CN110919306B - Processing and manufacturing process of core-inlaid bronze turbine blank - Google Patents
Processing and manufacturing process of core-inlaid bronze turbine blank Download PDFInfo
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- CN110919306B CN110919306B CN201911180306.9A CN201911180306A CN110919306B CN 110919306 B CN110919306 B CN 110919306B CN 201911180306 A CN201911180306 A CN 201911180306A CN 110919306 B CN110919306 B CN 110919306B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
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Abstract
一种嵌芯青铜涡轮坯加工制造工艺，通过离心铸造、拉削、锯切、车一、插齿、扩散、压装、退火、扩散、车二这些步骤进行的。本发明有益的效果是：采用离心铸造的青铜铸管作为青铜齿套的坯料，减少了砂型铸造和重力铸造的气孔缺陷，采用拉削工艺提高了内表面加工效率，采用锯切坯料可以减少后续加工余量，接近近终成型，扩散退火使界面形成冶金结合，提高了涡轮的使用寿命，这些工艺措施显著的降低了废品率和生产成本，并有利于生产自动化改造，使用效果好，利于推广。A core-embedded bronze turbine blank processing and manufacturing process is carried out through the steps of centrifugal casting, broaching, sawing, turning 1, gear shaping, diffusion, press fitting, annealing, diffusion, and turning 2. The beneficial effects of the invention are as follows: the centrifugally cast bronze casting tube is used as the blank of the bronze tooth sleeve, which reduces the porosity defects of sand casting and gravity casting, the broaching process is used to improve the processing efficiency of the inner surface, and the sawing blank can be used to reduce the follow-up Machining allowance, near-finish molding, diffusion annealing to form metallurgical bond at the interface, and improve the service life of the turbine. These process measures significantly reduce the scrap rate and production cost, and are conducive to the automatic transformation of production. The use effect is good, which is conducive to promotion.
Description
Technical Field
The invention relates to a machining and manufacturing process of a core-embedded bronze turbine blank.
Background
The bronze turbine is a commonly used transmission part in gear transmission and has the advantage of good wear resistance. In order to reduce the cost of the integrally cast bronze turbine, cast bronze is usually adopted as a gear ring, cast iron or steel is adopted as a mandrel to be embedded into the gear ring, and the manufacturing process mainly comprises two steps: the first method is that a gear ring blank is manufactured by sand casting, the surface of the gear ring blank and the outer surface of a mandrel blank are machined, the gear ring blank expands after being heated, and the mandrel is inserted into an inner hole of the gear ring blank to form interference fit; and the second method is that gravity casting is utilized, the core shaft with the groove on the surface is put into a metal mold to be used as a core, bronze liquid is directly cast, the casting is taken out after cooling, the bronze material is embedded into the groove of the core shaft and combined with the surface of the core shaft, and then machining treatment is carried out subsequently. Although the two manufacturing methods have simple process flows, the problems of more air hole defects, low yield and large cutting allowance exist, and the interface bonding strength of the bronze and the mandrel material is low, so that the bronze and the mandrel material are easy to fall off in use.
Disclosure of Invention
The invention aims to solve the problems in the prior art, provides a machining and manufacturing process of a core-embedded bronze turbine blank, solves the problems of more air hole defects, low yield and large cutting machining allowance in the conventional machining of the core-embedded bronze turbine blank, and meets the requirement for machining the core-embedded bronze turbine blank.
The invention adopts the technical scheme for solving the technical problems that: the processing and manufacturing process of the core-inlaid bronze turbine blank comprises the following steps:
the first step, centrifugal casting, which is to produce a hollow bronze cylinder by adopting a centrifugal casting mode;
secondly, broaching, namely taking the hollow bronze cylinder obtained in the first step, and processing an inner hole by using a forming broach by taking the excircle of the hollow bronze cylinder as a clamping reference, wherein the broach is divided into two parts, the former part is used for processing the inner hole, the latter part is used for processing the inner teeth in a forming way, and a blank is obtained after processing;
thirdly, sawing, namely blanking the blank obtained in the second step by using a circular saw or a band saw according to the drawing requirements;
fourthly, turning the first lathe, and turning the outer end face of the cast mandrel;
fifthly, gear shaping, namely, gear shaping is carried out on the mandrel, and a groove is machined;
sixthly, heating, namely putting the blanks sawn in the third step into an induction coil, simultaneously pressing the upper surface of the blanks by using an annular die, and carrying out induction heating to 600-700 ℃;
step seven, press mounting, namely press mounting the mandrel with the groove processed in the step five into the bronze tooth blank, and forming interference fit after cooling;
eighthly, annealing, namely putting the cooled workpiece into a heat treatment furnace for diffusion annealing treatment, and then preserving heat for 3-5 hours;
and step nine, turning the second gear, and processing two matching end surfaces of the gear blank.
Further, the heat-retaining time in the eighth step is 4 hours.
In the machining and manufacturing process of the core-embedded bronze turbine blank, the first step is centrifugal casting, a hollow bronze cylinder is produced by adopting a centrifugal casting mode, a centrifugally cast bronze cast pipe is used as a blank of a bronze gear sleeve, the air hole defects of sand casting and gravity casting are reduced, the second step is broaching, the hollow bronze cylinder obtained in the first step is taken, an inner hole is machined by using a forming broach with the outer circle of the hollow bronze cylinder as a clamping reference, wherein the broach is divided into two parts, the inner circular hole is machined in the former part, the inner teeth are machined in the latter part in a forming mode, the blank is obtained after machining, the inner surface machining efficiency is improved by adopting the broaching process, the third step is sawing, the blank obtained in the second step is blanked by a circular saw or a band saw according to the drawing requirements, the sawing blank can reduce the subsequent machining allowance and is close to the final forming, the fifth step is first lathing, the outer end surface of a cast mandrel is machined, and fifthly, gear shaping, groove machining, sixth step, diffusion, namely putting the blank sawed in the third step into an induction coil, simultaneously pressing the upper surface of the blank by using an annular die, carrying out induction heating to 600-700 ℃, seventh step, press mounting, pressing the mandrel with the groove machined in the fifth step into a bronze tooth blank, cooling to form interference fit, eighth step, annealing, putting the cooled workpiece into a heat treatment furnace for diffusion annealing treatment, and then carrying out heat preservation for 3-5 hours, wherein the diffusion annealing enables the interface to form metallurgical bonding, and the service life of the turbine is prolonged.
The invention has the beneficial effects that: the processing and manufacturing process of the core-embedded bronze turbine blank has reasonable procedures, adopts the centrifugally cast bronze cast pipe as the blank of the bronze gear sleeve, reduces the air hole defects of sand casting and gravity casting, adopts the broaching process to improve the internal surface processing efficiency, adopts the sawing blank to reduce the subsequent processing allowance, is close to near-net forming, adopts diffusion annealing to form metallurgical bonding on the interface, improves the service life of the turbine, obviously reduces the rejection rate and the production cost by the process measures, is favorable for automatic production transformation, has good use effect and is favorable for popularization.
Detailed Description
The invention is further illustrated below:
the first embodiment is as follows:
the processing and manufacturing process of the core-inlaid bronze turbine blank comprises the following steps:
the first step, centrifugal casting, which is to produce a hollow bronze cylinder by adopting a centrifugal casting mode;
secondly, broaching, namely taking the hollow bronze cylinder obtained in the first step, and processing an inner hole by using a forming broach by taking the excircle of the hollow bronze cylinder as a clamping reference, wherein the broach is divided into two parts, the former part is used for processing the inner hole, the latter part is used for processing the inner teeth in a forming way, and a blank is obtained after processing;
thirdly, sawing, namely blanking the blank obtained in the second step by using a circular saw or a band saw according to the drawing requirements;
fourthly, turning the first lathe, and turning the outer end face of the cast mandrel;
fifthly, gear shaping, namely, gear shaping is carried out on the mandrel, and a groove is machined;
sixthly, heating, namely putting the blanks sawed in the third step into an induction coil, simultaneously pressing the upper surface of the blanks by using an annular die, and carrying out induction heating to 600 ℃;
step seven, press mounting, namely press mounting the mandrel with the groove processed in the step five into the bronze tooth blank, and forming interference fit after cooling;
eighthly, annealing, namely putting the cooled workpiece into a heat treatment furnace for diffusion annealing treatment, and then preserving heat for 3 hours;
and step nine, turning the second gear, and processing two matching end surfaces of the gear blank.
Example two:
the processing and manufacturing process of the core-inlaid bronze turbine blank comprises the following steps:
the first step, centrifugal casting, which is to produce a hollow bronze cylinder by adopting a centrifugal casting mode;
secondly, broaching, namely taking the hollow bronze cylinder obtained in the first step, and processing an inner hole by using a forming broach by taking the excircle of the hollow bronze cylinder as a clamping reference, wherein the broach is divided into two parts, the former part is used for processing the inner hole, the latter part is used for processing the inner teeth in a forming way, and a blank is obtained after processing;
thirdly, sawing, namely blanking the blank obtained in the second step by using a circular saw or a band saw according to the drawing requirements;
fourthly, turning the first lathe, and turning the outer end face of the cast mandrel;
fifthly, gear shaping, namely, gear shaping is carried out on the mandrel, and a groove is machined;
sixthly, heating, namely putting the blanks sawed in the third step into an induction coil, simultaneously pressing the upper surface of the blanks by using an annular die, and carrying out induction heating to 650 ℃;
step seven, press mounting, namely press mounting the mandrel with the groove processed in the step five into the bronze tooth blank, and forming interference fit after cooling;
eighthly, annealing, namely putting the cooled workpiece into a heat treatment furnace for diffusion annealing treatment, and then preserving heat for 4 hours;
and step nine, turning the second gear, and processing two matching end surfaces of the gear blank.
Example three:
the processing and manufacturing process of the core-inlaid bronze turbine blank comprises the following steps:
the first step, centrifugal casting, which is to produce a hollow bronze cylinder by adopting a centrifugal casting mode;
secondly, broaching, namely taking the hollow bronze cylinder obtained in the first step, and processing an inner hole by using a forming broach by taking the excircle of the hollow bronze cylinder as a clamping reference, wherein the broach is divided into two parts, the former part is used for processing the inner hole, the latter part is used for processing the inner teeth in a forming way, and a blank is obtained after processing;
thirdly, sawing, namely blanking the blank obtained in the second step by using a circular saw or a band saw according to the drawing requirements;
fourthly, turning the first lathe, and turning the outer end face of the cast mandrel;
fifthly, gear shaping, namely, gear shaping is carried out on the mandrel, and a groove is machined;
sixthly, heating, namely putting the blanks sawed in the third step into an induction coil, simultaneously pressing the upper surface of the blanks by using an annular die, and carrying out induction heating to 700 ℃;
step seven, press mounting, namely press mounting the mandrel with the groove processed in the step five into the bronze tooth blank, and forming interference fit after cooling;
eighthly, annealing, namely putting the cooled workpiece into a heat treatment furnace for diffusion annealing treatment, and then preserving heat for 5 hours;
and step nine, turning the second gear, and processing two matching end surfaces of the gear blank.
The core-inlaid bronze turbine blanks manufactured in the first embodiment, the second embodiment and the third embodiment of the invention are selected to be compared with the core-inlaid bronze turbine blanks manufactured by the conventional method, and the comparison result is as follows:
as can be seen from the above table, the machining and manufacturing process of the core-inlaid bronze turbine blank according to the first, second and third embodiments of the present invention has a low rejection rate, which is superior to that of the conventional method.
The embodiment of the invention has the characteristics that: the centrifugal casting bronze casting pipe is used as a blank of the bronze gear sleeve, so that the air hole defects of sand casting and gravity casting are reduced, the machining efficiency of the inner surface is improved by adopting a broaching process, the subsequent machining allowance can be reduced by adopting the sawing blank, the near-net shaping is approached, the metallurgical bonding is formed on the interface by diffusion annealing, the service life of the turbine is prolonged, the rejection rate and the production cost are obviously reduced by adopting the technological measures, the automatic production transformation is facilitated, the use effect is good, and the popularization is facilitated.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the claims.
Claims (2)
1. The machining and manufacturing process of the core-inlaid bronze turbine blank is characterized by comprising the following steps of:
(a) centrifugal casting, wherein a hollow bronze cylinder is produced by adopting a centrifugal casting mode;
(b) broaching, namely taking the hollow bronze cylinder obtained in the step (a), and processing an inner hole by using a forming broach by taking the excircle of the hollow bronze cylinder as a clamping reference, wherein the broach is divided into two parts, the former part is used for processing the inner hole, the latter part is used for processing the inner teeth in a forming way, and a blank is obtained after processing;
(c) sawing, namely blanking the blank obtained in the step (b) by using a circular saw or a band saw according to the drawing requirements;
(d) turning a first lathe, and turning the outer end face of the cast mandrel;
(e) gear shaping, namely, shaping the gear of the mandrel and processing a groove;
(f) heating, namely putting the sawn blank in the step (c) into an induction coil, simultaneously pressing the upper surface of the blank by using an annular die, and carrying out induction heating to 600-700 ℃;
(g) pressing, namely pressing the mandrel with the groove processed in the step (e) into the bronze tooth blank, and cooling to form interference fit;
(h) annealing, namely putting the cooled workpiece into a heat treatment furnace for diffusion annealing treatment, and then preserving heat for 3-5 hours, wherein the diffusion annealing enables an interface to form metallurgical bonding;
(i) turning a second gear blank, and processing two matching end surfaces of the gear blank.
2. The machining and manufacturing process of the core-inlaid bronze turbine blank according to claim 1, characterized in that: the heat preservation time in the step (h) is 4 hours.
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| CN201911180306.9A CN110919306B (en) | 2019-11-27 | 2019-11-27 | Processing and manufacturing process of core-inlaid bronze turbine blank |
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| US4096615A (en) * | 1977-05-31 | 1978-06-27 | General Motors Corporation | Turbine rotor fabrication |
| CN87108211A (en) * | 1987-12-22 | 1988-09-07 | 国家机械工业委员会郑州机械研究所 | The new technology of casting blank of copper worm gear |
| CN102500633A (en) * | 2011-09-28 | 2012-06-20 | 中国兵器工业第五九研究所 | Method for forming cup-shaped component with gear |
| CN103481033A (en) * | 2013-09-25 | 2014-01-01 | 新兴铸管股份有限公司 | Manufacturing method for double-metal seamless steel pipe through machining, assembling and extruding |
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| CN108526830A (en) * | 2018-07-24 | 2018-09-14 | 东北大学 | A kind of composite-making process of shaft forgings |
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