CN1600873A - Equipment and method for induction hardening stepped shaft - Google Patents
Equipment and method for induction hardening stepped shaft Download PDFInfo
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- CN1600873A CN1600873A CNA031512321A CN03151232A CN1600873A CN 1600873 A CN1600873 A CN 1600873A CN A031512321 A CNA031512321 A CN A031512321A CN 03151232 A CN03151232 A CN 03151232A CN 1600873 A CN1600873 A CN 1600873A
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- inductor block
- step shaft
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- 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
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
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Abstract
This invention relates to a method and the equipment for quenching stepped shaft heated by induction method. The induction heating quenching equipment is composed of: intermediate frequency induction electric power, simple numerical control quenching press, a transformer, centering device of inductor, electric conducting gang, quick changing device of inductor and the inductor. When proceeding the induction heating quenching the stepped shaft, the inductor moves from bottom to the top, from the large diameter end to the small diameter end of the stepped shaft with altogether 5 steps hardening, two stops at two surfaces (upper/bottom) of step of the stepped shaft. Advantages are: quenching with suitable depth, simple procedure.
Description
Technical field
The present invention relates to a kind of thermal treatment unit and method of mechanical component, relate in particular to a kind of step shaft induction hardening equipment and method.
Background technology
The step shaft that certain requirement of strength arranged is linked to each other by at least two different axle ladders of diameter as shown in Figure 1, and prior art is as follows to the manufacturing procedure of this step shaft:
Forging → normalizing → ball blast → rough turn → modified → ball blast → alignment → finish turning → surface hardening → tempering → grinding.
Surface hardening operation wherein is the important procedure that is related to step shaft workpiece surface hardness and intensity, generally adopts induction heat treatment to harden.When the portion of A shown in Fig. 1 was hardened, the induction heat processing method of prior art was to adopt two inductor blocks 11 and 12 respectively big footpath axle and path axle to be carried out induction quenching as shown in Figure 2, needs twice clamping.Because the influence that traditional round annular inductor block is originally experienced magnetoresistive effects such as magnetic field sharp angle effect, shielding effect, approach effect, form as shown in Figure 2 quenched zone 13 and quenched zone 14, in the very difficult control of effective case depth of the boundary transit site of footpath axle and path axle greatly, even there is not hardness.So must need the modified operation after rough turn in the traditional technical process, come proof strength by modified, and, need select the good steel of hardening capacity and hardenability for use, as medium carbon alloy steels such as 42CrMo, 40CrMnMo for the proof strength grade.Like this, there is following drawback in traditional technology:
A, for proof strength adopts high hardenability steel, material cost is increased;
B, the whole modified thermal treatment for guaranteeing that minimum diameter place intensity adopts have increased the thermal treatment cost;
C, consider tempering deformation, needing increases machining allowance, adds that the loss of the cutter that quenching and tempering hardness causes greater than normalizing hardness increases, and the machining cost is risen;
D, induction quenching adopt clamping twice, and production efficiency is reduced;
The boundary transit site of E, big footpath axle and path axle is owing to be in quality adjustment condition, and general hardness can not surpass 35HRC, existing under the situations such as cut, stress concentration, can make decrease of fatigue strength, has reduced work-ing life, easily causes the moment repeated stress failure yet.
Summary of the invention
Purpose of the present invention is in order to overcome the deficiencies in the prior art, to provide a kind of intermediate location of step shaft that can make to reach certain depth of hardening zone, and can simplify the step shaft induction hardening equipment and the method for the manufacturing procedure of step shaft.
The technical measures that the present invention taked are: a kind of step shaft induction hardening equipment, comprise medium frequency induction power supply, simple nc quenching machine, transformer, inductor block aligning gear, busbar and inductor block, described transformer, busbar and inductor block are linked in sequence into an integral body and are arranged on the simple nc quenching machine and with medium frequency induction power supply and are electrically connected; Described inductor block aligning gear is installed in and is used to control position of inductor on the simple nc quenching machine; Be characterized in: also comprise the inductor block fast replacing device, this inductor block fast replacing device is connected between busbar and the inductor block, and the inductor block fast replacing device is the modular structure part, comprises busbar link block and inductor block link block, and two modules interconnect with removably; Described busbar is coated with conductive resin with the end face that is connected between transformer and the inductor block fast replacing device, and adopts bolt to connect then; Described simple nc quenching machine adopts summary procedure control able to programme; Described transformer is the ferrite output transformer; Described busbar is provided with two groups of water-cooled tubes, is installed in respectively on the battery lead plate of both sides; Described inductor block is two coil structures ring-type inductor blocks, comprises inner ring inducing circle and outer ring hydrojet circle, and inner ring inducing circle fits tightly with outer ring hydrojet circle and links to each other.
Above-mentioned step shaft induction hardening equipment, wherein, the busbar link block of described inductor block fast replacing device comprises left battery lead plate, right battery lead plate, last strongback, following strongback, insulating barrier, two backing plates, two pressing plates and connecting key, insulating barrier is arranged between the left and right battery lead plate, upper and lower strongback is sealed on the two ends up and down of left and right battery lead plate, and left and right battery lead plate is used for linking to each other with two preceding battery lead plates of busbar respectively; Two backing plates are arranged on the both sides, upper end of left and right battery lead plate, two pressing plates respectively are pressed on two backing plates by a nonstandard screw and are used for inductor block link block and busbar link block are linked together, and connecting key vertically is arranged on and is used on the right battery lead plate being linked with the inductor block link block.
Above-mentioned step shaft induction hardening equipment, wherein, the inductor block link block of described inductor block fast replacing device comprises two web plates, two intermediate plates, two contact plates, insulcrete, guide plate, strap stiffener, water-cooled tube be connected keyway, two intermediate plates link to each other with two contact plates and are arranged on two web plates, one lateral bottom, insulcrete is folded in two web plates, between two intermediate plates and two contact plates, guide plate is arranged on the top of two web plate another sides and is used for linking to each other with the busbar link block, the bottom that strap stiffener is arranged on two web plates is used for two web plates are fixed together, water-cooled tube is arranged on a side that is provided with intermediate plate and contact plate of two web plates, two contact plates are used for linking to each other with inductor block, connect that keyway is arranged on a plate and with the inductor block link block on to be connected keyway suitable.
Above-mentioned step shaft induction hardening equipment, wherein, the inducing circle of described inductor block and the cross section of hydrojet circle are approximate rectangular, the interior side-lower of this two approximate rectangular circle all inwardly is shrunk to the inclined-plane for one jiao, side-lower has an inside projection in the inducing circle, the height of described hydrojet circle is greater than the height of inducing circle, the inclined-plane that is located on the hydrojet circle is exposed below the inducing circle, be equipped with a plurality of spray holes on the inclined-plane of hydrojet circle, the diameter of spray hole is 1.2～2.4mm, the spacing of adjacent two spray holes is 2～4mm, and the angle of spray hole axis and inductor axis is 35 °～55 °; Logical distilled water in the inducing circle, logical hardening liquid in the hydrojet circle.
A kind of method of step shaft induction quenching, described step shaft comprises big footpath axle and path axle, on the reducing place formation ladder plane of big footpath axle with the path axle, be characterized in, diameter according to step shaft is selected adaptive inductor block, and selects suitable device frequency and spray parameter, takes inductor block to move from lower to upper, shift to miner diameter end from the bigger diameter end of step shaft, harden according to the following steps:
Step 1, the mobile axle surface, big footpath of hardening:
Inductor block is placed the bottom of big footpath axle, select suitable device output rating and inductor block translational speed, inductor block is from bottom to top moved the main part on axle surface, big footpath is hardened;
Step 2, pause and to harden axle upper end, big footpath to the part between the ladder plane:
When inductor block moves to 1/3rd of its inducing circle and highly exposes the ladder plane of step shaft, reselect the equipment output rating, pause for some time, axle upper end, big footpath to the part between the ladder plane of step shaft is hardened;
Step 3, quick travel to next pause position of hardening:
Behind the completing steps 2, with inductor block quick travel to next pause position of hardening;
Step 4, pause and to harden the ladder plane to the part between the path axle front end:
When inductor block quick travel during to the ladder planes overlapping of the lower plane of its inducing circle and step shaft, reselect the equipment output rating, pause for some time, the part between ladder plane to the path axle lower end of step shaft is hardened;
Behind the completing steps 4, reselect equipment output rating and inductor block translational speed, inductor block is from bottom to top moved the main part on path axle surface is hardened;
Step 6, end:
Behind the completing steps 5, the spray that quenches is closed in switch-off power output, unclamps thimble, and step shaft is shifted out inductor block, quits work, and finishes its induction quenching process to step shaft.
The method of above-mentioned step shaft induction quenching, wherein, described device frequency is selected according to the diameter of step shaft, and when the diameter of step shaft changed between 12-64mm, device frequency was selected between 30-2kHz.
The method of above-mentioned step shaft induction quenching, wherein, the equipment output rating of described each step is that the product of surface-area of the pairing workpiece of active conductor of the specific power of workpiece and inductor block is then than a last efficiency factor, the specific power of workpiece reaches according to selected device frequency the requirement of step shaft depth of hardening zone is selected, when device frequency at 12-1kHz, when depth of hardening zone changed between 1.5-9.0mm, the specific power of workpiece was at 4-1.2kW/cm
2Between select.
The method of above-mentioned step shaft induction quenching, wherein, the inductor block translational speed of described step 1 and step 5 equals the virtual height (mm) of the ring sensor of twice divided by utilizing this ring sensor that workpiece surface is heated to 900 ℃ of institute's time spents (s).
The method of above-mentioned step shaft induction quenching, wherein, the residence time of described step 2 is 0.8-7.2 second, the residence time of step 4 is 0.6-4.2 second.
The method of above-mentioned step shaft induction quenching, wherein, described spray parameter comprises quenchant, spray pressure, quench media temperature and specific liquid rate;
Described quenchant is selected between poly-alkylene ethylene glycol, sodium polyacrylate, polyvinylpyrrolidone, poly-ethyl oxazoline, quick oil, oily, the conventional oil of middling speed and deep fat the requirement of quenching intensity according to the step shaft workpiece;
Described spray pressure-controlling is at 0.15～0.6MPa;
Described quench media temperature is controlled at 30～50 ℃;
Described specific liquid rate is controlled at 45～60 (10
-6.m
3/ cm
2.s).
Step shaft induction hardening equipment of the present invention and method, utilize medium frequency induction power supply, simple nc quenching machine, adopt custom-designed inductor block and inductor block fast replacing device, inductor block aligning gear, busbar, by choose reasonable and control, step shaft is carried out the continuous sweep induction heat treatment to device frequency, equipment output rating, inductor block translational speed, the specific position heating residence time and spray parameter.Both guaranteed that boundary, the large and small footpath of step shaft transit site has certain depth of hardening zone, can save the modified heat treatment step in preceding road of step shaft again.The advantage of bringing thus comprises following particular content:
A, because the whole military service region surface of step shaft has all been hardened by induction heat treatment uniformity ground, make member reach design strength, so can save in the step shaft course of processing the whole modified heat treatment step that adopts for assurance minimum diameter place intensity.That is: can adopt the thermal treatment process flow process of " normalizing+intermediate frequency continuous sweep heating, quench " to substitute the thermal treatment process flow process of traditional " modified+the segmentation induction heating, quenching ".
B, the selection grade is reduced.Adopted the high hardenability steel of high price in the past for proof strength, can adopting at a middle or low price now, non-hardened and tempered steel, the medium carbon low alloy steel of lattice replace.
C, for the workpiece (particularly minimum diameter is at the workpiece of φ below 64) of certain diameter, the intended diameter of axle is reduced, weight saving, increase thereby make such as the power output performance of the finished product such as automobile.
D, be main axial workpiece for bearing torsional load, complete surperficial continuous induction heat is handled and can be made a surface be in continuous high rigidity and compressive stress state, and heart portion is in the high tenacity state, thereby the fatigue strength of axle is improved, service life prolongs greatly.
E, owing to can save whole modified operation in the step shaft course of processing, can also bring following benefit:
E1, blank roughing surplus no longer need, and the part consumptive material will reduce 2-4mm;
E2, process-cycle shorten, and the goods cost reduces;
E3, the thermal treatment cost is reduced by half substantially, per kilogram part (weight after rough turn) can be saved modified cost more than 1.5 yuan at least;
E4, prolonged in the machine tool life-span greatly;
E5, make blank become possibility, so the industries such as automobile making that are specially adapted to produce in enormous quantities to the line production of not landing of finished product.
Description of drawings
Concrete characteristic performance of the present invention is further described by following embodiment and accompanying drawing thereof.
Fig. 1 is the structural representation of common step shaft;
Fig. 2 is the method synoptic diagram of A portion shown in prior art induction heating Fig. 1;
Fig. 3 is a step shaft induction hardening equipment synoptic diagram of the present invention;
Fig. 4 is the synoptic diagram that transformer, busbar, inductor block fast replacing device and the inductor block among the present invention links together;
Fig. 5 is the vertical view of Fig. 4;
Fig. 6 is the structural representation of the busbar among the present invention;
Fig. 7 is the vertical view of busbar shown in Figure 4;
Fig. 8 is that the B of busbar shown in Figure 4 is to side-view;
Fig. 9 is that the C-C of busbar shown in Figure 4 is to sectional view;
Figure 10 is the structural representation of the busbar link block of the inductor block fast replacing device among the present invention;
Figure 11 is the side-view of Figure 10;
Figure 12 is the vertical view of Figure 10;
Figure 13 is the D-D sectional view of Figure 10;
Figure 14 is the structural representation of the inductor block link block of the inductor block fast replacing device among the present invention;
Figure 15 is the side-view of Figure 14;
The E of Figure 16 Figure 15 is to view;
Figure 17 is the structural representation of the inductor block among the present invention;
Figure 18 is the side-view of Figure 17;
Figure 19 is the implementation procedure synoptic diagram of step shaft induction quenching method of the present invention;
Figure 20 is the effect synoptic diagram that hardens of step 2 pause heating quenching in the implementation procedure of step shaft induction quenching method of the present invention;
Figure 21 is the effect synoptic diagram that hardens of step 4 pause heating quenching in the implementation procedure of step shaft induction quenching method of the present invention.
Embodiment
Referring to Fig. 3, Fig. 4, Fig. 5, step shaft induction hardening equipment of the present invention comprises medium frequency induction power supply 21, simple nc quenching machine 22, transformer 23, inductor block aligning gear 24, busbar 25, inductor block fast replacing device 26 and inductor block 27.Transformer 23, busbar 25, inductor block fast replacing device 26 and inductor block 27 are linked in sequence into an integral body and are arranged on the simple nc quenching machine 22 and with medium frequency induction power supply 21 and are electrically connected, and inductor block aligning gear 24 is installed in the relative position that is used on the simple nc quenching machine 21 control inductor block and is heated workpiece.
The power tube of the medium frequency induction power supply 21 among the present invention adopts powerful IGBT pipe, and capable of fast starting, its frequency adopts 4-12kHz.
Simple nc quenching machine 22 among the present invention adopts summary procedure control able to programme.The mode that adopts induction hardening transformer to move need guarantee that also the speed of rotation of workpiece is adjustable continuously, the translational speed of inductor block is adjustable continuously, inductor block can pause at an arbitrary position with respect to workpiece, and the heating installation output rating of heating region optional position is adjustable.Concrete technical requirements is as follows:
(1), simple nc machine adopts a whole set of OTD system of Japan's FA NUC company to control.
(2), moving up and down of transformer bracket adopt servomotor, pretension ball-screw, spherical guide, repetitive positioning accuracy reaches ± 0.01mm up and down.
(3), drive the following top employing ac variable frequency speed regulation of Workpiece Rotating, adopt the frequency transformer (FRENIC5000G11 TYPE:FRN 1.5G11S-4CX) of company of Fuji, rotating speed 1-500RPM is adjustable continuously.
(4), thimble adopts the air pressure clamping on the clamping, ac variable frequency speed regulation is adopted in last thimble support up-and-down movement control, the frequency transformer (FRENIC5000G11 TYPE:FRN 1.5G11S-4CX) of company of employing Fuji, and 5-50HZ is adjustable continuously.
(5), go up the pneumatic clamping source of the gas of thimble and adopt 0.4-0.6MPa pressurized air.
(6), go up thimble auto-lock function will be arranged, following thimble bearing will have water-proof function.
(7), in effective clamping range, the concentricity requirement of thimble axial connecting line and inductor block central track trace reaches＜0.1mm up and down.
(8), system provides 0-10V reference power supply output signal for the quenching power supply, thereby can accurately control intermediate frequency power supply equipment output rating by the NC program.
(9), be handled easily, lathe the place ahead configuration button case, drawing type, there is state to adjust knob (programming, automatically, crawl, manually), manual relating operation button (clamping control, rotation control, transformer move control), program loop start button, the emergency stop push button under the state of a control, and button and correlation behavior demonstration pilot lamp such as checking for zero, crawl interlock conversion, electric power starting.
(10), the NC program uses the international standard G code, be simple and easy to use.
(11), 9 inches CRT of configuration show, can carry out dynamic monitoring to the workpiece working condition.
(12) but, system's handling procedure reaches 200, and is equipped with communication interface so that program of file copy, remote programmable.
(13), power supply: AC380V (three-phase 5 line systems)
(14), output power: the needs that satisfy servomotor, variable-frequency motor etc.
(15), NC power supply: DC24V
(16), control power supply: DC24V
(17), relevant quenching maximum length of workpiece, quenching maximum workpiece weight, the quenching maximum diamater of work, the mobile top speed of quenching etc. need offer device fabrication producer, so that manufacturer finally determines clamping maximum length (lathe height), main shaft maximum speed of revolution and servomotor, the required power of variable-frequency motor of quenching machine.
The ferrite intermediate frequency transformer that the transformer adopting volume is little, in light weight, loss power is little among the present invention.
The effect of the inductor block aligning gear 24 among the present invention is that the rotating shaft of the center of inductor block and workpiece is overlapped.Requiring vertically, (front and back) position adjustable is 0-100mm; Laterally (about) position adjustable is ± 15mm; The form that adopts line slideway load-bearing, screw mandrel to regulate is regulated front and back position in the front by rotary handle, drives the side screw mandrel in the front by conical gear and regulates position, the left and right sides.Words with good conditionsi, the method self-centering of configurable driven by servomotor, probe detection.
Referring to Fig. 6, cooperation is referring to Fig. 7, Fig. 8, Fig. 9, and the busbar 25 in the step shaft induction hardening equipment of the present invention comprises water-cooled tube 251, two preceding battery lead plates 252, two rear electrode plates 253, two intermediate electrode plate 254, insulating barrier 255 and cooling tube joint 256.Battery lead plates 252 and two rear electrode plates 253 are arranged on the rear and front end of two intermediate electrode plate 254 and the two ends of two intermediate electrode plate 254 are clamped in therebetween before two, insulating barrier 255 is made by polytetrafluoroethylmaterial material, be arranged between two intermediate electrode plate 254, adopting the nylon screw rod is firm, can prevent inter-electrode short-circuit reliably, play arcing.Water-cooled tube 251 is a copper tube, is divided into two groups and is three shaped as frames and is installed in respectively on two intermediate electrode plate 254, and two edges up and down of water pipe are pressed on the both sides up and down of intermediate electrode plate 254, can effectively cool off busbar, makes it be not easy heating and burns out.Battery lead plate 252 is used for linking to each other with inductor block fast replacing device 26 before two, and two rear electrode plates 253 are used for linking to each other with transformer 23, and its connection end face is coated with conductive resin, and is fastening with stainless steel bolt, connects closely reliable, good conductivity.
Referring to Figure 10, Figure 14, cooperate referring to Fig. 4.Inductor block fast replacing device 26 in the step shaft induction hardening equipment of the present invention is the modular structure part, comprises busbar link block 261 (see figure 10)s and inductor block link block 262 (seeing Figure 14).
Referring to Figure 10, cooperation is referring to Figure 11, Figure 12, Figure 13, and busbar link block 261 comprises left battery lead plate 2611, right battery lead plate 2612, last strongback 2613, following strongback 2614, insulating barrier 2615, two backing plates 2616, two pressing plates 2617 and connecting key 2618.Insulating barrier 2615 is arranged between left battery lead plate 2611 and the right battery lead plate 2612, and last strongback 2613 and following strongback 2614 are sealed on the two ends up and down of left and right battery lead plate, and left and right battery lead plate is used for linking to each other with two preceding battery lead plates 252 of busbar 25 respectively.Two backing plates 2616 are arranged on the both sides, upper end of left and right battery lead plate, and two pressing plates 2617 respectively are pressed on two backing plates by a nonstandard screw and are used for inductor block link block 262 and busbar link block 261 are linked together; Connecting key 2618 is vertically set on the left side of right battery lead plate 2612.
See also Figure 14, cooperation is referring to Figure 15, Figure 16, inductor block link block 262 comprises two web plates 2621, two intermediate plates 2622, two contact plates 2623, insulcrete 2624, guide plate 2625, strap stiffener 2626 and water-cooled tube 2627, be provided with on a plate 2621 with busbar link block 261 on connecting key 2618 adaptive be connected keyway 2628, two intermediate plates 2622 link to each other with two contact plates 2623 and are arranged on two web plates, 2,621 one lateral bottoms, insulcrete 2624 is folded in two web plates 2621, between two intermediate plates 2622 and two contact plates 2623, guide plate 2625 is arranged on the top of two web plate another sides and is used for linking to each other with busbar link block 261, the bottom that strap stiffener 2626 is arranged on two web plates is used for two web plates are fixed together, water-cooled tube 2627 is arranged on a side that is provided with intermediate plate and contact plate of two web plates, and two contact plates 2623 are used for linking to each other with inductor block 27.The characteristics of the inductor block fast replacing device 26 among the present invention are: be connected closely, reliable good conductivity with busbar 25; Adopt water-cooling system, be not easy heating; Adopt to connect the keyway location, the installation multiplicity is good; When inductor block is installed, can make inductor block maintenance level automatically; When inductor block is installed, can make inductor block finely tune 0-10mm by adjusting screw in Z-direction; Modular structure, the inductor block link block 262 of inductor block fast replacing device can disassemble together with inductor block 27 easily by the mode of unclamping the pressing plate 2617 on the busbar link block 261, also can change inductor block fast by the mode of the coupling screw of outwarding winding.
See also Figure 17, cooperate referring to Figure 18, the inductor block 27 in the step shaft induction hardening equipment of the present invention comprises two conducting platess 271, two water-cooled tubes 272, insulcrete 273, two quench fluid tubes 274, inner ring inducing circle 275 and outer ring hydrojet circle 276.Two conducting platess 271 and 272 corresponding linking to each other of two water-cooled tubes, insulcrete 273 is folded between two conducting platess 271 and between two water-cooled tubes 272, the other end of two water-cooled tubes 272 and 275 corresponding linking to each other of inducing circle, two quench fluid tubes 274 and 276 corresponding linking to each other of outer ring hydrojet circle.Two conducting platess 271 also are electrically connected with inductor block link block 262.The inducing circle 275 among the present invention and the cross section of hydrojet circle 276 are approximate rectangular, are shrunk to inclined-plane 2751 in interior side-lower one angle of inducing circle 275, and there is an outside projection 2752 inboard that is close to the inducing circle 275 on this inclined-plane.2751 existence makes inductor block when pausing as the position of Figure 21, can slow down the magneticinduction sharp angle effect to sharp corner; 2752 existence makes the proximity effect at induction coil inside protrusions place and the sharp angle effect of sharp corner reach certain balance.Be shrunk to inclined-plane 2761 in interior side-lower one angle of hydrojet circle 276.The height of hydrojet circle 276 exposes below the inducing circle inclined-plane 2761 that is located on the hydrojet circle greater than the height of inducing circle 275.Be equipped with a plurality of spray holes on the inclined-plane of hydrojet circle, the diameter of spray hole is 1.2～2.4mm, and the spacing of adjacent two spray holes is 2～4mm, and the angle of spray hole axis and inductor axis is 35 °～55 °; Logical distilled water in the inducing circle, logical hardening liquid in the hydrojet circle.
The method of step shaft induction quenching of the present invention, as shown in figure 19 [in Figure 19, workpiece 28 is arranged in the center of inductor block 27 (figure only shows the representative of the inner ring of its inducing circle as inductor block), rely on thimble 291 and thimble 292 clampings location (thimble 292 control Workpiece Rotating speed, thimble 291 is pneumatic scalable, the conveniently assemble and disassemble workpiece), workpiece 28 comprises big footpath axle 281 and path axle 282, form ladder plane 283 at the reducing place, and carry out the transition to the path axle through a relief groove 284.], take inductor block 27 to move from lower to upper, shift to the mode of path axle 282 ends from big footpath axle 281 ends of step shaft 28 and carry out:
At first should select suitable inductor block internal diameter and height according to the diameter in the big footpath of step shaft, its principle is, the monolateral spacing in selected inductor block inwall and the big footpath of step shaft is 1.5-4mm, and the height of selected inductor block is 1-2cm.The inductor block 27 that chooses is placed the bottom of big footpath axle 281, choose reasonable device frequency, equipment output rating, inductor block translational speed and spray parameter, inductor block 27 from bottom to top being moved the main part on axle 281 surfaces, big footpath is hardened, is interval 31 in Figure 19;
When inductor block 27 moves to 1/3rd of its inducing circle 275 and highly exposes the ladder plane 283 of step shaft, in Figure 19 position 32; Reselect the equipment output rating, pause t1 second, axle 281 upper ends, big footpath to the part between the ladder plane 283 of step shaft 28 is hardened; Its effect is the dash area 32 ' among the figure as shown in figure 20.
Follow inductor block 27 quick travel to next stall position; Its moving section is interval 33 in Figure 19.
When inductor block 27 quick travel when the lower plane of its inducing circle 275 overlaps with the ladder plane 283 of step shaft 28, it in Figure 19 position 34, reselect the equipment output rating, pause t2 second, the part between ladder plane 283 to the path axle lower end of step shaft is hardened; Its effect is the dash area 34 ' among the figure as shown in figure 21.
After the hardening of completing place 34, reselect equipment output rating and inductor block translational speed, inductor block is from bottom to top moved the main part on path axle surface is from bottom to top hardened.Be interval 35 in Figure 19.
Finish after the hardening of path axle surface main part, switch-off power output, close the spray that quenches, unclamp thimble 291, inductor block is shifted out step shaft, quit work, finish its induction quenching process step shaft.
The device frequency of induction quenching is pressed the given data of table 1 according to the diameter of step shaft and is selected.
The selection of table 1 device frequency
| The diameter of step shaft (mm) | ??12～ ??16 | ????16～ ????24 | ????24～ ????32 | ??30～ ??40 | ????36～ ????48 | ????42～ ????56 | ????48～ ????64 |
| Frequency (kHz) | ??30 | ????12 | ????8 | ??5 | ????3.5 | ????2.5 | ????2 |
Equipment output rating during the motion scan heating reaches according to the selected device frequency requirement of step shaft depth of hardening zone is selected by following formula:
P
j＝P
L/k
P
L＝P
0×S
LG
In the following formula, P
jBe the output rating (kW) of medium frequency induction power supply, P
LBe workpiece induction heating power demand (kW), just act on the active power on the workpiece, K is the efficient of the induction hardening transformer and the inductor block of intermediate frequency equipment, during the scanning heating, contribution to case depth can reach between the 0.50-0.60, and at the ladder intersection, its contribution to case depth can only reach between the 0.40-0.5, P
0Be workpiece specific power, S
LGSurface-area (cm for the pairing workpiece of active conductor of inductor block
2);
During the motion scan heating, specific power P
0Press the given data of table 2 and select, consider production efficiency, heat little axle head and select higher value for use, heat big axle head and select intermediate value for use.
The selection of specific power during the heating of table 2 motion scan
| Frequency (kHz) | Depth of hardening zone (mm) | Specific power (kW/cm 2) | ||
| Low value | Intermediate value | High value | ||
| ????12 | ????1.5～2.3 | ????1.6 | ????2.6～3 | ????4 |
| ????2.3～3.0 | ????1.2 | ????2.4～2.8 | ????3.5 | |
| ????3.0～4.0 | ????1.2 | ????2.2～2.4 | ????3 | |
| ????4 | ????2.3～3.0 | ????1.6 | ????2.6～3 | ????4 |
| ????3.0～4.0 | ????1.2 | ????2.2～2.4 | ????3.5 | |
| ????4.0～5.0 | ????1.2 | ????2.2～2.4 | ????3 | |
| ????1 | ????5.0～7.0 | ????1.2 | ????2～2.2 | ????3.0 |
| ????7.0～9.0 | ????1.2 | ????2～2.2 | ????3.0 | |
Inductor block translational speed during the motion scan heating is determined by following formula:
V=2h/t
h(but in 33 zones as shown in figure 19, the translational speed of inductor block need be selected in 15-20 (mm/s) scope.)
In the formula, v is inductor block translational speed (mm/s), and h is the virtual height (mm) of ring sensor, t
hFor utilizing virtual height for the ring sensor of h workpiece surface to be heated to 900 ℃ of institute's time spents (s), this time is provided by following formula:
t
h≈(5.667×V
DS′)/P
0×π×d×h
In the formula, V
DS' be the diathermanous volume (cm of workpiece when reaching effective case depth
3), be main shaft-like workpiece to bearing torsional stress, get V
DS' ≈ (1.15～1.25) * V
DS, V
DSFor at effective case depth be technical requirements in the volume of the hardening region of prescribing a time limit, d is the diameter (cm) of step shaft.
Inductor block dead time t1 and t2 are determined by following method:
t1≈[5.667×(d×2δ-4δ
2)]/P
0×d????(s)
The δ of this moment is the dark limit (cm) of the effective case depth that requires of drawing, and d is the diameter (cm) of the big end of step shaft.
t2≈[5.667×(d×δ-δ
2)]/P
0×d??????(s)
The δ of this moment is the dark limit (cm) of the effective case depth that requires of drawing, and d is the diameter (cm) of step shaft small end.
P
0Specific power (the kW/cm that should select for use during for pause
2), half of the specific power value the when value of selecting for use heats for scanning.
The spray parameter of induction quenching comprises quenchant, spray pressure, quench media temperature and specific liquid rate, and quenchant is pressed table 3 according to the step shaft workpiece to the requirement of quenching intensity (H value) and selected;
The selection of table 3 quenchant
| Quenchant | The H value | |
| Polymkeric substance | Poly-alkylene ethylene glycol | ????0.7-2 |
| Sodium polyacrylate | ????0.3-0.9 | |
| Polyvinylpyrrolidone | ????0.3-0.9 | |
| Poly-ethyl oxazoline | ????0.3-2 | |
| Oil | Oily fast | ????0.8-0.9 |
| Middling speed oil | ????0.5-0.8 | |
| Conventional oil | ????0.3-0.5 | |
| Deep fat | ????0.3-2 | |
The spray pressure-controlling is at 0.15～0.6MPa;
Quench media temperature is controlled at 30～50 ℃;
Specific liquid rate is controlled at 45～60 (10
-6.m
3/ cm
2.s).
Three embodiment are provided below.Because case depth is a scope, and is in a transition state near the ladder, the equipment output rating among the following embodiment, dead time, all can be according to the effective case depth situation of metallographic examination, one among a small circle in adjustment.
Embodiment 1
The step shaft diameter: small end 12mm, hold 16mm greatly; Material is No. 45 steel.Case depth requires to be 1.5-2.5mm that hardened layer requires continuous distribution.
Select the inductor block specification for use: internal diameter 20mm, height 1.2cm;
The selection device frequency is 30kHz, and selecting poly-alkylene ethylene glycol is quenchant, and control spray pressure is that 0.15～0.6MPa, quench media temperature are that 30～50 ℃, specific liquid rate are 45～60 (10
-6.m
3/ cm
2.s);
The heating quenching step:
Inductor block is placed the bottom of big footpath axle, and selecting the equipment output rating is 36-43kW, and the inductor block translational speed is 5.37mm/s, inductor block is from bottom to top moved the main part on axle surface, big footpath is hardened.When inductor block moved to 1/3rd of its inducing circle and highly exposes the ladder plane of step shaft, selecting the equipment output rating was 24.9-30kW, pause 1.18-1.4 second, axle upper end, big footpath to the part between the ladder plane of step shaft was hardened.Then with the ladder planes overlapping of inductor block quick travel to the lower plane and the step shaft of its inducing circle, selecting the equipment output rating is 21.5-26kW, pause 0.59-0.7 second, the part between ladder plane to the path axle lower end of step shaft is hardened.Selecting the equipment output rating at last is 31.2-37.5kW, and the inductor block translational speed is 8.68mm/s, inductor block is from bottom to top moved the main part on path axle surface is hardened.
Embodiment 2
The step shaft diameter: small end 30mm, hold 35mm greatly; Material is the 40Cr steel.Case depth requires to be 3.5-5.5mm that hardened layer requires continuous distribution.
Select the inductor block specification for use: internal diameter 40mm, height 2cm;
The selection device frequency is 5kHz, and selecting poly-ethyl oxazoline is quenchant, and control spray pressure is that 0.15～0.6MPa, quench media temperature are that 30～50 ℃, specific liquid rate are 45～60 (10
-6.m
3/ cm
2.s);
The heating quenching step:
Inductor block is placed the bottom of big footpath axle, and selecting the equipment output rating is 120-142kW, and the inductor block translational speed is 6.22mm/s, inductor block is from bottom to top moved the main part on axle surface, big footpath is hardened.When inductor block moved to 1/3rd of its inducing circle and highly exposes the ladder plane of step shaft, selecting the equipment output rating was 82.5-99kW, pause 2.85-3.4 second, axle upper end, big footpath to the part between the ladder plane of step shaft was hardened.Then with the ladder planes overlapping of inductor block quick travel to the lower plane and the step shaft of its inducing circle, selecting the equipment output rating is 81.3-97.5kW, pause 1.48-1.77 second, the part between ladder plane to the path axle lower end of step shaft is hardened.Selecting the equipment output rating at last is 118-142kW, and the inductor block translational speed is 8.56mm/s, inductor block is from bottom to top moved the main part on path axle surface is hardened.
Embodiment 3
The step shaft diameter: small end 54mm, hold 64mm greatly; Material is the 42CrMo steel.Case depth requires to be 6-9mm that hardened layer requires continuous distribution;
Select the inductor block specification for use: internal diameter 70mm, height 2cm
The selection device frequency is 2kHz, and the selection deep fat is a quenchant, and control spray pressure is that 0.15～0.6MPa, quench media temperature are that 30～50 ℃, specific liquid rate are 45～60 (10
-6.m
3/ cm
2.s);
The heating quenching step:
Inductor block is placed the bottom of big footpath axle, and the equipment output rating is 190-228kW, and the inductor block translational speed is 2.91mm/s, inductor block is from bottom to top moved the main part on axle surface, big footpath is hardened.When inductor block moved to 1/3rd of its inducing circle and highly exposes the ladder plane of step shaft, selecting the equipment output rating was 130.7-157kW, pause 5.64-6.8 second, axle upper end, big footpath to the part between the ladder plane of step shaft was hardened.Then with the ladder planes overlapping of inductor block quick travel to the lower plane and the step shaft of its inducing circle, selecting the equipment output rating is 126.8-152kW, pause 2.84-3.41 second, the part between ladder plane to the path axle lower end of step shaft is hardened.Selecting the equipment output rating at last is 185-220kW, and the inductor block translational speed is 4.07mm/s, inductor block is from bottom to top moved the main part on path axle surface is hardened.
Claims (10)
1, a kind of step shaft induction hardening equipment, comprise medium frequency induction power supply, simple nc quenching machine, transformer, inductor block aligning gear, busbar and inductor block, described transformer, busbar and inductor block are linked in sequence into an integral body and are arranged on the simple nc quenching machine and with medium frequency induction power supply and are electrically connected; Described inductor block aligning gear is installed in and is used to control position of inductor on the simple nc quenching machine; It is characterized in that: also comprise the inductor block fast replacing device, this inductor block fast replacing device is connected between busbar and the inductor block, the inductor block fast replacing device is the modular structure part, comprises busbar link block and inductor block link block, and two modules interconnect with removably; Described busbar is coated with conductive resin with the end face that is connected between transformer and the inductor block fast replacing device, and adopts bolt to connect then; Described simple nc quenching machine adopts summary procedure control able to programme; Described transformer is the ferrite output transformer; Described busbar is provided with two groups of water-cooled tubes, is installed in respectively on the battery lead plate of both sides; Described inductor block is two coil structures ring-type inductor blocks, comprises inner ring inducing circle and outer ring hydrojet circle, and inner ring inducing circle fits tightly with outer ring hydrojet circle and links to each other.
2, step shaft induction hardening equipment according to claim 1, it is characterized in that: the busbar link block of described inductor block fast replacing device comprises left battery lead plate, right battery lead plate, last strongback, following strongback, insulating barrier, two backing plates, two pressing plates and connecting key, insulating barrier is arranged between the left and right battery lead plate, upper and lower strongback is sealed on the two ends up and down of left and right battery lead plate, and left and right battery lead plate is used for linking to each other with two preceding battery lead plates of busbar respectively; Two backing plates are arranged on the both sides, upper end of left and right battery lead plate, two pressing plates respectively are pressed on two backing plates by a nonstandard screw and are used for inductor block link block and busbar link block are linked together, and connecting key vertically is arranged on and is used on the right battery lead plate being linked with the inductor block link block.
3, step shaft induction hardening equipment according to claim 1, it is characterized in that: the inductor block link block of described inductor block fast replacing device comprises two web plates, two intermediate plates, two contact plates, insulcrete, guide plate, strap stiffener, water-cooled tube be connected keyway, two intermediate plates link to each other with two contact plates and are arranged on two web plates, one lateral bottom, insulcrete is folded in two web plates, between two intermediate plates and two contact plates, guide plate is arranged on the top of two web plate another sides and is used for linking to each other with the busbar link block, the bottom that strap stiffener is arranged on two web plates is used for two web plates are fixed together, water-cooled tube is arranged on a side that is provided with intermediate plate and contact plate of two web plates, two contact plates are used for linking to each other with inductor block, connect that keyway is arranged on a plate and with the inductor block link block on to be connected keyway suitable.
4, step shaft induction hardening equipment according to claim 1, it is characterized in that: the inducing circle of described inductor block and the cross section of hydrojet circle are approximate rectangular, the interior side-lower of this two approximate rectangular circle all inwardly is shrunk to the inclined-plane for one jiao, side-lower has an inside projection in the inducing circle, the height of described hydrojet circle is greater than the height of inducing circle, the inclined-plane that is located on the hydrojet circle is exposed below the inducing circle, be equipped with a plurality of spray holes on the inclined-plane of hydrojet circle, the diameter of spray hole is 1.2～2.4mm, the spacing of adjacent two spray holes is 2～4mm, and the angle of spray hole axis and inductor axis is 35 °～55 °; Logical distilled water in the inducing circle, logical hardening liquid in the hydrojet circle.
5, a kind of method of step shaft induction quenching, described step shaft comprises big footpath axle and path axle, on the reducing place formation ladder plane of big footpath axle with the path axle, it is characterized in that: the diameter according to step shaft is selected adaptive inductor block, and select the suitable device frequency and spray parameter, take inductor block to move from lower to upper, shift to miner diameter end, harden according to the following steps from the bigger diameter end of step shaft:
Step 1, the mobile axle surface, big footpath of hardening:
Inductor block is placed the bottom of big footpath axle, select suitable device output rating and inductor block translational speed, inductor block is from bottom to top moved the main part on axle surface, big footpath is hardened;
Step 2, pause and to harden axle upper end, big footpath to the part between the ladder plane:
When inductor block moves to 1/3rd of its inducing circle and highly exposes the ladder plane of step shaft, reselect the equipment output rating, pause for some time, axle upper end, big footpath to the part between the ladder plane of step shaft is hardened;
Step 3, quick travel to next pause position of hardening:
Behind the completing steps 2, with inductor block quick travel to next pause position of hardening;
Step 4, pause and to harden the ladder plane to the part between the path axle front end:
When inductor block quick travel during to the ladder planes overlapping of the lower plane of its inducing circle and step shaft, reselect the equipment output rating, pause for some time, the part between ladder plane to the path axle lower end of step shaft is hardened;
Step 5, the mobile path axle surface of hardening:
Behind the completing steps 4, reselect equipment output rating and inductor block translational speed, inductor block is from bottom to top moved the main part on path axle surface is hardened;
Step 6, end:
Behind the completing steps 5, the spray that quenches is closed in switch-off power output, unclamps thimble, and step shaft is shifted out inductor block, quits work, and finishes its induction quenching process to step shaft.
6, the method for step shaft induction quenching according to claim 5 is characterized in that: described device frequency is selected according to the diameter of step shaft, and when the diameter of step shaft changed between 12-64mm, device frequency was selected between 30-2kHz.
7, the method for step shaft induction quenching according to claim 5, it is characterized in that: the equipment output rating of described each step is that the product of surface-area of the pairing workpiece of active conductor of the specific power of workpiece and inductor block is then than a last efficiency factor, the specific power of workpiece reaches according to selected device frequency the requirement of step shaft depth of hardening zone is selected, when device frequency at 12-1kHz, when depth of hardening zone changed between 1.5-9.0mm, the specific power of workpiece was at 4-1.2kW/cm
2Between select.
8, the method for step shaft induction quenching according to claim 5 is characterized in that: the inductor block translational speed of described step 1 and step 5 equals the virtual height (mm) of the ring sensor of twice divided by utilizing this ring sensor that workpiece surface is heated to 900 ℃ of institute's time spents (s).
9, the method for step shaft induction quenching according to claim 5 is characterized in that: the residence time of described step 2 is 0.8-7.2 second, and the residence time of step 4 is 0.6-4.2 second.
10, the method for step shaft induction quenching according to claim 5 is characterized in that: described spray parameter comprises quenchant, spray pressure, quench media temperature and specific liquid rate;
Described quenchant is selected between poly-alkylene ethylene glycol, sodium polyacrylate, polyvinylpyrrolidone, poly-ethyl oxazoline, quick oil, oily, the conventional oil of middling speed and deep fat the requirement of quenching intensity according to the step shaft workpiece;
Described spray pressure-controlling is at 0.15～0.6MPa;
Described quench media temperature is controlled at 30～50 ℃;
Described specific liquid rate is controlled at 45～60 (10
-6.m
3/ cm
2.s).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB031512321A CN1282753C (en) | 2003-09-26 | 2003-09-26 | Equipment and method for induction hardening stepped shaft |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB031512321A CN1282753C (en) | 2003-09-26 | 2003-09-26 | Equipment and method for induction hardening stepped shaft |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1600873A true CN1600873A (en) | 2005-03-30 |
| CN1282753C CN1282753C (en) | 2006-11-01 |
Family
ID=34659894
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB031512321A Expired - Fee Related CN1282753C (en) | 2003-09-26 | 2003-09-26 | Equipment and method for induction hardening stepped shaft |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN1282753C (en) |
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100460526C (en) * | 2006-06-15 | 2009-02-11 | 万向电动汽车有限公司 | Longitudinal inductor and scanning quenching technology for stepped axle longitudinal inductor |
| CN101921902A (en) * | 2010-08-13 | 2010-12-22 | 中国第一汽车集团公司 | Induction quenching method of shifting guide shaft of automatic transmission |
| CN101928819A (en) * | 2010-08-24 | 2010-12-29 | 湘电集团有限公司 | Method and equipment for carrying out continuous induction hardening on stepped shaft neck and arc transitional surface |
| CN101787425B (en) * | 2009-07-31 | 2011-11-30 | 中国一拖集团有限公司 | Large variable diameter shaft part induction heat-treatment and quenching technical method |
| CN101824516B (en) * | 2009-03-02 | 2012-03-28 | 湖北新火炬科技股份有限公司 | Supersonic frequency quenching process for roller path of hub bearing assembly |
| CN103572030A (en) * | 2012-07-24 | 2014-02-12 | 洪泽县汽车半轴制造有限公司 | Novel auto semi-axle quenching process |
| CN104294028A (en) * | 2014-10-23 | 2015-01-21 | 安徽精科机器有限公司 | Quenching process for step shaft components |
| CN105331792A (en) * | 2015-10-21 | 2016-02-17 | 第一拖拉机股份有限公司 | Quenching inductor for low-speed large-torque drive wheel axle and size confirmation method |
| CN106755908A (en) * | 2016-12-05 | 2017-05-31 | 湖南南方宇航高精传动有限公司 | A kind of processing method of flexible pin shaft |
| CN111304412A (en) * | 2020-03-04 | 2020-06-19 | 中国重汽集团济南动力有限公司 | Induction quenching process of inflation and deflation shaft head |
| CN113874530A (en) * | 2019-05-23 | 2021-12-31 | 日本制铁株式会社 | Movable quenching device and movable quenching method |
| WO2024057406A1 (en) * | 2022-09-13 | 2024-03-21 | 日本製鉄株式会社 | Mobile hardening method and mobile hardening device |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100460526C (en) * | 2006-06-15 | 2009-02-11 | 万向电动汽车有限公司 | Longitudinal inductor and scanning quenching technology for stepped axle longitudinal inductor |
| CN101824516B (en) * | 2009-03-02 | 2012-03-28 | 湖北新火炬科技股份有限公司 | Supersonic frequency quenching process for roller path of hub bearing assembly |
| CN101787425B (en) * | 2009-07-31 | 2011-11-30 | 中国一拖集团有限公司 | Large variable diameter shaft part induction heat-treatment and quenching technical method |
| CN101921902A (en) * | 2010-08-13 | 2010-12-22 | 中国第一汽车集团公司 | Induction quenching method of shifting guide shaft of automatic transmission |
| CN101921902B (en) * | 2010-08-13 | 2013-09-25 | 中国第一汽车集团公司 | Induction quenching method of shifting guide shaft of automatic transmission |
| CN101928819A (en) * | 2010-08-24 | 2010-12-29 | 湘电集团有限公司 | Method and equipment for carrying out continuous induction hardening on stepped shaft neck and arc transitional surface |
| CN103572030A (en) * | 2012-07-24 | 2014-02-12 | 洪泽县汽车半轴制造有限公司 | Novel auto semi-axle quenching process |
| CN104294028A (en) * | 2014-10-23 | 2015-01-21 | 安徽精科机器有限公司 | Quenching process for step shaft components |
| CN105331792A (en) * | 2015-10-21 | 2016-02-17 | 第一拖拉机股份有限公司 | Quenching inductor for low-speed large-torque drive wheel axle and size confirmation method |
| CN106755908A (en) * | 2016-12-05 | 2017-05-31 | 湖南南方宇航高精传动有限公司 | A kind of processing method of flexible pin shaft |
| CN106755908B (en) * | 2016-12-05 | 2018-05-11 | 湖南南方宇航高精传动有限公司 | A kind of processing method of flexible pin shaft |
| CN113874530A (en) * | 2019-05-23 | 2021-12-31 | 日本制铁株式会社 | Movable quenching device and movable quenching method |
| CN111304412A (en) * | 2020-03-04 | 2020-06-19 | 中国重汽集团济南动力有限公司 | Induction quenching process of inflation and deflation shaft head |
| CN111304412B (en) * | 2020-03-04 | 2022-03-04 | 中国重汽集团济南动力有限公司 | Induction quenching process of inflation and deflation shaft head |
| WO2024057406A1 (en) * | 2022-09-13 | 2024-03-21 | 日本製鉄株式会社 | Mobile hardening method and mobile hardening device |
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Owner name: SHANGHAI GKN HUAYU DRIVELINE SYSTEMS CO., LTD. Free format text: FORMER NAME: NATIEFU DRIVE SHAFTS CO., LTD., SHANGHAI |
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| CP01 | Change in the name or title of a patent holder |
Address after: 201315 Cambridge Road 950, Cambridge industry zone, Shanghai, Pudong Patentee after: SHANGHAI GKN HUAYU DRIVELINE SYSTEMS Co.,Ltd. Address before: 201315 Cambridge Road 950, Cambridge industry zone, Shanghai, Pudong Patentee before: Shanghai GKN Drive Shaft Co.,Ltd. |
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Granted publication date: 20061101 |