CN114657555A - Shield tunneling machine hob ring remanufacturing method - Google Patents
Shield tunneling machine hob ring remanufacturing method Download PDFInfo
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- CN114657555A CN114657555A CN202210285878.9A CN202210285878A CN114657555A CN 114657555 A CN114657555 A CN 114657555A CN 202210285878 A CN202210285878 A CN 202210285878A CN 114657555 A CN114657555 A CN 114657555A
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- 238000000034 method Methods 0.000 title claims abstract description 33
- 230000005641 tunneling Effects 0.000 title claims description 17
- 239000000843 powder Substances 0.000 claims abstract description 115
- 238000005253 cladding Methods 0.000 claims abstract description 72
- 238000004372 laser cladding Methods 0.000 claims abstract description 29
- 238000001514 detection method Methods 0.000 claims abstract description 14
- 239000010720 hydraulic oil Substances 0.000 claims abstract description 5
- 238000012216 screening Methods 0.000 claims abstract description 4
- 238000003466 welding Methods 0.000 claims abstract description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical group [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 30
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 24
- 229910052759 nickel Inorganic materials 0.000 claims description 14
- 229910052742 iron Inorganic materials 0.000 claims description 12
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 7
- 150000002910 rare earth metals Chemical class 0.000 claims description 6
- 230000005674 electromagnetic induction Effects 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 238000002360 preparation method Methods 0.000 abstract description 2
- 239000000155 melt Substances 0.000 abstract 2
- 239000010410 layer Substances 0.000 description 37
- 238000005336 cracking Methods 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 230000004927 fusion Effects 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000011812 mixed powder Substances 0.000 description 4
- 238000010146 3D printing Methods 0.000 description 3
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- 230000007704 transition Effects 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
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- 238000010790 dilution Methods 0.000 description 2
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- 244000137852 Petrea volubilis Species 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000007499 fusion processing Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
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- 229910052751 metal Inorganic materials 0.000 description 1
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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
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
- C23C24/106—Coating with metal alloys or metal elements only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/64—Treatment of workpieces or articles after build-up by thermal means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/10—Pre-treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- 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
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/06—Surface hardening
- C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
-
- 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
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/26—Methods of annealing
-
- 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
- C21D6/00—Heat treatment of ferrous alloys
- C21D6/004—Heat treatment of ferrous alloys containing Cr and Ni
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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
- C21D6/00—Heat treatment of ferrous alloys
- C21D6/005—Heat treatment of ferrous alloys containing Mn
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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
- C21D6/00—Heat treatment of ferrous alloys
- C21D6/008—Heat treatment of ferrous alloys containing Si
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
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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
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
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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
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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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
- C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
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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
- C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D9/00—Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
- E21D9/06—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining
- E21D9/08—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining with additional boring or cutting means other than the conventional cutting edge of the shield
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Abstract
The invention belongs to the technical field of shield machine part preparation, and particularly discloses a shield machine hobbing cutter ring remanufacturing method which comprises the processes of nondestructive disassembly, stress detection and three-dimensional cladding, wherein firstly, welding check rings and cutter head hydraulic oil of a shield machine are taken out, and then the cutter ring and the cutter head are respectively heated and cooled to be naturally separated; carrying out stress detection on the cutter ring by utilizing an X-ray, and screening out the cutter ring meeting the remanufacturing cladding requirement; and sequentially performing low-hardness powder laser cladding, medium-hardness powder laser cladding and high-hardness powder laser cladding on the screened cutter ring, wherein the HRC of the low-hardness powder is 25 +/-2, and the HRC of the medium-hardness powder is as follows: 40 plus or minus 2, and high-hardness powder HRC:57 plus or minus 2. This application adopts the harmless mode to take out, detects the cutter ring that gets off dismantling, carries out low temperature again after the screening and melts and cover refabrication, increases its wear resistance, has solved the wasting of resources when traditional blade disc cutter ring replaces again, has promoted the success rate that melts and covers the process simultaneously.
Description
Technical Field
The invention belongs to the technical field of shield machine part preparation, and particularly relates to a shield machine hob ring remanufacturing method.
Background
The hob is a core part of the shield machine for digging into the rock to be broken, the using amount is large, the abrasion is fast, the whole cutterhead needs to be disassembled after the abrasion loss of the hob of the cutterhead reaches the minimum using specified value, the disassembled cutterhead mechanically disassembles the cutter ring by means of external force, the cutter ring is broken and cannot be reused, so that the waste of resources and the pollution to the environment are caused, and the investment cost is increased to a certain extent.
Accordingly, further developments and improvements are still needed in the art.
Disclosure of Invention
In order to solve the above problems, a method for remanufacturing a hob ring of a shield machine is proposed. The invention provides the following technical scheme:
a remanufacturing method of a shield tunneling machine hob ring comprises the following steps:
s1, lossless disassembly: firstly, taking out hydraulic oil of a welding retainer ring and a cutter head of the shield tunneling machine, and then respectively heating and cooling the cutter ring and the cutter head to naturally separate the cutter ring and the cutter head;
s2, stress detection: carrying out stress detection on the cutter ring by utilizing an X-ray, and screening out the cutter ring meeting the remanufacturing cladding requirement;
s3, three-dimensional cladding: and sequentially performing low-hardness powder laser cladding, medium-hardness powder laser cladding and high-hardness powder laser cladding on the screened cutter ring, wherein the HRC of the low-hardness powder is 25 +/-2, and the HRC of the medium-hardness powder is as follows: 40 plus or minus 2, and high-hardness powder HRC:57 plus or minus 2.
Further, the low-hardness powder is nickel-based powder, and the nickel-based powder comprises the following components in percentage by mass: c is less than or equal to 0.01; si is less than or equal to 0.5; mn is less than or equal to 0.5; cr 20-23; ni is more than or equal to 60; Re-Ce 0.3; 8-10 parts of Mo; fe is less than or equal to 5.
Further, in the low-hardness powder laser cladding process, laser cladding parameters are as follows: the cladding power is 1400W, the powder feeding is 15.6g/min, the rotating speed of the cutter ring is 9mm/s, 5 layers are clad by using nickel-based powder, and the thickness of each layer is 0.65 mm.
Further, the high-hardness powder is an iron-based powder, and the iron-based powder comprises the following components in percentage by mass: c0.06; 0.9 of Si; 0.4 of Mn; cr 17.4; ni 5; nb 0.5; b0.2; fe 73.
Further, in the laser cladding process of the high-hardness powder, the laser cladding parameters are as follows: cladding power is 1600W, powder feeding is 17.2g/min, the rotating speed of a cutter ring is 9mm/s, 32 layers are clad by using iron-based powder, and the thickness of each layer is 0.75 mm.
Further, the medium hardness powder comprises a first medium hardness powder and a second medium hardness powder, and the medium hardness powder is prepared by the following steps: the nickel-based powder and the iron-based powder are mixed according to the ratio of 1:1 and 1:7, and respectively adding a first medium-hardness powder and a second medium-hardness powder which are obtained by adding 1% of Re-Ce light rare earth powder by mass.
Further, in the medium-hardness powder laser cladding process, laser cladding parameters are as follows: cladding power of 1450W, powder feeding of 15.6g/min, rotating speed of the cutter ring of 9mm/s, cladding of 3 layers of the first medium-hardness powder, and thickness of each layer of 0.65 mm.
Further, continuously cladding second medium-hardness powder on the outer surface of the first medium-hardness powder, wherein the second medium-hardness powder is cladded with 3 layers, and the thickness of each layer is 0.65 mm.
Further, in the nondestructive disassembly process, the outer part of the cutter ring is heated by an electromagnetic induction coil, the cutter head is cooled when the temperature is 200 ℃, the cutter ring is continuously heated to 500-600 ℃, the temperature is kept, and the cutter ring is heated to expand and is separated from the cutter head after 2-4 min.
Furthermore, in the stress detection process, the top and two sides of the cutter ring are detected at three points.
Has the beneficial effects that:
1. after the cutter ring of the cutter head reaches a threshold value, taking out the cutter ring in a nondestructive mode;
2. detecting the disassembled cutter ring, and performing cladding remanufacturing when the detected cutter ring meets the composite remanufacturing requirement;
3. the wear-resisting property of the hob is improved through cladding remanufacturing, so that the resource waste caused by replacement of the traditional hob ring of the hob is solved, and the usability cost ratio of the hob is improved through cladding remanufacturing;
4. the stepped stable transition of hardness is realized by layer-by-layer cladding of cladding powder with different hardness, and the cracking of a matrix is prevented in the process of not heating;
5. by adjusting the laser power, the annealing treatment is carried out on the previous cladding layer, so that the relative concentration of stress is reduced, and the lower temperature is kept.
Drawings
FIG. 1 is a schematic view of cladding sample (a) and micro Vickers hardness test (b) according to an embodiment of the present invention;
FIG. 2 is a micro Vickers hardness test result of a low hardness powder laser-clad sample according to an embodiment of the present invention;
FIG. 3 is a result of Vickers hardness testing of a hardness powder laser-clad sample according to an embodiment of the present invention;
FIG. 4 shows the results of the micro Vickers hardness measurements of the high hardness powder laser-clad sample according to the embodiment of the present invention.
Detailed Description
In order to make the technical solutions of the present invention better understood, the following description of the technical solutions of the present invention with reference to the accompanying drawings of the present invention is made clearly and completely, and other similar embodiments obtained by a person of ordinary skill in the art without any creative effort based on the embodiments in the present application shall fall within the protection scope of the present application. In addition, directional terms such as "upper", "lower", "left", "right", etc. in the following embodiments are directions with reference to the drawings only, and thus, the directional terms are used for illustrating the present invention and not for limiting the present invention.
A remanufacturing method of a cutter ring for a shield tunneling machine comprises the following steps:
s1, disassembling: heating the cutter ring by using an induction coil by using a thermal expansion principle, and disassembling the cutter ring on the cutter head;
firstly, a lathe is used for taking off a welding check ring at the connecting part of a cutter head and a cutter ring, the cutter ring is heated to cause the expansion of hydraulic oil, so that the hydraulic oil in the cutter head is taken out in advance, the diameter of an electromagnetic induction coil (the width of the cutter ring is 1/2) is 10cm larger than that of the cutter ring, the outer part of the cutter ring is heated, the cutter head is cooled when the temperature is 200 ℃, the cutter ring is continuously heated to 500-600 ℃, the temperature is kept, and the cutter ring is heated to expand and is separated from the cutter head after 2-4 min.
S2, detection: carrying out stress detection on the cutter ring and judging whether cracks after stress concentration occur or not;
stress measurement by X-ray:
the X-ray diffraction stress instrument adopts a model 350A produced by an Ainstant (Handan) manufacturer, and carries out residual stress measurement on the wear surface and the side surface of a hob after service, so as to detect the stress distribution of a hob ring of the hob after use, and formulate an anti-cracking scheme through the detected stress, thereby selecting proper powder for laser cladding.
Firstly, slightly polishing the surface of the cutter ring by using sand paper, and respectively detecting the extrusion stress on the top and the two sides of the cutter ring. The detection of two sides of the cutter ring in a fixed state requires that the machine rotates by 45 degrees, the two side surfaces are uneven, a collimator with the diameter of 2mm needs to be adopted, a relatively large collimator is adopted on the uneven surface, a larger area can be intercepted, and relative data are accurate. The machine detects the top of the cutter ring at an angle of 0 degrees, and the relatively flat top is detected by a collimator with the diameter of 1 mm. And (4) formulating an anti-cracking scheme through the detected stress, and selecting proper powder for laser cladding.
S3, 3D printing: 3D printing cladding shield tunneling machine cutter device supports the inner side of a cutter ring through a triangular chuck, and then selects proper cladding powder to carry out cladding process; the cladding process and the cladding powder components are researched, and the required product is finally achieved by cladding the powder with low hardness, medium hardness and high hardness in sequence for transition.
The 3D printing adopts a YLS-4000 type optical fiber laser, the laser radiation wavelength is 1070 and 1080nm, and the laser head light spot is 3mm in diameter. The protective gas is nitrogen or argon.
The overlap ratio in the printing parameters is set to be 50%, and when the overlap ratio is 50%, the range of the cladding layer and the fusion layer of each layer is the largest, and the cladding efficiency is the largest.
The defocusing amount of the laser is set to be 13mm, the defocusing amount is related to a focus collected by the powder feeder, the efficiency of powder absorption power is directly determined by the defocusing amount, and the powder melting and base layer fusion effect is also determined.
The base material of the cutter ring is forged H13 steel, the hardness is HRC:55 (the hardness is higher), the external diameter after service is 423mm, and the widest position of the cutter ring is 24 mm. Because the cladding height is about 30mm generally and the hardness is high, the cladding is difficult to succeed under the condition of not preheating in the past, so that the analysis of the original matrix material is needed, and the powder material can be clad under the condition of not preheating is searched.
In order to take account of cladding, adhesion and hardness, powder with low cladding hardness, medium cladding hardness and high cladding hardness is selected in sequence to carry out step-shaped stable transition, cracking of a matrix is prevented in the process of not heating, and a product with required hardness is finally formed.
And the detection of the hardness experimental data is to clad the test block cut from the cutter ring and carry out microhardness detection after cladding. In order to ensure that the experimental cladding effect is consistent with the actual cladding parameters, 40 × 40mm sections are adopted for cladding, and sampling is carried out from the substrate, the cladding bottom layer, the middle part and the surface layer at sampling intervals of 0.5mm if points are taken, as shown in fig. 1.
The laser cladding parameters of the low-hardness powder laser cladding are as follows:
the cladding power is 1400W, the powder feeding is 15.6g/min, and the rotating speed of the cutter ring is 9 mm/s. The low-hardness powder is Ni-based powder, the cladding thickness is 3.25mm, each cladding layer is 0.65mm, and 5 cladding layers are formed. As shown in fig. 2, the hardness of the cladding 5 layer is 50, 40, 30, 27 and 25 respectively according to the result of the microscopic vickers hardness test of the cladding sample. The nickel-based metal powder is selected as a cladding material of a fusion layer, and the components in percentage by mass are shown in the following table 1:
TABLE 1
The C element in the nickel-based powder is lower than 0.01, the stability of the hardness of the heated powder is guaranteed, the Si and Mn elements guarantee the hardness and the ductility, the Ni element has very good ductility, the weight fraction of more than 60 percent can well prevent cracking when the tensile stress is faced, the Re-Ce element is a rare earth element, 1 percent of light rare earth is added on the basis of the nickel-based powder, the light rare earth has very good ductility and tensile resistance, and the mutual fusion of H13 steel and the nickel-based material can be guaranteed under the condition of no preheating.
The laser cladding parameters of medium-hardness powder laser cladding are as follows:
the cladding power is 1450W, the powder feeding is 15.6g/min, and the rotating speed of the cutter ring is 9 mm/s.
The iron-based powder comprises the following components in percentage by mass in table 2:
TABLE 2
Mixing nickel-based powder and iron-based powder according to the ratio of 1:1, adding 1% of Re-Ce light rare earth powder on the basis of the mixed powder, and cladding an alloy powder layer with the thickness of 2mm and the hardness of HRC (Rockwell hardness) of 2mm at 35.
Then mixing nickel-based powder and iron-based powder according to a ratio of 1:7, adding 1% Re-Ce light rare earth powder on the basis of the mixed powder, wherein the cladding thickness is 2mm, and the cladding hardness of 2mm is HRC: 45 alloy powder layer.
Cladding 3 layers of mixed powder in a ratio of 1:1, wherein the thickness of each layer is 0.65mm, and the hardness of the first 3 layers is respectively 30, 35 and 35 as shown in figure 3.
Cladding 3 layers of the mixed powder with the ratio of 1:7, wherein the thickness of each layer is 0.65mm, and the hardness of the rear 3 layers is 40, 45 and 46 respectively as shown in figure 3.
Re-Ce is added to the cladding layer to provide better elongation and to resist tensile stress. Different elongation rates are obtained by adding different percentages of light rare earth elements.
Light rare earth elements with different proportions are cladded to be used as tensile test bars. The test shows that the elongation at 1% is 20%, and the elongation does not increase along with the lifting proportion.
The laser cladding parameters of the high-hardness powder laser cladding are as follows:
the cladding power is 1600W, the powder feeding is 17.2g/min, and the rotating speed of the cutter ring is 9 mm/s. And cladding by using iron-based powder, wherein the thickness of a cladding single layer is 0.75mm, the cladding thickness is 24mm, and as shown in figure 4, the hardness detection result is HRC (Rockwell hardness) of 55-57. When a layer is clad, the powder is melted at high temperature and fused with the matrix, dilution can be generated in the fusion process, a certain dilution rate is obtained, the hardness of the matrix and the hardness of the powder can be fused with each other, so that the hardness of the powder is diluted, and the hardness is not detected to be reduced or increased in time when the layer is clad.
In order to keep the temperature within 200 ℃ all the time, the laser power is increased, the last cladding layer is annealed due to the increase of the laser power, the relative concentration of stress is reduced, the temperature is kept, the cladding thickness is increased, the cladding high-hardness powder meets the use requirement, and the cladding thickness of each layer is increased while the cladding power is increased for a better cladding effect.
The average hardness of the cladding cutter ring cover surface layer is 700HV (60HRC), the hardness of the base body is 660HV (58HRC), the average hardness of the bottom layer is 330HV (35HRC), the layer depth of the base body is 5mm, the cladding depth is 15mm, the powder selected for the bottom layer is better in ductility, and the powder selected for the surface layer is higher in hardness and wear resistance. The cladding powder has a uniform tissue structure and is free of defects.
After cladding, the cladding layer is put into a cutter head for fixation through heating expansion, and the performance of the cladding layer is superior to the hardness and the wear resistance of the original cutter ring (H13).
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
The present invention has been described in detail, and it should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
Claims (10)
1. The remanufacturing method of the shield tunneling machine hob ring is characterized by comprising the following steps:
s1, lossless disassembly: firstly, taking out hydraulic oil of a welding retainer ring and a cutter head of the shield tunneling machine, and then respectively heating and cooling the cutter ring and the cutter head to naturally separate the cutter ring and the cutter head;
s2, stress detection: carrying out stress detection on the cutter ring by utilizing an X-ray, and screening out the cutter ring meeting the remanufacturing cladding requirement;
s3, three-dimensional cladding: and sequentially performing low-hardness powder laser cladding, medium-hardness powder laser cladding and high-hardness powder laser cladding on the screened cutter ring, wherein the HRC of the low-hardness powder is 25 +/-2, and the HRC of the medium-hardness powder is as follows: 40 plus or minus 2, and high-hardness powder HRC:57 plus or minus 2.
2. The remanufacturing method of a shield tunneling machine hob cutter ring according to claim 1, wherein the low hardness powder is nickel-based powder, and the nickel-based powder comprises the following components in percentage by mass: c is less than or equal to 0.01; si is less than or equal to 0.5; mn is less than or equal to 0.5; cr 20-23; ni is more than or equal to 60; Re-Ce 0.3; 8-10 parts of Mo; fe is less than or equal to 5.
3. The remanufacturing method of a shield tunneling machine hob ring according to claim 2, wherein in the low hardness powder laser cladding process, laser cladding parameters are as follows: the cladding power is 1400W, the powder feeding is 15.6g/min, the rotating speed of the cutter ring is 9mm/s, 5 layers are clad by using nickel-based powder, and the thickness of each layer is 0.65 mm.
4. The remanufacturing method of a shield tunneling machine hob ring according to claim 1, wherein the high hardness powder is an iron-based powder, and the iron-based powder comprises the following components in percentage by mass: c0.06; si 0.9; 0.4 of Mn; cr 17.4; ni 5; nb 0.5; b0.2; fe 73.
5. The remanufacturing method of a shield tunneling machine hob cutter ring according to claim 4, wherein in the high hardness powder laser cladding process, laser cladding parameters are as follows: cladding power is 1600W, powder feeding is 17.2g/min, the rotating speed of a cutter ring is 9mm/s, 32 layers are clad by using iron-based powder, and the thickness of each layer is 0.75 mm.
6. The remanufacturing method of a shield tunneling machine hob ring according to claim 4, wherein the medium hardness powder comprises a first medium hardness powder and a second medium hardness powder, and the medium hardness powder is prepared by: the nickel-based powder and the iron-based powder are mixed according to the ratio of 1:1 and 1:7, and respectively adding a first medium-hardness powder and a second medium-hardness powder which are obtained by adding 1% of Re-Ce light rare earth powder by mass.
7. The remanufacturing method of a shield tunneling machine hob cutter ring according to claim 6, wherein in the medium-hardness powder laser cladding process, laser cladding parameters are as follows: cladding power of 1450W, powder feeding of 15.6g/min, rotating speed of the cutter ring of 9mm/s, cladding of 3 layers of the first medium-hardness powder, and thickness of each layer of 0.65 mm.
8. The shield tunneling machine hob ring remanufacturing method according to claim 7, wherein cladding of the second medium hardness powder is continued on an outer surface where the first medium hardness powder is clad, wherein the second medium hardness powder is clad with 3 layers each having a thickness of 0.65 mm.
9. The remanufacturing method of the shield tunneling machine hob cutter ring according to claim 1, wherein in the nondestructive disassembly process, the electromagnetic induction coil is used for heating the outside of the hob cutter ring, when the temperature is 200 ℃, the temperature of the cutter disc is reduced, the temperature of the cutter ring is kept after the cutter ring is continuously heated to 500-600 ℃, and the cutter ring is thermally expanded and separated from the cutter disc after 2-4 min.
10. The remanufacturing method of a shield tunneling machine hob ring according to claim 1, wherein three points are detected on the top and two sides of the hob ring in the stress detection process.
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Non-Patent Citations (1)
| Title |
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| 吕耀辉著: "等离子弧熔覆再制造技术及应用", 31 May 2019, 哈尔滨：哈尔滨工业大学出版社, pages: 18 - 19 * |
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