CN1224496C - High-strength non-cracking antiwear precise hollow axle and its making technology - Google Patents
High-strength non-cracking antiwear precise hollow axle and its making technology Download PDFInfo
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- CN1224496C CN1224496C CN 01133642 CN01133642A CN1224496C CN 1224496 C CN1224496 C CN 1224496C CN 01133642 CN01133642 CN 01133642 CN 01133642 A CN01133642 A CN 01133642A CN 1224496 C CN1224496 C CN 1224496C
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Abstract
The present invention discloses a high strength non-cracking antiwear precise hollow shaft and making technology thereof, and the present invention relates to mines, building materials, metallurgy, machinery, etc. The present invention adopts C, Si, Mn, Cr as essential elements, and adds a small amount of Ni, Mo, V, and the rest elements are low alloy cast steel of Fe. The present invention comprises the steps: smelting in a matching furnace, casting blank, annealing, rough turning, adjusting quality, finish turning, milling, drilling and reaming. Tissues are homogeneous sorbite, and compared with the existing hollow shaft made of ZG35SiMn, the strength, the toughness and the hardness are respectively enhanced more than 44%, 227%, 32%. The present invention has the castability defects of no air hole, sand inclusion, etc. The present invention has the advantages of no fabrication stress, high precision, heat resistance, abrasion resistance, shock resistance, long service life and low cost. The present invention exports 2 0000 tons, and enterprises obtain net gain 6107 0000 dollars. The present invention has wide popularization value.
Description
Technical field
The present invention relates to a kind of accurate hollow axle of high-strength abrasion-proof non-cracking, be mainly used in the industries such as mine, building materials, metallurgy, electric power, machinery. It is grinding, the various ores of refinement or its half-finished various sleeping grinding machine (also claiming the pipe mill) that revolves, as: raw material grinding mill (raw material mill), grog grind the pass key member in the equipment such as (cement mill), oven dry mill, coal mill. The invention still further relates to the manufacturing process of the accurate hollow axle of a kind of high-strength abrasion-proof non-cracking.
The technology background
In the prior art field, no matter be advanced center transmission or the grinding machine of the Edge-Transmission mode that falls behind, no matter be to grind on a large scale refinement production or carry out the grinding machine that grinding refinement is on a small scale produced with the rotation of petty action amount with the rotation of large momentum, exist generally that hollow axle intensity is low, shock resistance poor toughness, not wear-resisting, easy fracture, replacing is frequent, manufacturing cost and use cost is high phenomenon. For many years, it is that machinery manufacturing industry and application industry are badly in need of the Technological Economy difficult problem that solves and fail all the time fundamentally to solve comprehensively in one's power always.
Cause the reason of the above results many and complicated. At first, with regard to structure, grinding machine has charging end and discharge end, (one of thin wall cylinder body end is with large flange and every grinding machine must assemble a thin-walled T tubular hollow axle at the charging end of grinding mill barrel, uniform multilayer articulation connection holes on the Flange Plane, the other end is not flanged), this kind hollow axle is commonly called as charging hollow axle. And discharge end must assemble a thin-walled worker tubular hollow axle (one of thin wall cylinder body end is with large flange, and the little flange of other end band, and also uniform multilayer articulation hole on every Flange Plane is used for connecting), and this kind hollow axle also weighs up material hollow axle. No matter be charging or discharging hollow axle, its flange and cylindrical body must be processed shaping after the one casting.
The maximum external diameter of and hollow axle different with specification according to purposes, weight, axially length, wall thickness are also different; Generally maximum external diameter is between 1500mm～5000mm in the connection place, weight about 2 tons～12 tons, axially length between 1000mm～2000mm, the bearing shell thick 60mm～100mm that is that faces the wall and meditates. Every grinding machine is connected with the large end flanges plane of two hollow axles respectively by a plurality of hinged bolts by the Flange Plane at two ends, the grinding mill barrel left and right sides; And the bearing shell face on the hollow axle cylindrical body cylindrical is partly to contain shape by the isometrical babbit ball tiling in the contour spherical bearing block in two ends to hold up; It is bearing grinding mill barrel, liner plate, abrasive body---the gross weights such as steel ball or steel rod and grinding charge material are that 100 to several hundred tons the percussion of constantly carrying out with the cylindrical shell rotation is therebetween ground, started (instantaneous subtracting heavily), falls (hurried impact) and enter again percussion and grind to potassium steel in complete in the cylindrical shell, and such one is periodically variable vibration collision and impacts.
With regard to the application operating mode that grinding machine is determined by production technology, oven dry mill (namely entering material one side by being blown into up to 450 ℃～550 ℃ hot-air seasoning, Yi Bian grind refinement) is arranged, going out material is dry powder-shaped. At this moment, the hollow axle is also standing near with the heat effect as the lonneal except being subject to the vibration impact; Wet grinding mill (namely advance quantitative material and inject gauge water, on one side with grinding machine rotation homogenizing, grind voluntarily refinement on one side) is arranged, and institute goes out material and is slurry mud shape. At this moment, the hollow axle is mainly bearing to grind and is impacting; Enter the larger material of grinding machine granularity with normal temperature in addition, though be not blown into hot blast, but in the grinding machine rotation, can produce very large grinding heat between the high manganese steel lining plate of main abrasive body steel ball, steel rod and material and grinding mill barrel inwall, make the interior temperature of grinding mill barrel up to more than 180 ℃, and with the raising of rotating speed, strengthen and grind heat. Undoubtedly, the hollow axle must bear heavily loaded oscillatory impact and strong heat effect.
With regard to the mill driving mode, center transmission (connected by empty axle head lid among the output shaft of the deceleration machine of center transmission and the grinding machine, realize synchronous rotary, this kind deceleration machine is generally by Denmark's import, every valency 270～5,400,000 yuan do not wait) is arranged; This kind kind of drive hollow bearing is impacted by huge moment of torsion stress and heavy duty property cycle of oscillation. (also use bolt-connection at bull gear of grinding mill barrel cover, by a motor drives deceleration machine, the deceleration machine passes through gear shaft to also have Edge-Transmission, drive bull gear and grinding mill barrel synchronous rotary, its floor space is large, and transmission efficiency is low, power consumption is high, and dry sound is large). In this kind of drive, the hollow axle is also bearing heavily loaded shear stress except bearing the impact of heavy duty property cycle of oscillation, the raw material grinding mill of edge transmission or oven dry mill, the hollow axle also can be subject to the thermal deformation effect of strong grinding heat or input heat, has reduced intensity, the toughness of hollow axle.
So the height of the wearability of the intensity of hollow axle, impact resistance, bearing shell face and manufacturing precision is the key that determines hollow axle length in service life.
Nearly decades, Japan, Germany, Russia and domestic some large factory: generally all be to adopt the common middle carbon cast steel of ZG35 to make the hollow axle such as Shanghai Heavy Machines Plant, Luoyang mining machinery plant etc., although the casting of ZG35, processing property and repair welding are relatively good, but because hollow axle physique structure belongs to major diameter, long cylinder book wall, T shape or worker's shape hollow pipe fitting, molten steel diffusing area is large during casting, route is long, passage is narrow, and it is slow that molten steel expands the flow velocity degree undoubtedly. Along with the continuous reduction flowability of casting liquid steel temperature is more and more poorer, and the cast gate director time is the high temperature shape, easily butterfly-shaped shortbread, molten sand. So pore, folder sand, segregation, crackle, shrinkage cavity even tomography often appear in hollow axis blank foundry goods, the blank qualification rate is very low.
Many producers should make the hollow axle have certain intensity, hardness to save again manufacturing cost, so they with the normalizing of ZG35 blank after directly processing be shaped, so remaining casting stress and processing stress, all be present among the hollow axle finished product without the repair welding stress of temper.
In recent years, many manufacturing firms are on the one hand for reducing cost, process in rough turn rear repair welding to observability casting defective for ease of machining and hollow axle on the other hand, adopted blank that ZG35 or ZG45 the are made direct technique that is shaped of processing after complete annealing. Hardly realize that ZG35 or ZG45 cast steel are being eliminated or reduced casting stress through annealing, when improving machinability and weldability, its intensity, hardness and wearability can drop to the performance of A3 steel approaching significantly; No matter the large tracts of land to bearing shell face and Zone R territory in the processing process of blank after normalizing or annealing in process is processed without the repair welding of preheating and tempering, when sharply increasing distortional stress, can cause again the bearing shell surface hardness seriously uneven on the one hand; On the other hand, give the user with the temporary transient qualified or substantially qualified illusion of outward appearance. To be exactly the hollow axle but find seriously defectively placing when rechecking after the several months for this, and the minority product autoclasis phenomenon also occurs or uses running not steady, just occurred in 3 months drawing watt or the basic reason of phenomenon of rupture in less than.
In view of carbon cast steel material among the common employing of the existing hollow axle ZG35 is made, even if so normalizing or modified after, its comprehensive mechanical performance is also not so good, press the chemical composition of GB11352-89 or GB979-67, through normalizing, tempering or modifier treatment, mechanical properties data is at most only: σ respectivelyb＝51kg/mm
2，δ＝18％，ψ＝25％，α
k＝35J/cm
2, HB=154-160; The hollow axle adopts ZG45 to make, the same science that lacks. Press the chemical composition of GB5676-85 or GB11352-89, even if its best mechanical performance of tempering can not satisfy the needs that the hollow axle is used operating mode after normalizing, particularly impact flexibility is lower, and its concrete data are: σb＝58kg/mm
2；δ
z＝15％；ψ＝21％；
α
k＝30J/cm
2。
Be worth being pointed out that: to the chemical composition of ZG35, ZG45 in the existing standard of China except composition control scope is arranged in GB979-67, and in GB5676-85 and GB11352-89, all each constituent content is defined as unique value, do not explicitly point out the concrete effectively control scope amount of its composition, smelt the control content difficulty except causing, cause the actual ZG35 that dispatches from the factory of each factory or ZG45 element composition, performance difference very large. Standard should be the summary of long-term practice experience and the comprehensive crystallization of theoretical research distillation, and its reply instructs production practices that specific operability and authority are arranged. Obviously, GB5676-85 and GB11352-89 still have To be improved.
Moreover existing hollow axle is directly to process shaping after annealing or the normalizing fully, and its comprehensive mechanical performance data can be more much lower than above-mentioned numerical value. Add the cast inside defective that the cast steel blank generally exists: pore, folder sand, crackle, segregation etc. and multiple internal stress (as; Casting residual stress, repair welding, processing stress etc.) distortion that causes, inevitablely seriously affect the manufacturing quality of hollow axle, mechanical intensity and service life.
Development along with mechanical industry, use the needs of operating mode for further satisfying grinding machine hollow axle, the enterprise that finds domestic several technical equipment processing ability richness at the beginning of 2000 has begun to adopt ZG35SiMn or the ZG40Cr hollow axis blank of casting, levels by the direct technique that is shaped of processing after normalizing, the tempering. Though the hollow axle that adopts aforesaid way to process adopts ZG35 or ZG45 to improve a lot on intensity, hardness, the tough still lower (α of its shock resistancek＝32J/cm
2), still can not satisfy comprehensive requirement that the hollow axle is used operating mode. Now the performance data with them are listed as follows:
| Standard No. | Material | Mechanical performance | Heat treatment | ||||
| σ b | δ | ψ | α k | HB | |||
| JB/ZQ4297-86 | ZG35SiMn | 578N/mm | 12％ | 20％ | 30J/cm 2 | 182 | Blank normalizing+tempering |
| ZG40Cr | 637N/mm | 18％ | 26％ | 33J/cm 2 | 212 | ||
In addition because ZG45, the casting of ZG40Cr and ZG35SiMn is poor than ZG35, so must enlarge the water route by strengthening blank allowance when adopting their casting hollow axis blanks, to increase fluidity molten steel, so not only increased blank weight expense, and expense and power consumption expense when having increased machine table, bring more casting defective can for simultaneously the hollow axis blank. After rough turn, without preheating, the repair welding stress of whole tempering can be hidden in product in large quantities to the casting defective. When the hollow axle be subject to that rotary load impacts and effect up to the hot blast of the heat of the grinding more than 180 ℃ or 450～550 ℃ under the distortion of multiple effect of stress will inevitably occur, thereby affected service life even at once fracture. Particularly ZG40Cr its casting property when casting hollow axis blank seems poorer, also usually cracks during tempering, so it only can be used for the small hollow axis blank of casting.
Import hollow axle, service life, generally in 8～10 years, it was expensive, generally was about 60000 yuan/tons; The hollow axle that present domestic quality is best, be generally 3～5 years its service life, most between 1～2 year; Also have many hollow axles to use just cracked in 1～2 month; Cause often stopping production or maintenance, seriously affected production progress and product quality and the economic benefit of manufacturer, domestic very high because making hollow axle scrappage, so its price is also very expensive, generally about 25000 yuan/tons～30000 yuan/tons.
Hollow axle service life is short, and manufacturing cost and use cost is high, is to be badly in need of for many years solving in the production industry such as domestic mine, building materials, metallurgy, electric power and the machinery manufacturing industry and all the time a unsolved technology, economic headache always.
Summary of the invention
The accurate hollow axle that the purpose of this invention is to provide a kind of high-strength abrasion-proof non-cracking, it has without pore, without crackle, without casting property defectives such as folder sand, exists without the manufacturing distortional stress; Intensity is high, the shock resistance good toughness; The heavy burden carrying turns steadily, high temperature resistant, non-cracking; Wear-resistant, long service life, the characteristics that manufacturing cost and use cost is low have satisfied the requirement of grinding machine hollow axle applying working condition fully.
Another object of the present invention provides the manufacturing process of the accurate hollow axle of a kind of high-strength abrasion-proof non-cracking of the present invention.
For reaching above purpose, the inventor costs up to more than 30 ten thousand yuan through investigating repeatedly as long as five years, analyze, test, studying, and finally succeeds, and its technical measures are as follows:
What the present invention selected is take C, Si, Mn, Cr as main added elements, additional a small amount of Ni, Mo, V element; The average carbon content of this kind cast steel is 0.2%, and much smaller than 1%, and average alloy content only is 2.765%, less than 3%; Simultaneously its on average to contain carbon equivalent (Ceq) only be 0.4714866%, and its highest carbon equivalent Ceqmax that contains also only is 0.548196%; The highest carbon equivalent Ceqmax=0.670833% low 0.121917% that contains than ZG35 (GB5676-85). Therefore, it has better casting, repair welding, heat treatment and processing property than ZG35.
The present invention in one's power carbon equivalent that on average contains of cast steel hangs down 0.120388%, 0.116013%, 0.144343% respectively than the carbon equivalent that on average contains of ZG45 (GB979-67), ZG35SiMn, ZG40Cr (JB/ZQ4297-86), and obviously it has more superior casting, repair welding and heat treatment than this three. This is to be avoided or reduce hollow axis blank casting property defective, improves the blank qualification rate, reduces the key foundation of cost. This kind cast steel blank is again after implementing manufacturing process provided by the present invention, microscopic structure is even sorbite, and it shows good comprehensive mechanical performance, special intensity and shock resistance toughness, up to the present, the domestic material that more suitably is used for making the hollow axle than it that also still finds no.
The assembly element wt percentage of cast steel of the present invention is:
C：0.18～0.22；Si：0.55～0.85；Mn：0.65～0.90；Cr：0.4～0.65；
Ni：0.35～0.60；Mo：0.15～0.30；V：0.04～0.085；P≤0.03；
S≤0.03；Fe：96.335～97.68。
Carbon among the present invention (C) is a part of to form iron element solid solution and and Fe formation cementite (Fe in solid solution in α-Fe3C), C also with the unnecessary alloying element of solid solution in ferrite form alloy carbide: VC (V is insoluble in the cementite, directly and C in conjunction with formation VC), Mo2C、Mn
7C
3、Cr
7C
3 Simultaneously also and be dissolved in cementite (Fe3C) alloying element forms the alloy cementite of lattice complexity jointly: (Fe.Cr)3C、(Fe.Mn)
3C、(Fe.Mo)
3C、(Cr.Fe)
23C
6、(Mo.Fe)
23C
6Deng; Thereby intensity, hardness and the wearability of steel alloy have been improved; For crystal grain after making heat treatment the thinnest: grain size≤20 μ m2, should there be enough intensity that good shock resistance toughness is arranged again, its phosphorus content is controlled between 0.18%～0.22% in the present invention.
Silicon (Si), Si often allocates into the deoxidation agent, and when content≤0.85%, all solid solutions improve intensity, the hardness of ferrite strongly in ferrite, and its change in toughness is very little; When content＞0.85%, its toughness significantly descends; Si and has the increase fluidity molten steel except improving tempering stability, improve the effect of casting performance. So the content of Si is controlled between 0.55%～0.85% among the present invention.
Manganese (Mn) is to be dissolved in ferrite to form alloy ferrite α-Fe (Mn) and form alloy carbide Mn7C
3With alloy cementite (Fe.Mn)3C improves quenching degree, homogenizing tissue, the important element of raising intensity, hardness and toughness; In addition, Mn energy and impurity S form MnS and certainly remove with the slag form, so Mn has the function of purify hot metal and automatic impurity removing. Simultaneously, Mn also is good deoxidation agent, reduces the fragility of steel, improves the quality of steel. Because of Mn content＜0.9% the time, the intensity of steel, hardness are to increase with its content, and that shock resistance toughness changes in this scope is very little; But when Mn content＞0.9%, its shock resistance toughness sharply descends. For both reaching the reinforcement effect, toughness is descended, be controlled between 0.65%～0.90% so contain the Mn amount among the present invention.
Chromium (Cr), their somes of molybdenum (Mo) are dissolved in ferrite, form alloy ferrite α-Fe (Cr), α-Fe (Mo); Another partly forms the stable alloy carbide of particulate, dispersion: Cr7C
3、Mo
2C; Also some is dissolved in cementite (Fe3C) in, equally with trickle, disperse, fill the air and stablize the alloy cementite: (Fe.Cr)3C、(Fe.Mo)
3C、(Cr.Fe)
23C
6Be present in the crystal boundary of high temperature austenite and between crystal boundary Deng state, except hindering Austenite Grain Growth, and obtain for quenching and to obtain even fine grain sorbite tissue after fine-grained martensitic and the tempering and have laid a good foundation, thereby improve significantly its intensity, hardness and wearability; Cr, Mo also have the effect that C curve is moved to right and significantly improve quenching degree simultaneously. The Cr constituent content is≤1% the time, its intensity, hardness and impact flexibility are to increase with the increase that contains Cr, but when Cr content＞1%, the notched bar impact strength of steel but sharply descends, for both reaching the reinforcement effect, and the purpose that toughness does not descend, so Cr content is controlled between 0.40%～0.65% among the present invention; And Mo contains≤7% the time, the intensity of steel and hardness increase with the increase that contains the Mo amount, but the toughness of steel can be with the increase that contains the Mo amount by 245J/cm2Sharply drop to 68.6J/cm2, particularly when the Mo amount of containing＞0.4% in the steel, its toughness descends remarkable especially; Allocating into of Mo can be improved tempering stability in addition, avoids high temperature temper brittleness. So the content of Mo should be controlled between 0.15%～0.30%.
Nickel (Ni) is to be dissolved in ferrite, forms the important element that alloy ferrite α-Fe (Ni) realizes solution strengthening; When containing Ni＜3%, the intensity of its steel, hardness, toughness all increase with the increase of ni content. When its content surpassed 3%, the toughness of steel had downward trend, should reach the reinforcement effect, plans as a whole again organic assembly of each element, also will consider cost simultaneously, so ni content is controlled in 0.35%～0.60% scope among the present invention.
Vanadium (V), V and C form disperse, carbonization vanadium (VC) and (Vx of tiny and extreme hardness (HRC=71-75)2C), it is present in the crystal boundary of high temperature austenite and between crystal boundary, strong ground resistance hinders growing up of crystal grain; When V content is 0.04%～01%, and temperature is 912 ℃～960 ℃, and its austenite crystal changes very little, therefore, and the sorbite tissue after the allocating significantly refinement into and quench of V after martensite and the high temperature tempering. Undoubtedly, it has greatly improved intensity, hardness and the wearability of steel. Organic assembly of double other each alloying element of event among the present invention, the content of V is defined as 0.04%～0.085%.
Phosphorus (P), P descend steel plasticity and toughness at normal temperatures, and promote C, Mn to produce the tendency of segregation in the crystallization process of steel, thus among the present invention P content be defined as≤0.03%.
Sulphur (S), S exists with the form of FeS and MnS in steel. MnS enters slag, but FeS and Fe can generate low-melting eutectic, is distributed on the crystal boundary, has weakened the crystal boundary adhesion, makes steel when the hot power of being subjected to, very easily break, so in the invention content of S be controlled at≤0.03% scope in.
Among the present invention because S, P impurity amount are few, the choosing amount of joining of Si, Mn, Mo, V is that its toughness is descended, can improve in the scope of its intensity, hardness again, and the amount of allocating into of Cr, Ni has not only improved its intensity, hardness but also improved widely its shock resistance toughness; Particularly multiple alloy carbide and alloy cementite: VC, Mo2C、Mn
3C、(Fe.Cr)
3C、(Fe.Mn)
3C、(Fe.Mo)
3C etc. with trickle, even, fill the air shape and be distributed in the crystal boundary or between crystal boundary, when improving its intensity, hardness, wearability, improved significantly its high temperature resistant property, so it is still keeping extremely high intensity, wearability and shock resistance toughness below 540 ℃.
Its used cast steel of accurate hollow axle of a kind of high-strength abrasion-proof non-cracking of the present invention, adopting electric furnace to join stove by chemical composition smelts, can adopt Al for carrying out final deoxidation treatment, tapping temperature is 1570 ℃～1580 ℃, treat that spectrum analysis confirms that its chemical composition meets the requirements, can cast when molten steel temperature is 1550 ℃～1560 ℃. Its concrete production technology is as follows:
1. the casting of blank: tapping temperature is 1570 ℃～1580 ℃, and the casting temperature is 1550 ℃～1560 ℃,
Foundry goods should be unpacked at 260 ℃～280 ℃, carries out immediately sand removal and the work of cutting rising head after unpacking,
Cutting is watered the rising head casting temperature and be should be 200 ℃～250 ℃.
2. to the processing of foundry goods defective: after 200 ℃～250 ℃ polishings of part casting defective band temperature of foundry goods surface observability are removed, the repair welding of employing J507Cr-Ni welding rod, weld seam should be continuous, smooth, and welding slag should be removed totally; After the weldering thing being spattered in overlap, burr, weldering scar and weldering adopts high speed emery wheel polishing totally or again to advance stove integral body to be preheated to 250 ℃～280 ℃ and to carry out above-mentioned mill, benefit work in the lump.
3. annealing in process: the blank integral body after will leveling is advanced stove and is heated to 880 ℃～900 ℃ and be incubated 6～8 hours and cool off with stove.
4. machining:
(1) line: blank is hung on platform just looking for and be coated with white powder by the workpiece center line perpendicular to platform, by inside and outside footpath, each step, the monolateral 3mm～5mm that all stays in both ends of the surface medial and lateral rules.
(2) rough turn: the blank hollow axle that will rule hangs on big vertical lathe, by line look for carry out after just clamping rough turn.
(3) to the processing of foundry goods cast inside defective: the semi-finished product after rough turn are surpassed spy, particularly Zone R territory and bearing shell face 100% surpass spy, to the inherent defective found and observability defective dig clearly clean after, using welding gun flame local preheating to 200 ℃～250 ℃ adopts the J507Cr-Ni welding rods to carry out repair welding, welding slag must be removed totally, and weld seam should be continuous, smooth.
(4) modifier treatment: will surpass and visit qualified semi-finished product hollow axle integral body and advance stove and be heated to 880 ℃～890 ℃, and oil is cold after being incubated 3～5 hours. It is reheated to 580 ℃～620 ℃ again, and it is cold or empty cold to be incubated 2～4 hours oil.
(5) smart car: modified qualified semi-finished product hollow axle is hung on large-scale lathe, after just looking for, will hold greatly first the smart car in Zone R territory of external diameter, outer side plane and junction, interior hole to be shaped, internally semifinishing is carried out in the hole simultaneously, and on the bearing shell cylindrical, gently be with a cutter (wide about 20mm, incision degree of depth 0.5mm) to look for the positive plane of reference as turn-over. Just look for behind the turn-over, the Zone R territory at hole, the outer side plane of little end and external diameter, the spacing R shape of bearing shell external diameter and left and right sides step, big or small two ends inner side plane and place, bearing shell cylindrical body boundary in the smart car, monolateral surplus is all stayed 0.2mm～0.4mm everywhere, and is to be ground.
(6) correct grinding: the semi-finished product hollow axle of smart car is finish grinded shaping by the drawing dimensional requirement.
(7) line: the hollow axle is hung on large platform, draw the articulation hole center line and beat foreign dotting punch in the two ends Flange Plane.
(8) bore, ream: by drawing boring, then adopt reamer to finish ream each hole and be shaped. The hollow axle of manufacturing has reached technology, the economic effect of making us unprecedented satisfaction as stated above.
Now with the present invention in one's power a kind of accurate hollow axle of high-strength abrasion-proof non-cracking and concrete technology, the economic data (containing mean value) of domestic existing top hollow axle be listed as follows:
| The hollow Spindle Name | Mechanical performance | The blank qualification rate | Product percent of pass | Make precision | Life cycle | The production cost | Contain the tax valency to factory | Tax | Profit | ||||||
| σ b | α k | HB | |||||||||||||
| N/mm 2 | J/cm 2 | Complete qualified % | Incomplete qualified % | Defective % | ％ | End face run-out (mm) | Degree (mm) in the difference | Tiling out-of-roundness (mm) | Year | Yuan/ton | Yuan/ton | Yuan/ton | Yuan/ton | ||
| Hollow axle of the present invention | ≥833 | ≥98 | ≥240 | 85 | 15 | 0 | 100 | ≤0.04 | ≤0.02 | ≤0.03 | 16-20 | 14900- 16550 | 25000-30 000 | 1731.68- 2306.04 | 8368.32-1 1143.96 |
| Domestic existing top hollow axle | 578 | 30 | 182 | 10 | 63 | 27 | 60 | 0.2-0.3 | 0.12-0 .3 | 0.04-0 .08 | 3-5 | 17880- 21500 | 25000-30 000 | 1220.75- 1457.35 | 5899.25-7 042.65 |
| Improve percentage | 44％ | 227％ | 32％ | 750％ | 320％ | 67％ | 5-7.5 doubly | 6-15 doubly | 1-2 doubly | 4-5 doubly | Average every ton few 3965 yuan | The identical pins price | 50.77％ | 50.77％ | |
The present invention is compared with existing technology, and has following remarkable advantage and obvious economic effect:
(1) intensity (σb), shock resistance toughness (α k) and case hardness improve respectively 44% and 227%, 32%;
(2) without casting property defectives such as pore, crackle, folder sand, the crystalline phase even tissue is stable, eliminated because of casting property defect repair welding and the residual stress due to processing, make the manufacturing precision of high level obtain property of a specified duration preservation, thereby avoided under heavily loaded rotary impact and the conduction of strong heat, heat radiation, the hollow axle is because being subjected to inside and outside distortional stress to converge the phenomenon that ruptures:
(3) make precision and significantly improve, wherein degree improves 6～15 times in the difference; The non-perpendicularity of two ends centering axle line improves 5～7.5 times; The out-of-roundness of bearing shell face and circular cone degree all improve l～2 times;
(4) the significantly raising of intensity, toughness, wearability and manufacturing precision, deliver the steady property except having improved significantly hollow axle service life and grinding machine, the more important thing is and be to improve rotating speed, thereby improved mill hourly output and significantly improve and use in one's power product quality and the economic benefit of enterprise:
(5) long service life is 4～5 times of existing hollow axle product, thereby reduced widely cost that user in one's power changed, used the hollow axle and the production suspension induced losses that causes because of frequent replacing and the labour cost of removing stage makeup and costume the hollow axle;
(6) the complete qualification rate of blank improves 7.5 times, has not only reduced significantly scrapping and reprocess the production cost that occurs because of blank in the manufacturing of hollow axle, and has established solid foundation for hollow axle manufacturing qualification rate reaches 100%; The complete qualification rate of product improves 67%, is the synthesis result of strict implement each working link of the present invention. So keep under the condition of identical selling price significantly improve making precision, every ton of profit gained of hollow axle product of the present invention and (national tax, the land tax) volume of paying taxes all improve 51%.
If the whole nation is 250 big-and-middle cement plants only, by average 10 grinding machines of every family, 2 hollow axles of every grinding machine, 5 tons of every average net weight of hollow axle, they be 4 years by existing hollow axle average service life, and every ton of hollow axle is to 27500 yuan of calculating of the price at factory (contain lifting, tie up, deliver goods and 17% national tax, land tax), so, the per 4 years whole nations need to change hollow axle net weight and are: 25000 tons, blank is heavily about: 40000 tons; Hollow axle purchase commodity is: 68.75 hundred million yuan; The order of hollow axle, completion are checked and accepted and come and gone trip expenses for twice is 2,000,000 yuan (it is 2 people that every factory singly takes advantage of at every turn, and everyone singly takes advantage of 1000 yuan of lump sums of limit to use at every turn); Change hollow axle production suspension induced losses and service charge: 5,000 ten thousand yuan (it is pretty troublesome to change the hollow axle: need unload material, abrasive body, steel ball or steel rod and cylindrical shell liner plate, refill liner plate, main abrasive material steel ball or steel rod and material etc. after the hollow axle fills. Every grinding machine replacing hollow axle approximately need be with 7 days, and every replacing once stops production with labour cost with 20000 yuan of calculating); Then 4 years whole nations use in one's power the hollow axle only 250 enterprises need 69.27 hundred million yuan altogether. Then 16 years whole nations only 250 main big-and-middle-sized producers of building material industry need change the hollow axle 4 times, its rolled steel dosage and expense are as follows:
Change hollow axle net weight: 100,000 tons, heavily about 160,000 tons of blank, hollow axle purchase commodity is: 27,500,000,000 yuan; The hollow axle is ordered goods, and checks and accepts to come and go travel allowance: 8,000,000 yuan; Change hollow axle production suspension induced losses and service charge: 20,000 ten thousand yuan (200,000,000 yuan); Then total cost is: 277.08 hundred million yuan (27,700,010,800 yuan).
If use in one's power a kind of accurate hollow axle of high-strength abrasion-proof non-cracking of the present invention, in 16～20 years, also only need to change so a hollow axle, total cost and existing hollow axle occur and equate the data in 4 years in its casting steel consumption and institute, thereby in 16 years be national saving hollow axle manufacturing steel 75% (120,000 tons); Saving fund 75% (207.81 hundred million yuan). Because the present invention in one's power a kind of accurate hollow axle of high-strength abrasion-proof non-cracking makes quality with outward appearance and is better than Japan, Germany, Denmark's product including, as arrive the RMB price of China by its import: 60000 yuan/tons, even more preferential 25% and under the condition of dollar exchange rate constant (1: 8.3), 20000 tons of annual outlets, then can create 900,000,000 yuan of the output values every year, for country earns foreign exchange: 1.084337 hundred million dollars, if country gives entirely to refund preferential policy, remove sea, ocean expense far away and tariff, then enterprise can obtain net income every year: 5.0688 hundred million yuans, amount to: 6,107 ten thousand dollars.
Quality is good, cost is low so the accurate hollow axle of a kind of high-strength abrasion-proof non-cracking involved in the present invention has, the characteristics of small investment, instant effect, and it can obtain very significant economic benefit for enterprise and country in a short time. Therefore, it has extensively actively use value, promotional value and fruitful economic worth.
Concrete enforcement mode
Be further to explain the present invention, existing with the present invention in one's power a kind of accurate hollow axle and manufacturing process of high-strength abrasion-proof non-cracking provide three examples, concrete implementing process is as follows:
By the present invention in one's power chemical composition join the stove melting, treat that temperature in the time of 1575 ℃, detects its chemical composition, except casting at 1550 ℃ behind the slag; When foundry goods is cooled to 270 ℃ of unpacking sand removals; It is 240 ℃ that the rising head temperature is watered in the sand removal cutting.
2. to the processing of foundry goods defective: through carefully checking in the foundry goods hollow axle a small amount of spilehole is arranged, shallow stratified sand one place, after adopting the polishing of high speed emery wheel clean, band temperature (215 ℃) is carried out repair welding, and welding rod is J507Cr-Ni; Weld seam is continuous, smooth.
3. annealing in process: the blank integral body after will leveling is advanced stove and is heated to 890 ℃ and be incubated 7 hours and cool off with stove.
4. machining:
(1) line: blank is hung on platform just looking for and be coated with white powder by the workpiece center line perpendicular to platform, by inside and outside footpath, each step, the monolateral 4mm that all stays in both ends of the surface medial and lateral rules.
(2) rough turn: the blank hollow axle that will rule hangs on big vertical lathe, by line look for carry out after just clamping rough turn.
(3) to the processing of foundry goods cast inside defective: the semi-finished product after rough turn are surpassed spy, R zone and bearing shell face are 100% to carry out, only find that the Zone R territory has≤one of 0.3mm pin hole shape spilehole, after digging clearly totally, use welding gun flame local preheating to 230 a ℃ employing J507Cr-Ni welding rod and carry out repair welding, welding slag has been removed totally, and weld seam is continuous, smooth.
(4) modifier treatment: will surpass and visit qualified semi-finished product hollow axle integral body and advance stove and be heated to 885 ℃, and oil is cold after being incubated 4 hours. Again it is reheated to 600 ℃, and it is cold to be incubated 2 hours oil.
(5) smart car: modified qualified semi-finished product hollow axle is hung on large-scale lathe, after just looking for, will hold greatly first the smart car in Zone R territory of external diameter, outer side plane and junction, interior hole to be shaped, internally semifinishing is carried out in the hole simultaneously, and on the bearing shell cylindrical, gently be with a cutter (wide about 20mm, the about 0.5mm of the incision degree of depth) to look for the positive plane of reference as turn-over. Turn-over is by just looking for, and the interior hole of smart car, little end be side plane and external diameter thereof outward, the Zone R territory at bearing shell external diameter and the left and right sides spacing R shape step, big or small two ends inner side plane and place, bearing shell cylindrical body boundary, and monolateral surplus should be stayed 0.25mm everywhere, and is to be ground.
(6) correct grinding: the semi-finished product hollow axle of smart car is finish grinded shaping by the drawing dimensional requirement.
(7) line: the hollow axle is hung on large platform, draw the articulation hole center line and beat foreign dotting punch in the two ends Flange Plane.
(8) bore, ream: by drawing boring, then adopt reamer to finish ream each hole and be shaped. More than be the concrete steps of example 1, example 2,3 duplicates. Three examples are specialize study part and mechanical performance, purposes and the effect list as follows:
| Embodiment | The chemistry composition | Machine subtracts performance | Purposes and effect | ||||||||||||||
| C | Si | Mn | Cr | Mo | Ni | V | P | S | Fe | σx s | σ b | δ | ψ | α k | HB | ||
| ％ | ％ | ％ | ％ | ％ | ％ | ％ | ％ | ％ | ％ | N/mm 2 | N/mm 2 | ％ | ％ | J/cm 2 | |||
| 1 | 0.21 | 0.76 | 0.89 | 0.54 | 0.28 | 0.36 | 0.082 | 0.018 | 0.015 | 96.845 | 676 | 921 | 11.3 | 47 | 94 | 269 | 2 on 3 * 11 meters ball mill input and output materials of Φ hollow axle, the so far operation of coming into operation on June 18th, 98 is good. |
| 2 | 0.22 | 0.56 | 0.75 | 0.48 | 0.17 | 0.49 | 0.076 | 0.019 | 0.017 | 97.278 | 660 | 853 | 12 | 50 | 99.2 | 258 | 2 on 2.2 * 13 meters cement grinding machines of Φ hollow axle, come into operation and do not find so far fault in October, 99. |
| 3 | 0.19 | 0.84 | 0.67 | 0.64 | 0.23 | 0.58 | 0.046 | 0.02 | 0.019 | 96.765 | 647 | 823 | 16 | 57.65 | 104 | 248 | 2 on 2.2 * 11 meters cement grinding machines of Φ input and output material hollow axle drops into so far not maintenance in February, 2000. |
Claims (2)
1, a kind of accurate hollow axle of high-strength abrasion-proof non-cracking, its assembly element wt percentage is:
C：0.18～0.22； Si：0.55～0.85；Mn：0.65～0.90；Cr：0.4～0.65；
Ni：0.35～0.60；Mo：0.15～0.30；V ：0.04～0.085；P≤0.03；
S≤0.03； Fe：96.335～97.68。
2, a kind of manufacturing process of accurate hollow axle of high-strength abrasion-proof non-cracking, it comprises the following steps:
(1) casting of blank: at first join the stove melting according to following chemical composition, its assembly element wt percentage is:
C：0.18～0.22； Si：0.55～0.85；Mn：0.65～0.90； Cr：0.4～0.65；
Ni:0.35～0.60; Mo:0.15～0.30; V: 0.04～0.085; P≤0.03; S≤0.03; Fe:96.335～97.68, tapping temperature is 1570 ℃～1580 ℃, and the casting temperature is 1550 ℃～1560 ℃, and foundry goods should be unpacked at 260 ℃～280 ℃, carry out immediately sand removal and the work of cutting rising head after unpacking, cutting is watered the rising head casting temperature and be should be 200 ℃～250 ℃;
(2) to the processing of foundry goods defective: after 200 ℃～250 ℃ polishings of part casting defective band temperature of foundry goods surface observability are removed, the repair welding of employing J507Cr-Ni welding rod, weld seam should be continuous, smooth, and welding slag should be removed totally; After the weldering thing being spattered in overlap, burr, weldering scar and weldering adopts high speed emery wheel polishing totally or again to advance stove integral body to be preheated to 250 ℃～280 ℃ and to carry out above-mentioned mill, benefit work in the lump;
(3) annealing in process: the blank integral body after will leveling is advanced stove and is heated to 880 ℃～900 ℃ and be incubated 6～8 hours and cool off with stove;
(4) machining:
1. line: blank is hung on platform just looking for and be coated with white powder by the workpiece center line perpendicular to platform, by inside and outside footpath, each step, the monolateral 3mm～5mm that all stays in both ends of the surface medial and lateral rule;
2. rough turn: the blank hollow axle that will rule hangs on big vertical lathe, by line look for carry out after just clamping rough turn;
3. to the processing of foundry goods cast inside defective: the semi-finished product after rough turn are surpassed spy, answer 100% to carry out to Zone R territory and bearing shell face, to the inherent defective found and observability defective dig clearly clean after, use welding gun flame local preheating to 200 ℃～250 ℃, adopt the J507Cr-Ni welding rod to carry out repair welding, welding slag is removed clean, and weld seam should be continuous, smooth;
4. modifier treatment: the semi-finished product hollow axle that will surpass spy advances stove and is heated to 880 ℃～890 ℃, and oil is cold after being incubated 3～5 hours, it is reheated to 580 ℃～620 ℃ again, and it is cold or empty cold to be incubated 2～4 hours oil;
5. smart car: modified qualified semi-finished product hollow axle is hung on lathe, after just looking for, will hold greatly first the smart car in Zone R territory of external diameter, outer side plane and junction, interior hole to be shaped, internally semifinishing is carried out in the hole simultaneously, and on the bearing shell cylindrical, gently look for the positive plane of reference with a cutter as turn-over, just look for behind the turn-over, hole, the outer side plane of little end and external diameter thereof in the smart car, the Zone R territory at bearing shell external diameter and the left and right sides spacing R shape step, big or small two ends inner side plane and place, bearing shell cylindrical body boundary, monolateral should stay 0.2mm～0.4mm everywhere, to be ground;
6. finish grind: the semi-finished product hollow axle of smart car is finish grinded shaping;
7. line: the hollow axle is hung on platform, draw the articulation hole center line and beat foreign dotting punch in the two ends Flange Plane;
8. bore, ream: boring also adopts reamer to finish ream each hole shaping.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 01133642 CN1224496C (en) | 2001-11-07 | 2001-11-07 | High-strength non-cracking antiwear precise hollow axle and its making technology |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 01133642 CN1224496C (en) | 2001-11-07 | 2001-11-07 | High-strength non-cracking antiwear precise hollow axle and its making technology |
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| CN1363444A CN1363444A (en) | 2002-08-14 |
| CN1224496C true CN1224496C (en) | 2005-10-26 |
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Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102114511B (en) * | 2009-12-31 | 2012-05-30 | 山西晋西精密机械有限责任公司 | Machining method of cylindrical spinning mandrel |
| CN101885135B (en) * | 2010-06-13 | 2015-07-22 | 上海市机械制造工艺研究所有限公司 | Method for manufacturing hammer shaft of single-stage hammer crusher |
| CN102399533A (en) * | 2011-09-26 | 2012-04-04 | 宁国市东方碾磨材料有限责任公司 | Wear-resistant and corrosion-resistant nano-abrasive material and preparation method thereof |
| CN103103920B (en) * | 2013-02-02 | 2015-03-25 | 四川天元机械工程股份有限公司 | Manufacturing method for tempering cable clip applied to suspension bridge |
| CN108075598A (en) * | 2017-11-23 | 2018-05-25 | 江阴市永兴机械制造有限公司 | A kind of machine shaft and its processing method |
| CN108115112A (en) * | 2017-12-29 | 2018-06-05 | 重庆全茂合渝科技有限公司 | A kind of processing technology of the automobile-used double crosslinking gear shaft of motor |
| CN108730175A (en) * | 2018-07-25 | 2018-11-02 | 苏州利达铸造有限公司 | A kind of alloy pump case and its processing method |
| CN111546009A (en) * | 2020-05-15 | 2020-08-18 | 淮北良信矿山机器有限公司 | Manufacturing method of mining machinery axle |
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