CN115011909B - Large-tillage-depth rotary blade surface spraying remelting integrated processing method - Google Patents
Large-tillage-depth rotary blade surface spraying remelting integrated processing method Download PDFInfo
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- CN115011909B CN115011909B CN202210690196.6A CN202210690196A CN115011909B CN 115011909 B CN115011909 B CN 115011909B CN 202210690196 A CN202210690196 A CN 202210690196A CN 115011909 B CN115011909 B CN 115011909B
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- 238000003672 processing method Methods 0.000 title claims abstract description 28
- 230000006698 induction Effects 0.000 claims abstract description 86
- 239000011248 coating agent Substances 0.000 claims abstract description 45
- 238000000576 coating method Methods 0.000 claims abstract description 45
- 239000007921 spray Substances 0.000 claims abstract description 36
- 238000003971 tillage Methods 0.000 claims abstract description 30
- 238000010891 electric arc Methods 0.000 claims abstract description 29
- 239000011159 matrix material Substances 0.000 claims abstract description 26
- 239000000463 material Substances 0.000 claims abstract description 14
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 238000012545 processing Methods 0.000 claims abstract description 9
- 238000004140 cleaning Methods 0.000 claims abstract description 5
- 239000002344 surface layer Substances 0.000 claims description 10
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 8
- 238000005253 cladding Methods 0.000 claims description 6
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- 238000005728 strengthening Methods 0.000 claims description 4
- 239000011247 coating layer Substances 0.000 claims description 3
- 239000000155 melt Substances 0.000 claims description 3
- 230000008021 deposition Effects 0.000 claims description 2
- 230000000694 effects Effects 0.000 abstract description 3
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- 229910000897 Babbitt (metal) Inorganic materials 0.000 description 1
- 229910000906 Bronze Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000013473 artificial intelligence Methods 0.000 description 1
- 239000010974 bronze Substances 0.000 description 1
- 231100000481 chemical toxicant Toxicity 0.000 description 1
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- 239000002131 composite material Substances 0.000 description 1
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- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
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Classifications
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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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention discloses a large-tillage-depth rotary blade surface spraying remelting integrated processing method, which comprises the following steps: pretreating the surface of the rotary tillage cutter until the matrix material is exposed; installing rotary blades and positioning an arc spraying gun and an induction coil; carrying out oil discharge and cleaning on the part to be sprayed of the rotary tillage cutter; the electric arc spray gun capable of running along the arrangement direction of the rotary blade atomizes the melted material into micro-droplets by using compressed air and sprays the micro-droplets onto the surface of the rotary blade to form a compact coating, and the coating and a matrix of the rotary blade are in a mechanical combination state; simultaneously, induction coil that can march along the setting direction of rotary blade carries out induction heating to the rotary blade, utilizes the heat that the vortex produced to melt coating and the base member top layer of rotary blade in the twinkling of an eye, makes the mechanical bonding state on the rotary blade form metallurgical bonding. The processing method of the invention is characterized in that the surface spraying-induction remelting integrated processing is constructed, and the obtained wear-resistant coating has compact coating and good bonding effect with the matrix.
Description
Technical Field
The invention relates to the technical field of equipment remanufacturing, in particular to a surface spraying and remelting integrated processing method for a large-tillage-depth rotary blade.
Background
Rotary blades are generally operated in environments containing pesticides, fertilizers or some moist and corrosive environments, and rub against broken stones or crop residues in the soil, and with vibration, impact and the like, abrasion is one of the main causes of the failure of rotary blades. The scholars propose to manufacture large-tillage deep-tillage knives by using surface strengthening technology, which is represented by: surface laser shock strengthening and surface chromizing. Literature (Zhao Li et al. Surface properties after laser shock peening of large tillage rotary blades [ J ]. University of Yangzhou university (Nature science edition), 2014, 17 (03): 36-40) discloses that laser peening is mainly used for preventing surface stress concentration, but has limited effect of improving wear resistance of rotary blade workpieces; the literature (Zhao Yufeng, etc. the optimization of the surface chromizing process of the rotary blade with 65Mn steel and the study of the wear resistance [ J ]. The agricultural machinery research, 2012, 34 (10): 156-160) discloses that the hard surface layer formed by the surface chromizing of the rotary blade workpiece is thin, the preparation time is long (9 h), and the practical application is also very difficult. In recent years, surface coating technology has received increasing attention, and its application in the field of wear-resistant surface preparation is also becoming more and more widespread. Document (Mo Weiwei et al. State of the art and trend of thermal spraying technology towards the artificial intelligence era [ J ]. Powder metallurgy industry, 2021, 31 (04): 94-99) discloses typical coating techniques: based on laser, plasma spraying, cold spraying, supersonic flame spraying, cladding of electric arcs, build-up welding, spraying, etc.
In recent years, arc spraying technology has been rapidly developed, and a smooth, dense, high-quality coating with high bond strength can be obtained by the arc spraying technology, and it is counted that the market share of arc spraying application is approaching the third place in all thermal spraying technologies. With the development of arc spraying technology, the types of arc spraying wires are more and more, such as composite wires, babbitt metal wires, aluminum bronze wires and the like, so that the oxidation resistance, the heat insulation, the electrical conductivity and the wear resistance of the coating are also gradually provided with a relatively complete system, and the performance of the coating is greatly improved.
The electric arc spraying is to use electric arc as heat source, to melt metal by electric arc burning between two continuous power supply wires, then to atomize the melted material into micro-droplets by compressed air, and to spray the micro-droplets onto the surface of the workpiece to form a coating. The disadvantages of the arc spraying technique are mainly: some of the powder particles are unlikely to melt entirely during spraying, resulting in insufficient deformation of the particles when they strike the surface of the substrate, and voids or cavities are inevitably present between the particles after cooling and solidification, which can reduce the performance of the coating. In addition, the bonding between the coating and the matrix is mainly mechanical bonding (the molten drops with certain kinetic energy collide with the surface of the roughened substrate and form mechanical occlusion with the protrusions and depressions on the surface), the bonding strength is not very high, and the rapid cooling and larger temperature gradient of particles in the coating preparation process generally cause the generation of residual tensile stress in the coating, so that the problems of limited work piece interface and pore defects and rotary tillage impact resistance of the technical method are common in the industry.
Disclosure of Invention
The invention aims at solving the problems existing in the prior art and provides a large-tillage-depth rotary blade surface spraying and remelting integrated processing method.
The invention aims at solving the problems through the following technical scheme:
a large-tillage-depth rotary blade surface spraying remelting integrated processing method is characterized by comprising the following steps of: the processing method comprises the following steps:
A. pretreating the surface of a rotary blade, removing oxide on the surface and exposing a matrix material;
B. the rotary blade is arranged on a clamping jaw of a position changer, a nozzle of an arc spraying gun in a high-speed arc spraying device faces the rotary blade, and an induction coil in an induction remelting device is sleeved on the rotary blade;
C. oil discharging and cleaning are carried out on the part of the rotary blade, which is exposed out of the matrix material and is to be sprayed, so that the surface of the rotary blade is ensured to be sufficiently clean;
D. the electric arc spray gun capable of running along the arrangement direction of the rotary blade atomizes the melted material into micro-droplets by using compressed air and sprays the micro-droplets onto the surface of the rotary blade to form a compact coating, and the coating and a matrix of the rotary blade are in a mechanical combination state;
E. when the arc spraying gun sprays, the induction coil which can advance along the setting direction of the rotary blade carries out induction heating on the rotary blade, and the coating layer and the substrate surface layer of the rotary blade are instantaneously melted by the heat generated by vortex, so that the mechanical bonding state on the rotary blade forms metallurgical bonding.
And B, the positioner clamping jaw can drive the rotary blade to rotate in the step D and/or the step E according to the requirement.
And B and D arc spraying guns are respectively connected with the anode and the cathode of an arc power supply through an anode wire rod and a cathode wire rod, and when the end parts of the anode wire rod and the cathode wire rod are in contact with each other, the generated arc instantly melts the end parts of the wire rods.
And the induction coils in the step B and the step E are arranged on the coil mounting seat and are connected with an induction power supply.
The high-speed electric arc spraying device and the induction remelting device in the step B are arranged at the movable end of the three-dimensional guiding device; or the high-speed electric arc spraying device in the step B is arranged on the movable end of the three-dimensional guiding device, and the induction remelting device in the step B is arranged on the end of the mechanical arm of the industrial robot, so that the three-dimensional guiding device and the industrial robot can be matched with each other, and an electric arc nozzle of the high-speed electric arc spraying device and an induction coil of the induction remelting device can synchronously travel along the arrangement direction of the rotary blade.
The electric arc spraying guns in the step B and the step D are arranged on a main shaft of a numerical control machine tool through a spray gun connector, electric arc spraying operation is carried out on rotary blades, and the positions of the electric arc spraying guns are represented by a three-dimensional vector function p (t):
p(t)＝[p x (t),p y (t),p z (t)] T
wherein p (t) is the position of the spray gun in a space Cartesian coordinate system at the moment t; p is p x (t) is the position of the spray gun on the X axis in a space Cartesian coordinate system at the moment t; p is p y (t) is the position of the spray gun at time t on the Y axis in a spatial Cartesian coordinate system; p is p z (t) is the position of the spray gun at the moment t on the Z axis in a space Cartesian coordinate system; t is the spraying time and T is the coating thickness.
The induction coils in the step B and the step E are connected to the tail end of the mechanical arm of the industrial robot through a coil mounting seat, induction cladding operation is carried out on the rotary blade by the induction coils along with path planning of the industrial robot while electric arc spraying, and the spatial attitude of the induction coils is represented by a three-dimensional vector function o (t):
o(t)＝[o x (t),o y (t),o z (t)] T
wherein o (t) is the rotation angle of an induction coil working with the industrial robot at the moment t in a space Cartesian coordinate system; o (o) x (t) is the rotation angle of the induction coil on the X axis in a space Cartesian coordinate system, which accompanies the operation of the industrial robot at time t; o (o) y (t) is time tRotation angle of the induction coil on the Y-axis in a spatial cartesian rectangular coordinate system accompanying the operation of the industrial robot; o (o) z And (t) is the rotation angle of the induction coil working with the industrial robot at the moment t on the Z axis in a space Cartesian rectangular coordinate system.
The numerical control machine tool and the industrial robot are connected through a network cable, a rapid instruction code is input into a control system of the numerical control machine tool to operate the industrial robot, and the numerical control machine tool and the industrial robot mutually determine the state of the other side through a display interface, so that the processing operation that arc spraying and induction remelting work simultaneously and do not interfere is realized; the rotation matrix can be established through the rotation angle parameters in the space Cartesian rectangular coordinate system of the induction coil on the industrial robot, the fixed coordinate system can be converted into the rotation coordinate system through operation, and finally the total vector function a (t) of the spray gun pose is obtained as follows:
a(t)＝[p(t)o(t)] T
in the formula, a (t) is the pose vector of the spray gun at the moment t.
The coating strengthening thickness in the step D is 200-1000 mu m, the deposition rate is 14kg/h, the diameter of the wire rod for the arc spraying gun is 1.2-2.2 mm, and the feeding rate is 120-200 mm/min.
The base material in the step A is 65Mn, and the melted material in the step D is nickel-based alloy.
The induction coil is arranged on a coil mounting seat which is arranged at the tail end of a mechanical arm of the industrial robot; the mechanical arm of the industrial robot has six joints connected and each joint is provided with a corresponding stepping motor.
The induction coil, the positive electrode wire and the negative electrode wire are all made of conductive materials.
The invention relates to a processing device used in a large-tillage-depth rotary blade surface spraying remelting integrated processing method, which comprises the following technical principles:
the inlet end of the arc spraying gun is arranged at the lower end of the main shaft through a spray gun connector, the outlet end of the arc spraying gun is moved to be right above the rotary blade under the adjustment of the three-dimensional guiding device, and the distance between the arc spraying gun and the rotary blade is adjusted according to the gap discharge state of the arc power supply; when the arc spraying gun moves towards the rotary blade, the arc spraying gun takes an arc power supply as a heat source to melt a coating material, then compressed air is utilized to atomize the melted material into micro-droplets, the micro-droplets are sprayed on the surface of the rotary blade to form a coating, the coating on the surface of the rotary blade after arc spraying is mechanically combined with a substrate, and the micro-droplets collide with the surface of the rotary blade to form mechanical occlusion with the bulges and the depressions on the surface.
The induction coil is arranged on the coil mounting seat and is connected to the three-dimensional guiding device or the industrial robot through the coil mounting seat, the induction coil is driven by the three-dimensional guiding device or the industrial robot to carry out induction heating on the rotary blade along the arrangement direction of the rotary blade through connecting an induction power supply, and the position of the induction coil is adjusted timely according to the gap position between the arc spraying gun and the rotary blade; the arc spraying gun is used for spraying the rotary tillage cutter and simultaneously the induction coil is driven by the three-dimensional guiding device or the industrial robot to perform induction heating on the rotary tillage cutter along the setting direction of the rotary tillage cutter by connecting an induction power supply, and the coating and the surface layer of the matrix of the rotary tillage cutter are instantaneously melted, so that the mechanical bonding state on the rotary tillage cutter forms metallurgical bonding.
Further, the rotary tillage cutter is clamped and arranged on the position changing machine through the clamping jaw of the position changing machine, and is driven by the position changing machine to rotate around the axis of the rotary tillage cutter, so that the processing device can spray and remelt the irregular profile compounded by the bending and twisting of the rotary tillage cutter integrally.
Compared with the prior art, the invention has the following advantages:
the integrated processing method has the advantages that the spraying and cladding integrated heat source energy density is high, the electric arc spraying and remelting operations are almost carried out synchronously, the production efficiency is improved, the effects of reducing the internal thermal stress of the coating and reducing the energy consumption are achieved, the problems of mechanical combination, strong crack sensitivity and pore defects of the coating and the matrix during electric arc spraying are solved, the metallurgical combination is formed between the rotary blade coating and the surface layer of the matrix, the substrate performance is greatly improved, the excellent combination strength is achieved, and the impact resistance is better.
The integrated processing method provided by the invention has the advantages that the color and luster of the coating formed on the surface of the large-tillage rotary blade are uniform, the internal structure of the coating is uniform after the coating is subjected to spray remelting through analysis and test, such as a metallographic specimen shows that the nickel-based alloy cladding layer is metallurgically bonded with the 65Mn base material, no metallurgical defect exists, the surface flatness is high, and the manufacturing requirement of the large-tillage rotary blade is met.
When the integrated processing method is used for processing the large-tillage rotary blade, the whole process is simple, the flow is curable, the preparation process is stable, the energy consumption is low, and the powder utilization rate is high; the environment-friendly protective cover does not relate to the use of any toxic chemical, does not generate toxic waste, is environment-friendly, and can avoid injuring operators through conventional protection.
Drawings
FIG. 1 is a schematic diagram of an integrated processing method for spraying and remelting the surface of a large-tillage rotary blade;
FIG. 2 is a three-dimensional structure diagram of a device adopted by the surface spraying and remelting integrated processing method of the large-tillage rotary blade;
FIG. 3 is a schematic view of the connection of the arc spraying gun and the main shaft of the present invention;
FIG. 4 is a schematic view of the structure of rotary blade on the high speed arc spraying device and the positioner in the X-Z plane;
FIG. 5 is a schematic view of the combined state structure of the arc spraying gun, the induction coil and the rotary blade workpiece;
FIG. 6 is a schematic diagram of a connection structure between an induction coil and an industrial robot according to the present invention;
FIG. 7 is a schematic diagram of the connection structure of the rotary blade and the positioner of the present invention.
Wherein: 1-a protective cover of a machine tool; 2-a workbench; 3-a machine tool body; 4-a first sliding guide rail; 5-a third sliding guide rail; 6, a motor; 7-a screw rod; 8-a main shaft; 9-sliding guide rail seat; 10-arc spraying gun; 11-a second sliding rail; 12-an induction coil; 13-an industrial robot; 14-a positioner; 15-positioner jaws; 16-arc power supply; 17-an inductive power supply; 18-coil mounting base; 19-positive electrode wire; 20-a negative electrode wire; 21-spray gun joint.
Detailed Description
The device according to the invention is further described below with reference to the drawings and examples, but the scope of the invention is not limited to the examples, and modifications or improvements can be made by a person skilled in the art on the basis of the basic idea of the invention, without departing from the scope of the basic idea of the invention.
As shown in fig. 1: the surface spraying and remelting integrated processing method for the large-tillage rotary blade comprises the following steps: A. pretreating the surface of a rotary blade, removing oxide on the surface and exposing a matrix material; B. the rotary blade is arranged on a clamping jaw 15 of a position changer, a nozzle of an arc spraying gun 10 in a high-speed arc spraying device faces the rotary blade, and an induction coil 12 in an induction remelting device is sleeved on the rotary blade; C. oil discharging and cleaning are carried out on the part of the rotary blade, which is exposed out of the matrix material and is to be sprayed, so that the surface of the rotary blade is ensured to be sufficiently clean; D. the arc spraying gun 10 capable of running along the arrangement direction of the rotary blade atomizes the melted material into micro-droplets by using compressed air and sprays the micro-droplets onto the surface of the rotary blade to form a compact coating, and the coating and a matrix of the rotary blade are in a mechanical combination state; E. while the arc spraying gun 10 sprays, the induction coil 12 which can run along the arrangement direction of the rotary blade carries out induction heating on the rotary blade, and the coating layer and the substrate surface layer of the rotary blade are instantaneously melted by the heat generated by vortex flow, so that the mechanical bonding state on the rotary blade forms metallurgical bonding.
As shown in fig. 2-7, the processing device adopted by the large-tillage-depth rotary blade surface spraying and remelting integrated processing method comprises a high-speed electric arc spraying device and an induction remelting device, wherein an electric arc spray gun 10 in the high-speed electric arc spraying device and an induction coil 12 in the induction remelting device are sequentially arranged along the setting direction of the rotary blade, the electric arc spray gun 10 with a nozzle facing the rotary blade and the induction coil 12 sleeved on the rotary blade can travel along the setting direction of the rotary blade, the rotary blade is clamped by a positioner clamping jaw 15 and is arranged on a positioner 14, a base of the positioner 14 is arranged on a machine tool body 3, and the rotary blade can rotate around the axis of the rotary blade under the driving of the positioner 14; the arc spraying gun 10 is correspondingly connected with the anode and the cathode of the arc power supply 16 through an anode wire 19 and a cathode wire 20 respectively, and atomizes the melted material into micro-droplets by using compressed air to spray the micro-droplets on the surface of the rotary blade to form a coating, and the coating and a matrix of the rotary blade are in a mechanical combination state; the arc spraying gun 10 can realize spraying on the rotary blade, and simultaneously, the induction coil 12 connected with the induction power supply 17 can carry out induction heating on the rotary blade immediately after the spraying step, and instantly melt the coating of the rotary blade and the surface layer of the matrix, so that the mechanical bonding state on the rotary blade forms metallurgical bonding; in this device, the distance between the arc spraying gun 10 and the rotary blade is adjusted according to the gap discharge state of the arc power source 16, and the position of the induction coil 12 is adjusted in time according to the gap position between the arc spraying gun 10 and the rotary blade.
The following provides a structural form of a specific embodiment of a processing device adopted by the surface spraying and remelting integrated processing method of the large-tillage rotary blade.
As shown in fig. 2-7: the machining device comprises a machine tool protection cover 1, a workbench 2, a machine tool body 3, a first sliding guide rail 4, a third sliding guide rail 5, a motor 6, a screw rod 7, a main shaft 8, a sliding guide rail seat 9, an arc spray gun 10, a second sliding guide rail 11, an induction coil 12, an industrial robot 13, a position shifter 14, a position shifter clamping jaw 15, an arc power supply 16, an induction power supply 17, a coil mounting seat 18, a positive electrode wire 19, a negative electrode wire 20 and a spray gun joint 21. The first sliding guide rail 4 arranged along the Y-axis direction is arranged on the machine tool body 3, the workbench 2 arranged on the first sliding guide rail 4 can slide and move along the arrangement direction of the first sliding guide rail 4 under the action of the corresponding driving mechanism, the workbench 2 is provided with a second sliding guide rail 11 arranged along the X-axis direction, and the second sliding guide rail 11 is perpendicular to the first sliding guide rail 4; a vertically arranged sliding guide rail seat 9 is arranged on the second sliding guide rail 11, and the sliding guide rail seat 9 can slide and move along the arrangement direction of the second sliding guide rail 11 under the action of a corresponding driving mechanism; the sliding guide rail seat 9 is provided with a third sliding guide rail 5 which is perpendicular to the first sliding guide rail 4 and the second sliding guide rail 11, a main shaft 8 which is arranged on the third sliding guide rail 5 and is arranged along the Z-axis direction can vertically slide along the third sliding guide rail 5 under the action of the motor 6, and the lower end of the main shaft 8 is connected with an arc spraying gun 10 through a spraying gun connector 21; the arc spraying gun 10 is connected to the positive electrode of the arc power supply 16 through a positive electrode wire 19, and the negative electrode wire 20 is connected to the negative electrode of the arc power supply 16. The induction coil 12 connected with the induction power supply 17 is arranged on a coil mounting seat 18 and is connected to the tail end of the mechanical arm of the industrial robot 13 through the coil mounting seat 18; the rotary blade is clamped and arranged on the position shifter 14 by the position shifter clamping jaw 15, the base of the position shifter 14 is arranged on the machine tool body 3, and the rotary blade rotates around the axis under the drive of the position shifter 14.
When the rotary tillage machine is used, the arc spraying gun 10 moves on the first sliding guide rail 4 along the Y-axis direction, so that the outlet end of the arc spraying gun 10 moves to be right above the rotary tillage cutter, and then the arc spraying gun 10 moves linearly along the Z-axis direction under the drive of the motor 6 so as to adjust the distance between the arc spraying gun 10 and the rotary tillage cutter; the arc spraying gun 10 atomizes molten material into micro-droplets using compressed air, forms a coating on the surface of the rotary blade, and moves straight in the X-axis direction. The arc spraying gun 10 sprays the rotary blade, and simultaneously, the induction coil 12 is connected with the induction power supply 17 under the drive of the industrial robot 13, and the induction power supply is used for carrying out induction heating on the rotary blade along the X-axis direction immediately after the spraying step, so that the coating and the surface layer of the matrix of the rotary blade are instantaneously melted, and the mechanical bonding state on the rotary blade forms metallurgical bonding; meanwhile, the rotary tillage cutter is driven by the position changer 14 to rotate around the axis according to the requirement, so that the processing device can spray and remelt the irregular profile compounded by the rotary tillage cutter in an integral way.
Example 1
As shown in fig. 1, 4 and 5, the application environment of the integrated processing method provided in this embodiment includes: the rotary blade workpiece fixture comprises a positioner 14 for fixing a rotary blade workpiece, an arc spraying gun 10 connected with a main shaft 8 of a numerical control machine tool through a spraying gun joint 21, an arc power supply 16 connected with a positive electrode wire 19 and a negative electrode wire 20, an induction coil 12 fixed on an industrial robot 13 through a coil mounting seat 18, and an induction power supply 17 electrified with the induction coil 12.
The embodiment comprises the following steps:
A. preprocessing the surface of the rotary tillage cutter, and manually polishing to remove oxides on the surface, so as to ensure that the surface of the workpiece is exposed out of the matrix material 65Mn;
B. a high-speed electric arc spraying device and an induction remelting device are respectively integrated on a numerical control machine tool and a mechanical arm of an industrial robot 13, and rotary blades are clamped on a positioner clamping jaw 15 of a positioner 14;
C. oil discharging and cleaning are carried out on the part to be sprayed of the rotary blade, so that the surface of the rotary blade is ensured to be sufficiently clean;
D. the arc spraying gun 10 of the high-speed arc spraying device is used for spraying the surface of the rotary blade, the arc spraying gun 10 can move along the X-axis direction of the rotary blade, in the operation process, when the ends of the positive electrode wire 19 and the negative electrode wire 20 made of the nickel-based alloy are contacted with each other, the generated arc melts the ends of the wires, and micro-droplets formed by atomizing the melted materials are sprayed on the surface of the rotary blade at a high speed by means of compressed air, so that a compact coating and a workpiece matrix are formed into mechanical combination;
E. when arc spraying is carried out on rotary blades, a rapid instruction code is input into a control system of a numerical control machine tool to operate the industrial robot 13, the numerical control machine tool and the industrial robot 13 mutually determine the opposite side state through a display interface, an induction coil 12 is fixed on the tail end of a mechanical arm of the industrial robot 13 through a coil mounting seat 18, and induction heating is carried out on the rotary blades by connecting an induction power supply 17 to advance along the X-axis direction, so that spraying operation and induction remelting operation can be synchronously carried out, alloy powder preset on a substrate is enabled to reach a molten state by utilizing heat generated by eddy current, and metallurgical bonding is carried out on the surfaces of rotary blade workpieces.
The integrated processing method adopts the arc spraying technology to spray the surface of the large-tillage rotary blade to form a coating, and simultaneously, the induction coil 12 is connected with the induction power supply 17 to carry out induction heating on the rotary blade during the arc spraying, so as to instantly melt the coating on the surface of the rotary blade and the surface layer of the matrix, eliminate the defects of a rotary blade workpiece caused by the arc spraying, refine, for example, coating grains, and form metallurgical bonding between the rotary blade coating and the surface layer of the matrix, thereby achieving excellent bonding strength; meanwhile, the special rotary blade has excellent pertinence to the irregular profile compounded by bending and twisting of the rotary blade with large tilling depth; the process method can synchronously realize electric arc spraying and cladding, has urgent research value, and has good economic benefit and industrial application potential.
The above embodiments are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited by the above embodiments, and any modification made on the basis of the technical scheme according to the technical idea of the present invention falls within the protection scope of the present invention; the technology not related to the invention can be realized by the prior art.
Claims (8)
1. A large-tillage-depth rotary blade surface spraying remelting integrated processing method is characterized by comprising the following steps of: the processing method comprises the following steps:
A. pretreating the surface of a rotary blade, removing oxide on the surface and exposing a matrix material;
B. the rotary blade is arranged on a clamping jaw of a position changer, a nozzle of an arc spraying gun in a high-speed arc spraying device faces the rotary blade, and an induction coil in an induction remelting device is sleeved on the rotary blade;
C. removing oil and cleaning the part of the rotary blade exposed out of the matrix material to be sprayed;
D. the electric arc spray gun capable of running along the arrangement direction of the rotary blade atomizes the melted material into micro-droplets by using compressed air and sprays the micro-droplets onto the surface of the rotary blade to form a compact coating, and the coating and a matrix of the rotary blade are in a mechanical combination state;
E. when the arc spraying gun sprays, the induction coil which can move along the arrangement direction of the rotary blade carries out induction heating on the rotary blade, and the coating layer and the surface layer of the matrix of the rotary blade are instantaneously melted by the heat generated by vortex flow, so that the mechanical bonding state on the rotary blade forms metallurgical bonding;
the clamping jaw of the positioner in the step B can drive the rotary blade to rotate in the step D and/or the step E according to the requirement;
the high-speed electric arc spraying device in the step B is arranged at the movable end of the three-dimensional guiding device, the induction remelting device in the step B is arranged at the tail end of the mechanical arm of the industrial robot, and the three-dimensional guiding device and the industrial robot can be matched with each other, so that an electric arc nozzle of the high-speed electric arc spraying device and an induction coil of the induction remelting device can synchronously travel along the arrangement direction of the rotary blade.
2. The large-tillage-depth rotary blade surface spraying remelting integrated processing method is characterized by comprising the following steps of: and B and D arc spraying guns are respectively connected with the anode and the cathode of an arc power supply through an anode wire rod and a cathode wire rod, and when the end parts of the anode wire rod and the cathode wire rod are in contact with each other, the generated arc instantly melts the end parts of the wire rods.
3. The large-tillage-depth rotary blade surface spraying remelting integrated processing method is characterized by comprising the following steps of: and the induction coils in the step B and the step E are arranged on the coil mounting seat and are connected with an induction power supply.
4. The large-tillage-depth rotary blade surface spraying remelting integrated processing method according to any one of claims 1 to 3, which is characterized in that: the electric arc spraying guns in the step B and the step D are arranged on a main shaft of a numerical control machine tool through a spray gun connector, electric arc spraying operation is carried out on rotary blades, and the positions of the electric arc spraying guns are represented by a three-dimensional vector function p (t):
p(t)＝[p x (t),p y (t),p z (t)] T
wherein p (t) is the position of the spray gun in a space Cartesian coordinate system at the moment t; p is p x (t) is the position of the spray gun on the X axis in a space Cartesian coordinate system at the moment t; p is p y (t) is the position of the spray gun at time t on the Y axis in a spatial Cartesian coordinate system; p is p z (t) is the position of the spray gun at the moment t on the Z axis in a space Cartesian coordinate system; t is the spraying time and T is the coating thickness.
5. The integrated processing method for spraying and remelting the surface of the large-tillage rotary blade according to claim 4, which is characterized in that: the induction coils in the step B and the step E are connected to the tail end of the mechanical arm of the industrial robot through a coil mounting seat, induction cladding operation is carried out on the rotary blade by the induction coils along with path planning of the industrial robot while electric arc spraying, and the spatial attitude of the induction coils is represented by a three-dimensional vector function o (t):
o(t)＝[o x (t),o y (t),o z (t)] T
wherein o (t) is the rotation angle of an induction coil working with the industrial robot at the moment t in a space Cartesian coordinate system; o (o) x (t) is the rotation angle of the induction coil on the X axis in a space Cartesian coordinate system, which accompanies the operation of the industrial robot at time t; o (o) y (t) is the rotation angle of the induction coil on the Y axis in the space Cartesian coordinate system, which accompanies the operation of the industrial robot at time t; o (o) z And (t) is the rotation angle of the induction coil working with the industrial robot at the moment t on the Z axis in a space Cartesian rectangular coordinate system.
6. The integrated processing method for spraying and remelting the surface of the large-tillage rotary blade according to claim 5, which is characterized in that: the numerical control machine tool and the industrial robot are connected through a network cable, a rapid instruction code is input into a control system of the numerical control machine tool to operate the industrial robot, and the numerical control machine tool and the industrial robot mutually determine the state of the other side through a display interface, so that the processing operation that arc spraying and induction remelting work simultaneously and do not interfere is realized; the rotation matrix is established through rotation angle parameters in an induction coil space Cartesian rectangular coordinate system on the industrial robot, a fixed coordinate system can be converted into a rotation coordinate system through operation, and finally the total vector function a (t) of the arc spraying gun pose is obtained as follows:
a(t)＝[p(t)o(t)] T
in the formula, a (t) is the pose vector of the spray gun at the moment t.
7. The large-tillage-depth rotary blade surface spraying remelting integrated processing method according to any one of claims 1 to 3, which is characterized in that: the coating strengthening thickness in the step D is 200-1000 mu m, the deposition rate is 14kg/h, the diameter of the wire rod for the arc spraying gun is 1.2-2.2 mm, and the feeding rate is 120-200 mm/min.
8. The large-tillage-depth rotary blade surface spraying remelting integrated processing method according to any one of claims 1 to 3, which is characterized in that: the base material in the step A is 65Mn, and the melted material in the step D is nickel-based alloy.
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| CN114196902A (en) * | 2021-12-02 | 2022-03-18 | 曲作鹏 | Double-heat-source collaborative remelting device and method for water wall coating |
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| JPH02129383A (en) * | 1988-11-08 | 1990-05-17 | Dai Ichi High Frequency Co Ltd | Formation of film |
| CN110216029A (en) * | 2018-03-02 | 2019-09-10 | 中国石油化工股份有限公司 | A kind of sucker rod spray welding unit |
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