) smelting a high manganese steel material to form molten metal, pouring the molten metal into a casting mold cavity to obtain a roller core of the grinding roller, sequentially assembling the small head of the roller shell lining plate provided with the key groove in the step (7) on the small head of the roller core provided with a clamping groove structure, knocking flat iron into the key groove on the contact surface of the upper ends of the roller core and the roller shell lining plate to be locked and fixed when 1 roller shell lining plate is installed, inserting a pin shaft into a semicircular groove on the side surface of the roller shell lining plate, and pressing and fixing the pin shaft by two lining plates when the adjacent roller shell lining plates are installed; assembling the large head of the reference roller skin lining plate at the corresponding position of the roller core with a threaded hole, and fixing the reference roller skin lining plate on the surface of the roller core by using a spherical bolt plug. And (3) inserting a pin shaft into a hole between the side contact surfaces of the two lining plates after penetrating through the through hole of the roller core, covering a resin gasket on the spherical bolt plug and the pin shaft, and fully welding to obtain the ceramic alloy composite grinding roller compounded by the metal ceramic roller skin lining plate and the roller core, which is easy to disassemble, process, repair and wear resistant.
Example 3
(1) Carrying out surface metallization pretreatment on silicon carbide particles with the particle size of 10-30 meshes, and coating titanium powder and iron powder on the surfaces of the silicon carbide particles;
(2) uniformly mixing pretreated silicon carbide particles with sodium carbonate according to a certain proportion, wherein the addition amount of the sodium carbonate is 5 percent of the mass of the silicon carbide particles;
(3) adding a certain proportion of yttrium oxide powder into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle size of the yttrium oxide powder is 200-500 meshes, and the adding amount is 6% of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying for 48 hours at 150 ℃, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part;
(5) fixing the ceramic prefabricated part in the step (4) on the surface of the casting mold cavity of the roller skin lining plate, and placing a sand box on a vibration platform, so that the infiltration effect of the wear-resistant alloy molten iron is better, and the combination with ceramic particles is firmer; sequentially pouring two materials, namely high-chromium cast iron molten metal and low-carbon steel molten metal, wherein the high-chromium cast iron preferentially infiltrates the ceramic preform, and the low-carbon steel is metallurgically bonded with the high-chromium cast iron to obtain a metal ceramic roller skin lining plate which is respectively provided with three layers of ceramic preform/high-chromium cast iron/low-carbon steel from the vertical downward direction of a working surface;
(6) carrying out heat treatment on the roller skin lining plate to ensure that the surface hardness of the roller skin lining plate reaches 58-62 HRC;
(7) machining the metal ceramic roller skin lining plate obtained in the step (6), drilling a threaded hole on the upper end surface of the reference lining plate, and forming key grooves on the upper end surfaces of other lining plates;
(8) smelting a ductile cast iron material to form molten metal, pouring the molten metal into a casting mold cavity to obtain a roller core of the grinding roller, sequentially assembling the small head of the roller shell lining plate provided with the key groove in the step (7) on the small head of the roller core provided with a clamping groove structure, knocking flat iron into the key groove on the contact surface of the upper ends of the roller core and the roller shell lining plate to be locked and fixed when 1 roller shell lining plate is installed, inserting a pin shaft into a semicircular groove on the side surface of the roller shell lining plate, and pressing and fixing the pin shaft by the two lining plates when the adjacent roller shell lining plates are installed; assembling the large head of the reference roller skin lining plate at the corresponding position of the roller core with a threaded hole, and fixing the reference roller skin lining plate on the surface of the roller core by using a spherical bolt plug. And (3) inserting a pin shaft into a hole between the side contact surfaces of the two lining plates after penetrating through the through hole of the roller core, covering a resin gasket on the spherical bolt plug and the pin shaft, and fully welding to obtain the ceramic alloy composite grinding roller compounded by the metal ceramic roller skin lining plate and the roller core, which is easy to disassemble, process, repair and wear resistant.
Example 4
(1) Carrying out surface metallization pretreatment on tungsten carbide particles with the particle size of 10-30 meshes, and coating titanium powder and nickel powder on the surfaces of the tungsten carbide particles;
(2) uniformly mixing the pretreated tungsten carbide particles with polyvinyl alcohol according to a certain proportion, wherein the addition amount of the polyvinyl alcohol is 8 percent of the mass of the tungsten carbide particles;
(3) adding a certain proportion of silicon carbide powder into the mixture and uniformly mixing to obtain a particle mixture, wherein the particle size of the silicon carbide powder is 200-500 meshes, and the adding amount is 10 percent of the mass of the mixture;
(4) uniformly loading the particle mixture into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 200 ℃ for 72 hours, and demoulding after drying out of the oven to obtain a honeycomb-shaped ceramic prefabricated part;
(5) fixing the ceramic prefabricated part in the step (4) on the surface of the casting mold cavity of the roller skin lining plate, and placing a sand box on a vibration platform, so that the infiltration effect of the wear-resistant alloy molten iron is better, and the combination with ceramic particles is firmer; sequentially pouring two materials, namely molten metal of high manganese steel and molten metal of medium carbon steel, wherein the high manganese steel preferentially infiltrates the ceramic preform, and the medium carbon steel is metallurgically bonded with the high manganese steel to obtain a metal ceramic roller skin lining plate which is respectively provided with three layers of a ceramic preform/the high manganese steel/the medium carbon steel from the vertical downward direction of a working surface;
(6) carrying out heat treatment on the roller skin lining plate to ensure that the surface hardness of the roller skin lining plate reaches 58-62 HRC;
(7) machining the metal ceramic roller skin lining plate obtained in the step (6), drilling a threaded hole on the upper end surface of the reference lining plate, and forming key grooves on the upper end surfaces of other lining plates;
(8) smelting a high manganese steel material to form molten metal, pouring the molten metal into a casting mold cavity to obtain a roller core of the grinding roller, sequentially assembling the small head of the roller shell lining plate provided with the key groove in the step (7) on the small head of the roller core provided with a clamping groove structure, knocking flat iron into the key groove on the contact surface of the upper ends of the roller core and the roller shell lining plate to be locked and fixed when 1 roller shell lining plate is installed, inserting a pin shaft into a semicircular groove on the side surface of the roller shell lining plate, and pressing and fixing the pin shaft by two lining plates when the adjacent roller shell lining plates are installed; assembling the large head of the reference roller skin lining plate at the corresponding position of the roller core with a threaded hole, and fixing the reference roller skin lining plate on the surface of the roller core by using a spherical bolt plug. And the pin shaft penetrates through the through hole of the roller core and is inserted into a hole between the side contact surfaces of the two lining plates. And covering resin gaskets on the spherical bolt plugs and the pin shafts and fully welding to obtain the high-wear-resistance ceramic alloy composite grinding roller with the metal ceramic roller skin lining plate and the roller core which are compounded, and the grinding roller is easy to disassemble, process and repair.
The structure of one embodiment of the finally manufactured ceramic alloy composite grinding roller is shown in fig. 1 to 13 and comprises a ceramic prefabricated part 1, a metal ceramic composite roller skin lining plate 2, a grinding roller core 3, a clamping groove 4, a ball bolt plug 5, a pin shaft 6, a resin gasket 7, a key groove 8, flat iron 9, wear-resistant alloy 10 and carbon steel 11.
The surface of the ceramic prefabricated member 1 is in a honeycomb shape or a grid shape, the thickness of the ceramic prefabricated member is 10-50mm, and the bottom surface of the ceramic prefabricated member is a plane or a curved surface.
The metal ceramic composite roll skin lining plate 2 is formed by combining three materials of a ceramic prefabricated part 1, a wear-resistant alloy 10 and carbon steel 11, the ceramic prefabricated part 1 is fixed on the surface of a casting cavity of the roll skin lining plate, two materials of a wear-resistant alloy metal liquid and a carbon steel metal liquid are sequentially poured, a ceramic prefabricated body is preferentially infiltrated by the wear-resistant alloy, the carbon steel is metallurgically combined with the wear-resistant alloy, and the metal ceramic roll skin lining plate 2 with three layers of the ceramic prefabricated part, the wear-resistant alloy and the carbon steel respectively vertically downward from a working surface is obtained.
The grinding roller core 3 is cast by a parent metal material, firstly, the parent metal material forms molten metal, and then the molten metal is poured into a casting mold cavity to obtain the grinding roller core 3.
When the non-reference roller shell lining plate is assembled specifically, the small end of the machined metal ceramic composite roller shell lining plate 2 is assembled at the small end of the roller core provided with a clamping groove 4, the clamping groove is arc-shaped or chamfered, and the angle is smaller than 90 degrees. Every time 1 roller skin lining plate is installed, a flat iron 9 is knocked into a key groove 8 on the contact surface of the roller core and the upper end of the roller skin lining plate to be locked and fixed, then a pin shaft 6 is inserted into a semicircular groove on the side surface of the roller skin lining plate, the two lining plates are pressed and fixed with the pin shaft when the adjacent roller skin lining plates are installed, the shape of the key groove 8 is trapezoidal or rectangular, and the distance between the key groove at the roller skin and the center of a grinding roller is slightly larger than the distance between the key groove at the roller core and the center of the grinding roller.
Wherein, as shown in fig. 9, the lateral surface of the roller skin lining plate is provided with a semicircular groove.
As shown in fig. 10, the inner arc surface of the metal ceramic composite roll skin lining plate 2 is provided with a groove, and the area of the groove accounts for 50-70% of the area of the curved surface.
When the reference roller skin lining plate is assembled, the large head of the reference roller skin lining plate is assembled at the corresponding position of the roller core 3 of the grinding roller, which is provided with a threaded hole, and the reference roller skin lining plate is fixed on the surface of the roller core by using a spherical bolt plug 5. And the pin shaft 6 penetrates through the through hole of the roller core and is inserted into a hole between the side contact surfaces of the two lining plates. And covering a resin gasket 7 on the spherical bolt plug and the pin shaft, and fully welding to obtain the ceramic alloy composite grinding roller which is compounded by the metal ceramic roller skin lining plate and the roller core, is easy to disassemble, process and repair and has high wear resistance.
Although the present invention has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. The manufacturing method of the ceramic alloy composite grinding roller which is easy to disassemble, process and repair and has high wear resistance is characterized in that: the method comprises the following steps:
(1) carrying out surface metallization pretreatment on ceramic particles with the particle size of 10-30 meshes;
(2) uniformly mixing the pretreated ceramic particles with a binder according to a certain proportion, wherein the addition amount of the binder is 1-8% of the mass of the ceramic particles;
(3) adding a certain proportion of ceramic powder into the mixture obtained in the step (2) and uniformly mixing to obtain a particle mixture, wherein the particle size of the ceramic powder is 200-500 meshes, and the adding amount is 1-10% of the mass of the mixture;
(4) uniformly loading the particle mixture obtained in the step (3) into a foamed ceramic boat mould, putting the whole ceramic boat after compaction into a drying oven for drying at 50-200 ℃ for 24-72 hours, and demoulding after drying out of the oven to obtain a ceramic prefabricated member;
(5) fixing the ceramic prefabricated part in the step (4) on the surface of the casting mold cavity of the roll skin lining plate, placing a sand box on a vibration platform, and pouring two materials of wear-resistant alloy metal liquid and carbon steel metal liquid in sequence, wherein the ceramic prefabricated part is preferentially infiltrated by the wear-resistant alloy metal liquid, and the carbon steel is metallurgically bonded with the wear-resistant alloy to obtain a metal ceramic roll skin lining plate which is respectively provided with three layers of a ceramic prefabricated part/wear-resistant alloy/carbon steel from the vertical downward working surface;
(6) carrying out heat treatment on the metal ceramic roller skin lining plate obtained in the step (5) to ensure that the working surface hardness of the metal ceramic roller skin lining plate reaches 58-62 HRC;
(7) machining the metal ceramic roller skin lining plate obtained in the step (6), drilling a threaded hole on the upper end surface of the reference lining plate, and forming key grooves on the upper end surfaces of other lining plates;
(8) smelting a parent metal material to form molten metal, pouring the molten metal into a casting mold cavity to obtain a roller core of the grinding roller, sequentially assembling the small head of the roller shell lining plate provided with the key groove in the step (7) into the small head of the roller core provided with the clamping groove, knocking flat iron into the key groove on the contact surface of the upper ends of the roller core and the roller shell lining plate to be locked and fixed when 1 roller shell lining plate is installed, inserting a pin shaft into a semicircular groove on the side surface of the roller shell lining plate, and pressing and fixing the pin shaft by the two lining plates when the adjacent roller shell lining plates are installed; assembling the big head of the reference roller skin lining plate at the corresponding position of the roller core with a threaded hole, fixing the reference roller skin lining plate on the surface of the roller core by using a spherical bolt plug, penetrating a pin shaft through a through hole of the roller core and inserting into a hole between contact surfaces of the side surfaces of the two lining plates, covering a resin gasket on the spherical bolt plug and the pin shaft and fully welding to obtain the easily detachable, easily processed, repairable and high-wear-resistant ceramic alloy composite grinding roller compounded by the metal ceramic roller skin lining plate and the roller core.
2. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the ceramic particle metallization pretreatment is to coat the surface of the ceramic particle with copper powder, titanium powder, nickel powder or a mixture of any two of the copper powder, the titanium powder and the nickel powder.
3. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the ceramic particles are one or the combination of any more of alumina, zirconia, silicon carbide, titanium carbide, tungsten carbide and titanium nitride.
4. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the binder is one or the combination of any more of silica sol, water glass, aluminum sol, sodium carbonate, polyvinyl alcohol and phenolic resin.
5. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the ceramic powder is one or the combination of any more of boron carbide, silicon carbide and yttrium oxide.
6. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the wear-resistant alloy molten metal is high-chromium cast iron or high-manganese steel.
7. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the carbon steel metal liquid is low-carbon steel or medium-carbon steel.
8. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the matrix metal material is one of nodular cast iron, low-carbon steel or medium-carbon steel.
9. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the surface of the ceramic prefabricated part is in a honeycomb shape or a grid shape, the thickness of the prefabricated part is 10-50mm, and the surface of the ceramic prefabricated part is a plane or a curved surface.
10. The method for manufacturing the easily detachable, easily machined, repairable and high wear-resistant ceramic alloy composite grinding roller according to claim 1, wherein the method comprises the following steps: the shape of the key groove is trapezoidal or rectangular, and the distance between the key groove at the roller skin and the center of the grinding roller is slightly larger than the distance between the key groove at the roller core and the center of the grinding roller.
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| CN115156540A (en) * | 2022-06-12 | 2022-10-11 | 华能国际电力股份有限公司营口电厂 | Preparation method of metal ceramic composite grinding roller |
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Denomination of invention: A manufacturing method for easy disassembly, easy processing, repairable, and high wear-resistant ceramic alloy composite grinding roller Effective date of registration: 20231024 Granted publication date: 20210921 Pledgee: Nantong Jiangsu rural commercial bank Limited by Share Ltd. Pledgor: NANTONG GAOXIN WEARABLE TECHNOLOGY Co.,Ltd. Registration number: Y2023980062526 |