采煤机截齿齿体耐磨性能研究
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摘要
截齿由于其恶劣的工作环境,每开采1万吨煤消耗截齿400~1300个,中国目前年产煤约12亿吨,因此作为采煤机上的易损件,其需求量是非常大的。截齿系统中的齿体部分磨损失效占到其总体失效的45~50%。由于它的大消耗量,所以若能提高截齿的耐磨性能,会产生巨大的经济效益。
本文针对于采煤机截齿磨损失效的问题,采用多种化学热处理对齿体材料40CrNiMo进行强化处理,利用XRD、扫描电镜进行渗层分析,并与未强化试样进行耐磨性对比试验,最终确定出最佳处理工艺,并探讨了齿体磨损机理。
(1)气体渗碳后得到的渗层厚度约为1.3mm,碳化物弥散分布,对基体起到弥散强化作用。
(2)在渗硼剂配方为52%旧渗硼剂+35%FeB+ 5%KBF+ 8%稀土氧化物(CeO)下,渗硼工艺为930℃×8h,渗硼层的相主要为Fe2B,最终的渗硼层的厚度约为123μm,平均显微硬度约为HV1518.6。
(3)在渗铌剂配方为50%铌铁+32%AL_2O_3+ 10%NH_4Cl+ 8%稀土氧化镧(La_2O_3)下,渗铌工艺为990℃×7h,渗铌层的相主要为NbC,最终的渗铌层的厚度约为10μm,平均显微硬度约为HV2770。
(4)在模拟截齿磨损环境下,耐磨性能从大到小依次为碳-铌复合渗,碳-硼复合渗,渗碳,未化学热处理强化试样。截齿试样的主要失效形式是磨粒磨损,磨损方式一般为切削和犁沟。
The consumption of cutting pick is from 400 to 1300 to explore 10000 tons coal because of poor working conditions. At present, the annual output of coal is 1.2 billion tons in China, with the result of which the quantity of cutting pick is very large. The failures of cutting pick body parts in cutting systems account from 45% to 50% over all the failure of wear failure. Because of the quantity of consumption, it will permit enormous economic benefits if the wear resistance of cutting teeth can be improved.
This article studies the wear failure of shearers cutting pick, variety of chemical heat treatment is applied to improve strength, XRD and SEM are used to analysis of diffusion layer and comparison with non-strength sample, find the best heat treatment and discuss the wear mechanism
(1) Gas carburizing workers get the carburized layer thickness is about 1.3mm; carbides dispersed on the substrate play the role of dispersion strengthening.
(2) In the formula for making boronizing agent: the old formula of 52% boronizing agent +35% FeB + 5% KBF + 8% CeO, the infiltration of boron thermal process is at 930℃for 8 hours, the main phase boride layer is the Fe_2B, the final thickness of boride layer is about 123μm, the average hardness of about HV 1518.6.
(3) In the seepage niobium formula is 50% niobium iron +32% AL_2O_3+ 10% NH4Cl + 8%La_2O_3, the seepage niobium process is at 990℃for 7 hours, seepage niobium layer phase mainly is NbC, niobium layer permeability was the final thickness of about 10μm, the average hardness of approximately HV2770.
(4) In a simulated environment of abrasion, the wear resistance in order from largest to smallest is C-Nb composite diffusion; C-B composite diffusion, carburizing, heat treatment is not enhanced chemical samples. Pick the main failure mode of the sample is abrasive wear, the wear mode generally cutting and plowing.
本文针对于采煤机截齿磨损失效的问题,采用多种化学热处理对齿体材料40CrNiMo进行强化处理,利用XRD、扫描电镜进行渗层分析,并与未强化试样进行耐磨性对比试验,最终确定出最佳处理工艺,并探讨了齿体磨损机理。
(1)气体渗碳后得到的渗层厚度约为1.3mm,碳化物弥散分布,对基体起到弥散强化作用。
(2)在渗硼剂配方为52%旧渗硼剂+35%FeB+ 5%KBF+ 8%稀土氧化物(CeO)下,渗硼工艺为930℃×8h,渗硼层的相主要为Fe2B,最终的渗硼层的厚度约为123μm,平均显微硬度约为HV1518.6。
(3)在渗铌剂配方为50%铌铁+32%AL_2O_3+ 10%NH_4Cl+ 8%稀土氧化镧(La_2O_3)下,渗铌工艺为990℃×7h,渗铌层的相主要为NbC,最终的渗铌层的厚度约为10μm,平均显微硬度约为HV2770。
(4)在模拟截齿磨损环境下,耐磨性能从大到小依次为碳-铌复合渗,碳-硼复合渗,渗碳,未化学热处理强化试样。截齿试样的主要失效形式是磨粒磨损,磨损方式一般为切削和犁沟。
The consumption of cutting pick is from 400 to 1300 to explore 10000 tons coal because of poor working conditions. At present, the annual output of coal is 1.2 billion tons in China, with the result of which the quantity of cutting pick is very large. The failures of cutting pick body parts in cutting systems account from 45% to 50% over all the failure of wear failure. Because of the quantity of consumption, it will permit enormous economic benefits if the wear resistance of cutting teeth can be improved.
This article studies the wear failure of shearers cutting pick, variety of chemical heat treatment is applied to improve strength, XRD and SEM are used to analysis of diffusion layer and comparison with non-strength sample, find the best heat treatment and discuss the wear mechanism
(1) Gas carburizing workers get the carburized layer thickness is about 1.3mm; carbides dispersed on the substrate play the role of dispersion strengthening.
(2) In the formula for making boronizing agent: the old formula of 52% boronizing agent +35% FeB + 5% KBF + 8% CeO, the infiltration of boron thermal process is at 930℃for 8 hours, the main phase boride layer is the Fe_2B, the final thickness of boride layer is about 123μm, the average hardness of about HV 1518.6.
(3) In the seepage niobium formula is 50% niobium iron +32% AL_2O_3+ 10% NH4Cl + 8%La_2O_3, the seepage niobium process is at 990℃for 7 hours, seepage niobium layer phase mainly is NbC, niobium layer permeability was the final thickness of about 10μm, the average hardness of approximately HV2770.
(4) In a simulated environment of abrasion, the wear resistance in order from largest to smallest is C-Nb composite diffusion; C-B composite diffusion, carburizing, heat treatment is not enhanced chemical samples. Pick the main failure mode of the sample is abrasive wear, the wear mode generally cutting and plowing.
引文
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[3]黄云庆.热处理工艺对截齿钎焊接头强度的影响.金属热处理,1994(2):12-15
[4]刘加强.提高采煤机截齿质量的新途径.金属热处理,1995(7):35-36
[5]康晓敏,张平,李贵轩.采煤机截齿失效研究与实践[J].煤矿机械,2002 (9): 32-33.
[6]赵运才,庞佑霞.采煤机截齿磨粒磨损浅析[J].矿山机械,1997(2):11-12.
[7]葛长路.矿山机械磨损与抗磨损技术.1994
[8]磨损失效分析案例汇集案例17.北京:机械工业出版社,1995.
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[10]李晓豁,槐金文,姜健.截齿损耗及影响因素的分析[J].黑龙江科技学院学报.2002,12(1):1-4.
[11]张建军,刘晓周.关于采煤机截齿冲击韧性值的探讨[J].西山科技,2000.6(3):3,8,9.
[12]郝春玲.提高截齿钎焊质量的途径[J].煤矿机械,2003年第4期:57-58.
[13]黄云庆,章博,熊柏仁.几种采煤机截齿用钢的性能[J].金属热处理,1995,2: 6-9
[14] D.J.Vracalle,Jr,L.B.Lundberg, H.Herman.Titanium carbide coatings fabrieated by the vacuum plasma spraying process[J],surface and CoatingsTechnology,1996,(86-87):70-74.
[15] Guilemany J M,Fernandez J,Delgado J,et al. Effects of thickness coating on the electrochemical behaviour of themal spray Cr3C2-NiCr coatings [J].Surface and coatings teclmology,2002,153:107-113.
[16]姚树玉,李惠琪.采煤机堆焊涂层截齿热处理工艺研究[J].金属热处理,2004 29(9):40-43.
[17] WANG Yao-wen,CHEN Qiang,SUN Zhen-guo,et al.Relationship between sound sigal and weld status in Plasma are welding[J],Trans.Nonferrous Met.Soe.China,2001,11(l):54-57.
[18] R.L.Sun,J.F.Mao,D.Z.Yang.Microstructural characterization of NICr1BsiC laser clad layer on titanium alloy substrate[J],Surface and Coatings Technology,2002,(150):199-204.
[19] CHEN Zhenda,LIM Leong Chew,QIAN Ming. Laser cladding of WC-Ni ComPosite,Journal of Materials Processing Technology[J],1996,(62):321-323.
[20] Ehsan Toyserkani,Amir khajepour,Steve Corbin.3-D finite element modeling of laser cldding by powder injection:effects of laser pulse shaping on the process[J],Optics and Lasers inEngineering, 2004,(4l):849-867.
[21] L.X.Cai,C.M.Wang,H.M.Wang. Laser cladding for wear-resistant Cr-alloyed Ni2Si-NiSi intermetallic composite coatings[J],Materials Letters,2003,(57):2914-2918.
[22] L.Sexton,S.Lavin,G..Byme,A.Kennedy.Laser cladding of aerospace materials [J],Journal of Materials Processing Technology,2002,(122):63-68.
[23] GU Yu—Xi . WeIding of speciaI engine“ng materiaIs[M] . Shenyang: Liaoning Science and TechnologyPreSs,1998.
[24]从善海,邱玲慧.牙轮钻头的碳硼复合渗[J].金属热处理,1992,1:54-57.
[25] Md. Aminul Islam, Md. Mohar Ali Bepari,KaziMd. Shorowordi. Dry sliding wear in case-hardened niobium microalloyed steels. Journal of Materials Processing Technology,2005,160:401-409.
[26]从善海.碳-铌复合渗20CrNiMo钢的耐磨性能研究[J].金属热处理,2009,34(10):61-64
[27] Ludema K C.Mechanism.based modeling of friction and wear[J].Wear,1996,200:l-7.
[28]稳诗铸.材料磨损研究进展与思考[J].摩擦学报: 2008
[29]赵运才,高彩云,庞佑霞.煤的磨料磨损特性分析[J].煤炭技术,1999,18(1):16,25,26.
[30]孙大乐范群姚利松.奥氏体化保温时间对高速钢工作辊组织和耐磨性的影响[J],金属热处理,2005(12):9-12.
[31]赵运才,唐果宁.采煤机截齿齿体材料及工艺分析[J],矿山机械,1999(12):22-23.
[32]姬玉媛.怎样选好矿用截齿的刀体材料及热处理方式[J],MC现代零部2007(2):64-65.
[33]黄云庆,章勃,熊柏仁.几种采煤机截齿用钢的性能[J],金属热处理,1995(2):6-9
[34]陈宝清.离子束材料改性原理及工艺[M],北京:国防工业出版社,1995,120-122
[35]郭丹丹,毛君.掘进机截齿失效形式与对策分析[J],辽宁工程技术大学学报,2006(25)(增刊):247-248.
[36]刘邦武.等离子束表面冶金耐磨镐型截齿的研究[D],山东青岛:山东科技大学,2005.
[37]何士胜译.英国金刚石截齿的研究与试验[J],采掘机械化简讯,1990(9):26-26.
[38]赵国刚,毛新宇,陈洪玉等.采煤机低合金高强韧性铸钢截齿的研究[J].煤炭学报,1998,23(3):314-317.
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