CN115226515A - 一种锯链刀齿及制备工艺 - Google Patents
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Abstract
一种锯链刀齿,包括锯链本体及与锯链本体连接的若干刀齿,刀齿的刃部包括基体以及设于基体外的阶梯性强化单元,阶梯性强化单元包括从内到外依次设置的若干硬度逐渐升高的强化层,若干强化层的硬度梯度排布满足于:能够在使用过程中使刃部具备自锐利能力。一种锯链刀齿的制备工艺,包括在刀齿刃部的基体外镀制若干从内到外硬度逐渐增加的强化层的步骤。本发明涉及锯链技术领域,通过梯度硬度的设计方法,将刀齿刃部硬度从外表面到基体逐次下降,使刀齿刃部在工作过程中具有自锐利能力,从而延长锋利保持期,提高切削效率。
Description
技术领域
本发明属于锯链技术领域,具体涉及一种锯链刀齿及制备工艺。
背景技术
随着世界园林行业的发展,市场上对锯链的需求一直增长。受锯链工作环境和使用工况影响,为保持高的切削效率,需要定期对锯链进行磨刃维护,使锯链刀齿一直保持在锋利状态。但刀齿磨刃就需要将链条从油锯设备上拆下,然后再使用专用锉刀进行磨刃,这就极大影响了工作效率。工人们为避免出现这种情况,在进山作业时会提前多备链条,一段时间后带下山集中维护。这样就节省了维护时间,但仍然存在磨刃过于频繁造成的时间浪费,以及携带过多备用链条上下山造成的不便。
解决上述问题的方法就是延长锯链刀齿的锋利保持期,这跟刀齿刃部的硬度和耐磨性有关。传统技术方案都是采用在刀齿刃部镀硬Cr的方式来提高刀齿刃部耐磨性,但在市场使用过程中仍然存在磨刃过于频繁的反馈。
发明内容
为克服现有技术的不足,本发明公开了一种锯链刀齿及制备工艺,该锯链刀齿通过梯度硬度的设计方法,将刀齿刃部硬度从外表面到基体逐次下降,使刀齿刃部在工作过程中具有自锐利能力,即在切削工作中刃部可以自行磨锐,从而延长锋利保持期,提高切削效率。
为实现上述目的,本发明的技术方案是:
一种锯链刀齿,包括锯链本体及与锯链本体连接的若干刀齿,所述的刀齿的刃部包括基体以及设于基体外的阶梯性强化单元,所述的阶梯性强化单元包括从内到外依次设置的若干硬度逐渐升高的强化层,所述的强化层由金属表面强化工艺制成,若干强化层的硬度梯度排布满足于:能够在使用过程中使刃部具备自锐利能力。
优选的,所述的强化层的数量为若干个,最接近基体的强化层的硬度大于基体的硬度。
优选的,相邻强化层之间的硬度梯度在1000HV以下。
优选的,所述的强化层为Cr镀层或者Ti镀层或者Cr与Ti相结合的镀层或者其他金属的复合强化层或者金属基陶瓷复合涂层。
一种锯链刀齿的制备工艺,包括在刀齿刃部的基体外镀制若干从内到外硬度逐渐增加的强化层的步骤,在镀制过程中,使与基体邻近的强化层的硬度大于基体的硬度,各个强化层的硬度梯度排布满足于:能够在使用过程中使刀齿刃部具备自锐利能力。
优选的,在镀制强化层之前,对基体外表面进行表面淬火处理,淬硬层厚度为基体厚度的30%以内。
优选的,在镀制强化层之前,对基体外表面进行喷砂处理。
优选的,在强化层制备过程中,使相邻强化层之间的硬度梯度小于1000HV。
优选的,刀齿的整体热处理工艺选用普通淬回火工艺或等温淬回火工艺,刀齿整体热处理后制备强化层。
优选的,表面淬火工艺为激光表面淬火或者高频淬火或者其他表面淬火工艺。
优选的,所述的强化层可选用物理气相沉积或者化学气相沉积制备工艺。
本发明一种锯链刀齿及制备工艺的有益效果为:本发明通过梯度硬度的设计方法,将刀齿刃部硬度从外表面到基体逐次下降,使刀齿刃部在工作过程中具有自锐利能力,即在切削工作中刃部可以自行磨锐,从而延长锋利保持期,提高切削效率。
附图说明
图1:刀齿刃部示意图(A所在区域为刃部);
图2:硬度梯度分布示意图;
图3:锯切效率变化曲线;
1:刃部的上部,2:刃部的中部,3:刃部的下部,4:最表面强化层,5:中间强化层,6:基体。
具体实施方式
以下所述,仅为本发明的较佳实施例而已,并非用于限定本发明的保护范围,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
实施例1:
一种锯链刀齿,如图1、2所示,包括锯链本体及与锯链本体连接的若干刀齿,所述的刀齿的刃部,即图1中A所在区域,结合图2所示,刃部包括基体以及设于基体外的阶梯性强化单元,所述的阶梯性强化单元包括从内到外依次设置的若干硬度逐渐升高的强化层,所述的强化层由金属表面强化工艺制成,若干强化层的硬度梯度排布满足于:能够在使用过程中使刀齿刃部具备自锐利能力。
如图2所示,所述的强化层的数量为2个,即中间强化层5及最表面强化层4。当然,也可以根据需要将强化层设置为3或4个或者设置为4个以上,注意,最接近基体的强化层的硬度应大于基体的硬度。
如图2所示,相邻强化层之间的硬度梯度在1000HV以下,目的是为了降低相邻强化层之间应力差异、降低裂纹敏感度、提高结合强度,同时如此阶梯性设置,可以使刀齿在与物料磨损时使硬度低的强化层先磨损,硬度稍高的邻近强化层后磨损,以此类推,通过阶梯性的磨损,可以使刀齿整体实现自锐利能力。当然,由于链齿的使用情境较多,在特殊情况下也可以使相邻强化层之间的硬度梯度超过1000HV。
如图1、2所示,所述的强化层为Cr镀层或者Ti镀层或者Cr与Ti相结合的镀层或者其他金属的复合镀层或者金属基陶瓷复合涂层。当然,根据需要也可以选取其他金属表面强化工艺制成的强化层。
实施例2、
在实施例1的基础上,本实施例进一步公开了:
一种锯链刀齿的制备工艺,如图1-3所示,包括在刀齿刃部的基体外镀制若干从内到外硬度逐渐增加的强化层的步骤,在镀制过程中,使与基体邻近的强化层的硬度大于基体的硬度,各个强化层的硬度梯度排布满足于:能够在使用过程中使刀齿刃部具备自锐利能力。
如图2所示,在镀制强化层之前,对基体外表面进行表面淬火处理,淬硬层厚度为基体厚度的30%以内。
如图2所示,在镀制强化层之前,为提高基体与外来强化层的结合强度,对刀齿的基体外表面进行喷砂处理。
如图2所示,在强化层制备过程中,使相邻强化层之间的硬度梯度小于1000HV。
如图1、2所示,刀齿的整体热处理工艺选用普通淬回火工艺或等温淬回火工艺,刀齿整体热处理后制备强化层。以刀齿选用68CrNiMo材质为例,经过热处理后的刀齿整体硬度应在50-57HRC之间。
表面淬火工艺为激光表面淬火或者高频淬火或者其他表面淬火工艺。
如图2所示,所述的强化层选用物理气相沉积或者化学气相沉积制备工艺。例如选用磁控溅射制备TiN薄膜,其硬度可达2000HV以上。
实施例3:
图1中区域A为所说刀齿刃部,在刀齿切削木材时,刃部整体与木材接触,因为刃部的上部1、刃部的中部2两个区域直接参与木材纤维的横向切断和纵向切断,所以这两个区域磨损最为严重。
为使刃部可以保持较长的锋利保持期,对刀齿刃部表面进行了硬度梯度处理,以2个强化层为例,硬度梯度分布如图2所示,最表面强化层4、中间强化层5、基体6的硬度阶梯下降。
下面以68CrNiMo材质锯链刀齿为例,对刀齿处理方式和硬度梯度进行说明。
刀齿整体淬火和回火热处理完成后,基体6的硬度在50-57HRC之间,然后将整体热处理后的基体利用高频激光束对基体中的刃部的上部1、刃部的中部2、刃部的下部3等区域进行激光表面淬火,在保证一定的韧性和较高的硬度前提下,建议基体表面的硬度在750-800HV左右,激光淬火完成后,将基体表面进行镀Cr处理,依次形成中间强化层5及最表面强化层4,刀齿按照上述工艺制作完成后,基体6、中间强化层5及最表面强化层4三层硬度成梯度分布。
在切割木材时,最表面强化层4硬度高,耐磨性能优于中间强化层5,而中间强化层5的耐磨性能优于基体6,所以在木材切削时基体6会优先磨损,然后磨损中间强化层5,最后是最表面强化层4,这样就使刀齿刃部在使用过程中一直自行磨刃,使刃部保持锋利状态。同时,由于中间强化层5的加入,对切削效率的提高也有明显的促进作用。经切削测试,按照梯度硬度设计制作的新锯链锋利保持期较传统制作工艺制作的锯链提高了20%以上,切削效率提高了10%以上。
Claims (10)
1.一种锯链刀齿,其特征为:包括锯链本体及与锯链本体连接的若干刀齿,所述的刀齿的刃部包括基体以及设于基体外的阶梯性强化单元,所述的阶梯性强化单元包括从内到外依次设置的若干硬度逐渐升高的强化层,所述的强化层由金属表面强化工艺制成,若干强化层的硬度梯度排布满足于:能够在使用过程中使刃部具备自锐利能力。
2.如权利要求1所述的一种锯链刀齿,其特征为:所述的强化层的数量为若干个,最接近基体的强化层的硬度大于基体的硬度。
3.如权利要求1所述的一种锯链刀齿,其特征为:相邻强化层之间的硬度梯度在1000HV以下。
4.如权利要求1所述的一种锯链刀齿,其特征为:所述的强化层为Cr镀层或者Ti镀层或者Cr与Ti相结合的镀层或者其他金属的复合镀层或者金属基陶瓷复合涂层。
5.一种锯链刀齿的制备工艺,其特征为:包括在刀齿刃部的基体外镀制若干从内到外硬度逐渐增加的强化层的步骤,在镀制过程中,使与基体邻近的强化层的硬度大于基体的硬度,各个强化层的硬度梯度排布满足于:能够在使用过程中使刀齿刃部具备自锐利能力。
6.如权利要求5所述的一种锯链刀齿的制备工艺,其特征为:在镀制强化层之前,对基体外表面进行表面淬火处理,淬硬层厚度为基体厚度的30%以内;在镀制强化层之前,对基体外表面进行喷砂处理。
7.如权利要求5所述的一种锯链刀齿的制备工艺,其特征为:在强化层制备过程中,使相邻强化层之间的硬度梯度小于1000HV。
8.如权利要求5所述的一种锯链刀齿的制备工艺,其特征为:刀齿的整体热处理工艺选用普通淬回火工艺或等温淬回火工艺,刀齿整体热处理后制备强化层。
9.如权利要求8所述的一种锯链刀齿的制备工艺,其特征为:表面淬火工艺为激光表面淬火或者高频淬火或者其他表面淬火工艺。
10.如权利要求5所述的一种锯链刀齿的制备工艺,其特征为:所述的强化层选用物理气相沉积或者化学气相沉积制备工艺。
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