CN108555468A - A kind of online welding and restoring process of large size spur gear - Google Patents
A kind of online welding and restoring process of large size spur gear Download PDFInfo
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- CN108555468A CN108555468A CN201810378064.3A CN201810378064A CN108555468A CN 108555468 A CN108555468 A CN 108555468A CN 201810378064 A CN201810378064 A CN 201810378064A CN 108555468 A CN108555468 A CN 108555468A
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- broken teeth
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
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- Mechanical Engineering (AREA)
- Arc Welding In General (AREA)
Abstract
The invention discloses a kind of online welding and restoring process of large-scale spur gear, feature is that the technique is carried out according to preparation, soldering, welding post-processing before welding, and wherein soldering includes cleaning before weldment position adjusts and welds, equating and weldment heat at welding broken teeth, transition prime coat welds, overlay cladding welding；It after the completion of welding, is compared with the tooth block first made, extra weld seam cuts equating with plasma (orifice) gas slicing, and then with angle grinder substantially reconditioning, stress elimination operation is finally carried out to meet tooth block size.It is an advantage of the invention that completing the online REPAIR WELDING to gear part position to be welded in narrow space; the straight-tooth of heap postwelding is reached by hand lapping meets operating size; surface does not have any weld defect; ensure follow-up quality operation cycle; save the repair time; maintenance cost is reduced, shutdown loss is reduced, is provided safeguard for rationally group production.
Description
Technical field
The invention belongs to gear service technique fields more particularly to a kind of for large-scale spur gear broken teeth on yire mill
Online welding and restoring process.
Background technology
Yire mill is responsible for rolling for rim flange, and main transmission is to pass through main gear reducer, main transmission by main motor
Axis, bevel gear, big small Spur gear drive home roll vertical shaft and horizontal roll to rotate and realize respectively, and wherein small Spur gear is mounted in main transmission
On axis, the large-scale spur gear engaged on horizontal roll axis, mainly taking turns by intermeshing a pair of big small Spur gear
Play a part of to match rotating speed when hoop milling train work and transmits torque.With the lengthening of yire mill working time, the straight-tooth of occlusion
Wheel acts in load operating for a long time, and whole broken teeth locally occurs in large-scale spur gear (m=28, Z=73), affects the operating essence of shafting
Larger vibration and noise are generated when spending, and yire mill being made to work.Since yire mill spur gear is bulky, dismantles, hangs
All there is certain difficulty in dress and transport, transport to producer's reparation, and the period is long, and the spare parts purchasing period needed for the replacement of scene is long, for as early as possible
It resumes production, needs to carry out REPAIR WELDING from breaking part to broken teeth at the scene.In the prior art, various gear wears, fracture weldering
It is more universal to connect reparation application, has narration in many documents, but also for large-scale spur gear broken teeth site welding reparation application
It is more rare.
Invention content
For overcome the deficiencies in the prior art, the purpose of the present invention is to provide a kind of online REPAIR WELDINGs of large-scale spur gear
Technique is completed in narrow space to operations such as heating, welding, the heat preservations of gear part position to be welded, and the straight-tooth of heap postwelding passes through
Grinding, which reaches, meets operating size, and surface does not have any weld defect, ensures follow-up quality operation cycle.
To achieve the above object, the present invention adopts the following technical scheme that：
The online welding and restoring process of a kind of large size spur gear, its main feature is that the technique carries out in accordance with the following steps：
Prepare before step 1 welding
1) construction condition：Water, power supply system are closed on all yire mills, remove around large-scale spur gear zero
Part opens babinet top semicircle, exposes large-scale spur gear, and fracture tooth is moved to horizontal position, fracture is cleared up with cleaning agent
Tooth rim encloses and neighbouring babinet, and in addition welding place does not have draught and be equipped with carry on construction work at night lighting installation and fire distinguisher；
2) heating device：Oxy-acetylene bottle, heat tape；
3) welding and ancillary equipment：Welding equipment includes Digital Control contravariant craft DC welder, digitized pulse
Gas shielded arc welding, back chipping coordinate plasma gouge using high-power welding machine；Ancillary equipment includes angle grinder, file, hand hammer, flat
Shovel, insulation barrel, tooth block, temperature measurer, magnifying glass, heat-preservation cotton；
Step 2 soldering
1) it is cleaned before the adjustment of weldment position and weldering：Make welding broken teeth everywhere in upper horizontal position, in spur gear center both sides
It is fixed with supporting rack, large size spur gear moves when preventing from carrying out repairing welding；Iron rust, water and grease at removal welding broken teeth；
2) equating and weldment heating at broken teeth are welded：It will be welded at broken teeth using plasma gouge before the welding of transition prime coat
Cutting equating complies with welding requirements；Then weld is heated with oxy-acetylene, rest part is uniformly pre- using heat tape
Heat welds and is preheating to 250 DEG C or so at broken teeth, and 40 DEG C/h of rest part preheating temperature uniformly rises, and temperature measurer is surveyed per half an hour
Amount is primary, to avoid non-uniform high-temperature heating, causes to generate micro-crack inside base material, the area of preheating all covers, in this way
Local temperature difference stress can be reduced, improves interior tissue, prevents or reduce hardened structure；
3) transition prime coat welds：Transition prime coat root is welded using Digital Control contravariant Manual direct current when welding
Machine, welding rod arc welding can relax along bottom periphery built-up welding according to broken teeth area, block form be formed, then in box
The heart starts, and to both sides symmetrically built-up welding, welding rod can make straight line or draw triangle arc manipulation, and arc length is 4~6mm weldings, even
Continuous welding, both sides are had a break；After the completion of the welding of transition prime coat, surface is cleared up using angle grinder, with 3~4 times of amplification microscopies
Look into that whether there is or not weld defects；
4) overlay cladding welds：Digitized pulse gas shielded arc welding, amplification electric current, welding wire are used when two layers or more a large amount of built-up welding
It can make straight line or crescent arc manipulation, continuous to weld using medium 18~25mm of arc length weldings, both sides are had a break, each layer of weldering
It is gone through after connecing, after confirming zero defect, then welds next layer, confirm zero defect continuous sequence layer by layer；When close to vertex angle,
Welding current is more lower than bottom electric current, fills up welding bead, when built-up welding, the entire lateral surface of broken teeth, corresponding large size spur gear
Tooth block shape；According to overlay cladding needs, gage of wire is adjusted, makes the broken teeth shape of welding close to the tooth form of tooth block,
To reduce the reconditioning quality of built-up welding tooth, outside can suitably relax weld size close to toothed area, and both sides can directly be seen without undercut
It examines, it is also possible to 3~4 times of lens examination；
Step 3 welding post-processing
1) it after the completion of welding, is compared using the tooth block first made, extra weld seam is cut with plasma (orifice) gas slicing
Equating, then with angle grinder substantially reconditioning, to meet tooth block size；
2) eliminate welding stress, with oxy-acetylene and electric heater unit continue to be heated to 250 around weld seam and weldment~
400 DEG C, asbestos wrapping is slowly cooled to room temperature, reduces postwelding hardenability, avoids embrittlement；Finally accurately ground using angle grinder again
The horizontal teeth of the whole built-up welding of mill, it is completely corresponding with the tooth form of tooth block, meet whole spur gear rotating requires.
Further, welding equipment includes HT400D Digital Control contravariant craft DC welders in the step 1,
Nb~500P digitized pulse gas shielded arc weldings, back chipping using the welding machines of high-power ZX5~630 cooperation plasma gouge LGK~
100MA。
Further, moisture removal and grease are removed with oxyacetylene torch when cleaning before being welded in the step 2, with emery cloth or mill
Cut abrasive machine polishing derusting.
Further, it remains that interlayer temperature is not less than 100 DEG C when overlay cladding welds in the step 2, removes weld part
Position is left outside, and rest part is covered with asbestos board and heat-preservation cotton heat-barrier material, and electric heater unit adjusts the temperature difference, reduces heat
Amount loses and prevents operator by hyperthermia radiation.
Further, the weldment material used in the step 2 is 35# steel, and welding material is welding rod, E5015350~400 DEG C of welding rod bakes constant temperature after 2h, on-demand；Welding wire, SWE711 flux-cored wires, table
Face zero defect, specificationGas is carbon dioxide, purity 99.8%.
Further, welding rod, E5015 are used when the transition prime coat weldingWelding electricity
Flow 120~180A, 26 ± 1V of arc voltage, 15 ± 1cmmin of speed of welding-1, the selection of electric current is conducive to welding layer and base material very
Good fusion,
Further, SWE711 flux-cored wires, surface zero defect, specification ￠ 1.2mm, weldering are used when the overlay cladding welding
Meet 280~360A of electric current, 30 ± 1V of arc voltage, 25 ± 1cmmin of speed of welding-1。
Compared with prior art, it is an advantage of the invention that being completed to gear part position to be welded in wire bonding in narrow space
Reparation is connect, the straight-tooth of heap postwelding is reached by hand lapping meets operating size, and surface does not have any weld defect, ensures follow-up
Operation cycle, quality, saved the repair time, reduces maintenance cost, reduces shutdown loss, provided safeguard for rationally group production.
Description of the drawings
With reference to embodiment attached drawing, the present invention will be further described.
Fig. 1 is large-scale spur gear partial schematic diagram of the invention；
Fig. 2 is gear tooth breakage bottom welding seam schematic diagram of the present invention；
Fig. 3 is transition prime coat schematic diagram at present invention welding broken teeth；
Fig. 4 is gear tooth breakage molding weld seam weldering schematic diagram of the present invention；
Fig. 5 is tooth block schematic diagram of the present invention.
In figure：3- transition prime coat 4- overlay cladding 5- tooth blocks at 1- large size spur gears 2- welding broken teeths.
Specific implementation mode
With reference to specific embodiment, the present invention will be further described.
Referring to Fig.1, shown in Fig. 2, Fig. 3, Fig. 4, Fig. 5, the online welding and restoring process of a kind of large size spur gear, its main feature is that should
Technique carries out in accordance with the following steps：
Prepare before step 1 welding
1) construction condition：Water, power supply system are closed on all yire mills, remove around large-scale spur gear 1 zero
Part opens babinet top semicircle, exposes large-scale spur gear 1, and fracture tooth is moved to horizontal position, fracture is cleared up with cleaning agent
Tooth rim encloses and neighbouring babinet, and in addition welding place does not have draught and be equipped with carry on construction work at night lighting installation and fire distinguisher；
2) heating device：Oxy-acetylene bottle, heat tape；
3) welding and ancillary equipment：Welding equipment includes Digital Control contravariant craft DC welder, digitized pulse
Gas shielded arc welding, back chipping coordinate plasma gouge using high-power welding machine；Ancillary equipment includes angle grinder, file, hand hammer, flat
Shovel, insulation barrel, tooth block, temperature measurer, magnifying glass, heat-preservation cotton；
Step 2 soldering
1) it is cleaned before the adjustment of weldment position and weldering：2 are made at welding broken teeth to be in upper horizontal position, in spur gear center both sides
It is fixed with supporting rack, large size spur gear 1 moves when preventing from carrying out repairing welding；2 iron rust, water and grease at removal welding broken teeth；
2) equating and weldment heating at broken teeth are welded：Transition prime coat 3 uses plasma gouge that will weld broken teeth before welding
2 cutting equating of place complies with welding requirements；Then weld is heated with oxy-acetylene, rest part is uniform using heat tape
It preheats, 2 are preheating to 250 DEG C or so at welding broken teeth, and 40 DEG C/h of rest part preheating temperature uniformly rises, and temperature measurer is per half an hour
It measuring once, to avoid non-uniform high-temperature heating, causes to generate micro-crack inside base material, the area of preheating all covers, this
Sample can reduce local temperature difference stress, improve interior tissue, prevent or reduce hardened structure；
3) transition prime coat welds：3 root of transition prime coat is welded using Digital Control contravariant Manual direct current when welding
Machine, welding rod arc welding can relax along bottom periphery built-up welding according to broken teeth area, block form be formed, then in box
The heart starts, and to both sides symmetrically built-up welding, welding rod can make straight line or draw triangle arc manipulation, and arc length is 4~6mm weldings, even
Continuous welding, both sides are had a break；After the completion of transition prime coat 3 welds, surface is cleared up using angle grinder, with 3~4 times of amplification microscopies
Look into that whether there is or not weld defects；
4) overlay cladding welds：Digitized pulse gas shielded arc welding, amplification electric current, welding wire are used when two layers or more a large amount of built-up welding
It can make straight line or crescent arc manipulation, continuous to weld using medium 18~25mm of arc length weldings, both sides are had a break, each layer of weldering
It is gone through after connecing, after confirming zero defect, then welds next layer, confirm zero defect continuous sequence layer by layer；When close to vertex angle,
Welding current is more lower than bottom electric current, fills up welding bead, when built-up welding, the entire lateral surface of broken teeth, corresponding large size spur gear 1
5 shape of tooth block；According to 4 needs of overlay cladding, gage of wire is adjusted, makes the broken teeth shape of welding close to the tooth of tooth block 5
Shape, to reduce the reconditioning quality of built-up welding tooth, outside can suitably relax weld size close to toothed area, and both sides, can be direct without undercut
Observation, it is also possible to 3~4 times of lens examination；
Step 3 welding post-processing
1) it after the completion of welding, is compared using the tooth block 5 first made, extra weld seam is cut with plasma (orifice) gas slicing
Equating, then with angle grinder substantially reconditioning, to meet tooth block size；
2) eliminate welding stress, with oxy-acetylene and electric heater unit continue to be heated to 250 around weld seam and weldment~
400 DEG C, asbestos wrapping is slowly cooled to room temperature, reduces postwelding hardenability, avoids embrittlement；Finally accurately ground using angle grinder again
The horizontal teeth of the whole built-up welding of mill, it is completely corresponding with the tooth form of tooth block, meet whole spur gear rotating requires.
Welding equipment includes HT400D Digital Control contravariant craft DC welders, Nb~500P digitlizations in step 1
Pulse gas-shielded weldering, back chipping is using the welding machines of high-power ZX5~630 cooperation plasma gouge LGK~100MA.
Moisture removal and grease are removed with oxyacetylene torch when cleaning before being welded in step 2, is removed with emery cloth or the polishing of abrasive grinding wheel machine
Rust.
Remain that interlayer temperature is not less than 100 DEG C when overlay cladding 4 welds in step 2, except welding position is left outside,
Rest part is covered with asbestos board and heat-preservation cotton heat-barrier material, and electric heater unit adjusts the temperature difference, is reduced thermal loss and is prevented
Only operator is by hyperthermia radiation.
The weldment material used in step 2 is 35# steel, and welding material is welding rod, E5015 ￠ 3.2mm, ￠ 4.0mm, weldering
350~400 DEG C of item bakes constant temperature after 2h, on-demand；Welding wire, SWE711 flux-cored wires, surface zero defect, specification ￠ 1.2mm；
Gas is carbon dioxide, purity 99.8%.
Welding rod, E5015 ￠ 3.2mm, ￠ 4.0mm, 120~180A of welding current, electric arc are used when transition prime coat 3 welds
26 ± 1V of voltage, 15 ± 1cmmin of speed of welding-1, the selection of electric current is conducive to welding layer and base material fuses well,
Overlay cladding 4 weld when use SWE711 flux-cored wires, surface zero defect, specification ￠ 1.2mm, welding current 280~
360A, 30 ± 1V of arc voltage, 25 ± 1cmmin of speed of welding-1。
The foregoing is merely a prefered embodiment of the invention, but scope of protection of the present invention is not limited thereto, any to be familiar with sheet
In the technical scope disclosed by the present invention, the change or replacement that can be readily occurred in should all be covered those skilled in the art
Within protection scope of the present invention, therefore, protection scope of the present invention should be subject to the protection domain that claim is defined.
Claims (7)
1. a kind of online welding and restoring process of large size spur gear, it is characterised in that the technique carries out in accordance with the following steps：
Prepare before step 1 welding
1) construction condition：Water, power supply system are closed on all yire mills, are removed large-scale spur gear surrounding components, are beaten
Unpacking, body top is semicircle, and fracture tooth is moved to horizontal position by the large-scale spur gear of exposing, is cleared up fracture tooth rim with cleaning agent and is enclosed
And neighbouring babinet, in addition welding place does not have draught and is equipped with carry on construction work at night lighting installation and fire distinguisher；
2) heating device：Oxy-acetylene bottle, heat tape；
3) welding and ancillary equipment：Welding equipment includes Digital Control contravariant craft DC welder, digitized pulse gas
Protection weldering, back chipping coordinate plasma gouge using high-power welding machine；Ancillary equipment includes angle grinder, file, hand hammer, flat chisel, guarantor
Wen Tong, tooth block, temperature measurer, magnifying glass, heat-preservation cotton；
Step 2 soldering
1) it is cleaned before the adjustment of weldment position and weldering：Make welding broken teeth everywhere in upper horizontal position, in spur gear center both sides branch
Support is fixed；Iron rust, water and grease at removal welding broken teeth；
2) equating and weldment heating at broken teeth are welded：It will be welded at broken teeth and be cut using plasma gouge before the welding of transition prime coat
Equating complies with welding requirements；Then weld is heated with oxy-acetylene, rest part is uniformly preheated using heat tape, is welded
It connects and is preheating to 250 DEG C or so at broken teeth, 40 DEG C/h of rest part preheating temperature uniformly rises, and temperature measurer measures one per half an hour
It is secondary；
3) transition prime coat welds：Transition prime coat root uses Digital Control contravariant craft DC welder, weldering when welding
The welding of electric arc can relax along bottom periphery built-up welding according to broken teeth area, form block form, then be opened with box center
Begin, to both sides symmetrically built-up welding, welding rod can make straight line or draw triangle arc manipulation, and arc length is 4~6mm weldings, sequential welding
It connects, both sides are had a break；After the completion of the welding of transition prime coat, surface is cleared up using angle grinder, is had with 3~4 times of lens examinations
Welding defect；
4) overlay cladding welds：Use digitized pulse gas shielded arc welding, amplification electric current, welding wire that can make when two layers or more a large amount of built-up welding
Straight line or crescent arc manipulation, continuous to weld using medium 18~25mm of arc length weldings, both sides are had a break, after each layer of welding
It goes through, after confirming zero defect, then welds next layer, confirm zero defect continuous sequence layer by layer；When close to vertex angle, welding
Electric current is more lower than bottom electric current, fills up welding bead, when built-up welding, the entire lateral surface of broken teeth, and the tooth form of corresponding large size spur gear
Model shape；According to overlay cladding needs, gage of wire is adjusted, makes the broken teeth shape of welding close to the tooth form of tooth block, outside
Close to toothed area, it can suitably relax weld size, both sides can directly be observed without undercut, it is also possible to 3~4 times of amplification microscopy
It looks into；
Step 3 welding post-processing
1) it after the completion of welding, being compared using the tooth block first made, extra weld seam cuts equating with plasma (orifice) gas slicing,
Then with angle grinder substantially reconditioning, meet tooth block size；
2) welding stress is eliminated, is continued to being heated to 250~400 around weld seam and weldment with oxy-acetylene and electric heater unit
DEG C, asbestos wrapping is slowly cooled to room temperature, reduces postwelding hardenability, avoids embrittlement；Angle grinder precision ground is finally used again
The horizontal teeth of whole built-up welding, it is completely corresponding with the tooth form of tooth block.
2. a kind of online welding and restoring process of large-scale spur gear according to claim 1, it is characterised in that：The step 1
Middle welding equipment includes HT400D Digital Control contravariant craft DC welders, Nb~500P digitized pulse gas shields
Weldering, back chipping is using the welding machines of high-power ZX5~630 cooperation plasma gouge LGK~100MA.
3. a kind of online welding and restoring process of large-scale spur gear according to claim 1, it is characterised in that：The step 2
Moisture removal and grease are removed with oxyacetylene torch when being cleaned before middle weldering, with emery cloth or the polishing derusting of abrasive grinding wheel machine.
4. a kind of online welding and restoring process of large-scale spur gear according to claim 1, it is characterised in that：The step 2
Remain that interlayer temperature is not less than 100 DEG C when middle overlay cladding welding, except welding position is left outside, rest part uses asbestos
Plate and heat-preservation cotton heat-barrier material cover, and electric heater unit adjusts the temperature difference.
5. a kind of online welding and restoring process of large-scale spur gear according to claim 1, it is characterised in that：The step 2
The middle weldment material used is 35# steel, and welding material is welding rod, E5015 ￠ 3.2mm, ￠ 4.0mm, 350~400 DEG C of bakings of welding rod
Constant temperature after roasting 2h, it is on-demand；Welding wire, SWE711 flux-cored wires, surface zero defect, specification ￠ 1.2mm；Gas is titanium dioxide
Carbon, purity 99.8%.
6. a kind of online welding and restoring process of large-scale spur gear according to claim 1, it is characterised in that：The transition is beaten
Welding rod, E5015 ￠ 3.2mm, ￠ 4.0mm, 120~180A of welding current, 26 ± 1V of arc voltage, welding are used when backing weld
15 ± 1cmmin of speed-1, the selection of electric current is conducive to welding layer and base material fuses well.
7. a kind of online welding and restoring process of large-scale spur gear according to claim 1, it is characterised in that：The overlay cladding
SWE711 flux-cored wires, surface zero defect, specification ￠ 1.2mm, 280~360A of welding current, arc voltage 30 are used when welding
± 1V, 25 ± 1cmmin of speed of welding-1。
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| CN201810378064.3A CN108555468B (en) | 2018-04-25 | 2018-04-25 | Online welding repair process for large straight gear |
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| CN201810378064.3A CN108555468B (en) | 2018-04-25 | 2018-04-25 | Online welding repair process for large straight gear |
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| CN110735908A (en) * | 2019-10-29 | 2020-01-31 | 中交烟台环保疏浚有限公司 | Method for repairing broken gear |
| CN111250824A (en) * | 2020-03-30 | 2020-06-09 | 安徽马钢设备检修有限公司 | Welding device and repair process for inner hole wear surface of upper cross beam of large hydraulic press |
| CN112388245A (en) * | 2020-10-28 | 2021-02-23 | 贵州西能电力建设有限公司 | Welding repair method for broken teeth of large gear of ball mill |
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| CN115026511A (en) * | 2022-05-07 | 2022-09-09 | 金川集团股份有限公司 | Method for repairing broken large gear ring and gear teeth of large and medium-sized ball mills |
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