CN112247475A - Repairing, processing and remanufacturing technology for large-scale equipment oil cylinder - Google Patents
Repairing, processing and remanufacturing technology for large-scale equipment oil cylinder Download PDFInfo
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- CN112247475A CN112247475A CN202011094741.2A CN202011094741A CN112247475A CN 112247475 A CN112247475 A CN 112247475A CN 202011094741 A CN202011094741 A CN 202011094741A CN 112247475 A CN112247475 A CN 112247475A
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- oil cylinder
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- 238000005516 engineering process Methods 0.000 title claims abstract description 11
- 238000000227 grinding Methods 0.000 claims abstract description 46
- 239000010720 hydraulic oil Substances 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 30
- 239000003921 oil Substances 0.000 claims abstract description 22
- 230000008439 repair process Effects 0.000 claims abstract description 21
- 238000005096 rolling process Methods 0.000 claims abstract description 17
- 230000008569 process Effects 0.000 claims abstract description 11
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 10
- 239000010959 steel Substances 0.000 claims abstract description 10
- 238000007789 sealing Methods 0.000 claims description 23
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 18
- 229910052804 chromium Inorganic materials 0.000 claims description 17
- 239000011651 chromium Substances 0.000 claims description 17
- 238000007747 plating Methods 0.000 claims description 11
- 230000009471 action Effects 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 230000006835 compression Effects 0.000 claims description 3
- 238000007906 compression Methods 0.000 claims description 3
- 238000009713 electroplating Methods 0.000 claims description 3
- 230000001105 regulatory effect Effects 0.000 claims description 3
- 230000008859 change Effects 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 10
- 238000005265 energy consumption Methods 0.000 abstract description 3
- 239000000725 suspension Substances 0.000 description 8
- 238000001125 extrusion Methods 0.000 description 5
- 238000003825 pressing Methods 0.000 description 5
- 238000005299 abrasion Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 208000034189 Sclerosis Diseases 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
Images
Classifications
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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
- B23P6/00—Restoring or reconditioning objects
-
- 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
Abstract
The invention discloses a large-scale equipment oil cylinder repairing, processing and remanufacturing technology, which comprises the following specific steps: the first step is as follows: repairing the cylinder barrel by adopting a boring, grinding and rolling integrated process, determining the size of a bored hole, and removing an original hardened layer; the second step is that: then grinding the inner wall of the cylinder barrel to improve the surface smoothness; the third step: and finally, rolling and processing to recover the original surface hardness of the inner wall of the cylinder barrel. The hydraulic oil cylinder designed by the invention has great significance in repair, and the key point is to have a good repair process, so that the cost of an enterprise can be saved, the urgent need of production can be met, the production cost can be reduced, the use of steel can be saved, the energy consumption can be reduced, and the energy can be saved and the consumption can be reduced.
Description
Technical Field
The invention relates to the technical field of oil cylinders, in particular to a technology for repairing, processing and remanufacturing an oil cylinder of large equipment.
Background
The hydraulic oil cylinder is an important part in engineering machinery and has the functions of transmitting power, finishing operation action, improving operation efficiency and the like. Therefore, the quality of the hydraulic oil cylinder directly determines the overall quality of the engineering machinery, so that the good quality of the hydraulic oil cylinder is ensured.
Hydraulic rams are durable components that are relatively complex to manufacture. Meanwhile, a large amount of steel is consumed in manufacturing of the hydraulic oil cylinder, so most enterprises hope to repair and utilize the hydraulic oil cylinder for many times. Because the difficulty of repairing the oil cylinder is increased compared with the difficulty of manufacturing the oil cylinder, the service life of the oil cylinder is greatly different from the service life of the oil cylinder due to insufficient attention of enterprises.
The repairing process of the hydraulic oil cylinder is described below by taking the front and rear suspension for a large mine car as an example.
About 1.2 million large-scale mine cars exist in the country, each car averagely consumes about 1 suspension, each suspension is about 3 tons, steel consumption is 3.6 ten thousand tons if all new cars are replaced, steel can be repaired and reused if 50% -70%, steel is saved by 1.8-2.5 ten thousand tons each year, and the suspension repair significance is great. The suspension is a special hydraulic oil cylinder which reciprocates for a long time, the manufacturing difficulty is very high, the quality is slightly defective, and the service life and the performance can not meet the requirements of equipment. The suspension failure is mainly shown as the abrasion of each reciprocating part and the sealing failure of a rubber sealing element under the normal condition; suspension leakage is caused, the bearing capacity is reduced, and replacement is required; most enterprises hang the sealing member for the suspension and then continue to use, and the result is not ideal, and the sealing member leaks again after being used for a short time and is forced to be changed again. Therefore, the method has been tracked and researched for many years, and a set of effective repair process is explored; therefore, the invention provides a repairing, processing and remanufacturing technology for an oil cylinder of large equipment, and aims to solve the problems.
Disclosure of Invention
The invention aims to provide a technology for repairing, processing and remanufacturing an oil cylinder of large equipment, so as to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme:
the utility model provides a large equipment hydro-cylinder repairing and processing and refabrication technique, includes hydro-cylinder repairing and processing and refabrication technique, the concrete step of hydro-cylinder repairing and processing is as follows:
the first step is as follows: repairing the cylinder barrel by adopting a boring, grinding and rolling integrated process, determining the size of a bored hole, and removing an original hardened layer;
the second step is that: then grinding the inner wall of the cylinder barrel to improve the surface smoothness;
the third step: finally, rolling and processing are carried out to recover the original surface hardness of the inner wall of the cylinder barrel;
the fourth step: the piston rod is repaired, firstly, the piston rod is subjected to chromium removal treatment, the chromium removal cannot be carried out in an electroplating bath, but grinding processing is carried out in a grinding machine, the grinding speed in the grinding processing is 15% -25% faster than the normal grinding speed, the grinding feed amount is 40% -50% smaller, and the chromium coating is completely removed in a grinding mode;
the fifth step: then carrying out chromium plating treatment, wherein the chromium plating layer is 110-130% of the original design, and carrying out grinding processing again after the chromium plating is finished to finish the processing of the piston rod;
the specific steps of the oil cylinder remanufacturing technology are as follows:
the first step is as follows: the cylinder, the piston rod changes than former design size after above-mentioned processing, the cylinder internal diameter will be greater than the diameter of piston rod, consequently, the sealing member that former design chooseed for use can not directly be used mechanically, must adjust the compression volume of sealing member, to this have two kinds of methods, one, preferentially adopt, choose former design sealing member for use, increase supplementary sealed in the sealing member slot, this kind of method is applicable to the interior warp of cylinder, the piston rod diameter increases or reduces the use within 1 millimeter, and can maintain many times, the expense is lower, two, customize special sealing member, it is great to change when cylinder internal diameter and piston rod diameter size: when the thickness is 1-2 mm, a customized sealing element needs to be configured, and the method is high in repair cost and does not need to be adopted as much as possible;
the second step is that: after the whole hydraulic oil cylinder is repaired, the service life of the hydraulic oil cylinder is 120 percent of that of an original piece through field use and examination, the output performance, the motion trail and the like are consistent with those of the original piece, and the performance requirements of the whole equipment are met;
the third step: the hydraulic oil cylinder is not a consumable product which is discarded once, but a durable product which can be repaired repeatedly, but the repair frequency of the hydraulic oil cylinder is strictly and reasonably regulated, because the fatigue damage of steel cannot be repaired, the hydraulic oil cylinder is actually a pressure container under the action of high-pressure oil, the cylinder barrel and the piston rod can be subjected to fatigue damage, in practice, the repair frequency of the hydraulic oil cylinder of the engineering machinery with large load is found to be 4 times most reasonable, and the repair frequency of the hydraulic oil cylinder of other mechanical machinery with small load can be 8-10 times.
As a further scheme of the invention: in the first step of the oil cylinder repairing and processing, the processing amount of the boring hole is 0.1-0.2 mm.
As a still further scheme of the invention: in the fourth step of the oil cylinder repairing processing, the grinding speed in the grinding processing is 20% faster than the normal grinding speed.
As a still further scheme of the invention: in the fourth step of the oil cylinder repairing processing, the grinding feed amount is small by 50%.
As a still further scheme of the invention: in the fifth step of the oil cylinder repairing and processing, the thickness of the chromium plating layer is 120% of the original design.
Compared with the prior art, the invention has the beneficial effects that: the hydraulic oil cylinder designed by the invention has great significance in repair, and the key point is to have a good repair process, so that the cost of an enterprise can be saved, the urgent need of production can be met, the production cost can be reduced, the use of steel can be saved, the energy consumption can be reduced, and the energy can be saved and the consumption can be reduced.
Drawings
Fig. 1 is a schematic structural diagram of a special grinding head for repairing, processing and remanufacturing a large-scale equipment oil cylinder.
Fig. 2 is a schematic structural diagram of a special rolling head for repairing, processing and remanufacturing technology of a large-scale equipment oil cylinder.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-2, in an embodiment of the present invention, a repairing, processing and remanufacturing technology for a large-scale equipment cylinder,
1. repairing the cylinder barrel: the method is carried out by adopting a boring, grinding and rolling integrated process.
According to the inner diameter abrasion condition of the cylinder barrel, the size of the boring hole is determined, the machining amount of the general boring hole is small and about 0.1-0.2 mm, and the original hardened layer is removed.
The inner wall of the cylinder barrel is ground to improve the surface finish, the inner circle of the general cylinder barrel is ground by an inner grinder or a honing machine, but the formed cylinder barrel of the oil cylinder is difficult to ensure the processing integrity and the processing precision by the method, so that the traditional grinding mode is changed, a common lathe is matched with a specially designed grinding head to carry out grinding, the cylinder barrel is driven by the lathe to rotate at a high speed, the special grinding head is arranged on a follow-up rest of the lathe and can adjust the grinding amount and the rotating speed of the grinding head according to requirements, and the inner diameter of the grinding cylinder barrel is fast and good by the method (see figure 1).
And finally, rolling and pressing to recover the original surface hardness of the inner wall of the cylinder barrel, wherein the traditional rolling and pressing process is realized by using a rolling head, is only suitable for the cylinder barrel processing of a through hole, and the cylinder barrel with one sealed side can not be rolled, and the rolling and pressing process is also realized by using a common lathe and matching a specially designed rolling wheel, so that the rolling and pressing quality is higher than that of the traditional rolling and pressing head, and the surface hardness meets the design requirement (see figure 2).
The roll extrusion is the process of hardening to the metal surface, and traditional roll extrusion is overhead to have a plurality of rollers to roll extrusion to the surface along with the work piece rotation, and the roll extrusion orbit has coincidence and discontinuous phenomenon, and the coincidence part can make the metal surface excessive hardening press, and the discontinuous part can make the surface not have the sclerosis layer, consequently, traditional roll extrusion's surface quality is inhomogeneous, directly influences the cylinder life-span. The rolling track of the roller rolling processing is continuous and stable without superposition, so the surface hardening quality is uniform, and the service life of the cylinder barrel is long. The cylinder barrel is basically restored to the same quality level as a new piece after being processed by the procedures, and the cylinder barrel is repaired as new.
2. And (3) repairing the piston rod: the piston rod is firstly subjected to dechroming treatment, dechroming cannot be performed in an electroplating bath, grinding processing is performed on a grinding machine, the grinding speed during grinding processing is 20% higher than the normal grinding speed, and the grinding feeding amount is 50% smaller. Until the chromium coating is completely ground off. Then carrying out chromium plating treatment, wherein the thickness of the chromium plating layer is 120 percent of the original design. And grinding again after the chromium plating is finished until the surface of the piston rod meets the design requirement.
3. The cylinder barrel and the piston rod are subjected to the treatment and then are changed from the original design size, the inner diameter of the cylinder barrel needs to be larger, and the diameter of the piston rod needs to be smaller. Therefore, the sealing element selected by the original design can not be directly applied, and the compression amount of the sealing element must be adjusted. One method is preferably adopted, the originally designed sealing element is selected, and the auxiliary sealing element is additionally arranged in the groove of the sealing element, so that the method is suitable for the use of the diameter of the inner diameter and the diameter of the piston rod of the cylinder barrel within 1 mm, can be maintained for many times, and is low in cost. Secondly, customizing a special sealing element, and when the size of the inner diameter of the cylinder barrel and the diameter of the piston rod are changed greatly: when the diameter is 1-2 mm, a customized sealing element needs to be configured, and the method has high repair cost and does not need to be adopted as much as possible.
4. After the whole hydraulic oil cylinder is repaired, the service life of the hydraulic oil cylinder is 120% of that of an original piece through field use and examination, the output performance, the motion trail and the like are consistent with those of the original piece, and the performance requirements of the whole equipment are met.
5. The hydraulic oil cylinder is not a consumable product which is discarded once, but a durable product which can be repaired repeatedly. But the repair frequency of the hydraulic oil cylinder is strictly and reasonably regulated, and because the fatigue damage of steel cannot be repaired, the hydraulic oil cylinder is actually a pressure container under the action of high-pressure oil, the cylinder barrel and the piston rod can be subjected to fatigue damage. In practice, the repair times of the hydraulic oil cylinder of the heavy-load engineering machinery are found to be most reasonable 4 times, and the repair times of the hydraulic oil cylinder of other small-load engineering machinery can be 8 times or more.
The working principle of the invention is as follows:
the hydraulic oil cylinder designed by the invention has great significance in repair, and the key point is to have a good repair process, so that the cost of an enterprise can be saved, the urgent need of production can be met, the production cost can be reduced, the use of steel can be saved, the energy consumption can be reduced, and the energy can be saved and the consumption can be reduced.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (5)
1. The utility model provides a large equipment hydro-cylinder repairing and processing and refabrication technique, includes hydro-cylinder repairing and processing and refabrication technique, its characterized in that, the concrete step of hydro-cylinder repairing and processing is as follows:
the first step is as follows: repairing the cylinder barrel by adopting a boring, grinding and rolling integrated process, determining the size of a bored hole, and removing an original hardened layer;
the second step is that: then grinding the inner wall of the cylinder barrel to improve the surface smoothness;
the third step: finally, rolling and processing are carried out to recover the original surface hardness of the inner wall of the cylinder barrel;
the fourth step: the piston rod is repaired, firstly, the piston rod is subjected to chromium removal treatment, the chromium removal cannot be carried out in an electroplating bath, but grinding processing is carried out in a grinding machine, the grinding speed in the grinding processing is 15% -25% faster than the normal grinding speed, the grinding feed amount is 40% -50% smaller, and the chromium coating is completely removed in a grinding mode;
the fifth step: then carrying out chromium plating treatment, wherein the chromium plating layer is 110-130% of the original design, and carrying out grinding processing again after the chromium plating is finished to finish the processing of the piston rod;
the specific steps of the cylinder remanufacturing technology are as follows:
the first step is as follows: the cylinder, the piston rod changes than former design size after above-mentioned processing, the cylinder internal diameter will be greater than the diameter of piston rod, consequently, the sealing member that former design chooseed for use can not directly be used mechanically, must adjust the compression volume of sealing member, to this have two kinds of methods, one, preferentially adopt, choose former design sealing member for use, increase supplementary sealed in the sealing member slot, this kind of method is applicable to the interior warp of cylinder, the piston rod diameter increases or reduces the use within 1 millimeter, and can maintain many times, the expense is lower, two, customize special sealing member, it is great to change when cylinder internal diameter and piston rod diameter size: when the thickness is 1-2 mm, a customized sealing element needs to be configured, and the method is high in repair cost and does not need to be adopted as much as possible;
the second step is that: after the whole hydraulic oil cylinder is repaired, the service life of the hydraulic oil cylinder is 120 percent of that of an original piece through field use and examination, the output performance, the motion trail and the like are consistent with those of the original piece, and the performance requirements of the whole equipment are met;
the third step: the hydraulic oil cylinder is not a consumable product which is discarded once, but a durable product which can be repaired repeatedly, but the repair frequency of the hydraulic oil cylinder is strictly and reasonably regulated, because the fatigue damage of steel cannot be repaired, the hydraulic oil cylinder is actually a pressure container under the action of high-pressure oil, the cylinder barrel and the piston rod can be subjected to fatigue damage, in practice, the repair frequency of the hydraulic oil cylinder of the engineering machinery with large load is found to be 4 times most reasonable, and the repair frequency of the hydraulic oil cylinder of other mechanical machinery with small load can be 8-10 times.
2. The oil cylinder repairing and processing step as claimed in claim 1, wherein in the first step, the processing amount of the boring hole is 0.1-0.2 mm.
3. The cylinder repairing process according to claim 1, wherein in said fourth step, a grinding speed in the grinding process is 20% faster than a normal grinding speed.
4. A cylinder reconditioning process step as recited in claim 1, wherein said fourth step has a grinding feed of less than 50%.
5. The cylinder repairing process according to claim 1, wherein in the fifth step, the thickness of the chrome plating layer is 120% of the original design.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011094741.2A CN112247475A (en) | 2020-10-14 | 2020-10-14 | Repairing, processing and remanufacturing technology for large-scale equipment oil cylinder |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202011094741.2A CN112247475A (en) | 2020-10-14 | 2020-10-14 | Repairing, processing and remanufacturing technology for large-scale equipment oil cylinder |
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