CN112065952A - Drum-shaped gear rail wheel for coal mining machine and preparation method thereof - Google Patents
Drum-shaped gear rail wheel for coal mining machine and preparation method thereof Download PDFInfo
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- 238000005242 forging Methods 0.000 claims abstract description 20
- 238000005422 blasting Methods 0.000 claims abstract description 17
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- 238000007670 refining Methods 0.000 claims abstract description 12
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
- F16H55/02—Toothed members; Worms
- F16H55/06—Use of materials; Use of treatments of toothed members or worms to affect their intrinsic material properties
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- 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
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
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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
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/32—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for gear wheels, worm wheels, or the like
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21C—MINING OR QUARRYING
- E21C29/00—Propulsion of machines for slitting or completely freeing the mineral from the seam
- E21C29/22—Propulsion of machines for slitting or completely freeing the mineral from the seam by wheels, endless tracks or the like
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
- F16H55/02—Toothed members; Worms
- F16H55/08—Profiling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
- F16H55/02—Toothed members; Worms
- F16H55/17—Toothed wheels
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Abstract
The invention discloses a drum-shaped rack wheel for a coal mining machine, which comprises a rack wheel main body and a plurality of drum-shaped teeth, wherein tooth surfaces of the drum-shaped teeth are smoothly transited to arc drum-shaped curved surfaces from tooth surface central lines to two sides to form drum-shaped tooth surfaces, a bearing matching through hole is formed in the central position of the rack wheel main body, and a plurality of connecting keys are arranged on the surface of the rack wheel main body. The invention also discloses a method for preparing the crowned rack rail wheel for the coal mining machine, which is obtained by processing the 18Cr2Ni4WA alloy steel. The invention increases the contact area of the drum-shaped gear rail wheel and the pin row through the drum-shaped tooth surface, reduces the contact stress of the drum-shaped gear rail wheel and the pin row, prolongs the service life of the drum-shaped gear rail wheel, and has the advantages of excellent unbalance loading resistance, stable transmission and strong bearing capacity; the invention improves the tensile strength, bending strength, contact strength and toughness of the drum-shaped gear rail wheel through refining, forging, heat treatment, carburizing and shot blasting.
Description
Technical Field
The invention belongs to the technical field of rack rail wheels for coal mining machines, and particularly relates to a crowned rack rail wheel for a coal mining machine and a preparation method thereof.
Background
The traction mode of the modern coal mining machine is an onboard alternating-current variable-frequency speed-regulating rack rail-pin rail type chainless traction, the walking of the modern coal mining machine is completely realized by a rack rail wheel on a pin row, similar to gear-rack type transmission, the output torque of a traction part is converted into the traction force and the traction speed of a walking mechanism, and the coal mining machine is driven to walk, so that the modern coal mining machine is a heavy-load stress member. The rack wheel is a special gear, is meshed with a pin row on a scraper conveyor, belongs to open transmission, and is suitable for testing of complex geological conditions such as variable pitch and no lubrication. Particularly, the high-power heavy-load coal mining machine has large dead weight and needs to realize quick traction, which inevitably brings large traction resistance, so that the walking load of the coal mining machine is increased, the rack rail wheel is easy to be damaged abnormally, the service life of the rack rail wheel is greatly shortened, the normal operation of the coal mining machine is seriously influenced, and unnecessary economic loss is caused to coal mines. The high-power heavy-duty coal mining machine is important equipment for realizing high yield and high-efficiency production of coal mine enterprises, aims to improve the meshing form of a rack wheel and a pin row, prolongs the service life of the rack wheel, realizes the rapid traction of a traveling mechanism of the high-power heavy-duty coal mining machine, and urgently needs to research and develop a high-performance and high-reliability rack wheel in order to meet the high-yield and high-efficiency production requirements of coal mines. The toothed rail wheel with high reliability and the preparation method thereof need to be obtained by carrying out all-round research on tooth profile design, material selection, heat treatment modes and the like.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a crowned rack rail wheel for a coal mining machine aiming at the defects of the prior art. The crowned rack rail wheel improves the meshing contact condition of the crowned rack rail wheel and the pin row through a crowned tooth surface, increases the meshing contact area of the crowned rack rail wheel and the pin row, has the advantages of excellent unbalance loading resistance and good adaptability, can well adapt to horizontal bending and vertical bending changes of a working surface, prolongs the service life of the rack rail wheel, has the characteristics of high strength, high hardness and high wear resistance, avoids the defects of extrusion and stress concentration of the edge of the crowned rack rail wheel, reduces the economic loss caused by broken teeth and abnormal wear, saves the loss of coal mine accessories and reduces the labor intensity of workers.
In order to solve the technical problems, the technical scheme provided by the invention is as follows: the drum-shaped rack rail wheel for the coal mining machine is characterized by comprising a rack rail wheel main body and a plurality of drum-shaped teeth arranged on the outer edge of the rack rail wheel main body in a surrounding mode, tooth surfaces of the drum-shaped teeth are smoothly transited to arc drum-shaped curved surfaces from tooth surface central lines to two sides to form drum-shaped tooth surfaces, the tooth surface central lines are overlapped with tooth-shaped meshing lines of the drum-shaped rack rail wheel, a bearing matching through hole matched with a bearing is formed in the central position of the rack rail wheel main body, and a plurality of connecting keys are arranged on the surface of the rack rail wheel main body in a surrounding mode along the bearing matching through hole.
The invention relates to a rack rail wheel for a coal mining machine, which is a special gear and is meshed with a pin row of a scraper conveyor, the tooth profile of the rack rail wheel is an involute and cycloid compound gear, when the coal mining machine normally works, the rack rail wheel rotates and moves in translation on the pin row and is well meshed with the pin row, and circular motion is converted into linear motion through a rack rail wheel and pin row moving pair. The drum-shaped rack rail wheel for the coal mining machine is provided, the drum-shaped rack rail wheel is matched and meshed with a concave pin row, the contact area of the drum-shaped rack rail wheel meshed with the pin row is increased through the drum-shaped tooth surface, so that the contact condition of the drum-shaped rack rail wheel and the pin row is improved, the contact stress of the drum-shaped rack rail wheel and the pin row is reduced, the service life of the drum-shaped rack rail wheel is prolonged, the vibration during gear transmission is reduced, the transmission is ensured to be more stable, and the rotation is realized after the drum-shaped rack rail wheel is matched with a driving large gear through a bearing matching through hole matched with a bearing, the application on the travelling mechanism of the high-power heavy-load coal mining machine with the rapid traction is realized, the high-yield and high-efficiency production requirements of a coal mine are met, the drum-shaped toothed rail wheel can still normally run when meeting horizontal bending and vertical bending changes of a working surface or suffering from sundries such as gangue, the transmission impact increase caused by unbalanced load and unbalanced load can not occur, the defect of intensified abrasion of the toothed rail wheel is caused, the drum-shaped toothed rail wheel can not be excessively abraded or broken teeth in a short period, the drum-shaped toothed rail wheel also has the advantages of excellent anti-unbalanced load performance, good adaptability, stable transmission and strong bearing capacity.
In addition, the invention also provides a preparation method of the crowned rack rail wheel for the coal mining machine, which is characterized by comprising the following steps:
firstly, vacuum smelting 18Cr2Ni4WA alloy steel, and then refining to obtain a drum-shaped gear wheel precursor;
forging the precursor of the crowned rack wheel obtained in the step one, normalizing, cooling in air, and tempering to obtain a tempered precursor of the crowned rack wheel;
thirdly, performing contour machining and rough machining of the tooth profile of the gear teeth on the tempered drum-shaped rack rail wheel precursor obtained in the second step, and then performing aging treatment to obtain a drum-shaped rack rail wheel blank;
step four, milling the crowned rack and rail wheel blank obtained in the step three to obtain a milled crowned rack and rail wheel blank;
step five, performing carburizing treatment on the milled crowned rack rail wheel blank obtained in the step four to obtain a carburized crowned rack rail wheel blank;
step six, shot blasting is carried out on the carburized crowned rack rail wheel blank obtained in the step five, and the shot-blasted crowned rack rail wheel blank is obtained;
and step seven, performing finish machining on the drum-shaped rack wheel blank subjected to shot blasting obtained in the step six to obtain the drum-shaped rack wheel.
The method described above, wherein the refining in step one is secondary refining. The invention reduces harmful elements in the 18Cr2Ni4WA alloy steel, refines structure crystal grains in the 18Cr2Ni4WA alloy steel, obtains the best comprehensive mechanical property, and ensures that the tensile strength, the bending strength, the contact strength, the plasticity and the toughness of the drum-shaped gear rail wheel are improved by smelting outside the furnace for secondary refining.
The method is characterized in that the forging ratio of the forging in the step two is 3.2-3.5, the normalizing temperature is 940-960 ℃, the tempering temperature is 640-660 ℃, the grain size of the tempered drum-shaped gear rail wheel precursor is 7 grades, and the band-shaped structure is 2 grades. The invention presses the inner hole of the drum-shaped rack wheel precursor by controlling the forging ratio, and the cast dendrite is broken, so that the longitudinal and transverse mechanical properties of the drum-shaped rack wheel precursor are obviously improved.
The method is characterized in that the contour machining and the rough machining of the tooth profile of the gear tooth in the third step are carried out by linear cutting, machining allowance is reserved, and the temperature of the aging treatment is 640-660 ℃. The invention adopts the linear cutting to leave the drum-shaped rack rail wheel tooth profile with the processing allowance, has the advantages of high processing precision and convenient operation, is convenient for subsequent processing by leaving the processing allowance, takes the processing allowance after forging into account that the processing allowance is larger and has larger processing stress, carries out aging treatment, further removes the forging residual stress and the cutting stress of mechanical processing, and is beneficial to the subsequent processing.
The method is characterized in that the milling process in the fourth step is as follows: the method comprises the steps of performing 3D modeling and three-dimensional machining simulation on a crowned rack rail wheel blank based on UGNX8.5 software to generate a workpiece machining tool track, reading in IMSPost post-processing software to generate a machine tool machining program, realizing five-axis linkage through a numerical control turning and milling composite machining center, milling the crowned rack rail wheel blank by adopting high-speed cutting with small tool consumption and rapid feeding, polishing all edge chamfers, enlarging fillets at transition positions and obtaining the milled crowned rack rail wheel blank. The invention generates the path of a workpiece processing cutter and a machine tool processing program through software, has the advantages of convenient operation and high processing precision, realizes five-axis linkage through a numerical control turning and milling composite processing center, finishes milling the drum-shaped tooth surface by adopting high-speed cutting with small tool amount quick feed, polishes all edge chamfers, enlarges the fillet of a transition part, improves the surface smoothness of a milled drum-shaped track wheel blank, eliminates the cutting stress and the processing thermal stress of the tooth surface of the milled drum-shaped track wheel blank, and thereby prolongs the service life of the drum-shaped track wheel.
The method described above is characterized in that the carburizing process in step five is performed by: carrying out deep carburization on the tooth surface of the milled drum-shaped gear rail wheel blank by adopting upper computer simulation intelligent control carburization, carrying out high-temperature tempering for four times at 660-680 ℃ after carburization is finished, carrying out oil cooling quenching at 790-810 ℃ after high-temperature tempering, cleaning after oil cooling quenching, sequentially carrying out low-temperature tempering at 190-210 ℃ and 170-190 ℃ after cleaning is finished, and carrying out liquid nitrogen cryogenic treatment at-130-110 ℃ after low-temperature tempering to obtain the carburized drum-shaped gear rail wheel blank with the carburized layer depth of 6-7 mm. The invention adopts the host computer to simulate the intelligent control of carburization, and has the advantages of convenient operation, high carburization precision and uniform carburization depth.
The method is characterized in that the shot blasting process in the sixth step is as follows: and (3) projecting the tooth surface of the carburized drum-shaped gear rail wheel blank by adopting a high-speed shot flow to obtain the shot-blasted drum-shaped gear rail wheel blank. The invention adopts the high-speed projectile for projection, so that the tooth surface of the carburized drum-shaped toothed rail wheel blank is subjected to elastic-plastic deformation to form favorable changes such as residual compressive stress, hardness strengthening, tissue thinning and the like, the anti-engagement capacity of the drum-shaped toothed rail wheel is improved, and the fatigue strength and the wear resistance of the drum-shaped toothed rail wheel are improved.
The method described above, wherein the finish machining in step seven is a finish machining of the bearing fitting through hole. The invention is convenient for the practical application of the crowned rack rail wheel by finely processing the bearing matching through hole, and can be matched with other mechanisms for use.
The method is characterized in that the yield strength of the crowned rack wheel is not less than 1080MPa, the tensile strength is not less than 1330MPa, and the impact toughness value is not less than 105J/cm2The reduction of area is not less than 52%, the hardness of the tooth surface of the drum-shaped gear rail wheel is 58-62 calculated by HRC, and the hardness of the tooth core is 36-42 calculated by HRC.
Compared with the prior art, the invention has the following advantages:
1. the crowned rack rail wheel of the invention increases the engaging contact area of the crowned rack rail wheel and the pin row through the crowned tooth surface, reduces the contact stress of the crowned rack rail wheel and the pin row, prolongs the service life of the crowned rack rail wheel, reduces the vibration during the gear transmission, ensures the transmission to be more stable, the bearing matching through hole matched with the bearing is arranged to realize rotation after being matched with the driving big gear, the application on the travelling mechanism of the fast traction high-power heavy-duty coal mining machine is realized, the high-yield and high-efficiency production requirement of a coal mine is met, the drum-shaped toothed rail wheel can still normally run when meeting horizontal bending and vertical bending changes of a working surface or suffering from sundries such as gangue and the like, and the drum-shaped toothed rail wheel can not generate excessive wear or broken teeth in a short period, the drum-shaped gear rail wheel also has the advantages of excellent unbalance loading resistance, good adaptability, stable transmission and strong bearing capacity.
2. According to the invention, UG NX8.5 software and IMSPost software are matched to obtain a processing program, then five-axis linkage is realized through a numerical control turning and milling composite processing center, a crowned rack and rail wheel blank is milled by high-speed cutting with small tool amount and rapid feeding, the tooth surface smoothness of the crowned rack and rail wheel teeth is improved, the defects of extrusion and stress concentration of the edge of the crowned rack and rail wheel teeth are avoided, the cutting stress and the processing thermal stress of the tooth surface of the milled crowned rack and rail wheel blank are eliminated, and the service life of the crowned rack and rail wheel is prolonged.
3. The invention obtains the crowned rack rail wheel by processing the 18Cr2Ni4WA alloy steel through refining, forging, normalizing, tempering, rough machining, aging treatment, milling, carburizing, shot blasting and the like, so that the crowned rack rail wheel obtains the best comprehensive mechanical property, and the yield strength, the tensile strength, the impact toughness, the reduction of area, the bending strength, the contact strength and the toughness of the crowned rack rail wheel are improved.
4. According to the invention, the upper computer is adopted to simulate intelligent control of carburization through the drum-shaped rack rail wheel, so that stable carbon concentration distribution is obtained, the drum-shaped rack rail wheel is ensured to have the carburized layer depth of 6-7 mm, the rigidity, hardness and wear resistance of the drum-shaped rack rail wheel are greatly improved, and the practical performance of the drum-shaped rack rail wheel is improved.
5. The invention improves the anti-occlusion capability of the rack rail wheel and prolongs the fatigue life of the drum-shaped rack rail wheel by carrying out shot blasting treatment on the tooth surface of the drum-shaped rack rail wheel.
6. The drum-shaped gear rail wheel has the advantages of strong bearing capacity, high transmission strength and long service life, reduces the maintenance period, reduces the labor intensity of coal mine workers, and saves the cost.
The technical solution of the present invention is further described in detail by the accompanying drawings and examples.
Drawings
FIG. 1 is a schematic diagram of the construction of a crowned rack and pinion gear of the present invention.
Fig. 2 is a sectional view a-a of fig. 1.
FIG. 3 is a sectional view taken along line B-B of FIG. 1
FIG. 4 is a diagram illustrating the use of the crowned track wheel of the present invention.
Fig. 5 is a cross-sectional view C-C of fig. 4.
Description of reference numerals:
1-a crowned rack and rail wheel; 1-a rack wheel body; 1-2-crowned teeth;
1-3-bearing fit through holes; 1-4-a linkage; 2-driving the bull gear;
3, bearing sleeves; 4, lining; 5-distance sleeve;
6, sealing the cover; 7, a bolt; 8, a bearing;
9-connecting teeth.
Detailed Description
The crowned rack wheel for a coal cutter of the present invention is described in detail by way of example 1.
Example 1
As shown in fig. 1, 2 and 3, the crowned rack wheel 1 for the coal mining machine of the embodiment includes a rack wheel main body 1-1 and a plurality of crowned teeth 1-2 arranged around the outer edge of the rack wheel main body 1-1, wherein the tooth surface of the crowned teeth 1-2 smoothly transitions to an arc crowned curved surface from the tooth surface central line to both sides to form a crowned tooth surface, the tooth surface central line is overlapped with the tooth-shaped meshing line of the crowned rack wheel 1, a bearing matching through hole 1-3 matched with a bearing is formed in the central position of the rack wheel main body 1-1, and a plurality of connecting keys 1-4 are arranged on the surface of the rack wheel main body 1-1 along the periphery of the bearing matching through hole 1-3 in a surrounding manner.
As shown in fig. 4 and 5, the usage of the crowned rack wheel of the present invention is: a large driving gear 2 provided with a bearing sleeve 3, a lining 4, a distance sleeve 5, a sealing cover 6 and a rolling bearing 8 is connected with a drum-shaped rack rail wheel 1, connecting keys 1-4 and connecting teeth 9 are matched with each other, then the large driving gear 2 and the large driving gear 1 are connected into a whole by fastening through a bolt 7, the large driving gear 2 is connected with a traction speed reducing mechanism, the output torque and the rotating speed of a traction motor are transmitted to the large driving gear 2, and the drum-shaped rack rail wheel 1 is driven to rotate and move in a translation mode on a pin row, so that a coal mining machine is driven to walk.
The method of making the crowned rail wheel of the present invention is described in detail in examples 2-4.
Example 2
The embodiment comprises the following steps:
firstly, vacuum smelting 18Cr2Ni4WA alloy steel, and then carrying out secondary refining outside a furnace to obtain a drum-shaped gear wheel precursor;
forging the precursor of the crowned rack wheel obtained in the step one, normalizing, cooling in air, and tempering to obtain a tempered precursor of the crowned rack wheel; the forging ratio of the forging is 3.5, the normalizing temperature is 960 ℃, the tempering temperature is 640 ℃, the grain size of the tempered drum-shaped gear rail precursor is 7 grades, and the band-shaped structure is 2 grades;
thirdly, performing contour machining and rough machining of the tooth profile of the gear teeth on the tempered drum-shaped rack rail wheel precursor obtained in the second step, and then performing aging treatment to obtain a drum-shaped rack rail wheel blank; the contour machining and the rough machining of the tooth profile of the gear tooth are carried out by adopting linear cutting, machining allowance is reserved, and the temperature of the aging treatment is 650 ℃;
step four, milling the crowned rack and rail wheel blank obtained in the step three to obtain a milled crowned rack and rail wheel blank; the milling process comprises the following steps: carrying out 3D modeling and three-dimensional machining simulation on the crowned rack rail wheel blank based on UG NX8.5 software to generate a workpiece machining tool track, then reading in IMSPost post-processing software to generate a machine tool machining program, then realizing five-axis linkage through a numerical control turning and milling composite machining center, milling the crowned rack rail wheel blank by adopting high-speed cutting with small tool consumption and rapid feeding, polishing all edge chamfers, enlarging a transition part fillet, and obtaining the milled crowned rack rail wheel blank;
step five, performing carburizing treatment on the milled crowned rack rail wheel blank obtained in the step four to obtain a carburized crowned rack rail wheel blank; the carburizing process comprises the following steps: carrying out deep carburization treatment on the tooth surface of the milled drum-shaped gear rail wheel blank by adopting upper computer simulation intelligent control carburization, carrying out high-temperature tempering for four times at 660 ℃ after carburization is finished, carrying out oil-cooling quenching at 800 ℃ after high-temperature tempering, cleaning after oil-cooling quenching, sequentially carrying out low-temperature tempering at 210 ℃ and 180 ℃ after cleaning, and carrying out liquid nitrogen deep cooling treatment at-130 ℃ after low-temperature tempering to obtain the carburized drum-shaped gear rail wheel blank with the carburized layer depth of 6-7 mm;
step six, shot blasting is carried out on the carburized crowned rack rail wheel blank obtained in the step five, and the shot-blasted crowned rack rail wheel blank is obtained; the shot blasting process comprises the following steps: projecting the tooth surface of the carburized drum-shaped gear rail wheel blank by adopting high-speed shot flow to obtain the shot-blasted drum-shaped gear rail wheel blank;
step seven, performing finish machining on the drum-shaped rack and rail wheel blank subjected to shot blasting obtained in the step six to obtain a drum-shaped rack and rail wheel; and the finish machining is to finish machine the mounting bearing matching holes 1-3.
Through detection, the thickness of the carburized layer of the crowned rack rail wheel of the embodiment is 6 mm-7 mm, the tooth surface carburized layer of the crowned rack rail wheel is tempered implicit martensite, a small amount of fine net-shaped carbide and a small amount of residual austenite, the tooth core part of the crowned rack rail wheel is tempered sorbite, the yield strength of the crowned rack rail wheel is 1090MPa, the tensile strength is 1360MPa, and the impact toughness value is 110J/cm2The reduction of area is 55%, the hardness of the tooth surface of the crowned rail wheel is 58-62 in HRC, and the hardness of the tooth core is 36-42 in HRC.
The drum-shaped gear rail wheel prepared by the embodiment is practically used, the service life is as long as 9 months, 750 ten thousand tons of coal are accumulated, and the running speed is 1230 kilometers.
Example 3
The embodiment comprises the following steps:
firstly, vacuum smelting 18Cr2Ni4WA alloy steel, and then carrying out secondary refining outside a furnace to obtain a drum-shaped gear wheel precursor;
forging the precursor of the crowned rack wheel obtained in the step one, normalizing, cooling in air, and tempering to obtain a tempered precursor of the crowned rack wheel; the forging ratio of the forging is 3.2, the normalizing temperature is 940 ℃, the tempering temperature is 650 ℃, the grain size of the tempered drum-shaped rail wheel precursor is 7 grades, and the band-shaped structure is 2 grades;
thirdly, performing contour machining and rough machining of the tooth profile of the gear teeth on the tempered drum-shaped rack rail wheel precursor obtained in the second step, and then performing aging treatment to obtain a drum-shaped rack rail wheel blank; the contour machining and the rough machining of the tooth profile of the gear tooth are carried out by adopting linear cutting, machining allowance is reserved, and the temperature of the aging treatment is 660 ℃;
step four, milling the crowned rack and rail wheel blank obtained in the step three to obtain a milled crowned rack and rail wheel blank; the milling process comprises the following steps: carrying out 3D modeling and three-dimensional machining simulation on the crowned rack rail wheel blank based on UG NX8.5 software to generate a workpiece machining tool track, then reading in IMSPost post-processing software to generate a machine tool machining program, then realizing five-axis linkage through a numerical control turning and milling composite machining center, milling the crowned rack rail wheel blank by adopting high-speed cutting with small tool consumption and rapid feeding, polishing all edge chamfers, enlarging a transition part fillet, and obtaining the milled crowned rack rail wheel blank;
step five, performing carburizing treatment on the milled crowned rack rail wheel blank obtained in the step four to obtain a carburized crowned rack rail wheel blank; the carburizing process comprises the following steps: carrying out deep carburization treatment on the tooth surface of the milled drum-shaped gear rail wheel blank by adopting upper computer simulation intelligent control carburization, carrying out high-temperature tempering for four times at 670 ℃ after the carburization is finished, carrying out oil-cooling quenching at 790 ℃ after the high-temperature tempering, cleaning after the oil-cooling quenching, sequentially carrying out low-temperature tempering at 200 ℃ and 190 ℃ after the cleaning is finished, and carrying out liquid nitrogen deep cooling treatment at-120 ℃ after the low-temperature tempering to obtain the carburized drum-shaped gear rail wheel blank with the carburized layer depth of 6-7 mm;
step six, shot blasting is carried out on the carburized crowned rack rail wheel blank obtained in the step five, and the shot-blasted crowned rack rail wheel blank is obtained; the shot blasting process comprises the following steps: projecting the tooth surface of the carburized drum-shaped gear rail wheel blank by adopting high-speed shot flow to obtain the shot-blasted drum-shaped gear rail wheel blank;
step seven, performing finish machining on the drum-shaped rack and rail wheel blank subjected to shot blasting obtained in the step six to obtain a drum-shaped rack and rail wheel; and the finish machining is to finish machine the mounting bearing matching hole.
Through detection, the thickness of the carburized layer of the crowned rack-and-rail wheel of the embodiment is 6 mm-7 mm, the tooth surface carburized layer of the crowned rack-and-rail wheel is tempered implicit martensite, a small amount of fine net-shaped carbide and a small amount of residual austenite, the tooth core part of the crowned rack-and-rail wheel is tempered sorbite, the yield strength of the crowned rack-and-rail wheel is 1085MPa, and the tensile strength is 1350MPa and impact toughness value of 108J/cm2The reduction of area is 52%, the hardness of the tooth surface of the crowned rail wheel is 58-62 in HRC, and the hardness of the tooth core is 36-42 in HRC.
The drum-shaped gear rail wheel prepared by the embodiment is practically used, the service life is as long as 8 months, 662 ten thousand tons of coal are accumulated, and the running speed is 1090 kilometers.
Example 4
The embodiment comprises the following steps:
firstly, vacuum smelting 18Cr2Ni4WA alloy steel, and then carrying out secondary refining outside a furnace to obtain a drum-shaped gear wheel precursor;
forging the precursor of the crowned rack wheel obtained in the step one, normalizing, cooling in air, and tempering to obtain a tempered precursor of the crowned rack wheel; the forging ratio of the forging is 3.3, the normalizing temperature is 950 ℃, the tempering temperature is 660 ℃, the grain size of the tempered drum-shaped gear rail precursor is 7 grades, and the band-shaped structure is 2 grades;
thirdly, performing contour machining and rough machining of the tooth profile of the gear teeth on the tempered drum-shaped rack rail wheel precursor obtained in the second step, and then performing aging treatment to obtain a drum-shaped rack rail wheel blank; the contour machining and the rough machining of the tooth profile of the gear tooth are carried out by adopting linear cutting, machining allowance is reserved, and the temperature of the aging treatment is 640 ℃;
step four, milling the crowned rack and rail wheel blank obtained in the step three to obtain a milled crowned rack and rail wheel blank; the milling process comprises the following steps: carrying out 3D modeling and three-dimensional machining simulation on the crowned rack rail wheel blank based on UG NX8.5 software to generate a workpiece machining tool track, then reading in IMSPost post-processing software to generate a machine tool machining program, then realizing five-axis linkage through a numerical control turning and milling composite machining center, milling the crowned rack rail wheel blank by adopting high-speed cutting with small tool consumption and rapid feeding, polishing all edge chamfers, enlarging a transition part fillet, and obtaining the milled crowned rack rail wheel blank;
step five, performing carburizing treatment on the milled crowned rack rail wheel blank obtained in the step four to obtain a carburized crowned rack rail wheel blank; the carburizing process comprises the following steps: carrying out deep carburization treatment on the tooth surface of the milled drum-shaped gear rail wheel blank by adopting upper computer simulation intelligent control carburization, carrying out high-temperature tempering for four times at 680 ℃ after carburization is finished, carrying out oil-cooling quenching at 810 ℃ after high-temperature tempering, cleaning after oil-cooling quenching, sequentially carrying out low-temperature tempering at 190 ℃ and 170 ℃ after cleaning is finished, and carrying out liquid nitrogen deep cooling treatment at-110 ℃ after low-temperature tempering to obtain the carburized drum-shaped gear rail wheel blank with the carburized layer depth of 6-7 mm;
step six, shot blasting is carried out on the carburized crowned rack rail wheel blank obtained in the step five, and the shot-blasted crowned rack rail wheel blank is obtained; the shot blasting process comprises the following steps: projecting the tooth surface of the carburized drum-shaped gear rail wheel blank by adopting high-speed shot flow to obtain the shot-blasted drum-shaped gear rail wheel blank;
step seven, performing finish machining on the drum-shaped rack and rail wheel blank subjected to shot blasting obtained in the step six to obtain a drum-shaped rack and rail wheel; and the finish machining is to finish machine the mounting bearing matching hole.
Through detection, the thickness of the carburized layer of the drum-shaped rack and rail wheel of the embodiment is 6mm to 7mm, the tooth surface carburized layer of the drum-shaped rack and rail wheel is tempered implicit martensite, a small amount of fine meshed carbide and a small amount of residual austenite, the tooth core part of the drum-shaped rack and rail wheel is tempered sorbite, the yield strength of the drum-shaped rack and rail wheel is 1080MPa, the tensile strength is 1330MPa, and the impact toughness value is 105J/cm2The reduction of area is 52%, the hardness of the tooth surface of the crowned rail wheel is 58-62 in HRC, and the hardness of the tooth core is 36-42 in HRC.
The drum-shaped gear rail wheel prepared by the embodiment is practically used, the service life is as long as 8 months, 653 ten thousand tons of coal are accumulated, and the running speed is 1026 kilometers.
The above description is only for the preferred embodiment of the present invention, and is not intended to limit the present invention in any way. Any simple modification, change and equivalent changes of the above embodiments according to the technical essence of the invention are still within the protection scope of the technical solution of the invention.
Claims (10)
1. The drum-shaped gear rail wheel for the coal mining machine is characterized in that the drum-shaped gear rail wheel (1) comprises a gear rail wheel main body (1-1) and a plurality of drum-shaped teeth (1-2) arranged on the outer edge of the gear rail wheel main body (1-1) in a surrounding mode, the tooth surfaces of the drum-shaped teeth (1-2) are smoothly transited to arc drum-shaped curved surfaces from tooth surface central lines to two sides to form drum-shaped tooth surfaces, the tooth surface central lines are overlapped with tooth-shaped meshing lines of the drum-shaped gear rail wheel (1), a bearing matching through hole (1-3) matched with a bearing is formed in the center of the gear rail wheel main body (1-1), and a plurality of connecting keys (1-4) are arranged on the surface of the gear rail wheel main body (1-1) in a surrounding mode along the periphery of the bearing matching through hole (1.
2. A method of making a crowned rail wheel for a coal mining machine as claimed in claim 1, characterized in that the method comprises the steps of:
firstly, vacuum smelting 18Cr2Ni4WA alloy steel, and then refining to obtain a drum-shaped gear wheel precursor;
forging the precursor of the crowned rack wheel obtained in the step one, normalizing, cooling in air, and tempering to obtain a tempered precursor of the crowned rack wheel;
thirdly, performing contour machining and rough machining of the tooth profile of the gear teeth on the tempered drum-shaped rack rail wheel precursor obtained in the second step, and then performing aging treatment to obtain a drum-shaped rack rail wheel blank;
step four, milling the crowned rack and rail wheel blank obtained in the step three to obtain a milled crowned rack and rail wheel blank;
step five, performing carburizing treatment on the milled crowned rack rail wheel blank obtained in the step four to obtain a carburized crowned rack rail wheel blank;
step six, shot blasting is carried out on the carburized crowned rack rail wheel blank obtained in the step five, and the shot-blasted crowned rack rail wheel blank is obtained;
and step seven, performing finish machining on the drum-shaped rack wheel blank subjected to shot blasting obtained in the step six to obtain the drum-shaped rack wheel.
3. The method according to claim 2, wherein the refining in step one is secondary refining.
4. The method according to claim 2, wherein the forging ratio of the forging in the second step is 3.2-3.5, the temperature of the normalizing treatment is 940-960 ℃, the temperature of the tempering treatment is 640-660 ℃, the grain size of the tempered drum-shaped gear rail precursor is 7 grades, and the band-shaped structure is 2 grades.
5. The method according to claim 2, wherein the outline machining and the rough gear tooth profile machining in the third step are performed by wire cutting with machining allowance, and the temperature of the aging treatment is 640-660 ℃.
6. The method according to claim 2, wherein the milling in step four is performed by: the method comprises the steps of performing 3D modeling and three-dimensional machining simulation on a crowned rack rail wheel blank based on UG NX8.5 software to generate a workpiece machining tool track, reading in IMSPost post-processing software to generate a machine tool machining program, realizing five-axis linkage through a numerical control turning and milling composite machining center, milling the crowned rack rail wheel blank by adopting high-speed cutting with small tool consumption and rapid feeding, polishing all edge chamfers, enlarging fillets at transition positions and obtaining the milled crowned rack rail wheel blank.
7. The method of claim 2, wherein the carburizing process in step five is performed by: carrying out deep carburization on the tooth surface of the milled drum-shaped gear rail wheel blank by adopting upper computer simulation intelligent control carburization, carrying out high-temperature tempering for four times at 660-680 ℃ after carburization is finished, carrying out oil cooling quenching at 790-810 ℃ after high-temperature tempering, cleaning after oil cooling quenching, sequentially carrying out low-temperature tempering at 190-210 ℃ and 170-190 ℃ after cleaning is finished, and carrying out liquid nitrogen cryogenic treatment at-130-110 ℃ after low-temperature tempering to obtain the carburized drum-shaped gear rail wheel blank with the carburized layer depth of 6-7 mm.
8. The method according to claim 2, wherein the shot peening process in the sixth step is: and (3) projecting the tooth surface of the carburized drum-shaped gear rail wheel blank by adopting a high-speed shot flow to obtain the shot-blasted drum-shaped gear rail wheel blank.
9. Method according to claim 2, characterized in that the finishing in step seven is a finishing of the bearing-fitting through-hole (1-3).
10. The method of claim 2, wherein the yield strength of the crowned rail wheel is no less than 1080MPa, the tensile strength is no less than 1330MPa, and the impact toughness value is no less than 105J/cm2The reduction of area is not less than 52%, the hardness of the tooth surface of the drum-shaped gear rail wheel is 58-62 calculated by HRC, and the hardness of the tooth core is 36-42 calculated by HRC.
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