An automated manufacturing method for thick base composite material sliding bearing

Abstract

The application provides a kind of thick base composite material sliding bearing automatic manufacturing method, comprising the following steps: processing metal base; a plurality of positioning holes or points are arranged on the metal base according to the rule; the surface of the metal base is treated; the connector is installed in the arranged positioning hole or bonded on the positioning point; the connector and the metal base are integrated by laser welding; the connector / metal base combination after welding is placed in the mold, polyaryletherketone is added, after integrated forming, the finished product is formed after post-processing and finishing. The application can solve the stress concentration phenomenon after the combination of the existing mechanical processing method and polyaryletherketone, adopt the body laser gas protection welding technology, without using any flux and welding rod, welding wire and other auxiliary welding materials, the welding combination of the connector and the surface treated metal base is realized by computer aided control manipulator, the quality and efficiency are improved, and the unit time cost is greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of composite material bearing technology, and in particular to an automated manufacturing method for thick-based composite material sliding bearings. Background Technology

[0002] Sliding bearings operate under sliding friction. They offer many advantages, such as high load capacity, smooth operation, reliability, and noiselessness. Traditional sliding bearings are mostly made of metal materials, but the manufacturing and maintenance costs of metal components are constantly increasing. Based on considerations of lightweighting, efficiency, and environmental protection, replacing metal materials with composite materials can reduce costs and weight, and solve the problems of not being able to meet requirements such as high temperature and chemical resistance.

[0003] There are three existing methods for manufacturing composite sliding bearings: the first involves mechanically fixing the composite working layer and the sliding bearing metal matrix; the second involves using thermomolding to embed the composite working layer and the sliding bearing metal matrix into each other, achieving integrated bearing manufacturing; and the third involves creating different connection structures in the sliding bearing metal matrix and then effectively combining the composite working layer and the sliding bearing metal matrix into a single unit using thermomolding. The first method is severely limited in application due to its complex structure, high cost, and narrow applicability. The second method is constrained by existing process technologies, with complex interlocking structure design and processing, low efficiency, high cost, and difficulty in achieving industrial-scale production. The third method is currently the optimal technological approach for the industrial-scale production of composite sliding bearings. Among the publicly available manufacturing technologies for composite sliding bearings, thin-based three-layer composite sliding bearings have achieved automated industrial production. However, the publicly available manufacturing methods for thick-based composite sliding bearings do not yet meet the requirements for industrial automation. For example, the method disclosed in patent number CN102979817 B, "Elastic Metal-Plastic Tile and Manufacturing Method Thereof," achieves automated manufacturing through the connection of connecting posts to the tile base. However, due to limitations in stud welding technology, it cannot effectively connect connecting posts of different shapes to the tile base as designed for application. Furthermore, it cannot guarantee the connection strength between the composite resin layer and the tile base, posing a risk of edge warping and detachment. This method does not involve microscopic roughening of the periphery, which may lead to weak adhesion during the metal-plastic fusion bonding process. The method disclosed in patent CN111941712A, "Manufacturing Method of Polyetheretherketone High-Performance Sliding Bearing," involves creating a regular convex-concave surface on the steel substrate, processing multiple layers of stainless steel wire mesh according to the convex-concave surface structure, and then welding the multiple layers of stainless steel wire mesh to the working surface of the steel substrate using a "four-way continuous" spot welding method. This method is prone to warping, which leads to a decrease in the bonding strength between the polyetheretherketone and the stainless steel wire mesh, resulting in a low yield and reduced bearing life. In product application, the polyetheretherketone and the stainless steel wire mesh, or the stainless steel wire mesh and the steel substrate, may detach. The design structure is complex, the manufacturing process is difficult, the reliability is low, the cost is high, the efficiency is low, the product quality consistency is difficult to guarantee, and it is not easy to automate the production process.The patent CN111361188 A, "Metal-Plastic Composite Sliding Bearing and Manufacturing Method Thereof," discloses a method for directly manufacturing connecting structures on the surface of a sliding bearing metal substrate using 3D printing technology. This solves the reliability problem of connecting different shaped connecting structures to the metal substrate and also enables continuous automation. The method involves placing modified polyetheretherketone (PEEK) powder into a concave mold, leveling it, placing a convex mold inside, and then pressing the thermoplastic mold in a press. The thermoplastic mold is then heated. This technology uses 3D printing to lay powder layer by layer, resulting in low overall efficiency and high production costs. It can only be used for small-batch, high-end products; therefore, this technology cannot be applied to mass industrial production. Summary of the Invention

[0004] To address the aforementioned technical problems, an automated manufacturing method for thick-based composite sliding bearings is provided to overcome the shortcomings of the existing technology. The technical means employed in this invention are as follows:

[0005] An automated manufacturing method for thick-based composite sliding bearings includes the following steps: processing a metal matrix; surface treating the surface of the metal matrix; processing connectors of different shapes; arranging the connectors according to a regular design and positioning them on the surface of the metal matrix by mechanical positioning or bonding; combining the connectors and the metal matrix into a connector / metal matrix assembly by laser welding; placing the welded connector / metal matrix assembly into a mold, adding polyaryletherketone (PAK) to it, and integrally molding the PAK and the connector / metal matrix assembly to form a semi-finished composite sliding bearing; and finally, completing the final product through post-processing and finishing.

[0006] Furthermore, the mechanical positioning or adhesive positioning is based on a number of positioning holes or points arranged according to a design pattern on the surface of the metal substrate; positioning the connector on the surface of the metal substrate by mechanical positioning or adhesive means specifically inserting the connector into the arranged positioning holes or adhesive positioning points.

[0007] Furthermore, the connector includes a head, a middle section, and a bottom. The head of the connector is a cone or a spherical segment, the middle section is a drum-shaped cylinder or a hollowed-out section, and the bottom section is a cylinder. The height of the connector is 3-6 mm, and the spacing between adjacent sections is 5-20 mm. The connector serves as a transitional connection. The rounded head design can solve the stress concentration phenomenon after combining existing machining methods with polyaryletherketone. The material of the connector is carbon steel or stainless steel.

[0008] Furthermore, the surface treatment of the metal substrate is specifically achieved by a sandblasting machine to change the surface roughness. The diameter of the micropores formed by sandblasting is less than 0.5 mm, the sand mesh is 50-100 mesh, the sandblasting angle is 30-60 degrees, and the local dwell time is 2-5 seconds.

[0009] Furthermore, after the surface treatment of the metal substrate, the surface of the sandblasted metal substrate is treated to ensure that there is no sand or gravel on the surface of the metal substrate, and then the surface of the metal substrate is cleaned.

[0010] Furthermore, by using a robotic arm for CNC positioning, the connector can be automatically positioned in the positioning hole of the metal substrate or fixed-point bonding can be achieved.

[0011] Furthermore, laser body welding is used to bond the connector and the metal substrate into a single unit. The weld pull-out strength reaches 15-30 MPa.

[0012] Furthermore, the added polyaryletherketone is 2-5 mm higher than the head of the linker.

[0013] As one integrated molding technology, the steps for integrating polyaryletherketone (PAEK) with the linker / metal matrix assembly specifically include: molding the modified PAEK powder with the linker / metal matrix assembly using a molding method, and forming an integrated metal-plastic bearing blank through cold pressing and hot pressing. Specifically, the mixed PAEK material is dried in a 120℃ drying oven for 2-3 hours. The linker / metal matrix assembly and powder are added to the mold sequentially, leveled, and then cold-pressed on a press to remove air at a pressure of 40-50 MPa. The cold pressing and air removal are repeated 1-3 times, and the holding time is 5-15 minutes. The mold is then heated to a constant temperature of 360-400℃ for 1-3 hours, followed by hot pressing on a press at a pressure of 15-40 MPa for 1-3 hours. The mold is then demolded after being air-cooled to below 100℃.

[0014] As another integrated molding technology, the steps of integrating polyaryletherketone (PAEK) with the connector / metal matrix assembly specifically include: cutting PAEK sheets into the required size, heating the connector / metal matrix assembly, and pressing the cut sheet into the connector / metal matrix assembly under certain pressure to form an integrated metal-plastic bearing blank.

[0015] Specifically: the substrate is heated to 360-400℃, the pressure of the polyaryletherketone plate is 5-20MPa, and the pressure is removed and the mold is demolded when the substrate cools to below 100℃.

[0016] Furthermore, after the polyaryletherketone and the linker / metal matrix assembly are integrally molded, the integral metal-plastic bearing blank is heat-treated by being kept at 200°C for 2 hours and then cooled in the furnace, followed by fine treatment.

[0017] This invention employs bulk laser gas-shielded welding technology, eliminating the need for any flux, welding rods, or welding wires. A computer-aided robotic arm achieves the welding of the connector to a surface-treated metal substrate, improving quality and efficiency while significantly reducing unit time costs. It is a highly efficient, energy-saving, environmentally friendly, and automated manufacturing method. Furthermore, modified polyaryletherketone (PAEK) sheets are pressed or molded to create an integrated metal-plastic bearing. The connector, with a conical or spherical cap head, addresses the stress concentration issues that arise when combining PAEK with existing machining methods. Compared to conventional connector designs and stainless steel wire mesh welding, it reduces warping, increases welding success rate, improves product quality and lifespan, and lowers manufacturing costs. This process utilizes bulk laser welding under gas protection, assisted by computer-controlled automated operation, similar to traditional 3D printing. It effectively addresses the low layer-by-layer powder placement efficiency and high unit time costs of existing 3D printing technologies. Surface sandblasting further enhances the adhesion between the PAEK material and the metal, resolving the issue of edge detachment. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the shape of the connector in one embodiment of the present invention.

[0020] Figure 2 This is a schematic diagram of the shape of the connector in another embodiment of the present invention.

[0021] Figure 3 This is a schematic diagram of the arrangement of the connectors on the surface of a metal substrate in one embodiment of the present invention. (a) is a top view; (b) is a side cross-sectional view.

[0022] Figure 4 The diagram shows the arrangement of the connectors on the surface of a metal substrate in another embodiment of the present invention. (a) is a top view; (b) is a side cross-sectional view.

[0023] Figure 5 The connector of the present invention and Figure 3 The diagram shows a metal substrate integrated into a single unit.

[0024] Figure 6 The connector of the present invention and Figure 4 The diagram shows a metal substrate integrated into a single unit. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] An automated manufacturing method for thick-based composite sliding bearings includes the following steps: processing a metal matrix; surface treating the surface of the metal matrix; processing connectors of different shapes; arranging the connectors according to a regular design and positioning them on the surface of the metal matrix by mechanical positioning or bonding; combining the connectors and the metal matrix into a connector / metal matrix assembly by laser welding; placing the welded connector / metal matrix assembly into a mold, adding polyaryletherketone (PAK), and integrally molding the PAK with the connector / metal matrix assembly to form a semi-finished composite sliding bearing; and finally, after post-processing and finishing, forming the finished product. In this embodiment, the processed connector shape is as follows: Figure 1 , Figure 2 As shown, in other alternative embodiments, the connector can also be other shapes that facilitate connection, such as the shape of the metal substrate. Figures 3-6 As shown, its overall specifications can be a regular shape, a fan shape as shown in the diagram, or a shape designed according to different design requirements. Its surface can be a flat surface or a concave surface with a preset curvature, etc.

[0027] Example 1

[0028] In this embodiment, the head of the selected connector is a cone. This embodiment of the invention discloses an automated manufacturing method for composite material sliding bearings, including the following steps:

[0029] Step 1, Metal substrate processing: Process a metal substrate to the required size according to the usage requirements;

[0030] Step 2, Machining of positioning holes on the metal substrate surface: Machining blind holes with a diameter of φ4-6mm and a depth of 1-5mm on the metal substrate;

[0031] Step 3, Surface treatment of metal substrate: Use a sandblasting machine to treat the surface of the metal substrate. The sand mesh size is 50-100 mesh, the sandblasting angle is 30-60 degrees, and the local dwell time is 2-5 seconds to ensure that the surface of the metal substrate has been sandblasted and micro-pores are formed on the surface.

[0032] Step 4, Dust Removal and Cleaning: The surface of the sandblasted metal substrate is treated with an air gun to ensure that there is no sand or gravel on the surface of the metal substrate, and then the surface is cleaned with anhydrous ethanol or gasoline.

[0033] Step 5, Assembly: Using a CNC positioning robot, the connector is inserted into the positioning hole processed in Step 2;

[0034] Step 6, Laser Welding: Under gas protection, the connector is laser-welded to bond the connector and the metal substrate into a whole.

[0035] Step 7, Integrated molding: As an optional method, specifically, the modified polyaryletherketone powder is molded with the assembly prepared in step 6 by means of compression molding, and the metal matrix and the modified polyaryletherketone are integrated by cold pressing and hot pressing.

[0036] As an alternative method, specifically, commercially available polyaryletherketone sheets are processed and cut to the required size. After the metal substrate is heated by induction heating or other heating methods, the cut sheet is pressed into the assembly made in step 6 under certain pressure to form an integrated metal-plastic bearing.

[0037] Step 8: Post-treatment. After being kept at 200℃ for 2 hours, the blank formed in Step 7 is subjected to heat treatment to remove bonding stress.

[0038] Step 9: Finishing. The metal-plastic bearing shell processed in Step 8 is finished by turning and grinding to meet the required dimensions.

[0039] Example 2

[0040] As a specific implementation method, this invention discloses an automated manufacturing method for composite material sliding bearings, including the following steps: Step 1: Process Q235 metal base according to the sample size of 152*152*50mm. In this embodiment, carbon steel is selected as the metal base.

[0041] Step 2: Machining blind holes with a depth of 1.9mm and a diameter of φ4mm on the metal substrate;

[0042] Step 3: Transfer the processed metal tile base to a sandblasting machine, use 50-mesh sand and an incident angle of 45° to sandblast the surface of the metal tile base;

[0043] Step 4: Use an air gun to clean the surface dust of the sandblasted metal substrate, then rinse it in a sealed tank of anhydrous ethanol to further clean the surface, and let it dry completely.

[0044] Step 5: Welding: The connector is installed in the positioning hole by alternating action of the robotic arm and the spot welding beam. The spot beam performs 180° diagonal welding or full welding to achieve welding of the connector on the entire surface of the metal substrate.

[0045] Step 6: Clean the welded surface again with anhydrous ethanol and let it dry completely.

[0046] Step 7: Integrated molding: Using a molding method, the connector / metal matrix assembly prepared in Step 6 is placed into a mold, and then a certain amount of modified polyaryletherketone powder is added to the surface of the connector. Through cold and hot pressing, the polyaryletherketone and the connector / metal matrix assembly are integrated to form a composite material sliding bearing semi-finished product.

[0047] Step 8: After post-processing and finishing, the finished product is formed.

[0048] The composite sliding bearing prepared in this embodiment exhibits excellent overall performance. Each process is controllable and easily automated, resulting in low cost and high efficiency. It can be applied in fields such as hydropower, wind power, gearboxes, and special engineering. Compared to existing technologies, it avoids stress concentration after the connector is bonded to polyaryletherketone (PAK), reduces warping and edge detachment, improves product success rate, enhances product quality and service life, and lowers manufacturing costs. Furthermore, it employs on-body laser gas shielded welding technology, eliminating the need for any flux, welding rods, or welding wires. Computer-aided robotic arms achieve the welding of the connector to the surface-treated metal substrate, improving efficiency and reducing unit time costs.

[0049] 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 or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automated manufacturing method for thick-based composite sliding bearings, characterized in that, Includes the following steps: Processing the metal substrate; treating the surface of the metal substrate; Process connectors of different shapes; Arranged according to a regular design, the connectors are positioned on the surface of the metal substrate by mechanical positioning or adhesive bonding. A connector / metal substrate assembly is formed by combining the connector and the metal substrate into a single unit through laser welding. The welded connector / metal matrix assembly is placed in a mold, polyaryletherketone is added to it, and the polyaryletherketone is integrally molded with the connector / metal matrix assembly to form a composite material sliding bearing semi-finished product. The finished product is formed through post-processing and finishing. The connector includes a head, a middle part, and a bottom. The head of the connector is a cone or a spherical segment, the middle part of the connector is a drum-shaped cylinder or a hollow body, and the bottom of the connector is a cylinder. The height of the connector is 3-6mm, and the adjacent spacing is 5-20mm. Surface treatment of the metal substrate is specifically achieved by sandblasting machine to change the surface roughness. The micropore diameter formed by sandblasting is less than 0.5mm, the sand mesh is 50-100 mesh, the sandblasting angle is 30-60 degrees, and the local dwell time is 2-5 seconds. The robotic arm uses CNC positioning to automatically clamp the connector into the positioning hole. Laser welding is used to combine the connector and the metal substrate into a whole, with a welding pull-out strength of 15-30MPa.

2. The automated manufacturing method for thick-based composite sliding bearings according to claim 1, characterized in that, The mechanical positioning or adhesive positioning is based on a number of positioning holes or points arranged according to a design pattern on the surface of the metal substrate; positioning the connector on the surface of the metal substrate by mechanical positioning or adhesive means specifically inserting the connector into the arranged positioning holes or adhesive positioning points.

3. The automated manufacturing method for thick-based composite sliding bearings according to claim 1, characterized in that, The added polyaryletherketone is 2-5 mm above the head of the linker.

4. The automated manufacturing method for thick-based composite sliding bearings according to claim 1, characterized in that, The steps for integrally molding polyaryletherketone (PAEK) with a linker / metal matrix assembly specifically include: molding the modified PAEK powder with the linker / metal matrix assembly using a molding method, forming an integral metal-plastic bearing blank through cold pressing and hot pressing. Specifically, the mixed PAEK material is dried in a 120℃ drying oven for 2-3 hours. The linker / metal matrix assembly and powder are added to the mold sequentially, leveled, and then cold-pressed on a press to remove air at a pressure of 40-50 MPa. The cold pressing is repeated 1-3 times, and the holding time is 5-15 minutes. The mold is then heated to a constant temperature of 360-400℃ for 1-3 hours, followed by hot pressing on a press at a pressure of 15-40 MPa for 1-3 hours. The mold is then demolded after being air-cooled to below 100℃.

5. The automated manufacturing method for thick-based composite sliding bearings according to claim 1, characterized in that, The steps for integrally molding polyaryletherketone (PAEK) with the connector / metal matrix assembly specifically include: cutting PAEK sheets to the required size, heating the connector / metal matrix assembly, and pressing the cut sheet into the connector / metal matrix assembly under certain pressure to form an integral metal-plastic bearing blank.

6. The automated manufacturing method for thick-based composite sliding bearings according to claim 5, characterized in that, The substrate is heated to 360-400℃, and the pressure of the polyaryletherketone plate is 5-20MPa. Once the substrate cools to below 100℃, the pressure is removed and the mold is demolded.

7. The automated manufacturing method for thick-based composite sliding bearings according to claim 1, 4, 5, or 6, characterized in that, After the polyaryletherketone and the linker / metal matrix assembly are integrally molded, the integral metal-plastic bearing blank is heat-treated by being kept at 200°C for 2 hours and then cooled in the furnace, followed by fine treatment.

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