CN103069017B - 制造轴承环的方法、轴承环和轴承 - Google Patents
制造轴承环的方法、轴承环和轴承 Download PDFInfo
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- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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Abstract
一种由具有端部的至少一个钢棒(12)制造轴承环(14、34、36)的方法。该方法包括如下步骤:将所述至少一个钢棒(12)形成为至少一个环段,以及闪光对接焊接所述至少一个环段的端部(12a、12b)以制作环。该方法还包括在所述闪光对接焊接前使所述至少一个钢棒(12)相邻于要闪光对接焊接的所述表面(12a、12b)相邻的表面(12c、12d)的至少部分(C)渗碳的步骤。
Description
技术领域
本发明涉及由至少一个钢棒制造轴承环的方法。本发明还涉及轴承环和包括这样轴承环的轴承。
背景技术
闪光对接焊接或"闪光焊接"是电阻焊技术,用于接合金属轨道、杆、链或管的段,其中该段端对端对齐且通电,产生熔化且焊接该段的端部的电弧,产生极强且光滑的接合点。
闪光对接焊接电路通常由低电压、高电流的能源(通常为焊接变压器)以及两个夹具电极组成。要焊接的两个段夹在电极中且靠拢在一起直至它们相遇,以轻轻接触。给变压器通电导致高密度电流流过彼此接触的区域。闪光开始,该段用足够的力压在一起且快速保持闪光作用。在热梯度已经建立在要焊接的两个段上后,突然施加顶锻力以完成焊接。该顶锻力从焊接区域挤出熔渣、氧化物和熔化的金属,在加热金属的冷却区域中留下焊接增加物。然后,接合点允许在夹子打开以释放焊接物前略微冷却。焊接增加物可留在本位或通过剪切去除,而焊接物仍然很热,或者研磨,取决于需要。
焊接的轴承环可经受焊接后热处理,例如渗碳,以便增加其表面硬度、耐磨性和/或疲劳和拉伸强度。渗碳是热处理工艺,其中在存在另一个材料的情况下加热铁或钢部件,该另一个材料由于其分解而释放碳。部件的外表面将具有比原始材料高的碳含量。当铁或钢部件通过淬火快速冷却时,外表面上的高碳含量变得很硬,而芯部保持柔软(即柔性)和韧性。
发明内容
本发明的目标是提供一种由至少一个钢棒制造轴承环的经过改进的方法。
该目标通过包括下面步骤的方法实现,将至少一个钢棒形成为至少一个环段,以及闪光对接焊接该至少一个环段的端部以制作环。该方法还包括在所述闪光对接焊接前渗碳在后续闪光对接焊接接合点附近的所述至少一个钢棒的表面的至少一部分的步骤,该表面相邻于将要进行闪光对接焊接的表面。因此,一旦环段的端部已经闪光对接焊接在一起,由构成整个环的单一环段构成一个环。作为选择,一个环由多个环段构成,每个环段构成环的一部分,因此,一旦相邻环段的端部已经闪光对接焊接在一起,就形成了整个环。
因为该方法包括在闪光对接焊接步骤前渗碳至少一个钢棒的表面的至少部分,该表面相邻于将要进行闪光对接焊接的表面,所以该表面上的碳将朝着加热金属的较冷区域运送,即朝着焊接轴承环或焊接轴承环段的内部表面和外部表面,其后来可构成滚道表面,而不是保留在焊接点附近。因此,移位的碳将进一步提高焊接轴承环/环段的在其内部和外部表面处的表面硬度、耐磨性和/或疲劳和拉伸强度。这样的方法提供具有良好焊接接合的焊接轴承环,其没有或基本上没有碳,并且没有原本会发生的结构弱点的区域。因此,这样的方法提供了经过改善的焊接轴承环,其具有高度的结构完整性。
根据本发明的实施例,渗碳至少一个钢棒的表面的至少一部分的步骤在将至少一个钢棒形成为至少一个环段之前执行。如果在形成至少一个钢棒前执行渗碳,则与可同时在渗碳炉中渗碳的轴承环或轴承环段的数量相比,在一定容量的渗碳炉中可同时渗碳更多数量的钢棒。因此,减少了制造时间、成本和复杂性。这对大尺寸的轴承环(直径为0.5m、1m、2m、3m甚至大于3m)尤其是正确的,在此情况下它不仅减少了制造时间、成本和复杂性,而且减少了空间需求,即可减小所需的工厂和炉子的尺寸。
根据本发明的另一个实施例,该方法包括将多个钢棒形成为环段的步骤,其中当所述各环段已经闪光对接焊接在一起以形成环时,每个环段构成环的50%、25%、15%或者小于15%。应当注意的是,不同尺寸的多个环段可选择性地闪光对接焊接在一起以制作环。
根据本发明的另一个实施例,该方法包括在至少一个钢棒形成至少一个环段之前将该至少一个钢棒成型的步骤。在成型该至少一个钢棒的步骤中,至少一个钢棒可采用诸如火焰切割、激光切割、喷水切割或等离子体切割的方法切割成所需的尺寸。根据本发明的实施例,渗碳步骤在成型步骤之前执行。
根据本发明的实施例,渗碳步骤包括均匀或非均匀渗碳下面的至少一个:相邻于将要闪光对接焊接的表面的至少一个钢棒的表面的至少一部分,相邻于将要闪光对接焊接的表面的至少一个钢棒的整个表面,或者至少一个钢棒的所有表面。
根据本发明的进一步实施例,至少一个钢棒包括钢,其碳含量为0.10至1.10重量-%,优选为0.2至0.7重量-%,更优选为0.2-0.4重量-%。
根据本发明的实施例,该方法包括在闪光对接焊接步骤后去除任何焊接增加物的步骤,该焊接增加物例如包含焊渣、氧化物和/或熔化金属。
本发明还涉及轴承环,例如通过弯曲通过将具有端部的至少一个钢棒形成为至少一个环段并且闪光对接焊接至少一个环段的端部以制作环而形成该轴承环。通过闪光对接焊接接合的径向截面显示出在闪光对接焊接点上增加的渗碳深度,即在闪光对接焊接附近的渗碳层的深度大于仅渗碳而没有闪光对接焊接的轴承环部分中的渗碳层的深度。
根据本发明的实施例,该轴承环构成轴承的内环或外环。
本发明还涉及包括根据本发明任何实施例的轴承环的轴承。该轴承可为滚珠轴承、滚针轴承、锥形滚珠轴承、球形滚珠轴承、环形滚珠轴承、推力轴承或用于任何应用的轴承,其中经受了交互赫兹应力,例如,滚动接触或滚动和滑动的结合。该轴承例如可用在汽车、风力、船舶、金属制造或其它机器应用上,在这些应用中要求高耐磨性和/或增加的疲劳和拉伸强度。
附图说明
在下文,将通过参考附图的非限定性实施例进一步说明本发明,附图中:
图1-3示出了根据本发明的实施例的方法步骤,
图4示出了在根据本发明实施例的方法的闪光对接焊接步骤期间焊接点附近的碳的运动,
图5示出了在根据本发明实施例的闪光对接焊接步骤后的轴承环,
图6示出了根据本发明实施例的轴承环的径向截面,
图7示出了根据本发明实施例的方法步骤,
图8示出了根据本发明实施例的轴承,以及
图9-11示出了钢棒的各部分,其可根据本发明的不同实施例渗碳。
应注意附图没有按比例绘制,并且为了清楚起见夸大了一定特征的尺寸。
具体实施方式
图1-3示出了根据本发明实施例的方法的各种方法步骤。图1示出了包括钢,具有两个相对端部的钢棒10,并且其碳含量为0.2-0.4重量-%。首先钢棒10被渗碳以获得渗碳的钢棒12。在所示的实施例中,钢棒10的整个表面已经被渗碳。然而,可仅渗碳钢棒10的一个或多个表面的一部分。例如,钢棒10要焊接在一起的端部表面10a、10b以及最靠近端部表面10a和10b的侧表面10c和10d部分可被渗碳。也就是,采用任何传统方法钢棒10的表面10a、10b、10c、10d的至少一部分可被均匀或非均匀渗碳从而形成连续或非连续的渗碳层,其中钢棒在另一个材料存在的情况下被加热,该另一个材料随其分解释放出碳,并且钢棒然后通过淬火被快速冷却。
应当注意的是,在所示实施例中示出的钢棒12的端部12a、12b包括与钢棒12的侧表面12c、12d形成90度的端部。然而,钢棒12可包括端部12a、12b,其与每个钢棒的侧表面12c、12d形成大于或小于90度的角度,也就是钢棒12可包括对角倾斜的端部。
根据本发明的选择性实施例,钢棒10可形成为开口轴承环或轴承环段,并且该开口轴承环或轴承环段的至少一个表面的至少一部分可在该开口轴承环/轴承环段的端部闪光对接焊接以形成环之前被渗碳。
图2示出了渗碳的钢棒12,其已经形成开口轴承环14,具有两个渗碳的端部12a、12b。应当注意的是,渗碳的钢棒12可选择性地形成为环段,然后两个或多个环段可闪光对接焊接在一起以形成轴承环。
图3示出了要闪光对接焊接在一起的开口轴承环的渗碳端部12a、12b。开口轴承环14的渗碳端部12a、12b夹紧且以受到控制的速率靠拢并且从变压器16施加电流。电弧产生在两个渗碳的端部12a、12b之间。在开始闪光对接焊接工艺时,电弧间隙18足够大以露出且清洁两个渗碳的表面12a、12b。减小且然后关闭和打开间隙18在两个渗碳的表面12a、12b中产生热量。当两个渗碳表面12a、12b的温度已经达到锻造温度时,在图3中块箭头19的方向上施加压力(或者可活动端部稳步前进压向静止端部)。闪光产生在两个渗碳的表面12a、12b之间,这导致焊接区域中的碳从表面12a、12b朝着轴承环的内侧和外侧表面12c、12d径向向外流动,如图4中的箭头20所示,产生了清洁的焊接点。
例如,在水、油或聚合物基淬火中冷却后,可去除累积在焊接的轴承环的内侧和外侧表面12d和12c上的任何的焊接增加物22(如图5所示)。根据本发明的实施例,焊接的轴承环可经受第二热处理和顶锻力以进一步改善其结构完整性。
图6示出了通过根据本发明的轴承环的闪光对接焊接接合点的径向截面24,即通过沿着图5中所示线26切割轴承环获得的径向截面。径向截面24示出了芯区,其包括未渗碳材料28和基本上均匀厚度的渗碳表面层30。然而,增加的渗碳深度32可在闪光对接焊接点附近找到。
图7示出了根据本发明的实施例从钢棒制造轴承环的方法的各种步骤。该方法包括如下步骤:将具有端部的钢棒的至少一个表面的至少一部分渗碳,将钢棒形成为开口轴承环,以及闪光对接焊接开口轴承环的端部。钢棒可在其形成为环之前成型,从而渗碳钢棒的至少一部分的步骤可在成型步骤之前或之后执行。
图8示出了轴承32的示例,即滚动元件轴承,其尺寸范围可为10mm直径到几米直径,并且负荷承载量为几十克至几千吨。也就是,根据本发明的轴承32可为任何尺寸,并且具有任何的负荷承载量。轴承32具有内环34和外环36,它们其中之一或二者可由根据本发明的轴承环构造,并且具有一组滚动元件38。滚动元件轴承32的内环34、外环36和/或滚动元件38以及滚动元件轴承32的所有滚动接触部分优选由钢制造,其包括0.20至0.40重量-%的碳。
图9示出了钢棒12,其中端部表面12a的至少一部分(C)(要闪光对接焊接的部分)以及侧表面12c的部分(C)已经渗碳,从而端部表面12a以及侧表面12c已经渗碳的部分彼此相邻。
图10示出了钢棒12,其中端部表面12a的至少一部分(C)(要闪光对接焊接的部分)和整个侧表面12c已经渗碳。
图11示出了钢棒12,其中整个端部表面12a(即要闪光对接焊接的部分)和整个侧表面12c已经渗碳。
应当注意的是,端部表面12a以及侧表面12c已经渗碳的部分(C)不必如所示实施例示出的那样彼此相邻。还应当注意的是,渗碳部分(C)不必如所示实施例示出的那样形成均匀的连续层,即渗碳表面上的渗碳深度是可变化的,并且例如一个或多个掩模可用于仅渗碳将要被渗碳的表面的一个或多个部分。
本发明在权利要求范围内的进一步修改对本领域的技术人员是显而易见的。
Claims (11)
1.一种由具有端部的至少一个钢棒(12)制造轴承环(14、34、36)的方法,其包括如下步骤:将所述至少一个钢棒(12)形成为至少一个环段,以及闪光对接焊接所述至少一个环段的端部以制作环,其特征在于它包括在所述闪光对接焊接前使所述至少一个钢棒(12)的表面(12c、12d)的至少一部分(C)渗碳的步骤,该表面(12c、12d)相邻于将要进行闪光对接焊接的表面(12a、12b)。
2.根据权利要求1所述的方法,其特征在于它包括也使所述至少一个钢棒的表面(12a、12b)的至少一部分(C)渗碳的步骤,该表面(12a、12b)要被闪光对接焊接。
3.根据权利要求1或2所述的方法,其特征在于所述渗碳步骤在将所述至少一个钢棒(12)形成为所述至少一个环段之前执行。
4.根据权利要求1所述的方法,其特征在于它包括将多个钢棒(12)形成为多个环段的步骤,其中当所述环段已经闪光对接焊接在一起以形成环时,每个环段构成环的50%、25%、15%或小于15%。
5.根据权利要求1所述的方法,其特征在于它包括在所述至少一个钢棒(12)形成所述至少一个环段之前使其成型的步骤。
6.根据权利要求1所述的方法,其特征在于所述渗碳步骤包括渗碳下面的至少其中一个:相邻于将要闪光对接焊接的表面(12a、12b)的所述至少一个钢棒的表面(12c、12d)的至少一部分,相邻于将要闪光对接焊接的表面(12a、12b)的所述至少一个钢棒的整个表面。
7.根据权利要求1所述的方法,其特征在于所述钢棒(12)包括钢,其碳含量为0.1-1.1重量-%。
8.根据权利要求1所述的方法,其特征在于它包括在所述闪光对接焊接步骤后的去除任何焊接增加物(22)的步骤。
9.一种轴承环(14、34、36),其通过将至少一个钢棒形成为至少一个环段且闪光对接焊接所述至少一个环段的端部而制造,其特征在于通过闪光对接焊接接合点(22)的径向截面(24)在所述闪光对接焊接接合点(22)展现出增加的渗碳深度(35)。
10.根据权利要求9所述的轴承环,其特征在于它构成轴承(32)的内环(34)或外环(36)。
11.一种轴承(32),其特征在于它包括根据权利要求9或10的轴承环(34、36)。
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PCT/SE2011/000099 WO2012002868A1 (en) | 2010-07-02 | 2011-05-27 | Method of making a bearing ring, a bearing ring and a bearing |
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US (1) | US9239076B2 (zh) |
EP (1) | EP2588632A1 (zh) |
JP (1) | JP5907961B2 (zh) |
KR (1) | KR20130139826A (zh) |
CN (1) | CN103069017B (zh) |
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- 2011-05-27 WO PCT/SE2011/000099 patent/WO2012002868A1/en active Application Filing
- 2011-05-27 EP EP11801225.1A patent/EP2588632A1/en not_active Withdrawn
- 2011-05-27 US US13/807,998 patent/US9239076B2/en not_active Expired - Fee Related
- 2011-05-27 CN CN201180041021.2A patent/CN103069017B/zh not_active Expired - Fee Related
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JP5907961B2 (ja) | 2016-04-26 |
CN103069017A (zh) | 2013-04-24 |
RU2013104386A (ru) | 2014-08-10 |
EP2588632A1 (en) | 2013-05-08 |
RU2570594C2 (ru) | 2015-12-10 |
JP2013538935A (ja) | 2013-10-17 |
US20130209015A1 (en) | 2013-08-15 |
BR112012031477A2 (pt) | 2016-11-01 |
KR20130139826A (ko) | 2013-12-23 |
US9239076B2 (en) | 2016-01-19 |
WO2012002868A1 (en) | 2012-01-05 |
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