Axle repairing method and axle

Abstract

The invention provides an axle repairing method and an axle, and relates to the technical field of axle repairing. The method comprises the following steps: irradiating a laser beam on the surface of a to-be-repaired part of the axle wheel seat to form a molten pool; alloy steel powder is added into the molten pool through a cladding head; the axle is controlled to rotate at the preset rotating speed, the cladding head is controlled to do translational motion in the axial direction of the axle at the preset speed, and cladding is conducted on the inner edge of the to-be-repaired part from the outer edge of the to-be-repaired part in a spiral track; when cladding is carried out to the inner edge, cladding is carried out again from the outer edge to the inner edge in a spiral track, and cladding is repeated for multiple circles; cladding the outer edge of the axle rotating shaft and the two sides of the axle key groove to form a first cladding layer; and the steps are repeated, and laser beams are adopted to irradiate the first cladding layer to continuously form the multiple cladding layers. Through the technical means, the problems of resource waste and high replacement cost caused by axle damage in related technologies are solved.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of axle repair, and particularly relates to an axle repair method and an axle. BACKGROUND

[0002] As a core bearing component of rail transit locomotive vehicles, the structural integrity and service reliability of the axle are directly related to the running safety of the whole vehicle. Due to long-term bearing of complex alternating loads, the axle is prone to surface damage such as bumping, scratching, fretting wear and the like during manufacturing, assembly or operation, which does not affect the overall structural strength, but often causes the whole axle to be scrapped due to the inability to repair.

[0003] In view of the high cost of axle materials, long manufacturing cycle and high added value, the traditional replacement method not only causes resource waste, but also increases operation and maintenance costs. How to reduce costs and increase benefits in the utilization of axles while ensuring safety is currently a hot research topic. SUMMARY

[0004] The present disclosure provides an axle repair method and an axle, thereby avoiding resource waste and reducing operation and maintenance costs.

[0005] According to one aspect of the present disclosure, an axle repair method is provided, which comprises: irradiating a laser beam on a surface of a to-be-repaired part of an axle wheel seat to form a molten pool; adding alloy steel powder to the molten pool through a cladding head; controlling the axle to rotate at a preset rotating speed, and controlling the cladding head to move in translation along an axial direction of the axle at a preset speed; starting from an outer edge of the to-be-repaired part, the cladding is performed in a spiral trajectory towards an inner edge of the to-be-repaired part; when the cladding reaches the inner edge, the cladding is restarted from the outer edge in a spiral trajectory towards the inner edge, and the cladding is repeated for multiple turns; the outer edge of the axle shaft and both sides of the axle key groove are cladded to form a first cladding layer; the above steps are repeated, and the laser beam is irradiated on the first cladding layer to continue forming multiple cladding layers.

[0006] In one embodiment of the present disclosure, the particle size of the alloy steel powder ranges from 53 to 150 pm; the alloy steel powder is sieved by using an 80-mesh sieve; and the sieved alloy steel powder is placed in a vacuum drying box and dried at 80 DEG C for a preset number of minutes.

[0007] In one embodiment of the present disclosure, the composition of the alloy steel powder is: 0.04% to 0.08% of carbon, 0.50% to 0.80% of silicon, 1.00% to 1.50% of manganese, 0.80% to 1.30% of chromium, less than or equal to 0.40% of nickel, less than or equal to 0.40% of copper, 0.10% to 0.40% of molybdenum, less than or equal to 0.010% of phosphorus, less than or equal to 0.010% of sulfur, and the rest is iron.

[0008] In one embodiment of the present disclosure, before the laser beam is irradiated on the surface of the to-be-repaired part of the axle seat to form a molten pool, the method further comprises: machining the to-be-repaired part to remove defects on the surface of the to-be-repaired part; and performing oil removal treatment and rust removal treatment on the to-be-repaired part.

[0009] In one embodiment of the present disclosure, after the outer edge of the axle shaft and the two sides of the axle key groove are cladded to form a first cladding layer, the method further comprises: turning and grinding the first cladding layer.

[0010] In one embodiment of the present disclosure, the adjacent cladding layers are staggered.

[0011] In one embodiment of the present disclosure, the diameter of the axle seat after forming the multi-layer cladding layer is 2mm larger than the original size of the axle seat.

[0012] In one embodiment of the present disclosure, the above steps are repeated to continue forming the multi-layer cladding layer by irradiating the first cladding layer with the laser beam, comprising: after each cladding layer is formed, turning and grinding the cladding layer.

[0013] In one embodiment of the present disclosure, after the outer edge of the axle shaft and the two sides of the axle key groove are cladded to form a first cladding layer, the method further comprises: tilting the cladding head by a preset angle to cladding the outer edge of the axle shaft and the two sides of the axle key groove to form the first cladding layer.

[0014] According to another aspect of the present disclosure, a kind of axle is provided by any of the above methods.

[0015] In one embodiment of the present disclosure, the laser beam is irradiated on the surface of the to-be-repaired part of the axle seat to form a molten pool; alloy steel powder is added to the molten pool by the cladding head; the axle is controlled to rotate at a preset speed, the cladding head is controlled to move along the axial direction of the axle at a preset speed, and cladding is carried out from the outer edge of the to-be-repaired part to the inner edge of the to-be-repaired part in a spiral trajectory; when cladding to the inner edge, cladding is restarted from the outer edge to the inner edge in a spiral trajectory, and multiple cladding circles are repeated; the outer edge of the axle shaft and the two sides of the axle key groove are cladded to form a first cladding layer; the above steps are repeated to continue forming a multi-layer cladding layer by irradiating the first cladding layer with the laser beam. Through the above technical means, the problem of resource waste and high replacement cost caused by axle damage in the related art is solved, thereby avoiding resource waste and reducing operation and maintenance cost.

[0016] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0017] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate embodiments consistent with the present disclosure and, together with the description, further serve to explain the principles of the present disclosure. It is to be understood that the drawings are designed solely for purposes of illustration to be used in conjunction with the description. It is to be understood that the drawings are designed solely for purposes of illustration and are not necessarily drawn to scale. Where appropriate, similar reference numbers and / or symbols in different drawings have been used to identify similar and / or equivalent items.

[0018] Figure 1 A schematic diagram of a vehicle axle repair system is shown.

[0019] Figure 2 A flowchart of a vehicle axle repair method is shown.

[0020] Figure 3 A schematic diagram of a vehicle axle is shown.

[0021] Figure 4 A schematic diagram of a cladding process of a cladding apparatus is shown.

[0022] Figure 5 A flowchart of another vehicle axle repair method is shown.

[0023] Figure 6 A schematic diagram of an electronic device is shown. DETAILED DESCRIPTION

[0024] Example implementations will now be described more fully with reference to the accompanying drawings. Example implementations may, however, be implemented in many different forms and should not be construed as limited to the implementations set forth herein; rather, these implementations are provided so that this disclosure will be thorough and complete, and will fully convey the scope of example implementations to those skilled in the art. The described features, structures, or characteristics can be combined in one or more implementations.

[0025] In addition, the drawings are to be perceived in a schematic way and are not necessarily drawn to scale. Identical reference numerals in different drawings denote the same or similar parts, and thus repeated description thereof will be omitted. Some of the block diagrams shown in the drawings are functional entities that do not necessarily have to correspond to physically or logically independent entities. These functional entities can be implemented in software, or in one or more hardware modules or integrated circuits, or in different network and / or processor and / or microcontroller entities.

[0026] It should be understood that the various steps of the method implementations of the present disclosure can be performed in different orders and / or in parallel. In addition, the method implementations can include additional steps and / or omit performing the steps shown. The scope of the present disclosure is not limited in this respect.

[0027] It should be noted that the concepts of "first", "second", etc. mentioned in the present disclosure are only used to distinguish different axles, modules or units, and are not used to limit the order or interdependence of the functions performed by these axles, modules or units.

[0028] It should be noted that the modification of "one" or "multiple" mentioned in the present disclosure is illustrative but not limiting, and those skilled in the art should understand that "one or more" should be understood unless otherwise explicitly indicated in the context.

[0029] It should be noted that the embodiments of the present disclosure and the technical features in the embodiments can be combined with each other without conflict.

[0030] For the convenience of understanding, the following first explains several units or symbols involved in the present disclosure as follows: mm is the unit symbol of millimeter.

[0031] Φ is the symbol of diameter, used to mark the size of circular section, for example, Φ2.8mm represents the diameter of 2.8mm.

[0032] W is the unit symbol of watt, used to represent the size of laser power.

[0033] mm / min is the unit symbol of millimeter per minute, used to represent the scanning speed or feed speed, that is, the distance moved by the cladding head or tool along the path per minute.

[0034] g / min is the unit symbol of gram per minute, used to represent the powder feeding amount, that is, the mass of alloy steel powder fed into the molten pool per unit time.

[0035] % is the percentage symbol.

[0036] L / min is the unit symbol of liter per minute, used to represent the gas flow, including the powder feeding gas flow and the protective gas flow, reflecting the volume of gas passed per unit time.

[0037] MPa is the unit symbol of megapascal, 1MPa is equal to 10 6 pascal, used to represent the tensile strength, yield strength and other mechanical properties of materials.

[0038] J is the unit symbol of joule, used to represent the impact toughness, that is, the ability of materials to absorb energy under impact load.

[0039] ℃ is the unit symbol of Celsius, used to represent the temperature.

[0040] Ra is the symbol of the profile arithmetic mean deviation, which is a commonly used parameter of surface roughness, with the unit of microns (μm), and Ra = 3.2 means that the average height of the surface profile deviating from the center line is 3.2 microns.

[0041] μm is the unit symbol of microns.

[0042] r / min is the unit symbol of revolutions per minute, which is used to represent the speed of rotation of the main shaft or axle of the lathe.

[0043] Bal. represents the balance.

[0044] AKVJ is a way to represent impact toughness, where AKV represents the impact absorbed work measured by using a Charpy V-notch specimen, and J is the unit of energy. AKVJ is used to measure the ability of a metal material to resist fracture under impact load, and the larger the value, the better the toughness of the material.

[0045] Figure 1 A schematic diagram of a vehicle axle repair system in an embodiment of the present disclosure is shown, which includes a setting module 101, a control module 102 and a cladding device 103.

[0046] The setting module 101 can receive user control parameters for the cladding device 103, such as the number of cladding layers and the number of cladding layers per cladding layer.

[0047] The control module 102 can be installed with an application program to control the cladding device 103 to perform: The laser beam is irradiated on the surface of the to-be-repaired part of the axle wheel seat to form a molten pool; the alloy steel powder is added to the molten pool through the cladding head; the axle is controlled to rotate at a preset speed, the cladding head is controlled to move in translation along the axial direction of the axle at a preset speed, and the cladding is performed in a spiral trajectory from the outer edge of the to-be-repaired part to the inner edge of the to-be-repaired part; when cladding to the inner edge, the cladding is restarted from the outer edge to the inner edge in a spiral trajectory, and the cladding is repeated for multiple turns; the outer edge of the axle shaft and the two sides of the axle key groove are cladded to form a first layer of cladding layer; the above steps are repeated to continue forming multiple layers of cladding layer by irradiating the laser beam on the first layer of cladding layer.

[0048] The number of cladding turns per cladding layer is 2 to 3 turns, and the number of cladding layers is 2 to 3 layers.

[0049] The particle size range of the alloy steel powder is 53-150 μm; the alloy steel powder is sieved by using an 80-mesh sieve; and the sieved alloy steel powder is placed in a vacuum drying oven and dried at 80°C for a preset number of minutes.

[0050] The alloy steel powder has the following components: 0.04%-0.08% carbon, 0.50%-0.80% silicon, 1.00%-1.50% manganese, 0.80%-1.30% chromium, less than or equal to 0.40% nickel, less than or equal to 0.40% copper, 0.10%-0.40% molybdenum, less than or equal to 0.010% phosphorus, less than or equal to 0.010% sulfur, and the rest is iron.

[0051] Machining the to-be-repaired part to remove defects on the surface of the to-be-repaired part; and performing oil removal treatment and rust removal treatment on the to-be-repaired part.

[0052] Performing turning and grinding treatment on the first layer of cladding layers.

[0053] The adjacent cladding layers are stacked in a staggered manner.

[0054] The diameter of the axle wheel seat formed by the plurality of layers of cladding layers is 2 mm larger than the original size of the axle wheel seat.

[0055] After each layer of cladding layers is formed, turning and grinding treatment are performed on the cladding layer.

[0056] The cladding head is inclined by a preset angle, and the outer edge of the axle shaft and the two sides of the axle key groove are cladded to form the first layer of cladding layers.

[0057] Figure 2 A flowchart of a vehicle axle repairing method in the embodiment of the present disclosure is shown, which comprises the following steps as shown in Figure 2 S201, irradiating a laser beam on the surface of a to-be-repaired part of an axle wheel seat to form a molten pool; S202, adding alloy steel powder to the molten pool through a cladding head; S203, controlling the axle to rotate at a preset rotating speed, and controlling the cladding head to move in a translational motion along the axial direction of the axle at a preset speed, and starting from the outer edge of the to-be-repaired part, cladding in a spiral trajectory towards the inner edge of the to-be-repaired part; S204, when cladding to the inner edge, starting from the outer edge again, cladding in a spiral trajectory towards the inner edge, and repeating the cladding for multiple turns; S205, cladding the outer edge of the axle shaft and the two sides of the axle key groove to form the first layer of cladding layers; S206, repeating the above steps to continue forming the plurality of layers of cladding layers by irradiating a laser beam on the first layer of cladding layers.

[0058] Exemplarily, the axle is one of the key components of a rail transit vehicle, and the safety thereof directly relates to the safety of the whole vehicle.

[0059] ​Exemplarily, the wheel seat is a cylindrical fitting section on the axle for mounting the wheel, located at both ends of the axle, bearing complex load.

[0060] Exemplarily, the repair site is the area of the wheel seat surface with damage such as scratches, scratches, etc., which needs to be repaired by laser additive.

[0061] Exemplarily, the molten pool is a local liquid metal area formed when the laser beam irradiates the surface of the axle, used to receive alloy steel powder and realize metallurgical bonding.

[0062] Exemplarily, the alloy steel powder is a metal material used for laser cladding, which has matching components with the base, and can form a repair layer that meets the mechanical performance requirements.

[0063] Exemplarily, the cladding head is a device that synchronously guides the laser beam and the alloy steel powder to the surface of the workpiece, used to realize powder delivery and cladding forming.

[0064] Exemplarily, the preset rotation speed is the set speed of the axle rotating around its own axis during repair, used to form a uniform spiral trajectory in cooperation with the movement of the cladding head.

[0065] Exemplarily, the preset speed is the set speed of the cladding head moving along the axial direction of the axle, which cooperates with the rotation speed of the axle to control the cladding path and the overlap rate.

[0066] Exemplarily, the cladding path is the trajectory formed by the movement of the cladding head on the surface of the repair site of the wheel seat of the axle, used to guide the deposition position and sequence of the laser beam and the alloy steel powder.

[0067] Exemplarily, the overlap rate is the overlap ratio of the adjacent two cladding tracks in the width direction, used to ensure that the cladding layer covers continuously and has no missed area, and to improve the interlayer bonding quality.

[0068] Exemplarily, the spiral trajectory is a path form that continuously surrounds from the outer edge to the inner edge of the repair site, used to realize full coverage cladding.

[0069] Exemplarily, the outer edge of the axle shaft is the end edge of the transition area between the wheel seat and the shaft body, which is an area prone to damage and needs to be additionally cladded.

[0070] Exemplarily, the axle key groove is a groove structure on the end of the axle for transmitting torque, and its two sides are working surfaces, which need to be prevented from being damaged after machining.

[0071] Exemplarily, the first cladding layer is a metallurgical bonding layer formed after the first cladding of the wheel seat main body and the edge area, which serves as the basis for subsequent multi-layer stacking.

[0072] Exemplarily, the multi-layer cladding layer is formed by repeatedly performing the cladding step to stack the repair structure layer by layer on the first layer of cladding layer to reach the required size allowance.

[0073] In this embodiment, the laser beam is irradiated on the surface of the axle seat to be repaired to form a molten pool, and alloy steel powder is added to the molten pool through the cladding head; the axle rotates at a preset speed, the cladding head translates axially at a preset speed, and cladding is performed in a spiral trajectory from the outer edge of the part to be repaired to the inner edge; after reaching the inner edge, the process is repeated from the outer edge to ensure complete coverage; then edge cladding is performed on the outer edge of the axle shaft and the two sides of the axle key groove, thus forming the first layer of cladding layer; the above process is repeated to continue forming the multi-layer cladding layer on the first layer of cladding layer. Through the above technical means, the whole piece is not scrapped due to surface damage of the axle, thereby reducing the replacement cost and reducing resource waste.

[0074] The laser additive manufacturing method of the embodiments of the present disclosure is for an axle seat made of alloy steel, and the specific chemical composition of the axle seat is shown in Table 1:

[0075] Table 1

[0076] As shown in Table 1, the chemical composition (mass fraction) of the axle seat is: carbon (C) ≤0.37%, silicon (Si) ≤0.46%, manganese (Mn) ≤1.12%, chromium (Cr) ≤0.27%, nickel (Ni) ≤0.27%, copper (Cu) ≤0.27%, molybdenum (Mo) ≤0.05%, phosphorus (P) ≤0.015%, sulfur (S) ≤0.015%, and the rest is iron (Fe).

[0077] The main performance requirements of the axle seat are shown in Table 2:

[0078] Table 2

[0079] As shown in Table 2, the tensile strength of the axle seat is 550-650 MPa, the yield strength is ≥320 MPa, the elongation after fracture is ≥22%, the impact toughness AKU is ≥30 J, and the impact toughness AKV at -20°C is ≥17 J.

[0080] In one embodiment of the present disclosure, the particle size range of the alloy steel powder is 53-150 μm; the alloy steel powder is sieved using an 80-mesh sieve; and the sieved alloy steel powder is placed in a vacuum drying box and dried at 80°C for a preset number of minutes.

[0081] Exemplarily, the particle size range is the distribution interval of the particle size of the alloy steel powder, in units of microns (μm).

[0082] For example, an 80-mesh sieve is a standard sieve with 80 mesh openings per inch of length, which has a mesh size of about 178 pm, and is used to remove agglomerates and impurities in the powder.

[0083] For example, a vacuum drying oven is a device for drying materials under low pressure, which can effectively remove the moisture adsorbed by the powder without causing oxidation.

[0084] For example, the preset minutes are the drying time set in advance in the process procedure, which is used to ensure that the powder is sufficiently dried, such as 30 minutes.

[0085] In this embodiment, the alloy steel powder is sieved by an 80-mesh sieve, and the sieved alloy steel powder is placed in a vacuum drying oven and dried at 80°C for a preset number of minutes. Through the above technical means, the flowability and purity of the alloy steel powder are ensured, so as to avoid defects such as pores and incomplete fusion caused by moisture or impurities in the cladding process.

[0086] In an alternative embodiment, the particle size of the alloy steel powder ranges from 45 pm to 105 pm, the alloy steel powder is sieved by a 100-mesh sieve, and the sieved alloy steel powder is placed in an inert atmosphere drying oven and dried at 90°C for 40 minutes. Through the above technical means, the powder particle size distribution is further refined and the drying efficiency is improved, so as to improve the surface flatness and density of the cladding layer.

[0087] In one embodiment of the present disclosure, the composition of the alloy steel powder is: 0.04% to 0.08% of carbon, 0.50% to 0.80% of silicon, 1.00% to 1.50% of manganese, 0.80% to 1.30% of chromium, less than or equal to 0.40% of nickel, less than or equal to 0.40% of copper, 0.10% to 0.40% of molybdenum, less than or equal to 0.010% of phosphorus, less than or equal to 0.010% of sulfur, and the rest is iron.

[0088] The composition of the alloy steel powder is shown in Table 3:

[0089] Table 3

[0090] The chemical composition (mass fraction) of the alloy steel powder is: carbon (C) 0.04% to 0.08%, silicon (Si) 0.50% to 0.80%, manganese (Mn) 1.00% to 1.50%, chromium (Cr) 0.80% to 1.30%, nickel (Ni) ≤0.40%, copper (Cu) ≤0.40%, molybdenum (Mo) 0.10% to 0.40%, phosphorus (P) ≤0.010%, sulfur (S) ≤0.010%, and the rest is iron (Fe). Through the above technical means, the cladding layer has sufficient strength and wear resistance while maintaining high elongation and good impact toughness, thereby meeting the service performance requirements after repair of the axle wheel seat.

[0091] In an optional embodiment, the composition of the alloy steel powder is: 0.06% to 0.10% carbon, 0.40% to 0.70% silicon, 0.90% to 1.30% manganese, 0.60% to 1.00% chromium, 0.30% to 0.60% nickel, ≤0.30% copper, 0.15% to 0.35% molybdenum, ≤0.012% phosphorus, ≤0.012% sulfur, and the rest is iron. Through the above technical means, the carbon and nickel contents are moderately increased to enhance the strength and low-temperature toughness balance of the cladding layer, which is suitable for axle repair scenarios under higher load conditions.

[0092] In an embodiment of the present disclosure, before the laser beam is irradiated on the surface of the to-be-repaired part of the axle wheel seat to form a molten pool, the method further comprises: machining the to-be-repaired part to remove defects on the surface of the to-be-repaired part; and performing oil removal treatment and rust removal treatment on the to-be-repaired part.

[0093] Demonstratively, machining is a process of removing the damaged layer on the surface of the to-be-repaired part of the axle wheel seat by cutting, which is used to eliminate defects such as cracks, scratches, or bumps.

[0094] Demonstratively, oil removal treatment is an operation of removing cutting fluid, rust-proof oil, and other organic contaminants remaining on the surface of the to-be-repaired part after machining.

[0095] Demonstratively, rust removal treatment is an operation of removing oxide scale, rust, or other inorganic contaminants on the surface of the to-be-repaired part to improve the surface activity of the substrate.

[0096] In this embodiment, the to-be-repaired part is machined to remove defects on the surface of the to-be-repaired part, and the to-be-repaired part is subjected to oil removal treatment and rust removal treatment. Through the above technical means, the substrate surface is ensured to be clean, smooth, and pollution-free, thereby providing good metallurgical bonding conditions for subsequent laser cladding.

[0097] In an optional embodiment, before the laser beam is irradiated on the surface of the to-be-repaired part of the axle wheel seat to form a molten pool, the method further comprises: using a numerical control lathe to finish turning the to-be-repaired part to remove a surface layer with a depth of not less than 0.3 mm; and then sequentially performing alkaline cleaning to remove oil, high-pressure water washing, and sand blasting to remove rust, so that the surface cleanliness reaches Sa2.5 level. Through the above technical means, higher precision defect removal and more reliable surface activation are achieved, and then the cladding layer bonding strength and the microstructure uniformity are improved.

[0098] Illustratively, the Sa2.5 level is a standard grade of surface cleanliness.

[0099] In an embodiment of the present disclosure, after the outer edge of the axle shaft spindle and the two sides of the axle key groove are cladded to form a first layer of cladding layer, the method further comprises: turning and grinding the first layer of cladding layer.

[0100] Illustratively, the turning process is a process operation of cutting the first layer of cladding layer to control its size and preliminarily reduce the surface roughness.

[0101] Illustratively, the grinding process is a process operation of precisely machining the surface of the cladding layer after the turning process to further improve the dimensional accuracy and surface finish.

[0102] In this embodiment, through the above technical means, the first layer of cladding layer reaches the geometric accuracy and surface state required for subsequent multi-layer cladding, thereby guaranteeing the interlayer bonding quality and the overall repair appearance.

[0103] In an optional embodiment, after the outer edge of the axle shaft spindle and the two sides of the axle key groove are cladded to form a first layer of cladding layer, the method further comprises: using a numerical control lathe to turn the first layer of cladding layer at a spindle speed of 600 r / min, a feed speed of 0.4 mm / min, and a cutting depth of 0.25 mm, and then using a cylindrical grinding machine to grind at a spindle speed of 1000 r / min, a feed speed of 0.4 mm / min, and a cutting depth of 0.01 mm, so that the surface roughness reaches Ra=3.2. Through the above technical means, the cladding layer surface topography and residual stress distribution are accurately controlled, and then a stable and reliable substrate condition is provided for the second layer of cladding.

[0104] In an embodiment of the present disclosure, adjacent cladding layers are stacked in a staggered manner.

[0105] Illustratively, the staggered stacking is a stacking manner in which the adjacent cladding layers are offset from each other in the circumferential or axial position when deposited, which is used to avoid overlapping of the molten channels and accumulation of defects.

[0106] In this embodiment, the continuity of defects such as interlayer un-melted, porosity, etc. is reduced by the above technical means, thereby improving the overall density and mechanical uniformity of the multi-layer cladding structure.

[0107] In an alternative embodiment, the starting cladding position of the second layer cladding layer is offset by 45 degrees in the circumferential direction of the axle relative to the first layer cladding layer, and the pitch of the spiral trajectory is adjusted to be different from the first layer, realizing non-aligned staggered stacking. By the above technical means, the heat flow distribution and solidification structure orientation are optimized, thereby inhibiting the excessive growth of columnar grains and refining the grain structure.

[0108] In an embodiment of the present disclosure, the diameter of the axle wheel seat forming the multi-layer cladding layer is 2 mm larger than the original size of the axle wheel seat.

[0109] Illustratively, the original size is the designed diameter size of the axle wheel seat before damage and repair.

[0110] In this embodiment, sufficient allowance is reserved for subsequent turning and grinding finishing, thereby ensuring that the final size of the repaired wheel seat meets the assembly tolerance requirements.

[0111] In an alternative embodiment, the diameter of the axle wheel seat forming the multi-layer cladding layer is 2.5 mm larger than the original size of the axle wheel seat, and the roundness error control is maintained at ±0.1 mm in the radial direction. By the above technical means, the geometric precision is improved while ensuring the machining allowance, thereby reducing the uneven material removal and residual stress fluctuation in the finishing process.

[0112] In an embodiment of the present disclosure, the above steps are repeated to continue forming the multi-layer cladding layer by irradiating the laser beam on the first layer cladding layer, including: after each layer of cladding layer is formed, turning and grinding treatment is performed on the cladding layer.

[0113] In this embodiment, the above steps are repeated to continue forming the multi-layer cladding layer by irradiating the laser beam on the first layer cladding layer, and after each layer of cladding layer is formed, turning and grinding treatment is performed on the cladding layer, and then the next layer of cladding layer is continued to be formed. By the above technical means, the dimensional accuracy and surface state of the cladding layer are controlled layer by layer, thereby avoiding defect accumulation and ensuring the geometric consistency and metallurgical quality of the final repaired area.

[0114] In an optional embodiment, after each layer of cladding layer is formed, the numerical control lathe is used to perform turning processing at a spindle speed of 600 r / min, a feed speed of 0.4 mm / min and a cutting depth of 0.25 mm, and then the cylindrical grinding machine is used to perform grinding processing at a spindle speed of 1000 r / min, a feed speed of 0.4 mm / min and a cutting depth of 0.01 mm, so that the surface roughness of the layer reaches Ra=3.2, and whether the residual stress at a position 0.1 mm below the surface is lower than +100 MPa is detected. Through the above technical means, the interlayer stress regulation and morphology standardization are realized, and then the overall service reliability of the multilayer repair structure is improved.

[0115] In an embodiment of the present disclosure, when cladding to the inner edge, the cladding is restarted from the outer edge, and the cladding is performed to the inner edge in a spiral trajectory, and after repeating the cladding for multiple turns, the method further comprises: tilting the cladding head by a preset angle to perform cladding on the outer edge of the axle shaft and the two sides of the axle shaft key groove to form a first layer of cladding layer.

[0116] Exemplarily, the preset angle is an operation of adjusting the cladding head by a fixed angle relative to the normal direction of the surface of the axle shaft, which is used to improve the powder deposition effect of the complex geometric region.

[0117] In this embodiment, before cladding on the outer edge of the axle shaft and the two sides of the axle shaft key groove, the cladding head is tilted by a preset angle, thereby enhancing the cladding coverage capability of the geometric mutation region, so as to prevent defects after machining.

[0118] In an optional embodiment, when cladding to the inner edge, the cladding is restarted from the outer edge, and the cladding is performed to the inner edge in a spiral trajectory, and after repeating the cladding for multiple turns, the method further comprises: tilting the cladding head by 15 degrees, slowly swinging and scanning along the circumference of the axle shaft, and performing two-pass reinforced cladding on the outer edge of the axle shaft and the two sides of the axle shaft key groove to ensure that the thickness of the cladding layer in the edge region is not less than 0.8 mm. Through the above technical means, the material filling rate and the bonding strength of the edge region are improved, and then the structural integrity after subsequent finishing is ensured.

[0119] Figure 3 A schematic diagram of an axle in an embodiment of the present disclosure is shown as Figure 3

[0120] The rectangular frame represented by the thick line is a part to be repaired, which needs to be repaired by multi-layer spiral trajectory cladding to realize material supplement and size recovery. The region is the cylindrical surface part of the axle wheel seat, and the axial length thereof is marked as 8±2 mm, indicating that the size of the repair section in the axial direction is 8 mm, and the allowable tolerance is ±2 mm. The region is near the transition between the wheel seat and the axle body, and is a key part that bears the wheel pressing stress.

[0121] ​The dashed line represents the center line of the axle, used for symmetrical positioning of the repair area; the right side edge has an R-shaped round corner transition, indicating that the end of the wheel seat has a chamfer structure to reduce stress concentration.

[0122] Figure 4 A schematic diagram of a cladding process of a cladding device in an embodiment of the present disclosure is shown, as shown in Figure 4 . The laser beam is focused downward from the center of the two coaxial powder feeding cladding heads to the surface of the part to be repaired, forming a high-temperature molten pool; at the same time, alloy steel powder is added to the molten pool from the channels of the two cladding heads (the powder flow is the alloy steel powder flowing down); the protective gas is blown out from the annular nozzles outside the cladding heads, surrounding the molten pool to prevent oxidation; the molten pool cools and solidifies to form a cladding layer.

[0123] The process parameters of the cladding device are shown in Table 4:

[0124] Table 4

[0125] From Table 4, the process parameters are as follows: the laser spot is Φ2.8mm, the focal length is positive defocus 1mm, the laser power is 1800W, the scanning speed is 500-600mm / min, the powder feeding amount is 8-14g / min, the overlap rate is 40%-50%, the powder feeding gas flow is 3-5L / min, and the protective gas flow is 15-20L / min.

[0126] Figure 5 A flowchart of another axle repair method in an embodiment of the present disclosure is shown, as shown in Figure 5 . Powder treatment is a pretreatment operation such as screening and drying of alloy steel powder.

[0127] Defect removal by machining is to remove damaged areas such as scratches and scratches on the surface of the wheel seat by turning and other methods.

[0128] Surface treatment of the axle, i.e. cleaning treatment such as oil removal and rust removal on the machined surface to ensure the cleanliness of the substrate to meet the cladding bonding requirements.

[0129] Cladding device and process parameter setting, which is to set parameters such as laser power, scanning speed and powder feeding amount according to the material properties of the axle wheel seat.

[0130] Cladding path planning is to design cladding paths such as spiral trajectories according to the geometry of the part to be repaired.

[0131] According to another aspect of the present disclosure, a axle is provided, which is obtained by any of the above methods.

[0132] Those skilled in the art can understand that the various aspects of the present disclosure can be implemented as a system, method, or program product. Therefore, the various aspects of the present disclosure can be embodied as a whole hardware implementation, a whole software implementation (including firmware, microcode, etc.), or an implementation combining hardware and software aspects, which can be collectively referred to as "circuitry", "module" or "system" here.

[0133] The electronic device 600 according to this embodiment of the present disclosure will be described below with reference to Figure 6 Figure 6 The electronic device 600 shown is merely an example and should not bring any limitation to the function and use range of the embodiments of the present disclosure.

[0134] As Figure 6 shown, the electronic device 600 is in the form of a general computing device. The components of the electronic device 600 can include, but are not limited to, at least one processor 610, at least one memory 620, and a bus 630 connecting different system components, including the memory 620 and the processor 610.

[0135] The memory stores program codes which can be executed by the processor 610, so that the processor 610 performs the steps according to various exemplary embodiments of the present disclosure described in the "Exemplary Method" section of the present specification. For example, the processor 610 can perform the following steps of the above method embodiments: The laser beam is irradiated on the surface of the to-be-repaired part of the axle wheel seat to form a molten pool; the alloy steel powder is added to the molten pool through the cladding head; the axle is controlled to rotate at a preset speed, the cladding head is controlled to move in translation along the axial direction of the axle at a preset speed, and the cladding is performed in a spiral trajectory from the outer edge of the to-be-repaired part to the inner edge of the to-be-repaired part; when the cladding reaches the inner edge, the cladding is restarted from the outer edge to the inner edge in a spiral trajectory, and the cladding is repeated for multiple turns; the outer edge of the axle shaft and the two sides of the axle key groove are cladded to form a first layer of cladding layer; the above steps are repeated to continue to form multiple layers of cladding layers on the first layer of cladding layer by irradiating the laser beam.

[0136] The particle size range of the alloy steel powder is 53-150 μm; the alloy steel powder is sieved by using a 60-mesh sieve; and the sieved alloy steel powder is placed in a vacuum drying box and dried at 60°C for a preset number of minutes.

[0137] The composition of the alloy steel powder is: 0.04%-0.06% of carbon, 0.50%-0.60% of silicon, 1.00%-1.50% of manganese, 0.60%-1.30% of chromium, less than or equal to 0.40% of nickel, less than or equal to 0.40% of copper, 0.10%-0.40% of molybdenum, less than or equal to 0.010% of phosphorus, less than or equal to 0.010% of sulfur, and the rest is iron.​

[0138] Machining the repair site to remove defects from the surface of the repair site; and oil and rust removal treatment of the repair site.

[0139] Turning and grinding the first layer of cladding.

[0140] The adjacent cladding layers are stacked in a staggered manner.

[0141] The diameter of the axle wheel seat formed by the plurality of layers of cladding is 2mm larger than the original size of the axle wheel seat.

[0142] After each layer of cladding is formed, the layer of cladding is turned and ground.

[0143] The cladding head is tilted at a preset angle, and the outer edge of the axle shaft and the two sides of the axle key groove are cladded to form a first layer of cladding.

[0144] The memory 620 can include a readable medium in the form of volatile memory, such as a random access memory (RAM) 6201 and / or a cache memory 6202, and can further include a read-only memory (ROM) 6203.

[0145] The memory 620 can also include a program / utility 6204 having a set of program modules 6205, including but not limited to, an operating system, one or more application programs, other program modules, and program data, each or a combination thereof, which may

[0146] The bus 630 can represent one or more of several types of bus structures, including a memory bus or memory controller, a peripheral bus, a graphics acceleration bus, a processor or local bus using any of a variety of bus structures, and the like.

[0147] The electronic device 600 can also communicate with one or more external devices 640 such as a keyboard or pointing device, a Bluetooth device, or a database via I / O interface 650. The communication can be facilitated via a network adapter 660. As illustrated, the network adapter 660 is in communication with the other modules of the electronic device 600 through the bus 630. It should be appreciated that other hardware and / or software modules can be used in conjunction with the electronic device 600, including but not limited to microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data archival storage systems, etc.

[0148] In the disclosed exemplary embodiments, a computer readable storage medium is also provided, which can be a readable signal medium or a readable storage medium.

[0149] In some possible implementation manners, various aspects of the present disclosure can also be implemented as a program product, which includes a program code for causing an end device to perform the steps described in the above “specific embodiments” section according to various exemplary embodiments of the present disclosure when the program product is run on the end device.

[0150] More specific examples of the computer readable storage medium in the present disclosure can include but are not limited to: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any appropriate combination of the above.

[0151] In the present disclosure, the computer readable storage medium can include a data signal carried in the baseband or as a part of a carrier wave propagating through the transmission medium, in which a readable program code is carried. Such a propagated data signal can take multiple forms, including but not limited to an electromagnetic signal, an optical signal, or any appropriate combination of the above. The readable signal medium can also be any readable medium that can send, propagate or transfer a program for use by or in connection with an instruction execution system, an axle or a device.

[0152] Optionally, program code embodied on a computer readable storage medium can be transmitted by way of any appropriate medium, including, but not limited to wireless, wired, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

[0153] In particular embodiments, the program code implementing the methods of the present disclosure can be written in any combination of one or more programming languages, including an object oriented programming language such as Java, C++, or the like, and conventional procedural programming languages, such as the "C" programming language or similar programming languages. The program code can execute entirely on the user's computing device, partly on the remote computing device, as a stand-alone software package, partly on the user's computing device and partly on the remote computing device, or entirely on the remote or server. In the latter scenario, the remote computing device can be connected to the user's computing device through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection can be made to an external computing device such as through the Internet using an Internet Service Provider. In some embodiments, electronic circuitry including, for example, programmable logic circuitry, application specific circuitry, or field programmable gate array (FPGA) circuitry can execute the program code. In some embodiments, multiple computing devices can be used to execute the program code.

[0154] The computer program product or computer program of the embodiments of the present disclosure includes computer instructions stored in a computer readable storage medium. The processor of the computer device reads the computer instructions from the computer readable storage medium. The processor executes the computer instructions, so that the computer device performs the axle repair method provided in any of the various optional manners in the embodiments of the present disclosure.

[0155] It should be noted that although several modules or units of devices for action execution are mentioned in the foregoing detailed description, such division is not mandatory. Indeed, features and functionalities of two or more modules or units described above can be embodied in one module or unit according to embodiments of the present disclosure. Conversely, features and functionalities of one module or unit described above can be further divided into multiple modules or units.

[0156] Moreover, although the various steps of the methods of the present disclosure are described in a particular order in the figures, this is not required or implied in any way as to the order of the steps or that all illustrated steps be necessarily performed to achieve desirable results. Additionally or alternatively, certain steps can be omitted, combined into fewer steps, split into multiple steps, and / or performed in an order other than that described herein.

[0157] Through the description of the above embodiments, those skilled in the art can easily understand that the example embodiments described herein can be implemented by software, or by software in combination with necessary hardware. Therefore, the technical solutions according to the embodiments of the present disclosure can be embodied in the form of a software product, which can be stored in a non-volatile storage medium (which can be a CD-ROM, a USB flash disk, a mobile hard disk, or the like) or a network, and includes a number of instructions to make a computing device (which can be a personal computer, a server, a mobile terminal, or a network device, etc.) execute the methods according to the embodiments of the present disclosure.

[0158] Other embodiments of the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the features disclosed herein. The present disclosure is intended to cover any variations, uses, or adaptations of the present disclosure following the general principles thereof and including such departures from the present disclosure that come within known use or custom in the art to which the present disclosure pertains. The specification and examples are to be regarded as illustrative only, and the true scope of the present disclosure is indicated by the appended claims.

Claims

1. A method for repairing an axle, characterized in that, include: The laser beam is irradiated onto the surface of the part of the axle wheel seat to be repaired, forming a molten pool; Alloy steel powder is added to the molten pool through a cladding head; The axle is controlled to rotate at a preset speed, and the cladding head is controlled to move along the axis of the axle at a preset speed, starting from the outer edge of the part to be repaired and cladding towards the inner edge of the part to be repaired in a spiral trajectory; When the cladding reaches the inner edge, start again from the outer edge and clad towards the inner edge in a spiral trajectory, repeating the cladding process multiple times; The outer edge of the axle shaft and both sides of the axle keyway are clad to form the first cladding layer; Repeat the above steps, using a laser beam to irradiate the first cladding layer to continue forming multiple cladding layers.

2. The method according to claim 1, characterized in that, The particle size range of the alloy steel powder is 53–150 μm; The alloy steel powder was sieved using an 80-mesh sieve. The sieved alloy steel powder is placed in a vacuum drying oven and dried at 80°C for a preset time.

3. The method according to claim 1, characterized in that, The alloy steel powder comprises: 0.04%–0.08% carbon, 0.50%–0.80% silicon, 1.00%–1.50% manganese, 0.80%–1.30% chromium, less than or equal to 0.40% nickel, less than or equal to 0.40% copper, 0.10%–0.40% molybdenum, less than or equal to 0.010% phosphorus, less than or equal to 0.010% sulfur, with the remainder being iron.

4. The method according to claim 1, characterized in that, Before irradiating the surface of the axle wheel seat area to be repaired with a laser beam to form a molten pool, the method further includes: The area to be repaired is machined to remove surface defects. The area to be repaired is then subjected to degreasing and rust removal treatment.

5. The method according to claim 1, characterized in that, After cladding the outer edge of the axle shaft and both sides of the axle keyway to form the first cladding layer, the method further includes: The first cladding layer is then machined and ground.

6. The method according to claim 1, characterized in that, Adjacent cladding layers are stacked in a staggered manner.

7. The method according to claim 1, characterized in that, The diameter of the axle wheel seat forming the multi-layer cladding layer is 2 mm larger than the original size of the axle wheel seat.

8. The method according to claim 1, characterized in that, The process of repeating the above steps, using a laser beam to irradiate the first cladding layer to continue forming multiple cladding layers, includes: After each cladding layer is formed, it is machined and ground.

9. The method according to claim 1, characterized in that, When the cladding reaches the inner edge, the process restarts from the outer edge, cladding towards the inner edge in a spiral trajectory, repeating this process multiple times. The method further includes: The cladding head is tilted at a preset angle to clad the outer edge of the axle shaft and both sides of the axle keyway, forming the first cladding layer.

10. An axle, characterized in that, Obtained by the method as described in any one of claims 1-9.

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