WO2021082606A1 - 超耐磨浮封环及其加工方法和装置 - Google Patents

超耐磨浮封环及其加工方法和装置 Download PDF

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Publication number
WO2021082606A1
WO2021082606A1 PCT/CN2020/108067 CN2020108067W WO2021082606A1 WO 2021082606 A1 WO2021082606 A1 WO 2021082606A1 CN 2020108067 W CN2020108067 W CN 2020108067W WO 2021082606 A1 WO2021082606 A1 WO 2021082606A1
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Prior art keywords
floating seal
seal ring
wear
resistant
fan
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PCT/CN2020/108067
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English (en)
French (fr)
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喻拯昊
喻思纯
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武汉鑫华封机械制造有限责任公司
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Priority to US17/616,697 priority Critical patent/US11796062B2/en
Publication of WO2021082606A1 publication Critical patent/WO2021082606A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J15/00—Sealings
    • F16J15/16—Sealings between relatively-moving surfaces
    • F16J15/26—Sealings between relatively-moving surfaces with stuffing-boxes for rigid sealing rings
    • F16J15/28—Sealings between relatively-moving surfaces with stuffing-boxes for rigid sealing rings with sealing rings made of metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J15/00—Sealings
    • F16J15/16—Sealings between relatively-moving surfaces
    • F16J15/32—Sealings between relatively-moving surfaces with elastic sealings, e.g. O-rings
    • F16J15/3204—Sealings between relatively-moving surfaces with elastic sealings, e.g. O-rings with at least one lip
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J15/00—Sealings
    • F16J15/16—Sealings between relatively-moving surfaces
    • F16J15/34—Sealings between relatively-moving surfaces with slip-ring pressed against a more or less radial face on one member
    • F16J15/3496—Sealings between relatively-moving surfaces with slip-ring pressed against a more or less radial face on one member use of special materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

Definitions

  • the invention relates to the field of mechanical manufacturing, in particular to a super wear-resistant floating seal ring and a processing method and device thereof.
  • the sealing performance and working life of the floating seal ring are the core indicators of its quality.
  • the occurrence of oil leakage is a key sign of the failure of the floating seal ring seal.
  • There are many reasons for oil leakage Among them, the long working time and insufficient elasticity of the rubber ring can not compensate for the wear of the two iron ring working surfaces, which makes the gap between the bonding surfaces larger, and the leakage is the most direct and common cause.
  • replacing the floating seal is the only option. How to make the working surface of the floating seal ring more wear-resistant, the oil sealing effect and the working life more reliable and longer are the problems that need to be solved in the current production.
  • the purpose of the present invention is to provide a super wear-resistant floating seal ring and its processing method and device.
  • the use of a special floating seal ring structure can make the working surface more wear-resistant, prolong the working life of the floating seal ring, and the processing is simple. The problem of plane warping during grinding.
  • a super wear-resistant floating seal ring includes a ring body.
  • a "C"-shaped groove is opened on the working surface of the ring body, and a wear-resistant material layer is filled in the "C"-shaped groove to form a super wear-resistant core ring.
  • a slope protection structure is provided on both sides of the "C"-shaped groove, a slope surface is provided under the slope protection structure of the ring body, a compression notch is opened on the slope surface, and the compression notch is corresponding to the inner diameter of the ring body
  • a jack is opened at the position, and the width of the notch of the "C"-shaped groove is 2.5-5mm.
  • the wear-resistant material layer is filled with a mixed powder composed of chromium-molybdenum alloy powder, tungsten carbide alloy powder and ceramic sand powder into the "C"-shaped groove by means of laser or plasma arc welding.
  • the slope protection structure is 1.5-3mm higher than the working surface of the floating seal ring.
  • a method for processing a super wear-resistant floating seal ring includes the following specific steps:
  • Step 1 Use GCr15 bearing steel to process the ring body of the floating seal ring;
  • Step 2 Machining a "C"-shaped groove on the working surface of the ring body of the floating seal ring by machine turning;
  • Step 3 Fill-welding a mixed powder composed of chromium-molybdenum alloy powder, tungsten carbide alloy powder and ceramic sand powder in the "C"-shaped groove by laser or plasma arc welding to form a wear-resistant material layer;
  • Step 4 Open compression notches and sockets on the floating seal ring with the wear-resistant material layer, and install the floating seal ring on the three fan-shaped support plates;
  • Step 5 Install the three fan-shaped support plates on the grinder, and the grinder starts to grind the wear-resistant material layer of the floating seal ring to ensure that the flatness and smoothness of the oil seal working surface of the floating seal ring meet the quality standards.
  • the installation of the floating seal ring on the fan-shaped support plate specifically includes:
  • the positioning block on the fan-shaped support plate is inserted into the hole on the inner diameter of the floating seal ring so that the entire ring body is sleeved on the three fan-shaped support plates;
  • the fan-shaped support plate includes a base plate connected to the grinder, a mounting plate is arranged on the base plate, a positioning block matched with the socket is arranged on the outer side of the mounting plate, and the upper surface of the mounting plate is provided with a convenient bolt insertion Bolt hole, the bolt is inserted into the bolt hole to fix the workpiece pressure plate.
  • a processing device for a super wear-resistant floating seal ring includes a grinder.
  • Three fan-shaped support plates are installed on the grinder.
  • the fan-shaped support plate is equipped with a workpiece pressure plate.
  • the clamping block of the workpiece pressure plate is clamped into the ring body.
  • the fan-shaped support plate includes a base plate connected to the grinder, a mounting plate is arranged on the base plate, and a positioning block matched with the jack is arranged on the outer side of the mounting plate, and is provided on the upper surface of the mounting plate
  • the arc of the fan-shaped support plate is 120°, and the mounting plates of the three fan-shaped support plates form a round table so as to support the inner diameter of the floating seal ring.
  • the beneficial effect of the present invention is that the design of the wear-resistant core ring not only solves the problem of super wear resistance but also solves the problem of super difficult processing and difficult flatness quality, and creates good conditions for solving the difficulties.
  • the material cost is reduced, the quality advantage is outstanding, and it has the advantages of energy saving and environmental protection and has great market competitiveness.
  • Figure 1 is a schematic diagram of the floating seal ring structure of the present invention
  • FIG. 2 is a schematic diagram of the structure of the processing device of the present invention.
  • Figure 3 is a schematic diagram of the connection structure between the floating seal ring and the processing device of the present invention.
  • a super wear-resistant floating seal ring which is characterized by comprising a ring body 4, the working surface of the ring body 4 is provided with a "C"-shaped groove 40, and the "C"-shaped groove 40 is filled with resistant
  • the abrasive material layer 41 forms a super wear-resistant core ring.
  • a slope protection structure 42 is provided on both sides of the "C"-shaped groove 40.
  • a slope surface 43 is provided under the slope protection structure 42 of the ring body 4, and the slope surface 43 is
  • a compression notch 44 is provided, and an insertion hole 45 is provided at the inner diameter of the ring body 4 corresponding to the compression notch 44, and the width of the "C"-shaped groove 40 is 2.5-5 mm.
  • the wear-resistant material layer 41 is filled and welded into the "C"-shaped groove 40 by using a mixed powder composed of chromium-molybdenum alloy powder, tungsten carbide alloy powder and ceramic sand powder by means of laser or plasma arc welding.
  • the slope protection structure 42 is 1.5-3mm higher than the working surface of the floating seal ring.
  • a processing device for a super wear-resistant floating seal ring including a grinder 1.
  • Three fan-shaped support plates 2 are installed on the grinder 1, and a workpiece pressing plate 3 is mounted on the fan-shaped support plate 2 , The clamping block 6 of the workpiece pressing plate 3 is clamped into the pressing notch 44 of the ring body 4.
  • the fan-shaped supporting plate 2 includes a base plate connected to the grinder 1, and a mounting plate 7 is provided on the base plate.
  • the outer side of the mounting plate 7 is provided with a positioning block 9 matched with the socket 45, and the upper surface of the mounting plate 7 is provided with a bolt hole 8 to facilitate the insertion of the bolt 5, and the bolt 5 is inserted into the bolt hole 8 to fix the workpiece pressing plate 3 live.
  • the arc of the fan-shaped support plate 2 is 120°, and the mounting plates 7 of the three fan-shaped support plates 2 form a circular table so as to support the inner diameter of the floating seal ring.
  • a method for processing a super wear-resistant floating seal ring includes the following specific steps:
  • Step 1 Use GCr15 bearing steel to process the ring body 4 of the floating seal ring;
  • Step 2 A "C"-shaped groove 40 is machined by a machine tool on the working surface of the ring body 4 of the floating seal ring;
  • Step 3 Fill-welding a mixed powder composed of chromium-molybdenum alloy powder, tungsten carbide alloy powder and ceramic sand powder in the "C"-shaped groove 40 by laser or plasma arc welding to form a wear-resistant material layer 41;
  • Step 4 A compression notch 44 and a socket 45 are opened on the floating seal ring of the processed wear-resistant material layer 41, and the floating seal ring is installed on the three fan-shaped support plates 2;
  • Step 5 Install the three fan-shaped support plates 2 on the grinder 1, and the grinder 1 starts to grind the wear-resistant material layer 41 of the floating seal ring to ensure that the flatness and smoothness of the floating seal ring oil seal working surface reach the quality standard.
  • the installation of the floating seal ring on the fan-shaped support plate 2 specifically includes:
  • the positioning block 9 on the fan-shaped support plate 2 is inserted into the socket 45 on the inner diameter of the floating seal ring so that the entire ring body is sleeved on the three fan-shaped support plates 2;
  • the fan-shaped support plate 2 includes a base plate connected to the grinder 1.
  • a mounting plate 7 is provided on the base plate, and a positioning block 9 matching the socket 45 is provided on the outer side of the mounting plate 7.
  • a bolt hole 8 is provided on the surface to facilitate the insertion of the bolt 5, and the bolt 5 is inserted into the bolt hole 8 so as to fix the workpiece pressing plate 3.
  • Adopting unique process design first, processing the floating seal iron ring blanks, and opening a trough for the working surface to be filled with wear-resistant materials; second, using laser, plasma arc welding and other methods to produce new wear-resistant working surface bright bands Because the ring is a metallurgical combination, the newly created wear-resistant material working surface is firmly fused with the base material, and will never peel off; it is not only super wear-resistant, but also very resistant to axial and radial impact; this performance is absolutely superior Over cast ring; because the wear-resistant layer formed by melting is much harder than the base material, and has a certain thickness, it shows the advantages of cast iron, which is rather rigid, brittle, and non-deformable, which is beneficial to the wear-resistant surface The quality of the flatness is improved; third, in addition to the floating seal iron ring oil seal working surface, the bright belt fitting surface is a unique and original high-profile protruding design.
  • the super wear-resistant material is the "core” ring, and the inner and outer diameters of the "core” ring are on both sides
  • the slope-dam type "core-protecting slope" like a dam, covers the super wear-resistant material filled in to form a "wear-resistant core ring”; at the same time, there is at least 1.5-3mm between the high-convex wear-resistant layer and its footing. According to the difference of the diameter of the floating seal type gauge, the convex height value is set accordingly.
  • the end surface of the inner diameter forms a 3-6mm wide lubricating oil inlet, which is more lubricated than the old floating seal iron ring
  • the oil penetrates into the opening and doubles, and the increase of the opening is more conducive to the lubrication of the lubricating oil into the working surface, which is not only beneficial to the reduction of the working surface, but also helps to extend the service life; especially the "resistant" of this high-boss working surface
  • the "grinding core ring" design not only solves the problem of super wear resistance, but also solves the problem of super difficult processing and the difficulty of flatness and quality, creating good conditions for solving the difficulties.
  • the inner and outer diameter "core protection slope" and the base iron ring of the "wear-resistant core ring” made of wear-resistant materials are all ordinary steel, its hardness is not high, and it is easy to process and shape.
  • the sealing ring has a particularly high material hardness and is particularly wear-resistant, and the large end face needs to be processed across the entire surface. The processed surface is very wide, and it is also a key part with the highest quality requirements. The difficulty of processing becomes another important factor that makes it difficult to reduce the manufacturing cost; the present invention The original and unique new process design and construction measures, scientifically and ingeniously solve this problem.
  • the "wear-resistant core ring” made of new super wear-resistant materials most thoroughly and economically solves the difficulty of super abrasion resistance and long service life of the floating seal ring; the scientific and reasonable "high-boss wear-resistant core ring” Designed to make the high-hard phase material hard and brittle. It is difficult to process because the inner and outer diameters of the new "high boss wear-resistant core ring" are protected by steel material on both sides of the slope protection, and the "core” ring surface is 3mm wide and narrow The processing surface greatly reduces the processing difficulty, and other construction measures and tooling coordination also greatly reduce the processing cost. Realize high-efficiency production and meet quality standards.
  • the "wear-resistant core ring” is filled with super wear-resistant metal materials. Although there are rare metal precious metals in the proportion, only a little “good steel” is used on the blade. The material cost is greatly reduced, and the quality is greatly improved. Compared with the old casting The high chromium molybdenum and cemented carbide floating seal iron rings are all cast as a whole. In fact, only the 2-3mm thick wear-resistant layer of the working surface needs to be wear resistant. The rest of the entire floating seal ring matrix does not need to be equipped. What abrasion resistance. The remaining 95% of the rare precious metals in the matrix are all useless and wasted. This is also the reason why the cost of casting floating seal ring is so high that it is difficult to reduce.
  • the cost of its products can not be reduced by increasing its product cost; because the floating seal ring only needs the large-end working surface bright belt to resist wear, and once the working surface bright belt wears away the 1.5-3mm wear layer Later, the oil seal ring failed and was scrapped. This is because the resilience of the rubber ring has exceeded its limit, and it is simply unable to compensate for this wear space. As a result, a large gap occurs and oil leakage occurs.
  • the new material wear-resistant working surface of the super wear-resistant floating seal iron ring manufactured by the present invention is a high boss design with a height of 1.5-3mm (set by the size of different types of products), which is the thickness of the wear-resistant layer of the new material ,
  • a newly filled and molten working surface bright band ring of a floating seal iron ring, width 2-3mm x thickness 2-3mm x the outer circumference of this model product, only this point is the consumption of rare precious metals.
  • the iron ring must fail and be scrapped after the wear-resistant layer of the working surface is worn away at most 1.5-2.5mm in thickness.
  • a new type of super wear-resistant floating seal ring because it uses the hard phase material that is filled with super wear-resistant, it is used on the oil seal working surface where the floating seal ring needs to be super wear-resistant, and thus solves the problem that the floating seal ring is wear-resistant and super wear-resistant ,
  • the measures effectively solve the problem of the "wear-resistant core ring" of the super wear-resistant hard material floating seal ring, and the flatness, high precision and quality of the standard.
  • Each of the three fan-shaped support plates is equipped with a workpiece pressing plate on each outer plane, and each pressing plate has a sliding hole slot, corresponding to each fan-shaped support plate, two bolt holes are drilled and tapped, and the workpiece pressing plate is fixed on the fan-shaped support plate with bolts
  • the workpiece pressure plate has grooves that can be adjusted in the radial direction; the workpiece pressure plate extends into the compression groove of the floating seal ring, and the bolts are screwed to fix the workpiece pressure plate.
  • the thickness of the workpiece pressure plate is equal to the depth of the pressure groove, and the three workpiece pressure plates are lifted from the floating seal ring.
  • the large end face of the sealing ring presses the ring to be ground.
  • the surface width of the "wear-resistant core ring" is 2.5-5mm, although the material has high hardness and is particularly resistant to wear, because of the high boss design, the width of the worn surface is narrow, only a few millimeters, plus the inner and outer sides of the boss With steel slope protection structure, there will be no chipping and cracking problems, so the grinding difficulty is reduced, the processing is easy, and the pass rate is high.
  • the floating seal ring is almost ground without external force radial extrusion, so that the floating seal ring works brightly and eliminates the problem of plane warping. It can be solved easily, which completely guarantees the flatness processing to meet the quality requirements of high-standard and high-quality products.

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  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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Abstract

一种超耐磨浮封环及其加工方法和装置，环体（4）的工作面上开设有"C"形槽（40），在"C"形槽内填充有耐磨材料层（41）形成超耐磨芯环，所述"C"形槽的两侧设置有护坡结构（42），所述环体的护坡结构下方设置有斜坡面（43），所述斜坡面上开设有压紧槽口（44），在环体的内径上对应压紧槽口处开设有插孔（45）。所述加工方法包括加工出浮封环的环体；在环体上加工出"C"形槽；在"C"形槽内形成耐磨材料层；开设压紧槽口和插孔，并将浮封环安装到三块扇形支撑板（2）上；将三块扇形支撑板安装到研磨机（1）上，研磨机启动对浮封环的耐磨材料层进行研磨，以保证浮封环封油工作面的平面度及光洁度达到质量标准。浮封环工作寿命延长，而且加工简单，解决了磨削加工时平面翘曲难题。

Description

超耐磨浮封环及其加工方法和装置 技术领域
本发明涉及机械制造领域，具体为一种超耐磨浮封环及其加工方法和装置。
背景技术
浮封环的密封性能和工作寿命是其质量优劣的核心指标。发生漏油是浮封环密封失效的关键标志。漏油原因有许多，而其中工作时间长，胶圈弹性力不足，无法弥补两铁环工作面因磨损，使贴合面间隙变大，无法贴紧而泄漏是最直接，最普遍的原因。这时更换浮封是唯一选择。如何使浮封环工作面更耐磨损，封油效果及工作寿命更可靠更长久是现在生产中需要解决的问题。
发明内容
本发明的目的在于提供一种超耐磨浮封环及其加工方法和装置，采用特殊的浮封环结构能够使得工作面更加耐磨，使浮封环工作寿命延长，而且加工简单，解决了磨削加工时平面翘曲难题。
本发明的技术方案：
一种超耐磨浮封环，包括环体，所述环体的工作面上开设有“C”形槽，在“C”形槽内填充有耐磨材料层形成超耐磨芯环，所述“C”形槽的两侧设置有护坡结构，所述环体的护坡结构下方设置有斜坡面，所述斜坡面上开设有压紧槽口，在环体的内径上对应压紧槽口处开设有插孔，所述“C”形槽的槽口宽度为2.5-5mm。
所述耐磨材料层采用铬钼合金粉末、碳化钨合金粉末以及陶瓷砂粉末组成的混合粉末通过激光或等离子弧焊的方式填焊到“C”形槽内。
所述护坡结构相对于浮封环的工作面高出1.5-3mm。
一种超耐磨浮封环的加工方法，包括以下具体步骤：
步骤一.采用GCr15轴承钢加工出浮封环的环体；
步骤二.在浮封环的环体的工作面上通过机床车加工出“C”形槽；
步骤三.在“C”形槽内通过激光或等离子弧焊的方式填焊铬钼合金粉末、碳化钨合金粉末以及陶瓷砂粉末组成的混合粉末，形成耐磨材料层；
步骤四.在加工好耐磨材料层的浮封环上开设压紧槽口和插孔，并将浮封环安装到三块扇形支撑板上；
步骤五.将三块扇形支撑板安装到研磨机上，研磨机启动对浮封环的耐磨材料层进行研磨，以保证浮封环封油工作面的平面度及光洁度达到质量标准。
所述步骤四中，浮封环安装到扇形支撑板上具体包括：
S1.扇形支撑板上的定位块插入到浮封环的内径上的插孔内使得整个环体套在三块扇形支撑板上；
S2.将工件压板通过螺栓安装到扇形支撑板上，工件压板的卡块压紧安装到压紧槽口内。
所述扇形支撑板包括与研磨机连接的底座板，在底座板上设置安装板，所述安装板的外侧设置有与插孔配套的定位块，在安装板的上表面开设有方便螺栓插入的螺栓孔，螺栓插入到螺栓孔内从而将工件压板固定住。
一种超耐磨浮封环的加工装置，包括研磨机，在研磨机上安装有三块扇形支撑板，所述扇形支撑板上安装有工件压板，所述工件压板的卡块卡入到环体的压紧槽口内，所述扇形支撑板包括与研磨机连接的底座板，在底座板上设置安装板，所述安装板的外侧设置有与插孔配套的定位块，在安装板的上表面开设有方便螺栓插入的螺栓孔，螺栓插入到螺栓孔内从而将工件压板固定住。
所述扇形支撑板的弧度为120°，所述三块扇形支撑板的安装板正好组成一个圆台从而将浮封环的内径支撑住。
与现有技术相比，本发明的有益效果是：耐磨芯环的设计，既解决超耐磨难题又为解决超难加工，平面度质量难达标的难题，创造出解决难点的良好条 件，材料成本降低，质量优势突出，更具节能环保优点，有着极大的市场竞争力。
附图说明
图1为本发明的浮封环结构示意图；
图2为本发明的加工装置结构示意图；
图3为本发明的浮封环与加工装置连接结构示意图。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
本发明提供一种技术方案：
请参阅图一种超耐磨浮封环，其特征在于，包括环体4，所述环体4的工作面上开设有“C”形槽40，在“C”形槽40内填充有耐磨材料层41形成超耐磨芯环，所述“C”形槽40的两侧设置有护坡结构42，所述环体4的护坡结构42下方设置有斜坡面43，所述斜坡面43上开设有压紧槽口44，在环体4的内径上对应压紧槽口44处开设有插孔45，所述“C”形槽40的槽口宽度为2.5-5mm。
所述耐磨材料层41采用铬钼合金粉末、碳化钨合金粉末以及陶瓷砂粉末组成的混合粉末通过激光或等离子弧焊的方式填焊到“C”形槽40内。
所述护坡结构42相对于浮封环的工作面高出1.5-3mm。
请参阅图2和图3，一种超耐磨浮封环的加工装置，包括研磨机1，在研磨机1上安装有三块扇形支撑板2，所述扇形支撑板2上安装有工件压板3，所述工件压板3的卡块6卡入到环体4的压紧槽口44内，所述扇形支撑板2包括与研磨机1连接的底座板，在底座板上设置安装板7，所述安装板7的外侧设置有与插孔45配套的定位块9，在安装板7的上表面开设有方便螺栓5插入的螺栓 孔8，螺栓5插入到螺栓孔8内从而将工件压板3固定住。
所述扇形支撑板2的弧度为120°，所述三块扇形支撑板2的安装板7正好组成一个圆台从而将浮封环的内径支撑住。
一种超耐磨浮封环的加工方法，包括以下具体步骤：
步骤一.采用GCr15轴承钢加工出浮封环的环体4；
步骤二.在浮封环的环体4的工作面上通过机床车加工出“C”形槽40；
步骤三.在“C”形槽40内通过激光或等离子弧焊的方式填焊铬钼合金粉末、碳化钨合金粉末以及陶瓷砂粉末组成的混合粉末，形成耐磨材料层41；
步骤四.在加工好耐磨材料层41的浮封环上开设压紧槽口44和插孔45，并将浮封环安装到三块扇形支撑板2上；
步骤五.将三块扇形支撑板2安装到研磨机1上，研磨机1启动对浮封环的耐磨材料层41进行研磨，以保证浮封环封油工作面的平面度及光洁度达到质量标准。
所述步骤四中，浮封环安装到扇形支撑板2上具体包括：
S1.扇形支撑板2上的定位块9插入到浮封环的内径上的插孔45内使得整个环体套在三块扇形支撑板2上；
S2.将工件压板3通过螺栓5安装到扇形支撑板2上，工件压板3的卡块6压紧安装到压紧槽口44内。
所述扇形支撑板2包括与研磨机1连接的底座板，在底座板上设置安装板7，所述安装板7的外侧设置有与插孔45配套的定位块9，在安装板7的上表面开设有方便螺栓5插入的螺栓孔8，螺栓5插入到螺栓孔8内从而将工件压板3固定住。
采取独特工艺设计，一，将浮封铁环坯料车加工，开出工作面熔填耐磨材料的料槽；二，运用激光，等离子弧焊等方法，制造出新的耐磨工作面亮带环，由于是冶金结合，新造出的耐磨材料工作面与基材熔合牢固，绝不脱层剥离； 既超耐磨，又非常能抗轴向，径向冲撞击；这一性能绝对优越过铸造环；由于熔填出的耐磨层比基材硬度高出很多，且又具有一定厚实度，显现出铸铁类的宁折不弯的钢性，脆性，不变形的优点，有利于该耐磨面平面度的质量提升；三，加之浮封铁环封油工作面亮带贴合面是独特独创的高台凸出设计，超耐磨材料为“芯”环，“芯”环的内外径两边是坡坝式“护芯坡”，如同堤坝一样包护着填熔进去的超耐磨材料，形成“耐磨芯环”；同时，高凸面耐磨层与其基脚之间至少有1.5-3mm(依浮封型规直径大小不同而对应设定凸高值)的落差，一对工作面贴合后，内径的端面就形成3-6mm宽的润滑油渗入口，比旧式浮封铁环的润滑油渗入开口，成倍增大，开口增大更利于润滑油渗入工作面润滑，这既利于工作面减磨，也更有助于使用寿命的延长；特别是这一高凸台工作面的“耐磨芯环”设计，既解决超耐磨难题又为解决超难加工，平面度质量难达标的难题，创造出解决难点的良好条件。因为由耐磨材料制成的”耐磨芯环”的内外径“护芯坡”及基体铁环都是普通钢铁，其硬度不高，易于加工成型，相比旧式精密铸造的硬质合金浮封环，材质硬度特别高，特耐磨，且大端面需整面加工，加工面很宽，又是质量要求最高的重点关键部位，加工难度成为制造成本难以下降的又一个重要因素；本发明的独创独特的新型工艺设计及施工措施，科学巧妙的将这一难题彻底解决了。新型超耐磨材料制成的“耐磨芯环”最彻底最经济地解决了浮封环超耐磨损，超长使用寿命的难点；“高凸台耐磨芯环”这一科学合理的设计，使高硬质相材料又硬又脆难以加工的高难度难题，因新型“高凸台耐磨芯环”内外径有钢铁材料两边护坡保护，且“芯”环面宽3mm，窄小的加工面使加工难度极大降低，加之其它施工措施及工装配合也使加工成本大幅降低。实现高效率生产，质量达标。由此，高硬度难加工的难题被这种独特的新型“耐磨芯环”高凸台工作亮带面的独创科学设计以及还有配套的科学优化加工，工艺工装措施，施工方法等等合理有效方法全面彻底解决了.
“耐磨芯环”所熔填超耐磨金属材料，虽然配比有稀有金属贵金属，但只 在刀刃上用一点“好钢”，材料成本极大降低，质量大幅提升，相比旧式铸造的高铬钼及硬质合金浮封铁环，全是整体含量浇铸而成，其实只有工作面耐磨层2-3mm厚的一点点需要具备耐磨损，其余整个浮封环基体，根本无需具备什么耐磨性。其余下95％的基体中的稀有贵金属全部没用上，浪费了。这也是铸造浮封环成本居高难降的原因。而且，受铸造产品合格率的影响，更是加大其产品成本无法降低；由于浮封环只是需要大端工作面亮带耐磨损，并且一旦工作面亮带磨去1.5-3mm的磨损层后，该油封环就失效报废了。这是因为橡胶圈的回弹力已过极限，根本无力补偿这一磨损空间。从而出现较大间隙发生漏油。而本发明制造的超耐磨浮封铁环的新材料耐磨工作面，是高凸台设计，高度1.5-3mm(不同型规产品尺寸所限设定)，就是新材料耐磨层的厚度，一只浮封铁环的新填熔的工作面亮带环，宽2-3mm x厚2-3mm x该型号产品外圆周长，仅此一点的稀有贵金属的耗用。相比整体由稀有贵金属铸造而成的浮封环，同样也是最多磨去工作面耐磨层1.5-2.5mm厚度之后，该铁环一定失效报废。但由于铸造环整体都是稀有贵金属，则如此90％以上都是被弃之为“废物”，这无疑是稀缺资源的巨大浪费，也是其成本价格高居不下的根本原因。相比本发明的新型超耐磨浮封环，由于“好钢用在刀刃上”的科学设计，材料成本降低，质量优势突出，更具节能环保优点，有着极大的市场竞争力。
新型超耐磨浮封环，因为采用熔填超耐磨的硬质相材料，用在浮封环需要超耐磨损的封油工作面上并由此解决了浮封环抗磨损超耐磨，使用寿命长的质量核心指标；而针对超耐磨高硬度，高脆性材料加工难度大的困难，本发明针对这一加工难点采用独创独特的科学优化的工艺设计，切实有效的工装，及施工措施，有效解决了超耐磨硬质材料的浮封环“耐磨芯环”，平面度高精度质量达标的难题。
三块扇形支撑板每块外平面加装一块工件压板，每块压板上开滑孔槽，对应在每块扇形支撑板上钻2螺栓孔并攻丝，用螺栓将工件压板固定在扇形支撑 板上，工件压板有槽可向径向方向伸缩调节；工件压板伸入浮封环压紧槽口内，螺栓拧压固定工件压板，工件压板厚度与压紧槽口深度持平，三块工件压板从浮封环大端面按压住待磨环。
由于“耐磨芯环“面宽2.5-5mm，虽然材质硬度高且特别耐磨损，但因为是高凸台设计，其受磨面面宽较窄，只有几毫米，加之凸台的内外两边有钢铁护坡结构，不会发生崩边，裂纹问题，所以磨削难度下降，容易加工，合格率高。
同时，由于环内径用三个工件压板入槽或入孔的巧妙设计，浮封环几乎是无外力径向挤压下的磨削加工，使浮封环工作亮带面消除平面翘曲的难题迎刃而解，完全保证了平面度加工达到高标准优质产品的质量要求。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。

Claims (8)

  1. 一种超耐磨浮封环，其特征在于，包括环体(4)，所述环体(4)的工作面上开设有“C”形槽(40)，在“C”形槽(40)内填充有耐磨材料层(41)形成超耐磨芯环，所述“C”形槽(40)的两侧设置有护坡结构(42)，所述环体(4)的护坡结构(42)下方设置有斜坡面(43)，所述斜坡面(43)上开设有压紧槽口(44)，在环体(4)的内径上对应压紧槽口(44)处开设有插孔(45)，所述“C”形槽(40)的槽口宽度为2.5-5mm。
  2. 根据权利要求1所述的一种超耐磨浮封环，其特征在于，所述耐磨材料层(41)采用铬钼合金粉末、碳化钨合金粉末以及陶瓷砂粉末组成的混合粉末通过激光或等离子弧焊的方式填焊到“C”形槽(40)内。
  3. 根据权利要求1所述的一种超耐磨浮封环，其特征在于，所述护坡结构(42)相对于浮封环的工作面高出1.5-3mm。
  4. 一种超耐磨浮封环的加工方法，其特征在于，包括以下具体步骤：
    步骤一.采用GCr15轴承钢加工出浮封环的环体(4)；
    步骤二.在浮封环的环体(4)的工作面上通过机床车加工出“C”形槽(40)；
    步骤三.在“C”形槽(40)内通过激光或等离子弧焊的方式填焊铬钼合金粉末、碳化钨合金粉末以及陶瓷砂粉末组成的混合粉末，形成耐磨材料层(41)；
    步骤四.在加工好耐磨材料层(41)的浮封环上开设压紧槽口(44)和插孔(45)，并将浮封环安装到三块扇形支撑板(2)上；
    步骤五.将三块扇形支撑板(2)安装到研磨机(1)上，研磨机(1)启动对浮封环的耐磨材料层(41)进行研磨，以保证浮封环封油工作面的平面度及光洁度达到质量标准。
  5. 根据权利要求4所述的一种超耐磨浮封环的加工方法，其特征在于，所述步骤四中，浮封环安装到扇形支撑板(2)上具体包括：
    S1.扇形支撑板(2)上的定位块(9)插入到浮封环的内径上的插孔(45)内使得整个环体套在三块扇形支撑板(2)上；
    S2.将工件压板(3)通过螺栓(5)安装到扇形支撑板(2)上，工件压板(3)的卡块(6)压紧安装到压紧槽口(44)内。
  6. 根据权利要求5所述的一种超耐磨浮封环的加工方法，其特征在于，所述扇形支撑板(2)包括与研磨机(1)连接的底座板，在底座板上设置安装板(7)，所述安装板(7)的外侧设置有与插孔(45)配套的定位块(9)，在安装板(7)的上表面开设有方便螺栓(5)插入的螺栓孔(8)，螺栓(5)插入到螺栓孔(8)内从而将工件压板(3)固定住。
  7. 一种超耐磨浮封环的加工装置，其特征在于，包括研磨机(1)，在研磨机(1)上安装有三块扇形支撑板(2)，所述扇形支撑板(2)上安装有工件压板(3)，所述工件压板(3)的卡块(6)卡入到环体(4)的压紧槽口(44)内，所述扇形支撑板(2)包括与研磨机(1)连接的底座板，在底座板上设置安装板(7)，所述安装板(7)的外侧设置有与插孔(45)配套的定位块(9)，在安装板(7)的上表面开设有方便螺栓(5)插入的螺栓孔(8)，螺栓(5)插入到螺栓孔(8)内从而将工件压板(3)固定住。
  8. 根据权利要求7所述的一种超耐磨浮封环的加工装置，其特征在于，所述扇形支撑板(2)的弧度为120°，所述三块扇形支撑板(2)的安装板(7)正好组成一个圆台从而将浮封环的内径支撑住。
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