Method and device for repairing damage to a mounting surface of a shaft box

Abstract

This invention discloses a method and apparatus for repairing damage to the mounting surface of an axle housing. The method includes the following steps: obtaining dimensional measurements of corrosion pits at the damaged location on the mounting surface of the axle housing to determine the defect area, and removing the corrosion layer from the defect area using subtractive machining; classifying the defect areas and, based on the type of each defect area, spraying corresponding coatings to obtain corresponding repair areas; and performing subtractive remanufacturing on each repair area to restore the dimensions of the mounting surface. This method not only removes corrosion products from the mounting surface of the axle housing but also, based on machining to remove corrosion, efficiently and accurately restores the dimensions of the axle housing through a process of additive and subtractive machining. It eliminates the impact of traditional thermal repair methods on the part's microstructure, dimensional accuracy, and mechanical properties, further improving the service life of the axle housing.

Description

Technical Field

[0001] This invention relates to the field of rail transit technology, and in particular to a method and apparatus for repairing damage to the mounting surface of an axle box. Background Technology

[0002] Aluminum alloys, due to their high specific strength, high specific modulus, and good corrosion resistance, are widely used in transportation, vehicle manufacturing, aerospace, and other fields, and are important materials for lightweighting high-speed trains, automobiles, and aircraft. The axle box is a crucial component of the running gear of high-speed trains. Current technology typically uses high-strength aluminum alloys in the axle boxes of high-speed trains. To prevent galvanic corrosion at the contact surfaces between the axle box and other components, zinc phosphate paint is usually applied for protection. However, during vehicle operation, due to fretting wear, the zinc phosphate paint is easily damaged, exposing the substrate and causing galvanic corrosion at the axle box mounting surface. This results in various corrosion pits on the surface, leading to excessive surface roughness that fails to meet usage requirements.

[0003] The main current approach to addressing this issue is to remove the corrosion layer caused by galvanic corrosion on the mounting surface of the axle box through machining, thus resolving the surface roughness problem. However, after one or two machining operations, the dimensions of the axle box mounting surface reach their lower limit, and subsequent corrosion makes repair impossible, necessitating scrapping or sealing. This approach results in high maintenance costs and significant resource waste. Furthermore, commonly used material repair and remanufacturing technologies based on high-energy beams such as lasers, plasma, and electric arcs present a series of currently insurmountable problems when repairing 7-series high-strength aluminum alloys, including easy cracking of the workpiece, a large heat-affected zone, and low hardness of the repair layer.

[0004] In conclusion, there is an urgent need to develop new repair technologies and their supporting repair processes. Summary of the Invention

[0005] This invention provides a method and apparatus for repairing damage to the mounting surface of an axle box, which removes corrosion from the mounting surface of the axle box and, on this basis, can efficiently remove corrosion products and restore the dimensions of the axle box. This eliminates the impact of traditional thermal repair methods on the part's microstructure, dimensional accuracy, and mechanical properties, and further improves the service life of the axle box.

[0006] This invention provides a method for repairing damage to the mounting surface of an axle box, comprising the following steps:

[0007] Obtain the dimensional measurement results of the corrosion pits at the damaged location on the mounting surface of the axle box to determine the defect area at the damaged location, and remove the corrosion layer in the defect area by subtractive processing.

[0008] The defective areas are classified, and based on the type of each defective area, the corresponding defective areas are sprayed to obtain the corresponding repair areas;

[0009] Each of the repaired areas is remanufactured using subtractive materials to restore the dimensions of the mounting surface.

[0010] According to a method for repairing damage to a bearing housing mounting surface provided by the present invention, the step of obtaining the dimensional measurement results of the corrosion pits at the damaged location of the bearing housing mounting surface to determine the defect area at the damaged location, and removing the corrosion layer in the defect area by subtractive machining, further includes the following steps:

[0011] Based on the location of the corrosion pit, each defect region at the damage location is determined, and each defect region contains at least one corrosion pit;

[0012] The maximum depth of the corrosion pits and the area of ​​the corresponding defect region within the same defect region are obtained to determine the machining range.

[0013] Within each of the aforementioned machining processes, the corrosion layer in each of the defective regions is removed using the subtractive machining process.

[0014] According to a method for repairing damage to the mounting surface of a shaft housing provided by the present invention, the step of obtaining the maximum depth of the corrosion pits and the corresponding area of ​​the defective region within the same defective region to determine the machining range further includes the following steps:

[0015] Several corrosion pits are selected within the same defect area, and the depth of each selected corrosion pit is measured using a depth measuring instrument. The maximum depth of the corrosion pit is obtained by comparison.

[0016] Calculate the area of ​​the defective region;

[0017] The machining range is determined based on the maximum depth of the corrosion pit and the area of ​​the defect region;

[0018] Wherein, the area of ​​the machining treatment range is greater than the area of ​​the defect region, and the depth of the machining treatment range is not less than the maximum depth of the corrosion pit.

[0019] According to the present invention, a method for repairing damage to the mounting surface of a shaft box includes, after the step of removing the corrosion layer of each defective area by means of subtractive machining within each of the machining processing ranges, the method further includes the following steps:

[0020] The defective area after the subtractive processing is subjected to rounded corner transition treatment;

[0021] Wherein, the angle between the rounded corner of the defect area after the rounded corner transition treatment and the base surface is no greater than 30°.

[0022] According to a method for repairing damage to the mounting surface of a shaft box provided by the present invention, the step of classifying the defective areas and spraying corresponding coatings on the defective areas according to the type of each defective area to obtain the corresponding repair area further includes the following steps:

[0023] Obtain the length and width of each corrosion pit within the defect area;

[0024] Based on the length and width of each corrosion pit, the defect regions are classified to determine the type of the defect region; wherein, the type of defect region includes point defects, linear defects, and surface defects;

[0025] For the point-like defects, drive the spray gun to spray perpendicularly to the center of the defect area;

[0026] For the linear defect, the spray gun is driven to travel along the length of the defect area, and the travel path of the spray gun remains unchanged in the width direction. The number of reciprocating strokes of the spray gun is determined based on the maximum depth of the corrosion pit.

[0027] For the surface defects, the spray gun is driven to travel along the length and width of the defect area, and the number of reciprocating strokes of the spray gun is determined based on the maximum depth of the corrosion pit.

[0028] According to the present invention, a method for repairing damage to the mounting surface of a shaft box is provided, wherein the point defect is a corrosion pit whose length and width are both less than 5 mm; the linear defect is a corrosion pit whose length is greater than or equal to 5 mm and whose width is less than or equal to 5 mm; and all other defects besides the point defect and the linear defect are surface defects.

[0029] According to a method for repairing damage to a bearing housing mounting surface provided by the present invention, before the steps of obtaining the dimensional measurement results of the corrosion pit at the damaged location of the bearing housing mounting surface to determine the defect area at the damaged location, and removing the corrosion layer of the defect area by subtractive machining, the method further includes the following steps:

[0030] Laser cleaning is performed on the damaged areas of the mounting surface;

[0031] The damaged area is then cleaned to expose the corrosion pits.

[0032] According to a method for repairing damage to a bearing housing mounting surface provided by the present invention, the steps of laser cleaning the damaged area of ​​the mounting surface and surface cleaning the cleaned damaged area to expose corrosion pits further include the following steps:

[0033] The damaged areas of the mounting surface are cleaned using a laser cleaning system; wherein the laser power of the laser cleaning system is 50W to 120W, and the cleaning time is 2min to 5min.

[0034] The damaged area is cleaned using a high-pressure air gun to expose corrosion pits.

[0035] According to a method for repairing damage to the mounting surface of a shaft box provided by the present invention, before the steps of classifying the defective areas and spraying the defective areas accordingly based on the type of each defective area to obtain the corresponding repair area, the method further includes the following steps:

[0036] All pore-like areas within the defective region after the subtractive processing are sealed using plugs;

[0037] The defective areas after subtractive processing are subjected to sandblasting.

[0038] The defective area after sandblasting is preheated and sprayed.

[0039] According to the present invention, a method for repairing damage to the mounting surface of a shaft box is provided, wherein the surface roughness of the defective area after sandblasting is Ra 5.0 μm to 7.6 μm.

[0040] According to the present invention, a method for repairing damage to the mounting surface of a shaft box includes the following process parameters for preheating spraying:

[0041] The preheating spraying uses 7050 aluminum alloy powder with a particle size of 10μm to 60μm, the drying temperature of the powder is 70±5℃, and the preheating spraying time is 40min to 60min.

[0042] The preheating spraying uses 99.99% nitrogen gas as the spraying gas;

[0043] The pressure of the spraying gas is 3.5 MPa to 5.5 MPa;

[0044] The spraying distance for the preheated spraying is 5mm to 20mm;

[0045] The angle between the spray gun and the spraying surface for preheating spraying is not less than 60°.

[0046] The present invention also provides a device for repairing damage to the mounting surface of an axle box, which can perform the method for repairing damage to the mounting surface of an axle box as described above;

[0047] The axle box mounting surface damage repair device includes:

[0048] A dimensional measurement system is used to obtain dimensional measurement results of corrosion pits at the damaged locations of the axle box mounting surface;

[0049] A subtractive machining system is used to determine the defect area at the location of the damage based on the dimensional measurement results of the corrosion pit, and to remove the corrosion layer in the defect area using subtractive machining.

[0050] A spraying system is used to classify the defective areas and, based on the type of each defective area, spray the defective areas accordingly to obtain the corresponding repair areas.

[0051] A subtractive remanufacturing system is used to perform subtractive remanufacturing on each of the repair areas to restore the dimensions of the mounting surface.

[0052] The present invention provides a method for repairing damage to the mounting surface of an aluminum alloy axle box. This method innovatively introduces a cold spray additive manufacturing technique with low-temperature solid-state deposition of metal materials into additive (subtractive) remanufacturing technology. It achieves precise process path design through dimensional measurement and defect classification, thereby repairing damaged parts of the mounting surface of the aluminum alloy axle box. Different repair processes are formulated for different damage morphologies to solve the problems of high maintenance costs, difficult repair, and serious waste of resources in the existing aluminum alloy axle box repair.

[0053] The method described in this invention specifically determines the defective areas suitable for subtractive machining by measuring the dimensions of corrosion pits at the damaged locations of the axle housing mounting surface, thereby improving the accuracy of corrosion layer removal. This method achieves precise spraying by meticulously classifying the defective areas and applying appropriate coatings based on the type of each defective area. Furthermore, this method performs subtractive remanufacturing on each repair area to restore the dimensions of the mounting surface. Compared to existing technologies, this method no longer simply removes corrosion from the axle housing mounting surface through machining. Instead, it uses high-pressure cold spraying to add material to repair the corroded defective areas after subtractive machining. This not only removes corrosion products from the axle housing mounting surface but also efficiently and accurately restores the axle housing dimensions through a process of adding material followed by subtractive machining, eliminating the impact of traditional thermal repair methods on the part's microstructure, dimensional accuracy, and mechanical properties, further extending the service life of the axle housing.

[0054] Furthermore, the method described in this invention enables the application of high-pressure cold spraying technology to key load-bearing aluminum alloy components, which not only restores the surface condition of high-strength aluminum alloys but also repairs the strength and function of key components, playing an important role in promoting the application of high-pressure cold spraying technology in more industrial fields.

[0055] The present invention also provides a device for repairing damage to the mounting surface of axle box. By setting up a dimensional measurement system, a subtractive processing system, a spraying system and a subtractive remanufacturing system, the device can perform the above-mentioned method for repairing damage to the mounting surface of axle box, thereby possessing all the advantages of the above-mentioned method for repairing damage to the mounting surface of axle box, which will not be elaborated here. Attached Figure Description

[0056] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0057] Figure 1 This is a flowchart illustrating the method for repairing damage to the mounting surface of the axle box provided by the present invention. Detailed Implementation

[0058] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0059] The following is combined Figure 1 The present invention describes a method for repairing damage to the mounting surface of an axle box (hereinafter referred to as the "method") and an apparatus for repairing damage to the mounting surface of an axle box (hereinafter referred to as the "apparatus").

[0060] like Figure 1 As shown, the method for repairing damage to the mounting surface of the axle box according to the present invention includes the following steps:

[0061] S1. Obtain the dimensional measurement results of the corrosion pits at the damaged location on the mounting surface of the axle box to determine the defect area at the damaged location, and remove the corrosion layer in the defect area by subtractive processing.

[0062] S2. Classify the defective areas and, based on the type of each defective area, spray the corresponding defective areas to obtain the corresponding repair areas.

[0063] S3. Subtractive manufacturing is performed on each repair area to restore the dimensions of the mounting surface.

[0064] In the method described in this invention, step S1 involves measuring the dimensions of corrosion pits at the damaged location of the axle housing mounting surface to determine the defective areas suitable for subtractive machining, thereby improving the accuracy of corrosion layer removal. Step S2 involves meticulously classifying the defective areas and spraying them accordingly based on their type, achieving precise spraying. Furthermore, step S3 further involves subtractive remanufacturing of each repaired area to restore the dimensions of the mounting surface. Compared to existing technologies, this method no longer simply involves machining the axle housing mounting surface to remove corrosion. Instead, it employs additive manufacturing to repair the corroded defective areas using high-pressure cold spraying, building upon subtractive machining. This not only removes corrosion products from the axle housing mounting surface but also efficiently and accurately restores the axle housing dimensions through a process of additive manufacturing followed by subtractive machining. This eliminates the impact of traditional thermal repair methods on the part's microstructure, dimensional accuracy, and mechanical properties, further extending the service life of the axle housing.

[0065] To ensure that the corrosion pits at the damaged location are fully exposed so that subsequent dimensional measurements are more accurate and to avoid large discrepancies that could lead to errors in the determination and classification of the defective area, a surface pretreatment step is preferably included before step S1.

[0066] Preferably, the surface pretreatment step specifically includes the following steps:

[0067] S01. Perform laser cleaning on the damaged areas of the mounting surface;

[0068] S02. Clean the surface of the damaged area after cleaning to expose the corrosion pits.

[0069] To remove rust and contaminants from the mounting surface of the axle box and improve the accuracy and efficiency of subsequent dimensional measurements, steps S01 and S02 preferably further include:

[0070] S011. Use a laser cleaning system to clean the damaged areas of the mounting surface; wherein the laser power of the laser cleaning system is 50W to 120W, and the cleaning time is 2min to 5min.

[0071] S021. Use a high-pressure air gun to clean the surface of the damaged area after cleaning, so that the corrosion pits are exposed.

[0072] In step S011, the optimal cleaning time is 3 minutes to ensure that all corrosion pits within the damaged area are fully exposed.

[0073] In step S021, after laser cleaning, a high-pressure air gun is used to clean the surface again to ensure that no contaminants remain in the damaged area.

[0074] In some embodiments, step S1 above further includes the following steps:

[0075] S11. Based on the location of the corrosion pit, determine each defect region at the damage location, and each defect region contains at least one corrosion pit.

[0076] S12. Obtain the maximum depth of corrosion pits and the corresponding area of ​​the defect area within the same defect region to determine the machining range;

[0077] S13. Within each machining process range, the corrosion layer of each defect area is removed by subtractive machining.

[0078] Step S11 accurately divides the damaged location into several defect areas based on the distribution of corrosion pits, thereby setting specific process paths and parameters for each defect area to make the division and classification of each defect area at the damaged location more accurate and targeted. Then, step S12 calculates the maximum depth of the corrosion pits and the area of ​​the corresponding defect area to determine the depth and range of the subtractive machining process in the subsequent step S13, thus defining an accurate and clear machining range to avoid excessively deep or large subtractive machining and to protect the mounting surface of the shaft box.

[0079] In some specific embodiments, step S12 above further includes the following steps:

[0080] S121. Select several corrosion pits within the same defect area, and use a depth measuring instrument to measure the depth of each selected corrosion pit. By comparison, obtain the maximum depth of the corrosion pit.

[0081] S122. Calculate the area of ​​the defective region;

[0082] S123. Determine the machining range based on the maximum depth of the corrosion pit and the area of ​​the defect region.

[0083] Preferably, the area of ​​the machining treatment range is larger than the area of ​​the defect region, and the depth of the machining treatment range is not less than the maximum depth of the corrosion pit. This setting ensures that the subtractive processing range covers the entire defect region, avoiding any omissions in the corrosion layer removal operation, thus minimizing the subtractive processing range while maximizing the accuracy of corrosion layer removal.

[0084] Preferably, in order to better protect the defective areas after the subtractive processing, the following step is also included after step S13:

[0085] S14. Perform rounded corner transition treatment on the defective areas after subtractive processing.

[0086] In this method, the angle between the rounded corners of the defect area and the base surface after rounding transition is no greater than 30°. In other words, this method uses a corrosion pit depth measuring instrument to detect the depth of corrosion pits, so as to obtain a corrosion pit with the maximum corrosion depth among several corrosion pits. The depth of the corrosion pit with the maximum corrosion depth is taken as the maximum depth of the corrosion pit. On this basis, 0.2mm is added for subtractive processing of the corrosion pit surface. The edges of the processing area should be rounded to avoid sharp angles or right angles, and the angle with the base surface should not be greater than 30°.

[0087] The specific steps for measuring the depth of corrosion pits using a corrosion pit depth measuring instrument are as follows:

[0088] Place the axle box body flat on the platform with the mounting surface facing upwards;

[0089] Place the corrosion pit depth measuring instrument close to the mounting surface of the axle box, gently lower it so that the probe contacts the flat surface, zero the micrometer, then move the probe close to the edge of the mounting surface of the axle box, and adjust the height of the probe to be below the depth to be measured on the mounting surface of the axle box.

[0090] Lift the probe and move it directly above the area to be measured, then lower the probe to perform the measurement.

[0091] Randomly measure different parts of the corroded area, with no fewer than 5 measurement points, and record the maximum depth.

[0092] Based on the maximum depth and area of ​​the corrosion pit, and with an increase of 0.2mm, the machining process is determined. The repaired part of the axle box is subjected to subtractive machining to remove the corrosion layer. After completion, the machining depth is visually inspected to ensure it is sufficient.

[0093] In some embodiments, in order to better protect the mounting surface of the axle box during the repair process, it is preferable to further include the following step between step S1 and step S2:

[0094] S15. Use plugs to seal all pores in the defect area after subtractive processing;

[0095] S16. Sandblast the defective areas after subtractive processing.

[0096] S17. Preheat and spray the defective areas after sandblasting.

[0097] In preferred step S15, for ease of operation, the shaft housing to be repaired is preferably mounted on a special fixture. Using a special plug before sandblasting provides reliable protection for holes, especially threaded areas, within the defective region. Preferably, the special plug is made of a non-metallic material and does not interfere with the path of the sprayed particles.

[0098] In preferred step S16, the defective area after subtractive processing is roughened by sandblasting, thereby achieving a uniform, non-metallic rough surface. Preferably, the surface roughness of the defective area after sandblasting is Ra 5.0 μm to 7.6 μm. Preferably, 25-mesh brown corundum abrasive is used for sandblasting, with a sandblasting pressure of 0.3 MPa to 0.6 MPa, a sandblasting distance of 80 mm to 120 mm, a sandblasting angle of 40° to 70°, and a sandblasting time of 2 min to 5 min.

[0099] The preferred step S17, preheating spraying, preheats the mounting surface to be repaired, thereby drying the powder. The preferred preheating spraying process parameters specifically include: using 7050 aluminum alloy powder with a particle size of 10μm to 60μm; a powder drying temperature of 70±5℃; and a preheating spraying time of 40min to 60min; using 99.99% nitrogen as the spraying gas; a gas pressure of 3.5MPa to 5.5MPa; a spraying distance of 5mm to 20mm; and an angle of not less than 60° between the spray gun and the spraying surface.

[0100] In some embodiments, step S2 further includes the following steps:

[0101] S21. Obtain the length and width of each corrosion pit within the defect area;

[0102] S22. Based on the length and width of each corrosion pit, classify the defect areas to determine the type of defect area; among which, the types of defect areas include point defects, line defects and surface defects.

[0103] The dimensions of each corrosion pit are accurately obtained through step S21; the defect areas are accurately classified through step S22, thereby developing unique process paths for different types of defect areas. This makes the cold spraying process more targeted and unique, meets the process requirements of different areas, and improves the efficiency and quality of the spraying process.

[0104] Specifically, step S22 above further includes:

[0105] For point defects, the spray gun is driven perpendicular to the center of the defect area for spraying. Preferably, point defects are corrosion pits with a length and width of less than 5 mm. For linear defects, the spray gun is driven along the length of the defect area, and the travel path of the spray gun remains unchanged in the width direction. The number of reciprocating strokes of the spray gun is determined based on the maximum depth of the corrosion pit. Preferably, linear defects are corrosion pits with a length greater than or equal to 5 mm and a width less than or equal to 5 mm. For surface defects, the spray gun is driven along both the length and width directions of the defect area. The number of reciprocating strokes of the spray gun is determined based on the maximum depth of the corrosion pit. Preferably, all defects except point and linear defects are surface defects. The travel distance of the spray gun in the length direction and the movement distance in the width direction of the defect are set according to the actual area size.

[0106] It should be noted that, in order to further improve the quality and efficiency of the process, it is preferable that when two or more point defects are no more than 5mm apart, they are considered as surface defects and repaired by spraying according to the surface defect spraying process; when two or more line defects are no more than 5mm apart, they are considered as surface defects and repaired by spraying according to the surface defect spraying process.

[0107] In some embodiments, step S3 above further includes: using a milling cutter to process the repair area, taking the undamaged surface as the processing reference, and restoring the surface dimensions and roughness requirements of the repair area according to the original drawing to ensure the accuracy of the part.

[0108] The axle housing mounting surface damage repair device disclosed in this invention can perform the axle housing mounting surface damage repair method described above. This axle housing mounting surface damage repair device includes a dimensional measurement system, a subtractive machining system, a spraying system, and a subtractive remanufacturing system. The dimensional measurement system is used to obtain the dimensional measurement results of corrosion pits at the damage location of the axle housing mounting surface. The subtractive machining system is used to determine the defect area at the damage location based on the dimensional measurement results of the corrosion pits, and remove the corrosion layer in the defect area using subtractive machining. The spraying system is used to classify the defect areas and, based on the type of each defect area, spray the corresponding defect area to obtain the corresponding repair area. The subtractive remanufacturing system is used to perform subtractive remanufacturing on each repair area to restore the dimensions of the mounting surface.

[0109] This device, by incorporating a dimensional measurement system, a subtractive processing system, a spraying system, and a subtractive remanufacturing system, enables the axle box mounting surface damage repair device to perform the aforementioned axle box mounting surface damage repair method, thereby possessing all the advantages of the aforementioned axle box mounting surface damage repair method, which will not be elaborated further here.

[0110] In the description of the embodiments of the present invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0111] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention based on the specific circumstances.

[0112] In embodiments of the present invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0113] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0114] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for repairing damage to the mounting surface of an axle box, characterized in that, Includes the following steps: Obtain the dimensional measurement results of the corrosion pits at the damaged location on the mounting surface of the axle box to determine the defect area at the damaged location, and remove the corrosion layer in the defect area by subtractive processing. The defective regions are classified, and based on the type of each defective region, the corresponding defective regions are first sprayed using a cold spray additive manufacturing process to obtain the corresponding repair areas; the cold spray additive manufacturing process is a low-temperature solid-state deposition of metal materials. Then, each of the repaired areas is remanufactured using subtractive materials to restore the dimensions of the mounting surface; The step of obtaining the dimensional measurement results of the corrosion pits at the damaged location of the axle housing mounting surface to determine the defect area at the damaged location, and removing the corrosion layer in the defect area using subtractive machining, further includes the following steps: Based on the location of the corrosion pit, each defect region at the damage location is determined, and each defect region contains at least one corrosion pit; The maximum depth of the corrosion pits and the area of ​​the corresponding defect region within the same defect region are obtained to determine the machining range. Within each of the aforementioned machining processes, the corrosion layer in each of the aforementioned defective regions is removed by the aforementioned subtractive machining process; Prior to the steps of classifying the defective areas and spraying corresponding repair areas based on the type of each defective area, the method further includes the following steps: The defective areas after sandblasting are preheated and sprayed. The types of defect areas include point defects, linear defects, and surface defects. When the distance between two or more point defects does not exceed 5mm, they are considered surface defects and are repaired by spraying according to the surface defect spraying process. When the distance between two or more linear defects does not exceed 5mm, they are considered surface defects and are repaired by spraying according to the surface defect spraying process. For the surface defects, the spray gun is driven to travel along the length and width of the defect area, and the number of reciprocating strokes of the spray gun is determined based on the maximum depth of the corrosion pit.

2. The method for repairing damage to the mounting surface of the axle box according to claim 1, characterized in that, The step of obtaining the maximum depth of the corrosion pits and the corresponding area of ​​the defect region within the same defect region to determine the machining range further includes the following steps: Several corrosion pits are selected within the same defect area, and the depth of each selected corrosion pit is measured using a depth measuring instrument. The maximum depth of the corrosion pit is obtained by comparison. Calculate the area of ​​the defective region; The machining range is determined based on the maximum depth of the corrosion pit and the area of ​​the defect region; Wherein, the area of ​​the machining treatment range is greater than the area of ​​the defect region, and the depth of the machining treatment range is not less than the maximum depth of the corrosion pit.

3. The method for repairing damage to the mounting surface of the axle box according to claim 1, characterized in that, After the step of removing the corrosion layer from each of the defective regions using the subtractive machining process within each of the machining processing ranges, the method further includes the following step: The defective area after the subtractive processing is subjected to rounded corner transition treatment; Wherein, the angle between the rounded corner of the defect area after the rounded corner transition treatment and the base surface is no greater than 30°.

4. The method for repairing damage to the mounting surface of the axle box according to claim 1, characterized in that, The step of classifying defective areas and spraying corresponding coatings on each defective area based on its type to obtain a corresponding repair area further includes the following steps: Obtain the length and width of each corrosion pit within the defect area; Based on the length and width of each corrosion pit, the defect areas are classified to determine the type of the defect areas; For the point-like defects, drive the spray gun to spray perpendicularly to the center of the defect area; For the linear defect, the spray gun is driven to travel along the length of the defect area, and the travel path of the spray gun remains unchanged in the width direction. The number of reciprocating strokes of the spray gun is determined based on the maximum depth of the corrosion pit.

5. The method for repairing damage to the mounting surface of the axle box according to claim 4, characterized in that, The point defects are corrosion pits whose length and width are both less than 5 mm; the linear defects are corrosion pits whose length is greater than or equal to 5 mm and whose width is less than or equal to 5 mm; all other defects besides the point defects and the linear defects are surface defects.

6. The method for repairing damage to the mounting surface of the axle box according to any one of claims 1 to 5, characterized in that, Before the steps of obtaining the dimensional measurement results of the corrosion pits at the damaged location of the axle housing mounting surface to determine the defect area at the damaged location, and removing the corrosion layer in the defect area using subtractive machining, the following steps are also included: Laser cleaning is performed on the damaged areas of the mounting surface; The damaged area is then cleaned to expose the corrosion pits.

7. The method for repairing damage to the mounting surface of the axle box according to claim 6, characterized in that, The step of laser cleaning the damaged area of ​​the mounting surface and then surface cleaning the damaged area to expose the corrosion pits further includes the following steps: The damaged areas of the mounting surface are cleaned using a laser cleaning system; wherein the laser power of the laser cleaning system is 50W to 120W, and the cleaning time is 2min to 5min. The damaged area is cleaned using a high-pressure air gun to expose corrosion pits.

8. The method for repairing damage to the mounting surface of the axle box according to any one of claims 1 to 5, characterized in that, Before the steps of classifying the defective areas and spraying corresponding repair areas based on the type of each defective area, the following steps are also included: All pore-like areas within the defective region after the subtractive processing are sealed using plugs; The defective areas after subtractive processing are subjected to sandblasting. The defective area after sandblasting is preheated and sprayed.

9. The method for repairing damage to the mounting surface of the axle box according to claim 8, characterized in that, The surface roughness of the defective area after sandblasting is Ra 5.0 μm to 7.6 μm.

10. The method for repairing damage to the mounting surface of the axle box according to claim 8, characterized in that, The preheating spraying process parameters include: The preheating spraying uses 7050 aluminum alloy powder with a particle size of 10μm to 60μm, the drying temperature of the powder is 70±5℃, and the preheating spraying time is 40min to 60min. The preheating spraying uses 99.99% nitrogen gas as the spraying gas; The pressure of the spraying gas is 3.5 MPa to 5.5 MPa; The spraying distance for the preheated spraying is 5mm to 20mm; The angle between the spray gun and the spraying surface for preheating spraying is not less than 60°.

11. A device for repairing damage to the mounting surface of an axle box, characterized in that, It can perform the method for repairing damage to the mounting surface of the axle box as described in any one of claims 1 to 10; The axle box mounting surface damage repair device includes: A dimensional measurement system is used to obtain dimensional measurement results of corrosion pits at the damaged locations of the axle box mounting surface; A subtractive machining system is used to determine the defect area at the location of the damage based on the dimensional measurement results of the corrosion pit, and to remove the corrosion layer in the defect area using subtractive machining. A spraying system is used to classify the defective areas and, based on the type of each defective area, spray the defective areas accordingly to obtain the corresponding repair areas. A subtractive remanufacturing system is used to perform subtractive remanufacturing on each of the repair areas to restore the dimensions of the mounting surface.

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