CN113664469B - Manufacturing method for improving reliability of spraying and lubricating flow passage of rocker arm shell of coal mining machine - Google Patents
Manufacturing method for improving reliability of spraying and lubricating flow passage of rocker arm shell of coal mining machine Download PDFInfo
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- CN113664469B CN113664469B CN202110959088.XA CN202110959088A CN113664469B CN 113664469 B CN113664469 B CN 113664469B CN 202110959088 A CN202110959088 A CN 202110959088A CN 113664469 B CN113664469 B CN 113664469B
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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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Abstract
The invention discloses a manufacturing method for improving reliability of a spraying and lubricating runner of a rocker arm shell of a coal mining machine, which sequentially comprises the following steps: casting, welding process standard, first rough machining, tempering, second rough machining, runner and wear-resistant layer welding, stress relief annealing, hydraulic test, semi-finishing, hydraulic test, finishing, hydraulic test and the like, wherein part of runner holes are machined during the second rough machining, scrap iron in the holes is cleaned after the runner holes are machined, the runner holes are blocked by plugs, and casting defects found during machining, removing and repairing welding are removed, wherein the runner holes comprise water holes and oil holes; and during semi-finishing, processing other runner holes except the runner holes which are finished by the second rough machining, forming process holes which are vertically communicated with the other runner holes, removing scrap iron in the process holes and the other runner holes, and plugging by plugs. The invention solves the problem that the iron filings are easy to block the flow channel, 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 reliability of spraying and lubricating runners of the rocker arm shell of the coal mining machine.
Background
The coal mining machine 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 coal mining machine. In the coal mining process, a large amount of coal dust can be generated, when the coal dust flying in underground air reaches a certain concentration, violent explosion can occur, so that a set of inner and outer spraying devices are arranged on the coal mining machine to play roles of spraying and dust falling, reducing equipment temperature and wet cutting. Particularly, the rocker arm shell is a cast blank, and casting defects such as air holes, sand holes and the like often exist, and a runner on the shell is communicated with a plurality of runner holes, so that the use requirement under severe working conditions is difficult to meet if iron filings are blocked or blank defects leak.
In the prior art, the spray flow passage and a plurality of flow passage holes on the rocker arm shell are communicated with each other, and the spray flow passage and a plurality of flow passage holes are mostly arranged in a semi-finishing stage and a finishing stage after tempering so as not to shift and deform due to tempering. In the processing process, iron scraps easily enter a welded runner, the cleaning difficulty is high, and if the runner cover plate is blocked in a hydrostatic test, the runner cover plate needs to be welded again after being cut and cleaned, so that labor, materials and time are wasted. In addition, the rocker arm shell is a casting blank, and casting defects such as air holes and sand holes are frequently caused, after the runner holes are finished through semi-finishing and finishing, two adjacent Kong Cuan channels are frequently formed, water in the runners leaks into the inner cavity, repair welding work is increased, and product quality is reduced.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a manufacturing method for improving the reliability of a spraying and lubricating runner of a rocker arm shell of a coal mining machine, and aims to solve the problems that scrap iron is easy to block the runner and the quality of products is affected by leakage repair welding.
The technical scheme of the invention is as follows: the manufacturing method for improving the reliability of the spraying and lubricating flow passage of the rocker arm shell of the coal mining machine is characterized by comprising the following steps in sequence: casting, normalizing, marking, welding process reference, first rough machining, sand removal, inspection, first repair welding, quenching and tempering, shot blasting, flaw detection, marking, second rough machining, inspection, welding a runner and a wear-resistant layer, stress relief annealing, shot blasting, hydraulic test, marking, semi-finishing, inspection, second repair welding, hydraulic test, finishing, drilling, clamping, hydraulic test, tightness test, reference removal, grinding, inspection and warehousing, wherein part of runner holes are machined during the second rough machining, scrap iron in the runner holes is cleaned after the runner holes are machined, the runner holes are blocked by plugs, and casting defects found during machining, removal and repair welding are machined, wherein the runner holes comprise water holes and oil holes; and during semi-finishing, processing other runner holes except the runner holes finished by the second rough machining, forming process holes communicated with the other runner holes, removing scrap iron in the process holes and the other runner holes, and plugging by plugs.
Further, when other runner holes are processed in the semi-finishing process, firstly, the aperture is smaller than the nominal diameter, scrap iron is removed, and then the runner holes are processed to be of a size.
Further, the process hole processed in the semi-finishing process and the other runner holes are vertically communicated.
Further, when the opening position of the process hole processed in the semi-finishing process is on the water channel plate guard plate, an opening with the diameter larger than that of the process hole is formed on the water channel plate guard plate and is connected with the process hole.
Further, the aperture of the process hole processed in the semi-finishing is phi 25, phi 30, phi 35 or phi 40.
Further, the second rough machining process further comprises machining the plane of the wear-resistant layer and the range profile of the wear-resistant layer according to the graph, leaving allowance according to the single side of the line, enabling the step and the arc transition part to be in butt joint with the blank and smooth in transition, and countersinking holes to be welded with the wear-resistant layer around the orifice according to the size of a counter bore of the drawing.
Compared with the prior art, the invention has the advantages that:
Through increase the rough machining process of second time before welding runner and wearing layer process after quenching and tempering process, carry out the processing of runner hole, avoided welding runner apron reprocessing again, the processing volume is big, iron fillings are many and the problem that is difficult to clear up, also can avoid the iron fillings to move everywhere in the runner in the process of transporting between the process after the shutoff runner hole simultaneously. In addition, the deep casting defects which do not completely react after hardening and tempering can be found by processing the runner holes in the second rough machining, and repair welding treatment is timely carried out, so that the deep casting defects are avoided after the runner cover plate is welded and then semi-finished and finished, the deep casting defects are found after all the runner holes are drilled, the repair welding workload after finishing can be reduced, and the influence on the product quality is reduced.
Drawings
FIG. 1 is a schematic illustration of a water course tooling hole without a guard plate.
FIG. 2 is a schematic illustration of a waterway tooling hole with a guard plate.
Detailed Description
The invention is further illustrated, but is not limited, by the following examples.
The invention relates to a manufacturing method for improving reliability of a spraying and lubricating runner of a rocker arm shell of a coal mining machine, which specifically comprises the following steps: casting, normalizing, scribing, welding process reference, first rough machining, sand removal, inspection, first repair welding, tempering, shot blasting, flaw detection, scribing, second rough machining, inspection, welding a runner and a wear-resistant layer, stress relief annealing, shot blasting, hydraulic test, scribing, semi-finishing, inspection, second repair welding, hydraulic test, finishing, drilling, clamping, hydraulic test, tightness test, reference removal, polishing, inspection and warehousing. The process of 'second rough machining' is added between the previous processes of hardening and tempering, welding the runner and the wear-resistant layer.
In the above steps, the "first roughing" procedure is as follows: surfaces that have roughness requirements for the part are for example: holes, planes, circular arcs and the like are machined (rough milling and rough boring), 5mm allowance is required to be reserved on one side of each surface, the center distance of each shaft is +0.25mm, the cap opening is milled to be flat with the shell Ping Huajie, and the appearance of the cutter inspection is attractive (the machining of the large bottom hole of the insert screw sleeve is deepened by 5mm according to the drawing).
The contents of the first repair welding process are as follows: for casting blank defects that are exposed by inspection after the first roughing, for example: and the pores, the sand holes, the cracks and the like are subjected to welding repair, so that preparation is made for the subsequent manufacturing process, and the influence on the subsequent working procedures is reduced.
The "second roughing" procedure is as follows: 1. and (3) milling according to the plane range of the wear-resistant layer to be welded according to the drawing, reserving 1mm allowance according to the single side of the line, enabling the step and arc transition part to be in butt joint with the blank and smooth in transition, welding holes of the wear-resistant layer around the hole opening, and countersinking the hole opening. 2. And (3) spot-drilling and drilling runner holes, namely timely cleaning scrap iron after the runner holes are machined, and then protecting by plugs. 3. And (3) milling the runner, deepening steps and the groove bottom if the notch of the runner is a machined surface (for example, the plane has 5mm allowance, the knife inspection depth is according to the dimension of the graph +5), and knife inspection is carried out according to the dimension of the graph if the notch is a blank surface. And (5) immediately processing and removing the casting defects found during processing, and performing subsequent repair welding.
The contents of the process of welding the runner and the wear-resistant layer are as follows: 1. polishing and cleaning the runner (including the hole communicated with the runner), and cleaning scrap iron in the holes, repairing and welding concave-convex parts in the runner and polishing and leveling the concave-convex parts. 2. Repair welding defects and welding runner cover plates, wherein after the repair welding is required to remove defective carbon planes, impurities such as greasy dirt, rust, moisture and the like on the surface of a base metal are cleaned, and welding seams of the runner cover plates are required to be full and flush with a shell, so that the welding defects such as cracks, air holes, slag inclusion and the like are avoided. After welding, checking the quality of the welding seam of the runner, polishing the convex part and leveling the shell, repairing and leveling the concave part and the shell, cleaning welding slag spatter, and ensuring attractive appearance. 3. And (3) welding the wear-resistant layer, spraying anti-splashing liquid before welding, removing welding slag after welding, welding the wear-resistant layer according to the figure, avoiding orifice steps and countersink planes, and externally placing 10mm on a single side to ensure attractive appearance.
The "semi-finishing" process is described as follows: 1. surfaces that have roughness requirements for the part are for example: semi-finishing (semi-finish milling and semi-finish boring) is carried out on holes, planes, circular arcs and the like, 1mm allowance is reserved on one side of each surface, most of the surfaces requiring knife inspection are machined to be of the size, and steps with no tolerance requirement on the inner cavity are in place. 2. And (3) performing point drilling, boring and boring on the rest runner holes, and forming process holes, wherein the smoothness is required to be ensured by processing in a dividing way, the processing aperture is smaller than the nominal diameter, scrap iron is removed, and then the processing is performed to the size. Selecting process holes 2 with opening diameters of phi 25, phi 30, phi 35 and phi 40 according to the figure size and the position and the water channel width on the water channel plate 1 to be communicated with the water holes 3, wherein the process holes 2 are perpendicular to the water holes 3, and the depth of the process holes 2 is executed by exceeding the axis of the water holes 3, as shown in figure 1; if the water channel plate 1 is provided with the guard plate 4, the guard plate 4 is provided with an opening 5 with a diameter 10mm larger than the opening diameter of the process hole 2, and as shown in fig. 2, the depth of the process hole 2 is also performed to exceed 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 hole is removed and protected by a plug. The oil hole is similar to the water hole in processing, the water hole vertically communicated with the oil hole is processed, and scrap iron is removed after processing is finished and protected by a plug.
The content of the finishing process is as follows: surfaces that have roughness requirements for the part are for example: and (3) carrying out finish machining (finish milling and finish boring) on holes, planes, circular arcs and the like, carrying out repeated cutting inspection on the surface requiring cutting inspection according to the drawing to obtain the size, and processing each pin hole to obtain the size, a center hole of each screw hole point (drilling and tapping each screw hole in the subsequent drilling process), wherein the defects of geometric tolerance, dimensional tolerance, surface roughness within the required range, such as scratch, drag mark and the like are required to be ensured according to the drawing.
The "hydrostatic test" procedure is as follows: 1. before the test, the oil duct and the water channel are cleaned up by using a tool, then the patency test is carried out on each flow channel respectively, the impurity content condition in the effluent is checked, and the patency test is finished after the effluent is columnar jet. 2. And (3) carrying out a hydrostatic test, wherein the hydrostatic test requires that each spray water channel is pressurized to 12.7MPa (specific numerical value is according to the technical requirement of drawing), and maintaining the pressure for 15 minutes, checking whether each position leaks water or not, and timely processing. And after the test, draining water, drying by high-pressure air, screwing a plug for protection, and making a test record table.
The prior manufacturing method comprises the steps of casting, normalizing, scribing, welding process standard, rough machining, sand cleaning, inspection, repair welding 1, quenching and tempering, shot blasting, flaw detection, welding a runner and a wear-resistant layer, stress relief annealing, shot blasting, hydrostatic test 1, scribing, semi-finishing, inspection, repair welding 2, hydrostatic test 2, finishing, drilling, clamping, hydrostatic test 3, tightness test, reference removal, polishing, inspection and warehousing, wherein the total processing time is about 400 hours, the processing time of the embodiment of the invention is about 430 hours, but the processing time of the prior manufacturing method is about 35 to 40 hours, and the processing time of the prior manufacturing method is about 440 hours, and the prior manufacturing method only needs to carry out machining according to the process sequence, so that the rocker arm shell manufactured by adopting the method has no runner blockage and leakage, and the manufacturing cycle is shortened by about 10 hours while the quality is improved and the cost of a welding material and a runner cover plate required for repair is saved under the condition of comprehensively considering repair.
Claims (3)
1. The manufacturing method for improving the reliability of the spraying and lubricating flow passage of the rocker arm shell of the coal mining machine is characterized by comprising the following steps in sequence: casting, normalizing, marking, welding process reference, first rough machining, sand removal, inspection, first repair welding, quenching and tempering, shot blasting, flaw detection, marking, second rough machining, inspection, welding a runner and a wear-resistant layer, stress relief annealing, shot blasting, hydraulic test, marking, semi-finishing, inspection, second repair welding, hydraulic test, finishing, drilling, clamping, hydraulic test, tightness test, reference removal, grinding, inspection and warehousing, wherein part of runner holes are machined during the second rough machining, scrap iron in the runner holes is cleaned after the runner holes are machined, the runner holes are blocked by plugs, and casting defects found during machining, removal and repair welding are machined, wherein the runner holes comprise water holes and oil holes; the method comprises the steps of machining other runner holes except the runner holes which are finished through secondary rough machining, forming process holes which are vertically communicated with the other runner holes, removing scrap iron in the process holes and the other runner holes, and plugging the process holes by plugs.
2. The method of claim 1, wherein the semi-finishing process has a bore diameter of phi 25, phi 30, phi 35 or phi 40.
3. The method for improving the reliability of a spraying and lubricating runner of a rocker arm shell of a coal mining machine according to claim 1, wherein the second rough machining process further comprises machining a plane of a wear-resistant layer and a range profile of the wear-resistant layer according to a graph, leaving allowance according to a single side of a line, smoothly connecting a step and an arc transition part with a blank in a butt joint way, and countersinking holes to be welded with the wear-resistant layer around an orifice according to the size of a counter bore of the drawing.
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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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| 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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| CN113664469B true CN113664469B (en) | 2024-06-07 |
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| GB2010355A (en) * | 1977-11-19 | 1979-06-27 | Winster Eng Ltd | System for Supplying Pressurised Fluid to Underground Mining Machine |
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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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