CN113664469A - Manufacturing method for improving reliability of spraying and lubricating flow channel of rocker arm shell of coal mining machine - Google Patents
Manufacturing method for improving reliability of spraying and lubricating flow channel of rocker arm shell of coal mining machine Download PDFInfo
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- CN113664469A CN113664469A CN202110959088.XA CN202110959088A CN113664469A CN 113664469 A CN113664469 A CN 113664469A CN 202110959088 A CN202110959088 A CN 202110959088A CN 113664469 A CN113664469 A CN 113664469A
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- flow passage
- runner
- spraying
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 30
- 239000003245 coal Substances 0.000 title claims abstract description 16
- 238000005065 mining Methods 0.000 title claims abstract description 16
- 238000005507 spraying Methods 0.000 title claims abstract description 16
- 230000001050 lubricating effect Effects 0.000 title claims abstract description 13
- 238000003466 welding Methods 0.000 claims abstract description 48
- 238000003754 machining Methods 0.000 claims abstract description 40
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 37
- 238000000034 method Methods 0.000 claims abstract description 34
- 230000008569 process Effects 0.000 claims abstract description 28
- 230000008439 repair process Effects 0.000 claims abstract description 23
- 230000002706 hydrostatic effect Effects 0.000 claims abstract description 18
- 229910052742 iron Inorganic materials 0.000 claims abstract description 18
- 238000012545 processing Methods 0.000 claims abstract description 18
- 230000007547 defect Effects 0.000 claims abstract description 15
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 238000005266 casting Methods 0.000 claims abstract description 13
- 238000005496 tempering Methods 0.000 claims abstract description 10
- 238000000137 annealing Methods 0.000 claims abstract description 5
- 238000007689 inspection Methods 0.000 claims description 21
- 238000005553 drilling Methods 0.000 claims description 9
- 238000005422 blasting Methods 0.000 claims description 8
- 238000004140 cleaning Methods 0.000 claims description 7
- 239000004576 sand Substances 0.000 claims description 7
- 230000007704 transition Effects 0.000 claims description 6
- 238000001514 detection method Methods 0.000 claims description 4
- 238000000227 grinding Methods 0.000 claims description 4
- 210000001503 joint Anatomy 0.000 claims description 3
- 238000004891 communication Methods 0.000 claims 1
- 238000003801 milling Methods 0.000 description 5
- 230000001681 protective effect Effects 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000002817 coal dust Substances 0.000 description 2
- 238000007730 finishing process Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000013439 planning Methods 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000012958 reprocessing Methods 0.000 description 1
- 238000010079 rubber tapping Methods 0.000 description 1
- 238000006748 scratching Methods 0.000 description 1
- 230000002393 scratching effect Effects 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
Images
Classifications
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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
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention discloses a manufacturing method for improving the reliability of spraying and lubricating flow passages of a rocker arm shell of a coal mining machine, which sequentially comprises the following steps of: the method comprises the following steps of casting, welding process reference, primary rough machining, tempering, secondary rough machining, welding a runner and a wear-resistant layer, stress relief annealing, hydrostatic testing, semi-finishing, hydrostatic testing, finish machining, hydrostatic testing and the like, wherein part of runner holes are machined during secondary rough machining, scrap iron in the holes are cleaned after the runner holes are machined, the runner holes are plugged by plugs, casting defects found during machining and repair welding are removed, and the runner holes comprise water holes and oil holes; and processing other flow passage holes except the flow passage hole which is finished by the secondary rough machining during the semi-finish machining, arranging process holes which are vertically communicated with the other flow passage holes, removing scrap iron in the process holes and the other flow passage holes, and plugging by using plugs. The invention solves the problem that the flow channel is easy to be blocked by scrap iron, and improves the product quality.
Description
Technical Field
The invention relates to a manufacturing method of a rocker arm shell of a coal mining machine, in particular to a manufacturing method for improving the reliability of spraying and lubricating flow passages of the rocker arm shell of the coal mining machine.
Background
The shearer generally comprises a cutting part, a loading part, a walking part (traction part), a motor, an operation control system, an auxiliary device and the like, and a rocker arm shell is an important part on the cutting part of the shearer. During coal mining, a large amount of coal dust is generated, when the coal dust flying in the underground air reaches a certain concentration, violent explosion can occur, so that a set of inner and outer spraying devices are arranged on a coal mining machine to perform the functions of spraying dust fall, reducing the temperature of equipment and wet cutting. Particularly, the rocker arm shell is a cast blank and often has casting defects such as air holes and sand holes, and a flow channel on the shell is communicated with a plurality of flow channel holes, so that the use requirement under severe working conditions is difficult to meet if iron chips are blocked or the blank defects are leaked.
In the prior art, the spray flow channel on the rocker arm shell and a plurality of flow channel holes are processed in a communicating mode, and the processing is mostly carried out in a semi-finishing stage and a finishing stage after hardening and tempering so as to prevent position deviation and deformation caused by hardening and tempering. In the machining process, iron scraps easily enter the welded flow channel, the cleaning difficulty is high, if blockage occurs in the hydraulic test, the flow channel cover plate needs to be cut and cleaned and then welded again, and labor, materials and time are wasted. In addition, the rocker arm shell is a cast blank, so that casting defects such as air holes and sand holes often exist, after the runner holes are machined by semi-finishing and finish machining, two adjacent holes are communicated frequently, water of the runner leaks into the inner cavity, repair welding work is increased, and product quality is also reduced.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a manufacturing method for improving the reliability of spraying and lubricating flow channels of a rocker arm shell of a coal mining machine, and aims to solve the problems that the flow channels are easily blocked by scrap iron and the product quality is influenced by leakage repair welding.
The technical scheme of the invention is as follows: a manufacturing method for improving reliability of spraying and lubricating flow passages of a rocker arm shell of a coal mining machine is characterized by sequentially comprising the following steps of: casting → normalizing → marking → welding process benchmark → first rough machining → sand cleaning → inspection → first repair welding → tempering → shot-blasting → flaw detection → second rough machining → inspection → welding runner and wearing layer → stress relief annealing → shot-blasting → hydrostatic test → marking → semi-finishing → inspection → second repair welding → hydrostatic test → finishing → drilling → clamping → hydrostatic test → tightness test → de-benchmark → grinding → inspection → warehousing, the second rough machining processes part of the runner hole, and cleans iron in the hole after the runner hole is processed and blocks the runner hole with a plug, processes and removes the casting defect found at the time of repair welding, the runner hole includes water hole and oil hole; and processing other flow passage holes except the flow passage hole which is finished by the secondary rough machining during the semi-finish machining, arranging process holes communicated with the other flow passage holes, removing scrap iron in the process holes and the other flow passage holes, and plugging by plugs.
Further, when other runner holes are processed in the semi-finishing, the hole diameter is firstly processed to be smaller than the nominal diameter, scrap iron is removed, and then the semi-finishing is processed to the size.
Further, the process hole processed in the semi-finishing process and the other flow passage holes vertically flow.
Furthermore, when the opening position of the fabrication hole processed in the semi-finishing is on the water channel plate protective plate, an opening hole with the diameter larger than that of the fabrication hole is formed in the water channel plate protective plate and connected with the fabrication hole.
Further, the diameter of the process hole processed in the semi-finishing is phi 25, phi 30, phi 35 or phi 40.
Further, the second rough machining also comprises machining the plane of the wear-resistant layer and the range outline of the wear-resistant layer according to a drawing, reserving allowance according to a single side of a line, enabling the step and the arc transition part to be in butt joint with the blank to be in round transition, and facing the hole, to which the wear-resistant layer is welded, around the hole opening according to the size of the counter bore in the drawing.
Compared with the prior art, the invention has the advantages that:
through behind the quenching and tempering process, increase the rough machining process of second time before welding runner and wearing layer process, carry out the processing in runner hole, avoided having welded runner apron reprocessing again, the handling capacity is big, iron fillings are many and be difficult to the problem of clearance, also can avoid the process to move everywhere in the runner in the transportation behind the shutoff runner hole simultaneously. In addition, the deep casting defects which are not completely reacted after hardening and tempering can be found by processing the runner holes in the second rough machining process, repair welding treatment is carried out in time, the deep casting defects are not found after all the runner holes are drilled after semi-finishing and finishing machining of the runner cover plate is completed, repair welding workload after finishing machining can be reduced, and influence on product quality is reduced.
Drawings
FIG. 1 is a schematic view of processing a water channel fabrication hole without a guard plate.
FIG. 2 is a schematic view of processing a water channel fabrication hole with a guard plate.
Detailed Description
The present invention is further illustrated by the following examples, which are not to be construed as limiting the invention thereto.
The invention relates to a manufacturing method for improving reliability of spraying and lubricating flow passages of a rocker arm shell of a coal mining machine, which specifically comprises the following steps: casting → normalizing → marking off → welding process benchmark → first rough machining → sand cleaning → inspection → first repair welding → tempering → shot blasting → flaw detection → marking off → second rough machining → inspection → welding runner and wearing layer → stress relief annealing → shot blasting → hydrostatic test → marking off → semi-finishing → inspection → second repair welding → hydrostatic test → finishing → drilling → clamping → hydrostatic test → sealing test → de-benchmark → grinding → inspection → warehousing. A 'secondary rough machining' procedure is added between the previous procedures of tempering, welding a runner and a wear-resistant layer.
In the process of the steps, the content of the first rough machining process is as follows: surfaces that have roughness requirements for parts such as: holes, planes, arcs and the like are processed (rough milling and rough boring), 5mm allowance is required to be left on one side of each surface, the center distance of each shaft is plus 0.25mm from each gear, a cap opening is milled to be smoothly connected with a shell, and the appearance of a cutter is ensured to be attractive (the processing of a big bottom hole of an insert sleeve is deepened by 5mm according to a drawing).
The content of the first repair welding procedure is as follows: defects in the cast blank exposed by inspection after the first roughing are for example: air holes, sand holes, cracks and the like are welded for repair, so that preparation is made for the subsequent manufacturing process, and the influence on the subsequent process is reduced.
The content of the second rough machining procedure is as follows: 1. and (3) welding the plane range of the wear-resistant layer according to the requirement of a drawing, milling, reserving 1mm of allowance according to a single side of a line, enabling the step and the arc transition part to be in butt joint with the blank to form a round transition, welding holes of the wear-resistant layer around the hole opening, and facing the hole opening. 2. And (3) pointing and drilling a flow channel hole, wherein scrap iron is required to be cleaned in time after the flow channel hole is machined, and then the scrap iron is protected by a plug. 3. Milling the runner, deepening the step and the bottom of the groove if the notch of the runner is a machined surface (for example, if the plane has 5mm allowance, the depth of the tool inspection is plus 5 according to the drawing size), and performing tool inspection according to the drawing size if the notch is a blank surface. And (4) processing and removing the defects of the casting in time during processing, and performing subsequent repair welding.
The process of welding the runner and the wear-resistant layer comprises the following steps: 1. polishing and cleaning the flow channel (including the hole communicated with the flow channel), wherein scrap iron in the hole is required to be cleaned, and the concave and convex part of the flow channel is subjected to repair welding and polished to be flat. 2. Repairing welding defects and welding a runner cover plate, wherein after carbon planing for removing the defects is required for repairing welding, impurities such as oil stain, rust, moisture and the like on the surface of a base material are cleaned, and welding seams of the runner cover plate are required to be full and flush with a shell and have no welding defects such as cracks, air holes, slag inclusion and the like. And after welding, the quality of the welding seam of the runner is checked, the bulge is polished to be level with the shell, the sunken part is repaired and welded to be level with the shell, welding slag is cleared, and the attractive appearance is ensured. 3. Welding the wear-resistant layer, spraying anti-splashing liquid before welding, removing welding slag after welding, welding the wear-resistant layer according to a diagram, avoiding an orifice step and a countersink plane, externally placing 10mm on a single side, and ensuring attractive appearance.
The content of the semi-finishing process is as follows: 1. surfaces that have roughness requirements for parts such as: and performing semi-finish machining (semi-finish milling and semi-finish boring) on holes, planes, arcs and the like, wherein 1mm of allowance is required to be reserved on the single side of each surface, most of the surfaces requiring tool inspection are machined to the size, and steps with tolerance-free inner cavities are also in place. 2. And (3) pointing, drilling and boring the rest runner holes and arranging process holes, wherein the smoothness is ensured by processing in multiple times, the processing hole diameter is smaller than the nominal diameter, scrap iron is removed, and then the processing is carried out to the size. Selecting a fabrication hole 2 with opening diameters of phi 25, phi 30, phi 35 and phi 40 on the water channel plate 1 according to the size position of the figure and the width of the water channel to be communicated with a water hole 3, wherein the fabrication hole 2 is vertical to the water hole 3, and the depth of the fabrication hole 2 is executed by exceeding the axis of the water hole 3, as shown in figure 1; if the protective plate 4 is arranged on the water channel plate 1, an opening 5 with the diameter 10mm larger than that of the opening of the process hole 2 is arranged on the protective plate 4, and as shown in figure 2, the depth of the process hole 2 is also performed by exceeding the axis of the water hole 3. After the processing is finished, scrap iron of the water channel, the transverse hole and the water inlet and outlet holes is removed and protected by plugs. The oil hole is processed to be similar to the water hole, processes the water hole vertically communicated with the oil hole, and removes scrap iron and protects with a plug after the processing is completed.
The contents of the fine machining process are as follows: surfaces that have roughness requirements for parts such as: carrying out finish machining (finish milling and finish boring) on holes, planes, arcs and the like, machining the holes, the planes, the arcs and the like to the size according to a drawing, carrying out re-tool inspection on the surface requiring tool inspection, machining each pin hole to the size, drilling a center hole of a screw hole point (drilling and tapping each screw hole in the subsequent drilling process), and ensuring that the form and position tolerance, the size tolerance and the surface roughness are in the required range according to the drawing and the defects of scratching, tool dragging marks and the like are not allowed to appear on each surface.
The contents of the "hydrostatic test" procedure are: 1. cleaning the oil channel and the water channel by using a tool before the test, respectively carrying out a smoothness test on each flow channel, checking the impurity-containing condition of the effluent, and finishing the smoothness test after the effluent is columnar. 2. And performing a hydrostatic test, wherein the hydrostatic test requires that each spray water channel is pressurized to 12.7MPa (the specific numerical value is according to the technical requirement of a drawing), the pressure is maintained for 15min, and whether water leaks from each position is checked in the period, and the water is treated in time. After the test, water is discharged, the plug is screwed on for protection after the high-pressure air is used for drying, and a test record table is made.
The conventional manufacturing method comprises the steps of casting → normalizing → marking → welding process reference → rough machining → sand cleaning → inspection → repair welding 1 → tempering → shot blasting → flaw detection → welding runner and wear-resistant layer → stress relief annealing → shot blasting → hydrostatic test 1 → marking → semi-finishing → inspection → repair welding 2 → hydrostatic test 2 → finishing → drilling → hydrostatic test 3 → sealing test → de-reference → grinding → inspection → warehousing, the total processing time is about 400 hours, while the processing time of the embodiment of the present invention is about 430 hours, but the repair time of the conventional manufacturing method is about 35 to 40 hours, and about 440 hours, while the repair of the conventional manufacturing method requires carbon planning, welding and machining of welded holes, while the present invention only needs machining according to the process sequence, and the rocker arm shell manufactured by the present invention has no flow channel blockage and leakage, and under the comprehensive consideration of repair, the invention improves the quality, shortens the manufacturing period by about 10 hours, and saves the cost of welding materials and runner cover plates required by repair.
Claims (6)
1. A manufacturing method for improving reliability of spraying and lubricating flow passages of a rocker arm shell of a coal mining machine is characterized by sequentially comprising the following steps of: casting → normalizing → marking → welding process benchmark → first rough machining → sand cleaning → inspection → first repair welding → tempering → shot-blasting → flaw detection → second rough machining → inspection → welding runner and wearing layer → stress relief annealing → shot-blasting → hydrostatic test → marking → semi-finishing → inspection → second repair welding → hydrostatic test → finishing → drilling → clamping → hydrostatic test → tightness test → de-benchmark → grinding → inspection → warehousing, the second rough machining processes part of the runner hole, and cleans iron in the hole after the runner hole is processed and blocks the runner hole with a plug, processes and removes the casting defect found at the time of repair welding, the runner hole includes water hole and oil hole; and processing other flow passage holes except the flow passage hole which is finished by the secondary rough machining during the semi-finish machining, arranging process holes which are vertically communicated with the other flow passage holes, removing scrap iron in the process holes and the other flow passage holes, and plugging by using plugs.
2. The manufacturing method for improving the reliability of the spraying and lubricating flow passage of the shell of the coal mining machine rocker arm according to claim 1, characterized in that when other flow passage holes are semi-finished, the hole diameter is firstly processed to be smaller than the nominal diameter, scrap iron is removed, and then the other flow passage holes are processed to be the size.
3. The manufacturing method for improving the reliability of the spraying and lubricating flow passage of the shell of the coal mining machine rocker arm as claimed in claim 1, wherein the technical hole processed in the semi-finishing is in vertical flow communication with the other flow passage holes.
4. The manufacturing method for improving the reliability of the spraying and lubricating flow channel of the shell of the coal mining machine rocker arm as claimed in claim 1, wherein when the opening of the fabrication hole machined in the semi-finishing is positioned on the guard plate of the water channel plate, a hole with a diameter larger than that of the fabrication hole is formed in the guard plate of the water channel plate to connect with the fabrication hole.
5. The manufacturing method for improving the reliability of the spraying and lubricating flow passage of the shell of the rocker arm of the coal mining machine as claimed in claim 4, wherein the diameter of the process hole machined in the semi-finishing is phi 25, phi 30, phi 35 or phi 40.
6. The manufacturing method for improving the reliability of the spraying and lubricating flow channel of the shell of the coal mining machine rocker arm according to claim 1, characterized in that the second rough machining further comprises the step of machining the plane of the wear-resistant layer and the range profile of the wear-resistant layer according to a drawing, a margin is reserved according to a single side of a line, the step and the arc transition part are in butt joint with a blank to form a circle and have smooth transition, and holes to be welded with the wear-resistant layer around the hole opening are reamed flat according to the size of a counter bore in the drawing.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110959088.XA CN113664469B (en) | 2021-08-20 | 2021-08-20 | Manufacturing method for improving reliability of spraying and lubricating flow passage of rocker arm shell of coal mining machine |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110959088.XA CN113664469B (en) | 2021-08-20 | 2021-08-20 | Manufacturing method for improving reliability of spraying and lubricating flow passage of rocker arm shell of coal mining machine |
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| CN113664469A true CN113664469A (en) | 2021-11-19 |
| CN113664469B CN113664469B (en) | 2024-06-07 |
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Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2010355A (en) * | 1977-11-19 | 1979-06-27 | Winster Eng Ltd | System for Supplying Pressurised Fluid to Underground Mining Machine |
| CN104385046A (en) * | 2014-10-27 | 2015-03-04 | 沈阳黎明航空发动机(集团)有限责任公司 | Method for cleaning runner holes of bearing casing part of engine |
| CN105537533A (en) * | 2015-12-10 | 2016-05-04 | 湖州中联机械制造有限公司 | Casting process of rocking arm of coal mining machine |
| CN205237508U (en) * | 2015-12-23 | 2016-05-18 | 天地上海采掘装备科技有限公司 | Coal -winning machine rocking arm casing preparation facilities with anticorrosive characteristic in water route |
| CN107627075A (en) * | 2016-07-19 | 2018-01-26 | 成都源云机械有限公司 | A kind of heavy-duty coal mining machine towing tank body processing technology |
| CN110259931A (en) * | 2019-07-18 | 2019-09-20 | 天地科技股份有限公司上海分公司 | Rocker arm of coal mining machine oil sump cooling device |
| CN110629122A (en) * | 2019-11-06 | 2019-12-31 | 西安煤矿机械有限公司 | High-strength cast steel material for rocker arm shell of coal mining machine and preparation process of high-strength cast steel material |
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-
2021
- 2021-08-20 CN CN202110959088.XA patent/CN113664469B/en active Active
Patent Citations (8)
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| CN110629122A (en) * | 2019-11-06 | 2019-12-31 | 西安煤矿机械有限公司 | High-strength cast steel material for rocker arm shell of coal mining machine and preparation process of high-strength cast steel material |
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| CN113664469B (en) | 2024-06-07 |
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