Additive manufacturing method of seamless steel tube perforating roller

Abstract

The additive manufacturing method is applied to the seamless steel tube perforating roller, and the seamless steel tube perforating roller comprises an inlet cone and an outlet cone which are connected in the axial direction of the seamless steel tube perforating roller; the additive manufacturing method comprises the following steps: integrally turning the roller surface of the seamless steel pipe perforating roller; a plurality of long grooves distributed in the circumferential direction are formed in a multi-layer cladding area on the roller surface, intervals are formed between the long grooves, and the length direction of the long grooves is consistent with the length direction of the seamless steel pipe perforating roller; wherein the multi-layer cladding area is a roller surface of the inlet cone and a roller surface of a first section of the outlet cone connected with the inlet cone; the remaining part of the outlet cone is a single-layer cladding area; preheating the roller surface of the seamless steel pipe perforating roller; at least one time of laser cladding is conducted on the multi-layer cladding area, and the long groove is repaired after each time of laser cladding; covering laser cladding is carried out on the whole roller surface, and the long grooves are repaired after covering laser cladding; and slowly cooling.

Description

Technical Field

[0001] The invention relates to a method for manufacturing a roller, in particular to a method for manufacturing a perforated roller. Background Art

[0002] Seamless steel pipe is a widely used economical steel. In the production process of seamless steel pipe, especially the production process of high alloy steel, the perforation roller surface wears very seriously, which not only affects the surface quality of the pipe, but also reduces the service life, increases the roller replacement time, and seriously affects the production capacity of high alloy steel.

[0003] By laser cladding, the surface of the perforated roller can be modified by cladding materials containing different active elements on the surface of the perforated roller substrate to prepare a coating that is metallurgically bonded to the substrate and has excellent wear resistance, corrosion resistance, fatigue resistance, oxidation resistance and other properties.

[0004] However, due to the complex rolling process and deformation stress during the perforation process, the middle position of the inlet cone is subjected to the greatest stress and the deepest wear, while the outlet cone has very little wear, and the degree of wear at different positions varies. At the same time, in order to increase friction and ensure bite-in, the inlet cone is slotted. There are still many problems in the use of laser cladding repair perforation rollers, such as insufficient single-layer cladding thickness of the inlet cone and excessive wear; pits within 50mm behind the high point of the roller surface, which poses a quality risk; excessive wear at the slotted position after cladding, resulting in crack defects on the surface of the pipe, etc.

[0005] The Chinese patent document with the publication number CN110396689A and the publication date of November 1, 2019, entitled "A method for preparing a centrifugal roller strengthened by laser cladding", discloses the following steps: S1, pre-treat the centrifugal roller: turn the processed centrifugal roller along the working roller surface and clean the surface after turning to remove oxide scale, impurities and oil stains; S2, prepare alloy powder that is resistant to high temperature wear and magma erosion; S3, install the centrifugal roller on a processing machine tool of a high-power semiconductor laser, and use the alloy powder to synchronously deliver the alloy powder to the position through laser scanning, and use the alloy powder to perform surface laser cladding on the surface of the centrifugal roller working roller; S4, perform coloring and flaw detection on the laser cladding layer, and then grind the laser cladding layer; S5, package the centrifugal roller strengthened by laser cladding for standby use. The service life of the strengthened centrifugal roller prepared by it is more than 3 times that of the traditional cladding stainless steel centrifugal roller. However, this scheme still cannot adapt to the special working conditions of seamless steel pipe perforation, and cannot be applied to the surface cladding of perforated rollers. Summary of the invention

[0006] The object of the present invention is to provide an additive manufacturing method for a seamless steel pipe perforating roller, which can improve the wear resistance of the perforating roller, reduce the wear rate of the perforating roller, reduce the total roller replacement time, and improve the single-cycle production capacity.

[0007] In order to achieve the above-mentioned object, the present invention proposes an additive manufacturing method for a seamless steel tube perforating roller, which is applied to a seamless steel tube perforating roller, wherein the seamless steel tube perforating roller comprises an inlet cone and an outlet cone connected along its axial direction; the additive manufacturing method comprises the steps of:

[0008] The roller surface of the seamless steel pipe perforating roller is turned as a whole;

[0009] A plurality of long grooves distributed along the circumferential direction are opened in the multi-layer cladding area on the roller surface, and there is a gap between each long groove, and the length direction of the long groove is consistent with the length direction of the seamless steel pipe perforating roller; the multi-layer cladding area is the roller surface of the inlet cone and the roller surface of the first section of the outlet cone connected to the inlet cone; the remaining part of the outlet cone is a single-layer cladding area;

[0010] Preheat the roller surface of the seamless steel pipe perforating roller;

[0011] Perform at least one laser cladding operation in the multi-layer cladding area, and repair the elongated groove after each laser cladding operation;

[0012] Performing a layer of cover laser cladding on the entire roller surface, and repairing the long groove after the cover laser cladding;

[0013] Cool slowly.

[0014] Furthermore, in the additive manufacturing method of the seamless steel tube perforating roller described in the present invention, the overall turning of the roller surface of the seamless steel tube perforating roller specifically includes: determining the turning depth based on the set number of cladding layers, the maximum wear depth of the roller surface of the perforating roller and the single-layer cladding thickness, so as to perform overall turning of the roller surface of the perforating roller.

[0015] Furthermore, in the additive manufacturing method of the seamless steel pipe perforating roller of the present invention, the turning depth S 改车 for:

[0016] S 改车 =(K-1)×S 单层 +S 最深 +2~6;

[0017] Where K represents the set number of cladding layers, S 单层 Indicates the thickness of a single layer of cladding; S 最深 It indicates the maximum wear depth of the perforated roller surface obtained by measurement, wherein the unit parameters of single-layer cladding thickness, maximum wear depth of the perforated roller surface and turning depth are all mm.

[0018] Furthermore, in the additive manufacturing method of the seamless steel tube perforating roller described in the present invention, the multi-layer cladding area includes a plurality of sub-regions with different numbers of cladding layers arranged along the axial direction of the seamless steel tube perforating roller, wherein the number of cladding layers of each sub-region decreases along the direction from the inlet cone end face to the outlet cone end face.

[0019] That is, in some embodiments of the present invention, the multi-layer cladding region can be divided into a plurality of sub-regions, and the sub-regions have different numbers of cladding layers.

[0020] In some embodiments, the number of cladding layers in each sub-region decreases along the direction from the inlet cone end face to the outlet cone end face. For example, the multi-layer cladding region is divided into three sub-regions, and the number of cladding layers in the three sub-regions can be 5, 4, 3, or 4, 3, 2 respectively.

[0021] In some other embodiments, all the multi-layer cladding regions are applied with the same number of cladding layers, such as 3 layers or 2 layers.

[0022] Furthermore, in the additive manufacturing method of the seamless steel tube perforating roller described in the present invention, the first section of the outlet cone is an area extending 50 mm from the high point toward the end face of the outlet cone, and the high point is the position where the outlet cone and the inlet cone are connected.

[0023] Furthermore, in the additive manufacturing method of the seamless steel tube perforating roller of the present invention, after the step of integrally turning the roller surface of the seamless steel tube perforating roller and before the step of opening a plurality of elongated grooves distributed in the circumferential direction in the multi-layer cladding area on the roller surface, the method further includes the following steps:

[0024] A 30-60° chamfer is processed at the intersection of the multi-layer cladding area and the single-layer cladding area.

[0025] This operation procedure can avoid stress concentration.

[0026] Furthermore, in the additive manufacturing method of the seamless steel tube perforating roller described in the present invention, the starting position of the elongated groove in the length direction is 100-300 mm away from the inlet cone end face.

[0027] Furthermore, in the additive manufacturing method of the seamless steel pipe perforating roller described in the present invention, the length of the elongated groove is 200-400 mm, the width is 15-30 mm, and the depth is 0.3-2 mm.

[0028] Providing long grooves on the roller surface can increase the friction between the perforating roller and the processed metal material.

[0029] Furthermore, in the additive manufacturing method of the seamless steel pipe perforating roller described in the present invention, a chamfer of 30-60° is processed on the edge of the elongated groove.

[0030] This operation step can avoid insufficient powder thickness and stress concentration during laser cladding.

[0031] Furthermore, in the additive manufacturing method of the seamless steel tube perforating roller described in the present invention, in the step of preheating the roller surface of the seamless steel tube perforating roller, the overall roller surface temperature is controlled to be ≥150°C, and the temperature of the cladding zone is 300-350°C.

[0032] Furthermore, in the additive manufacturing method of the seamless steel tube perforating roller described in the present invention, the alloy powder used in laser cladding is nickel-based alloy powder or cobalt-based alloy powder.

[0033] Furthermore, in the additive manufacturing method of the seamless steel pipe perforating roller described in the present invention, the laser cladding power can be 2700-3200W, the spot diameter can be φ3-4mm, the scanning speed can be 1800-2500mm / min, the overlap amount can be 0.6-1mm, the powder output can be 18-28g / min, and the thickness of each cladding layer can be 0.8-1.5mm.

[0034] The additive manufacturing method of the seamless steel pipe perforating roller of the present invention has the following advantages and

[0035] Beneficial effects:

[0036] The present invention sets different cladding layer thicknesses according to the different wear degrees of the inlet cone and the outlet cone of the perforating roller. The inlet cone of the perforating roller and a part of the outlet cone behind the high point are clad with multiple layers, and the remaining part of the outlet cone is clad with one layer, which is conducive to achieving technical effects efficiently and at low cost.

[0037] The present invention adopts a method of first opening a long groove and then cladding, and then determining the position of the long groove after cladding and then processing, thereby ensuring that the groove position and other positions on the roller surface maintain the same thickness, avoiding the large difference in wear depth caused by different cladding thicknesses and causing surface defects of the steel pipe;

[0038] In a preferred embodiment of the present invention, a formula for the thickness of the old roller turning is proposed according to the thickness of the laser cladding layer and the deepest wear depth, and the thickness of the roller surface turning can be conveniently determined by applying the formula;

[0039] In a preferred embodiment of the present invention, in order to avoid cladding quality defects and stress concentration at the junction of multi-layer and single-layer cladding and the edge of the groove, chamfering is performed to facilitate powder shedding and cladding. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 A flow chart showing the steps of an additive manufacturing method for a seamless steel tube perforating roller according to the present invention in one embodiment.

[0041] Figure 2Schematically showing a multi-layer cladding area and a single-layer cladding area on a seamless steel pipe perforating roll in one embodiment. DETAILED DESCRIPTION

[0042] The additive manufacturing method of the seamless steel tube perforating roller described in the present invention will be further explained and illustrated below in conjunction with specific embodiments and the accompanying drawings of the specification. However, such explanation and illustration do not constitute an improper limitation on the technical solution of the present invention.

[0043] Figure 1 A flow chart showing the steps of an additive manufacturing method for a seamless steel tube perforating roller according to the present invention in one embodiment.

[0044] like Figure 1 As shown, in one embodiment, the additive manufacturing method of the seamless steel pipe perforating roller includes the steps of:

[0045] S1: Determine the geometric structure of the laser cladding layer, that is, determine the multi-layer cladding area and the single-layer cladding area on the perforated roller, and the number of cladding layers in each cladding area.

[0046] Figure 2 The multi-layer cladding area and the single-layer cladding area on the seamless steel pipe perforating roller under one embodiment are schematically shown.

[0047] from Figure 2 It can be seen that the seamless steel pipe perforating roller has an inlet cone and an outlet cone connected along its axial direction, and the slopes of the two parts are different. The connection between the inlet cone and the outlet cone is a high point 3. In the present invention, the roller surface of the seamless steel pipe perforating roller is divided into a multi-layer cladding area 1 and a multi-layer cladding area 2, wherein the multi-layer cladding area includes the roller surface of the inlet cone and the roller surface of the first section of the outlet cone connected to the inlet cone, and the remaining part of the outlet cone is a single-layer cladding area.

[0048] exist Figure 2 In the embodiment shown, the distance m after the entrance cone and the high point 3 is a multi-layer cladding area. In some embodiments, m can be 50 mm.

[0049] In a specific example, the number of cladding layers in the multi-layer cladding area may be 2 layers.

[0050] Of course, in some other embodiments, the multi-layer cladding area can also be divided into a plurality of sub-areas with different numbers of cladding layers arranged along the axial direction of the seamless steel tube perforating roller, wherein the number of cladding layers of each sub-area decreases along the direction from the inlet cone end face to the outlet cone end face. For example, the multi-layer cladding area is divided into three sub-areas, and the number of cladding layers of the three sub-areas can be 5, 4, 3, or 4, 3, 2, respectively.

[0051] S2: inspecting and integrally turning the roller surface of the seamless steel pipe perforating roller. In some embodiments, the S2 step may specifically include:

[0052] S21: Determine the turning depth based on the set number of cladding layers, the maximum wear depth of the roller surface of the perforated roller, and the thickness of the single-layer cladding to perform overall turning on the roller surface of the perforated roller.

[0053] In some embodiments, the turning depth S can be determined based on the following formula: 改车 :

[0054] S 改车 =(K-1)×S 单层 +S 最深 +2~6;

[0055] Where K represents the set number of cladding layers, S 单层 Indicates the thickness of a single layer of cladding; S 最深 It indicates the maximum wear depth of the perforated roller surface obtained by measurement, wherein the unit parameters of single-layer cladding thickness, maximum wear depth of the perforated roller surface and turning depth are all mm.

[0056] For example, in a specific example, the maximum wear depth of the perforated roller surface is measured to be 9 mm, and the single-layer cladding thickness of the laser cladding is set to be 1.1 mm. According to the formula: 改车 =(K-1)×S 单层 +S 最深 +2~6, when the number of cladding layers in the multi-layer cladding area is set to 2, the turning depth S of the multi-layer cladding area can be obtained by entering the parameters 1改车 =(2-1)*1.1+9+5=15.1mm; the turning depth S of the single-layer cladding area 2改车 It is: (1-1)*1.1+9+5=14mm.

[0057] S22: A 45° chamfer is performed at the junction of laser cladding multi-layer and single-layer to avoid stress concentration.

[0058] S23: A plurality of long grooves distributed along the circumferential direction are opened in the multi-layer cladding area on the roller surface, and there are intervals between the long grooves. The length direction of the long grooves is consistent with the length direction of the seamless steel pipe perforating roller.

[0059] In a specific example, a long groove is opened at a position 200 mm from the inlet end face of the roller surface toward the outlet cone, with a length of 210 mm, a width of 20 mm, and a depth of 0.5 mm. Preferably, the edge is chamfered at 45° after the groove is opened to avoid insufficient powder thickness and stress concentration during laser cladding.

[0060] S24: After roller surface turning, use a gauge to check the roller shape.

[0061] S25: Use magnetic particle inspection to ensure that there are no defects such as cracks, pits and rust residue on the roller surface.

[0062] S3: Clamp and clean the perforated roller to remove magnetic powder, grease and other stains on the roller surface.

[0063] S4: Preheat the roller surface to make the roller surface temperature ≥150°C and the cladding area 320°C. The alloy powder is nickel-based and dried. In some embodiments, the preheating energy source can be liquefied petroleum gas or a high-frequency electromagnetic induction coil.

[0064] S5: Base laser cladding; perform at least one laser cladding in the set multi-layer cladding area; after each cladding is completed, use a ruler to measure the position of the long groove.

[0065] In some embodiments, the specific operation method of using a ruler to measure the position of the long groove can be: place the ruler flat on the position of the long groove after cladding, the intersection of the light-transmitting and non-light-transmitting positions is the slot edge, and the edge position is marked. Connect the marks with a line, the coil is the position of the long groove, and the long groove position is ground out as required.

[0066] S6: Cover surface laser cladding, cladding the entire roller surface with a layer, and then repair the long groove again.

[0067] It should be noted that, in some embodiments, the parameters of each laser cladding can be controlled as follows: the laser cladding power can be 2700-3200W, the spot diameter can be φ3-4mm, the scanning speed can be 1800-2500mm / min, the overlap amount can be 0.6-1mm, the powder output can be 18-28g / min, and the thickness of each cladding layer can be 0.8-1.5mm.

[0068] In a more specific example, the laser cladding power can be set to 2900W, the spot diameter is φ3.5mm, the scanning speed is 2000mm / min, the overlap is 0.8mm, the powder output is 22g / min, and the cladding thickness of each layer is 1.1mm.

[0069] S7: Slow cooling.

[0070] In some embodiments, the entire perforated roller may be wrapped with asbestos cloth for slow cooling, and the wrapping thickness may be 4 to 10 mm.

[0071] S8: Roller surface inspection, check whether there are macroscopic pores, cracks and other defects on the roller surface and repair the defects. After grinding off the black skin on the surface of the cladding layer, use a pallet to check the roller surface profile, measure the hardness and element composition, and finally perform flaw detection.

[0072] It can be seen that the present invention adopts a scheme of dividing the cladding area into zones, and a long groove is opened on the roller surface before laser cladding. After cladding, only the size of the long groove needs to be restored, thereby avoiding the disadvantages of local thinning of the cladding layer caused by grooving after cladding and large difference in grooving depth due to poor repeated clamping accuracy.

[0073] The present invention repairs the old perforated roller by laser cladding, which greatly reduces the wear rate of the roller surface and can greatly improve the competitiveness of the production line.

[0074] In addition, the combination of the various technical features in this case is not limited to the combination described in the claims of this case or the combination described in the specific embodiments. All technical features recorded in this case can be freely combined or combined in any way unless there is a contradiction between them.

[0075] It should also be noted that the above-listed embodiments are only specific embodiments of the present invention. Obviously, the present invention is not limited to the above embodiments, and similar changes or modifications made therewith can be directly derived or easily associated with the contents disclosed by those skilled in the art from the present invention, and all should belong to the protection scope of the present invention.

Claims

1. An additive manufacturing method for a seamless steel tube perforating roller, which is applied to a seamless steel tube perforating roller, wherein the seamless steel tube perforating roller comprises an inlet cone and an outlet cone connected along its axial direction; characterized in that: The additive manufacturing method comprises the steps of: The roller surface of the seamless steel pipe perforating roller is turned as a whole; A plurality of long grooves distributed along the circumferential direction are opened in the multi-layer cladding area on the roller surface, and there is a gap between each long groove, and the length direction of the long groove is consistent with the length direction of the seamless steel pipe perforating roller; the multi-layer cladding area is the roller surface of the inlet cone and the roller surface of the first section of the outlet cone connected to the inlet cone; the remaining part of the outlet cone is a single-layer cladding area; Preheat the roller surface of the seamless steel pipe perforating roller; Perform at least one laser cladding operation in the multi-layer cladding area, and repair the elongated groove after each laser cladding operation; Performing a layer of cover laser cladding on the entire roller surface, and repairing the long groove after the cover laser cladding; Cool slowly.

2. The additive manufacturing method for a seamless steel pipe perforating roller according to claim 1, characterized in that: The overall turning of the roller surface of the seamless steel pipe perforating roller specifically includes: determining the turning depth based on the set number of cladding layers, the maximum wear depth of the roller surface of the perforating roller and the single-layer cladding thickness to perform overall turning on the roller surface of the perforating roller.

3. The additive manufacturing method for seamless steel pipe perforating roller according to claim 2, characterized in that: The turning depth S 改车 for: S 改车 =(K-1)×S 单层 +S 最深 +2~6; Where K represents the set number of cladding layers, S 单层 Indicates the thickness of a single layer of cladding; S 最深 Indicates the maximum wear depth of the perforated roller surface measured.

4. The additive manufacturing method for a seamless steel pipe perforating roller according to claim 1, characterized in that: The multi-layer cladding area includes a plurality of sub-areas with different numbers of cladding layers arranged along the axial direction of the seamless steel pipe perforating roller, wherein the number of cladding layers of each sub-area decreases along the direction from the inlet cone end face to the outlet cone end face.

5. The additive manufacturing method of the seamless steel pipe perforating roller according to claim 1, characterized in that: The first section of the outlet cone is a region extending 50 mm from the high point toward the end face of the outlet cone, and the high point is the position where the outlet cone and the inlet cone are connected.

6. The additive manufacturing method of the seamless steel pipe perforating roller according to claim 1, characterized in that: After the step of integrally turning the roller surface of the seamless steel pipe perforating roller and before the step of opening a plurality of elongated grooves distributed along the circumferential direction in the multi-layer cladding area on the roller surface, the method further includes the following steps: A 30-60° chamfer is processed at the intersection of the multi-layer cladding area and the single-layer cladding area.

7. The additive manufacturing method of the seamless steel pipe perforating roller according to claim 1, characterized in that: The starting position of the elongated groove in the length direction is 100-300 mm away from the inlet cone end face.

8. The additive manufacturing method for a seamless steel pipe perforating roller according to claim 1, characterized in that: The elongated groove has a length of 200-400 mm, a width of 15-30 mm, and a depth of 0.3-2 mm.

9. The additive manufacturing method of the seamless steel pipe perforating roller according to claim 1, characterized in that: A chamfer of 30-60° is processed on the edge of the elongated groove.

10. The additive manufacturing method of seamless steel pipe perforating roller according to claim 1, characterized in that: In the step of preheating the roller surface of the seamless steel pipe perforating roller, the overall roller surface temperature is controlled to be ≥150°C, and the temperature of the cladding zone is 300-350°C.

11. The additive manufacturing method of seamless steel pipe perforating roller according to claim 1, characterized in that: The alloy powder used in laser cladding is nickel-based alloy powder or cobalt-based alloy powder.

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