WO2020215710A1 - Cutting pick for coal cutter and machining method therefor - Google Patents

Cutting pick for coal cutter and machining method therefor Download PDF

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Publication number
WO2020215710A1
WO2020215710A1 PCT/CN2019/119603 CN2019119603W WO2020215710A1 WO 2020215710 A1 WO2020215710 A1 WO 2020215710A1 CN 2019119603 W CN2019119603 W CN 2019119603W WO 2020215710 A1 WO2020215710 A1 WO 2020215710A1
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Prior art keywords
workpiece
phosphating
saponification
pick
tank
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PCT/CN2019/119603
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French (fr)
Chinese (zh)
Inventor
李保华
王新廷
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安徽澳德矿山机械设备科技股份有限公司
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Priority to AU2019442805A priority Critical patent/AU2019442805B2/en
Publication of WO2020215710A1 publication Critical patent/WO2020215710A1/en

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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
    • C21D1/26—Methods of annealing
    • C21D1/32—Soft annealing, e.g. spheroidising
    • 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
    • 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
    • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
    • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21C—MINING OR QUARRYING
    • E21C35/00—Details of, or accessories for, machines for slitting or completely freeing the mineral from the seam, not provided for in groups E21C25/00 - E21C33/00, E21C37/00 or E21C39/00
    • E21C35/18—Mining picks; Holders therefor
    • E21C35/183—Mining picks; Holders therefor with inserts or layers of wear-resisting material

Definitions

  • the embodiment of the present invention relates to the technical field of coal mining consumables tools, in particular to a pick for a coal shearer and a processing method thereof.
  • Concept mining pick is one of the vulnerable parts in coal mining and roadway driving machinery, and is the main tool for coal falling and crushing.
  • picks There are many types of picks.
  • the general structure is to inlay a cemented carbide tip on a quenched and tempered low-alloy structural steel body. The picks bear high periodic compressive stress, shear stress, and impact load during work.
  • the main failure modes of picks when in use are the tool tip falling off, chipping and tool tip and tool body wear. Under certain working conditions, the failure of the pick body is often caused by the breaking of the tool body. Since the mechanical properties of the pick body directly affect the service life of the pick, a reasonable selection of the material of the pick body and effective heat treatment method can reduce the wear and break of the pick body and reduce the consumption of the shearer pick It is of positive significance to increase the overall economic benefits of coal mining production, increase the operating rate of coal mining machinery, and increase coal mining production.
  • the most significant process proposed at present is to combine the heat treatment of the picks and the phosphorus soap treatment of the picks to maximize the change of its surface smoothness, wear resistance, surface hardness and Internal stress, to achieve the purpose of prolonging the service life of the pick, but most of the existing heat treatment methods are quenching, annealing or tempering, etc. There are various heating and cooling methods, but the general heat treatment methods cannot completely match the picks. The work of the processing technology is likely to cause problems such as thick oxide layer on the surface of the workpiece and excessive oil pollution.
  • the existing phosphating The treatment will inevitably generate phosphating slag. If the phosphating slag is not controlled and isolated, it will not only pollute the phosphating solution and shorten its service life, but also attach to the surface of the workpiece and affect the quality of the phosphating film and the wear resistance.
  • the embodiment of the present invention provides a pick for a coal shearer and a processing method thereof, which adopts isolated gas convection and hot water cooling annealing treatment, and separates the phosphating slag to avoid the formation of the phosphating reaction.
  • the membrane is mixed with the precipitation to solve the large area oxidation of the workpiece surface caused by the annealing method in the prior art, and a large amount of oil stains are generated, the polishing and cleaning takes a long time, the cleaning cost is high, the amount of pollution is large, and the bonding ability of the phosphating film is poor , The problem of low wear resistance.
  • a pick for a coal shearer comprising a connecting shaft portion and a cutting top cap, the connecting shaft portion and the cutting top cap are integrally formed, and the The outer surface of the cutting top cap is provided with a number of evenly distributed inner sinking grooves, the side section of the inner sinking grooves is in a triangular structure, and the outer edge of each inner sinking groove is provided with an extension inclined surface.
  • the outer surface of the connecting shaft portion and the cutting top cap is provided with a wear-resistant phosphate film layer and a saponification film layer.
  • the connecting shaft part and the size transition section of the cutting top cap are smoothly connected.
  • the present invention also designs a pick processing method for coal shearer, which includes the following steps:
  • Step 100 blanking and smelting, centralizing the workpiece in the combustion chamber and slowly heating it;
  • Step 200 spheroidizing annealing, taking the workpiece out of the combustion chamber, and controlling the cooling rate of the workpiece;
  • Step 300 shot blasting to remove oxidation, use a shot blasting machine to polish and polish the oxide layer on the surface of the workpiece, and clean the oil on the surface of the workpiece;
  • Step 400 Phosphorus saponification once, and the cleaned work piece is placed in the phosphating tank and the saponification tank according to the procedure to plasticize the surface of the work piece;
  • Step 500 Perform a cold extrusion to modify the workpiece after the phosphor soap plasticity by extrusion;
  • Step 600 secondary phosphorus saponification, the workpiece after the primary extrusion is placed in the phosphating pool and the saponification pool again to plasticize the surface of the primary workpiece;
  • Step 700 secondary cold extrusion, performing secondary extrusion modification on the workpiece after phosphor soap plasticity
  • step 800 the outer circle is processed. After the workpiece is cooled to room temperature, the outer surface of the workpiece is processed by a turning method to produce picks.
  • step 200 the specific steps of spheroidizing annealing are:
  • Step 201 The combustion chamber continues to heat the workpiece until the temperature reaches 735°C-740°C, and the pick steel body workpiece is burned at this temperature for 20-30 minutes;
  • Step 202 Take the workpiece out of the combustion chamber and move it to a vacuum cooling furnace for isolation and cooling, pass argon into the vacuum cooling furnace, and control the cooling rate to maintain 2-3°C/s through air convection;
  • Step 203 After 10-15 minutes of isolation and cooling, spray circulating cooling hot water to the workpiece in the vacuum cooling furnace, and control the cooling rate to maintain 5-10°C/s;
  • Step 204 When the surface temperature of the workpiece drops to room temperature, take out the workpiece from the vacuum cooling furnace.
  • step 300 the method for cleaning the surface of the workpiece is specifically as follows:
  • the cleaned workpiece is salvaged from the acid solution tank, and the nozzle at the upper end of the acid solution tank is used for secondary acid spray washing until the surface of the strengthened workpiece is free of impurities and oil.
  • the operation steps of rolling the workpiece are specifically as follows:
  • a linear moving table is set on the edge of the acid solution tank, and a Z-shaped cleaning rod is installed on the linear moving table through a bearing.
  • the Z-shaped cleaning rod can be rotated under the support of the lifting platform;
  • a cleaning roller for rubbing the workpiece is installed on the Z-shaped cleaning rod through a bearing.
  • the workpiece after the first cold extrusion needs to be pickled and cleaned, and the surface dirt that adheres to the workpiece during the extrusion is washed off.
  • step 400 the realization steps of the phosphating reaction and the saponification reaction are specifically:
  • Step 401 A stage that can move up and down is added to the bottom of the phosphating tank, a number of evenly parallel workpiece loading lanes are set on the stage, and precipitation sloping plates are set on both sides of each workpiece loading lane.
  • the sedimentation inclined plate is combined with the workpiece loading channel to form a conical inclined plate sedimentation tank.
  • Step 402 Install frame-shaped supports that can be extended up and down on both sides of each workpiece loading channel, and a detachable filter semi-permeable membrane is arranged in the frame-shaped supports;
  • Step 403 Press and shrink the frame-shaped bracket downwards, insert the workpiece on the sinking slot on the workpiece loading channel, and then lift and stretch the frame-shaped bracket to form a guardrail;
  • Step 404 Set an arc-shaped collection ship plate at the bottom of the conical inclined plate sedimentation tank, and collect the phosphated sediment in the arc-shaped collection ship plate;
  • Step 405 Place the phosphated workpiece in a saponification tank for saponification treatment.
  • the phosphating tank and the saponification tank can be shaken up, down, left and right according to the frequency, so that the surface of the workpiece is uniformly phosphated and a uniform phosphate film is formed.
  • the present invention uses vacuum isolation annealing treatment method to change the internal organizational stress of the workpiece to ensure that the performance of the workpiece meets the needs of the coal mining process.
  • the rare air isolation convection and hot water cooling control cooling method can avoid the workpiece Oily impurities are generated on the surface, while avoiding oxidation of the workpiece surface, reducing the cost of workpiece cleaning, and improving the adhesion of the subsequent phosphor soap treatment film;
  • the phosphating reaction tank of the present invention can selectively control ion penetration to form an isolation effect between the workpiece and the phosphating slag, avoiding excessive phosphating slag pollution and shortening the service life of the phosphating solution, while also preventing The proximity of the phosphating slag to the surface of the workpiece affects the quality of the phosphating film, preventing the phosphating slag from destroying the density of the phosphating film, thereby improving the adhesion and corrosion resistance of the phosphating film coating.
  • Figure 1 is a schematic diagram of the overall structure of a pick in an embodiment of the present invention.
  • Fig. 2 is a schematic diagram of the cutting process flow in the embodiment of the present invention.
  • the present invention provides a pick for a shearer, which includes a connecting shaft 1 and a cutting top cap 2.
  • the connecting shaft 1 and the cutting top cap 2 are integrally formed, and the connecting shaft 1 and the cutting top
  • the size transition sections of the top cap 2 are smoothly connected, and the outer surface of the cutting top cap 2 is provided with a number of evenly distributed inner sinking grooves 3, and the side section of the inner sinking grooves 3 is a triangular structure, and each The outer edges of each of the inner sinking grooves 3 are provided with an extension inclined surface.
  • the outer surface of the connecting shaft 1 and the cutting top cap 2 is provided with a wear-resistant phosphate film layer and a saponification film layer.
  • the wear-resistant phosphate film layer and the saponification film layer are obtained by subjecting the pick body to a phosphor soap process. After phosphating and saponification, a large amount of lubricating oil can be absorbed to reduce wear and increase the corrosion resistance and wear resistance of the pick surface.
  • the present invention also designs a processing method for picks for coal mining machines, so as to obtain a wear-resistant phosphate film layer and a saponification film layer on the surface of the picks, as shown in Figure 2. It mainly includes the following steps;
  • Step 100 blanking and smelting, centralizing the workpiece in the combustion chamber and slowly heating it;
  • Step 200 spheroidizing annealing, taking the workpiece out of the combustion chamber, and controlling the cooling rate of the workpiece;
  • spheroidizing annealing refers to slowly heating the metal to austenitic steel, keeping it for a sufficient time, and then cooling it at an appropriate speed.
  • Step 201 The combustion chamber continues to heat the workpiece until the temperature reaches 735-740°C, and the pick steel body workpiece is burned at this temperature for 20-30 minutes;
  • This temperature range causes the steel to transform into austenite when heated.
  • the grains of austenitic steel are relatively small, and the grain boundaries are irregularly curved. After 20-30 minutes of heat preservation, the crystal grains will grow, and the grain boundaries can tend to be flattened.
  • Step 202 Take the workpiece out of the combustion chamber, move it to a vacuum cooling furnace for isolation and cooling, pass argon into the vacuum cooling furnace, and control the cooling rate to maintain 2-3°C/s through air convection;
  • Austenite is the most densely packed lattice structure with high density, so the volume mass of austenite is smaller than the volume mass of ferrite, martensite and other phases in steel. Therefore, when the steel is heated to the austenite phase region, the volume shrinks. When cooling, when the austenite transforms into ferrite-pearlite and other structures, the volume expands, which easily causes internal stress and deformation.
  • the austenite In order to avoid the deformation and expansion of the workpiece, the austenite needs to be slowly cooled. Therefore, the calcined workpiece is first cooled at a cooling rate of 2-3°C/s. The cooling and argon convection are separated in a vacuum cooling furnace. The cooling method is to isolate the air, reduce the oxidation degree of the steel body in the high temperature state, and ensure the rapid formation of the phosphorus soap reaction.
  • Step 203 After 10-15 minutes of isolation and cooling, spray circulating cooling hot water to the workpiece in the vacuum cooling furnace, and control the cooling rate to maintain 5-10°C/s;
  • Step 204 When the surface temperature of the workpiece drops to room temperature, take out the workpiece from the vacuum cooling furnace.
  • Using hot water to continue cooling the workpiece can avoid internal stress and deformation caused by the cold stimulation of the workpiece, and on the other hand, it can avoid the oxidation of the surface layer of the workpiece caused by the dissolved oxygen in the water, and it can also speed up the cooling rate and improve production efficiency.
  • the picks need to withstand high periodic compressive stress, shear stress and impact load when cutting coal and rock, and the temperature of the pick will rise due to frictional impact during the long-term cutting of coal and rock.
  • the cutter body is required to have both wear resistance and good impact resistance.
  • austenite is a high-temperature phase, which is formed by the inverse eutectoid transformation of pearlite.
  • the main function of spheroidizing annealing is to make the flake cementite and proeutectoid cementite in the pearlite become Spherical, uniformly distributed in the ferrite matrix (this organization is called spheroidized pearlite). Therefore, the carbon steel using this embodiment of spheroidizing annealing has low hardness, improves machinability, eliminates residual stress, stabilizes size, reduces deformation and cracking tendency, refines grains, adjusts organization and eliminates organizational defects, and adapts to the needs of coal mining environment .
  • Step 300 shot blasting to remove oxidation, use a shot blasting machine to polish and polish the oxide layer on the surface of the workpiece, and clean the oil on the surface of the workpiece;
  • shot blasting is used to remove surface oxide scale and impurities, improve the appearance quality, facilitate the subsequent phosphor soap coating processing, and improve the adhesion of the phosphor soap film.
  • shot blasting is used to improve the internal stress of the pick, and high-speed moving projectiles are used.
  • the continuous impact of the flow strengthens the surface of the workpiece, forcing the surface and surface of the target to change in the cyclic deformation process.
  • the specific manifestations are: the microstructure is modified; the non-uniform plastic deformation of the outer surface layer introduces residual compressive stress, and the inner surface layer generates residual tensile stress; the outer surface roughness changes. Thereby improving the fatigue fracture resistance of the material, preventing fatigue failure and plastic deformation, and improving fatigue life.
  • the annealing process in this embodiment does not use oil quenching or other operations that come into contact with oil, the amount of oil on the workpiece itself is not much, so the use of the above annealing method is convenient for the implementation of phosphating operations, and the use of acid solutions
  • the oil removal operation can be completed by cleaning, without the need to fully remove oil in the oil removal tank, so the cleaning cost and waste water treatment cost can be reduced.
  • step 300 the specific method for cleaning the surface of the workpiece is:
  • the pulse jet nozzle is used to remove the particles on the surface of the workpiece.
  • the polished oxide layer particles can be separated from the workpiece under the action of the jet, so as to achieve the first level cleaning. This step can be roughly removed Most impurities on the workpiece.
  • the acid solution tank can dissolve the oil, and the surface of the workpiece can be cleaned by rolling rubbing.
  • Greasy dirt and fine particles are subjected to secondary cleaning, this step can concentrate on removing most of the impurities on the workpiece;
  • the workpiece is placed on the lifting platform in the acid solution tank.
  • the oil on the surface of the workpiece can be dissolved in the acid solution, and the lifting method of the workpiece is carried out through the up and down lifting type of the workpiece to facilitate the transfer of the workpiece after cleaning and the subsequent processing operating;
  • the second step is to set up a linear moving table on the edge of the acid solution tank, and install a Z-shaped cleaning rod on the linear moving table through a bearing.
  • the Z-shaped cleaning rod can be rotated under the support of the lifting table.
  • the linear moving table can follow the acid solution tank.
  • the long side of the Z-shaped cleaning rod can be rotated around the bearing installation point under the action of external force, and the Z-shaped cleaning rod can rotate with the up and down displacement of the lifting platform, which does not hinder the normal operation of the lifting platform. operating;
  • a cleaning roller for rubbing the workpiece is installed on the Z-shaped cleaning rod through a bearing.
  • the linear moving table drives the Z-shaped cleaning rod to move synchronously. Due to the friction between the cleaning roller and the workpiece on the lifting platform, the cleaning roller will It can rotate when linearly shifting to realize rolling rubbing of the workpiece, which can remove the oil residue on the surface of the workpiece and the fine slag of the polished steel to improve the cleaning effect.
  • the cleaned workpiece is salvaged from the acid solution pool, and the nozzle at the upper end of the acid solution pool is used for secondary acid spray flushing until the surface of the strengthened workpiece is free of impurities and oil stains.
  • the workpiece can be impacted by a higher-pressure water stream. The small amount of particles adhering to the surface of the workpiece is further rinsed to achieve complete cleaning.
  • the acid strength of the solution used in the secondary acid spray flushing is relatively low, which can prevent the pickling solution from entering the phosphating tank and causing the phosphating solution to become too acidic and affecting the phosphating effect.
  • the above steps can avoid the configuration of multiple sets of cleaning equipment, reduce cleaning costs, and reduce environmental pollution.
  • the surface of the cleaned workpiece is smooth and clean, which facilitates the uniform attachment of the phosphate film, avoids damage to the phosphate film, and improves wear resistance.
  • the bonding force between the material and the workpiece steel prevents the phosphating film from falling off.
  • the use of acidic solution for cleaning can further remove the oxide layer on the surface of the metal workpiece, improve the cleanliness of the surface of the workpiece, and prevent the surface of the workpiece from being unable to be coated during the phosphorus soap reaction.
  • Step 400 Phosphorus saponification once, and the cleaned work piece is placed in the phosphating tank and the saponification tank according to the procedure to plasticize the surface of the work piece;
  • the phosphating treatment of the workpiece in the phosphating pool is to place the workpiece in a medium-temperature zinc-calcium phosphating solution to form a layer of light gray to dark gray on the surface of the workpiece in a short time .
  • a medium-temperature zinc-calcium phosphating solution to form a layer of light gray to dark gray on the surface of the workpiece in a short time .
  • Hardly soluble in water, fine and dense phosphate film-zinc phosphate film process phosphating solution temperature is 60-80°C
  • phosphating time is 10-20min
  • free acidity is 1.2-2.4
  • total acidity is 16 -26.
  • Saponification treatment is to put the phosphated workpiece in a soap solution containing saturated fatty acid soap with 16-18 carbon, anti-friction extreme pressure agent and drawing lubricant.
  • the above components in the soap solution and the zinc and phosphorus on the surface of the workpiece The chemical film reaction forms fatty acid zinc film and soap film layer.
  • the fatty acid zinc film and soap film layer increase the plastic thickness of the deformation zone of the workpiece, and form a lubricating film in the mold hole and the processed material, which can greatly reduce heat and prevent metal sintering And melt adhesion, etc., due to the anti-friction medium and plasticity in the drawing die and drawing parts, thereby improving the surface finish and processing accuracy of the drawn product, reducing the wear between the drawing tool and the drawing die, and the pH of the saponification solution
  • the value is 7.8-8.8, the temperature of the saponification solution is 70-80°C, and the saponification treatment time is 15-30 min.
  • the following phosphating reaction method is used to control excessive phosphating slag from contacting the surface of the workpiece, thereby improving the adhesion of the phosphating film.
  • Step 401 A stage that can move up and down is added to the bottom of the phosphating tank, a number of evenly parallel workpiece loading lanes are set on the stage, and precipitation sloping plates are set on both sides of each workpiece loading lane.
  • the sedimentation inclined plate is combined with the workpiece loading channel to form a conical inclined plate sedimentation tank.
  • Step 402 Install frame-shaped supports that can be extended up and down on both sides of each workpiece loading channel, and a detachable filter semi-permeable membrane is arranged in the frame-shaped supports;
  • the stage can be shaken up, down, left, and right according to the frequency, so that the surface of the workpiece can undergo a uniform phosphating reaction, and a uniform phosphate film can be formed.
  • the workpiece can be installed on the workpiece loading channel for phosphating treatment.
  • the phosphating slag generated during the phosphating treatment will sink to the conical inclined plate sedimentation tank for collection, so the contact between the workpiece and the phosphating slag can be isolated to avoid Too much phosphating slag adheres to the surface of the workpiece to improve the adhesion between the phosphating film and the workpiece.
  • the stage can shake up, down, left, and right according to the frequency, which can uniform the solubility of the phosphating solution and improve the efficiency of phosphating reaction. And in the shaking process, the metal ions such as Fe 2+ and Zn 2+ oxidized by the workpiece are dispersed into the solution to further increase the contact area between the surface of the workpiece and the phosphating solution and increase the phosphating reaction activity rate.
  • the filter semipermeable membrane only selectively allows the oxidized Fe 3+ to pass through the filter semipermeable membrane and enter the filter semipermeable In the solution on the outside of the membrane, it can only penetrate the semi-permeable filter membrane in the forward direction, and cannot pass through the semi-permeable filter membrane in the reverse direction to enter the inside of the semi-permeable filter membrane again, that is, the outer surface of the semi-permeable filter membrane does not affect the solution.
  • the permeation effect of other ions can only selectively isolate Fe 3+ ions and prevent the penetration of phosphating slag precipitation.
  • the inner side of the filtering semipermeable membrane only selectively permeates Fe 3+ ions, and other Ions are impermeable.
  • This semi-permeable filter membrane ensures the normal operation of phosphate precipitation and crystallization into the phosphate film, and prevents the phosphate slag from floating on the phosphate film and affects the stacking and adhesion effect of the phosphate film.
  • Step 403 Press and shrink the frame-shaped bracket downwards, insert the workpiece on the sinking slot on the workpiece loading channel, and then lift and stretch the frame-shaped bracket to form a guardrail;
  • Step 404 Set an arc-shaped collection ship plate at the bottom of the conical inclined plate sedimentation tank, and collect the phosphated sediment in the arc-shaped collection ship plate;
  • the frame-shaped bracket can be contracted to facilitate the placement of the workpiece on the sinking slot on the workpiece loading channel. At the same time, the frame-shaped bracket can be stretched to form a guardrail, selectively permeating Fe 3+ to prevent the phosphating slag from affecting the phosphating film Attached effect.
  • the phosphating slag sinks along the conical inclined plate sedimentation tank, and the arc-shaped collecting ship plate can directly collect the phosphating slag to avoid pollution to the phosphating solution.
  • Step 405 Place the phosphated workpiece in a saponification tank for saponification treatment.
  • Both the phosphating treatment and the saponification treatment provide protection to the base metal and prevent the metal from being corroded to a certain extent. It is used for primer before painting to improve the adhesion and anti-corrosion ability of the paint film layer. It is used in the metal cold working process. The anti-friction lubrication is used to facilitate the next cold extrusion treatment and avoid the internal stress and deformation of the workpiece.
  • Step 500 Perform a cold extrusion to modify the workpiece after the phosphor soap plasticity by extrusion;
  • the workpiece after a cold extrusion needs to be pickled and cleaned, and the surface dirt adhering to the workpiece during the extrusion is cleaned off.
  • Step 600 secondary phosphorus saponification, the workpiece after the primary extrusion is placed in the phosphating pool and the saponification pool again to plasticize the surface of the primary workpiece;
  • Step 700 secondary cold extrusion, performing secondary extrusion modification on the workpiece after phosphor soap plasticity
  • step 800 the outer circle is processed. After the workpiece is cooled to room temperature, the outer surface of the workpiece is processed by a turning method to produce picks.
  • the invention discloses a pick for a coal mining machine, comprising a connecting shaft part and a cutting top cap, the connecting shaft part and the cutting top cap are integrally formed, and the outer surface of the cutting top cap is provided with a number of inner sinking grooves; also disclosed
  • the cutting tooth processing method for coal mining machine includes the following steps: cutting and smelting; spheroidizing annealing, removing the workpiece from the combustion chamber, controlling the cooling rate of the workpiece; removing the oxidation by shot blasting, and polishing the oxide layer on the surface of the workpiece. And clean the oil on the surface of the workpiece; primary phosphorus saponification; primary cold extrusion; acid cleaning; secondary phosphorus saponification; secondary cold extrusion; external processing.
  • the vacuum-isolated annealing treatment method changes the internal organizational stress of the workpiece to ensure that the performance of the workpiece adapts to the needs of the coal mining process.
  • the rare air isolation convection and the hot water cooling control method can prevent the surface of the workpiece from oily impurities and at the same time.
  • the surface of the workpiece is oxidized, reducing the cost of workpiece cleaning, and improving the adhesion of the subsequent phosphor soap treatment film;
  • the phosphating reaction tank can selectively control ion penetration, forming a separation between the workpiece and the phosphating slag, and avoid excessive Phosphating slag contaminates and shortens the service life of the phosphating solution.

Abstract

A cutting pick for a coal cutter and a machining method therefor. The cutting pick for a coal cutter comprises a connection shaft portion (1) and a cutting top cap (2), the connection shaft portion (1) and the cutting top cap (2) being integrally formed, and several internal recessed clamping grooves (3) being provided on an outer surface of the cutting top cap (2). The machining method for the cutting pick of a coal cutter comprises the following steps: blanking and burning; performing spheroidizing annealing, taking a workpiece out of a combustion chamber, and controlling the cooling speed of the workpiece; performing shot blasting and oxidation removal, polishing an oxide layer on the surface of the workpiece, and cleaning oil contamination on the surface of the workpiece; performing primary phosphorous saponification; performing primary cold extrusion; performing acidic cleaning; performing secondary phosphorous saponification; performing secondary cold extrusion; and performing cylindrical machining.

Description

一种采煤机用的截齿及其加工方法Pick tooth for coal shearer and processing method thereof
本申请要求在2019年4月22日提交中国专利局、申请号为201910323666.3、发明名称为“一种采煤机用的截齿及其加工方法”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。This application claims the priority of a Chinese patent application filed with the Chinese Patent Office on April 22, 2019, the application number is 201910323666.3, and the invention title is "A pick for coal shearer and its processing method". The entire content of the application is approved The reference is incorporated in this application.
技术领域Technical field
本发明实施例涉及采煤耗材工具技术领域，具体涉及一种采煤机用的截齿及其加工方法。The embodiment of the present invention relates to the technical field of coal mining consumables tools, in particular to a pick for a coal shearer and a processing method thereof.
背景技术Background technique
概念矿用截齿是采煤及巷道掘进机械中的易损件之一，是落煤及碎煤的主要工具。常用材质从国内部分煤矿实际使用的进口、国产的截齿来看，刀体材质多为42CrMo、35CrMnSi等钢种，也有煤矿在采用国内新研制的Si-Mn-Mo系准贝氏体钢，截齿的种类很多，一般结构是在经淬火、回火处理的低合金结构钢刀体上镶嵌硬质合金刀头，截齿在工作时承受高的周期性压应力、切应力、冲击负荷。Concept mining pick is one of the vulnerable parts in coal mining and roadway driving machinery, and is the main tool for coal falling and crushing. Commonly used materials Judging from the imported and domestic picks actually used in some domestic coal mines, most of the cutter body materials are 42CrMo, 35CrMnSi and other steel grades, and some coal mines are using the newly developed domestic Si-Mn-Mo series pseudo-bainitic steel. There are many types of picks. The general structure is to inlay a cemented carbide tip on a quenched and tempered low-alloy structural steel body. The picks bear high periodic compressive stress, shear stress, and impact load during work.
截齿在使用时的主要失效形式为刀头脱落、崩刀和刀头、刀体磨损，在某些工况条件下也经常因为刀体折断造成截齿的失效。由于截齿刀体的机械性能好坏直接影响截齿的使用寿命，所以合理选择截齿刀体的材质和有效的热处理方式，对减少截齿刀体的磨损折断、降低采煤机截齿消耗量、提高采煤机械运转率、增加采煤生产的综合经济效益，都有积极的意义。为了提高截齿的耐磨性能，目前提出加工效果比较显著的工艺就是结合使用对截齿热处理和对截齿进行磷皂处理，以最大化的改变其表面光滑性、耐磨性、表面硬度和内部应力，达到延长截齿使用寿命的目的，但是现有的热处理方式大多为淬火、退火或者回火等等，加热和冷却的方式各式各样，但是普遍的热处理方式不能完全匹配截齿的加工工艺工作，容易造成工件表面氧化层厚、油污多等问题，不能完全适应于对截齿的加工工艺，有可能造成清洗资源浪费，以及影响磷皂工艺的处理效率；另外现有的磷化处理必然会生成磷化渣，如果不对磷化渣进行控制隔离，不但会污染磷化液，缩短其使用寿命，同时还会附着在工件表面影响磷化膜质量和耐磨效果。The main failure modes of picks when in use are the tool tip falling off, chipping and tool tip and tool body wear. Under certain working conditions, the failure of the pick body is often caused by the breaking of the tool body. Since the mechanical properties of the pick body directly affect the service life of the pick, a reasonable selection of the material of the pick body and effective heat treatment method can reduce the wear and break of the pick body and reduce the consumption of the shearer pick It is of positive significance to increase the overall economic benefits of coal mining production, increase the operating rate of coal mining machinery, and increase coal mining production. In order to improve the wear resistance of the picks, the most significant process proposed at present is to combine the heat treatment of the picks and the phosphorus soap treatment of the picks to maximize the change of its surface smoothness, wear resistance, surface hardness and Internal stress, to achieve the purpose of prolonging the service life of the pick, but most of the existing heat treatment methods are quenching, annealing or tempering, etc. There are various heating and cooling methods, but the general heat treatment methods cannot completely match the picks. The work of the processing technology is likely to cause problems such as thick oxide layer on the surface of the workpiece and excessive oil pollution. It cannot be fully adapted to the processing technology of the pick, which may cause waste of cleaning resources and affect the processing efficiency of the phosphor soap process; in addition, the existing phosphating The treatment will inevitably generate phosphating slag. If the phosphating slag is not controlled and isolated, it will not only pollute the phosphating solution and shorten its service life, but also attach to the surface of the workpiece and affect the quality of the phosphating film and the wear resistance.
发明内容Summary of the invention
为此，本发明实施例提供一种采煤机用的截齿及其加工方法，采用隔离式的气体对流和热水降温的退火处理方式，以及分离磷化渣，避免磷化反应中的成膜与沉淀接触混合，以解决现有技术中由于退火方式造成工件表面大面积的氧化，以及产生大量油污，抛光清洗耗费时间长，清洗成本高，污染量大，以及磷化膜粘接能力差，耐磨能力低的问题。To this end, the embodiment of the present invention provides a pick for a coal shearer and a processing method thereof, which adopts isolated gas convection and hot water cooling annealing treatment, and separates the phosphating slag to avoid the formation of the phosphating reaction. The membrane is mixed with the precipitation to solve the large area oxidation of the workpiece surface caused by the annealing method in the prior art, and a large amount of oil stains are generated, the polishing and cleaning takes a long time, the cleaning cost is high, the amount of pollution is large, and the bonding ability of the phosphating film is poor , The problem of low wear resistance.
为了实现上述目的，本发明的实施方式提供如下技术方案：一种采煤机用的截齿，包括连接轴部和切割顶帽，所述连接轴部与切割顶帽一体化成型，并且所述切割顶帽的外表面设有若干均匀分布的内沉卡槽，所述内沉卡槽的侧剖面呈三角形结构，并且每个所述内沉卡槽的外边缘均设有外延斜面。In order to achieve the above objective, the embodiments of the present invention provide the following technical solutions: a pick for a coal shearer, comprising a connecting shaft portion and a cutting top cap, the connecting shaft portion and the cutting top cap are integrally formed, and the The outer surface of the cutting top cap is provided with a number of evenly distributed inner sinking grooves, the side section of the inner sinking grooves is in a triangular structure, and the outer edge of each inner sinking groove is provided with an extension inclined surface.
作为本发明的一种优选方案，所述连接轴部与切割顶帽的外表面设有耐磨磷化膜层和皂化膜层。As a preferred solution of the present invention, the outer surface of the connecting shaft portion and the cutting top cap is provided with a wear-resistant phosphate film layer and a saponification film layer.
作为本发明的一种优选方案，所述连接轴部与切割顶帽的尺寸过渡段均为光滑连接。As a preferred solution of the present invention, the connecting shaft part and the size transition section of the cutting top cap are smoothly connected.
另外本发明还设计了一种采煤机用的截齿加工方法，包括如下步骤：In addition, the present invention also designs a pick processing method for coal shearer, which includes the following steps:
步骤100、下料炼烧，将工件集中置于燃烧室内缓慢加热；Step 100, blanking and smelting, centralizing the workpiece in the combustion chamber and slowly heating it;
步骤200、球化退火，将工件从燃烧室取出，控制工件冷却速度；Step 200, spheroidizing annealing, taking the workpiece out of the combustion chamber, and controlling the cooling rate of the workpiece;
步骤300、抛丸清除氧化，使用抛丸机将工件表面的氧化层打磨抛光，并清洗工件表面的油污；Step 300, shot blasting to remove oxidation, use a shot blasting machine to polish and polish the oxide layer on the surface of the workpiece, and clean the oil on the surface of the workpiece;
步骤400、一次磷皂化，将清洗后的工件按照工序置入磷化池和皂化池，对工件表面塑性；Step 400: Phosphorus saponification once, and the cleaned work piece is placed in the phosphating tank and the saponification tank according to the procedure to plasticize the surface of the work piece;
步骤500、一次冷挤压，将磷皂塑性后的工件进行一次挤压改性；Step 500: Perform a cold extrusion to modify the workpiece after the phosphor soap plasticity by extrusion;
步骤600、二次磷皂化，将一次挤压后的工件重新置入磷化池和皂化池，对初级工件表面二次塑性；Step 600, secondary phosphorus saponification, the workpiece after the primary extrusion is placed in the phosphating pool and the saponification pool again to plasticize the surface of the primary workpiece;
步骤700、二次冷挤压，将磷皂塑性后的工件进行二次挤压改性；Step 700, secondary cold extrusion, performing secondary extrusion modification on the workpiece after phosphor soap plasticity;
步骤800、外圆加工，将工件冷却至室温后，使用车削方法加工工件的外圆表面生产截齿。In step 800, the outer circle is processed. After the workpiece is cooled to room temperature, the outer surface of the workpiece is processed by a turning method to produce picks.
作为本发明的一种优选方案，在步骤200中，球化退火的具体步骤为：As a preferred solution of the present invention, in step 200, the specific steps of spheroidizing annealing are:
步骤201、燃烧室持续加热工件直至温度达到735℃-740℃，保持此温度煅烧截齿钢体工件20-30min；Step 201: The combustion chamber continues to heat the workpiece until the temperature reaches 735°C-740°C, and the pick steel body workpiece is burned at this temperature for 20-30 minutes;
步骤202、将工件从燃烧室取出，移至真空冷却炉内隔离冷却，向真空冷却炉中通入氩 气，通过空气对流方式，控制冷却速度保持在2-3℃/s；Step 202: Take the workpiece out of the combustion chamber and move it to a vacuum cooling furnace for isolation and cooling, pass argon into the vacuum cooling furnace, and control the cooling rate to maintain 2-3°C/s through air convection;
步骤203、隔离冷却10-15min后，向真空冷却炉内的工件喷淋循环冷却热水，控制冷却速度保持在5-10℃/s；Step 203: After 10-15 minutes of isolation and cooling, spray circulating cooling hot water to the workpiece in the vacuum cooling furnace, and control the cooling rate to maintain 5-10°C/s;
步骤204、当工件表面温度降低至室温时，从真空冷却炉取出工件。Step 204: When the surface temperature of the workpiece drops to room temperature, take out the workpiece from the vacuum cooling furnace.
作为本发明的一种优选方案，在步骤300中，清理工件表面油污的方式具体为：As a preferred solution of the present invention, in step 300, the method for cleaning the surface of the workpiece is specifically as follows:
首先，使用抛丸机去除工件表面氧化层的同时，利用脉冲喷气口清除工件表面的颗粒；First of all, use the shot blasting machine to remove the surface oxide layer of the workpiece, and use the pulse jet to remove the particles on the surface of the workpiece;
其次，将打磨完成的工件置于酸性溶液池内进行滚动式搓揉，清理工件上的油污和打磨颗粒；Secondly, place the polished workpiece in the acid solution pool for rolling rubbing to clean up the oil and grinding particles on the workpiece;
最后，将清洗后的工件从酸性溶液池打捞，并且利用酸性溶液池上端的喷头进行二次酸性喷淋冲洗，直至强化工件表面无杂质油污。Finally, the cleaned workpiece is salvaged from the acid solution tank, and the nozzle at the upper end of the acid solution tank is used for secondary acid spray washing until the surface of the strengthened workpiece is free of impurities and oil.
作为本发明的一种优选方案，对工件进行滚动式搓揉的操作步骤具体为：As a preferred solution of the present invention, the operation steps of rolling the workpiece are specifically as follows:
将工件放置在酸性溶液池内的升降台上；Place the workpiece on the lifting platform in the acid solution tank;
在酸性溶液池的边缘设置线性移动台，在线性移动台上通过轴承安装Z字清洗杆，Z字清洗杆在升降台的支撑下可转动；A linear moving table is set on the edge of the acid solution tank, and a Z-shaped cleaning rod is installed on the linear moving table through a bearing. The Z-shaped cleaning rod can be rotated under the support of the lifting platform;
在Z字清洗杆上通过轴承安装搓揉工件的清洁辊。A cleaning roller for rubbing the workpiece is installed on the Z-shaped cleaning rod through a bearing.
作为本发明的一种优选方案，在步骤600进行二次磷皂化之前，需要对一次冷挤压后的工件进行酸洗清污，将工件在挤压时粘附的表面污物清洗脱落。As a preferred solution of the present invention, before performing the secondary phosphorous saponification in step 600, the workpiece after the first cold extrusion needs to be pickled and cleaned, and the surface dirt that adheres to the workpiece during the extrusion is washed off.
作为本发明的一种优选方案，在步骤400中，磷化反应和皂化反应的实现步骤具体为：As a preferred solution of the present invention, in step 400, the realization steps of the phosphating reaction and the saponification reaction are specifically:
步骤401、在磷化池的底部增设可上下移动的载物台，在载物台上设置若干个均匀平行分布的工件装载道，并且在每条工件装载道的两侧均设置沉淀斜板，沉淀斜板与工件装载道结合组成锥形斜板沉淀槽。Step 401: A stage that can move up and down is added to the bottom of the phosphating tank, a number of evenly parallel workpiece loading lanes are set on the stage, and precipitation sloping plates are set on both sides of each workpiece loading lane. The sedimentation inclined plate is combined with the workpiece loading channel to form a conical inclined plate sedimentation tank.
步骤402、在每条工件装载道的两侧均安装可上下伸缩的框型支架，并且框型支架内设置可拆卸的过滤半透膜；Step 402: Install frame-shaped supports that can be extended up and down on both sides of each workpiece loading channel, and a detachable filter semi-permeable membrane is arranged in the frame-shaped supports;
步骤403、将框型支架向下按压收缩，将工件安插在工件装载道上的下沉卡槽上，然后在将框型支架向上提拉伸长形成护栏；Step 403: Press and shrink the frame-shaped bracket downwards, insert the workpiece on the sinking slot on the workpiece loading channel, and then lift and stretch the frame-shaped bracket to form a guardrail;
步骤404、在锥形斜板沉淀槽的底部设置弧形收集船板，将磷化沉渣集中收纳在弧形收集船板内；Step 404: Set an arc-shaped collection ship plate at the bottom of the conical inclined plate sedimentation tank, and collect the phosphated sediment in the arc-shaped collection ship plate;
步骤405、将磷化后的工件置于皂化池内进行皂化处理。Step 405: Place the phosphated workpiece in a saponification tank for saponification treatment.
作为本发明的一种优选方案，所述磷化池和皂化池可按照频率进行上下左右方向的抖动，使得工件表面均匀进行磷化反应，并生成均匀的磷化膜。As a preferred solution of the present invention, the phosphating tank and the saponification tank can be shaken up, down, left and right according to the frequency, so that the surface of the workpiece is uniformly phosphated and a uniform phosphate film is formed.
本发明的实施方式具有如下优点：The embodiments of the present invention have the following advantages:
(1)本发明通过真空隔离的退火处理方式，改变工件内部组织机构应力，保证工件的性能适应采煤过程的需求，另外通过稀有空气隔离对流和热水冷控降温的方式，均可避免工件表面产生油污杂质，同时避免工件表面氧化，降低工件清洗的成本，提高后续磷皂处理覆膜的粘接力；(1) The present invention uses vacuum isolation annealing treatment method to change the internal organizational stress of the workpiece to ensure that the performance of the workpiece meets the needs of the coal mining process. In addition, the rare air isolation convection and hot water cooling control cooling method can avoid the workpiece Oily impurities are generated on the surface, while avoiding oxidation of the workpiece surface, reducing the cost of workpiece cleaning, and improving the adhesion of the subsequent phosphor soap treatment film;
(2)本发明的磷化反应池可选择性控制离子渗透，形成工件与磷化渣之间的隔离作用，可避免过多的磷化渣污染并缩短磷化液的使用寿命，同时还防止磷化渣接近工件表面影响磷化膜质量，防止磷化渣破坏磷化膜的密集性，从而提高磷化薄膜涂层的附着力和耐腐蚀性。(2) The phosphating reaction tank of the present invention can selectively control ion penetration to form an isolation effect between the workpiece and the phosphating slag, avoiding excessive phosphating slag pollution and shortening the service life of the phosphating solution, while also preventing The proximity of the phosphating slag to the surface of the workpiece affects the quality of the phosphating film, preventing the phosphating slag from destroying the density of the phosphating film, thereby improving the adhesion and corrosion resistance of the phosphating film coating.
附图说明Description of the drawings
为了更清楚地说明本发明的实施方式或现有技术中的技术方案，下面将对实施方式或现有技术描述中所需要使用的附图作简单地介绍。显而易见地，下面描述中的附图仅仅是示例性的，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据提供的附图引伸获得其它的实施附图。In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only exemplary. For those of ordinary skill in the art, other implementation drawings can be derived from the provided drawings without creative work.
本说明书所绘示的结构、比例、大小等，均仅用以配合说明书所揭示的内容，以供熟悉此技术的人士了解与阅读，并非用以限定本发明可实施的限定条件，故不具技术上的实质意义，任何结构的修饰、比例关系的改变或大小的调整，在不影响本发明所能产生的功效及所能达成的目的下，均应仍落在本发明所揭示的技术内容得能涵盖的范围内。The structure, ratio, size, etc. shown in this manual are only used to match the content disclosed in the manual for people familiar with this technology to understand and read. They are not used to limit the implementation of the present invention, so it is not technical. The substantive meaning of the above, any structural modification, proportional relationship change or size adjustment, without affecting the effects and objectives of the present invention, should still fall within the technical content disclosed in the present invention. Can cover the range.
图1为本发明实施方式中的截齿整体结构示意图；Figure 1 is a schematic diagram of the overall structure of a pick in an embodiment of the present invention;
图2为本发明实施方式中的截齿加工流程示意图。Fig. 2 is a schematic diagram of the cutting process flow in the embodiment of the present invention.
图中：In the picture:
1-连接轴部；2-切割顶帽；3-内沉卡槽。1-Connect the shaft; 2-cut the top cap; 3-inner sink card slot.
具体实施方式Detailed ways
以下由特定的具体实施例说明本发明的实施方式，熟悉此技术的人士可由本说明书所揭 露的内容轻易地了解本发明的其他优点及功效，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。The following specific examples illustrate the implementation of the present invention. Those familiar with this technology can easily understand the other advantages and effects of the present invention from the contents disclosed in this specification. Obviously, the described embodiments are part of the embodiments of the present invention. , Not all examples. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present invention.
实施例1Example 1
如图1所示，本发明提供了一种采煤机用的截齿，包括连接轴部1和切割顶帽2，连接轴部1与切割顶帽2一体化成型，连接轴部1与切割顶帽2的尺寸过渡段均为光滑连接，并且所述切割顶帽2的外表面设有若干均匀分布的内沉卡槽3，所述内沉卡槽3的侧剖面呈三角形结构，并且每个所述内沉卡槽3的外边缘均设有外延斜面。As shown in Figure 1, the present invention provides a pick for a shearer, which includes a connecting shaft 1 and a cutting top cap 2. The connecting shaft 1 and the cutting top cap 2 are integrally formed, and the connecting shaft 1 and the cutting top The size transition sections of the top cap 2 are smoothly connected, and the outer surface of the cutting top cap 2 is provided with a number of evenly distributed inner sinking grooves 3, and the side section of the inner sinking grooves 3 is a triangular structure, and each The outer edges of each of the inner sinking grooves 3 are provided with an extension inclined surface.
连接轴部1与切割顶帽2的外表面设有耐磨磷化膜层和皂化膜层，耐磨磷化膜层和皂化膜层是将截齿本体进行磷皂工艺而得，截齿经磷化和皂化后可吸附大量的润滑油而减少磨檫，并且增加截齿表面的防腐蚀和耐磨性能。The outer surface of the connecting shaft 1 and the cutting top cap 2 is provided with a wear-resistant phosphate film layer and a saponification film layer. The wear-resistant phosphate film layer and the saponification film layer are obtained by subjecting the pick body to a phosphor soap process. After phosphating and saponification, a large amount of lubricating oil can be absorbed to reduce wear and increase the corrosion resistance and wear resistance of the pick surface.
实施例2Example 2
为了获得上述采煤机用截齿，本发明还设计了一种采煤机用截齿的加工方法，以此在截齿的表面获得耐磨磷化膜层和皂化膜层，如图2所示，主要包括如下步骤；In order to obtain the above-mentioned picks for coal mining machines, the present invention also designs a processing method for picks for coal mining machines, so as to obtain a wear-resistant phosphate film layer and a saponification film layer on the surface of the picks, as shown in Figure 2. It mainly includes the following steps;
步骤100、下料炼烧，将工件集中置于燃烧室内缓慢加热；Step 100, blanking and smelting, centralizing the workpiece in the combustion chamber and slowly heating it;
步骤200、球化退火，将工件从燃烧室取出，控制工件冷却速度；Step 200, spheroidizing annealing, taking the workpiece out of the combustion chamber, and controlling the cooling rate of the workpiece;
上述步骤是对截齿工件的热处理操作，其中球化退火指的是将金属缓慢加热到奥氏体钢，并且保持足够时间，然后以适宜速度冷却。The above steps are heat treatment operations on the pick workpiece, where spheroidizing annealing refers to slowly heating the metal to austenitic steel, keeping it for a sufficient time, and then cooling it at an appropriate speed.
下面将对球化退火的具体步骤进行细化，主要包括：The specific steps of spheroidizing annealing will be refined below, mainly including:
步骤201、燃烧室持续加热工件直至温度达到735-740℃，保持此温度煅烧截齿钢体工件20-30min；Step 201: The combustion chamber continues to heat the workpiece until the temperature reaches 735-740°C, and the pick steel body workpiece is burned at this temperature for 20-30 minutes;
此温度范围使得钢在加热转变为奥氏体，奥氏体钢的晶粒比较细小，晶粒边界呈不规则的弧形。经过20-30min的保温，晶粒将长大，晶粒边界可趋向平直化。This temperature range causes the steel to transform into austenite when heated. The grains of austenitic steel are relatively small, and the grain boundaries are irregularly curved. After 20-30 minutes of heat preservation, the crystal grains will grow, and the grain boundaries can tend to be flattened.
步骤202、将工件从燃烧室取出，移至真空冷却炉内隔离冷却，向真空冷却炉中通入氩气，通过空气对流方式，控制冷却速度保持在2-3℃/s；Step 202: Take the workpiece out of the combustion chamber, move it to a vacuum cooling furnace for isolation and cooling, pass argon into the vacuum cooling furnace, and control the cooling rate to maintain 2-3°C/s through air convection;
奥氏体是最密排的点阵结构，致密度高，故奥氏体的体积质量比钢中铁素体、马氏体等相的体积质量小。因此，钢被加热到奥氏体相区时，体积收缩，冷却时，奥氏体转变为铁素体—珠光体等组织时，体积膨胀，容易引起内应力和变形。Austenite is the most densely packed lattice structure with high density, so the volume mass of austenite is smaller than the volume mass of ferrite, martensite and other phases in steel. Therefore, when the steel is heated to the austenite phase region, the volume shrinks. When cooling, when the austenite transforms into ferrite-pearlite and other structures, the volume expands, which easily causes internal stress and deformation.
为了避免工件产生变形和膨胀，需要对奥氏体进行缓慢降温处理，因此首先以冷却速度为2-3℃/s对煅烧的工件进行降温处理，在真空冷却炉内隔离冷却和氩气对流的冷却方式，均为了隔离空气，降低钢体在高温状态下的氧化程度，保证磷皂反应的快速生膜。In order to avoid the deformation and expansion of the workpiece, the austenite needs to be slowly cooled. Therefore, the calcined workpiece is first cooled at a cooling rate of 2-3°C/s. The cooling and argon convection are separated in a vacuum cooling furnace. The cooling method is to isolate the air, reduce the oxidation degree of the steel body in the high temperature state, and ensure the rapid formation of the phosphorus soap reaction.
步骤203、隔离冷却10-15min后，向真空冷却炉内的工件喷淋循环冷却热水，控制冷却速度保持在5-10℃/s；Step 203: After 10-15 minutes of isolation and cooling, spray circulating cooling hot water to the workpiece in the vacuum cooling furnace, and control the cooling rate to maintain 5-10°C/s;
步骤204、当工件表面温度降低至室温时，从真空冷却炉取出工件。Step 204: When the surface temperature of the workpiece drops to room temperature, take out the workpiece from the vacuum cooling furnace.
使用热水继续冷却工件，一方面可避免对工件的冷刺激造成内应力和变形，另一方面避免水内的溶解氧引起工件表层氧化，同时也可加快冷却速度，提高生产效率。Using hot water to continue cooling the workpiece can avoid internal stress and deformation caused by the cold stimulation of the workpiece, and on the other hand, it can avoid the oxidation of the surface layer of the workpiece caused by the dissolved oxygen in the water, and it can also speed up the cooling rate and improve production efficiency.
截齿在切割煤岩时需要承受高的周期性压应力、切应力和冲击负荷，并且截齿长时间切割煤岩过程中由于摩擦冲击，还会造成截齿温度升高，在如此复杂工况条件下工作的截齿，就要求其刀体既要耐磨又应具有较好的耐冲击性能。The picks need to withstand high periodic compressive stress, shear stress and impact load when cutting coal and rock, and the temperature of the pick will rise due to frictional impact during the long-term cutting of coal and rock. In such complex working conditions For picks that work under conditions, the cutter body is required to have both wear resistance and good impact resistance.
在铁碳相图中，奥氏体是高温相，是珠光体逆共析转变而成，球化退火的主要作用是使珠光体内的片状渗碳体以及先共析渗碳体都变为球粒状，均匀分布于铁素体基体中(这种组织称为球化珠光体)。因此使用本实施方式球化退火的碳钢硬度低、改善切削加工性，消除残余应力，稳定尺寸，减少变形与裂纹倾向，细化晶粒，调整组织和消除组织缺陷，适应采煤环境的需求。In the iron-carbon phase diagram, austenite is a high-temperature phase, which is formed by the inverse eutectoid transformation of pearlite. The main function of spheroidizing annealing is to make the flake cementite and proeutectoid cementite in the pearlite become Spherical, uniformly distributed in the ferrite matrix (this organization is called spheroidized pearlite). Therefore, the carbon steel using this embodiment of spheroidizing annealing has low hardness, improves machinability, eliminates residual stress, stabilizes size, reduces deformation and cracking tendency, refines grains, adjusts organization and eliminates organizational defects, and adapts to the needs of coal mining environment .
步骤300、抛丸清除氧化，使用抛丸机将工件表面的氧化层打磨抛光，并清洗工件表面的油污；Step 300, shot blasting to remove oxidation, use a shot blasting machine to polish and polish the oxide layer on the surface of the workpiece, and clean the oil on the surface of the workpiece;
此步骤利用抛丸清理去除表面氧化皮和杂质，提高外观质量，便于后面的磷皂镀膜加工，提高磷皂膜的粘附能力，同时利用抛丸强化改善截齿内部应力，使用高速运动的弹丸流连续冲击被强化工件表面，迫使靶材表面和表层在循环性变形过程中变化。具体表现为：显微组织结构发生改性；非均匀的塑变外表层引入残余压应力，内表层产生残余拉应力；外表面粗糙度发生变化。从而提高材料的疲劳断裂抗力，防止疲劳失效和塑性变形，提高疲劳寿命。In this step, shot blasting is used to remove surface oxide scale and impurities, improve the appearance quality, facilitate the subsequent phosphor soap coating processing, and improve the adhesion of the phosphor soap film. At the same time, shot blasting is used to improve the internal stress of the pick, and high-speed moving projectiles are used. The continuous impact of the flow strengthens the surface of the workpiece, forcing the surface and surface of the target to change in the cyclic deformation process. The specific manifestations are: the microstructure is modified; the non-uniform plastic deformation of the outer surface layer introduces residual compressive stress, and the inner surface layer generates residual tensile stress; the outer surface roughness changes. Thereby improving the fatigue fracture resistance of the material, preventing fatigue failure and plastic deformation, and improving fatigue life.
另外由于在本实施方式中的退火过程中，没有使用油淬或者其他接触到油污的操作，因此工件本身的油污量并不多，因此使用上述退火方式便于磷化作业的实施操作，利用酸性溶液清洗即可完成除油操作，而不需在除油槽中充分除油，因此可减少清洗成本和废水处理成本。In addition, because the annealing process in this embodiment does not use oil quenching or other operations that come into contact with oil, the amount of oil on the workpiece itself is not much, so the use of the above annealing method is convenient for the implementation of phosphating operations, and the use of acid solutions The oil removal operation can be completed by cleaning, without the need to fully remove oil in the oil removal tank, so the cleaning cost and waste water treatment cost can be reduced.
另外在步骤300中，清理工件表面油污的方式具体为：In addition, in step 300, the specific method for cleaning the surface of the workpiece is:
首先，使用抛丸机去除工件表面氧化层的同时，利用脉冲喷气口清除工件表面的颗粒，打磨掉的氧化层颗粒在喷气作用下，可脱离工件，从而实现一级清理，此步骤可粗略清除工件上的多数杂质。First of all, while using a shot blasting machine to remove the surface oxide layer of the workpiece, the pulse jet nozzle is used to remove the particles on the surface of the workpiece. The polished oxide layer particles can be separated from the workpiece under the action of the jet, so as to achieve the first level cleaning. This step can be roughly removed Most impurities on the workpiece.
喷气清洁后，将打磨完成的工件置于酸性溶液池内进行滚动式搓揉，清理工件上的油污和细颗粒，酸性溶液池可溶解油污，同时通过滚动式搓揉的清洗方式可将工件表面的油污和细颗粒进行二级清理，此步骤可集中清除工件上的多数杂质；After air-jet cleaning, place the polished workpiece in an acid solution tank for rolling rubbing to clean up the oil and fine particles on the workpiece. The acid solution tank can dissolve the oil, and the surface of the workpiece can be cleaned by rolling rubbing. Greasy dirt and fine particles are subjected to secondary cleaning, this step can concentrate on removing most of the impurities on the workpiece;
其中需要说明的是，目前大多清洗设备均匀超声波清洗，可极大改善对工件表面的清洁能力，但是超声波清洗机的成本高，而且后期维护比较复杂困难，另外超声波清洗机的空间有限，不能大量清洗截齿工件，资源浪费成本大，清洗效率不明显，因此需要对工件进行机械滚动式搓揉的清洗，增加批量清洗的截齿工件数量，同时保证清洁能力。It should be noted that most of the current cleaning equipment is uniform ultrasonic cleaning, which can greatly improve the cleaning ability of the surface of the workpiece. However, the cost of the ultrasonic cleaning machine is high, and the later maintenance is more complicated and difficult. In addition, the space of the ultrasonic cleaning machine is limited. Cleaning pick workpieces is a waste of resources and cost, and the cleaning efficiency is not obvious. Therefore, the workpiece needs to be cleaned by mechanical rolling and rubbing to increase the number of pick workpieces to be cleaned in batches while ensuring the cleaning ability.
因此，对工件进行滚动式搓揉的操作步骤具体为：Therefore, the specific operation steps for rolling the workpiece are as follows:
第一步，将工件放置在酸性溶液池内的升降台上，工件表面的油污可在酸性溶液内溶解，并且通过上下升降式的工件承载方式，便于对清洗完成后的工件转移，方便进行后续加工操作；In the first step, the workpiece is placed on the lifting platform in the acid solution tank. The oil on the surface of the workpiece can be dissolved in the acid solution, and the lifting method of the workpiece is carried out through the up and down lifting type of the workpiece to facilitate the transfer of the workpiece after cleaning and the subsequent processing operating;
第二步，在酸性溶液池的边缘设置线性移动台，在线性移动台上通过轴承安装Z字清洗杆，Z字清洗杆在升降台的支撑下可转动，线性移动台可沿着酸性溶液池的长边进行循环式的线性移动，并且在外力的作用下，Z字清洗杆可绕着轴承安装点旋转，Z字清洗杆可随着升降台的上下移位转动，不妨碍升降台的正常操作；The second step is to set up a linear moving table on the edge of the acid solution tank, and install a Z-shaped cleaning rod on the linear moving table through a bearing. The Z-shaped cleaning rod can be rotated under the support of the lifting table. The linear moving table can follow the acid solution tank. The long side of the Z-shaped cleaning rod can be rotated around the bearing installation point under the action of external force, and the Z-shaped cleaning rod can rotate with the up and down displacement of the lifting platform, which does not hinder the normal operation of the lifting platform. operating;
第三步，在Z字清洗杆上通过轴承安装搓揉工件的清洁辊，线性移动台带动Z字清洗杆同步移动，由于清洁辊与升降台上的工件之间的摩擦力，则清洁辊将会在线性移位时转动，实现对工件的滚动式搓揉，可将工件表面的油污残留，以及打磨的钢材细渣清除，改善清洁效果。In the third step, a cleaning roller for rubbing the workpiece is installed on the Z-shaped cleaning rod through a bearing. The linear moving table drives the Z-shaped cleaning rod to move synchronously. Due to the friction between the cleaning roller and the workpiece on the lifting platform, the cleaning roller will It can rotate when linearly shifting to realize rolling rubbing of the workpiece, which can remove the oil residue on the surface of the workpiece and the fine slag of the polished steel to improve the cleaning effect.
滚动搓揉清洁后，将清洗后的工件从酸性溶液池打捞，并且利用酸性溶液池上端的喷头进行二次酸性喷淋冲洗，直至强化工件表面无杂质油污，使用压强较大的水流冲击工件，可进一步将工件表面粘附的少量颗粒杂质冲洗，实现完全清洗。After rolling, rubbing and cleaning, the cleaned workpiece is salvaged from the acid solution pool, and the nozzle at the upper end of the acid solution pool is used for secondary acid spray flushing until the surface of the strengthened workpiece is free of impurities and oil stains. The workpiece can be impacted by a higher-pressure water stream. The small amount of particles adhering to the surface of the workpiece is further rinsed to achieve complete cleaning.
二次酸性喷淋冲洗使用的溶液酸性强度比较低，可避免酸洗液进入磷化池而造成磷化液酸度过大，影响磷化效果。The acid strength of the solution used in the secondary acid spray flushing is relatively low, which can prevent the pickling solution from entering the phosphating tank and causing the phosphating solution to become too acidic and affecting the phosphating effect.
上述步骤可避免配置多组清洗设备，减少清洗成本，并且降低对环境的污染，另外清洗 完毕的工件表面光滑整洁，便于磷化膜的均匀着附，避免造成磷化膜破损，同时改善耐磨材料与工件钢件之间的粘结力，防止磷化膜脱落。The above steps can avoid the configuration of multiple sets of cleaning equipment, reduce cleaning costs, and reduce environmental pollution. In addition, the surface of the cleaned workpiece is smooth and clean, which facilitates the uniform attachment of the phosphate film, avoids damage to the phosphate film, and improves wear resistance. The bonding force between the material and the workpiece steel prevents the phosphating film from falling off.
另外使用酸性溶液进行清洗，可进一步的去除金属工件表面的氧化层，改善工件表面的洁净度，避免造成在磷皂反应时工件表面无法覆膜。In addition, the use of acidic solution for cleaning can further remove the oxide layer on the surface of the metal workpiece, improve the cleanliness of the surface of the workpiece, and prevent the surface of the workpiece from being unable to be coated during the phosphorus soap reaction.
步骤400、一次磷皂化，将清洗后的工件按照工序置入磷化池和皂化池，对工件表面塑性；Step 400: Phosphorus saponification once, and the cleaned work piece is placed in the phosphating tank and the saponification tank according to the procedure to plasticize the surface of the work piece;
需要补充说明的是，工件在磷化池的磷化处理，也称磷酸盐处理，是将工件置于中温锌钙系磷化液中，在短时间内工件表面形成一层浅灰色至深灰色、难溶于水、细而致密的磷酸盐薄膜—锌磷化膜的过程，磷化液温度为60-80℃，磷化时间为10-20min，游离酸度为1.2-2.4，总酸度为16-26。What needs to be added is that the phosphating treatment of the workpiece in the phosphating pool, also called phosphate treatment, is to place the workpiece in a medium-temperature zinc-calcium phosphating solution to form a layer of light gray to dark gray on the surface of the workpiece in a short time , Hardly soluble in water, fine and dense phosphate film-zinc phosphate film process, phosphating solution temperature is 60-80℃, phosphating time is 10-20min, free acidity is 1.2-2.4, total acidity is 16 -26.
皂化处理，是将已经磷化好的工件置于含有16-18碳的饱和脂肪酸皂、减磨极压剂和拉拔润滑剂的皂液中，皂液中的以上成分与工件表面的锌磷化膜反应形成脂肪酸锌膜和皂膜层，脂肪酸锌膜和皂膜层增加了工件加工变形区的塑性厚度，在模具孔和加工材料件形成润滑膜，可大幅度减小热量，防止金属烧结和熔粘等，由于在拉模和拉件中起到减磨介质和塑性作用，从而提高拉拔产品的表面光洁度和加工精度，减少拉拔工具和拉拔模间的磨损，皂化溶液的pH值为7.8-8.8，皂化溶液的温度为70-80℃，皂化处理时间为15-30min。Saponification treatment is to put the phosphated workpiece in a soap solution containing saturated fatty acid soap with 16-18 carbon, anti-friction extreme pressure agent and drawing lubricant. The above components in the soap solution and the zinc and phosphorus on the surface of the workpiece The chemical film reaction forms fatty acid zinc film and soap film layer. The fatty acid zinc film and soap film layer increase the plastic thickness of the deformation zone of the workpiece, and form a lubricating film in the mold hole and the processed material, which can greatly reduce heat and prevent metal sintering And melt adhesion, etc., due to the anti-friction medium and plasticity in the drawing die and drawing parts, thereby improving the surface finish and processing accuracy of the drawn product, reducing the wear between the drawing tool and the drawing die, and the pH of the saponification solution The value is 7.8-8.8, the temperature of the saponification solution is 70-80°C, and the saponification treatment time is 15-30 min.
由于在磷化反应时，工件表面溶解下来的铁只有一部分Fe2+能参与成膜，另外一部分Fe2+被氧化成Fe3+，Fe3+与磷酸根结合形成不溶性的磷酸铁(即磷化渣)从溶液汇总析出，而如果不对过多的磷化渣进行控制处理，不但会污染磷化液，缩短其使用寿命，同时还会在形成磷化膜的时候，附着在工件表面，影响磷化膜的粘接能力，造成磷化膜容易脱落的问题，严重影响磷化结果。Because during the phosphating reaction, only part of the iron dissolved on the surface of the workpiece can participate in the film formation, and the other part of Fe2+ is oxidized to Fe3+, and Fe3+ combines with phosphate to form insoluble iron phosphate (ie phosphating slag). If the excessive phosphating slag is not controlled, it will not only pollute the phosphating solution and shorten its service life, but also adhere to the surface of the workpiece when the phosphating film is formed, affecting the bonding ability of the phosphating film. Causes the problem that the phosphating film is easy to fall off, which seriously affects the phosphating result.
因此本实施方式将通过下面的磷化反应方式，来控制过多的磷化渣接触到工件表面，从而提高磷化膜的附着能力。Therefore, in this embodiment, the following phosphating reaction method is used to control excessive phosphating slag from contacting the surface of the workpiece, thereby improving the adhesion of the phosphating film.
磷化池进行磷化反应的实现步骤具体为：The specific steps of the phosphating pool for the phosphating reaction are as follows:
步骤401、在磷化池的底部增设可上下移动的载物台，在载物台上设置若干个均匀平行分布的工件装载道，并且在每条工件装载道的两侧均设置沉淀斜板，沉淀斜板与工件装载道结合组成锥形斜板沉淀槽。Step 401: A stage that can move up and down is added to the bottom of the phosphating tank, a number of evenly parallel workpiece loading lanes are set on the stage, and precipitation sloping plates are set on both sides of each workpiece loading lane. The sedimentation inclined plate is combined with the workpiece loading channel to form a conical inclined plate sedimentation tank.
步骤402、在每条工件装载道的两侧均安装可上下伸缩的框型支架，并且框型支架内设置可拆卸的过滤半透膜；Step 402: Install frame-shaped supports that can be extended up and down on both sides of each workpiece loading channel, and a detachable filter semi-permeable membrane is arranged in the frame-shaped supports;
特别说明的是，载物台可按照频率进行上下左右方向的抖动，使得工件表面均匀进行磷化反应，并生成均匀的磷化膜。In particular, the stage can be shaken up, down, left, and right according to the frequency, so that the surface of the workpiece can undergo a uniform phosphating reaction, and a uniform phosphate film can be formed.
工件可安装在工件装载道上进行磷化处理，在磷化处理中产生的磷化渣将会下沉至锥形斜板沉淀槽内收集，因此可隔离工件与磷化渣之间的接触，避免磷化渣过多粘附在工件表面，提高磷化膜与工件之间的粘接力。The workpiece can be installed on the workpiece loading channel for phosphating treatment. The phosphating slag generated during the phosphating treatment will sink to the conical inclined plate sedimentation tank for collection, so the contact between the workpiece and the phosphating slag can be isolated to avoid Too much phosphating slag adheres to the surface of the workpiece to improve the adhesion between the phosphating film and the workpiece.
上述步骤的具体实现原理如下：首先工件安插在工件装载道上进行磷化反应时，载物台可按照频率进行上下左右方向的抖动，可均匀磷化液的溶度，提高磷化反应处理效率，并且在抖动的过程中，将工件氧化的Fe 2+、Zn 2+等金属离子分散到溶液中，进一步提高工件表面与磷化液的接触面积，提高磷化反应活性速度。 The specific realization principle of the above steps is as follows: First, when the workpiece is placed on the workpiece loading channel for phosphating reaction, the stage can shake up, down, left, and right according to the frequency, which can uniform the solubility of the phosphating solution and improve the efficiency of phosphating reaction. And in the shaking process, the metal ions such as Fe 2+ and Zn 2+ oxidized by the workpiece are dispersed into the solution to further increase the contact area between the surface of the workpiece and the phosphating solution and increase the phosphating reaction activity rate.
而且在磷化反应时，Fe 2+、Zn 2+等金属离子分散到溶液的过程中，过滤半透膜只选择性的允许被氧化的Fe 3+穿过过滤半透膜进入到过滤半透膜外侧的溶液内，从而只能正向透过过滤半透膜，不能反向透过过滤半透膜再次进入过滤半透膜内部，也就是说，过滤半透膜的外侧面不影响溶液中其他离子的渗透作用，只对Fe 3+离子进行选择性隔离，也阻止磷化渣沉淀的透入，同时过滤半透膜的内侧面只对Fe 3+离子进行选择性透过，而其他的离子则不能透过。 Moreover, during the phosphating reaction, when Fe 2+ , Zn 2+ and other metal ions are dispersed into the solution, the filter semipermeable membrane only selectively allows the oxidized Fe 3+ to pass through the filter semipermeable membrane and enter the filter semipermeable In the solution on the outside of the membrane, it can only penetrate the semi-permeable filter membrane in the forward direction, and cannot pass through the semi-permeable filter membrane in the reverse direction to enter the inside of the semi-permeable filter membrane again, that is, the outer surface of the semi-permeable filter membrane does not affect the solution. The permeation effect of other ions can only selectively isolate Fe 3+ ions and prevent the penetration of phosphating slag precipitation. At the same time, the inner side of the filtering semipermeable membrane only selectively permeates Fe 3+ ions, and other Ions are impermeable.
此种过滤半透膜保证磷酸盐沉淀结晶成为磷化膜的正常操作，而避免磷化渣浮游在磷化膜上，影响磷化膜的堆集附着效果。This semi-permeable filter membrane ensures the normal operation of phosphate precipitation and crystallization into the phosphate film, and prevents the phosphate slag from floating on the phosphate film and affects the stacking and adhesion effect of the phosphate film.
步骤403、将框型支架向下按压收缩，将工件安插在工件装载道上的下沉卡槽上，然后在将框型支架向上提拉伸长形成护栏；Step 403: Press and shrink the frame-shaped bracket downwards, insert the workpiece on the sinking slot on the workpiece loading channel, and then lift and stretch the frame-shaped bracket to form a guardrail;
步骤404、在锥形斜板沉淀槽的底部设置弧形收集船板，将磷化沉渣集中收纳在弧形收集船板内；Step 404: Set an arc-shaped collection ship plate at the bottom of the conical inclined plate sedimentation tank, and collect the phosphated sediment in the arc-shaped collection ship plate;
框型支架可收缩，便于将工件安插在工件装载道上的下沉卡槽上，同时框型支架可拉伸，形成护栏，选择性的透过Fe 3+，避免磷化渣影响磷化膜的着附效果。 The frame-shaped bracket can be contracted to facilitate the placement of the workpiece on the sinking slot on the workpiece loading channel. At the same time, the frame-shaped bracket can be stretched to form a guardrail, selectively permeating Fe 3+ to prevent the phosphating slag from affecting the phosphating film Attached effect.
磷化渣沿着锥形斜板沉淀槽下沉，弧形收集船板可直接收集磷化渣，避免对磷化液产生污染。The phosphating slag sinks along the conical inclined plate sedimentation tank, and the arc-shaped collecting ship plate can directly collect the phosphating slag to avoid pollution to the phosphating solution.
步骤405、将磷化后的工件置于皂化池内进行皂化处理。Step 405: Place the phosphated workpiece in a saponification tank for saponification treatment.
磷化处理和皂化处理的作用均是给基体金属提供保护，在一定程度上防止金属被腐蚀，用于涂漆前打底，提高漆膜层的附着力与防腐蚀能力，在金属冷加工工艺中起减摩润滑使用，便于下一步的冷挤压处理，避免工件内部应力变形。Both the phosphating treatment and the saponification treatment provide protection to the base metal and prevent the metal from being corroded to a certain extent. It is used for primer before painting to improve the adhesion and anti-corrosion ability of the paint film layer. It is used in the metal cold working process. The anti-friction lubrication is used to facilitate the next cold extrusion treatment and avoid the internal stress and deformation of the workpiece.
步骤500、一次冷挤压，将磷皂塑性后的工件进行一次挤压改性；Step 500: Perform a cold extrusion to modify the workpiece after the phosphor soap plasticity by extrusion;
进行二次磷皂化之前，需要对一次冷挤压后的工件进行酸洗清污，将工件在挤压时粘附的表面污物清洗脱落。Before the secondary phosphorus saponification, the workpiece after a cold extrusion needs to be pickled and cleaned, and the surface dirt adhering to the workpiece during the extrusion is cleaned off.
步骤600、二次磷皂化，将一次挤压后的工件重新置入磷化池和皂化池，对初级工件表面二次塑性；Step 600, secondary phosphorus saponification, the workpiece after the primary extrusion is placed in the phosphating pool and the saponification pool again to plasticize the surface of the primary workpiece;
步骤700、二次冷挤压，将磷皂塑性后的工件进行二次挤压改性；Step 700, secondary cold extrusion, performing secondary extrusion modification on the workpiece after phosphor soap plasticity;
步骤800、外圆加工，将工件冷却至室温后，使用车削方法加工工件的外圆表面生产截齿。In step 800, the outer circle is processed. After the workpiece is cooled to room temperature, the outer surface of the workpiece is processed by a turning method to produce picks.
虽然，上文中已经用一般性说明及具体实施例对本发明作了详尽的描述，但在本发明基础上，可以对之作一些修改或改进，这对本领域技术人员而言是显而易见的。因此，在不偏离本发明精神的基础上所做的这些修改或改进，均属于本发明要求保护的范围。Although the present invention has been described in detail above with general descriptions and specific embodiments, some modifications or improvements can be made on the basis of the present invention, which is obvious to those skilled in the art. Therefore, these modifications or improvements made without departing from the spirit of the present invention belong to the scope of the present invention.
工业实用性Industrial applicability
本发明公开了采煤机用的截齿，包括连接轴部和切割顶帽，连接轴部与切割顶帽一体化成型，并且切割顶帽的外表面设有若干个内沉卡槽；还公开了采煤机用的截齿加工方法，包括如下步骤：下料炼烧；球化退火，将工件从燃烧室取出，控制工件冷却速度；抛丸清除氧化，将工件表面的氧化层打磨抛光，并清洗工件表面的油污；一次磷皂化；一次冷挤压；酸性清洗；二次磷皂化；二次冷挤压；外圆加工。通过真空隔离的退火处理方式，改变工件内部组织机构应力，保证工件的性能适应采煤过程的需求，另外通过稀有空气隔离对流和热水冷控降温的方式，避免工件表面产生油污杂质，同时避免工件表面氧化，降低工件清洗的成本，提高后续磷皂处理覆膜的粘接力；磷化反应池可选择性控制离子渗透，形成工件与磷化渣之间的隔离作用，可避免过多的磷化渣污染并缩短磷化液的使用寿命，同时还防止磷化渣接近工件表面影响磷化膜质量，防止磷化渣破坏磷化膜的密集性，从而提高磷化薄膜涂层的附着力和耐腐蚀性。The invention discloses a pick for a coal mining machine, comprising a connecting shaft part and a cutting top cap, the connecting shaft part and the cutting top cap are integrally formed, and the outer surface of the cutting top cap is provided with a number of inner sinking grooves; also disclosed The cutting tooth processing method for coal mining machine includes the following steps: cutting and smelting; spheroidizing annealing, removing the workpiece from the combustion chamber, controlling the cooling rate of the workpiece; removing the oxidation by shot blasting, and polishing the oxide layer on the surface of the workpiece. And clean the oil on the surface of the workpiece; primary phosphorus saponification; primary cold extrusion; acid cleaning; secondary phosphorus saponification; secondary cold extrusion; external processing. The vacuum-isolated annealing treatment method changes the internal organizational stress of the workpiece to ensure that the performance of the workpiece adapts to the needs of the coal mining process. In addition, the rare air isolation convection and the hot water cooling control method can prevent the surface of the workpiece from oily impurities and at the same time. The surface of the workpiece is oxidized, reducing the cost of workpiece cleaning, and improving the adhesion of the subsequent phosphor soap treatment film; the phosphating reaction tank can selectively control ion penetration, forming a separation between the workpiece and the phosphating slag, and avoid excessive Phosphating slag contaminates and shortens the service life of the phosphating solution. At the same time, it prevents the phosphating slag from approaching the surface of the workpiece and affecting the quality of the phosphating film, preventing the phosphating slag from destroying the density of the phosphating film, thereby improving the adhesion of the phosphating film coating And corrosion resistance.

Claims (10)

  1. 一种采煤机用的截齿，其特征在于，包括连接轴部(1)和切割顶帽(2)，所述连接轴部(1)与切割顶帽(2)一体化成型，并且所述切割顶帽(2)的外表面设有若干均匀分布的内沉卡槽(3)，所述内沉卡槽(3)的侧剖面呈三角形结构，并且每个所述内沉卡槽(3)的外边缘均设有外延斜面。A pick for a shearer, which is characterized by comprising a connecting shaft portion (1) and a cutting top cap (2), the connecting shaft portion (1) and the cutting top cap (2) are integrally formed, and the The outer surface of the cutting top cap (2) is provided with a number of evenly distributed inner sinking grooves (3), the side section of the inner sinking grooves (3) is a triangular structure, and each of the inner sinking grooves (3) 3) The outer edges are all provided with an extension slope.
  2. 根据权利要求1所述的一种采煤机用的截齿及其加工方法，其特征在于：所述连接轴部(1)与切割顶帽(2)的外表面设有耐磨磷化膜层和皂化膜层。The pick for a coal mining machine and its processing method according to claim 1, characterized in that: the outer surface of the connecting shaft portion (1) and the cutting top cap (2) is provided with a wear-resistant phosphate film Layer and saponified film layer.
  3. 根据权利要求1所述的一种采煤机用的截齿及其加工方法，其特征在于：所述连接轴部(1)与切割顶帽(2)的尺寸过渡段均为光滑连接。The pick for a coal mining machine and its processing method according to claim 1, characterized in that the size transition sections of the connecting shaft portion (1) and the cutting top cap (2) are smoothly connected.
  4. 一种采煤机用的截齿加工方法，其特征在于：包括如下步骤：A cutting tooth processing method for a shearer is characterized in that it comprises the following steps:
    步骤100、下料炼烧，将工件集中置于燃烧室内缓慢加热；Step 100, blanking and smelting, centralizing the workpiece in the combustion chamber and slowly heating it;
    步骤200、球化退火，将工件从燃烧室取出，控制工件冷却速度；Step 200, spheroidizing annealing, taking the workpiece out of the combustion chamber, and controlling the cooling rate of the workpiece;
    步骤300、抛丸清除氧化，使用抛丸机将工件表面的氧化层打磨抛光，并清洗工件表面的油污；Step 300, shot blasting to remove oxidation, use a shot blasting machine to polish and polish the oxide layer on the surface of the workpiece, and clean the oil on the surface of the workpiece;
    步骤400、一次磷皂化，将清洗后的工件按照工序置入磷化池和皂化池，对工件表面塑性；Step 400: Phosphorus saponification once, and the cleaned work piece is placed in the phosphating tank and the saponification tank according to the procedure to plasticize the surface of the work piece;
    步骤500、一次冷挤压，将磷皂塑性后的工件进行一次挤压改性；Step 500: Perform a cold extrusion to modify the workpiece after the phosphor soap plasticity by extrusion;
    步骤600、二次磷皂化，将一次挤压后的工件重新置入磷化池和皂化池，对初级工件表面二次塑性；Step 600, secondary phosphorus saponification, the workpiece after the primary extrusion is placed in the phosphating pool and the saponification pool again to plasticize the surface of the primary workpiece;
    步骤700、二次冷挤压，将磷皂塑性后的工件进行二次挤压改性；Step 700, secondary cold extrusion, performing secondary extrusion modification on the workpiece after phosphor soap plasticity;
    步骤800、外圆加工，将工件冷却至室温后，使用车削方法加工工件的外圆表面生产截齿。In step 800, the outer circle is processed. After the workpiece is cooled to room temperature, the outer surface of the workpiece is processed by a turning method to produce picks.
  5. 根据权利要求4所述的一种采煤机用的截齿加工方法，其特征在于，在步骤200中，球化退火的具体步骤为：The method for processing picks for coal mining machines according to claim 4, characterized in that, in step 200, the specific steps of spheroidizing annealing are:
    步骤201、燃烧室持续加热工件直至温度达到735℃-740℃，保持此温度煅烧截齿钢体工件20-30min；Step 201: The combustion chamber continues to heat the workpiece until the temperature reaches 735°C-740°C, and the pick steel body workpiece is burned at this temperature for 20-30 minutes;
    步骤202、将工件从燃烧室取出，移至真空冷却炉内隔离冷却，向真空冷却炉中通入氩气，通过空气对流方式，控制冷却速度保持在2-3℃/s；Step 202: Take the workpiece out of the combustion chamber, move it to a vacuum cooling furnace for isolation and cooling, pass argon into the vacuum cooling furnace, and control the cooling rate to maintain 2-3°C/s through air convection;
    步骤203、隔离冷却10-15min后，向真空冷却炉内的工件喷淋循环冷却热水，控制 冷却速度保持在5-10℃/s；Step 203: After 10-15 minutes of isolation and cooling, spray circulating cooling hot water to the workpiece in the vacuum cooling furnace, and control the cooling rate to maintain 5-10°C/s;
    步骤204、当工件表面温度降低至室温时，从真空冷却炉取出工件。Step 204: When the surface temperature of the workpiece drops to room temperature, take out the workpiece from the vacuum cooling furnace.
  6. 根据权利要求4所述的一种采煤机用的截齿加工方法，其特征在于，在步骤300中，清理工件表面油污的方式具体为：The method for processing picks for coal mining machines according to claim 4, characterized in that, in step 300, the method of cleaning the surface of the workpiece is specifically as follows:
    首先，使用抛丸机去除工件表面氧化层的同时，利用脉冲喷气口清除工件表面的颗粒；First of all, use the shot blasting machine to remove the surface oxide layer of the workpiece, and use the pulse jet to remove the particles on the surface of the workpiece;
    其次，将打磨完成的工件置于酸性溶液池内进行滚动式搓揉，清理工件上的油污和打磨颗粒；Secondly, place the polished workpiece in the acid solution pool for rolling rubbing to clean up the oil and grinding particles on the workpiece;
    最后，将清洗后的工件从酸性溶液池打捞，并且利用酸性溶液池上端的喷头进行二次酸性喷淋冲洗，直至强化工件表面无杂质油污。Finally, the cleaned workpiece is salvaged from the acid solution tank, and the nozzle at the upper end of the acid solution tank is used for secondary acid spray washing until the surface of the strengthened workpiece is free of impurities and oil.
  7. 根据权利要求6所述的一种采煤机用的截齿加工方法，其特征在于，对工件进行滚动式搓揉的操作步骤具体为：The method of processing a pick for a coal shearer according to claim 6, wherein the operation steps of rolling and kneading the workpiece are specifically:
    将工件放置在酸性溶液池内的升降台上；Place the workpiece on the lifting platform in the acid solution tank;
    在酸性溶液池的边缘设置线性移动台，在线性移动台上通过轴承安装Z字清洗杆，Z字清洗杆在升降台的支撑下可转动；A linear moving table is set on the edge of the acid solution tank, and a Z-shaped cleaning rod is installed on the linear moving table through a bearing. The Z-shaped cleaning rod can be rotated under the support of the lifting platform;
    在Z字清洗杆上通过轴承安装搓揉工件的清洁辊。A cleaning roller for rubbing the workpiece is installed on the Z-shaped cleaning rod through a bearing.
  8. 根据权利要求4所述的一种采煤机用的截齿加工方法，其特征在于，在步骤600进行二次磷皂化之前，需要对一次冷挤压后的工件进行酸洗清污，将工件在挤压时粘附的表面污物清洗脱落。The method for processing picks for coal mining machines according to claim 4, characterized in that, before performing the secondary phosphorus saponification in step 600, the workpiece after the first cold extrusion needs to be pickled and cleaned, and the workpiece The dirt on the surface adhered during squeezing is washed off.
  9. 根据权利要求4所述的一种采煤机用的截齿加工方法，其特征在于，在步骤400中，磷化反应和皂化反应的实现步骤具体为：The method for processing picks for coal mining machines according to claim 4, characterized in that, in step 400, the steps of realizing phosphating reaction and saponification reaction are specifically:
    步骤401、在磷化池的底部增设可上下移动的载物台，在载物台上设置若干个均匀平行分布的工件装载道，并且在每条工件装载道的两侧均设置沉淀斜板，沉淀斜板与工件装载道结合组成锥形斜板沉淀槽。Step 401: A stage that can move up and down is added to the bottom of the phosphating tank, a number of evenly parallel workpiece loading lanes are set on the stage, and precipitation sloping plates are set on both sides of each workpiece loading lane. The sedimentation inclined plate is combined with the workpiece loading channel to form a conical inclined plate sedimentation tank.
    步骤402、在每条工件装载道的两侧均安装可上下伸缩的框型支架，并且框型支架内设置可拆卸的过滤半透膜；Step 402: Install frame-shaped supports that can be extended up and down on both sides of each workpiece loading channel, and a detachable filter semi-permeable membrane is arranged in the frame-shaped supports;
    步骤403、将框型支架向下按压收缩，将工件安插在工件装载道上的下沉卡槽上，然后在将框型支架向上提拉伸长形成护栏；Step 403: Press and shrink the frame-shaped bracket downwards, insert the workpiece on the sinking slot on the workpiece loading channel, and then lift and stretch the frame-shaped bracket to form a guardrail;
    步骤404、在锥形斜板沉淀槽的底部设置弧形收集船板，将磷化沉渣集中收纳在弧形收集船板内；Step 404: Set an arc-shaped collection ship plate at the bottom of the conical inclined plate sedimentation tank, and collect the phosphated sediment in the arc-shaped collection ship plate;
    步骤405、将磷化后的工件置于皂化池内进行皂化处理。Step 405: Place the phosphated workpiece in a saponification tank for saponification treatment.
  10. 根据权利要求8所述的一种采煤机用的截齿加工方法，其特征在于，所述磷化池和皂化池可按照频率进行上下左右方向的抖动，使得工件表面均匀进行磷化反应，并生成均匀的磷化膜。The method for processing picks for coal mining machines according to claim 8, characterized in that the phosphating pool and the saponification pool can be shaken up, down, left and right according to frequency, so that the surface of the workpiece can be phosphated evenly And generate a uniform phosphate film.
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