CS267947B1 - The method of welding the functional part of the pins to the crankshafts - Google Patents
The method of welding the functional part of the pins to the crankshafts Download PDFInfo
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Abstract
Spósob Je určený na výrobu novýoh, alebo dodatkové vylepáenie novýoh, alebo čiastočne opotřebených, alebo na renováoiu čiastočne, alebo úplné opotřebených zalomenýoh hriadeíov najma spálováoioh motorov, ale aj kompresorov, plastových vývev, čerpadiel a roznyoh strojov metAdou elektrlokóho oblúka pod tavivom, alebo metAdou elektrického oblúka v ochraně plynov, a to V sériovom.procese výroby, resp. opravy. Účely sposobu spočivajú v zmoučeni, najma skrátenia oelkovej dlžky zalomeného hriadela a to až na úroven predpisaného limitu, vo zvýáeni únavovej pevnosti a životnosti. Podstata sposobu spočiva v tom. že teplo teohnologlokého prooesu navárania sa ukládá postupné so zvyčujúoou tendenoiou, atriedavo okolo stredného hlavného čapu. Ako prvé sa navárajú kútové přechody hlavnýoh čapov, potom ojničnýoh čapov. Potom v rovnakom poradí sa navárajú váloové ploohy hlavnýoh čapov a po nich ojničnýoh čapov. Je definované poradle určitýoh druhov prldavnýoh materiálov, tepelné hranioe predohrevu a limitovanie popúčlaoioh teplot po úplnom navařeni. Po tepelnom apraoováni a jeho opraoovani vykazuje zalomený hriadel spravidla lepáie vlastnosti ako nový, pri zniženýoh obstarávaoioh nákladech.The method is intended for the production of new or additional repair of new or partially worn out shafts, or for the renovation of partially or completely worn out shafts, especially of internal combustion engines, but also of compressors, plastic vacuum pumps, pumps and various machines by the method of electric arc under flux or by the method of electric arc in gas protection, in the serial process of production or repair. The purposes of the method are to grind, in particular to shorten the total length of the bent shaft up to the level of the prescribed limit, to increase the fatigue strength and service life. The essence of the method is that the heat of the technological welding process is deposited gradually with the usual tendency, and alternately around the central main pin. First, the angular transitions of the main journals are welded, then the connecting rod journals. Then, in the same order, the cylindrical surfaces of the main journals are welded, and then the connecting rod journals. The order of certain types of filler materials, the thermal limit of preheating and the limitation of the peak temperatures after complete welding are defined. After heat treatment and its treatment, the bent shaft usually exhibits better properties than a new one, with reduced procurement costs.
Description
cs 267 947 B1 1en 267 947 B1 1
Vynález ga týlca sposobu navárauia funkčnýoh časti čapov zalomených hriadeiov meto-dou elektrického oblúka pod tavlvom, alebo elektrickým oblúkom v oohrannej atmosféřeplynu.The present invention relates to a method of welding a functional part of the cranked shaft by an electric arc method under a melt or electric arc in an atmospheric gas atmosphere.
Doposial sú známe viaoeré sposoby najma renováoie funkčnýoh časti čapov zalomenýohhriadeiov, pričom vžetky sú orientované na zalomené hriadele spalovacích motorov. Tietopostupy v súčasnej době využlvajú dve základné metédy: naváranie a striekanie. Pro navá-ranie sa používáJú dve metody: elektriokým oblúkom pod tavlvom a eloktriokým oblúkomv oohrane plynu. V obooh prípadooh Je oharakteristloká postupnost: navárajú sa prv vál-cové ploohy vžetkýoh hlavnýoh čapov a potom ojničnýoh čapov, potom sa navárajú přechodymedzi jednotlivým čapom a ramenami zalomeného hriadela makkým přídavným materiálem sozvýženými plastiokými vlastnostami, pričom sa postupuje od Jedného konoa zalomeného hri-adela k druhému. Používá sa aj nasledovná postupnost operáoil: ako prvé sa navárajú vžet-ky válcové ploohy a to ako hlavnýoh, tak ako nasledujú za sebou od jedného konoa zalome-ného hriadela k druhému, a v rovnakom smere a slede sa potom navárajú preohody medzi čap-ni a ramenami. Pre striekanie sa po už lva jú dve metédy: plameňoprážková a íiarové strieka-nie. Menej sa použlvajú nikelalumlniové medzivrstvy a funkoiou podkladov, ktoré sa naná-žajú ako prvé, v analogiokej postupnosti, ako při konečnýoh nánosooh v predohádzajúoiohprípadooh. Pri plamenoprážkovom a žiarovom striekanl sa najčastejžio použlvajú prážkyna báze Ni. VSeobeoný priemer dosahovaných tvrdosti po návare Je HRo 40 a po nasledujú-oom popuštěni sa zvyžuje až na HRo 48. Celkové změny dlžky zalomeného hriadela žtandard-ného typu: 4-váleo, dlžky 00a 600 mm + 80 mm - dosahuje skrátenie o 1,5 až 2 mm, v inýohprípadooh sa překročila uvedená hranloa skrátenia o 2 mm a vyskytlo sa takmer nerieži-telné obvodové vyosenie a hádzanie zalomeného hriadela až o 3,5 mm vzhladom na strednýhlavný čap, po navařeni a dokončeni tepelnýoh práo. V oblasti dynamiokej únosnosti ná-varu vyskytlo sa v mnohých prípadooh znlženie únavové j pevnosti na hranioi 12 % a týmaj znlženie životnosti. Medzi ekonomioky zvláít náročné doposial patři nejma technolo-gie striekania kovov v plameni, kde sú zvlážt vysoké náklady na přídavný materiál, Strie-kanie je v niektorýoh prípadooh nadmieru hlučné.Up to now, bonding methods are known, in particular the renovation of the functional part of the cranked pins, whereby the threads are oriented on crankshafts of internal combustion engines. Currently, these two approaches use two basic methods: surfacing and spraying. Two methods are used for winding: electric arc under melt and eletric arc in gas. In the case of the case, there is a characteristic sequence: first, the cylindrical flats are welded to the barrel of the main bolt and then the connecting rod bolt, then welded through the individual bolt and arms of the cranked shaft with the additive material with the raised plastic properties, moving from the one can of the angled shaft to to the other. The following sequence of operations is also used: first, the cylindrical flats are welded as the main one, as they follow one another from one canopy of the crank shaft to the other, and then the welds between the pin and the end are welded in the same direction and herring and shoulders. There are two methods for spraying: flame-spraying and irrigation. Smaller non-aluminum interlayers are used, and the functions of substrates which are applied first, in an analogous sequence, as in the final deposit in the predetermined case. In the case of flame-spraying and hot spraying, Ni base bases are most commonly used. The average diameter of the hardness reached after welding is HR 40 and after tempering it rises to HRo 48. The total change of the standard crank shaft length: 4-roll, length 00a 600 mm + 80 mm - reaches a shortening of 1.5 up to 2 mm, in which case the shortening edge has been exceeded by 2 mm and there is an almost irreparable circumferential misalignment and throwing of the crank shaft by up to 3.5 mm with respect to the central bar, after welding and finishing of the heat bar. In the area of dynamic load-bearing capacity, many fatigue strengths have been reduced in many cases, with a reduction of 12% and a reduction in service life. Among the economics of particular interest so far are, in particular, metal spraying technology, where the cost of the additive material is particularly high, and spraying is somewhat noisy in some cases.
Podstata nového 3posobu navárania funkčnýoh časti čapov zalomenýoh hriadeiov spočí-vá najma v tom, že naváral sa začlna návarmi kútovýoh prechodov stredného, alebo středunajbližžieho hlavného čapu do ramien zalomenia hriadela, pokračuje sa návarmi kútovýohprechodov SalSioh hlavnýoh čapov do ramien zalomenia hriadela, potom sa navárajú kótovépreohody ojničnýoh Čapov do ramien zalomenia hriadela prvou naváraoou elektrodou a v rov-nakom slede a porad! sa navárajú vžetky váloové ploohy hlavnýoh a ojničnýoh čapov dru-hou naváraoou elektrodou, striedavo okolo stredného alebo středu najbližžieho hlavnéhočapu, ku konoom zalomeného hriadela, pričom naváranie sa zakonči popúžtaním pri teplo-to 165 až 580 °C. Sálej je podstata nového sposobu závislá na podmienkaoh, definovanýchtým, že kótové preohody do ramien sa navárajú prvou naváraoou elektrodou ohemiokého zlo-ženia 0,07 hmot. uhllka, 1,95 % hmot. kremlka, 1,5 % hmot. niklu, 0,45 hmot. ohrOmu,0,45 hmot. molybdénu, a ostatok železo a atrednomangánové kyslé tavené tavivo pre au-tomatické a poloautomatiokó zváranie a naváranie uhlikovýoh oceli a váloové ploohy sanavárajú druhou naváraoou elektrOdou ohemiokého z loženi a 0,10 až 0,35 % hmot. uhllka, 0,20 až θ,4θ % hmot. kremlka, 0,6 až 1,2 % hmot, mangánu, 3,0 až 5*0 % hmot, ohromu, 0,45 $ až 0,55 -Í> hmot, molybdénu, 0,2 až 0,4 jí hmot. médi a ostatok železo a stredno-mangánové kyslé tavivo pre automatioké a poloautomatiokó zváranie a naváranie uhlikovýohoceli, Jednosměrným pulzným prúdora, alebo jednosměrným prúdom velkosti 170 až 190 As kladnou polaritou na zváraoej elektrOde, pri napatí 27 až 29 V, naváraoou rýohlostou22 až 50 m.h~\ v případe valoovýoh ploch so stúpanlm návarovej húsenioe 3 až 5 mm, ot"1,s navazujaoim překrytím, po predohreve zalomeného hriadela na teplotu 300 °C, s udržiava-nim teploty ohřevu nad hranioou 200 °C v priebehu navárania, bez preruženia naváraoiehoprooesu. Výhody nového sposobu sú: zmenženie skrátenia (predíženia) zalomeného hriadela po-sobenlm navárania, na referenčněj dlžke až na hodnoty + 0,1 mm. Predplsaná toleraneia 2 CS 267 947 B1 při dlžke zalomeného hriadeía 517 mm jo +0,1 a - 0,3 mm. Obvodové hédzanie vzhladomstredný hlavný čap po úplnom dokončení tepelnýoh práč nepřekračuje hodnotu 1,1 mm a jetiež tirčené veíkostou nerovnoměrnosti při rozděleni hmot a noanýoh prierezov zalomeniahriadeía. Únavovými skúžkami aa ověřilo ako výnimočné zniženie únavovej pevnosti max,o hodnotu - 34 5°» tak Jej zvýčenie 00a 15 %, pri kritiokej hladino zatoženia, pri inojhladině zataženie zvýženie únavovej pevnosti až o 9° % proti originálnemu nového zalo-menému hriadoíu, Tým aa ekvivalentně zvySuje tiež životnost o priemeroú hodnotu 10až 30 %, Medzi zaznamenané výhody patři tiež konečné zniženie treoioho momentu v pre-vádzke zalomeného hriadeía a to priemernou hodnotou okolo 7 až 8 $ oproti klaaiokémuhriadoíu. Této skutočnost ovplyvňuje kladné spotřebu paliva spaiovaoieho motora. Spoaobvylučuje potřebu podkladovej medzivretvy pri súčasnom vzoatupe kvality, Teohnologiokýproces mé minlmélnu až zanedbatelné hlučnost a hygienioky bol zaradený do kategorie B,dýmová trioda č, 1, Tvrdost nóvarov mé hodnoty 43 až b5 BRo, po tepelnom spraoovani48 až 49 BRo. Spfiaob poskytuje úplné roprodukovateíné výsledky. Ekonomické účinnostnovej metódy sa pohybuje od l45 do 121 %, podlá stavu zalomeného hriadeía a použitojteohnológie,The essence of the new method of welding a functional part of the shaft crankshafts is, in particular, that it is welded to the shaft bends of the intermediate or mid-center main shaft to the crankshaft arms, with the SalSioh corner bolts to the crankshaft arms, then dimensional conversions are welded. connecting rods of pins in the crank arms of the shaft by the first welded electrode and in the same sequence and meetings! welds all the cylindrical heads and the connecting rods with a second welded electrode, alternately around the middle or center of the nearest main pin, to the cranked shaft, terminating in weaving at 165 to 580 ° C. The nature of the novel process depends on the condition defined by the fact that the dimensional overhangs of the arms are welded with a first welded electrode of 0.07 mass%. % carbon, 1.95 wt. quartz, 1.5 wt. of nickel, 0.45 wt. wt. molybdenum, and the remainder iron and an ananganganic acid melt flux for automatic and semi-automatic welding and welding of carbon steel, and the vacuum plates are serrated by a second welded electrode of the bed and 0.10 to 0.35 wt. % carbon, 0.20 to θ, 4θ% by weight. silicon, 0.6 to 1.2% by weight, manganese, 3.0 to 5% by weight, 0.45 to 0.55% by weight, molybdenum, 0.2 to 0.4% by weight . medium and iron and medium-manganese acid flux for automatic and semi-automatic welding and welding with carbon steel, unidirectional pulse jet, or unidirectional current of 170 to 190 As positive polarity on welded electrode, at 27 to 29 volts, welded to 22 to 50 mh ~ in the case of a rolling surface with a cladding pitch of 3 to 5 mm, rpm "1", with a subsequent overlap, after preheating the crankshaft to 300 ° C, with a heating temperature above 200 ° C during the welding, without overcoating Advantages of the new process are: Reducing the shortening (extension) of the cranked shaft by welding, to a reference length of up to + 0.1 mm Pre-filled tolerance 2 CS 267 947 B1 with a crankshaft length of 517 mm and +0.1 and - 0.3 mm Circumferentially rounded central pivot after complete completion of thermal thermal washing machine does not exceed 1.1 mm unevenness in the distribution of matter and the cross section of zalomeniahriadeia. Fatigue tests have proven to be an exceptional reduction in fatigue strength of max, by - 34 5 ° »so its increase of 00a to 15%, at criterion level of load, at inlay load increase of fatigue strength by up to 9% against the original new zalo-less heater, Team and, equivalently, increases the service life by an average value of 10 to 30%. Among the advantages noted is also the final reduction of the treoio moment in the crank shaft operation by an average value of about $ 7 to $ 8 compared to the clown shaft. This fact affects the fuel economy of the fueling engine. Excluding the need for an intermediate intermediate layer with simultaneous quality assurance, the method of my miniscule to negligible noise and hygiene has been categorized as B, smoke triode No. 1, Hardness hardness 43 to b5 BRo, after heat treatment 48 to 49 BRo. Spfiaob provides complete yieldable results. The economical efficiency method ranges from 1,445 to 121%, according to the cranked shaft condition and use theology,
Skúčka sposobu bola v jednom'pripade vykonané na kiúkovýoh hriadolooh typu Z 8001, M 634, 4 VD a SMD 14. Bola použitá metóda elektriokého oblúka pod tavivom, přídavný ma-teriál trubičková elektroda, na návary prstenoov v kútovýoh preohodooh a na návaryvrstiev válcových časti diferenoovaneJ ohemiokej skladby (pívá a druhé haváraoia elektró-da chemického zloženia uvedeného v podstatě nového sposobu), kladný pól elektriokého na-váraoieho zdroja na navéraoej elektróde. Sálej bolo použité strednomangénové kyslé tave-né tavivo pre automatioké a poloautomatioké zváranie a navéranie uhlikovýoh ooeli(F-101), prip, v áalžej časti bola použité metóda elektriokého oblúka v oohrannom plyne,drát C 215 0 1,2 mm + pól a plyn COg, alebo zmes C0„ + Ar. Parametre navérania preohodovčapov do ramien U=27 V, Ial68 A až 180 A, v=30 m,h” , parametre navérania valoovýoh čas-ti čapov Us27 V, I%190 až 200 A, v=25,4 m,h”\ ss6 nn.ot“\ Skúčky boli vykonané na 8,až 10, kusoch jednotlivýoh. druhov zalomených hriadelov s predohrevmi na teplotu 300 až310 °C pri udrženi teploty nad 200 a 220 °C. Navéranie začínalo névarom překrytého prs-tenoa kútovýoh preohodov hlavnýoh čapov do ramien zalomeného hriadeía, pričom po ověře-ni optimélnosti postupu ako prvý sa navéral zvolený preohod hlavného čapu, naohédzajú-oeho sa v střede dížky zalomeného hriadeía.The process test was, in one case, carried out on a Z 8001, M 634, 4 VD and SMD 14 type crankshaft. Under arc flux method, additional material tubular electrode was used, for ring flanges in the corner and on the cylindrical section. a differentiated hemisphere composition (drinking and second electrode crashes of the chemical composition of the essentially new method), the positive pole of the electrofusion source on the electrode electrode. Sálj was used a medium-manganese acid melting flux for automatic and semi-automatic welding and coil welding of carbon steel (F-101), in which the electric arc method was used in the flue gas, wire C 215 0 1.2 mm + pole and gas COg, or a mixture of C0 + Ar. Parameters of rewind rewinders U = 27 V, Ial68 A to 180 A, v = 30 m, h ”, parameters of winding valleys of pegs Us27 V, I% 190 to 200 A, v = 25,4 m, h” ss6 nn.ot “The bits were made on 8, up to 10, single pieces. types of crankshafts with preheating to 300-310 ° C while maintaining temperatures above 200 and 220 ° C. Welding began with the overlap of the overlapped main cone of the main pin into the crankshaft arms, and after checking the optimumness of the procedure, the selected overlap of the main cone, located at the center of the crank shaft, was selected.
Vo vSetkýoh pripadooh skúSok sa začínalo navéranie na strednom, alebo středu naj-bližšom hlavnom čapě, névarom kútovýoh preohodov, potom na ojničnýoh čapooh a rovnako sav slede a poradí, navérali váloové ploohy prvým, resp, druhým druhom navéraoej elOktródy,vždy striedavo na obe strany stredného alebo středu najbližčieho hlavného čapat. Pódia dru-hu materiálu zalomeného hriadeía boli volené a odskúSané popúčtaoie teploty zniženia nor-málně J popúStacej teploty vždy o 50 °C, teda v hranioiaoh teplot od 165 do 5Q0 °C, po do-bu 2, až 5, hodin, s pozvolným poklesom teploty na vzduohu na hodnotu 20 °C,At the end of the test, winding on the center or center of the nearest major pivot began, then the corner pivot, then on the pivot pin, as well as the succession and sequence, casting the pendulum by the first and second second navodes, alternately on both sides the middle or middle of the nearest major cap. The grades of the crank shaft type were selected and tested to reduce the temperature of the normal J tempering temperature by 50 ° C, that is to say at temperatures ranging from 165 to 50 ° C, for 2 to 5 hours, with gradual by decreasing the air temperature to 20 ° C
Po dosiahnutl stabilněj teploty 20 °C celého zalomeného hriadeía sa priatúpilo k me-raniu tvarovýoh a rozměrových zmien na povodnom telese, k opraoovaniu a zatažovaoimskúSkém k hodnoteniu meohaniokýoh vlastnosti a očakévatelnej životnosti u každého zalo-meného hriadeía zvléSt. Meranie bolo vykonané porovnáním s povodným, novým zalomenýmhriadelom. Do slehnuté výsledky (v priemere sa tieto výsledky dosiahli aj u 3alSloh skú-Sok zalomených hriadeíov, navarenýoh met ódou elektriokého oblúka v plynové j ochraně):Upon reaching a stable temperature of 20 [deg.] C. of the crank shaft, the shaping and dimensional variations of the flooded body were added to the pelletizing and retracting for evaluation of the cohesive properties and the expected lifetime of each embedded shaft. The measurement was made by comparison with the flooded, new cranked shaft. The results (on average, these results were also achieved in the 3alSloh scooter shafts, welded by the electric arc method in gas protection):
Treoi moment Nm - klaeioký hriadel - zébehový : 5,5 - prevádzkový : 1,095 i- navařený hriadel - základný : 5,755 - prevádzkový : 1,086. Závěr: treoi moment stúpa počas (zanedbatelnéj) doby zébehu o 00a 4,63 %, klesá počasprevédzky o viao ako 8,21 %, čo sa prejavi v zniženi spotřeby energie. Únavová pevnost: - pri zétaži 70/15 Wí bol počet umrtvovaoíoh oyklov - klasický hriadelTreo moment Nm - low shaft - running: 5,5 - operating: 1,095 i- welded shaft - basic: 5,755 - operating: 1,086. Conclusion: treoi moment increases during (negligible) dwell time by 00 and 4.63%, decreases during the time by viao than 8.21%, which is reflected in the reduction of energy consumption. Fatigue Strength: - at 70/15 Wi was the number of corners - the classic shaft
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CS878092A CS267947B1 (en) | 1987-11-12 | 1987-11-12 | The method of welding the functional part of the pins to the crankshafts |
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CS878092A CS267947B1 (en) | 1987-11-12 | 1987-11-12 | The method of welding the functional part of the pins to the crankshafts |
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