新型球磨机高锰钢衬板的开发与应用
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摘要
通过对球磨机衬板用耐磨材料的应用情况、工况条件、性能要求、合金元素作用的分析,针对鞍钢矿山公司齐大山选矿厂球磨机使用Mn_(13)耐磨衬板的条件下,设计了一种新型耐磨铸钢Mn_(13)Cr_2Ti钢,其控制成分为:C:1.20～1.30%,Si:0.40%～0.60%,Mn:12.5%～14.0%,Cr:1.5%～2.2%,Ti:0.1%～0.14%,V:0.15%～0.25%,Mo:0.3%～0.5%,P:＜0.05%,S:＜0.03%。在此基础上,对Mn_(13)Cr_2Ti钢的淬透性、热处理工艺、耐磨性进行了试验研究,并制定了熔炼、铸造、热处理工艺,进行了生产小试和装机试运行。试验结果表明,设计的Mn_(13)Cr_2Ti钢淬透性良好,能满足大型球磨机衬板的淬透性要求。其在1050℃奥氏体化后淬火+250℃×8小时回火后的综合机械性能较好,抗拉强度σ_b＞700MPa,无缺口冲击韧性σ_k＞150J/cm~2。组织分析表明,此时形成的回火马氏体+贝氏体+回火屈氏体+残余奥氏体+弥散碳化物的组织是其具有优良的综合机械性能的原因。此时其耐磨性好,比Mn_(13)提高15%～35%。生产小试与装机运行结果表明,Mn_(13)Cr_2Ti钢衬板的生产工艺较为简单,熔炼、铸造、热处理工艺易于掌握,使用寿命是Mn_(13)衬板的1.3倍。而技术经济分析则表明,Mn_(13)Cr_2Ti钢衬板的生产成本虽然略高于Mn_(13)衬板,但综合考虑磨矿效率与磨耗成本后,生产每吨Mn_(13)Cr_2Ti钢衬板仍可比Mn_(13)衬板多获利1230元,已经累计取得经济效益296400元,具有明显的经济与社会效益。
In this paper,the development of anti-wearing iron and steel is reviewed.Based on the situation that Mnl3 is used in QIDASHAN concentration plant of mine company in ANSHAN steel,a new kind of anti-wearing steel is designed which is called Mn_(13)Cr_2Ti through analyzing the wear behavior of the lining boards using in ball mills,the component of alloy elements and the particular demands of lining boards using in mine's ball mills.The cast structure,the quenched structure,mechanical property,the anti-wearing property and the producing process of the Mn_(13)Cr_2Ti steel has been studied. The composition range of alloy elements' is list as follows:C:1.20～1.30%,Si:0.40%～0.60%,Mn:12.5%～14.0%,Cr:1.5%～2.2%,Ti:0.1%～0.14%,V:0.15%～0.25%,Mo: 0.3%～0.5%,P＜0.05%,S＜0.03%.The result of application experiment shows that mechanical properties and anti-wearing property of Mn_(13)Cr_2Ti steel are optimized after the heat treatment of quenching after austenite at 1050℃and 8 hours' tempering at 250℃, the intensity exceeds 700MPa and the toughness is over 150J/cm~2.The fabric analysis shows that the organization of tempered martensite+bainite+temper troostite+retained austeninite+dispersion carbonide make it obtaining good comprehensive mechanical character.And the anti-wearing property of Mn_(13)Cr_2Ti steel is 15 percent to 35percent higher than Mn_(13)Industrial application shows that Mn_(13)Cr_2Ti steel lining board's producing process is simple and controllable and the durability of Mn_(13)Cr_2Ti steel lining board is 30 percent higher than Mnl3 lining board.And the cost-effectiveness analysis shows that the cost of Mn_(13)Cr_2Ti steel lining board production is a little higher than Mn_(13) lining board,but considering both of the efficiency of milling and the cost of tearing and wearing,the profit of Mn_(13)Cr_2Ti steel lining board is 1230 yuan more than Mn_(13)lining board.The economic benefit 296400 yuan has been obtained accumulative.It benefits to both economy and society markedly.
In this paper,the development of anti-wearing iron and steel is reviewed.Based on the situation that Mnl3 is used in QIDASHAN concentration plant of mine company in ANSHAN steel,a new kind of anti-wearing steel is designed which is called Mn_(13)Cr_2Ti through analyzing the wear behavior of the lining boards using in ball mills,the component of alloy elements and the particular demands of lining boards using in mine's ball mills.The cast structure,the quenched structure,mechanical property,the anti-wearing property and the producing process of the Mn_(13)Cr_2Ti steel has been studied. The composition range of alloy elements' is list as follows:C:1.20～1.30%,Si:0.40%～0.60%,Mn:12.5%～14.0%,Cr:1.5%～2.2%,Ti:0.1%～0.14%,V:0.15%～0.25%,Mo: 0.3%～0.5%,P＜0.05%,S＜0.03%.The result of application experiment shows that mechanical properties and anti-wearing property of Mn_(13)Cr_2Ti steel are optimized after the heat treatment of quenching after austenite at 1050℃and 8 hours' tempering at 250℃, the intensity exceeds 700MPa and the toughness is over 150J/cm~2.The fabric analysis shows that the organization of tempered martensite+bainite+temper troostite+retained austeninite+dispersion carbonide make it obtaining good comprehensive mechanical character.And the anti-wearing property of Mn_(13)Cr_2Ti steel is 15 percent to 35percent higher than Mn_(13)Industrial application shows that Mn_(13)Cr_2Ti steel lining board's producing process is simple and controllable and the durability of Mn_(13)Cr_2Ti steel lining board is 30 percent higher than Mnl3 lining board.And the cost-effectiveness analysis shows that the cost of Mn_(13)Cr_2Ti steel lining board production is a little higher than Mn_(13) lining board,but considering both of the efficiency of milling and the cost of tearing and wearing,the profit of Mn_(13)Cr_2Ti steel lining board is 1230 yuan more than Mn_(13)lining board.The economic benefit 296400 yuan has been obtained accumulative.It benefits to both economy and society markedly.
引文
铩颷1]李常锋,李文生,白创明.高锰钢球磨机衬板的生产技术[J].铸造技术,2004,6:405-406.
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[3]朱军,杨军.大型球磨机衬板材料的研究和应用[J].铸造技术,2005,26(12):1119-1121.
[4]温诗铸.摩擦学原理[M].北京:清华大学出版社,1990:412-430
[5]刘兴国.橡胶内衬球磨机的特点[J].山东陶瓷,2002,25(4):3-34
[6]周廷栋.超高锰钢ZGMn_(18)Cr_2组织及性能研究,四川大学.2003(05)
[7]赵学胜.球磨机衬板新材料的研究[J].中国矿业.2000(7):30-32.
[8]H.P.Jost.Tribology education and research[R].Jost ReP.DePartment ofEducation and Science,HMAO,London,1966.
[9]J.r.Burwell,Wear of Machine Elements[J].Wear,1957,No.1:115-119.
[10]仝健民.耐磨钢研究进展.水利电力机械[J].2003(02):12-13.
[11]曹菊艳.湿型球磨机槽行衬板工业性试验[J].铸造技术.2003(25).
[12]孙家枢.金属的磨损[M].北京:冶金工业出版社,1992:2-3.
[13]邵荷声,张清.金属的磨料磨损与耐磨材料[M].北京:机械工业出版社,1988:61-275.
[14]吴根炉.多元合金化耐磨铸钢的性能研究[J].安徽工业大学学报.2001.01.
[15]张得峰.耐磨锰钢组织性能与生产工艺的研究[D].兰州理工大学.2006.8.
[16]罗召光.球磨机衬板强韧化处理工艺研究[J].矿山机械.2002.04.
[17]张伟.球磨机衬板材质的研发和应用现状研究.莱钢科技 2005.5.
[18]黄汝清.新型球磨机衬板耐磨钢的研究及生产应用.昆明理工大学,2002.10.
[19]王荣滨,海燕.高锰钢破碎机齿板淬裂分析与强韧化处理[J].矿山机械,2002(1):10-12.
[20]刘英杰,成克强.磨损失效分析[M].北京:机械工业出版社,1991:2-21.
[21]张裕新等.湿式磨机磨球的腐蚀磨损[J].铸造,1999(11).
[22]邓海金.湿式条件下磨球的磨损及其选材[J].矿山机械,1988(8):19-26
[23]王道博,周家梅,刘吉安,杨士岭.济钢-炼铁厂球磨机衬板的改进[J].炼铁.2002(21):51-52.
铩颷24]张清.金属耐磨材料的发展近况[J].钢铁,1984,19(4)50-57.
[25]仝健民.低合金耐磨钢的合金设计[J].机械工程材料,1990,14(3):32-35.
[26]曲敬信,等.新型高强韧性、高耐磨性A-B钢及其抗冲击磨料磨损特性的研究[C].第五届全国金属耐磨材料学术会议文选集.1990.
[27]李恒德.高碳低合金钢锻造淬火钢球新工艺[J].机械工程材料,1990,14(3):59-60.
[26]李卫.耐磨钢铁件的市场与生产[J].铸造,2004,53(12):95-962.
[28]李茂林,常润,王定祥.磨机衬板磨损失效分析[M].北京:机械工业出版社,1985.
[29]罗元良等.磨球的应用与选材[J].矿山机械,1994(4):26-28.
[30]韩福生.低铬白口铸铁磨球的组织与性能研究.铸造,1993(6):16-20.
[31]邢建东等.在不同磨料磨损下高铬铸铁磨损过程的研究[D].铬系抗磨铸铁论文集,西安交通大学出版社,1986:15-39.
[32]符寒光.高铬铸铁基体组织对冲击磨损的影响.现代铸铁,1994(1):10-15
[33]王玉玮等.钒在高铬铸铁中的应用.铸造,1989(5):9-12
[34]张景辉等.变质高铬铸铁组织与性能的研究.铸造,1993(8):7-10
[35]丁厚福,崔方明,杜晓东.成分组织对衬板钢在腐蚀料浆环境下的冲击磨损性能与机理的影响[J].摩擦学报,2005,25(3):221-224.
[36]邵荷生,张清.金属的磨料磨损与耐磨材料[M].北京:机械工业出版社,1988:97-116.
[37]Sub Nam P.Overview of the Delimitation Theory of Wear[J].Wear,1977,44(1):1-16.
[38]Yang Y Y,Fang H S,Zheng Y K.The Failure Models Induced by White Layersduring Impact Wear[J].Wear,1995,185:17-22.
[39]王玉芳,王新龙.钢球磨机衬板失效原因分析及改进[J],冶金动力,2002(5):49-50.
[40]刘小鹏,张卫国,钟毅芳.机床模块化设计中的模块创建及应用.华中理工大学学报,2000(28):16-17.
[41]张后相.球磨机衬板选材分析,2005(33):55.
[42]朱军,杨军.大型球磨机衬板材料的研究和应用.铸造技术,2005,26(12):1119-1121.
[43]Lemster K,Graule T,Kueble J.Processing and microstructure of matrixcomposites prepared by pressureless Ti-activated infiltration using Fe-base and Ni-base alloys[J].Materials and Engineering,2003,(393):229-239.
铩颷44]Xu J,Ai JH,Xie XS,et al.Multi-element Ni-Cr-Mo-Cu surface alloyedlayer on steel using a double glow plasma process[J].Surface & CoatingTechnology,2003(69):142-147.
[45]Trudel.A.et.al.Effect of composition and heat treatment parameters onthe characteristics of austempered ductile irons.Can Metal.1997,365:289-298.
[2]许利民,吴静然,马世辉.球磨机衬板的选材及应用C[].承德石油高等专科学校学报,2005,7(2):23-25.
[3]朱军,杨军.大型球磨机衬板材料的研究和应用[J].铸造技术,2005,26(12):1119-1121.
[4]温诗铸.摩擦学原理[M].北京:清华大学出版社,1990:412-430
[5]刘兴国.橡胶内衬球磨机的特点[J].山东陶瓷,2002,25(4):3-34
[6]周廷栋.超高锰钢ZGMn_(18)Cr_2组织及性能研究,四川大学.2003(05)
[7]赵学胜.球磨机衬板新材料的研究[J].中国矿业.2000(7):30-32.
[8]H.P.Jost.Tribology education and research[R].Jost ReP.DePartment ofEducation and Science,HMAO,London,1966.
[9]J.r.Burwell,Wear of Machine Elements[J].Wear,1957,No.1:115-119.
[10]仝健民.耐磨钢研究进展.水利电力机械[J].2003(02):12-13.
[11]曹菊艳.湿型球磨机槽行衬板工业性试验[J].铸造技术.2003(25).
[12]孙家枢.金属的磨损[M].北京:冶金工业出版社,1992:2-3.
[13]邵荷声,张清.金属的磨料磨损与耐磨材料[M].北京:机械工业出版社,1988:61-275.
[14]吴根炉.多元合金化耐磨铸钢的性能研究[J].安徽工业大学学报.2001.01.
[15]张得峰.耐磨锰钢组织性能与生产工艺的研究[D].兰州理工大学.2006.8.
[16]罗召光.球磨机衬板强韧化处理工艺研究[J].矿山机械.2002.04.
[17]张伟.球磨机衬板材质的研发和应用现状研究.莱钢科技 2005.5.
[18]黄汝清.新型球磨机衬板耐磨钢的研究及生产应用.昆明理工大学,2002.10.
[19]王荣滨,海燕.高锰钢破碎机齿板淬裂分析与强韧化处理[J].矿山机械,2002(1):10-12.
[20]刘英杰,成克强.磨损失效分析[M].北京:机械工业出版社,1991:2-21.
[21]张裕新等.湿式磨机磨球的腐蚀磨损[J].铸造,1999(11).
[22]邓海金.湿式条件下磨球的磨损及其选材[J].矿山机械,1988(8):19-26
[23]王道博,周家梅,刘吉安,杨士岭.济钢-炼铁厂球磨机衬板的改进[J].炼铁.2002(21):51-52.
铩颷24]张清.金属耐磨材料的发展近况[J].钢铁,1984,19(4)50-57.
[25]仝健民.低合金耐磨钢的合金设计[J].机械工程材料,1990,14(3):32-35.
[26]曲敬信,等.新型高强韧性、高耐磨性A-B钢及其抗冲击磨料磨损特性的研究[C].第五届全国金属耐磨材料学术会议文选集.1990.
[27]李恒德.高碳低合金钢锻造淬火钢球新工艺[J].机械工程材料,1990,14(3):59-60.
[26]李卫.耐磨钢铁件的市场与生产[J].铸造,2004,53(12):95-962.
[28]李茂林,常润,王定祥.磨机衬板磨损失效分析[M].北京:机械工业出版社,1985.
[29]罗元良等.磨球的应用与选材[J].矿山机械,1994(4):26-28.
[30]韩福生.低铬白口铸铁磨球的组织与性能研究.铸造,1993(6):16-20.
[31]邢建东等.在不同磨料磨损下高铬铸铁磨损过程的研究[D].铬系抗磨铸铁论文集,西安交通大学出版社,1986:15-39.
[32]符寒光.高铬铸铁基体组织对冲击磨损的影响.现代铸铁,1994(1):10-15
[33]王玉玮等.钒在高铬铸铁中的应用.铸造,1989(5):9-12
[34]张景辉等.变质高铬铸铁组织与性能的研究.铸造,1993(8):7-10
[35]丁厚福,崔方明,杜晓东.成分组织对衬板钢在腐蚀料浆环境下的冲击磨损性能与机理的影响[J].摩擦学报,2005,25(3):221-224.
[36]邵荷生,张清.金属的磨料磨损与耐磨材料[M].北京:机械工业出版社,1988:97-116.
[37]Sub Nam P.Overview of the Delimitation Theory of Wear[J].Wear,1977,44(1):1-16.
[38]Yang Y Y,Fang H S,Zheng Y K.The Failure Models Induced by White Layersduring Impact Wear[J].Wear,1995,185:17-22.
[39]王玉芳,王新龙.钢球磨机衬板失效原因分析及改进[J],冶金动力,2002(5):49-50.
[40]刘小鹏,张卫国,钟毅芳.机床模块化设计中的模块创建及应用.华中理工大学学报,2000(28):16-17.
[41]张后相.球磨机衬板选材分析,2005(33):55.
[42]朱军,杨军.大型球磨机衬板材料的研究和应用.铸造技术,2005,26(12):1119-1121.
[43]Lemster K,Graule T,Kueble J.Processing and microstructure of matrixcomposites prepared by pressureless Ti-activated infiltration using Fe-base and Ni-base alloys[J].Materials and Engineering,2003,(393):229-239.
铩颷44]Xu J,Ai JH,Xie XS,et al.Multi-element Ni-Cr-Mo-Cu surface alloyedlayer on steel using a double glow plasma process[J].Surface & CoatingTechnology,2003(69):142-147.
[45]Trudel.A.et.al.Effect of composition and heat treatment parameters onthe characteristics of austempered ductile irons.Can Metal.1997,365:289-298.