WO2017113040A1 - 金属冷热切圆锯片及其制造工艺 - Google Patents

金属冷热切圆锯片及其制造工艺 Download PDF

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Publication number
WO2017113040A1
WO2017113040A1 PCT/CN2015/000942 CN2015000942W WO2017113040A1 WO 2017113040 A1 WO2017113040 A1 WO 2017113040A1 CN 2015000942 W CN2015000942 W CN 2015000942W WO 2017113040 A1 WO2017113040 A1 WO 2017113040A1
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Prior art keywords
saw blade
cold
circular saw
wear
tooth
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PCT/CN2015/000942
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English (en)
French (fr)
Inventor
郭继富
张艳龙
宋浩
王林
韩会杰
邵鸿丽
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唐山冶金锯片有限公司
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Priority to PCT/CN2015/000942 priority Critical patent/WO2017113040A1/zh
Publication of WO2017113040A1 publication Critical patent/WO2017113040A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D61/00—Tools for sawing machines or sawing devices; Clamping devices for these tools
    • B23D61/02—Circular saw blades
    • B23D61/04—Circular saw blades with inserted saw teeth, i.e. the teeth being individually inserted
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge

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  • the invention relates to a circular saw blade and a manufacturing process thereof, in particular to a metal cold and hot cutting circular saw blade and a manufacturing process thereof.
  • the metal hot and cold cutting circular saw blade is an indispensable cutting tool in the tube bar rolling production process, because it has fast processing efficiency and good cutting quality, and has been used for many years.
  • the sawtooth part mainly involved in the sawing is two sharp corners and a chisel edge portion.
  • the sharp corners and the cross edge are sharply rubbed against the workpiece, so that the workpiece is cut and the wearer itself is also worn.
  • the typical wear pattern is The chisel edge is widened and passivated, and the sharp corners are rounded to produce obvious cutting burrs, and finally the saw blade fails to be used. At this point, the saw blade needs to be sharpened again and the tooth tip hardened before it can be used again.
  • a metal hot and cold cut circular saw blade comprising a saw blade body, the outer circumference of the saw blade body being provided with a hardened wear layer.
  • the invention of the above technical solution has a hardened wear layer disposed in the outer circumference of the saw blade body, so that the saw blade maintains two sharp angles during operation, and is in a sharp state for a long time, reducing sawing.
  • Burr, extended sawing time, after the tooth passivation only need to repair the tooth shape, no need to re-quench the tooth tip, can restore the use effect, especially to meet the processing of high-strength, thick-wall difficult-to-cut workpiece.
  • a hardened wear layer is provided in the width of the outer circumference of the blade body and in the range of both sides.
  • the hardened wear layer is a process of surfacing or laser cladding.
  • the two sides of the outer circumference of the blade body have a flat plate structure, and the grooved structure is further provided on both sides of the tooth surface or the toothed structure in the width direction.
  • the two sides of the outer circumference of the blade body are in a side-gap structure, and the tooth-shaped structure is arranged in the width direction; or the two sides of the outer circumference of the blade body are flat and side-gap composite structures, and the width direction is arranged
  • a grooved structure is also provided on both sides of the toothed structure or the toothed structure.
  • Cladding hardened wear layer on the flat structure embedded cladding hardened wear layer on the slotted structure.
  • the hardened wear-resistant layer is clad on the side-gap structure, and the hardened wear-resistant wear layer is embedded on the grooved structure.
  • a manufacturing process of the aforementioned metal cold-hot-cut circular saw blade is carried out as follows:
  • Saw blade blanking Select medium-low carbon steel plate and ultra-low carbon steel plate as raw materials, and cut the raw material into a circular ring blank structure by plasma cutting, flame cutting or laser cutting;
  • Sheet heat treatment select separate quenching and tempering treatment to improve the performance of the sheet, or directly temper the raw materials with the highest performance;
  • Sheet leveling preliminary leveling of the heat-treated saw blade to meet the process requirements of conventional saw blades
  • the saw blade body After the leveling, the saw blade body is subjected to the turning, drilling, grinding process, or the required tooth structure is processed to be a semi-finished product;
  • the finely ground saw blade body should be fine-leveled to provide a good basic condition for subsequent processing
  • Pre-machining of the surfacing or cladding position For the semi-finished saw blade, the parts of the outer circumference of the sheet need to be welded or welded to the wear-resistant hardened layer by means of turning, milling and grinding. Processing the prepared shape;
  • the thickness of the hardened wear layer is between 0.5 and 3 mm, the radial width from the outer circle is selected as 1% to 10% of the diameter D of the saw blade; the hardness is 55 to 65 HRC. , metallurgical fusion with the saw blade body, strong bonding, no cracks;
  • finished product leveling eliminate the deformation of the sheet caused by the manufacture of the wear layer, so that it is convenient for subsequent processing;
  • the wear layer is made wider than the thickness of the saw blade itself, and the hardened wear layer of the saw blade is ground to make the wear layer smooth and the side gap angle uniform;
  • Tooth shape processing use laser cutting and wire cutting to open the teeth, then use the gear grinding machine to precisely sharpen the tooth angle, and finally meet the drawings. Or directly using a gear grinding machine to open the teeth, sharpening; or directly fine grinding the tooth structure;
  • the prepared shape is: a flat plate structure, a side gap structure or a thinned structure.
  • step g the hardened wear layer is finally required to satisfactorily saw the workpiece in the working condition below the line speed of 140 m/sec.
  • the manufacturing process of the hardened wear layer is: a surfacing process or a laser cladding process.
  • the surfacing process uses welding equipment and welding wire to weld uniformly on the sheet under the protective atmosphere, to achieve the predetermined thickness and joint strength at different levels, to control the degree of thermal deformation of the sheet, and to be within the correctable range, hardening resistance
  • the grinding layer requires uniform thickness, compactness and flatness for subsequent processing;
  • the laser cladding process uses laser source and alloy powder, and under the process parameters, the surface of the outer surface of the sheet is subjected to surface cladding, which is firm, crack-free and less deformed;
  • the cladding layer requires uniform thickness, compactness and flatness for subsequent processing.
  • the sawtooth is passivated. After sawing the workpiece, the phenomenon of burr, flash, and skew is generated, and the tooth-shaped sharpening and the sheet leveling are performed again, and the process requirements are met. Can be used again until the hardened wear layer is consumed.
  • the specific grinding method adopts a double-end grinding process, or a single-side grinding, turning and re-grinding process.
  • the slotted structure of the surfacing or cladding wear-resistant hardened layer is radially or at an angle to the radial direction.
  • the toothed structure may be an equilateral triangle tooth or other toothed structure.
  • Figure 1 is a schematic view showing the structure of the outer circumference of an equal-thickness flat saw blade of the present invention.
  • Figure 2 is a schematic view showing the structure of the outer circumference of the side-gap saw blade of the present invention.
  • Figure 3 is a schematic view showing the structure of the outer circumference of the thinned saw blade.
  • Fig. 4 is a structural schematic view showing the outer circumference of a bevel type non-equal thickness wear-resistant hardened layer and a flat saw blade.
  • Figure 5 is a side view of Figure 1.
  • Figure 6 is a side elevational view of the outer circumferential structure of a flat saw blade with a slotted configuration.
  • a metal hot and cold cut circular saw blade as shown in Figs. 1 and 5, the outer circumference of the saw blade body 1 is provided with a hardened wear resistant layer 3.
  • the hardened wear resistant layer 3 is provided in the width of the outer circumference of the saw blade body 1 and in the range of both side faces.
  • the hardened wear-resistant layer 3 is processed by laser cladding; in the embodiment, the outer circumference of the saw blade body 1 has a tooth-shaped structure 4 in the width direction, and the two sides of the outer circumference of the saw blade body 1 are of equal thickness
  • the flat structure, the hardened wear layer 3 is processed by a cladding process, and the hardened wear layer 3 is as shown in FIGS. 1 and 5.
  • Saw blade body 1 blanking Select medium-low carbon steel plate and ultra-low carbon steel plate as raw materials, and cut the raw material into a circular ring blank structure by plasma cutting, flame cutting or laser cutting.
  • Sheet heat treatment Select separate quenching and tempering treatment to improve the performance of the sheet, or directly temper the raw materials with the highest performance.
  • Sheet leveling preliminary leveling of the heat-treated saw blade to meet the process requirements of conventional saw blades.
  • Sheet preparation After the leveling, the saw blade body is processed into a semi-finished product through the processing of turning, drilling and grinding.
  • sheet fine leveling finely ground saw blade body should be fine-leveled to provide a good foundation for subsequent processing.
  • the tooth structure 4 may be an equilateral triangle structure or may be selected Other tooth types, such as rat teeth, wolf teeth, arc back teeth, etc.; the outer circumference of the saw blade body 1 needs to be welded to the wear-resistant hardened layer 3 to prepare the shape; the thick flat plate structure can Finishing the contour range (only for a slight removal), such as a thick flat structure or no need to finish the contour range, only need to process (or draw out) the contour boundary of the wear-resistant hardened layer 3 that needs to be clad Just fine.
  • the production of hardened wear-resistant layer is between 0.5 and 3 mm, and the radial width from the outer circle is selected as 1% to 10% of the diameter D of the saw blade; the hardness is 55-65HRC. It is metallurgically fused with the saw blade body, and the joint is firm and crack-free; the hardened wear-resistant layer finally needs to meet the saw blade to cut the workpiece normally under the working condition of the line speed of 140 m / sec.
  • Finishing the finished product Eliminate the deformation of the sheet caused by the manufacture of the wear-resistant layer, so that it is convenient for subsequent processing;
  • the hardened wear layer is made wider than the thickness of the saw blade itself, and the hardened wear layer of the saw blade is ground to make the wear layer smooth and the side gap angle uniform.
  • the specific grinding method adopts the double-end grinding process, or the one-side grinding, turning and grinding art.
  • Tooth shape processing Fine grinding the tooth structure.
  • the sawtooth is passivated. After sawing the workpiece, the phenomenon of burr, flash, and skew is generated, and the tooth-shaped sharpening and the sheet leveling are performed again, and the process requirements are met. Can be used again until the hardened wear layer is consumed; no need to re-quench the tooth tip, it can restore the use effect, reduce the saw blade consumption, especially suitable for normal processing of high-strength, thick-wall and other difficult-to-cut workpieces.
  • the blade piece 1 is an equal-thickness flat plate structure, and the blade piece body 1 has teeth of the outer circumference during the pre-processing of the cladding position.
  • a shallow groove structure 6 is disposed on both sides of the structure 4, and the hardened wear layer 3 is welded on the groove structure 6; as shown in FIG. 6, the grooved structure 6 of the wear-resistant hardened layer is There is an angle between the radial direction and the radial direction; the hardened wear layer 3 with different angular distributions can be melted.
  • Intermittent cladding with slotted structure 6 can reduce heat concentration and reduce deformation; reduce the use of cladding materials, which can save costs; avoid hardening at the root arc, which is beneficial to prevent cracking of the saw blade;
  • the tooth shape is pre-machined to reduce the difficulty and workload of subsequent tooth opening, and the consumption can be reduced in the subsequent continuous repair process.
  • the difference from the structure of the embodiment 1 is that during the blanking process of the saw blade body 1, the outer circumferential end of the saw blade body 1 is processed into an equal thickness thinning with the shoulder 5. Structure.
  • the manufacturing process of the hardened wear layer 3 is different from that of the first embodiment in that the hardened wear layer 3 is produced by a surfacing process, using welding equipment and welding wire, and uniformly welding on the sheet under a protective atmosphere.
  • the layer reaches the predetermined thickness, the joint strength, and controls the degree of thermal deformation of the sheet.
  • the hardened wear layer requires uniform thickness, compactness and flatness for subsequent processing: laser cladding process, using laser source and alloy Under the process parameters, the powder is surface-clad on the outer circumference of the sheet, which is firm, crack-free and less deformed; the cladding layer requires uniform thickness, compactness and flatness for subsequent processing.
  • the difference from the structure of the embodiment 1 is that the hardened wear-resistant layer 3 is finally formed into a bevel-type non-equal-thickness structure, and the saw blade body 1 has a flat plate-like structure as a whole.
  • the difference from the structure of the embodiment 3 is that the outer circumferential end of the saw blade body 1 is processed into a beveled thinned shape with the shoulder 5 during the cutting of the saw blade body 1. Structure; 3 layers of hardened wear layer are finally formed into an equal thickness slope structure.
  • the present invention is not limited to the above-mentioned examples, and the groove structure 6 on the blade piece 1 can be processed into various shapes such as angle, width, depth, and length according to actual needs; the outer circumferential structure of the blade piece 1 is in addition to the flat plate.
  • the shape structure, the backlash structure, the composite side gap structure can also be processed into any other shape, and the processing of the tooth structure, the fine grinding process, etc. can be omitted under the premise that the tooth structure is not required, directly in the hair defect In the process of material blanking, the outer circumference can be made into a disc-shaped structure. In short, as long as it meets the needs of saw blade processing.

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Abstract

一种圆锯片及其制造工艺，特别是一种金属冷热切圆锯片及其制造工艺。该圆锯片包括锯片片体（1），锯片片体（1）的外圆周设置有硬化耐磨层（3）。制造工艺是：锯片片体（1）下料、片体（1）热处理、片体（1）校平、片体（1）准备、片体（1）精校平、堆焊或熔覆位置的预加工、硬化耐磨层（3）的制作、成品校平、侧隙磨削、齿形加工、成品精平，使之达到工艺要求范围，具备上锯使用条件。该锯片片体（1）的外圆周内设置的硬化耐磨层（3），使锯片在工作时保持两个尖角在长时间内处于锋利状态，减少锯切毛刺、延长锯切时间，在瞻齿钝化后，仅需要修复齿形，不需要齿尖再淬火，就能恢复使用效果，尤其是能够满足高强度、厚壁难切工件的加工。

Description

金属冷热切圆锯片及其制造工艺 技术领域
本发明涉及一种圆锯片及其制造工艺，特别是一种金属冷热切圆锯片及其制造工艺。
背景技术
金属冷热切圆锯片是管棒型材轧制生产过程中必备的切断工具，因为具有快速的加工效率、较好的切断质量，沿用多年。
在锯片工作时，主要参与锯切的锯齿部位是两个尖角、横刃部分，尖角和横刃经过与工件剧烈磨擦，使工件被切断，同时自身也受到磨损，典型的磨损形态是横刃变宽而钝化，尖角磨圆后产生明显的切割毛刺，最后使锯片失效不能使用。此时需要将锯片重新刃磨、齿尖硬化，方可再次使用。
一般的金属冷热切圆锯片有两种类型，一是整体硬度在40HRC左右的单硬度锯片，锯齿磨损后仅需要重新刃磨就能使用，比较简单，存在的问题是，齿尖硬度较低，锯切寿命较短，频繁更换锯片会影响轧钢生产节奏。二是片体硬度在30HRC以下，齿尖部经过局部热处理达到50HRC以上的双硬度锯片，锯齿钝化后，需要刃磨齿形、齿尖再淬火，另外由于齿尖淬火时在碳素钢的基础上进行的局部淬火，硬化组织的耐磨性有限，虽然其锯切寿命高于单硬度锯片，但是在实际生产中还是不能满足客户要求，又是针对高强度、厚壁工件，锯切寿命更有明显的降低。
发明内容
本发明的目的在于提供一种减少锯切毛刺、延长锯切时间的金属冷热切圆锯片及其制造工艺。
本发明的属冷热切圆锯片采用如下技术方案：
一种金属冷热切圆锯片，包括锯片片体，锯片片体的外圆周设置有硬化耐磨层。
上述技术方案的本发明与现有技术相比，锯片片体的外圆周内设置的硬化耐磨层，使锯片在工作时保持两个尖角在长时间内处于锋利状态，减少锯切毛刺、延长锯切时间，在瞻齿钝化后，仅需要修复齿形，不需要齿尖再淬火，就能恢复使用效果，尤其是能够满足高强度，厚壁难切工件的加工。
上述技术方案的优选方案是：
锯片片体的外圆周的宽度以及两侧面的范围内设置有硬化耐磨层。
硬化耐磨层采用堆焊或激光熔覆的工艺。
锯片片体的外圆周的两侧面呈平板结构，宽度方向上设置有齿形结构或齿形结构的两侧面上还设置有开槽结构。
锯片片体的外圆周的两侧面呈侧隙式结构，宽度方向上设置有齿形结构；或锯片片体的外圆周的两侧面呈平板、侧隙式复合结构，宽度方向上设置有齿形结构或齿形结构的两侧面上还设置有开槽结构。
平板结构上熔覆硬化耐磨层：开槽结构上嵌入式熔覆硬化耐磨层。
侧隙形结构上熔覆硬化耐磨层，开槽结构上嵌入式熔覆硬化耐磨层。
一种前述的金属冷热切圆锯片的制造工艺，按如下步骤进行：
a、锯片片体下料：选择中低碳钢板、超低碳钢板作为原材料，采用等离子切割、火焰切割或激光切割的工艺方法，将原材料切割成圆环形毛坯结构；
b、片体热处理：选择单独的淬火回火处理，改善片体性能，或者直接将性能达标的原材料作一次回火处理；
c、片体校平：对热处理过的锯片片体进行初步校平，达到常规锯片的工艺要求；
d、片体准备：校平后的锯片片体要经过车削、钻削、磨削的加工过程，或再加工出需要的齿型结构，制作成半成品；
e、片体精校平：精磨削后的锯片片体要经过精校平，为后续加工提供良好的基础条件；
f、堆焊或熔覆位置的预加工：针对半成品锯片片体，采用车削、铣削、磨削的工艺手段，将片体的外圆周上需要堆焊或熔覆出耐磨硬化层的部位加工出准备形状；
g、硬化耐磨层的制作：硬化耐磨层的厚度尺寸在0.5～3毫米之间，从外圆开始的径向宽度选为锯片直径D的1％～10％；硬度在55～65HRC，与锯片本体成冶金融合、结合牢固、无裂纹；
h、成品校平：消除耐磨层制造引起的片体变形，使之便于后续加工；
i、侧隙磨削：耐磨层的制作要宽于锯片片体本身厚度，对锯片片体的硬化耐磨层进行磨削加工，使耐磨层表面光滑、侧隙角度均匀；
j、齿形加工：采用激光切割、线切割的方式开齿，再用磨齿机精确刃磨齿形角度，最后满足图纸要 求；或直接使用磨齿机开齿、刃磨连续完成；或直接精磨齿形结构；
k、成品精平：最终调整锯片的平度、端跳、应力，使之达到工艺要求范围，具备上锯使用条件。
上述制造工艺的优选方案是：
步骤f中，加工出的准备形状为：平板形结构、侧隙形结构或减薄形结构。
步骤g中，硬化耐磨层最后要满足锯片在140米/秒线速度以下工况里正常锯切工件。
步骤g中，硬化耐磨层的制作工艺为：堆焊工艺或激光熔覆工艺。
堆焊工艺，采用焊接设备、焊丝，在保护气氛之下，均匀的在片体上进行焊接，分层次达到预定厚度、连接强度，控制片体受热变形程度，在可校正范围之内，硬化耐磨层要求厚度均匀、致密、平整，便于后续加工；激光熔覆工艺，采用激光源、合金粉料，在工艺参数下，对片体外圆周进行表面熔覆，结合牢固、无裂纹、少变形；熔覆层要求厚度均匀、致密、平整，便于后续加工。
在锯片使用达到磨损需要修复的程度后，锯齿钝化，锯切工件后就要产生毛刺、飞边、切斜的现象，再次进行齿形刃磨、片体校平，达到工艺要求后即可再次使用，直到硬化耐磨层消耗完毕为止。
步骤i中，具体磨削方式采用双端对磨的工艺，或采用单侧磨削、翻转再磨的工艺。
堆焊或熔覆耐磨硬化层的开槽结构为径向或者与径向之间存在夹角。
步骤d中，齿型结构可以是正三角形齿或其他齿形结构。
附图说明
图1是本发明等厚形平板式锯片片体外圆周的结构示意图。
图2是本发明侧隙式锯片片体外圆周的结构示意图。
图3是减薄式锯片片体外圆周的结构示意图。
图4是斜面式非等厚型耐磨硬化层、平板式锯片片体外圆周的结构示意图。
图5是图1的侧视图。
图6是带有开槽式结构的平板式锯片片体外圆周结构的侧视图。
具体实施方式
下面结合附图及实施例详述本发明：
实施例1：
一种金属冷热切圆锯片，如图1和图5中所示的结构，锯片片体1的外圆周设置有硬化耐磨层3。
锯片片体1的外圆周的宽度以及两侧面的范围内设置有硬化耐磨层3。硬化耐磨层3采用激光熔覆的加工工艺；本实施例中的锯片片体1外圆周的宽度方向上具有齿形结构4，锯片片体1的外圆周的两侧面呈等厚形平板结构，硬化耐磨层3由熔覆式工艺加工而成，硬化耐磨层3如图1和图5中所示。
本实施例的加工工艺是：
a、锯片片体1下料：选择中低碳钢板、超低碳钢板作为原材料，采用等离子切割、火焰切割或激光切割的工艺方法，将原材料切割成圆环形毛坯结构。
b、片体热处理：选择单独的淬火回火处理，改善片体性能，或者直接将性能达标的原材料作一次回火处理。
c、片体校平：对热处理过的锯片片体进行初步校平，达到常规锯片的工艺要求。
d、片体准备：校平后的锯片片体要经过车削、钻削、磨削的加工过程，制作成半成品。
e、片体精校平：精磨削后的锯片片体要经过精校平，为后续加工提供良好的基础条件。
f、熔覆位置的预加工：针对半成品锯片片件，采用车削、铣削、磨削的工艺手段，或加工出需要的齿型结构4，齿形结构4可以是正三角形结构，也可以是选择其他齿型，比如鼠牙齿，狼牙齿，弧背齿等结构；将锯片片体1的外圆周上需要熔覆耐磨硬化层3的部位加工出准备形状；等厚形平板式结构，可以精加工出轮廓范围(只作略微去除即可)，等厚形平板式结构或者不需要精加工出轮廓范围，只需要加工(或者划出)出需要熔覆的耐磨硬化层3的轮廓界线即可。
g、硬化耐磨层的制作；硬化耐磨层的厚度尺寸在0.5～3毫米之间，从外圆开始的径向宽度选为锯片直径D的1％～10％；硬度在55～65HRC，与锯片本体成冶金融合、结合牢固、无裂纹；硬化耐磨层最后要满足锯片在140米/秒线速度以下工况里正常锯切工件。
b、成成品校平：消除耐磨层制造引起的片体变形，使之便于后续加工；
i、侧隙磨削：硬化耐磨层的制作要宽于锯片片体本身厚度，对锯片片体的硬化耐磨层进行磨削加工，使耐磨层表面光滑、侧隙角度均匀，具体磨削方式采用双端对磨的工艺，或采用单侧磨削、翻转再磨的工 艺。
j、齿形加工：将齿形结构进行精磨。
k、成品精平：最终调整锯片的平度、端跳、应力，使之达到工艺要求范围，具备上锯使用条件。
在锯片使用达到磨损需要修复的程度后，锯齿钝化，锯切工件后就要产生毛刺、飞边、切斜的现象，再次进行齿形刃磨、片体校平，达到工艺要求后即可再次使用，直到硬化耐磨层消耗完毕为止；无需要齿尖再淬火，就能恢复使用效果，降低锯片消耗，尤其适用能够满足高强、厚壁等难切工件的正常加工。
实施例2：
参见附图1和附图6，与实施例1的不同之处是：锯片片件1为等厚型平板结构，锯片片体1在熔覆位置预加工过程中，将外圆周的齿形结构4的两侧面上设置有较浅的开槽结构6，开槽结构6上熔覆硬化耐磨层3；如图6所示的结构，熔覆耐磨硬化层的开槽结构6为径向或者与径向之间存在夹角；可熔覆出不同角度分布的硬化耐磨层3。
带有开槽结构6的断续式熔覆可减少热量集中，减少变形；减少了熔覆用料的使用，可节省成本；避开齿根圆弧处的硬化，有利于防止锯片开裂；齿形预加工出来，减少后续开齿的难度和工作量，在后续的连续修复过程中，也能减少消耗。
实施例3：
如图3所示，与实施例1的结构不同之处是：锯片片体1下料过程中，将锯片片体1的外圆周端加工成带有台肩5的等厚形减薄式结构。
硬化耐磨层3的制作工艺与实施例1的不同之处是：硬化耐磨层3的制作采用堆焊工艺，采用焊接设备、焊丝，在保护气氛之下，均匀的在片体上进行焊接，分层次达到预定厚度，连接强度，控制片体受热变形程度，在可校正范围之内，硬化耐磨层要求厚度均匀、致密、平整，便于后续加工：激光熔覆工艺，采用激光源、合金粉料，在工艺参数下，对片体外圆周进行表面熔覆，结合牢固、无裂纹、少变形；熔覆层要求厚度均匀、致密、平整，便于后续加工。
实施例4：
如图4所示，与实施例1的结构的不同之处是：硬化耐磨层3最终成形为斜面式非等厚形结构，锯片片体1整体呈平板形结构。
实施例5：
如图2所示，与实施例3结构的不同之处是：锯片片体1下料过程中，将锯片片体1的外圆周端加工成带有台肩5的斜面式减薄形结构；硬化耐磨层3层终成形为等厚的斜坡式结构。
本发明不限于上述所列举，还可以将锯片片体1上的形槽结构6根据实际需要加工成角度、宽度、深度、长度不同等多样形状；锯片片体1的外圆周结构除了平板形结构、侧隙形结构、复合形侧隙结构，还可以加工成其他任意形状，还可以在不需要齿形结构的前提下，省略齿形结构的加工、精磨等工序，直接在毛坏材料下料的过程中将外圆周做成圆盘形结构即可，总之，只要符合锯片加工需要即可。

Claims (16)

  1. 一种金属冷热切圆锯片，包括锯片片体，其特征在于：锯片片体的外圆周设置有硬化耐磨层。
  2. 根据权利要求1所述的金属冷热切圆锯片，其特征在于：锯片片体的外圆周的宽度以及两侧面的范围内设置有硬化耐磨层。
  3. 根据权利要求1或2所述的金属冷热切圆锯片，其特征在于：硬化耐磨层采用堆焊或激光熔覆的工艺。
  4. 根据权利要求1所述的金属冷热切圆锯片，其特征在于：锯片片体的外圆周的两侧面呈平板结构，宽度方向上设置有齿形结构或齿形结构的两侧面上还设置有开槽结构。
  5. 根据权利要求1所述的金属冷热切圆锯片，其特征在于：锯片片体的外圆周的两侧面呈侧隙式结构，宽度方向上设置有齿形结构；或锯片片体的外圆周的两侧面呈平板、侧隙式复合结构，宽度方向上设置有齿形结构或齿形结构的两侧面上还设置有开槽结构。
  6. 根据权利要求3所述的金属冷热切圆锯片，其特征在于：平板结构上熔覆硬化耐磨层；开槽结构上嵌入式熔覆便化耐磨层。
  7. 根据权利要求4所述的金属冷热切圆锯片，其特征在于：侧隙形结构上熔覆硬化耐磨层，开槽结构上嵌入式熔覆硬化耐磨层。
  8. 一种如权利要求1至7中任意一项所述的金属冷热切圆锯片的制造工艺，按如下步骤进行：
    a、锯片片体下料：选择中低碳钢板、超低碳钢板作为原材料，采用等离子切割、火焰切割或激光切割的工艺方法，将原材料切割成圆环形毛坯结构；
    b、片体热处理：选择单独的淬火回火处理，改善片体性能，或者直接将性能达标的原材料作一次回火处理；
    c、片体校平：对热处理过的锯片片体进行初步校平，达到常规锯片的工艺要求；
    d、片体准备：校平后的锯片片体要经过车削、钴削、磨削的加工过程，或再加工出需要的齿型结构，制作成半成品；
    e、片体精校平：精磨削后的锯片片体要经过精校平，为后续加工提供良好的基础条件；
    f、堆焊或熔覆位置的预加工：针对半成品锯片片体，采用车削、铣削、磨削的工艺手段，将片体的外圆周上需要堆焊或熔覆出耐磨硬化层的部位加工出准备形状；
    g、硬化耐磨层的制作：硬化耐磨层的厚度尺寸在0.5～3毫米之间，从外圆开始的径向宽度选为锯片直径D的1％～10％；硬度在55～6511RC，与锯片本体成冶金融合、结合牢固、无裂纹；
    h、成品校平：消除耐磨层制造引起的片体变形，使之便于后续加工；
    i、侧隙磨削：耐磨层的制作要宽于锯片片体本身厚度，对锯片片体的硬化耐磨层进行磨削加工，使耐磨层表面光滑、侧隙角度均匀；
    j、齿形加工：采用激光切割、线切割的方式开齿，再用磨齿机精确刃磨齿形角度，最后满足图纸要求；或直接使用磨齿机开齿、刃磨连续完成；或直接精磨齿形结构；
    k、成品精平：最终调整锯片的平度、端跳、应力，使之达到工艺要求范围，具备上锯使用条件。
  9. 根据权利要求1所述的金属冷热切圆锯片的制造工艺，其特征在于：步骤f中，加工出的准备形状为：平板形结构、侧隙形结构或减薄形结构。
  10. 根据权利要求1所述的金属冷热切圆锯片的制造工艺，其特征在于：步骤g中，硬化耐磨层最后要满足锯片在140米/秒线速度以下工况里正常锯切工件。
  11. 根据权利要求1所述的金属冷热切圆锯片的制造工艺，其特征在于：步骤g中，硬化耐磨层的制作工艺为：堆焊工艺或激光熔覆工艺。
  12. 根据权利要求11所述的金属冷热切圆锯片的制造工艺，其特征在于：堆焊工艺，采用焊接设备、焊丝，在保护气氛之下，均匀的在片体上进行焊接，分层次达到预定厚度、连接强度，控制片体受热变形程度，在可校正范围之内，硬化耐磨层要求厚度均匀、致密、平整，便于后续加工；激光焙覆工艺，采用激光源、合金粉料，在工艺参数下，对片体外圆周进行表面熔覆，结合牢固、无裂纹、少变形；熔覆层要求厚度均匀、致密、平整，便于后续加工。
  13. 、根据权利要求11所述的金属冷热切圆锯片的制造工艺，其特征在于：在锯片使用达到磨损需要修复的程度后，锯齿钝化，锯切工件后就要产生毛刺、飞边、切斜的现象，再次进行齿形刃磨、片体校平，达到工艺要求后即可再次使用，直到硬化耐磨层消耗完毕为止。
  14. 根据权利要求8所述的金属冷热切圆锯片的制造工艺，其特征在于：步骤i中，具体磨削方式采用 双端对磨的工艺，或采用单侧磨削、翻转再磨的工艺。
  15. 根据权利要求8所述的金属冷热切圆锯片的制造工艺，其特征在于：步骤f中，堆焊或熔覆耐磨硬化层的开槽结构为径向或者与径向之间存在夹角。
  16. 根据权利要求8所述的金属冷热切圆锯片的制造工艺，其特征在于：步骤d中，齿型结构可以是正三角形齿或其他齿形结构。
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