CN100504117C - Steel-aluminum composite material pulley manufacture method - Google Patents
Steel-aluminum composite material pulley manufacture method Download PDFInfo
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- CN100504117C CN100504117C CNB2006100892729A CN200610089272A CN100504117C CN 100504117 C CN100504117 C CN 100504117C CN B2006100892729 A CNB2006100892729 A CN B2006100892729A CN 200610089272 A CN200610089272 A CN 200610089272A CN 100504117 C CN100504117 C CN 100504117C
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Abstract
The invention relates to a pulley made of steel-aluminum composite material and the manufacturing method and is especially suitable to be used on the derrick crown and the hoisting system of the oil well rig. The pulley is composed of an outer ring spoke and an inner ring rim which are made of steel and aluminum alloy respectively; the outer ring rim is cast or forged by medium carbon steel or low alloy steel; the inner ring spoke is integrally forged by aluminum alloy, the chemical compositions (w percent) are: Cu: 4.8-5.5, Mn: 0.5-1.2, Ti: 0.15-0.40, Al: the rest; the impurity control is that: Fe:is less than or equal to 0.15 percent, Si is less than or equal to 0.1 percent, Mg is less than or equal to 0.05 percent, Zn is less than or equal to 0.1 percent, total impurity is less than or equal to 0.4 percent, the solution treatment is adopted following the smelting and sand casting process, and the last process is the incomplete artificially aged heat treatment; the outer ring rim and the inner ring spoke adopt the thermocompression assembly, a countersunk head screw which is arranged in a rope groove is used for radially fastening the outer ring rim and the inner ring spoke; The surface of the rope groove shall receive magnetic particle inspection and intermediate frequency quenching after the assembly. The invention decreases the pulley weight by about 30% compared with the steel pulley; at the same time, the invention can guarantee the wearability of the rope groove of the pulley and the overall strength of the pulley; furthermore, the pulley has reliable structural performance.
Description
Technical field
The present invention relates to a kind of steel-aluminum composite material pulley manufacture method, it is supporting with derrick crown pulley and elevator system lifting pulley to be specially adapted to oil-well rig or well repairing machine.
Background technique
Derrick is one of vitals of oil-well rig, well repairing machine, and it is used to lay and hangs erecting equipment and instruments such as overhead traveling crane, tourist bus, hook, suspension ring, tongs in the drilling well production process, and removes, deposits drilling rod and drill collar.Because of derrick is that whole rising put, require derrick in satisfying drilling process, in the maximum load bearing capacity, enough rigidity and stability must be arranged, try one's best little weight and external dimension are arranged.Pulley be used on the derrick crown and tour vehicle systems on strength member, the pulley on the cover derrick can reach 16, reduce the weight of whole derrick, the weight that reduces pulley is one of its important channel, especially the crown sheave loss of weight is the most important.Because derrick is when hoisting, crown sheave from hydraulic lifting cylinder fulcrum farthest, derrick reaches as high as 47 meters, thereby the countertorque maximum that when derrick hoists, produces of pulley, derrick crossbeam maximum constantly the hoisting the initial stage at derrick exactly that meet with stresses, the weight that crown sheave is described is to derrick stress influence maximum.What overhead traveling crane and tourist bus pulley adopted on the rig at present is cast steel pulley or steel welded pulley, reduce weight if adopt the steel pulley to reduce sectional dimension, weight loss effect is not obvious, must select the breach from the structure and material of crown sheave, design the pulley of a kind of special construction and material, can guarantee to reduce to greatest extent pulley weight, can guarantee the wear resistance of rope race and the bulk strength of pulley again, thereby reduce derrick crown weight greatly, the stress that the derrick crossbeam bore when the reduction derrick hoisted.
Summary of the invention
The purpose of this invention is to provide a kind ofly, can guarantee the steel-aluminum composite material pulley manufacture method of the bulk strength of the wear resistance of rope race and pulley than steel pulley loss of weight about 30%.
Steel-aluminum composite material pulley of the present invention, the outer ring rim and the inner ring spoke that are respectively steel and aluminum alloy by material combine, the inner headed face of outer ring rim cooperates with the periphery of inner ring spoke, and radially fastening outer ring rim of some sunk screws and inner ring spoke are uniformly distributed along the circumference in the grooving of outer ring rim.
Also have a positioning boss on the interior circle of above-mentioned outer ring rim, also have the individual location ladder that coincide with positioning boss on the inner ring spoke cylindrical, location ladder and positioning boss end face contact matching.
Steel-aluminum composite material pulley of the present invention adopts following process step manufacturing:
I: the outer ring rim manufacturing technology steps is:
1. adopt casting of middle-carbon steel or low alloy steel or forging and molding;
2. machining.
II: inner ring spoke manufacturing technology steps is:
1. casting technique: adopt the aluminum alloy cast inblock to be shaped its Chemical composition (w%):
Cu:4.8~5.5 Mn:0.5~1.2 Ti:0.15~0.40 Al: surplus
Impurity content control Fe :≤0.15% Si≤0.1% Mg≤0.05% Zn≤0.1% total impurities≤0.4%
By above-mentioned Chemical composition melting, adopt carbon trichloride to add titanium dioxide during melting as refine agent, its addition is 0.5~0.8%, refining temperature: 700~740, refining time: 10~12 minutes, left standstill 10~15 minutes;
Sand casting process.
2. heat treatment process: solution treatment adds incomplete artificial aging
Solution treatment: foundry goods is heated to 535 ± 5 ℃, and holding time 5~9 hours continues to be heated to 545 ± 5 ℃, and holding time 5~9 hours is cooled off fast with 60~100 ℃ of water;
Incomplete artificial aging: with 160 ± 5 ℃ of the heating of the inner ring spoke after the solution treatment, holding time 6~9 hours slowly cools to room temperature then in air.
3. machining.
III: the assembly technology step of outer ring rim and inner ring spoke:
1. after outer ring rim being heated to 140~160 ℃, the interior circle of inner ring spoke along outer ring rim is pressed into assembling back natural cooling with press machine;
2. along the circumferential direction uniform some sunk screws that scribble the thread locking sealing compound are radially fastening with outer ring rim and inner ring spoke in the outer ring rim grooving, screw countersunk head place and outer ring rim welding, the soldering point place seamlessly transits with smooth the making with race of grinder buffing.
IV: outer ring rim grooving surface check of assembling back and treatment process:
1. grooving surface magnetic particle flaw detection;
2. grooving surface mid frequency induction hardening: heating-up temperature: 900 ± 10 ℃, carry out tempering after the quenching, tempering temperature: 200 ℃, holding time: 120 minutes.
The aluminum alloy inner ring spoke that the present invention adopts high steel outer ring rim of wear resistance and light weight and intensity to meet the demands on structural design combines, the design of the positioning step of the positioning boss of outer ring rim and inner ring spoke can accurately be located the assembling of outer ring rim and inner ring spoke vertically, and fastening screw trip bolt makes being connected of outer ring rim and inner ring spoke more reliable in the outer ring rim grooving.
The present invention is on manufacture method:
Outer ring rim is selected middle-carbon steel or low alloy steel casting for use or is forged, because middle-carbon steel and low alloy steel are satisfying under the prerequisite of intensity, have good comprehensive mechanical performance and good cost performance, be widely used and easily manufactured in most manufacturing industry, add, cast, forge the technology that comparative maturity is all arranged in the various technological methodes at smelting, heat treatment, machine, moreover the carbon content of middle-carbon steel and low alloy steel is relatively low, make material have good weldability, thereby to select middle-carbon steel or middle-low alloy steel for use be more appropriate as the material of pulley outer ring rim.
The inner ring spoke is selected cast aluminium alloy for use, and the selected reason of its Chemical composition is described below:
Cu is an alloying element main in such alloy, adds an amount of Mn and Ti again and carries out alloyage, and Si and Fe are the major impurity elements.Below each constituent element to influence division as follows:
Cu:Cu is an alloying element main in such alloy, and the solid solution of Cu energy is in aluminium, and the result of solid solution distorts the dot matrix of aluminium, and alpha solid solution is produced significant hardening effect.The solid solubility of Cu in aluminium has and varies with temperature and the characteristics of notable change, and promptly the solubility in alpha solid solution reduces along with decrease of temperature, according to these characteristics, can strengthen through heat treatment.Cu can improve alloy room temperature strength and hot strength, also improve simultaneously the machinability of alloy, but castability is relatively poor, the hot cracking tendency maximum of alloy when the mass fraction of Cu is 4~5% particularly, hot cracking tendency reduction when surpassing this content.The Cu content selected for use of the present invention is 4.8~5.5% thus, can avoid the big composition interval of hot cracking tendency effectively, makes it obtain the favorable mechanical performance.
Mn:Mn belongs to alloy element in aluminum alloy, its some is dissolved in alpha solid solution, and a part forms T (Al
12Mn
2Cu) phase.In process of setting, the dissolving of Mn in alpha solid solution promptly is in hypersaturated state, and when alloy carries out Quenching Treatment, the decomposition of solid solution takes place, and forms tiny T (Al
12Mn
2Cu) phase particle improves the yield strength of alloy and high-temperature behavior.
The effect of Ti:Ti is to form Al
3Ti as external crystallization nuclei and crystal grain thinning, improves mechanical property.
Fe:Fe is a kind of impurity to this kind aluminum alloy, and it forms Al with aluminium, copper
7Cu
2The Fe phase reduces the copper amount that can dissolve in the alpha solid solution, and alloy property is reduced.Thereby require Fe≤0.15%.
Si:Si also is a kind of impurity to this kind aluminum alloy, and it makes and forms ternary eutectic (α+Si+CuAl in the tissue
2), its fusing point is about 520~525 ℃, causes the foundry goods burning when alloy is heat-treated by normal standard, and Si reduces the high temperature specific elongation of alloy simultaneously.So Si content should strictly be controlled, and requires Si≤0.1%.
Heat treatment process adopts solution treatment to add incomplete artificial aging, and solution treatment can make to be strengthened constituent element and dissolve to greatest extent, and condition of high temperature undertissue is fixed is saved in room temperature, can improve the intensity and the plasticity of foundry goods, improves the decay resistance of alloy.Not exclusively artificial aging can obtain good comprehensive mechanical property thus owing to adopt lower aging temp and short holding time, promptly obtains than higher intensity and good plasticity and toughness.
Outer ring rim and inner ring spoke adopt the heat pressing process assembling, along the circumferential direction uniform some sunk screws that scribble the thread locking sealing compound are radially fastening with outer ring rim and inner ring spoke in the outer ring rim grooving, screw countersunk head place and outer ring rim welding, therefore the disengaging that can not produce two kinds of materials has reliable structural behaviour.The grooving of outer ring rim is the important process face of pulley, and magnetic particle flaw detection is carried out to outer ring rim grooving surface in outer ring rim and inner ring spoke assembling back, can guarantee the grooving reliable performance, and grooving surface mid frequency induction hardening can obtain good wear resistance.
The present invention is owing to the outer ring rim and the inner ring spoke that adopt material to be respectively steel and aluminum alloy combine, thereby effectively having reduced weight with respect to the pulley of whole steel, grooving surface magnetic particle flaw detection, mid frequency induction hardening have guaranteed the wear resistance and the reliability at this key job position of grooving.The inner ring spoke adopts the aluminum alloy cast inblock, the control of its Chemical composition, heat treatment process be implemented in the bulk strength requirement that has guaranteed pulley when obtaining light weight, outer ring rim and inner ring spoke adopt the structure and the method for be uniformly distributed along the circumference in hot pressing assembling, the race radially fastening outer ring rim of some sunk screws and inner ring spoke to guarantee that the structural behaviour of pulley integral is reliable.
Description of drawings
Fig. 1 is a structural representation plan view of the present invention
Fig. 2 is the side view of Fig. 1
Fig. 3 is the partial enlarged drawing of I among Fig. 1
Embodiment
Below in conjunction with accompanying drawing the present invention is further described.
To be used for 4000 meters H915 pulleys on the rig overhead traveling crane is example, and pulley maximum outside diameter φ 915mm is suitable for wirerope diameter φ 32mm, and the grooving radius is R17mm, directly is φ 825mm at the bottom of the pulley, and the grooving size design meets API SPEC 8A standard.
As Fig. 1, Fig. 2, shown in Figure 3, steel-aluminum composite material pulley adopts material to be respectively the outer ring rim 1 and the inner ring spoke 2 split composite structures of steel and aluminum alloy, the interior circle of outer ring rim 1 cooperates with the cylindrical of inner ring spoke 2, individual positioning boss 101 is arranged on the interior circle of outer ring rim 1, the individual location ladder 201 that coincide with positioning boss is arranged on inner ring spoke 2 cylindricals, location ladder 201 and positioning boss 101 end face contact matching, radially fastening outer ring rim 1 of some sunk screws 3 that are uniformly distributed along the circumference in the grooving 102 of outer ring rim 1 and inner ring spoke 2.
Above-mentioned steel-aluminum composite material pulley adopts following process step manufacturing:
(1) the outer ring rim manufacturing technology steps is: adopt middle-carbon steel cast form, machining.
(2) inner ring spoke manufacturing technology steps is:
A: casting technique:
Adopt the aluminum alloy cast inblock to be shaped its Chemical composition (wt%):
Cu:4.8~5.5 Mn:0.5~1.2 Ti:0.15~0.40 Al: surplus
Impurity F e :≤0.15% Si≤0.1% Mg≤0.05% Zn≤0.1% total impurities≤0.4%
Casting technique step: adopt carbon trichloride to add titanium dioxide as refine agent by above-mentioned Chemical composition melting, when the melting, its addition is 0.4~0.8%, refining temperature: 700~740 ℃, and refining time: 10~13 minutes, left standstill sand casting process 10~15 minutes.
B: casting after-baking technology: solution treatment adds incomplete artificial aging, and heat treatment process parameter sees the following form:
C: machining
(3) assembly technology of outer ring rim and inner ring spoke:
A: after outer ring rim is heated to 150 ℃, the interior circle of inner ring spoke along outer ring rim is pressed into press machine; Circle and inner ring spoke cylindrical are taked interference fit (H7/s6) in the outer ring rim.Press-fit that variation in pressure should be steady in the process, pressure gauge pressure rises suddenly when being pressed onto the position, should stop immediately compressing into. part natural cooling behind the hot charging.
B: along the circumferential direction uniform some sunk screws that scribble the thread locking sealing compound are radially fastening with outer ring rim and inner ring spoke in race, screw countersunk head place and outer ring rim welding, and the soldering point place seamlessly transits with smooth the making with race of grinder buffing.
(4) surface check of assembling back outer ring rim grooving and treatment process:
A: magnetic particle flaw detection is carried out on the grooving surface: use the P-1500 magnetic powder flaw detector to detect a flaw, the mode of magnetization is a circumferential magnetization, and the magnetic type is magnetic cream (red-water), and magnetizing current is 600A, and sensitivity test piece specification is A30/100.
B: grooving surface mid frequency induction hardening: special-purpose quenching apparatus is adopted in mid frequency induction hardening, heating continuously, and heating-up temperature: 900 ℃, output voltage: 700V, electric current: 160A, power 65KW, frequency: 7200HZ.Carry out tempering after the quenching, tempering temperature: 200 ℃, holding time: 120 minutes.
The present invention considers that in selection the linear expansion coeffcient of two kinds of unlike materials is inconsistent, the amount difference that material produces when pucker ﹠ bloat, according to the formula of line of material expansion coefficient:
Draw: d
l=a
l* l * d
T-------(2)
Can calculate in a certain temperature range according to formula (2), carbon steel or low alloy steel and the cast aluminium alloy swell increment on surface of contact is in 20 ℃~600 ℃ intervals, for its linear expansion coeffcient of carbon steel or low alloy steel
And for aluminum alloy material, its linear expansion coeffcient
Can calculate the linear expansion amount by formula (2), if part surface of contact size diameter less than 1000mm, their linear expansion amount difference is between 0.2~0.4mm, difference only is 0.1~0.2mm on radial direction.Though the linear expansion coeffcient of two kinds of materials is variant, when the material expanded by heating, the outer ring rim swell increment of cast steel is less than aluminum alloy inner ring spoke, aluminum alloy inner ring spoke produces the plastic deformation of trace like this, hardness is lower comparatively speaking owing to this material, and the plastic deformation of trace can be to two kinds of influences that material production is bigger.Conversely, if two kinds of materials in the time of 0 ℃~-40 ℃, produce shrink, at this moment aluminum alloy inner ring spoke contour projector deducts original magnitude of interference again greater than the cast steel outer ring rim, can be in the slit that produces on two kinds of material surface of contact about 0.1mm.Present embodiment cast steel outer ring rim and cast aluminium alloy inner ring spoke bond sizes on circumferential surface are φ 795mm, only are 0.39mm by calculating two kinds of materials difference on φ 795mm length, and only are 0.195mm on radial direction.In sum, no matter two kinds of materials are at expanded by heating or when meeting cold contraction, the expansion and the contour projector that produce are all very little, add that two kinds of materials have several fastening screw trip bolts again and coat the thread locking sealing compound fastening in a circumferential direction, so under working condition, can not produce the possibility that two kinds of materials break away from, have reliable structural behaviour.
Through trial-production, verification experimental verification, cast steel outer ring rim grooving working surface does not have casting defect, the grooving working surface carries out the I level quality that magnetic particle flaw detection reaches GB9444-88 before mid frequency induction hardening, the grooving surface can reach hardness 42~50HRC after the mid frequency induction hardening, the deep layer of quenching 5~10mm has guaranteed the wear resistance and the reliability at this key job position of grooving.The Chemical composition of aluminum alloy inner ring spoke reaches aforementioned requirement, and mechanical property reaches: σ b 〉=440~470MPa; σ 0.2 〉=255~305Mpa; σ-0.2 〉=275~285Mpa; σ-1 〉=90Mpa; δ 5 (%) 〉=8~15; HB 〉=120.Carried out whole test run test on aforementioned basis again, operation is normal.For the H915 pulley, this kind steel aluminum composite material pulley weight is 71kg, H915 steel pulley weight is 103kg, the steel pulley weight of the same size of steel aluminum composite material pulley weight ratio has reduced 30%, weight loss effect is apparent in view, by 10 calculating of pulley of an average bench drill machine, each pulley loss of weight 28~32kg, one bench drill machine only pulley weight just can reduce by 280~320kg, when hoisting, derrick just can reduce the countertorque that pulley produces by big spoke degree, thereby reduce the stress that the derrick crossbeam bears, improve the safety reliability of derrick.
Claims (1)
1, a kind of steel-aluminum composite material pulley manufacture method, described steel-aluminum composite material pulley is combined by outer ring rim (1) and the inner ring spoke (2) that material is respectively steel and aluminum alloy, the inner headed face of outer ring rim (1) cooperates with the periphery of inner ring spoke (2), the radially fastening outer ring rim of some sunk screws (3) (1) that are uniformly distributed along the circumference in the grooving (102) of outer ring rim (1) and inner ring spoke (2) is characterized in that: adopt following process step:
I: the outer ring rim manufacturing technology steps is:
1. adopt casting of middle-carbon steel or low alloy steel or forging and molding;
2. machining;
II: inner ring spoke manufacturing technology steps is:
1. casting technique: adopt the aluminum alloy cast inblock to be shaped its Chemical composition (w%):
Cu:4.8~5.5 Mn:0.5~1.2 Ti:0.15~0.40 Al: surplus
Impurity content control Fe :≤0.15% Si≤0.1% Mg≤0.05% Zn≤0.1% total impurities≤0.4%
By above-mentioned Chemical composition melting, adopt carbon trichloride to add titanium dioxide during melting as refine agent, its addition is 0.5~0.8%, refining temperature: 700~740, refining time: 10~12 minutes, left standstill 10~15 minutes;
Sand casting process;
2. heat treatment process: solution treatment adds incomplete artificial aging
Solution treatment: foundry goods is heated to 535 ± 5 ℃, and holding time 5~9 hours continues to be heated to 545 ± 5 ℃, and holding time 5~9 hours is cooled off fast with 60~100 ℃ of water;
Incomplete artificial aging: with 160 ± 5 ℃ of the heating of the inner ring spoke after the solution treatment, holding time 6~9 hours slowly cools to room temperature then in air;
3. machining;
III: the assembly technology step of outer ring rim and inner ring spoke:
1. after outer ring rim being heated to 140~160 ℃, the interior circle of inner ring spoke along outer ring rim is pressed into assembling back natural cooling with press machine;
2. along the circumferential direction uniform some sunk screws that scribble the thread locking sealing compound are radially fastening with outer ring rim and inner ring spoke in the outer ring rim grooving, screw countersunk head place and outer ring rim welding, the soldering point place seamlessly transits with smooth the making with race of grinder buffing;
IV: outer ring rim grooving surface check of assembling back and treatment process:
1. grooving surface magnetic particle flaw detection;
2. grooving surface mid frequency induction hardening: heating-up temperature: 900 ± 10 ℃, carry out tempering after the quenching, tempering temperature: 200 ℃, holding time: 120 minutes.
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CNB2006100892729A CN100504117C (en) | 2006-08-15 | 2006-08-15 | Steel-aluminum composite material pulley manufacture method |
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CN103803384B (en) * | 2014-03-13 | 2021-03-16 | 沈阳和世泰通用钛业有限公司 | Titanium steel composite elevator traction sheave and production method thereof |
CN103950856A (en) * | 2014-04-02 | 2014-07-30 | 杭州电子科技大学 | Assembly type crane pulley device |
CN104048019A (en) * | 2014-06-09 | 2014-09-17 | 昆山永合不锈钢制品有限公司 | Blade punch turning wheel structure |
CN104878173B (en) * | 2015-06-02 | 2017-03-01 | 山西煤矿机械制造股份有限公司 | A kind of heat-treatment quenching method of grinder hammerhead |
CN107061698A (en) * | 2017-01-05 | 2017-08-18 | 武汉春禾科技有限公司 | Wear-resistant externally-wound tension arm pulley |
CN106826129B (en) * | 2017-02-27 | 2019-05-07 | 昆山东岸海洋工程有限公司 | A kind of processing method of crank closer capstan winch |
CN107220426A (en) * | 2017-05-23 | 2017-09-29 | 珠海格力电器股份有限公司 | Belt pulley structure generation method and system |
CN107794392A (en) * | 2017-10-24 | 2018-03-13 | 徐州轩辕铝业有限公司 | A kind of aluminum refining agent and its application method |
CN109988953A (en) * | 2017-12-29 | 2019-07-09 | 中车戚墅堰机车车辆工艺研究所有限公司 | High-strength and high ductility Al-Cu system cast aluminium alloy gold and preparation method thereof and railway locomotive components |
CN108382992A (en) * | 2018-04-28 | 2018-08-10 | 上海振华港机重工有限公司 | A kind of full grooving hardness wear-resistant pulley and its processing technology |
CN110343914A (en) * | 2019-08-30 | 2019-10-18 | 安徽环宇铝业有限公司 | A kind of production technology of road guard-rail aluminium alloy rod |
CN111041304B (en) * | 2019-12-11 | 2021-09-14 | 兰州飞行控制有限责任公司 | Thermal cracking resistant Al-Cu series cast aluminum alloy and preparation method thereof |
CN111828593B (en) * | 2020-06-19 | 2022-04-22 | 合立智能装备有限责任公司 | Split type rope sheave |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH305807A (en) * | 1952-11-06 | 1955-03-15 | Barth Albert | Pulley. |
US3815201A (en) * | 1972-02-22 | 1974-06-11 | Teleflex Inc | Method for manufacturing a gear wheel |
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2006
- 2006-08-15 CN CNB2006100892729A patent/CN100504117C/en not_active Expired - Fee Related
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH305807A (en) * | 1952-11-06 | 1955-03-15 | Barth Albert | Pulley. |
US3815201A (en) * | 1972-02-22 | 1974-06-11 | Teleflex Inc | Method for manufacturing a gear wheel |
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