CN103710700A - Ceramic melt injection bionic enhancement method and equipment for valve sealing surface - Google Patents
Ceramic melt injection bionic enhancement method and equipment for valve sealing surface Download PDFInfo
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- CN103710700A CN103710700A CN201310437999.1A CN201310437999A CN103710700A CN 103710700 A CN103710700 A CN 103710700A CN 201310437999 A CN201310437999 A CN 201310437999A CN 103710700 A CN103710700 A CN 103710700A
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Abstract
The present invention provides a ceramic melt injection bionic enhancement method and equipment for a valve sealing surface. According to the present invention, a high energy beam ceramic melt injection method is adopted, and the wear resistance and fatigue resistance biological prototype is researched based on geometry area characteristics of a valve sealing surface from the bionic perspective; and from the valve sealing surface enhancement stress strain reduction perspective, the wear resistance and fatigue resistance structure of the biological prototype is "copied" on the valve sealing surface through laser melt injection so as to improve wear resistance and thermal fatigue resistance of the valve sealing surface, prolong the service life of the valve, and provide a new method for valve sealing surface enhancement.
Description
Technical field
The invention belongs to metal material processing field.
Background technology
Valve is the controlling elements in gas, liquid, powder material conveying system, has water conservancy diversion, dams, throttling regulates, prevent the functions such as refluence, shunting or overflow release.Valve generally should have sealing property, strength property, adjusting function, performance and trafficability performance.At present, approximately more than 6000 of China valve enterprises, wherein annual value of production surpass 5,000,000 yuan have 900.3, the valve company of domestic listing, i.e. center science and technology, big vast city share, Guangdong jewel.Last year, 3.7 hundred million yuan of center science and technology main business incomes, and big vast city share and Guangdong jewel main business income are all lower than center science and technology.Still there is larger gap in these enterprises with external similar enterprise in quality product.China's valve industry has the market external valve of the quilt enterprise of more than 100 hundred million yuan to capture every year, and wherein main share is the high-parameters valves such as core valve.To the year two thousand twenty China 51 million kilowatt nuclear power units that will go into operation, to the Chinese Nuclear Power installed capacity of the year two thousand twenty end, will reach 4,000 ten thousand kilowatts (4,000 ten thousand kilowatts of the year two thousand twenty end nuclear power operation scales, still have 1,800 ten thousand kilowatts of next five-year plans of carrying down).That is to say, from 2007, China will at least approve the construction of two million kilowatt nuclear power units every year., in 13 years from now on, China all will build the Nuclear power plants that a seated image " Daya Gulf " is the same every year.Wherein need approximately 1,000,000, core valve, total value is over 200 hundred million.Add market abroad, DEVELOPMENT PROSPECT will be very wide.As previously mentioned, valve sealing face is the key position of valve, it is the most important working face of valve, improve the wear resistance, solidity to corrosion of valve sealing face, the over-all properties such as high temperature resistant and directly extend work-ing life of valve, avoid occurring premature failure, thereby retrieve loss unnecessary in production, will greatly promote the development of industry and national economy, there is significant economic benefit and social effect.
The molten note technology of pottery has been considered to prepare one of ideal method of metal matrix composite layer at present, laser or plasma arc local melting metallic matrix, ceramic powder is injected in molten bath simultaneously, ceramic particle is frozen in the rapid solidification in molten bath, having realized matrix upper strata particle strengthens, improve metallic surface wear resistance and hardness, shown that laser melts note technology and at metal base surface, prepares the advantage of particulate reinforced composite layer.
The evolution of millions upon millions of years of occurring in nature organism surface process, formed very unique structure, the non-smooth surface that organism surface is comprised of geometries such as pit, convex closure, ripple, decorative pattern, strip, network or scales, organism surface cell cube size is from tens microns to tens millimeters, biological non-smooth surface has visbreaking, falls resistance, wear-resisting effect, and in moving process, tool has good wearability.Biological surface is wear-resisting, cracking resistance prototype is applied in valve seal surface strengthening field, has good development prospect.
Summary of the invention
According to an aspect of the present invention: provide the molten note of a kind of valve seal surface ceramic bionic reinforced equipment, described equipment is comprised of control unit, biomimetic features body vision supervisory system, ceramic accurate powder feeder, high energy beam producer and three degree of freedom numerical control table, NC table, and control unit is connected with biomimetic features body vision supervisory system, ceramic accurate powder feeder, high energy beam producer and the communication interface system of three degree of freedom numerical controlled machinery worktable respectively.Control unit comprises an industrial control computer, and this computer has the molten note of multiple dimensioned pottery strengthening layer technical module, valve sealing face biomimetic features body design module and the bionic reinforced digital control processing module of valve sealing face; The molten note of described multiple dimensioned pottery strengthening layer technical module comprises working process parameter database and biomimetic features body vision monitoring unit, in described database, each data logging comprises the trade mark of material, original microstructure, laser power, sweep velocity, the ceramic speed of molten note, defocusing amount, stupalith, ceramic particle size, ceramic volume fraction, ceramic dispersoid form, chemical composition, weave construction, microhardness, friction, wearing and tearing and thermal fatigue; Described biomimetic features body vision monitoring unit is mainly accepted vision hardware system picture signal, processes pottery molten note melted state and biomimetic features body shaped state, thereby controls pottery molten note processing parameter and five-shaft numerical control worktable linkage status; Described valve sealing face biomimetic features body design module is that the biology of selecting to have wear-resistant and crack-resistant function is living prototype, use theory of similitude, organism geometrical dimension, profile, system structure and function feature are simulated and parameter optimization, set up corresponding living model, for valve seal surface different characteristics, by Computer Numerical Simulation and characteristic parameter, optimize, from reducing valve seal surface strengthening stress-strain angle, design bionical cell cube and the coupling according to certain rules of different units body and form biomimetic features body; Bionical cell cube design comprises form, geometrical dimension, chemical composition, tissue morphology, ceramic particle size, ceramic volume fraction and the ceramic dispersoid form Design of bionical cell cube; The design of biomimetic features body comprises each bionical cell cube coupled mode and the design of coupling structural form; The bionic reinforced digital control processing module of described valve sealing face can form nc program automatically according to the valve sealing face biomimetic features body designing, and drives three degree of freedom numerical controlled machinery worktable; Also can generate nc program at the good valve sealing face surface biomimetic of other Computer Design structure, then import in this teaching system;
Coaxial vision sensing acquisition system is connected by fastening piece with laser apparatus, by CCD visual sensing pottery molten note melted state and biomimetic features body formed features, passes to biomimetic features body vision monitoring unit in control unit; Described high energy beam producer is laser or plasma arc generator; The accurate powder feeder of described pottery adopts the molten note of rear side ceramic particle, pottery comprises TiC, WC and SiC, powder feed rate 1～200 mg/s, and particle size is 10nm～1.0mm, in bionical cell cube, the volume fraction of pottery is 10%～50%, molten note layer thickness 0.01～2.0mm; Described three degree of freedom numerical controlled machinery worktable " valve by gripper chuck on lathe bed, at work, by driven by motor, rotated; Guide rail upright columns is bolted on lathe bed, Z-direction feed mechanism can move up and down along guide rail upright columns, driven by motor Y-direction feed mechanism the inside leading screw rotates, completing Y-direction feeding moves, high energy beam producer can be fixed on Y-direction feed mechanism left end by screw, coaxial vision is arranged on high energy beam producer, pottery accurate powder feeder by screw be fixed on motor after, ceramic powder can be provided, coaxial vision, ceramic accurate powder feeder together with high energy beam producer along with moving left and right of motor can be stretched into valve internal and carry out work.At valve seal function surface, utilize the method for the molten note processing of high energy beam pottery, effects on surface is dosed chemical element and bionic reinforced.Bionic reinforced is by valve seal surface biomimetic strengthening model, on valve seal surface, molten note ceramic particle forms biomimetic features body, the bionical cell cube width W 1 of arc is 0.1～5.0mm, the bionical cell cube degree of depth of arc L2 is 0.1～3.0mm, the bionical cell cube curvature of arc θ is 30～180 degree, circular bionical cell cube spacing W2 is 0.2～10.0mm, and circular bionical cell cube degree of depth L1 is 0.1～3.0mm, and circular bionical cell cube diameter d is 0.1～10.0mm.
From bionical angle, the molten note coupling of valve seal surface ceramic is proposed bionic reinforced, by living prototype resistance to wear, fatigue-resistant structures by the molten note of high energy beam pottery " copying " on valve seal surface, improve the wear resistance on valve seal surface, extend valve work-ing life, for valve seal surface strengthening provides a kind of new method.The molten note of a kind of high energy beam pottery valve seal New Surface Strengthening Technology is proposed, because the molten chemical composition of noting layer and matrix is easy gradient transition, without obvious interface, be conducive to solve laser or plasma-arc because chemical composition between cladding layer and matrix exists the cladding layer problem easy to crack causing compared with large gradient between the two.Because consolidation speed in the molten note process of high energy beam pottery is fast, can obtain some tissues that cannot obtain at equilibrium state and thing phase, with laser or plasma-arc comparison, be conducive to the preparation of valve seal surface abrasion resistance cracking resistance biomimetic features layer, therefore the molten note technology of pottery and bionics techniques are combined, for the strengthening of valve seal surface biomimetic, there is good development prospect.
Accompanying drawing explanation
Fig. 1 valve seal surface biomimetic strengthening device control texture block diagram
The main TV structure schematic diagram of Fig. 2 valve seal surface biomimetic strengthening device
Wherein: the ceramic accurate powder feeder 7 Y-direction feed mechanism 8 guide rail upright columns 9 motor 10 Z-direction feed mechanism 11 motor 12 high energy beam producers of 1 motor 2 lathe bed 3 chuck 4 valve 5 coaxial vision 6
Fig. 3 valve seal surface coupling biomimetic features body schematic diagram
Wherein: the bionical cell cube curvature of the circular bionical cell cube spacing L1 of the bionical cell cube degree of depth of the bionical cell cube width of the W1 arc L2 arc W2 circular bionical cell cube diameter θ arc of circular bionical cell cube depth d.
Embodiment
The bionic reinforced equipment of the molten note of valve seal surface ceramic, described equipment is comprised of control unit, biomimetic features body vision supervisory system, ceramic accurate powder feeder, high energy beam producer and three degree of freedom numerical control table, NC table, and control unit is connected with biomimetic features body vision supervisory system, ceramic accurate powder feeder, high energy beam producer and the communication interface system of three degree of freedom numerical controlled machinery worktable respectively.Control unit comprises an industrial control computer, and this computer has the molten note of multiple dimensioned pottery strengthening layer technical module, valve sealing face biomimetic features body design module and the bionic reinforced digital control processing module of valve sealing face; The molten note of described multiple dimensioned pottery strengthening layer technical module comprises working process parameter database and biomimetic features body vision monitoring unit, in described database, each data logging comprises the trade mark of material, original microstructure, laser power, sweep velocity, the ceramic speed of molten note, defocusing amount, stupalith, ceramic particle size, ceramic volume fraction, ceramic dispersoid form, chemical composition, weave construction, microhardness, friction, wearing and tearing and thermal fatigue; Described biomimetic features body vision monitoring unit is mainly accepted vision hardware system picture signal, processes pottery molten note melted state and biomimetic features body shaped state, thereby controls pottery molten note processing parameter and five-shaft numerical control worktable linkage status; Described valve sealing face biomimetic features body design module is that the biology of selecting to have wear-resistant and crack-resistant function is living prototype, use theory of similitude, organism geometrical dimension, profile, system structure and function feature are simulated and parameter optimization, set up corresponding living model, for valve seal surface different characteristics, by Computer Numerical Simulation and characteristic parameter, optimize, from reducing valve seal surface strengthening stress-strain angle, design bionical cell cube and the coupling according to certain rules of different units body and form biomimetic features body; Bionical cell cube design comprises form, geometrical dimension, chemical composition, tissue morphology, ceramic particle size, ceramic volume fraction and the ceramic dispersoid form Design of bionical cell cube; The design of biomimetic features body comprises each bionical cell cube coupled mode and the design of coupling structural form; The bionic reinforced digital control processing module of described valve sealing face can form nc program automatically according to the valve sealing face biomimetic features body designing, and drives three degree of freedom numerical controlled machinery worktable; Also can generate nc program at the good valve sealing face surface biomimetic of other Computer Design structure, then import in this teaching system;
Coaxial vision sensing acquisition system is connected by fastening piece with laser apparatus, by CCD visual sensing pottery molten note melted state and biomimetic features body formed features, passes to biomimetic features body vision monitoring unit in control unit; Described high energy beam producer is laser or plasma arc generator; The accurate powder feeder of described pottery adopts the molten note of rear side ceramic particle, pottery comprises TiC, WC and SiC, powder feed rate 1～200 mg/s, and particle size is 10nm～1.0mm, in bionical cell cube, the volume fraction of pottery is 10%～50%, molten note layer thickness 0.01～2.0mm; Described three degree of freedom numerical controlled machinery worktable " valve by gripper chuck on lathe bed, at work, by driven by motor, rotated; Guide rail upright columns is bolted on lathe bed, Z-direction feed mechanism can move up and down along guide rail upright columns, driven by motor Y-direction feed mechanism the inside leading screw rotates, completing Y-direction feeding moves, high energy beam producer can be fixed on Y-direction feed mechanism left end by screw, coaxial vision is arranged on high energy beam producer, pottery accurate powder feeder by screw be fixed on motor after, ceramic powder can be provided, coaxial vision, ceramic accurate powder feeder together with high energy beam producer along with moving left and right of motor can be stretched into valve internal and carry out work.At valve seal function surface, utilize the method for the molten note processing of high energy beam pottery, effects on surface is dosed chemical element and bionic reinforced.Bionic reinforced is by valve seal surface biomimetic strengthening model, on valve seal surface, molten note ceramic particle forms biomimetic features body, the bionical cell cube width W 1 of arc is 0.1～5.0mm, the bionical cell cube degree of depth of arc L2 is 0.1～3.0mm, the bionical cell cube curvature of arc θ is 30～180 degree, circular bionical cell cube spacing W2 is 0.2～10.0mm, and circular bionical cell cube degree of depth L1 is 0.1～3.0mm, and circular bionical cell cube diameter d is 0.1～10.0mm.
The bionic reinforced method steps of the molten note of valve seal surface ceramic is as follows:
1. will have valve clamping B to be processed on the fixture of rotating mechanism, closed power supply, starts three degree of freedom numerical control table, NC table, high energy beam generator power, vision collecting system and ceramic accurate powder feeder.
2. by three degree of freedom numerical control table, NC table, adjust high energy beam focus, the molten note of pottery and valve seal function surface relative position.
3. start " the molten note of multiple dimensioned pottery strengthening layer technical module ", input message, determines the molten note of high energy beam pottery Optimizing Process Parameters; Start " valve sealing face biomimetic features body design module ", for valve seal surface different characteristics, design biomimetic features body.
4. start " the bionic reinforced digital control processing module of valve sealing face ", according to the valve sealing face biomimetic features body designing, automatically form nc program.
5. start " processing starts ", the molten note of high energy beam pottery Optimizing Process Parameters is delivered to high energy beam producer, output high energy beam, is delivered to numerical control table, NC table by nc program, and digital control platform is controlled driven by servomotor working table movement according to work program.
6. in the course of processing, CCD vision monitoring pottery molten note melted state and biomimetic features body formed features, do local fine setting to high energy beam machined parameters and working table movement track, guarantees the bionic reinforced structure processing quality of valve seal function surface.
The molten note of valve sealing face pottery is bionic reinforced
Selection have wear-resistant and crack-resistant function as shell etc. be living prototype, use theory of similitude to set up corresponding living model, according to valve seal configuration of surface, material, constitutional features, by Computer Numerical Simulation and characteristic parameter, optimize, carry out valve seal surface biomimetic cell cube and structure design, utilize the molten note of high energy beam pottery to process the core valve with biomimetic features sealing face.Valve material is
16MnwC powder is injected by molten bath postmedian, mean sizes is 80 μ m, adopt negative out of focus 2.0mm, laser beam processing spot size is 4.0mm, laser power density 480 W/mm2, sweep velocity 1.0 m/min, powder feed rate 110 mg/s, in molten note layer, the volume fraction of pottery (WC) is 35%, pottery is with uniform gradient disperse form.In valve seal surface working, become certain bionical texture grid, as shown in Fig. 3 (a), this grid biomimetic features body is to be coupled to form according to certain rules by arc cell cube and circular cell body, and as shown in Figure 3 (b), in cell cube, disperse is melted and noted carbide ceramic particles in its depth direction cross section.Wherein the bionical cell cube width W 1 of arc is 2.0mm, the bionical cell cube degree of depth of arc L2 is 1.0mm, and circular bionical cell cube spacing W2 is 8.0mm, and circular bionical cell cube degree of depth L1 is 1.8mm, circular bionical cell cube diameter d is 3.0mm, and the bionical cell cube curvature of arc θ is 150 degree.After the molten note of valve seal surface laser is bionic reinforced, improve 1.5 times of valve work-ing lifes.
Claims (4)
1. a valve seal surface ceramic melts the bionic reinforced equipment of note, it is characterized in that: described equipment is comprised of control unit, biomimetic features body vision supervisory system, ceramic accurate powder feeder, high energy beam producer and three degree of freedom numerical control table, NC table, control unit is connected with biomimetic features body vision supervisory system, ceramic accurate powder feeder, high energy beam producer and the communication interface system of three degree of freedom numerical controlled machinery worktable respectively.
2. equipment according to claim 1, is characterized in that:
Control unit comprises an industrial control computer, and this computer has the molten note of multiple dimensioned pottery strengthening layer technical module, valve sealing face biomimetic features body design module and the bionic reinforced digital control processing module of valve sealing face;
The molten note of described multiple dimensioned pottery strengthening layer technical module comprises working process parameter database and biomimetic features body vision monitoring unit, in described database, each data logging comprises the trade mark of material, original microstructure, laser power, sweep velocity, the ceramic speed of molten note, defocusing amount, stupalith, ceramic particle size, ceramic volume fraction, ceramic dispersoid form, chemical composition, weave construction, microhardness, friction, wearing and tearing and thermal fatigue; Described biomimetic features body vision monitoring unit is mainly accepted vision hardware system picture signal, processes pottery molten note melted state and biomimetic features body shaped state, thereby controls pottery molten note processing parameter and five-shaft numerical control worktable linkage status;
Described valve sealing face biomimetic features body design module is that the biology of selecting to have wear-resistant and crack-resistant function is living prototype, use theory of similitude, organism geometrical dimension, profile, system structure and function feature are simulated and parameter optimization, set up corresponding living model, for valve seal surface different characteristics, by Computer Numerical Simulation and characteristic parameter, optimize, from reducing valve seal surface strengthening stress-strain angle, design bionical cell cube and the coupling according to certain rules of different units body and form biomimetic features body; Bionical cell cube design comprises form, geometrical dimension, chemical composition, tissue morphology, ceramic particle size, ceramic volume fraction and the ceramic dispersoid form Design of bionical cell cube; The design of biomimetic features body comprises each bionical cell cube coupled mode and the design of coupling structural form;
The bionic reinforced digital control processing module of described valve sealing face can form nc program automatically according to the valve sealing face biomimetic features body designing, and drives three degree of freedom numerical controlled machinery worktable; Also can generate nc program at the good valve sealing face surface biomimetic of other Computer Design structure, then import in this teaching system;
Coaxial vision sensing acquisition system is connected by fastening piece with laser apparatus, by CCD visual sensing pottery molten note melted state and biomimetic features body formed features, passes to biomimetic features body vision monitoring unit in control unit;
Described high energy beam producer is laser or plasma arc generator;
The accurate powder feeder of described pottery adopts the molten note of rear side ceramic particle, pottery comprises TiC, WC and SiC, powder feed rate 1～200 mg/s, and particle size is 10nm～1.0mm, in bionical cell cube, the volume fraction of pottery is 10%～50%, molten note layer thickness 0.01～2.0mm;
The valve of described " three degree of freedom numerical controlled machinery worktable ", at work, is rotated by driven by motor by gripper chuck on lathe bed; Guide rail upright columns is bolted on lathe bed, Z-direction feed mechanism can move up and down along guide rail upright columns, driven by motor Y-direction feed mechanism the inside leading screw rotates, completing Y-direction feeding moves, high energy beam producer can be fixed on Y-direction feed mechanism left end by screw, coaxial vision is arranged on high energy beam producer, pottery accurate powder feeder by screw be fixed on motor after, ceramic powder can be provided, coaxial vision, ceramic accurate powder feeder together with high energy beam producer along with moving left and right of motor can be stretched into valve internal and carry out work.
3. one kind is utilized the equipment described in claim 1 or 2 to carry out the bionic reinforced method of the molten note of valve seal function surface pottery, it is characterized in that: at valve seal function surface, the method of utilizing the molten note processing of high energy beam pottery, effects on surface is dosed chemical element and bionic reinforced.
4. method according to claim 3, it is characterized in that: bionic reinforced is by valve seal surface biomimetic strengthening model, on valve seal surface, molten note ceramic particle forms biomimetic features body, the bionical cell cube width W 1 of arc is 0.1～5.0mm, the bionical cell cube degree of depth of arc L2 is 0.1～3.0mm, the bionical cell cube curvature of arc θ is 30～180 degree, circular bionical cell cube spacing W2 is 0.2～10.0mm, circular bionical cell cube degree of depth L1 is 0.1～3.0mm, and circular bionical cell cube diameter d is 0.1～10.0mm.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN101642848A (en) * | 2008-08-04 | 2010-02-10 | 通用电气公司 | Laser processing system and method |
| CN103194750A (en) * | 2013-04-12 | 2013-07-10 | 浙江大学宁波理工学院 | Method for performing local simulation and enhancement on surface of die by laser melting injection |
| CN103252582A (en) * | 2013-04-12 | 2013-08-21 | 浙江大学宁波理工学院 | Laser wire-filling local bionic-texture manufacturing method and equipment for metal functional surfaces |
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Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101642848A (en) * | 2008-08-04 | 2010-02-10 | 通用电气公司 | Laser processing system and method |
| CN103194750A (en) * | 2013-04-12 | 2013-07-10 | 浙江大学宁波理工学院 | Method for performing local simulation and enhancement on surface of die by laser melting injection |
| CN103252582A (en) * | 2013-04-12 | 2013-08-21 | 浙江大学宁波理工学院 | Laser wire-filling local bionic-texture manufacturing method and equipment for metal functional surfaces |
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Application publication date: 20140409 |