CN111720430A - 一种复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺 - Google Patents
一种复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺 Download PDFInfo
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Abstract
本发明公开了一种复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺，包括包括顶盖、上密封圈、磁流体润滑剂、推力轴瓦、磁流体注入孔、轴瓦基底、轴瓦基底安装孔、螺线圈、线圈支座、环形线圈盘、通线孔、轴承基底和下密封圈，上密封圈和下密封圈分别安装在顶盖的内侧和轴承基底的内侧，顶盖安装于环形线圈盘上，磁流体润滑剂通过磁流体注入孔注入轴承内部的油沟内，并逐渐附着于推力轴瓦上，推力轴瓦与轴瓦基底通过轴瓦基底安装孔安装于环形线圈盘的凹槽内，轴承上部分整体通过环形线圈盘安装于轴承基底上。本发明特别适用于工况经常变化的大中小型等各类轴承，性能稳定可靠。
Description
技术领域
本发明属于滑动推力轴承技术领域，具体涉及一种复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺。
背景技术
传统轴承润滑剂及其润滑元素会随时间衰减，其衰减过程中的不可控性将引起一系列轴承摩擦、磨损问题。此外，油液还会随长时间的使用而变得浑浊，这是由于轴承摩擦副两接触材料相互运动形成的磨粒磨损以及外物的浸入，这将大大降低油品的质量，使得轴承寿命难以预测而成为工程隐患，严重影响生产效益，这就对轴承润滑管理及油品质量提出了更高的要求。
传统固定瓦平面推力轴承使用工况范围小，油膜承载性能低，瓦体可靠性差、摩擦损耗大，而可倾瓦推力轴承结构较复杂，轴瓦支撑不稳定情况下容易使得瓦面承载不均匀，且两者均需要额外的油冷循环系统。
磁流体是一种智能微纳米流体，其冷却、散热性能极佳。此外，由于磁流体同时具备流变特性和超顺磁性，可被外加磁场可靠控制，磁场梯度作用下的磁流体在轴承摩擦副中具有可观的减摩抗磨效果，起到极佳的润滑作用且不易泄露，使得轴承性能得到改善。
发明内容
本发明提出了一种复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺，特别适用于工况经常变化的大中小型等各类轴承，性能稳定可靠。
本发明的技术方案是这样实现的：
一种复合轴瓦的低阻式磁流体斜面推力轴承，其包括顶盖、上密封圈、磁流体润滑剂、推力轴瓦、磁流体注入孔、轴瓦基底、轴瓦基底安装孔、螺线圈、线圈支座、环形线圈盘、通线孔、轴承基底和下密封圈，所述上密封圈和下密封圈分别安装在顶盖的内侧和轴承基底的内侧，所述顶盖安装于所述环形线圈盘上，所述磁流体润滑剂通过所述磁流体注入孔注入轴承内部的油沟内，并逐渐附着于所述推力轴瓦上，所述推力轴瓦与所述轴瓦基底通过轴瓦基底安装孔安装于所述线圈支座和所述环形线圈盘的凹槽内，轴承上部分整体通过所述环形线圈盘安装于所述轴承基底上。
在本发明的复合轴瓦的低阻式磁流体斜面推力轴承，所述推力轴瓦由复合PEEK层、金属螺旋网状层、铜粉层组成，所述复合PEEK层、金属螺旋网状层、铜粉层三层厚度比例为2:1:1。
在本发明的复合轴瓦的低阻式磁流体斜面推力轴承，所述推力轴瓦为微斜面结构，所述微斜面结构能形成很强的油楔压力。
在本发明的复合轴瓦的低阻式磁流体斜面推力轴承，所述螺线圈设有6个，所述螺线圈由一根多扎铜线缠绕而成，并通过所述通线孔受控于外部的磁场控制电路。
在本发明的复合轴瓦的低阻式磁流体斜面推力轴承，所述推力轴承轴向载荷为10000N，所述推力轴承中轴颈为0.1m，所述环形线圈盘的转速为40r/s。
在本发明的复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺，具体加工步骤如下：
1）顶盖加工；采用不锈钢铸造工艺，形成坯料，在法兰上铣削均匀分布的6个M8的螺栓孔，在顶部中心镗出直径为104mm的孔，打通，在孔壁中间位置加工上密封圈的安装环形槽，在顶盖薄边出钻直径为4mm的磁流体注入孔，车法兰和顶圆倒角为1×45°，公差为0.02mm；
2）推力轴瓦与轴瓦基底复合层加工；首先使用球磨机将PEEK板料磨成粒径为90um的颗粒，利用热压法将70um的碳纤维颗粒粉末与PEEK颗粒粉末进行混合，对PEEK材料进行改性，再将改性PEEK材料加工成的复合PEEK层，热处理；
3）热处理完成后，将金属丝顺时针缠绕在直径2mm的黑色棒料上，加热形成金属螺旋网状层；
4）线切割不锈钢板，形成轴瓦基底层，并进行热处理；
5）采用升降式热压烧结炉将铜粉层热压烧结在不锈钢轴瓦基底上，再将金属螺旋网状层热压烧结在铜粉-不锈钢基底复合体上，最后将复合PEEK层热压在金属螺旋网-铜粉-不锈钢基底复合体上，形成初步复合试样；
6）精密磨削复合PEEK层表面，形成坡度，线切割加工试样外圆，镗内孔，铣油沟和M10螺栓孔，M10螺栓孔即为轴瓦基底安装孔，形成推力轴瓦与轴瓦基底复合层，推力轴瓦层为6个半扇形体，轴瓦基底为圆环形状，车出轴瓦基底倒角0.5×45°，公差为0.02mm；
7）线圈支座加工；采用不锈钢铸造工艺加工出线圈支座的初步形状，支座的圆环基底外径244mm、内径140mm、厚16mm，其基底上方依次相间分布6个高为30mm、直径为20mm和6个高为30mm、直径为30mm的圆柱；在直径为30mm的圆柱上铣出M10的螺栓孔；在圆环基底周围铣6个均匀分布的M6的螺栓孔，倒角为0.5×45°，公差为0.02mm；最后进行热处理；
8）螺线圈加工；使用3D打印机打印6个塑料螺线管，将螺线管依次置于线圈支座的6个直径为20mm圆柱支柱上，用一根多扎铜线依次缠绕在6个螺线管上形成6个螺线圈；
9）环形线圈盘加工；车削不锈钢棒料，镗直径为108mm的孔，在坯料上铣削出宽为51mm、深为46mm的环形槽，在环形槽铣相间分布的6个M6螺栓孔和6个M8螺栓孔，接着在外壁上方加工6个M8螺栓孔，在外壁周围钻一个直径为6mm的通线孔，打通外壁，倒角为0.5×45°，公差为0.02mm，最后对环形线圈盘进行热处理；
10）轴承基底加工；采用低碳钢铸造出轴承基底的初步形状，分四层，在最上方铣6个M8的螺栓孔，线在坯料中心镗直径108mm、深88mm的孔，再加工直径104mm、深12mm的孔，最后反方向加工直径134mm、深40mm的孔，在直径为104mm的孔壁中间位置加工出下密封圈的安装环形槽，倒角为0.5×45°，公差为0.02mm，最后对轴承基底进行热处理；
11）轴承装配；首先使用无锐边工具将涂抹润滑脂的下密封圈嵌入轴承基底上的环形槽内，通过6个M8螺栓将环形线圈盘安装于轴承基底正上方；
12）将6个塑料螺线管依次嵌入线圈支座的6个直径为20mm圆柱支柱上，用一根多扎铜线依次缠绕在6个塑料螺线管上形成6个螺线圈，接着将6个螺线圈与线圈支座整体通过6个M6螺栓安装于环形线圈盘的环形槽内，铜线两头多出来的线头通过通线孔拉出连接磁场控制电路；
13）通过轴瓦基底安装孔将推力轴瓦与轴瓦基底复合层安装于线圈支座正上方，由线圈支座与环形线圈盘共同支撑；
14）将转轴推力环置于推力轴瓦层正上方，转轴下端与下密封圈固定；
15）通过6个M8的螺栓将顶盖安装于环形线圈盘上方，将涂抹润滑脂的上密封圈嵌入顶盖上端的环形槽内，并与转轴上端固定；
16）通过磁流体注入孔将磁流体润滑剂注入推力轴瓦与轴瓦基底复合层的油沟内，完成装配。
实施本发明的这种复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺，具有以下有益效果：本案将纳米磁性流体作为立式推力轴承润滑剂，实现了减阻效果及防止了润滑剂的流失，并将PEEK、金属丝以及铜粉加工成改性材料复合轴瓦，实现了良好的耐磨性能，外部设置一个统一的磁场控制电路，可对每块轴瓦下方螺线圈产生的电磁场进行集中调控，从而改变轴瓦与推力环之间的的磁流体油膜厚度及油压，这就实现了以简单易维护的结构达到可倾瓦推力轴承的运转效果，特别适用于工况经常变化的大中小型轴承。
附图说明
图1为本发明复合轴瓦的低阻式磁流体斜面推力轴承的结构示意图；
图2为本发明复合轴瓦的低阻式磁流体斜面推力轴承的俯视示意图；
图3为本发明复合轴瓦的低阻式磁流体斜面推力轴承的剖视示意图；
图4为本发明复合轴瓦的低阻式磁流体斜面推力轴承中磁场控制示意图；
图5为本发明中推力轴瓦的结构示意图。
图中：顶盖1、磁流体润滑剂2，磁流体注入孔3、轴瓦基底4、螺线圈5、线圈支座6、轴承基底7、下密封圈8、环形线圈盘9、通线孔10、轴瓦基底安装孔11、推力轴瓦12、上密封圈13、磁场控制电路14、复合PEEK层15、金属螺旋网状层16、铜粉层17。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述。
如图1至5所示的本发明的这种复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺，其包括顶盖1、上密封圈13、磁流体润滑剂2、推力轴瓦12、磁流体注入孔3、轴瓦基底4、轴瓦基底安装孔11、螺线圈5、线圈支座6、环形线圈盘9、通线孔10、轴承基底7和下密封圈8，上密封圈13和下密封圈8分别安装在顶盖1的内侧和轴承基底7的内侧，顶盖1安装于环形线圈盘9上，磁流体润滑剂2通过磁流体注入孔3注入轴承内部的油沟内，并逐渐附着于推力轴瓦12上，推力轴瓦12与轴瓦基底4通过轴瓦基底安装孔11安装于线圈支座6和环形线圈盘9的凹槽内，轴承上部分整体通过环形线圈盘9安装于轴承基底7上，推力轴瓦12由复合PEEK层15、金属螺旋网状层16、铜粉层17组成，复合PEEK层15、金属螺旋网状层16、铜粉层17三层厚度比例为2:1:1，推力轴瓦12为微斜面结构，微斜面结构能形成很强的油楔压力，螺线圈5设有6个，螺线圈5由一根多扎铜线缠绕而成，并通过通线孔10受控于外部的磁场控制电路14， 推力轴承轴向载荷为10000N，推力轴承中轴颈为0.1m，环形线圈盘9的转速为40r/s，本发明的复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺，具体加工步骤如下：
1）顶盖1加工；采用不锈钢铸造工艺，形成坯料（内腔直径280mm、深70mm，法兰直径344mm、厚20mm），在法兰上铣削均匀分布的6个M8的螺栓孔（大孔直径16mm、深8mm，小孔打通），在顶部中心镗出直径为104mm的孔，打通，在孔壁中间位置加工上密封圈13的安装环形槽（槽深2mm、高4mm），在顶盖1薄边出钻直径为4mm的磁流体注入孔3，车法兰和顶圆倒角为1×45°，公差为0.02mm；
2）推力轴瓦12与轴瓦基底4复合层加工；首先使用球磨机将PEEK（聚醚醚酮）板料磨成粒径为90um的颗粒，利用热压法将70um的碳纤维颗粒粉末与PEEK颗粒粉末进行混合，对PEEK材料进行改性，再将改性PEEK材料加工成的复合PEEK层15（270mm×270mm×8mm），热处理；
3）热处理完成后，将金属丝顺时针缠绕在直径2mm的黑色棒料上，加热形成金属螺旋网状层16；
4）线切割不锈钢板，形成轴瓦基底4层（270mm×270mm×20mm），并进行热处理；
5）采用升降式热压烧结炉将铜粉层17热压烧结在不锈钢轴瓦基底4上，再将金属螺旋网状层16热压烧结在铜粉-不锈钢基底复合体上，最后将复合PEEK层15热压在金属螺旋网-铜粉-不锈钢基底复合体上，形成初步复合试样；
6）精密磨削复合PEEK层15表面，形成坡度，线切割加工试样外圆，镗内孔，铣油沟和M10螺栓孔（大孔直径20mm、深10mm，小孔打通），M10螺栓孔即为轴瓦基底安装孔11，形成推力轴瓦12与轴瓦基底4复合层，推力轴瓦12层为6个半扇形体（弧度为43°、瓦宽72、瓦长72、瓦包角为0.87rad、瓦块坡高279um），轴瓦基底4为圆环形状，车出轴瓦基底4倒角0.5×45°，公差为0.02mm；
7）线圈支座6加工；采用不锈钢铸造工艺加工出线圈支座6的初步形状，支座的圆环基底外径244mm、内径140mm、厚16mm，其基底上方依次相间分布6个高为30mm、直径为20mm和6个高为30mm、直径为30mm的圆柱；在直径为30mm的圆柱上铣出M10的螺栓孔（孔深20mm）；在圆环基底周围铣6个均匀分布的M6的螺栓孔（大孔直径12mm、深6mm，小孔打通），倒角为0.5×45°，公差为0.02mm；最后进行热处理；
8）螺线圈5加工；使用3D打印机打印6个塑料螺线管（外径50-0.2mm、内径20+0.2mm、壁厚1mm），将螺线管依次置于线圈支座6的6个直径为20mm圆柱支柱上，用一根多扎铜线依次缠绕在6个螺线管上形成6个螺线圈5；
9）环形线圈盘9加工；车削不锈钢棒料，镗直径为108mm的孔，在坯料上铣削出宽为51mm、深为46mm的环形槽（外径144mm、内径140mm），在环形槽铣相间分布的6个M6螺栓孔（孔深12mm），在环形槽铣相间分布的6个M6螺栓孔（孔深12mm）和6个M8螺栓孔（大孔直径16mm、厚6mm，小孔打通），接着在外壁上方加工6个M8螺栓孔（孔深20mm），在外壁周围钻一个直径为6mm的通线孔10，打通外壁，倒角为0.5×45°，公差为0.02mm，最后对环形线圈盘9进行热处理；
10）轴承基底7加工；采用低碳钢铸造出轴承基底的初步形状（呈“工”字型），分四层（上方圆盘直径为344mm、厚20mm，中间圆盘直径为274mm、厚80mm，第三层直径为344mm、厚20mm，最下层直径为394mm、厚20mm），在最上方铣6个M8的螺栓孔（孔深30mm），线在坯料中心镗直径108mm、深88mm的孔，再加工直径104mm、深12mm的孔，最后反方向加工直径134mm、深40mm的孔，在直径为104mm的孔壁中间位置加工出下密封圈8的安装环形槽（槽深2mm、高4mm），倒角为0.5×45°，公差为0.02mm，最后对轴承基底7进行热处理；
11）轴承装配；首先使用无锐边工具将涂抹润滑脂的下密封圈8嵌入轴承基底7上的环形槽内，通过6个M8螺栓将环形线圈盘9安装于轴承基底7正上方；
12）将6个塑料螺线管依次嵌入线圈支座6的6个直径为20mm圆柱支柱上，用一根多扎铜线依次缠绕在6个塑料螺线管上形成6个螺线圈5，接着将6个螺线圈5与线圈支座6整体通过6个M6螺栓安装于环形线圈盘9的环形槽内，铜线两头多出来的线头通过通线孔10拉出连接磁场控制电路14；
13）通过轴瓦基底安装孔11将推力轴瓦12与轴瓦基底4复合层安装于线圈支座6正上方，由线圈支座6与环形线圈盘9共同支撑；
14）将转轴推力环置于推力轴瓦12层正上方，转轴下端与下密封圈8固定；
15）通过6个M8的螺栓将顶盖1安装于环形线圈盘9上方，将涂抹润滑脂的上密封圈13嵌入顶盖1上端的环形槽内，并与转轴上端固定；
16）通过磁流体注入孔3将磁流体润滑剂2注入推力轴瓦12与轴瓦基底4复合层的油沟内，完成装配。至此，本发明发明目的得以完成。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (6)
1.一种复合轴瓦的低阻式磁流体斜面推力轴承，其特征在于，包括顶盖、上密封圈、磁流体润滑剂、推力轴瓦、磁流体注入孔、轴瓦基底、轴瓦基底安装孔、螺线圈、线圈支座、环形线圈盘、通线孔、轴承基底和下密封圈，所述上密封圈和下密封圈分别安装在顶盖的内侧和轴承基底的内侧，所述顶盖安装于所述环形线圈盘上，所述磁流体润滑剂通过所述磁流体注入孔注入轴承内部的油沟内，并逐渐附着于所述推力轴瓦上，所述推力轴瓦与所述轴瓦基底通过轴瓦基底安装孔安装于所述线圈支座和所述环形线圈盘上方，轴承上部分整体通过所述环形线圈盘安装于所述轴承基底上。
2.根据权利要求1所述的复合轴瓦的低阻式磁流体斜面推力轴承，其特征在于，所述推力轴瓦由复合PEEK层、金属螺旋网状层、铜粉层组成，所述复合PEEK层、金属螺旋网状层、铜粉层三层厚度比例为2:1:1。
3.根据权利要求1所述的复合轴瓦的低阻式磁流体斜面推力轴承，其特征在于，所述推力轴瓦为微斜面结构，所述微斜面结构能形成很强的油楔压力。
4.根据权利要求1所述的复合轴瓦的低阻式磁流体斜面推力轴承，其特征在于，所述螺线圈设有6个，所述螺线圈由一根多扎铜线缠绕而成，并通过所述通线孔受控于外部的磁场控制电路。
5.根据权利要求1所述的复合轴瓦的低阻式磁流体斜面推力轴承，其特征在于，所述推力轴承轴向载荷为10000N，所述推力轴承中轴颈为0.1m，所述环形线圈盘的转速为40r/s。
6.根据权利要求1至5任一所述的复合轴瓦的低阻式磁流体斜面推力轴承及其加工工艺，其特征在于，具体加工步骤如下：
1)顶盖加工；采用不锈钢铸造工艺，形成坯料，在法兰上铣削均匀分布的6个M8的螺栓孔，在顶部中心镗出直径为104mm的孔，打通，在孔壁中间位置加工上密封圈的安装环形槽，在顶盖薄边出钻直径为4mm的磁流体注入孔，车法兰和顶圆倒角为1×45°，公差为0.02mm；
2)推力轴瓦与轴瓦基底复合层加工；首先使用球磨机将PEEK板料磨成粒径为90um的颗粒，利用热压法将70um的碳纤维颗粒粉末与PEEK颗粒粉末进行混合，对PEEK材料进行改性，再将改性PEEK材料加工成的复合PEEK层，热处理；
3)热处理完成后，将金属丝顺时针缠绕在直径2mm的黑色棒料上，加热形成金属螺旋网状层；
4)线切割不锈钢板，形成轴瓦基底层，并进行热处理；
5)采用升降式热压烧结炉将铜粉层热压烧结在不锈钢轴瓦基底上，再将金属螺旋网状层热压烧结在铜粉-不锈钢基底复合体上，最后将复合PEEK层热压在金属螺旋网-铜粉-不锈钢基底复合体上，形成初步复合试样；
6)精密磨削复合PEEK层表面，形成坡度，线切割加工试样外圆，镗内孔，铣油沟和M10螺栓孔，M10螺栓孔即为轴瓦基底安装孔，形成推力轴瓦与轴瓦基底复合层，推力轴瓦层为6个半扇形体，轴瓦基底为圆环形状，车出轴瓦基底倒角0.5×45°，公差为0.02mm；
7)线圈支座加工；采用不锈钢铸造工艺加工出线圈支座的初步形状，支座的圆环基底外径244mm、内径140mm、厚16mm，其基底上方依次相间分布6个高为30mm、直径为20mm和6个高为30mm、直径为30mm的圆柱；在直径为30mm的圆柱上铣出M10的螺栓孔；在圆环基底周围铣6个均匀分布的M6的螺栓孔，倒角为0.5×45°，公差为0.02mm；最后进行热处理；
8)螺线圈加工；使用3D打印机打印6个塑料螺线管，将螺线管依次置于线圈支座的6个直径为20mm圆柱支柱上，用一根多扎铜线依次缠绕在6个螺线管上形成6个螺线圈；
9)环形线圈盘加工；车削不锈钢棒料，镗直径为108mm的孔，在坯料上铣削出宽为51mm、深为46mm的环形槽，在环形槽铣相间分布的6个M6螺栓孔和6个M8螺栓孔，接着在外壁上方加工6个M8螺栓孔，在外壁周围钻一个直径为6mm的通线孔，打通外壁，倒角为0.5×45°，公差为0.02mm，最后对环形线圈盘进行热处理；
10)轴承基底加工；采用低碳钢铸造出轴承基底的初步形状，分四层，在最上方铣6个M8的螺栓孔，线在坯料中心镗直径108mm、深88mm的孔，再加工直径104mm、深12mm的孔，最后反方向加工直径134mm、深40mm的孔，在直径为104mm的孔壁中间位置加工出下密封圈的安装环形槽，倒角为0.5×45°，公差为0.02mm，最后对轴承基底进行热处理；
11)轴承装配；首先使用无锐边工具将涂抹润滑脂的下密封圈嵌入轴承基底上的环形槽内，通过6个M8螺栓将环形线圈盘安装于轴承基底正上方；
12)将6个塑料螺线管依次嵌入线圈支座的6个直径为20mm圆柱支柱上，用一根多扎铜线依次缠绕在6个塑料螺线管上形成6个螺线圈，接着将6个螺线圈与线圈支座整体通过6个M6螺栓安装于环形线圈盘的环形槽内，铜线两头多出来的线头通过通线孔拉出连接磁场控制电路；
13)通过轴瓦基底安装孔将推力轴瓦与轴瓦基底复合层安装于线圈支座正上方，由线圈支座与环形线圈盘共同支撑；
14)将转轴推力环置于推力轴瓦层正上方，转轴下端与下密封圈固定；
15)通过6个M8的螺栓将顶盖安装于环形线圈盘上方，将涂抹润滑脂的上密封圈嵌入顶盖上端的环形槽内，并与转轴上端固定；
16)通过磁流体注入孔将磁流体润滑剂注入推力轴瓦与轴瓦基底复合层的油沟内，完成装配。
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| CN115111267A (zh) * | 2022-06-08 | 2022-09-27 | 华能花凉亭水电有限公司 | 一种混流式水轮机水导轴承结构 |
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