7期倍投倍数

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塔式起重机减速机摆线针轮的修复方法

文章出处:泰强减速机发布时间:2015-10-15 13:38:00
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QT16 型塔式起重机使用9 年后,在施工过程中突然出现塔身不能回转的故障,解体检修减速机时发现减速机第二级摆线针轮减速机上有多处裂纹、磨损和掉块情况。因无现货备件,决定采用焊补法修复。
    1 .可焊性分析
    摆线针轮减速机材质为GCr15,其含碳量高,淬硬倾向大,易出现裂纹和S 、P 偏析,热裂敏感性大,可焊性差。
    2 .补焊措施
    ( l )消除裂纹    根据裂纹形状、深度和长度的不同,用砂轮机先消除浅短裂纹,后消除深长裂纹。磨削顺序是从裂纹端头开始直至裂纹消除,以防止裂纹扩散,同时磨出坡口。对于未裂透的裂纹,使坡口底部圆滑过渡,以减少应力集中;对于裂透裂纹则开单V 形坡口。
    ( 2 )补焊工艺    将裂透裂纹校正使其表面处于一个平面内,点焊固定。补焊顺序是先焊短而浅的裂纹,再焊裂透裂纹,最后将缺损部位堆焊至原来形状。
    补焊短而浅的裂纹时,注意先从裂纹尾部起弧,以防焊接过程中出现裂纹,逐点焊接,边焊边观察。通过第一条裂纹补焊观察,未出现裂纹现象,也未出现新的裂纹,证明焊接工艺可行。
    补焊裂透裂纹时,背面焊接前必须用砂轮机彻底清根,露出金属光泽。
对于磨损、缺损部位应先去除油污、锈迹再进行补焊。
    ( 3 )焊接规范参数    因该零件要求耐磨性好、精度高,但可焊性差,故选用抗裂性能好、耐磨且机加工性能尚可的不锈钢焊条作为填充材料。其牌号为A307,规格为¢3.22mm ,加温至350 ℃ 烘烤2h , 焊接电流90-l00A ,焊接电压20-22V ,焊接线能量8-12kJ/cm。焊机为AX-320,反接。
    ( 4 )焊后处理整个零件焊后保温缓冷,待冷却到室温后上车床加工两平面,边缘多余的堆焊金属用锉刀修整,直至摆线针轮减速机恢复到原有几何尺寸。 

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