CN110387543B - Method for repairing planet carrier external spline through laser cladding welding - Google Patents

Method for repairing planet carrier external spline through laser cladding welding Download PDF

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CN110387543B
CN110387543B CN201910851791.1A CN201910851791A CN110387543B CN 110387543 B CN110387543 B CN 110387543B CN 201910851791 A CN201910851791 A CN 201910851791A CN 110387543 B CN110387543 B CN 110387543B
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spline
planet carrier
welded
tooth
hobbing
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CN110387543A (en
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秦玉京
杨会武
史仁贵
谢杰
王辉
薛强
杨方超
王先龙
王晟东
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Xian Coal Mining Machinery Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/42—Ferrous alloys, e.g. steel alloys containing chromium with nickel with copper
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/52—Ferrous alloys, e.g. steel alloys containing chromium with nickel with cobalt
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/106—Coating with metal alloys or metal elements only

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Abstract

The invention discloses a method for repairing an external spline of a planet carrier through laser cladding welding, which comprises the following steps: firstly, cleaning a planet carrier; secondly, primary hobbing of an external spline on the planet carrier; thirdly, cleaning spline teeth to be welded; fourthly, repairing an external spline on the planet carrier; and fifthly, secondary hobbing of the external spline on the planet carrier. The method has simple steps, reasonable design and good use effect, and can carry out laser cladding welding repair on the worn spline teeth in the external spline on the planet carrier, thereby saving the cost and raw materials, reducing the pollution to the environment and improving the recycling rate.

Description

Method for repairing planet carrier external spline through laser cladding welding
Technical Field
The invention belongs to the technical field of welding repair of an external spline of a planet carrier, and particularly relates to a method for repairing the external spline of the planet carrier through laser cladding welding.
Background
The planet carrier is an important component of a planet speed reducing mechanism in a rocker arm of a coal mining machine, belongs to a transmission mechanism under industrial and mining, bears larger load and torque, and is often severely extruded and worn and damaged on one side of an external spline of a planet carrier of a planet head of a cutting part (rocker arm) in the overhaul process of the coal mining machine, so that the whole planet carrier is scrapped and is greatly wasted. Because the production cycle of a planet carrier needs two months or even longer time under normal conditions, the production process is complex and the cycle is longer through the production links of manufacturing raw materials, forging, welding, heat treatment, processing and the like, and in addition, part of the production links are inevitable to pollute the environment. Therefore, a method for repairing the outer spline of the planet carrier through laser cladding welding with reasonable design is absent at present, the worn spline teeth in the outer spline on the planet carrier are repaired through laser cladding welding, the cost and the raw materials are saved, the pollution to the environment is reduced, and the recycling rate is improved.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for repairing the external spline of the planet carrier by laser cladding welding, which has the advantages of simple steps, reasonable design and good use effect, and can be used for repairing worn spline teeth in the external spline on the planet carrier by laser cladding welding, thereby saving cost and raw materials, reducing pollution to the environment and improving the recycling rate.
In order to solve the technical problems, the invention adopts the technical scheme that: a method for repairing an external spline of a planet carrier through laser cladding welding is characterized by comprising the following steps: the planet carrier comprises a planet carrier base, a connecting part arranged on the planet carrier base and an external spline arranged at the end part of the connecting part, and is characterized by comprising the following steps:
step one, cleaning a planet carrier:
cleaning the planet carrier to be repaired by adopting a mechanical part cleaning machine and adding an RSB-105 low-foam alkaline metal cleaning agent; wherein the cleaning time is 5 min-10 min; the outer spline on the planet carrier to be repaired comprises unworn spline teeth and worn spline teeth, the number of the unworn spline teeth is N ', the number of the worn spline teeth is N, both N ' and N are positive integers, N is more than or equal to 2, and N ' is more than or equal to 5;
step two, primary hobbing of an external spline on the planet carrier:
hobbing a plurality of worn spline teeth on a planet carrier to be repaired by adopting a hobbing machineObtaining spline teeth to be welded; wherein the tooth thickness of the spline tooth to be welded is denoted as D',
Figure BDA0002197191810000021
d represents the tooth thickness of the unworn spline teeth;
step three, cleaning the spline teeth to be welded:
cleaning spline teeth to be welded to obtain a planet carrier to be welded;
step four, repairing an external spline on the planet carrier:
step 401, preparing alloy powder;
step 402, mounting a planet carrier to be welded on a laser cladding welding machine;
step 403, under protective gas, respectively performing fusion welding on a plurality of to-be-welded spline teeth on the external spline by using a laser fusion welding machine in the same method, and performing fusion welding on the ith to-be-welded spline tooth on the external spline by using the laser fusion welding machine, wherein the specific process is as follows:
4031, adopting a laser cladding welding machine, feeding alloy powder, and welding the laser cladding head from one end of the ith spline tooth to be welded to the other end of the ith spline tooth to be welded along the tooth width direction of the ith spline tooth to be welded to form an upper cladding layer;
4032, a laser cladding welding machine is adopted, alloy powder is fed, and a laser cladding head is welded from the other end of the ith spline tooth to be welded to one end of the ith spline tooth to be welded along the tooth width direction of the ith spline tooth to be welded to form a next cladding layer; wherein the upper melting coating layer and the lower melting coating layer are distributed along the tooth surface of the ith spline tooth to be welded from the tooth root to the tooth top, and the lap joint rate between the upper melting coating layer and the lower melting coating layer is 55-60%;
4033, repeating 4031 and 4032 for multiple times until the tooth surface of the ith spline tooth to be welded is completely covered to form a fused coating;
4034, repeating the 4033 for multiple times until the thickness D' of the ith spline tooth to be welded after cladding welding meets the requirement
Figure BDA0002197191810000031
Completing the cladding welding of the ith spline tooth to be welded;
step 4035, operating the planet carrier to rotate so as to enable the external spline on the planet carrier to rotate, and performing fusion welding on the (i + 1) th spline tooth to be welded according to the method in the steps 4031 to 4034;
4036, repeating 4035 for multiple times to complete the fusion covering welding of the N spline teeth to be welded to obtain the external spline to be rolled; wherein i and N are positive integers, i is more than or equal to 1 and less than N, and i +1 is more than or equal to 2 and less than or equal to N;
step five, secondary gear hobbing of the external spline on the planet carrier:
step 501, according to the formula
Figure BDA0002197191810000032
Obtaining the required hobbing thickness L of the external spline to be subjected to hobbing;
step 502, respectively performing primary hobbing on the N external splines to be hobbed by using a hobbing machine to obtain N spline teeth of the primary hobbing; wherein the tooth thickness of the spline teeth of the N first-time hobbing is denoted as D1And is and
Figure BDA0002197191810000033
step 503, performing second hobbing on the spline teeth of the N first hobbings by using a hobbing machine to obtain N spline teeth of second hobbings; wherein, the tooth thickness of the spline teeth of the N second-time hobbing is marked as D2And is and
Figure BDA0002197191810000034
step 504, performing third hobbing on the spline teeth of the N second-time hobbing by using a hobbing machine to obtain N repaired spline teeth, and completing the repair of the external spline to obtain a repaired planet carrier; wherein the tooth thickness of the spline teeth of the N third-time hobbing is denoted as D3And is and
Figure BDA0002197191810000035
the method for repairing the planet carrier external spline through laser cladding welding is characterized by comprising the following steps: in the step 403, when a laser fusion welding machine is adopted to respectively perform fusion welding on a plurality of spline teeth to be welded on the external spline, the laser power of the laser fusion welding machine is 3000W-4000W, the protective gas is argon, the flow range of the protective gas is 15L/min-25L/min, and the spot size of laser emitted by the laser fusion welding machine is 1.5 mm-2.5 mm;
the welding current of the laser cladding welding machine is 200-220A, and the defocusing amount of the laser cladding welding machine ranges from 5mm to 10 mm.
The method for repairing the planet carrier external spline through laser cladding welding is characterized by comprising the following steps: in the third step, the spline teeth to be welded are cleaned in the following specific process:
step 301, polishing the spline teeth to be welded by adopting a file or a grinder to obtain polished external splines; wherein, the roughness of the tooth surface of the external spline after polishing is not more than 12.5 μm;
step 302, putting the polished external splines into purified water, brushing the splines by using a soft-bristle toothbrush, and then washing the splines three times by using the purified water;
303, dipping the glasses cloth in an acetone solution, and scrubbing the washed external spline; wherein the scrubbing time is 30-40 min, and the volume concentration of the acetone solution is 15-20%;
step 304, standing the scrubbed external spline in a room-temperature dust-free environment to obtain a planet carrier to be welded; wherein the standing time is 3-4 h.
The method for repairing the planet carrier external spline through laser cladding welding is characterized by comprising the following steps: the moving speed of the laser cladding head in the laser cladding welding machine along the tooth width direction of the ith spline tooth to be welded is 7-8 m/min.
The method for repairing the planet carrier external spline through laser cladding welding is characterized by comprising the following steps: and step five, obtaining the repaired planet carrier, and then detecting the repaired planet carrier:
step A, detecting the surface hardness of the external spline on the repaired planet carrier by using a Leeb hardness tester so that the surface hardness of the external spline on the repaired planet carrier meets HRC 38-HRC 42;
b, detecting the tooth surface roughness of the external spline on the repaired planet carrier by using a roughness meter so that the tooth surface roughness of the external spline on the repaired planet carrier is not more than 3.2 mu m;
step C, according to the formula
Figure BDA0002197191810000041
Obtaining the number k of the cross measurement teeth to be confirmed; wherein α represents the pressure angle of the external splines on the unworn planet carrier;
step D, when the span measurement tooth number is to be confirmed to be 0.5< K <2.5, obtaining the final span measurement tooth number K which is 2;
when the span measurement tooth number n-0.5 is not more than K and is less than n +0.5 to be confirmed, obtaining the final span measurement tooth number K, and then K is equal to n; wherein n is a natural number and is more than or equal to 3;
e, measuring one side of the first group of K spline teeth on the repaired external spline by adopting a micrometer to obtain a first common normal length W1；
Clamping a second group of K spline teeth on the repaired external spline by using a micrometer to perform two-side measurement to obtain a second common normal length W2；
A micrometer is adopted to clamp a third group of K spline teeth on the repaired external spline for three-side measurement, and a third common normal length W is obtained3(ii) a The center of the first group of K spline teeth, the center of the second group of K spline teeth and the third group of K spline teeth cover the N repaired spline teeth;
step F, according to the formula
Figure BDA0002197191810000051
Obtaining the common normal line length of the external spline on the repaired planet carrier
Figure BDA0002197191810000052
So that the common normal line length of the external spline on the repaired planet carrier
Figure BDA0002197191810000053
Equal to the common normal line length of the external splines on the unworn planet carrier.
The method for repairing the planet carrier external spline through laser cladding welding is characterized by comprising the following steps: the alloy powder in the step 401 comprises the following components in percentage by weight: 0.09-0.12 percent of Cu, 0.21-0.27 percent of Mo, 2.0-2.45 percent of Ni, 0.2-0.3 percent of Mn, 17.0-19.3 percent of Cr, 0.25-0.4 percent of Co and the balance of Fe; the particle size of the alloy powder is 15-53 mu m.
The method for repairing the planet carrier external spline through laser cladding welding is characterized by comprising the following steps: in step 402, the planet carrier to be welded is mounted on a laser cladding welding machine, and the specific process is as follows:
a first seal plate is arranged at one end, far away from the external spline, of the planet carrier to be welded, a second seal plate is arranged at one end, close to the external spline, of the planet carrier to be welded, and then the planet carrier to be welded is clamped on a laser fusion welding machine; the four-jaw chuck of the laser fusion welding machine is clamped at one end, far away from the external spline, of the planet carrier to be welded, the tailstock center of the laser fusion welding machine is tightly propped against the center of the end face of the second sealing plate, and the roller type supporting seat of the laser fusion welding machine is supported at the lower portion of the planet carrier to be welded.
The method for repairing the planet carrier external spline through laser cladding welding is characterized by comprising the following steps: and during the first gear hobbing of the external spline on the planet carrier in the step two, the first gear hobbing in the step 501, the second gear hobbing in the step 502 and the third gear hobbing in the step 503, the rotating speed of the gear hobbing machine is 45 r/min-50 r/min, and the feeding speed of the gear hobbing machine is 0.2 mm/r-0.3 mm/r.
Compared with the prior art, the invention has the following advantages:
1. the method has simple steps, reasonable design and convenient realization.
2. After the planet carrier is cleaned, carrying out primary gear hobbing on an external spline on the planet carrier to obtain a spline tooth to be welded, and cleaning the spline tooth to be welded to obtain the planet carrier to be welded; then, the planet carrier to be welded is installed on a laser cladding welding machine, and cladding welding repair is carried out on the external spline on the planet carrier to be welded by the laser cladding welding machine to obtain the external spline to be rolled; and then carrying out primary hobbing, secondary hobbing and tertiary hobbing on the external spline to be hobbed respectively to obtain a repaired planet carrier, carrying out laser cladding welding repair on the worn spline teeth in the external spline on the planet carrier, avoiding scrapping of the whole planet carrier, saving cost and raw materials, reducing pollution to the environment and meeting the requirements of a coal mining machine.
3. The invention respectively performs primary hobbing, secondary hobbing and tertiary hobbing on the external spline on the planet carrier during secondary hobbing, and aims to improve the hobbing precision, so that the repaired spline tooth obtained after the tertiary hobbing meets the requirement of the normal external spline on the planet carrier, and the damage to a hobbing machine is also avoided.
4. The invention has high welding efficiency, can quickly finish the repair of the external spline on the planet carrier, has simple operation process and greatly reduces the production cost.
In conclusion, the method has the advantages of simple steps, reasonable design and good use effect, and can be used for carrying out laser cladding welding repair on the worn spline teeth in the external spline on the planet carrier, thereby saving the cost and raw materials, reducing the pollution to the environment and improving the recycling rate.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
FIG. 1 is a schematic flow chart of the method of the present invention.
Fig. 2 is a schematic view of the installation of the planetary carrier of the present invention.
Description of reference numerals:
1-a planet carrier; 1-planet carrier base; 1-2-external splines;
1-3-linker; 2-1-a first sealing plate; 2-a second sealing plate;
3, laser melt-coating welding machine; 3-1-a four-jaw chuck; 3-2-tailstock centre;
3-roller type supporting seat.
Detailed Description
A method for repairing an external spline of a planet carrier by laser cladding welding is described by examples 1-3.
Example 1
As shown in fig. 1 and 2, the method of the present invention comprises the steps of:
the planet carrier 1 comprises a planet carrier base 1-1, a connecting part 1-3 arranged on the planet carrier base 1-1 and an external spline 1-2 arranged at the end part of the connecting part 1-3, and is characterized by comprising the following steps:
step one, cleaning a planet carrier:
cleaning the planet carrier 1 to be repaired by adopting a mechanical part cleaning machine and adding an RSB-105 low-foam alkaline metal cleaning agent; wherein the cleaning time is 5 min; the outer spline 1-2 on the planet carrier 1 to be repaired comprises unworn spline teeth and worn spline teeth, the number of the unworn spline teeth is N ', the number of the worn spline teeth is N, both N ' and N are positive integers, N is more than or equal to 2, and N ' is more than or equal to 5;
step two, primary hobbing of an external spline on the planet carrier:
hobbing a plurality of worn spline teeth on the planet carrier 1 to be repaired by using a hobbing machine to obtain spline teeth to be welded; wherein the tooth thickness of the spline tooth to be welded is denoted as D',
Figure BDA0002197191810000071
d represents the tooth thickness of the unworn spline teeth;
step three, cleaning the spline teeth to be welded:
cleaning spline teeth to be welded to obtain a planet carrier to be welded;
step four, repairing an external spline on the planet carrier:
step 401, preparing alloy powder;
step 402, mounting the planet carrier to be welded on a laser cladding welding machine 3;
step 403, under protective gas, respectively performing fusion welding on a plurality of to-be-welded spline teeth on the external spline 1-2 by using the laser fusion welding machine 3 in the same method, and then performing fusion welding on the ith to-be-welded spline tooth on the external spline 1-2 by using the laser fusion welding machine 3, wherein the specific process is as follows:
4031, adopting a laser cladding welding machine 3, feeding alloy powder, and welding an ith spline tooth to be welded by a laser cladding head 4 from one end of the ith spline tooth to be welded to the other end of the ith spline tooth to be welded along the tooth width direction of the ith spline tooth to be welded to form an upper cladding layer;
4032, a laser cladding welding machine 3 is adopted, alloy powder is fed, and a laser cladding head 4 is welded from the other end of the ith spline tooth to be welded to one end of the ith spline tooth to be welded along the tooth width direction of the ith spline tooth to be welded to form a next cladding layer; the upper melting coating layer and the lower melting coating layer are distributed along the tooth surface of the ith spline tooth to be welded from the tooth root to the tooth top, and the lap joint rate between the upper melting coating layer and the lower melting coating layer is 55%;
4033, repeating 4031 and 4032 for multiple times until the tooth surface of the ith spline tooth to be welded is completely covered to form a fused coating;
4034, repeating the 4033 for multiple times until the thickness D' of the ith spline tooth to be welded after cladding welding meets the requirement
Figure BDA0002197191810000081
Completing the cladding welding of the ith spline tooth to be welded;
step 4035, operating the planet carrier 1 to rotate so as to enable the external spline 1-2 on the planet carrier 1 to rotate, and performing fusion welding on the (i + 1) th spline tooth to be welded according to the method in the steps 4031 to 4034;
4036, repeating 4035 for multiple times to complete the fusion covering welding of the N spline teeth to be welded to obtain the external spline to be rolled; wherein i and N are positive integers, i is more than or equal to 1 and less than N, and i +1 is more than or equal to 2 and less than or equal to N;
step five, secondary gear hobbing of the external spline on the planet carrier:
step 501, according to the formula
Figure BDA0002197191810000082
Obtaining the required hobbing thickness L of the external spline to be subjected to hobbing;
step 502, respectively performing primary hobbing on the N external splines to be hobbed by using a hobbing machine to obtain N spline teeth of the primary hobbing; wherein the tooth thickness of the spline teeth of the N first-time hobbing is denoted as D1And is and
Figure BDA0002197191810000083
step 503, performing second hobbing on the spline teeth of the N first hobbings by using a hobbing machine to obtain N spline teeth of second hobbings; wherein, the tooth thickness of the spline teeth of the N second-time hobbing is marked as D2And is and
Figure BDA0002197191810000084
step 504, performing third gear hobbing on the spline teeth of the N second gear hobbing by using a gear hobbing machine to obtain N repaired spline teeth, completing the repair of the external spline 1-2, and obtaining a repaired planet carrier; wherein the tooth thickness of the spline teeth of the N third-time hobbing is denoted as D3And is and
Figure BDA0002197191810000085
in the embodiment, when the laser fusion welding machine 3 is used for respectively performing fusion welding on a plurality of spline teeth to be welded on the external spline 1-2 in the step 403, the laser power of the laser fusion welding machine 3 is 3000W, the shielding gas is argon, the flow range of the shielding gas is 15L/min, and the spot size of the laser emitted by the laser fusion welding machine 3 is 1.5 mm;
the welding current of the laser cladding welding machine 3 is 200A, and the defocusing amount range of the laser cladding welding machine 3 is 5 mm.
In this embodiment, the cleaning of the spline teeth to be welded in step three is as follows:
step 301, polishing the spline teeth to be welded by adopting a file or a grinder to obtain polished external splines; wherein, the roughness of the tooth surface of the external spline after polishing is not more than 12.5 μm;
step 302, putting the polished external splines into purified water, brushing the splines by using a soft-bristle toothbrush, and then washing the splines three times by using the purified water;
303, dipping the glasses cloth in an acetone solution, and scrubbing the washed external spline; wherein the scrubbing time is 30min, and the volume concentration of the acetone solution is 20%;
step 304, standing the scrubbed external spline in a room-temperature dust-free environment to obtain a planet carrier to be welded; wherein the standing time is 3 h.
In the embodiment, the moving speed of the laser cladding head 4 in the laser cladding welding machine 3 along the tooth width direction of the ith spline tooth to be welded is 7 m/min.
In this embodiment, obtain the planet carrier after restoreing in step five, later still need detect the planet carrier after restoreing:
step A, detecting the surface hardness of the external spline on the repaired planet carrier by using a Leeb hardness tester so that the surface hardness of the external spline on the repaired planet carrier meets HRC 38-HRC 42;
b, detecting the tooth surface roughness of the external spline on the repaired planet carrier by using a roughness meter so that the tooth surface roughness of the external spline on the repaired planet carrier is not more than 3.2 mu m;
step C, according to the formula
Figure BDA0002197191810000091
Obtaining the number k of the cross measurement teeth to be confirmed; wherein α represents the pressure angle of the external splines 1-2 on the unworn planet carrier 1;
step D, when the span measurement tooth number is to be confirmed to be 0.5< K <2.5, obtaining the final span measurement tooth number K which is 2;
when the span measurement tooth number n-0.5 is not more than K and is less than n +0.5 to be confirmed, obtaining the final span measurement tooth number K, and then K is equal to n; wherein n is a natural number and is more than or equal to 3;
step E, clamping the first group of K spline teeth on the repaired external spline 1-2 by using a micrometer to perform one-side measurement to obtain a first common normal length W1；
Using a micrometerMeasuring two sides of a second group of K spline teeth on the external spline 1-2 after the clamping and repairing to obtain a second common normal length W2；
A micrometer is adopted to clamp a third group of K spline teeth on the repaired external spline 1-2 for three-side measurement, and a third common normal length W is obtained3(ii) a The center of the first group of K spline teeth, the center of the second group of K spline teeth and the third group of K spline teeth cover the N repaired spline teeth;
step F, according to the formula
Figure BDA0002197191810000101
Obtaining the common normal line length of the external spline on the repaired planet carrier
Figure BDA0002197191810000102
So that the common normal line length of the external spline on the repaired planet carrier
Figure BDA0002197191810000103
Equal to the common normal line length of the external splines on the unworn planet carrier.
In this embodiment, the alloy powder in step 401 includes the following components in percentage by weight: 0.09% of Cu, 0.21% of Mo, 2.0% of Ni, 0.2% of Mn, 17.0% of Cr, 0.25% of Co and the balance of Fe; and the particle size of the alloy powder was 15 μm.
In this embodiment, in step 402, the planet carrier to be welded is mounted on the laser cladding welding machine 3, and the specific process is as follows:
a first seal plate 2-1 is arranged at one end, far away from the external spline 1-2, of the planet carrier to be welded, a second seal plate 2-2 is arranged at one end, close to the external spline 1-2, of the planet carrier to be welded, and then the planet carrier to be welded is clamped on a laser fusion welding machine 3; the four-jaw chuck 3-1 of the laser fusion welding machine 3 is clamped at one end, far away from the external spline 1-2, of the planet carrier to be welded, the tailstock center 3-2 of the laser fusion welding machine 3 is tightly propped against the center of the end face of the second seal plate 2-2, and the roller type supporting seat 3-3 of the laser fusion welding machine 3 is supported at the lower part of the planet carrier to be welded.
In this embodiment, when the primary hobbing of the external spline on the carrier in the step two, the primary hobbing in the step 501, the secondary hobbing in the step 502, and the third hobbing in the step 503 are performed, the rotation speed of the hobbing machine is 45r/min, and the feed speed of the hobbing machine is 0.2 mm/r.
In this embodiment, the order of the spline teeth to be welded is according to a plurality of worn spline teeth on the planet carrier 1 to be repaired, and the worn spline teeth are reversely ordered in a counterclockwise direction along the circumference.
In this embodiment, it should be noted that when the tooth surface wear amount of the spline teeth in the external splines 1-2 on the planet carrier 1 is greater than or equal to 0.15mm and less than 0.2mm, the tooth thickness of the worn spline teeth of the planet carrier 1 to be repaired is denoted as DxThen, then
Figure BDA0002197191810000111
In the present embodiment, the tooth surface of the spline tooth refers to a connection surface between the tooth crest and the tooth root of the spline tooth.
In this embodiment, the pressure angle α of the external splines 1-2 of the unworn planet carrier 1 is 30 °.
In this embodiment, it should be noted that, in the second step, a gear hobbing machine is adopted to perform gear hobbing on the tooth surfaces of the plurality of worn spline teeth on the planet carrier 1 to be repaired, so as to obtain spline teeth to be welded; in step 502, a hobbing machine is used for performing primary hobbing on the tooth surfaces of the N external splines to be hobbed respectively, in step 503, a hobbing machine is used for performing secondary hobbing on the tooth surfaces of the N external splines to be hobbed respectively, and in step 504, a hobbing machine is used for performing tertiary hobbing on the tooth surfaces of the N external splines to be hobbed respectively.
In this embodiment, a plurality of fusion-coated layers are welded repeatedly in step 4033, and firstly, welding deformation is reduced when laser fusion-coated welding is performed, and constraint stress of an external spline on a planet carrier is also reduced; secondly, heat input can be reduced, and the metallographic structure of the welding position of the cladding layer and the external spline is effectively ensured; thirdly, the upper cladding layer can be subjected to heat treatment for the lower cladding layer, the stress of the upper cladding layer is reduced, the resistance performance of a welding line is improved, and the stability of welding quality is improved.
In this embodiment, multiple welding is performed in step 4031 and step 4032, and firstly, defects such as air holes are not easily generated in order to avoid deformation of a welding material on an outer spline base material; secondly, the second welding bead reheats the first welding bead and the heat affected zone thereof, so that the structure and the performance of the heat affected zone are subjected to phase change recrystallization, fine isometric crystals are formed, the plasticity and the toughness are improved, and the welding shaping is improved.
In this embodiment, a first sealing plate 2-1 and a second sealing plate 2-2 are installed at two ends of the planet carrier, and firstly, the first sealing plate 2-1 and the second sealing plate 2-2 are respectively and fixedly connected to two ends of the planet carrier to be welded through bolts in order to utilize threaded holes at two end faces of the planet carrier to be welded, so that the planet carrier to be welded is convenient to clamp and disassemble; secondly, in order to avoid clamping the damage of the planet carrier to be welded in the laser cladding welding process.
In the embodiment, in the laser cladding welding process, the defocusing amount directly influences the heat treatment effect. When the defocusing amount is too large, the power density acting on the workpiece is too low to achieve the purpose of processing the external spline; when the defocusing amount is too small, the power density acting on the workpiece is too high, the laser irradiation point is easily melted, and the surface of the outer spline is damaged.
In the embodiment, in the fifth step, the first gear hobbing, the second gear hobbing and the third gear hobbing are respectively performed on the secondary gear hobbing of the external spline on the planet carrier, wherein the first gear hobbing is to remove the problems of uneven tooth surface, hard spots and the like of the spline on the external spline to be hobbed; the second time of hobbing is to remove the part of the tooth surface of the spline tooth on the external spline to be hobbed, which is larger than the unworn spline tooth, and reduce the load of the hobbing machine; and the third gear hobbing is to ensure that no galling exists on the tooth surface of the spline teeth, and the roughness meets the requirement, so that the precision of the gear hobbing is improved, the repaired spline teeth obtained after the third gear hobbing meet the requirement of an external spline on a normal planet carrier, and the damage to the gear hobbing machine is also avoided.
In the embodiment, when the four-jaw chuck 3-1 of the laser cladding welding machine 3 is clamped on the planet carrier base 1-1, a copper gasket needs to be laid between the planet carrier base 1-1 and the jaws of the four-jaw chuck 3-1, so that the four-jaw chuck 3-1 is prevented from damaging the planet carrier base 1-1, and the use effect is good.
In the embodiment, the planet carrier external spline is repaired by laser cladding welding, because the fusion performance of the laser cladding repair is good, the welding repair performance is excellent, and the repaired external spline is durable, so that the requirements of the planet carrier in a coal mining machine are met.
Example 2
In this example, the difference from example 1 is: the cleaning time in the step one is 10min, and the tooth thickness of the spline teeth to be welded in the step two
Figure BDA0002197191810000121
4032, the lap joint rate between the upper cladding layer and the lower cladding layer is 60%; the tooth thickness D' of the ith spline tooth to be welded after cladding welding in the step 4034 meets the requirement
Figure BDA0002197191810000122
The tooth thickness of the spline teeth of the N first-time hobbing in the step 502 meets the requirement
Figure BDA0002197191810000123
The tooth thickness of the spline teeth of the N second-time hobbing in the step 503 meets the requirement
Figure BDA0002197191810000124
The tooth thickness of the spline teeth of the N third-time hobbing in the step 504 meets the requirement
Figure BDA0002197191810000125
In the step 403, the laser power of the laser cladding welding machine 3 is 4000W, the flow range of the protective gas is 25L/min, and the spot size of the laser emitted by the laser cladding welding machine 3 is 2.5 mm; the welding current of the laser cladding welding machine 3 is 220A, and the defocusing amount range of the laser cladding welding machine 3 is 10 mm; in the step 303, the scrubbing time is 40min, and the volume concentration of the acetone solution is 15%; standing for 4h in step 304; the moving speed of a laser cladding head 4 in the laser cladding welding machine 3 along the tooth width direction of the ith spline tooth to be welded is 8 m/min; in the alloy powder in step 401The weight percentage of each component is as follows: 0.12% of Cu, 0.27% of Mo, 2.45% of Ni, 0.3% of Mn, 19.3% of Cr, 0.4% of Co and the balance of Fe; and the particle size of the alloy powder is 53 μm; the rotational speed of the gear hobbing machine is 50r/min, and the feed speed of the gear hobbing machine is 0.3 mm/r.
The other procedures in this example were the same as in example 1.
Example 3
The cleaning time in the step one is 7min, and the tooth thickness of the spline teeth to be welded in the step two
Figure BDA0002197191810000131
4032, the lap joint rate between the upper cladding layer and the lower cladding layer is 58%; the tooth thickness D' of the ith spline tooth to be welded after cladding welding in the step 4034 meets the requirement
Figure BDA0002197191810000132
The tooth thickness of the spline teeth of the N first-time hobbing in the step 502 meets the requirement
Figure BDA0002197191810000133
The tooth thickness of the spline teeth of the N second-time hobbing in the step 503 meets the requirement
Figure BDA0002197191810000134
The tooth thickness of the spline teeth of the N third-time hobbing in the step 504 meets the requirement
Figure BDA0002197191810000135
In the step 403, the laser power of the laser cladding welding machine 3 is 3500W, the protective gas is argon, the flow range of the protective gas is 20L/min, and the spot size of the laser emitted by the laser cladding welding machine 3 is 2 mm; the welding current of the laser cladding welding machine 3 is 210A, and the defocusing amount range of the laser cladding welding machine 3 is 8 mm; in the step 303, the scrubbing time is 35min, and the volume concentration of the acetone solution is 18%; standing for 3.5h in the step 304; the moving speed of the laser cladding head 4 in the laser cladding welding machine 3 along the tooth width direction of the ith spline tooth to be welded is 7.5 m/min; the alloy powder in the step 401 comprises the following components in percentage by weight: 0.11% of Cu, 0.24% of Mo, 2.2% of Ni, 0.25% of Mn, 18% of Cr, 0.35% of Co and the balance of Fe; and the grain size of the alloy powder is 35 μm; the rotational speed of the gear hobbing machine is 48r/min, and the feed speed of the gear hobbing machine is 0.25 mm/r.
The other procedures in this example were the same as in example 1.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and all simple modifications, changes and equivalent structural changes made to the above embodiment according to the technical spirit of the present invention still fall within the protection scope of the technical solution of the present invention.

Claims (1)

1. The method for repairing the external spline of the planet carrier through laser cladding welding is characterized in that the planet carrier (1) comprises a planet carrier base (1-1), a connecting part (1-3) arranged on the planet carrier base (1-1) and an external spline (1-2) arranged at the end part of the connecting part (1-3), and comprises the following steps:
step one, cleaning a planet carrier:
a mechanical part cleaning machine is adopted, and RSB-105 low-foam alkaline metal cleaning agent is added to clean the planet carrier (1) to be repaired; wherein the cleaning time is 5 min-10 min; the outer spline (1-2) on the planet carrier (1) to be repaired comprises unworn spline teeth and worn spline teeth, the number of the unworn spline teeth is N ', the number of the worn spline teeth is N, N ' and N are positive integers, N is larger than or equal to 2, and N ' is larger than or equal to 5;
step two, primary hobbing of an external spline on the planet carrier:
hobbing a plurality of worn spline teeth on a planet carrier (1) to be repaired by using a hobbing machine to obtain spline teeth to be welded; wherein the tooth thickness of the spline tooth to be welded is denoted as D',
Figure FDA0003063913580000011
d represents the tooth thickness of the unworn spline teeth;
step three, cleaning the spline teeth to be welded:
cleaning spline teeth to be welded to obtain a planet carrier to be welded;
step four, repairing an external spline on the planet carrier:
step 401, preparing alloy powder;
402, mounting a planet carrier to be welded on a laser cladding welding machine (3);
step 403, under protective gas, respectively carrying out cladding welding on a plurality of spline teeth to be welded on the external spline (1-2) by adopting a laser cladding welding machine (3) in the same method, and carrying out cladding welding on the ith spline tooth to be welded on the external spline (1-2) by adopting the laser cladding welding machine (3), wherein the specific process is as follows:
4031, adopting a laser cladding welding machine (3), feeding alloy powder, and welding the laser cladding head (4) from one end of the ith spline tooth to be welded to the other end of the ith spline tooth to be welded along the tooth width direction of the ith spline tooth to be welded to form a previous cladding layer;
4032, a laser cladding welding machine (3) is adopted, alloy powder is fed, and a laser cladding head (4) is welded from the other end of the ith spline tooth to be welded to one end of the ith spline tooth to be welded along the tooth width direction of the ith spline tooth to be welded to form a next cladding layer; the upper cladding layer and the lower cladding layer are arranged along the tooth surface of the ith spline tooth to be welded from the tooth root to the tooth top, and the lap joint rate between the upper cladding layer and the lower cladding layer is 55-60%;
4033, repeating the 4031 and the 4032 for multiple times until the tooth surface of the ith spline tooth to be welded is completely covered to form a cladding layer;
4034, repeating the 4033 for multiple times until the thickness D' of the ith spline tooth to be welded after cladding welding meets the requirement
Figure FDA0003063913580000021
Finishing the cladding welding of the ith spline tooth to be welded;
step 4035, operating the planet carrier (1) to rotate so as to enable the external spline (1-2) on the planet carrier (1) to rotate, and cladding and welding the (i + 1) th spline tooth to be welded according to the method in the steps 4031-4034;
4036, repeating 4035 for multiple times to complete the cladding welding of the N spline teeth to be welded to obtain the external spline to be rolled; wherein i and N are positive integers, i is more than or equal to 1 and less than N, and i +1 is more than or equal to 2 and less than or equal to N;
step five, secondary gear hobbing of the external spline on the planet carrier:
step 501, according to the formula
Figure FDA0003063913580000022
Obtaining the required hobbing thickness L of the external spline to be subjected to hobbing;
step 502, respectively performing primary hobbing on the N external splines to be hobbed by using a hobbing machine to obtain N spline teeth of the primary hobbing; wherein the tooth thickness of the spline teeth of the N first-time hobbing is denoted as D1And is and
Figure FDA0003063913580000023
step 503, performing second hobbing on the spline teeth of the N first hobbings by using a hobbing machine to obtain N spline teeth of second hobbings; wherein, the tooth thickness of the spline teeth of the N second-time hobbing is marked as D2And is and
Figure FDA0003063913580000024
step 504, performing third gear hobbing on the spline teeth of the N second gear hobbing by using a gear hobbing machine to obtain N repaired spline teeth, completing the repair of the external spline (1-2), and obtaining a repaired planet carrier; wherein the tooth thickness of the spline teeth of the N third-time hobbing is denoted as D3And is and
Figure FDA0003063913580000031
in the third step, the spline teeth to be welded are cleaned in the following specific process:
step 301, polishing the spline teeth to be welded by adopting a file or a grinder to obtain polished external splines; wherein, the roughness of the tooth surface of the external spline after polishing is not more than 12.5 μm;
step 302, putting the polished external splines into purified water, brushing the splines by using a soft-bristle toothbrush, and then washing the splines three times by using the purified water;
303, dipping the glasses cloth in an acetone solution, and scrubbing the washed external spline; wherein the scrubbing time is 30-40 min, and the volume concentration of the acetone solution is 15-20%;
step 304, standing the scrubbed external spline in a room-temperature dust-free environment to obtain a planet carrier to be welded; wherein the standing time is 3-4 h;
when a laser cladding welding machine (3) is used for cladding and welding a plurality of spline teeth to be welded on the external spline (1-2) respectively in the step 403, the laser power of the laser cladding welding machine (3) is 3000W-4000W, the protective gas is argon, the flow range of the protective gas is 15L/min-25L/min, and the spot size of laser emitted by the laser cladding welding machine (3) is 1.5 mm-2.5 mm;
the welding current of the laser cladding welding machine (3) is 200A-220A, and the defocusing amount of the laser cladding welding machine (3) ranges from 5mm to 10 mm;
the moving speed of a laser cladding head (4) in the laser cladding welding machine (3) along the tooth width direction of the ith spline tooth to be welded is 7-8 m/min;
and step five, obtaining the repaired planet carrier, and then detecting the repaired planet carrier:
step A, detecting the surface hardness of the external spline on the repaired planet carrier by using a Leeb hardness tester so that the surface hardness of the external spline on the repaired planet carrier meets HRC 38-HRC 42;
b, detecting the tooth surface roughness of the external spline on the repaired planet carrier by using a roughness meter so that the tooth surface roughness of the external spline on the repaired planet carrier is not more than 3.2 mu m;
step C, according to the formula
Figure FDA0003063913580000032
Obtaining the number k of the cross measurement teeth to be confirmed; wherein alpha represents the pressure angle of the external spline (1-2) on the unworn planet carrier (1);
step D, when the span measurement tooth number is more than 0.5 and less than 2.5 to be confirmed, obtaining the final span measurement tooth number K which is 2;
when the span measurement tooth number n-0.5 is more than or equal to K and less than n +0.5 to be confirmed, obtaining the final span measurement tooth number K, and then K is equal to n; wherein n is a natural number and is more than or equal to 3;
e, clamping the first group of K spline teeth on the repaired external spline (1-2) by using a micrometer to perform one-side measurement to obtain a first common normal length W1；
Clamping a second group of K spline teeth on the repaired external spline (1-2) by using a micrometer to perform two-side measurement to obtain a second common normal length W2；
A micrometer is adopted to clamp a third group of K spline teeth on the repaired external spline (1-2) to carry out three-side measurement to obtain a third common normal length W3(ii) a The center of the first group of K spline teeth, the center of the second group of K spline teeth and the third group of K spline teeth cover the N repaired spline teeth;
step F, according to the formula
Figure FDA0003063913580000041
Obtaining the common normal line length of the external spline on the repaired planet carrier
Figure FDA0003063913580000042
So that the common normal line length of the external spline on the repaired planet carrier
Figure FDA0003063913580000043
Equal to the common normal length of the external splines on the unworn planet carrier;
the alloy powder in the step 401 comprises the following components in percentage by weight: 0.09-0.12 percent of Cu, 0.21-0.27 percent of Mo, 2.0-2.45 percent of Ni, 0.2-0.3 percent of Mn, 17.0-19.3 percent of Cr, 0.25-0.4 percent of Co and the balance of Fe; the granularity of the alloy powder is 15-53 mu m;
in the step 402, the planet carrier to be welded is arranged on a laser cladding welding machine (3), and the specific process is as follows:
a first seal plate (2-1) is arranged at one end, far away from the external spline (1-2), of the planet carrier to be welded, a second seal plate (2-2) is arranged at one end, close to the external spline (1-2), of the planet carrier to be welded, and then the planet carrier to be welded is clamped on a laser cladding welding machine (3); the four-jaw chuck (3-1) of the laser cladding welding machine (3) is clamped at one end, far away from the external spline (1-2), of the planet carrier to be welded, a tailstock center (3-2) of the laser cladding welding machine (3) is tightly pressed against the center of the end face of the second sealing plate (2-2), and a roller type supporting seat (3-3) of the laser cladding welding machine (3) is supported at the lower part of the planet carrier to be welded;
and during the first gear hobbing of the external spline on the planet carrier in the step two, the first gear hobbing in the step 501, the second gear hobbing in the step 502 and the third gear hobbing in the step 503, the rotating speed of the gear hobbing machine is 45 r/min-50 r/min, and the feeding speed of the gear hobbing machine is 0.2 mm/r-0.3 mm/r.
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