CN114799751A - Method for remanufacturing inserted cutter ring by waste smooth cutter ring - Google Patents
Method for remanufacturing inserted cutter ring by waste smooth cutter ring Download PDFInfo
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- CN114799751A CN114799751A CN202210438961.5A CN202210438961A CN114799751A CN 114799751 A CN114799751 A CN 114799751A CN 202210438961 A CN202210438961 A CN 202210438961A CN 114799751 A CN114799751 A CN 114799751A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/40—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for rings; for bearing races
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
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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
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/22—Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
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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
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/24—Ferrous alloys, e.g. steel alloys containing chromium with vanadium
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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
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/28—Ferrous alloys, e.g. steel alloys containing chromium with titanium or zirconium
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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
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/36—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.7% by weight of carbon
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- 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 belongs to the technical field of cutters for shield/TBM (tunnel boring machine), and particularly relates to a method for remanufacturing a cutter ring with inserted teeth by using a waste smooth cutter ring. The method comprises the following steps: cleaning the surface of the waste smooth cutter ring, and screening out qualified waste smooth cutter rings for remanufacturing; integrally tempering the qualified waste smooth cutter ring at high temperature; machining the appearance of the waste smooth cutter ring; preparing a wear-resistant layer on the side surface of the waste smooth cutter ring; drilling a tooth hole at the cutting edge part of the waste smooth cutter ring, wherein the size of the tooth hole reaches the final assembly size; grinding hard alloy teeth; pressing alloy teeth on the cutter ring to finish the embedding and assembling of the alloy teeth; carrying out artificial aging treatment on the cutter ring subjected to tooth pressing; and the inner hole of the cutter ring is finely processed to meet the requirement of the assembly size of the cutter body. The cutter ring with the embedded teeth remanufactured by the method has higher yield strength because the cutter ring base body is made of the die steel material used by the smooth cutter ring, thereby having better tooth fixing effect on alloy teeth and ensuring better service performance of the remanufactured cutter ring with the embedded teeth.
Description
Technical Field
The invention belongs to the technical field of cutters for shield/TBM (tunnel boring machine), and particularly relates to a method for remanufacturing a cutter ring with inserted teeth by using a waste smooth cutter ring.
Background
The cutter ring is used as a core component for rock breaking of the hob, the service limit is reached when the cutter ring is worn by 20-30 mm, the consumption is high, the cutter ring is made of expensive die steel, and the cost of a single cutter ring accounts for 1/4-1/3 of the total cost of the hob, so that the cost of the cutter ring can be reduced by recycling and remanufacturing the cutter ring. For example, chinese patent application publication No. CN 113005451 a discloses a hob remanufacturing method, which includes the following steps: step 1, carrying out sealing pressure maintaining test on the disassembled hob assembly; step 2, heating the hob assembly qualified in the sealing pressure maintaining test by adopting an induction heating mode, and separating a hob body of the hob assembly from an old cutter ring; step 3, carrying out surface treatment on the old cutter ring, and carrying out quality detection on the treated old cutter ring; step 4, preheating the outer circle edge part of the old cutter ring qualified in quality detection; step 5, cladding or surfacing metal powder on the excircle of the old cutter ring to a set size and forming a remanufactured cutter ring; step 6, carrying out heat preservation and slow cooling on the remanufactured cutter ring; and 7, assembling the remanufactured cutter ring and the cutter body by adopting a hot-pack method after the interference fit value of the diameter of the inner hole of the remanufactured cutter ring and the diameter of the outer circle surface of the cutter body meets the requirement. The invention solves the problem of waste of old cutter ring resources in the traditional cutter ring replacing process, and reduces the use cost of the hob. But this cutter ring refabrication technique is through cladding or mode such as build-up welding with plain noodles cutter ring at old and useless cutter ring surface preparation wearing layer, refabrication becomes plain noodles cutter ring, and the wearing layer thickness of nevertheless this kind of technology preparation is thinner, it is limited to compare the remanufacturing cost performance promotion, it leads to the base body to soften to make the cutter ring base member produce the heat affected zone because of heat input in the refabrication process, influence the performance of refabrication cutter ring, consequently, the popularization and application scope is limited, need for more reasonable reliable old and useless cutter ring refabrication technique urgently.
Disclosure of Invention
The invention realizes remanufacturing the waste polished cutter ring into a new inserted cutter ring and realizes the reuse of the waste cutter ring. The invention carries out heat treatment on the waste smooth cutter ring to proper hardness, finishes shape finishing and drilling by machining, and finally inlays the hard alloy teeth to finish the manufacture of the new inserted cutter ring.
The invention discloses a method for remanufacturing an inserted hob by a waste smooth cutter ring, which comprises the following steps:
step 1: cleaning the surface of the waste smooth cutter ring, and screening out qualified waste smooth cutter rings for remanufacturing;
step 2: integrally tempering the qualified waste smooth cutter ring at high temperature;
and step 3: machining the appearance of the waste smooth cutter ring;
and 4, step 4: preparing a wear-resistant layer on the side surface of the waste smooth cutter ring;
and 5: drilling holes at the cutting edge part of the waste smooth cutter ring, wherein the size of the tooth hole reaches the final assembly size;
step 6: grinding the hard alloy teeth to meet the assembly size requirement of the hard alloy teeth and the tooth holes;
and 7: pressing alloy teeth on the waste smooth cutter ring to finish the embedding and assembling of the alloy teeth;
and 8: carrying out artificial aging treatment on the cutter ring subjected to tooth pressing;
and step 9: and (4) finishing the inner hole of the cutter ring to meet the requirement of the assembly size of the cutter body, and finishing the remanufacturing of the cutter ring.
Wherein, according to the different drilling equipment that adopts, step 4-step 5 can also be changed into the following steps:
step A: performing rough drilling on the cutting edge part of the waste smooth cutter ring, wherein a certain allowance is reserved for the size of a rough drilling tooth hole compared with the size of an assembly tooth hole, namely the size of the rough drilling tooth hole is required to be smaller than the size of the assembly tooth hole by 0.25-0.5 mm on one side;
and B: preparing a wear-resistant layer on the side surface of the waste smooth cutter ring;
and C: and finely twisting the tooth holes of the cutting edge of the cutter ring to enable the size of the tooth holes to reach the final assembly size.
Wherein, the step 1 specifically comprises the following steps: and removing oil stains and iron rust on the surface of the waste smooth cutter ring by adopting modes of sand blasting, shot blasting or wire brush polishing and the like, and then screening, wherein the screening method comprises visual inspection, coloring and flaw detection and size measurement.
Screening standard: (1) performing dye penetrant inspection on the surfaces of the waste smooth cutter rings, and determining that the waste smooth cutter rings have no defects such as cracks; (2) the radius of the lowest point of the cutting edge of the waste polished cutter ring is larger than or equal to the radius of the outer circle of the remanufactured inserted cutter ring, the radius of the inner hole of the waste cutter ring is smaller than the radius of the inner hole of the remanufactured inserted cutter ring, and in order to ensure the allowance of later machining and heat treatment, the difference between the radius of the inner hole of the waste polished cutter ring and the radius of the inner hole of the remanufactured inserted cutter ring is larger than or equal to 0.5 mm; (3) and the width of the cutting edge of the waste smooth cutter ring is more than or equal to the width of the cutting edge of the remanufactured inserted cutter ring. In order to improve the efficiency, a cutter ring edge width detection clamping plate is adopted, and if the clamping plate can be completely clamped into the cutter ring edge and a gap exists on the side surface, the cutter ring edge width detection clamping plate is unqualified; if the clamping plates can not be completely clamped into the cutting edge or are not gapped after being clamped into the cutting edge, the qualification is determined. The waste smooth cutter ring meeting the standard can be remanufactured.
During screening, the large-size waste smooth cutter ring can be selected for remanufacturing the small-size inserted cutter ring, and the outer diameter size of the large-size cutter ring can still meet the outer diameter requirement of the small-size inserted cutter ring after the large-size cutter ring is worn by 20-30 mm. For example, 18 inches of waste and old smooth cutter rings can be selected for remanufacturing 17 inches of insert cutter rings, and 20 inches of waste and old smooth cutter rings can be selected for remanufacturing 19 inches of insert cutter rings.
When the radius of the inner hole of the waste smooth cutter ring, the radius of the lowest point of the cutting edge or the width of the cutting edge does not meet the size requirement, the corresponding part of the waste cutter ring can be repaired by a laser cladding process. The cladding powder is atomized H13 steel powder with the granularity of 100-250 mu m, the cutter ring is preheated to 250-450 ℃ by a heating furnace or a resistance wire heating belt before laser cladding, cladding is carried out after heat preservation is carried out for 2-3H, and the cutter ring is directly placed into the heating furnace after cladding is finished, is subjected to heat preservation for 2-5H at 200-300 ℃ and then is cooled along with the furnace. By adopting the method, the unqualified cutter ring can meet the size requirement so as to improve the utilization rate of the waste smooth cutter ring, and then the subsequent remanufacturing step is carried out.
The step 2 specifically comprises the following steps: and (3) tempering the waste smooth cutter ring at high temperature in a heating furnace, setting the tempering temperature to be 500-650 ℃, the heating speed to be less than 60 ℃/h and the heat preservation time to be 2-6 h according to different materials of the waste smooth cutter ring, and then discharging and air cooling. And (4) measuring the hardness of the cutter ring after tempering, and controlling the hardness of the cutter ring within the range of 45-55 HRC. The purpose of the step is as follows: the hardness of the abandoned smooth cutter ring is generally 55-64 HRC, the hardness is high, the later-stage machining is not facilitated, the hardness of the cutter ring is reduced by adopting high-temperature tempering, and the later-stage machining is facilitated. Meanwhile, the hardness of the waste cutter ring is reduced, so that the toughness of the remanufactured inserted cutter ring is guaranteed, and cracking is avoided.
The step 3 specifically comprises the following steps: adopt equipment processing cutter ring blade and side such as lathe, detect the cardboard inspection with the cutter ring blade width after the processing is accomplished, guarantee that cutter ring outline and detection cardboard closely laminate.
The step 4 specifically comprises the following steps: carrying out laser cladding or plasma cladding on the side face of the cutter ring by using wear-resistant powder, preheating the cutter ring at 250-450 ℃ before cladding, carrying out cladding after heat preservation for 2-3 h, carrying out heat preservation and slow cooling by using a heating furnace or asbestos-wrapped modes after cladding, ensuring that the cooling speed is less than 40 ℃/h, and avoiding cracking and peeling of the cladding layer and even pulling damage to the cutter ring matrix caused by too high cooling speed. The wear-resistant powder comprises the following raw materials in percentage by mass: cr 10-20%, Ti 20-30%, C1-4%, and Fe in balance, and a small amount of elements V, W, Mo and the like can be additionally added to further improve the service performance of the powder.
And step 5 and step 6 both adopt conventional drilling and grinding processes, and because the alloy teeth are embedded into the tooth holes by adopting an interference cold embedding process, the interference magnitude between the tooth holes and the alloy teeth is strictly ensured to be 0.02-0.10 mm, and the tooth fixing effect of the base body on the alloy teeth is improved as much as possible on the premise of avoiding the cracking of the tooth holes.
The step 7 specifically comprises the following steps: and pressing the alloy teeth into the tooth holes by adopting a press. In order to ensure the consistency and accuracy of the alloy tooth embedding, the plastic deformation of the edge of the tooth hole caused by the misalignment of the alloy tooth and the tooth hole is avoided, and further the tooth fixing effect is influenced, and the auxiliary guide tool can be adopted for tooth embedding. Before the teeth are inlaid, the guide tool is aligned with the tooth holes, and then the alloy teeth are placed into the guide tool and pressed in by a press.
The step 8 specifically comprises the following steps: after the alloy teeth are pressed and assembled, due to the fact that interference assembly is adopted, large stress exists around the tooth holes, manual aging treatment is needed to be conducted to eliminate stress so as to avoid tooth hole cracking, the aging treatment is conducted in a heating furnace at the temperature of 200-280 ℃, the heat preservation time is 2-8 hours, and the alloy teeth are discharged from the furnace and cooled in air.
The step 9 specifically comprises the following steps: and (3) finishing the inner hole of the cutter ring, ensuring that the size of the inner hole meets the technical requirement of the size of the inner hole of the remanufactured cutter ring designed by a drawing, and finishing remanufacturing the inserted cutter ring by using the waste smooth cutter ring.
Interpretation of terms: the smooth cutter ring is a cutting edge prepared by adopting die steel and a cutter ring without being embedded with hard alloy or coated with a wear-resistant layer on the side surface.
The invention has the beneficial effects that:
the method for remanufacturing the cutter ring with the inserted teeth is easy to realize, the waste smooth cutter ring products are remanufactured into new cutter ring products with the inserted teeth, the waste components are recycled, the problem of die steel waste caused by direct waste of a large number of waste smooth cutter rings in the tunnel construction process is solved, the efficient recycling of the waste components is realized, the cutter cost in the tunnel construction is reduced, and the low-carbon and green development requirements are met.
The cutter ring with the embedded teeth remanufactured by the method has the advantages that the cutter ring base body is made of die steel materials used by the smooth cutter ring, and the yield strength of the cutter ring base body is higher, so that the tooth fixing effect on alloy teeth is better, and the looseness and falling off of the alloy teeth are avoided; and the wear resistance of the die steel is obviously superior to that of the alloy structural steel, so that the more excellent service performance of the remanufactured inserted cutter ring is ensured.
Drawings
Fig. 1 shows a process of remanufacturing an insert cutter ring from a waste plain cutter ring in embodiment 1.
Fig. 2 is a schematic structural diagram of a waste smooth cutter ring.
FIG. 3 is a schematic diagram of a remanufactured cutting insert ring.
FIG. 4 is a diagram of a waste smooth surface cutter ring edge width detection clamping plate and a standard determination diagram.
Fig. 5 is a schematic view of the guide auxiliary pressing tooth.
Fig. 6 shows the use of a conventional cutting insert in a 34m cut.
Fig. 7 shows the use of the remanufactured insert ring at 176m penetration.
In the attached drawing, 1 is a waste smooth cutter ring matrix, 2 is alloy teeth, 3 is a wear part, 4 is a cutter ring edge width detection clamping plate, 5 is a guide cylinder, and 6 is a wear-resistant layer.
Detailed Description
The present invention will be described in more detail with reference to the following embodiments for understanding the technical solutions of the present invention, but the present invention is not limited to the scope of the present invention.
Example 1
As shown in fig. 1, a method for remanufacturing an inserted cutter ring from a waste smooth cutter ring comprises the following steps:
step 1: cleaning the surface of the waste smooth cutter ring, and screening out qualified cutter rings for remanufacturing;
specifically, this embodiment is to old and useless 18 inches 5Cr5MoSiV1 material plain noodles cutter ring sandblast or polish the processing, removes surface greasy dirt and iron rust. The structure of the waste plain cutter ring is shown in figure 2. Selecting a cutter ring without fracture and edge breakage by adopting a visual method; adopting dye penetrant inspection to determine that the cutter ring has no defects such as cracks; adopting a cutter ring edge width detection clamping plate to detect the width of the cutting edge of the waste smooth cutter ring, and screening out cutter rings with no gap after the clamping plates can not be completely clamped into the cutting edge or clamped into the cutting edge, as shown in figure 4; measuring the size of an inner hole of the waste smooth cutter ring and the radius of the lowest point of the cutting edge of the waste smooth cutter ring, determining that the diameter of the inner hole of the waste smooth cutter ring is smaller than the diameter of the inner hole of the remanufactured insert cutter ring, wherein the difference between the radius of the inner hole of the waste smooth cutter ring and the radius of the inner hole of the remanufactured insert cutter ring is not less than 0.5mm, and the radius of the lowest point of the cutting edge of the waste smooth cutter ring is not less than the outer radius of the remanufactured insert cutter ring. When the radius of an inner hole of the waste smooth cutter ring, the radius of the lowest point of the cutting edge or the width of the cutting edge does not meet the size requirement, repairing the corresponding part by adopting a laser cladding process, wherein cladding powder is H13 atomized powder with the particle size of 100-250 mu m, heating the cutter ring to 270 ℃ before cladding, preserving heat for 2H, cladding, ensuring that the size of the relevant part meets the requirement, putting the waste cutter ring into a heating furnace after cladding, preserving heat for 3H at 220 ℃, and cooling along with the furnace.
The remanufacturing of the 17-inch inserted cutter ring is carried out on the waste polished cutter ring qualified by the standard screening, and the structure of the remanufactured inserted cutter ring is shown in figure 3.
Step 2: integrally tempering the qualified waste smooth cutter ring at high temperature;
specifically, the selected 18-inch waste 5Cr5MoSiV1 smooth cutter ring is tempered at high temperature, wherein the tempering temperature is 570-590 ℃, the temperature rise speed is less than 60 ℃/h, the heat preservation time is 4h, and then the cutter ring is discharged from a furnace and cooled in air. And measuring the hardness of the cutter ring after cooling to enable the hardness to be 49-52 HRC.
And step 3: machining the appearance of the waste smooth cutter ring;
specifically, adopt equipment processing cutter ring blade and side such as lathe, detect the cardboard inspection with the cutter ring blade width after the processing is accomplished, guarantee that the cutter ring outline closely laminates with detecting the cardboard.
And 4, step 4: preparing a wear-resistant layer on the side surface of the cutter ring;
specifically, the wear-resistant powder prepared by mixing 15% of chromium powder, 3% of graphite powder, 20% of titanium powder and 62% of nickel powder in percentage by mass is subjected to laser cladding on the side face of the cutter ring, the cutter ring is preheated at 290 ℃ before cladding, cladding is carried out after heat preservation is carried out for 2 hours, heat preservation is carried out in a heating furnace after cladding, the temperature is 200 ℃, heat preservation is carried out for 4 hours, and then furnace cooling is carried out.
And 5: drilling a hole at the cutting edge of the cutter ring, ensuring the fineness of a tooth hole, measuring the size of the tooth hole, and enabling the size of the tooth hole to reach the final assembly size;
step 6: grinding the hard alloy teeth to meet the assembly size requirement of the hard alloy teeth and the tooth holes;
specifically, a centerless grinder is adopted to grind the hard alloy teeth, the interference magnitude is selected to be 0.07mm according to the measured tooth hole size, and the final grinding size of the alloy teeth is determined and the alloy teeth are ground in place.
And 7: pressing alloy teeth on the cutter ring to finish the embedding and assembling of the alloy teeth;
specifically, an auxiliary guiding tool is adopted for inlaying the teeth, the guiding tool is aligned with the tooth holes before the teeth are inlaid, then the alloy teeth are placed into the guiding tool and pressed in by a press, and the inlaying is guaranteed to be in place, as shown in fig. 5.
And 8: carrying out artificial aging treatment on the cutter ring subjected to tooth pressing;
specifically, the remanufactured cutter ring after the tooth embedding is placed into a heating furnace, and the temperature is kept at 220 ℃ for 4 hours, and then the cutter ring is discharged from the furnace for air cooling.
And step 9: and (4) finishing the inner hole of the cutter ring to meet the requirement of the assembly size of the cutter body, and finishing the remanufacturing of the cutter ring.
Specifically, the inner hole of the remanufactured 17-inch inserted cutter ring is subjected to finish machining according to the design requirements of a drawing, and the remanufacturing process of the 18-inch waste polished cutter ring is completed.
Example 2
A method for remanufacturing an inserted cutter ring from a waste smooth cutter ring comprises the following steps:
step 1: cleaning the surface of the waste smooth cutter ring, and screening out qualified cutter rings for remanufacturing;
specifically, this embodiment is to old and useless 18 inches 5Cr5MoSiV1 material plain noodles cutter ring sandblast or polish the processing, removes surface greasy dirt and iron rust. Selecting a cutter ring without fracture and edge breakage by adopting a visual method; adopting dye penetrant inspection to determine that the cutter ring has no defects such as cracks; adopting a cutter ring edge width detection clamping plate to detect the width of the cutting edge of the waste smooth cutter ring, and screening out cutter rings with no gap after the clamping plates can not be completely clamped into the cutting edge or clamped into the cutting edge; measuring the size of an inner hole of the waste smooth cutter ring and the radius of the lowest point of the cutting edge of the waste smooth cutter ring, determining that the diameter of the inner hole of the waste smooth cutter ring is smaller than the diameter of the inner hole of the remanufactured insert cutter ring, wherein the difference between the radius of the inner hole of the waste smooth cutter ring and the radius of the inner hole of the remanufactured insert cutter ring is not less than 0.5mm, and the radius of the lowest point of the cutting edge of the waste smooth cutter ring is not less than the outer radius of the remanufactured insert cutter ring. When the radius of an inner hole of the waste smooth cutter ring, the radius of the lowest point of the cutting edge or the width of the cutting edge does not meet the size requirement, repairing the corresponding part by adopting a laser cladding process, wherein cladding powder is H13 atomized powder with the particle size of 100-250 mu m, heating the cutter ring to 270 ℃ before cladding, preserving heat for 2H, cladding, ensuring that the size of the relevant part meets the size requirement, putting the waste cutter ring into a heating furnace after cladding, preserving heat for 3H at 220 ℃, and cooling along with the furnace.
And (4) remanufacturing the 17-inch inserted cutter ring by using the waste polished cutter ring qualified by the standard screening.
And 2, step: integrally tempering the qualified waste smooth cutter ring at high temperature;
specifically, the selected 18-inch waste 5Cr5MoSiV1 smooth cutter ring is tempered at high temperature, wherein the tempering temperature is 570-590 ℃, the temperature rise speed is less than 60 ℃/h, the heat preservation time is 4h, and then the cutter ring is discharged from a furnace and cooled in air. And measuring the hardness of the cutter ring after cooling to enable the hardness to be 49-52 HRC.
And step 3: machining the appearance of the waste smooth cutter ring;
specifically, adopt equipment processing cutter ring blade and side such as lathe, detect the cardboard inspection with the cutter ring blade width after the processing is accomplished, guarantee that the cutter ring outline closely laminates with detecting the cardboard.
And 4, step 4: performing rough drilling of a tooth hole at the cutting edge of the cutter ring, wherein a certain allowance is reserved in the size of the rough drilling compared with the assembly size;
specifically, a drilling machine is used for roughly drilling at the cutting edge of the cutter ring, wherein the size of a tooth hole of the roughly drilled cutter ring is 0.25-0.5 mm smaller than the size of the final size of a drawing.
And 5: preparing a wear-resistant layer on the side surface of the cutter ring;
specifically, wear-resistant powder prepared by mixing 15% of chromium powder, 3% of graphite powder, 20% of titanium powder and 62% of nickel powder in percentage by mass is subjected to laser cladding on the side face of a cutter ring, the cutter ring is preheated at 290 ℃ before cladding, cladding is carried out after heat preservation is carried out for 2 hours, heat preservation is carried out in a heating furnace after cladding, the temperature is 200 ℃, heat preservation is carried out for 4 hours, and then furnace cooling is carried out.
Step 6: and (3) finely reaming the rough drilled toothed hole by adopting a reamer to meet the final size requirement of the drawing, ensuring the fineness of the toothed hole, and measuring the size of the toothed hole to enable the size of the toothed hole to reach the final assembly size.
And 7: grinding the hard alloy teeth to meet the assembly size requirement of the hard alloy teeth and the tooth holes;
specifically, a centerless grinder is adopted to grind the hard alloy teeth, the interference magnitude is selected to be 0.07mm according to the measured tooth hole size, and the final grinding size of the alloy teeth is determined and the alloy teeth are ground in place.
And 8: pressing alloy teeth on the cutter ring to finish the embedding and assembling of the alloy teeth;
specifically, the auxiliary guiding tool is adopted for inlaying teeth, the guiding tool is aligned with the tooth holes before the teeth are inlaid, then the alloy teeth are placed into the guiding tool and pressed in by a press, and the inlaying is guaranteed to be in place.
And step 9: carrying out artificial aging treatment on the cutter ring subjected to tooth pressing;
specifically, the remanufactured cutter ring after the tooth embedding is placed into a heating furnace, and the temperature is kept at 220 ℃ for 4 hours, and then the cutter ring is discharged from the furnace for air cooling.
Step 10: and (4) finishing the inner hole of the cutter ring to meet the requirement of the assembly size of the cutter body, and finishing the remanufacturing of the cutter ring.
Specifically, the inner hole of the remanufactured 17-inch inserted cutter ring is subjected to finish machining according to the design requirements of a drawing, and the remanufacturing process of the 18-inch waste polished cutter ring is completed.
Example 3
A method for remanufacturing an inserted cutter ring from a waste smooth cutter ring comprises the following steps:
step 1: cleaning the surface of the waste smooth cutter ring, and screening out qualified cutter rings for remanufacturing;
specifically, this embodiment is to the old and useless 20 cun Cr8Mo2VSi material plain noodles cutter ring of on-the-spot sandblast or the processing of polishing, gets rid of surface greasy dirt and iron rust. Selecting a cutter ring without fracture and edge breakage by adopting a visual method; adopting dye penetrant inspection to determine that the cutter ring has no defects such as cracks; adopting a cutter ring edge width detection clamping plate to detect the width of the cutting edge of the waste smooth cutter ring, and screening out cutter rings with no gaps after the clamping plates can not be completely clamped into the cutting edge or clamped into the cutting edge; measuring the size of an inner hole of the waste smooth cutter ring and the radius of the lowest point of the cutting edge of the waste smooth cutter ring, determining that the diameter of the inner hole of the waste smooth cutter ring is smaller than the diameter of the inner hole of the remanufactured insert cutter ring, wherein the difference between the radius of the inner hole of the waste smooth cutter ring and the radius of the inner hole of the remanufactured insert cutter ring is not less than 0.5mm, and the radius of the lowest point of the cutting edge of the waste smooth cutter ring is not less than the outer radius of the remanufactured insert cutter ring. When the radius of an inner hole of the waste smooth cutter ring, the radius of the lowest point of the cutting edge or the width of the cutting edge does not meet the size requirement, repairing the corresponding part by adopting a laser cladding process, wherein the cladding powder is H13 atomized powder with the particle size of 100-250 mu m, heating the cutter ring to 290 ℃ before cladding, preserving heat for 2H, cladding, ensuring that the size of the relevant part meets the size requirement, putting the waste cutter ring into a heating furnace after cladding, preserving heat for 3H at 250 ℃, and cooling along with the furnace.
And (4) remanufacturing the 19-inch inserted cutter ring by using the cutter ring qualified by the standard screening.
And 2, step: integrally tempering the qualified waste smooth cutter ring at high temperature;
specifically, the selected 20-inch waste Cr8Mo2VSi smooth cutter ring is tempered at high temperature, wherein the tempering temperature is 600-630 ℃, the temperature rise speed is less than 60 ℃/h, the heat preservation time is 4h, and then the cutter ring is discharged from a furnace and cooled in air. And measuring the hardness of the cutter ring after cooling to enable the hardness to be 49-52 HRC.
And step 3: machining the appearance of the waste smooth cutter ring;
specifically, adopt equipment processing cutter ring blade and side such as lathe, detect the cardboard inspection with the cutter ring blade width after the processing is accomplished, guarantee that the cutter ring outline closely laminates with detecting the cardboard.
And 4, step 4: preparing a wear-resistant layer on the side surface of the cutter ring;
specifically, wear-resistant powder prepared by mixing 20% of chromium powder, 4% of graphite powder, 25% of titanium powder and 51% of nickel powder in percentage by mass is subjected to laser cladding on the side face of a cutter ring, the cutter ring is preheated at 300 ℃ before cladding, cladding is carried out after heat preservation is carried out for 2 hours, heat preservation is carried out in a heating furnace after cladding, the temperature is 250 ℃, the heat preservation is carried out for 4 hours, and then furnace cooling is carried out.
And 5: drilling a hole at the cutting edge of the cutter ring, ensuring the fineness of a tooth hole, measuring the size of the tooth hole, and enabling the size of the tooth hole to reach the final assembly size;
step 6: grinding the hard alloy teeth to meet the assembly size requirement of the hard alloy teeth and the tooth holes;
specifically, a centerless grinder is used for grinding the hard alloy teeth, the interference magnitude is selected to be 0.03mm according to the measured tooth hole size, the final grinding size of the alloy teeth is determined, and the alloy teeth are ground in place.
And 7: pressing alloy teeth on the cutter ring to finish the embedding and assembling of the alloy teeth;
specifically, the auxiliary guiding tool is adopted for inlaying teeth, the guiding tool is aligned with the tooth holes before the teeth are inlaid, then the alloy teeth are placed into the guiding tool and pressed in by a press, and the inlaying is guaranteed to be in place.
And 8: carrying out artificial aging treatment on the cutter ring subjected to tooth pressing;
specifically, the remanufactured cutter ring after the tooth embedding is placed into a heating furnace, and the temperature is kept at 220 ℃ for 4 hours, and then the cutter ring is discharged from the furnace for air cooling.
And step 9: and (4) finishing the inner hole of the cutter ring to meet the requirement of the assembly size of the cutter body, and finishing the remanufacturing of the cutter ring.
Specifically, the inner hole of the remanufactured 19-inch inserted cutter ring is subjected to finish machining according to the design requirements of a drawing, and the remanufacturing process of the 20-inch waste polished cutter ring is completed.
Application examples
The conventional inserted cutter ring and the inserted cutter ring remanufactured by adopting the embodiment 2 are used for a certain hard rock TBM water diversion tunnel project in Zhejiang, the formation lithology is tuff about 100MPa, and the phenomena of loosening and falling off of alloy teeth occur when the conventional inserted cutter ring is tunneled for 34m in the using process, as shown in figure 6. When the remanufactured insert cutter ring is continuously tunneled for 176m, the problems of loosening and falling off of alloy teeth still do not occur, the abrasion loss of the cutter ring base body is small, and excellent service performance is shown as shown in figure 7. The inserted cutter ring remanufactured by the method obviously widens the application range of the inserted cutter ring and realizes the successful application of the inserted cutter ring in a hard rock stratum.
The above-described embodiments are merely preferred embodiments of the present invention, and not intended to limit the scope of the invention, so that equivalent changes or modifications in the structure, features and principles described in the present invention should be included in the claims of the present invention.
Claims (10)
1. A method for remanufacturing an inserted cutter ring from a waste smooth cutter ring is characterized by comprising the following steps:
step 1: cleaning the surface of the waste smooth cutter ring, and screening out qualified waste smooth cutter rings for remanufacturing;
step 2: integrally tempering the qualified waste smooth cutter ring at high temperature;
and step 3: machining the appearance of the waste smooth cutter ring;
and 4, step 4: preparing a wear-resistant layer on the side surface of the waste smooth cutter ring;
and 5: drilling a tooth hole at the cutting edge part of the waste smooth cutter ring, wherein the size of the tooth hole reaches the final assembly size;
step 6: grinding the hard alloy teeth to meet the assembly size requirement of the hard alloy teeth and the tooth holes;
and 7: pressing the alloy teeth prepared in the step 6 on the cutter ring obtained in the step 5 to finish the embedding and assembling of the alloy teeth;
and 8: carrying out artificial aging treatment on the cutter ring subjected to tooth pressing;
and step 9: and (3) finishing the inner hole of the cutter ring to meet the requirement on the assembly size of the cutter body, and finishing the remanufacturing of the cutter ring.
2. The method for remanufacturing an inserted cutter ring from a waste plain cutter ring according to claim 1, wherein the following steps are performed after the step 3:
step A: performing rough drilling on the cutting edge part of the waste smooth cutter ring, wherein the size of a rough drilled tooth hole is 0.25-0.5 mm smaller than that of an assembly tooth hole on one side;
and B: preparing a wear-resistant layer on the side surface of the waste smooth cutter ring;
and C: finely twisting the tooth holes of the cutting edges of the waste smooth cutter rings to enable the size of the tooth holes to reach the final assembly size;
then step 6 is performed.
3. The method for remanufacturing an inserted cutter ring from a waste smooth cutter ring according to claim 1 or 2, wherein the step 1 is specifically as follows: removing oil stains and iron rust on the surface of the waste smooth cutter ring by adopting a sand blasting, shot blasting or wire brush polishing mode, and then screening, wherein the screening method comprises visual inspection, coloring and flaw detection and size measurement;
the screening criteria were:
(1) performing dye penetrant inspection on the surfaces of the waste smooth cutter rings, and determining that the waste smooth cutter rings have no crack defects;
(2) the radius of the lowest point of the cutting edge of the waste smooth cutter ring is larger than or equal to the outer circle radius of the remanufactured inserted cutter ring, the radius of an inner hole of the waste smooth cutter ring is smaller than the radius of an inner hole of the remanufactured inserted cutter ring, and the difference between the radius of the inner hole of the waste smooth cutter ring and the radius of the inner hole of the remanufactured inserted cutter ring is larger than or equal to 0.5 mm;
(3) the width of the cutting edge of the waste smooth cutter ring is more than or equal to that of the cutting edge of the remanufactured inserted cutter ring.
4. The method for remanufacturing the cutter ring with the inserted teeth from the waste smooth cutter ring according to claim 3, wherein when the radius of the inner hole of the waste smooth cutter ring, the radius of the lowest point of the cutting edge or the width of the cutting edge does not meet the size requirement, the corresponding part of the waste smooth cutter ring is repaired by a laser cladding process; the cladding powder is atomized H13 steel powder with the granularity of 100-250 mu m, the waste smooth cutter ring is preheated to 250-450 ℃ before laser cladding, cladding is carried out after heat preservation is carried out for 2-3H, and the waste smooth cutter ring is directly cooled after heat preservation is carried out for 2-5H at 200-300 ℃ after cladding is finished.
5. The method for remanufacturing an inserted cutter ring from a waste smooth cutter ring according to claim 1 or 2, wherein the step 2 specifically comprises: performing high-temperature tempering on the waste smooth cutter ring, wherein the tempering temperature is 500-650 ℃, the temperature rise speed is less than 60 ℃/h, the heat preservation time is 2-6 h, and then performing air cooling; and (4) measuring the hardness of the cutter ring after tempering, and controlling the hardness of the cutter ring within the range of 45-55 HRC.
6. The method for remanufacturing the inserted cutter ring from the waste plain cutter ring according to claim 1 or 2, wherein the step 3 is specifically as follows: and (3) processing the cutting edge and the side face of the waste smooth cutter ring, and detecting the width of the waste smooth cutter ring after the processing is finished, so as to ensure that the outer contour of the waste smooth cutter ring meets the requirement of the inserted cutter ring.
7. The method for remanufacturing an inserted cutter ring from a waste smooth cutter ring according to claim 1 or 2, wherein the step 4 specifically comprises: carrying out laser cladding or plasma cladding on the side surface of the waste smooth cutter ring by using wear-resistant powder, preheating the cutter ring at 250-450 ℃ before cladding, carrying out cladding after heat preservation for 2-3 h, carrying out heat preservation and slow cooling at 200-250 ℃ after cladding, and ensuring that the cooling speed is less than 40 ℃/h.
8. The method for remanufacturing an inserted cutter ring from a waste smooth cutter ring according to claim 1 or 2, wherein the interference between the tooth holes and the alloy teeth is 0.02-0.10 mm.
9. The method for remanufacturing the cutter ring with the inserted teeth from the waste smooth cutter ring according to claim 1 or 2, wherein in the step 8, the aging treatment temperature is 200-280 ℃, the heat preservation time is 2-8 hours, and then air cooling is carried out.
10. The method for remanufacturing an inserted cutter ring from a waste smooth cutter ring according to claim 1 or 2, wherein the step 9 is specifically as follows: and (3) finishing the inner hole of the cutter ring to ensure that the size of the inner hole meets the size requirement of the inner hole of the remanufactured inserted cutter ring, and finishing remanufacturing the inserted cutter ring by using the waste smooth cutter ring.
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| CN202210438961.5A CN114799751B (en) | 2022-04-25 | 2022-04-25 | Method for remanufacturing cutter ring with tooth insert through waste smooth cutter ring |
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| JP2008260123A (en) * | 2007-04-12 | 2008-10-30 | Tera Autotech Corp | Recycling manufacturing method of fitting type microscopic bit |
| CN101633110A (en) * | 2008-10-21 | 2010-01-27 | 洛阳九久技术开发有限公司 | Cutter ring manufacturing process |
| CN105154876A (en) * | 2015-09-22 | 2015-12-16 | 中国兵器科学研究院宁波分院 | Waste cast steel travelling wheel remanufacturing method |
| CN109517966A (en) * | 2019-01-15 | 2019-03-26 | 常德市中天精密工具有限公司 | A kind of heat treatment method of break bar cutter ring |
| CN112696204A (en) * | 2021-02-03 | 2021-04-23 | 洛阳九久科技股份有限公司 | Rhombic cap-shaped tooth cutter ring and manufacturing process thereof |
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Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2008260123A (en) * | 2007-04-12 | 2008-10-30 | Tera Autotech Corp | Recycling manufacturing method of fitting type microscopic bit |
| CN101633110A (en) * | 2008-10-21 | 2010-01-27 | 洛阳九久技术开发有限公司 | Cutter ring manufacturing process |
| CN105154876A (en) * | 2015-09-22 | 2015-12-16 | 中国兵器科学研究院宁波分院 | Waste cast steel travelling wheel remanufacturing method |
| CN109517966A (en) * | 2019-01-15 | 2019-03-26 | 常德市中天精密工具有限公司 | A kind of heat treatment method of break bar cutter ring |
| CN112696204A (en) * | 2021-02-03 | 2021-04-23 | 洛阳九久科技股份有限公司 | Rhombic cap-shaped tooth cutter ring and manufacturing process thereof |
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| CN114799751B (en) | 2023-07-07 |
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