CN106180374A - 一种优质中碳波形弹簧的制备方法 - Google Patents
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Abstract
本发明公开了一种优质中碳波形弹簧的制备方法,该制备方法包括如下步骤:a)制备毛坯,b)预处理,c)碳氮共渗处理,d)热处理。本发明揭示了一种优质中碳波形弹簧的制备方法,该制备方法工序安排合理,实施简便,成本适中,制得波形弹簧综合性能优良,且表层具有突出的耐磨及耐蚀性能,使用性能及寿命优异。
Description
技术领域
本发明涉及一种波形弹簧的制备方法,尤其涉及一种综合性能优良,且表面耐磨及耐蚀性能突出的优质中碳波形弹簧的制备方法,属于轴承用弹簧技术领域。
背景技术
波形弹簧是一种广泛应用于电机、纺织机械、液压设备、汽车等行业的弹簧,又称波簧。波形弹簧是由若干波峰、波谷构成的薄片环状弹性金属元件,通常应用于载荷和变形量均不大,且要求弹簧刚度较小、需施加轴向预压力的场合。其制造方法通常是先将金属板材冲压成圆环状的毛坯,然后利用模具沿环形方向冲压波浪形状,最后经过热处理使之具有回弹性能。
现行的波形弹簧存在制备工艺复杂、制备成本偏高、稳定性能差等问题。通常,人们选用高碳高锰钢作为波形弹簧的材料,该材料具有良好的耐磨性和强度,但塑性及抗冲击能力较差,波形弹簧的使用寿命不高;为此,人们在原料中添加一种或多种合金元素,波形弹簧的综合力学性能得到极大提升,但其制备成本偏高,且制备工艺复杂。
发明内容
针对上述需求,本发明提供了一种优质中碳波形弹簧的制备方法,该制备方法工序安排合理,实施简便,成本适中,制得波形弹簧综合性能优良,且表层具有突出的耐磨及耐蚀性能。
本发明是一种优质中碳波形弹簧的制备方法,该制备方法包括如下步骤:a)制备毛坯,b)预处理,c)碳氮共渗处理,d)热处理。
在本发明一较佳实施例中,所述的步骤a)中,毛坯选用厚度0.25-0.3mm的中碳钢板;制备过程包括落料和压型工艺,压力机的公称吨位为140-150t,压力行程1.8-2mm;毛坯的内径为30-35mm,外径为40-45mm,波峰和波谷之间的波长约为18-20mm,振幅为5-5.5mm。
在本发明一较佳实施例中,,所述的步骤b)中,预处理工艺包括清洗和预热,清洗过程包括:脱脂、水洗、酸洗、水洗、烘干等;脱脂液的PH值为12-13;酸洗液的PH值为3-4;预热处理的温度控制在380℃-400℃。
在本发明一较佳实施例中,所述的步骤c)中,设备选用连续炉,渗碳剂选用丙烷,渗氮剂使用氨气,碳势设定为1-1.1,氨气的流量设置为80-100L/h;首先,进行渗碳处理,温度控制在820℃-830℃,处理时间约为1.5-2小时;然后,进行渗氮处理,温度控制在860℃-880℃,处理时间为2-2.5小时。
在本发明一较佳实施例中,所述的步骤d)中,热处理工艺包括分级淬火和低温回火;分级淬火的加热温度控制在880℃-900℃,淬火方式为油淬,油液温度控制在200℃-220℃,在热油中保温20-25分钟后空冷至室温;回火温度控制在为220℃-240℃,处理时间控制在40-50分钟,而后出炉空冷至室温。
本发明揭示了一种优质中碳波形弹簧的制备方法,该制备方法工序安排合理,实施简便,成本适中,制得波形弹簧综合性能优良,且表层具有突出的耐磨及耐蚀性能,使用性能及寿命优异。
附图说明
下面结合附图和具体实施方式对本发明作进一步详细的说明:
图1是本发明实施例优质中碳波形弹簧的制备方法的工序步骤图。
具体实施方式
下面结合附图对本发明的较佳实施例进行详细阐述,以使本发明的优点和特征能更易于被本领域技术人员理解,从而对本发明的保护范围做出更为清楚明确的界定。
图1是本发明实施例优质中碳波形弹簧的制备方法的工序步骤图;该制备方法包括如下步骤:a)制备毛坯,b)预处理,c)碳氮共渗处理,d)热处理。
实施例1
本发明提及的优质中碳波形弹簧的具体制备步骤如下:
a)制备毛坯,毛坯选用厚度0.25-0.27mm的中碳钢板,其含碳量约为0.51%-0.52%,含锰量约为0.65%-0.66%;制备过程包括落料和压型工艺,压力机的公称吨位为140-145t,压力行程1.8-2mm;毛坯的内径为30mm,外径为40mm,波峰和波谷之间的波长约为18mm,振幅为5mm;
b)预处理,预处理工艺包括清洗和预热,清洗过程包括:脱脂、水洗、酸洗、水洗、烘干等;脱脂液的PH值为12-13,处理时间为8-9分钟;酸洗液的PH值为3-4,处理时间为3-3.5分钟;预热处理的温度控制在380℃-390℃,时间约为30-32分钟;
c)碳氮共渗处理,设备选用连续炉,渗碳剂选用丙烷,渗氮剂使用氨气,碳势设定为1-1.1,氨气的流量设置为85-90L/h;首先,进行渗碳处理,温度控制在820℃,处理时间约为2小时;然后,进行渗氮处理,温度控制在860℃,处理时间约为2小时;制得的碳氮层厚度约为0.65-0.7mm,碳氮层中的含碳量约为0.7%,含氮量约为0.3%;
d)热处理,热处理工艺包括分级淬火和低温回火;分级淬火的加热温度控制在880℃-890℃,淬火方式为油淬,油液温度控制在200℃-210℃,在热油中保温25分钟后空冷至室温;回火温度控制在为220℃-230℃,处理时间控制在50分钟,而后出炉空冷至室温。
实施例2
本发明提及的优质中碳波形弹簧的具体制备步骤如下:
a)制备毛坯,毛坯选用厚度0.26-0.28mm的中碳钢板,其含碳量约为0.52%-0.53%,含锰量约为0.64%-0.65%;制备过程包括落料和压型工艺,压力机的公称吨位为145-150t,压力行程1.8-2mm;毛坯的内径为32mm,外径为42mm,波峰和波谷之间的波长约为19mm,振幅为5.2mm;
b)预处理,预处理工艺包括清洗和预热,清洗过程包括:脱脂、水洗、酸洗、水洗、烘干等;脱脂液的PH值为12-13,处理时间为9-10分钟;酸洗液的PH值为3-4,处理时间为3.5-4分钟;预热处理的温度控制在390℃-400℃,时间约为32-34分钟;
c)碳氮共渗处理,设备选用连续炉,渗碳剂选用丙烷,渗氮剂使用氨气,碳势设定为1-1.1,氨气的流量设置为90-95L/h;首先,进行渗碳处理,温度控制在830℃,处理时间约为1.6小时;然后,进行渗氮处理,温度控制在880℃,处理时间约为2小时;制得的碳氮层厚度约为0.7-0.75mm,碳氮层中的含碳量约为0.75%,含氮量约为0.35%;
d)热处理,热处理工艺包括分级淬火和低温回火;分级淬火的加热温度控制在890℃-900℃,淬火方式为油淬,油液温度控制在210℃-220℃,在热油中保温20分钟后空冷至室温;回火温度控制在为230℃-240℃,处理时间控制在45分钟,而后出炉空冷至室温。
本发明揭示了一种优质中碳波形弹簧的制备方法,其特点是:该制备方法工序安排合理,实施简便,成本适中,制得波形弹簧综合性能优良,且表层具有突出的耐磨及耐蚀性能,使用性能及寿命优异。
以上所述,仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本领域的技术人员在本发明所揭露的技术范围内,可不经过创造性劳动想到的变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应该以权利要求书所限定的保护范围为准。
Claims (5)
1.一种优质中碳波形弹簧的制备方法,其特征在于,该制备方法包括如下步骤:a)制备毛坯,b)预处理,c)碳氮共渗处理,d)热处理。
2.根据权利要求1所述的优质中碳波形弹簧的制备方法,其特征在于,所述的步骤a)中,毛坯选用厚度0.25-0.3mm的中碳钢板;制备过程包括落料和压型工艺,压力机的公称吨位为140-150t,压力行程1.8-2mm;毛坯的内径为30-35mm,外径为40-45mm,波峰和波谷之间的波长约为18-20mm,振幅为5-5.5mm。
3.根据权利要求1所述的优质中碳波形弹簧的制备方法,其特征在于,所述的步骤b)中,预处理工艺包括清洗和预热,清洗过程包括:脱脂、水洗、酸洗、水洗、烘干等;脱脂液的PH值为12-13;酸洗液的PH值为3-4;预热处理的温度控制在380℃-400℃。
4.根据权利要求1所述的优质中碳波形弹簧的制备方法,其特征在于,所述的步骤c)中,设备选用连续炉,渗碳剂选用丙烷,渗氮剂使用氨气,碳势设定为1-1.1,氨气的流量设置为80-100L/h;首先,进行渗碳处理,温度控制在820℃-830℃,处理时间约为1.5-2小时;然后,进行渗氮处理,温度控制在860℃-880℃,处理时间为2-2.5小时。
5.根据权利要求1所述的优质中碳波形弹簧的制备方法,其特征在于,所述的步骤d)中,热处理工艺包括分级淬火和低温回火;分级淬火的加热温度控制在880℃-900℃,淬火方式为油淬,油液温度控制在200℃-220℃,在热油中保温20-25分钟后空冷至室温;回火温度控制在为220℃-240℃,处理时间控制在40-50分钟,而后出炉空冷至室温。
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CN110747318A (zh) * | 2019-12-04 | 2020-02-04 | 界首市锦田农业机械装备有限公司 | 一种热卷弹簧的抗压处理方法 |
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