S2M wheel shows the wear process of the A wheel. The wear of the star wheel is mainly the abrasive wear between the star wheel tooth surface and the sintered ore at high temperature. 1.3 The welding area is determined according to the wear process. The plane of the hexagonal surface near the center part has a faster transition and less wear during the movement of the friction surface. Its main function is to make the six sides of the star wheel shaft wear evenly and the transmission is stable. The flat portion near the two corners is the main load-bearing area of ​​the transmission and is severely worn. When repairing the old star wheel axle inspection, treat it according to the wear condition of each surface. The already rounded surface requires the entire surface to be repaired, and the semi-circular surface of the wear is mainly repaired by the semi-circular surface. Although the plane of the hexagonal surface near the center portion does not function much in the transmission, it does not return to a plane when repaired. The star wheel is mainly to recover the worn and broken teeth, and to improve the number of online repairs of the star wheel. 2 Preparations 1 Old parts inspection The outer hexagonal wear of the star axle is uneven, the middle wear is serious, the minimum size of the opposite side is SW680, the drawing requirements are SW700-0.5 on the opposite side, 20mm smaller than the drawing size; the journal of the star axle, drawing The requirements are f36n6, f350u6, 7. After disassembly, the geometric accuracy and roughness are found to meet the drawing requirements. Found hexagonal geometry subject to wear as the star wheel SW716, drawings SW701 +1, drawing larger than 16mm. The residue star tooth portion of the sling is approximately half of the original height of the face portion of the peeling layer residual alloy serious "2 stars The repair of the axle is prepared by drilling 10 holes in the inner hole and drilling 10 holes in the depth. The deep sampling test star wheel material is ZG30Mn. The surface inspection and ultrasonic exploration are performed on the star wheel shaft flaw detection, and the grade is not more than 2 grade defects. If there are cracks and other defects affecting the strength inside the surface and the inside of the tissue, it must be completely processed before proceeding to the next step. Supplementary flaw detection results The implementation of the 3 star axle surfacing process 1 The formulation of the process plan Table 1 The pre-weld inspection of the front axle of the north axle head of the welding before the welding is shown in Table 1. The original adjustment, the north axle head It is 2mm higher than the south shaft head. During the rotation of the north shaft head, the outer circle is moved 4mm, and the C and D faces are deformed. The welding order C surface is convex on the north side, and is welded from the C side during welding. The welding reference is determined to be slightly worn on the outermost sides of the shaft in the range of about 800 mm. Based on this, the entire shaft is straightened to ensure that the hexagonal edge dimensions after surfacing are 700 mm. 16 round bars are marked by the alignment line. Four welding standards are welded on each side, the fillets are not welded, and about 1 mm is left in the middle. After the selection of the electrode is sampled at the designated part, the chemical composition is as follows: The reason for selecting D112 for the number c is as follows: The other chemical components of the element cable 2 The welding process adjusts the two ends of the shaft to the level with the roller. Cover the shaft body with electric blanket (except the shaft head), preheat to 10C, and keep warm for 4 hours. The whole temperature control is above 24CTC. The shaft body is a section of 450mm, and the section is symmetrically welded. The welding specification is as small as possible and evenly welded. The weld overlay is within ±2 mm of the thickness of the reference surface. Monitoring the entire welding process with a level to pay close attention to the deformation of the shaft, the overall deformation of the shaft is controlled within 1mm. As shown in Table 2: hour, slow cooling. The shaft body inspection after welding and annealing is shown in Table 3 and Table 4: Table 2 Welding North North Shaft Shaft Central South Shaft Head Table 3 After Welding North Shaft Head Shaft Middle South Shaft Head Table 4 Postweld Annealing North Shaft Head Shaft The machining of the 3.3-star axle of the Zhongnan shaft head is used as the reference surface, and the universal milling head is used to turn the angle processing. 3.4 Problems and Disposal Problems After machining, it was found that the original shaft body was not welded at 200mm from the starting position of the hexagonal dimension, and there was a transverse crack with a length of 30mm70mm. There were several longitudinal cracks on the machined surface. Analysis of the crack analysis: transverse crack The mother body is self-contained, because the surface of the original parent body is welded with a wear layer (the weld bead can be seen), the composition is similar to 38Cr2MnMV. The cold welding operation in use produces transverse cracks, and the cracks are distributed in the weld (width 25mm) Within the range of the ring, the deepest is 15mm and the shallow is 2mm. The longitudinal crack is a fatigue crack. The disposal plan for the crack is as follows. The crack is removed by a sander and the colorant is displayed after inspection. Heat repair welding. The heating temperature is 30CTC, and the welding is carried out with J506 welding rod. After welding for 3 hours after welding, it is slowly cooled, polished and leveled to ensure no new cracks. The theoretical calculation and practical test of the repair process of the 4 star wheel 1 prove that the structure of the hexagonal square in the star wheel is simple and feasible. For the star tooth portion, the 75-thickness and 16Mn steel plate are cut according to the missing tooth shape, butt welding and full penetration weld. The welding surfacing plate and the star wheel claw are grounded by a welding rod similar to the mother material, and the wear resistant alloy layer is deposited. 2 The process implementation plan is put on the platform with the flat surface of the star wheel as the reference, and the butt welding is performed according to the missing tooth shape, butt welding and full penetration weld. Use the D112 electrode to make the bottom of the surfacing surface and the star claws. The inner hole machining is based on the three teeth of the star wheel, and the inner hole is machined to a specified size, and the end face is seen as a reference for assembly. The hot pack will heat the finished star wheel inner sleeve and the star wheel, and the interference will be exceeded. 44mm~0.15mm. The axial positioning block on the star wheel before assembly and the angle marking line. After the assembly is completed, the end face of the inner sleeve shall not protrude from the end face of the star wheel, and the position of the three teeth of the star wheel and the inner six sides shall be in the same position. Circumferential Weld Welding Spot welding of hot-filled star wheel welds and welding of double-sided circumferential welds. The weld is subjected to non-destructive testing, and the temperature of the JB/T11345 is performed for 4 hours, and the furnace is cooled. Wear layer surfacing. Welding with alloy electrode 856, the thickness of the alloy layer of the star wheel claw after surfacing is not less than 10mm, and the thickness of the alloy layer of the spoke assembly plate is not less than 5mm. Pay attention to the deformation of the star wheel claw, and the symmetry deviation of the star wheel claw in the direction of the rotation axis is smaller than 2mnu 5.1 垦 wheel hexagonal SW bolt table 1 2ft wheel actual assembly width check table 2 width number 12345678259.5 3 group assembly (assembly diagram as shown below fl wheel assembly diagram (1) according to Table 1 data and the actual work of the star wheel The process, taking the minimum data in each number, grouping according to the formed minimum intermixing star wheel, the grouping is as follows: the SW tolerance minimum gap 3 *.64SW tolerance minimum gap 3 *.43SW tolerance minimum mixing 3 - 0.1 SW tolerance 696, minimum clearance 6 (2) assembly process is as follows: 1 mapping the center line of the star wheel axle, install the spacer. From the middle to the two ends of the assembly, the minimum between the star wheel and the ffi suite is 3mm, the direction of each group of gear teeth 60% difference If the gap is too small, increase the spacer at both ends to adjust. 2 During the assembly process, the pitch is checked, the pitch deviation is controlled within 30mm, and the spacing between the plates is 200mm. The interference between the simulated star wheel and the slab during the process of revolving. According to the actual size after assembly, the thickness of the spacer is ensured to be 70mm85mm. 3 After the inspection is correct, the bearing is assembled with the tension sleeve gear coupling. (1) The hexagonal dimension of the star wheel axle is 690mm on the opposite side, and the repairing parts meet various mechanical performance requirements and usage requirements. (2) The geometric dimension of each part of the star wheel, the alloy layer is firmly bonded, and there are no defects such as cracked pores. The plane of rotation of the tooth is in the range of 10 mm. (3) After the assembly, the total gap is 7 meters in the range of 7 meters. The first single-roller crusher was used in September 2003. The star-shaft condition is normal. In July 2005, the second set passed the hot apricot. Test run.
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邯2400 single roll crusher repair
Two single-roll crushers were rebuilt in the front mu. The single-roll crusher is located at the discharge port of the sintering machine, and breaks the large sintered ore of about 1000'C into small indium particles. The form of failure is mainly abrasive wear. The new purchase will cost 3.2 million yuan and the repair cost will be 800,000 yuan. The repair and use can greatly reduce the production cost. The single-roll crusher was originally used in foreign countries. The length of the star-wheel shaft is 11 meters and the maximum diameter is 694mm. It is difficult to ensure the strength and accuracy of the star-wheel axle surfacing during the repair. 1 Analysis of the wear process of the 1M axle during the wear process analysis The structure of the star wheel axle and the star wheel is shown in Figure 1 and Figure 2. The middle of the star axle is heavily worn due to the large working load in the middle. The same side of the hexagonal side is severely worn and the wear of the three sides is light due to the structural design features. In the design, the one-side gap between the star wheel and the star wheel axle is 1mm. It is assumed that the hexagonal inside the star wheel is a non-wearable rigid body. Due to the existence of the gap, the star wheel is only driven by two or three corners at the initial transmission. After a period of running-in, it becomes a hexagonal contact, and it enters a smooth running state. As the usage time increases, the friction surface between the star wheel and the star wheel axis gradually shifts from the corner of the star wheel shaft to the center of the hexagonal plane. The star wheel and the star wheel axis A relative rotation occurs between the drive positions. When the wear of the star axle reaches the ideal state as shown in Figure 5, the transmission is lost. Since the six faces of the star wheel are inconsistent in use, some of the friction surfaces will continue to move toward the adjacent angle after moving to the center until the surface is rounded and loses transmission. In the later stage, the friction surface gradually becomes 5 faces, 4 faces... 1 face. In practical applications, the hexagonal wear of the star wheel is inevitable, and the simultaneous wear of both sides will shorten the time of the hexagonal transmission and the wear of the star wheel axle. The process does not change too much.