CN113843584A - 低温环境下不易脆断的紧固件的加工方法 - Google Patents
低温环境下不易脆断的紧固件的加工方法 Download PDFInfo
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Abstract
本发明提供了一种低温环境下不易脆断的紧固件的加工方法,适合高寒地区,主要包括温镦、热处理、滚丝和表面处理几个过程。本发明提供的方法可以在冷镦法的基础上进行改进,能加工冷镦法不能加工的在低温情况下仍有良好性能的中、高强度金属及合金金属材料。本发明提供的无切屑丝纹滚压方法、先退火再淬火最后高温回火的处理方法和二次磷化表面处理等方法可以保证紧固件内部于金属纤维的连续性,在低温环境下,可以有效的抵消螺纹受力产生的应力集中,能产生产生二次硬化效应,保证低温环境下的综合力学强度,保证紧固件在低温环境下仍具有良好耐腐蚀特性,同时可以避免冷脆引起的延迟断裂。
Description
技术领域
本发明属于轨道交通用紧固件的制造领域,尤其涉及一种低温环境下不易脆断的紧固件的加工方法。
背景技术
轨道交通用用紧固件主要包括螺栓、螺钉、螺母和螺柱,紧固件的断裂失效是影响车辆安全运行的重大隐患。
诱发材料脆断的4个因素是材质不良、低温、加工工艺不佳导致的切口隐患和高速加载。在实际的使用工况中,低温我们是无法控制的,取决与高寒地区气候的变化,高速加载取决于高寒地区轨道交通行业的实际作业需求。作为高寒地区轨道交通设备使用的紧固件来说,一方面,需要选用低温环境下,仍然具有耐冲击、高强度的原材料,而普通的冷镦法无法加工这样的材质;另一方面,优化加工工艺控制产品加工出现的切口、裂纹和划痕,成为影响产品低温性能的重要因素,而现有的紧固件加工工艺对切口裂纹和划痕的控制并没有得到足够的重视;同时,需要优化热处理工艺,由此消除低温环境带来的延迟断裂的隐患;再者,也需要加强紧固件表面处理工艺,以保证在低温环境下,表面处理层对紧固件仍有很好的防护效果。
发明内容
基于上述问题和要求,本发明是在传统的“冷镦-滚丝-热处理-表面处理”工艺基础上,进行改进,提供了一种低温环境下不易脆断的紧固件的加工方法,包括以下过程:
温镦:选择线材盘条,下料切成所需胚料,胚料通过高频加热装置逐步加热到所需温度,再送入镦机,进行温锻、两次冲模挤压至成型;
热处理:将上述过程得到的胚件,在保护气氛下,先在热处理炉中加热并炉冷至常温进行退火处理,再次将胚料加热到奥氏体化温度淬火处理、最后高温回火一段时间后炉冷至常温;
滚丝:将上述过程所得胚件精细机加工至所需尺寸后,送入滚丝机进行无切屑螺纹滚压;
表面处理:除锈、喷丸表面处理后进行清洗、在磷酸盐和氟化钠为主要成分的槽液中进行磷化处理,磷化处理后加热保温去氢,即得到本发明所述方法制得的紧固件。
优选地、所述盘条材质为铜、铝合金、不锈钢、合金钢、钛合金等中的一种,所述下料切刀为圆切刀下料,所述高频加热装置加热温度为450℃-650℃,所述冲模的冲压速度为4-5mm/s,所述冲模模具是对冷镦模具进行调整优化制得:将模腔孔径尺寸放大0.15mm-0.25mm,通过激光相变硬化对模具表面进行处理。
优选地、所述保护气氛为甲醇和氮气的混合气体,所述退火处理的加热温度为800-850℃,保温40-60min,所述奥氏体化温度温度为890℃-950,保温30-50min,所述高温回火温度为545-640℃,持续90-120min。
优选地、所述滚丝压力为31-35kN,滚压圆周速度是18-27m/min。
优选地、所述磷化处理采用二次磷化处理方法,具体过程为:第一次预磷化处理7-10min后,将胚件取出,在酸溶液中浸泡酸洗1-5min,再高压冲洗干净进行第二次磷化30-40min,磷化温度为85-95℃;所述保温去氢温度为90-110℃,持续6-10h。
本发明的有益效果在于:
1、本发明提供的方法可以在冷镦法的基础上进行改进,通过增加高频加热装置和对模具改造,变成适合温镦法的加工设备,使其能加工冷镦法不能加工的在低温情况下仍有良好性能的中、高强度金属及合金金属材料。该改造能节约成本,具有良好的适用性。
2、将下料切刀改为圆切刀,可以减少下料时产生的切断撕裂,避免减少后续加工出现切口。相比传统的削切攻丝,本发明的无切屑的丝纹滚压方法可以保证紧固件内部于金属纤维的连续性,使紧固件表层金属发生体积位移,丝纹更加紧密,没有传统的削切攻丝产生的切口和细小裂纹,在低温环境下,仍然具有良好的抗疲劳强度。同时,本发明先进行热处理再滚丝,可以保证金属纤维形成的流线不被破坏,保留了滚丝产生的应力层,在低温环境下,可以有效的抵消丝纹受力产生的应力集中。
3、本发明提供的先退火、再淬火最后高温回火的处理方法,能产生产生二次硬化效应,保证低温环境下的抗拉强度,降低延迟断裂的几率。磷化处理适合高强度的紧固件,本发明提供的二次磷化表面处理方法,第一次磷化处理后,酸洗去杂质和不牢固的磷化层,使第二次的磷化得到的磷化膜和紧固件的结合力大大加强,能在不被改变丝纹整体形态及走势情况下增加磷化膜厚度,保证紧固件在低温环境下仍具有良好耐腐蚀特性。同时磷化处理后的保温去氢,可以有效避免氢脆引起的延迟断裂。
具体实施方式
以下通过本发明提供的方法制造的一种轨道交通用螺栓为例,和传统的“冷镦-滚丝-热处理-表面处理”方法制造的螺栓相比较,进一步阐述本发明。
对比例1:
传统的冷镦法无法加工高强度的钢材料,因此选用一般低碳的冷镦钢材料。图纸尺寸与实施例保持一致,采用现有工序制造:下料—冷镦—机加工—削切攻丝—淬火热处理—水冷—打磨清洗—烘干—喷油上漆。
实施例1:
以本发明提供的方法,选用高强度、韧性好同时具有一定可塑性的30CrNiMo8调质钢为原材料,用到的主要设备有:温度可控的电阻加热装置、镦机、无心外圆磨床、喷丸机、滚丝机、热处理炉、盐浴淬火炉、回火炉和磷化槽等。模具是在原有冷镦法所用的模具的基础上,将模腔孔径尺寸放大0.2mm,通过激光相变硬化对模具表面进行处理,使其表面硬度得到提升,模具用润滑剂是耐氧化的参杂二硫化钼和氧化硼的液体石蜡。
将30CrNiMo8调质钢盘条用圆切刀下料切成所需胚料,胚料通过电阻加热装置逐步加热到610℃,再送入镦机,进行温锻、两次冲模挤压至成型,冲压速度为控制在4mm/s。将所得到的胚件,在甲醇和氮气的混合气体的保护气氛下,先在热处理炉中加热到820℃,保温45min后炉冷至常温进行退火处理,再次将胚料在盐浴淬火炉中加热到奥氏体化温度910℃,保温40min后进行淬火处理,最后在回火炉575℃高温回火100min后炉冷至常温。将热处理后的胚件用无心外圆磨床等设备精细机加工至所需尺寸后送入滚丝机,在32kN的滚丝压力和24m/min滚压圆周速度作用下进行无切屑丝纹滚压。热后将所得胚件除锈、用喷丸机进行喷丸表面处理,清洗干净,在磷酸盐和氟化钠为主要成分的槽液中进行磷化处理,在87℃下,第一次预磷化处理7min后,将胚件取出,在酸溶液中浸泡酸洗4min,再高压冲洗干净进行第二次磷化35min,磷化处理后加热到95℃,保温8h去氢,即得到本发明所述方法制得的能改善低温环境下脆断机率的轨道交通用螺栓。
紧固件性能测试方式:根据GJB715.23A-2008的试验方式,测试抗拉强度和屈服强度,根据GJB715.26A-2015测试剪切破坏载荷,根据GJB715.30A-2002测试抗拉伸疲劳次数。
常温25℃环境下,对比例1和实施例1的紧固件按上述标准进行性能测试。
低温测试:向保温箱里充液氮来制造-90℃低温环境,按同样的方式对实施例1和对比例1的紧固件进行性能测试。
常温和低温测试其结果均以多个样品数据取平均值,见下表1。
表1:
由上表1可知,实施例的螺栓其综合力学性能远超对比例的普通螺栓,在-90℃低温环境下,本发明实施例中的螺栓,其综合力学性能下降幅度远低于对比例中的普通螺栓。
耐延迟断裂性能测试:本发明提供的一种低温环境下不易脆断的紧固件的加工方法制得的合格螺栓,在高寒地区正常使用15个月后替换下来作为测试样品组A,对比例1提供的螺栓在同样高寒地区环境下大气暴露15个月后作为对比测试样品组B,对样品进行慢应变速率拉伸试验,其结果见下表2。
表2:
从上表2可知,对比B组,A组式样在测试中均未发生断裂,具有良好的耐延迟断裂性能。
上述依据本发明为启示,通过上述的说明内容,相关工作人员完全可以在不偏离本项发明技术思想的范围内,进行多样的变更以及修改。本项发明的技术性范围并不局限于说明书上的内容,必须要根据权利要求范围来确定其技术性范围。
Claims (6)
1.一种低温环境下不易脆断的紧固件的加工方法,其特征在于,包括以下过程:
(1)温镦:选择线材盘条,下料切成所需胚料,胚料逐步加热到所需温度,再送入镦机,进行温锻、两次冲模挤压至成型;
(2)热处理:将过程(1)得到的胚件,在保护气氛下,进行退火处理,再将胚料加热到奥氏体化温度淬火处理、最后高温回火一段时间后炉冷至常温;
(3)滚丝:将过程(2)所得胚件精细机加工至所需尺寸后,送入滚丝机进行无切屑螺纹滚压;
(4)表面处理:除锈、喷丸表面处理后进行清洗、在磷酸盐和氟化钠为主要成分的槽液中进行磷化处理,磷化处理后加热保温去氢,即得到紧固件。
2.根据权利要求1所述的一种低温环境下不易脆断的紧固件的加工方法,其特征在于,过程(1)中:所述盘条材质为铜、铝合金、不锈钢、合金钢、钛合金中的一种,所述下料切刀为圆切刀下料,采用高频加热装置逐步加热至450℃-650℃,所述冲模的冲压速度为4-5mm/s。
3.根据权利要求2所述的一种低温环境下不易脆断的紧固件的加工方法,其特征在于,所述冲模模具是对冷镦模具进行调整优化制得:将模腔孔径尺寸放大0.15mm-0.25mm,通过激光相变硬化对模具表面进行处理。
4.根据权利要求1所述的一种低温环境下不易脆断的紧固件的加工方法,其特征在于,过程(2)中:所述保护气氛为甲醇和氮气的混合气体,所述在热处理炉中进行退火处理,退火温度为800-850℃,保温40-60min,所述奥氏体化温度温度为890℃-950,保温30-50min,所述高温回火温度为545-640℃,持续90-120min。
5.根据权利要求1所述的一种低温环境下不易脆断的紧固件的加工方法,其特征在于,过程(3)中:所述滚丝压力为31-35kN,滚压圆周速度是18-27m/min。
6.根据权利要求1所述的一种低温环境下不易脆断的紧固件的加工方法,其特征在于,过程(4)中:所述磷化处理采用二次磷化处理方法,具体过程为:第一次预磷化处理7-10min后,将胚件取出,在酸溶液中浸泡酸洗1-5min,再高压冲洗干净进行第二次磷化30-40min,磷化温度为85-95℃;所述保温去氢温度为90-110℃,持续6-10h。
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