Machining device and machining method for heat treatment
By designing a processing device for heat treatment, local quenching treatment can be performed on the company's existing box-type heating furnace using cover plates and heat-barrier media, solving the problems of long outsourcing processing cycles and excessive hardness, and achieving efficient and stable quenching results.
Patent Information
- Application Number
- CN202511413098.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-29
- Publication Date
- 2025-11-14
AI Technical Summary
In the existing technology, products that require quenching treatment during the production of large rollers need to be outsourced, resulting in long cycles and difficulty in quality control. In addition, the overall heating of ordinary box-type heating furnaces can easily lead to excessive hardness of non-quenched surfaces.
Design a processing device that includes symmetrical upper and lower cover plates, lifting rings, reinforcing ribs, tension bolts, and heat-barrier medium. Utilize the company's existing box-type heating furnace for localized quenching treatment. The heat transfer is blocked by the grooves in the cover plates and the heat-barrier medium to ensure that the non-quenched areas are not affected by heat.
No additional medium-frequency quenching equipment is required; it can be directly adapted to existing heating furnaces, shortening the production cycle, improving production efficiency, ensuring that the hardness of the quenched area meets the standards, and that the performance of the non-quenched area is stable, thereby improving the consistency of product quality.
Smart Images
Figure CN120945186A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of metal heat treatment technology, and in particular to a processing apparatus and processing method for heat treatment. Background Technology
[0002] In the production of large rollers, some products require surface hardening to meet hardness requirements. Currently, this type of hardening relies heavily on medium-frequency induction hardening equipment, but most companies lack such specialized equipment and outsource the process. Furthermore, outsourcing presents challenges such as long lead times and difficulties in quality control. While utilizing existing standard box-type heating furnaces for localized hardening could significantly reduce costs, these furnaces heat the entire surface, potentially leading to excessive hardness on the non-hardened surfaces. Therefore, a tooling device capable of providing thermal barrier protection for non-hardened areas is urgently needed to meet the localized heat treatment requirements of standard box-type heating furnaces. Summary of the Invention
[0003] The purpose of this invention is to provide a processing apparatus and processing method for heat treatment, which can solve the above-mentioned technical problems.
[0004] This invention provides a processing apparatus for heat treatment, comprising: Two cover plates are symmetrically arranged, one above the other, and the inner surface of the cover plates is provided with grooves that are adapted to the non-quenched area of the workpiece (large roller). Lifting ring, which is fixed to the outer surface of the cover plate, is used for the overall handling of tooling and workpiece; Reinforcing ribs are fixed to the outer surface of the cover plate to enhance the structural strength of the cover plate. Tighten the bolts, which run through the two cover plates, to fix the upper and lower cover plates to the workpiece placed between them; A heat-barrier medium is filled in the groove of the cover plate to prevent heat from being transferred to the non-quenched area of the workpiece during heat treatment.
[0005] Preferably, the reinforcing ribs are distributed radially and intersectingly along the cover plate.
[0006] Preferably, the lifting ring and the cover plate are integrally formed.
[0007] Preferably, the heat-barrier medium comprises an inner layer of asbestos and an outer layer of yellow clay, with the asbestos tightly surrounding and filling the groove, and the yellow clay uniformly covering the surface of the asbestos.
[0008] Preferably, the asbestos is high-temperature resistant asbestos rope, the yellow mud is refractory yellow mud, and the thickness of the yellow mud covering is 5-10mm.
[0009] Preferably, the number of tension bolts is 4-8, evenly distributed along the circumference of the cover plate, and the ends of the tension bolts are threaded with nuts.
[0010] The present invention also provides a processing method for heat treatment, based on the above-described processing apparatus, comprising the following steps: S1: Equipment preparation: Clean impurities from the groove in the cover plate; S2: Laying of heat barrier medium: Tightly wrap the asbestos rope around the groove of the cover plate, and then evenly apply yellow mud to the surface of the asbestos rope. S3: Workpiece clamping: Place the large roller to be heat-treated between the upper and lower cover plates to fully expose the outer diameter (quenching zone) of the roller; S4: Fixed positioning: Tighten the upper and lower cover plates by tightening the bolts to ensure that the workpiece does not move or shift. S5: Heat treatment: Use lifting rings to lift the fixture with the workpiece clamped into the box-type heating furnace, and heat the whole body according to the preset quenching process; S6: Segmented cooling: After heating is complete, first cool with water for 4-5 minutes, then switch to oil cooling for 30 minutes; S7: Post-treatment: After degreasing, remove the cover plate fixture and wipe the residual medium off the workpiece surface; S8: Aging and Inspection: Perform low-temperature aging treatment on the workpiece and inspect the surface hardness of the outer diameter of the roller.
[0011] Preferably, in step S5, the heating temperature of the preset quenching process is 850-950℃, and the holding time is 1-2 hours.
[0012] Preferably, in step S6, the water cooling uses flowing clean water at a temperature of 20-30°C; the oil cooling uses quenching oil at a temperature of 60-80°C.
[0013] Preferably, in step S8, the temperature of the low-temperature aging treatment is 150-200℃, and the holding time is 2-3 hours.
[0014] Beneficial effects: In this invention, the reinforcing ribs on the outer surface of the cover plate enhance structural strength and prevent deformation during heating. The lifting rings facilitate the overall handling of the tooling and workpiece, while the tightening bolts securely fix the upper and lower cover plates to the workpiece, ensuring relative stability of the device and workpiece during heat treatment. Operation is convenient and highly safe. No additional purchase of specialized medium-frequency quenching equipment is required; it directly adapts to existing ordinary box-type heating furnaces, avoiding significant equipment investment. Simultaneously, it eliminates the cost of outsourcing processing, solves the problem of long outsourcing cycles, and significantly shortens the production cycle, improving production efficiency. The cover plate groove precisely matches the non-quenched area of the workpiece, and the internal heat-barrier medium effectively blocks heat transfer, preventing the non-quenched surface from exceeding hardness standards due to overall heating. This ensures that the hardness of the quenched area meets standards and the performance of the non-quenched area remains stable, improving product quality consistency. Attached Figure Description To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific 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 from these drawings without creative effort.
[0015] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram illustrating the distribution of reinforcing ribs in this invention.
[0016] Explanation of reference numerals in the attached drawings: 1-Cover plate, 2-Workpiece, 3-Lifting ring, 4-Reinforcing rib, 5-Tightening bolt, 6-Heat barrier medium. Detailed Implementation
[0017] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and 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.
[0018] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," 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 this 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 this invention.
[0019] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0020] Example 1 A processing apparatus for heat treatment, such as Figure 1-2 As shown, the device includes two symmetrically arranged cover plates 1, which are the supporting components of the entire processing device. Their dimensions are adapted to the workpiece 2 (large roller) to be processed, ensuring complete coverage of the non-quenched area of the roller. The cover plates 1 are made of high-strength, high-temperature resistant materials, such as high-quality heat-resistant steel, which can maintain structural stability in the high-temperature environment of subsequent heat treatment and avoid affecting the protection effect on the non-quenched area of the workpiece due to high-temperature deformation. The inner surface of the cover plates 1 is provided with grooves that are adapted to the non-quenched area of the workpiece 2 (large roller). The shape, depth, and curvature of the grooves are designed according to the contour parameters of the non-quenched area of the roller to ensure that the two fit tightly, minimize the leakage of the heat barrier medium, and provide a stable containment space for the heat barrier medium, thereby more effectively blocking heat transfer.
[0021] The lifting ring 3 is integrally formed with the cover plate 1 and fixed to the outer surface of the cover plate 1. It is used for the overall handling of the tooling and workpiece. The lifting rings 3 are symmetrically arranged on the outer surface of the cover plate 1 to ensure uniform force distribution during lifting, preventing the tooling and workpiece from tilting or overturning during handling, ensuring operational safety, and also facilitating the precise lifting of the tooling with the workpiece clamped to the designated position inside the box-type heating furnace. The reinforcing ribs 4 are fixed to the outer surface of the cover plate 1 and are distributed radially and crosswise along the cover plate 1. They are used to enhance the structural strength of the cover plate and prevent bending or deformation during processing, handling, and high-temperature heat treatment. The reinforcing ribs are also made of a high-strength heat-resistant material similar to that of the cover plate.
[0022] Four tension bolts (5) penetrate the two cover plates (1) on the top and bottom sides, evenly distributed around the circumference of the cover plates (1). These bolts secure the workpiece between the cover plates. The even distribution ensures the clamping force is evenly distributed across the cover plates, preventing deformation due to excessive local clamping force. This also prevents workpiece displacement during heat treatment, maintaining positional accuracy in the quenching zone. The tension bolts are high-strength, wear-resistant bolts with excellent high-temperature resistance and tensile strength, maintaining stable clamping force even at high temperatures. A nut is threaded onto the end of each tension bolt (5). The nut fits tightly with the bolt, and the tightening can be adjusted according to clamping requirements. During clamping, a torque wrench is used to tighten the nut to the preset torque value, ensuring the required clamping force is achieved. This prevents workpiece loosening while avoiding over-clamping and damage.
[0023] The heat-barrier medium 6 fills the groove of the cover plate 1 to prevent heat transfer to the non-quenched area of the workpiece during heat treatment. The heat-barrier medium preferably comprises a composite structure of an inner layer of asbestos and an outer layer of clay. The asbestos is high-temperature resistant asbestos rope, tightly wrapped around and filling the groove. The high-temperature resistant asbestos rope has excellent high-temperature resistance, heat insulation, and flexibility, allowing it to tightly adhere to the inner wall of the groove and the surface of the non-quenched area of the workpiece, effectively blocking heat penetration. The outer layer of clay evenly covers the asbestos surface with a thickness of 5-10 mm. The clay is refractory clay, which has good high-temperature stability and sealing properties, further enhancing the heat insulation effect. It also secures the inner asbestos rope, preventing it from shifting or falling off during handling or heat treatment. This clay sealing method ensures that other parts of the roller are not immersed in the quenching medium during heat treatment, thereby achieving the purpose of localized quenching of the workpiece.
[0024] The present invention also provides a processing method for heat treatment, based on the above-described processing apparatus, comprising the following steps: S1: Equipment preparation: Clean impurities from the groove in the cover plate; S2: Laying of heat barrier medium: Tightly wrap the asbestos rope around the groove of the cover plate, and then evenly apply yellow mud to the surface of the asbestos rope. S3: Workpiece clamping: Place the large roller to be heat-treated between the upper and lower cover plates to fully expose the outer diameter (quenching zone) of the roller; S4: Fixed positioning: Tighten the upper and lower cover plates by tightening the bolts to ensure that the workpiece does not move or shift. S5: Heat treatment: Use lifting rings to lift the fixture with the workpiece clamped into the box-type heating furnace, and heat the whole body according to the preset quenching process; S6: Segmented cooling: After heating is complete, first cool with water for 4-5 minutes, then switch to oil cooling for 30 minutes; S7: Post-treatment: After degreasing, remove the cover plate fixture and wipe the residual medium off the workpiece surface; S8: Aging and Inspection: Perform low-temperature aging treatment on the workpiece and inspect the surface hardness of the outer diameter of the roller.
[0025] In step S5, the heating temperature of the preset quenching process is 850-950℃, and the holding time is 1-2 hours.
[0026] In step S6, water cooling uses flowing clean water at a temperature of 20-30℃; oil cooling uses quenching oil at a temperature of 60-80℃.
[0027] In step S8, the temperature of the low-temperature aging treatment is 150-200℃, and the holding time is 2-3 hours.
[0028] Working and usage process: 1. Thermal barrier medium filling First, the heat-barrier medium is filled by tightly wrapping the inner layer of high-temperature resistant asbestos rope around the inner wall of the groove on the inner surface of the cover plate. During this process, it is crucial to ensure the asbestos rope adheres well to the inner wall of the groove and the non-quenched area of the workpiece to be clamped. The density of the asbestos rope is adjusted manually by pressing to avoid gaps and ensure effective heat penetration. Next, refractory clay is evenly applied to the outer layer, maintaining a thickness of 5-10mm. The applied surface must be smooth and without omissions. This process enhances the heat insulation effect through the high-temperature stability and sealing properties of the refractory clay, and also secures the inner layer of asbestos rope, preventing displacement or detachment during subsequent handling or heat treatment. 2. Workpiece positioning and cover plate assembly Place the large roller to be processed smoothly directly above the groove of the lower cover plate, ensuring that the non-quenched area of the roller is precisely aligned with the groove of the lower cover plate, and that the quenched area is fully exposed without obstruction. Then, place the upper cover plate over the roller, making the upper and lower cover plates symmetrical, and ensuring that the groove of the upper cover plate fits tightly against the non-quenched area of the roller's upper surface. During this process, repeatedly adjust the relative positions of the cover plates and the roller to ensure that the grooves of the upper and lower cover plates completely cover the non-quenched area of the roller, avoiding any exposure of the non-quenched area. Simultaneously, ensure that the bolt holes of the upper and lower cover plates are perfectly aligned to prepare for subsequent bolt tightening. 3. Tightening and fixing operation Insert a predetermined number of tension bolts into the bolt holes of both the upper and lower cover plates, evenly spaced along their circumference, ensuring that each bolt passes vertically through the cover plate without tilting or jamming. Then, thread nuts onto the ends of the tension bolts and tighten them using a torque wrench to the predetermined torque value. During tightening, follow the principle of "symmetrical step-by-step tightening," that is, tighten the nuts in the opposite positions first, then gradually tighten the remaining nuts. This ensures that the clamping force of the bolts on the cover plates is evenly distributed throughout the cover plates, preventing deformation of the cover plates or workpiece due to excessive local clamping force. Simultaneously, monitor the tightening torque in real time using a torque wrench to ensure that the clamping force meets the predetermined requirements. This prevents the workpiece from loosening or shifting during subsequent processing and avoids damage to the workpiece caused by over-clamping, ultimately achieving a stable fixation of the upper and lower cover plates and the workpiece placed between them. 4. Overall hoisting of tooling and workpiece After the workpiece is clamped, the tooling and workpiece are moved as a whole using the symmetrically arranged lifting rings on the outer surface of the cover plate. The hooks of the lifting equipment are securely connected to the lifting rings; the symmetrical distribution of the lifting rings ensures even force distribution during lifting. Before lifting, the reliability of the connection between the hooks and lifting rings must be checked to ensure there is no risk of detachment. Then, the lifting equipment is started to slowly lift the tooling and workpiece. During this process, the status of the tooling and workpiece is observed in real time to prevent tilting, overturning, or other accidents, ensuring operational safety. 5. Positioning and heating inside the box-type heating furnace The fixture with the workpiece clamped is precisely hoisted to the designated position inside the box-type heating furnace. During hoisting, the hoisting speed and direction must be controlled to avoid collisions between the fixture and the inner wall of the heating furnace. After reaching the designated position, the fixture is slowly lowered to ensure it is placed stably without any displacement deviation. Then, the furnace door is closed, and the heating program is started according to the preset heat treatment process parameters (such as heating temperature, holding time, etc.). During the heating process, each component of the device plays a crucial role: the high-quality heat-resistant steel material of the upper and lower cover plates maintains structural stability in a high-temperature environment, preventing deformation from affecting the protection of the non-quenched areas of the workpiece; the reinforcing ribs further enhance the bending and deformation resistance of the cover plates; the heat barrier medium, through the heat insulation of the inner asbestos rope and the sealing of the outer yellow mud, effectively blocks heat transfer, preventing heat from penetrating into the non-quenched areas of the workpiece, ensuring that the quenched area only receives the target heat treatment; the tension bolts maintain a stable clamping force in a high-temperature environment, preventing the workpiece from shifting and ensuring the positional accuracy of the quenched area. 6. Follow-up processing stage After the box-type heating furnace completes the preset heat treatment program, the heating system is shut off. Once the furnace temperature has dropped to a safe range, the tooling and workpiece are lifted from the heating furnace to the designated cooling area using lifting equipment via the lifting rings on the cover plate. During the lifting process, safe operating principles must still be followed to prevent the tooling and workpiece from tilting or colliding. Upon reaching the cooling zone, wait for the workpiece to cool to room temperature. Use tools to loosen the nuts at the ends of the tension bolts, and remove the tension bolts one by one. Then, separate the upper and lower cover plates from the workpiece. Handle the workpiece gently during separation to avoid collision damage. Finally, clean any residual heat-barrier medium (such as residual asbestos rope and yellow mud) from the inner surface of the cover plates. Inspect the condition of the cover plates, tension bolts, lifting rings, and other components. If the components are undamaged, they can be cleaned, maintained, and stored to prepare for the next heat treatment process. If wear, deformation, or other problems are found, repair or replace them promptly to ensure the reliability of the equipment in subsequent use.
[0029] 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. A processing apparatus for heat treatment, characterized in that, include: Two cover plates are symmetrically arranged, one above the other, and the inner surface of the cover plates is provided with grooves that are adapted to the non-quenched areas of the workpiece. A lifting ring, which is fixed to the outer surface of the cover plate; Reinforcing ribs, which are fixed to the outer surface of the cover plate; Tighten the bolts, which run through the two cover plates, to fix the upper and lower cover plates to the workpiece placed between them; A heat-barrier medium is filled in the groove of the cover plate to prevent heat from being transferred to the non-quenched area of the workpiece during heat treatment.
2. The processing apparatus for heat treatment according to claim 1, characterized in that, The reinforcing ribs are distributed radially and intersectingly along the cover plate.
3. The processing apparatus for heat treatment according to claim 1, characterized in that, The lifting ring and the cover plate are integrally formed.
4. The processing apparatus for heat treatment according to claim 1, characterized in that, The heat-barrier medium comprises an inner layer of asbestos and an outer layer of yellow clay. The asbestos is tightly wrapped around and fills the groove, while the yellow clay is evenly covered on the surface of the asbestos.
5. The processing apparatus for heat treatment according to claim 4, characterized in that, The asbestos is high-temperature resistant asbestos rope, and the yellow mud is refractory yellow mud with a mud covering thickness of 5-10mm.
6. The processing apparatus for heat treatment according to claim 1, characterized in that, The number of tension bolts is 4-8, which are evenly distributed along the circumference of the cover plate, and the ends of the tension bolts are threaded with nuts.
7. A processing method for heat treatment, based on the processing apparatus according to any one of claims 1-6, characterized in that, Includes the following steps: S1: Equipment preparation: Clean impurities from the groove in the cover plate; S2: Laying of heat barrier medium: Tightly wrap the asbestos rope around the groove of the cover plate, and then evenly apply yellow mud to the surface of the asbestos rope. S3: Workpiece clamping: Place the large roller to be heat-treated between the upper and lower cover plates to fully expose the outer diameter of the roller; S4: Fixed positioning: Tighten the upper and lower cover plates by tightening the bolts to ensure that the workpiece does not move or shift. S5: Heat treatment: Use lifting rings to lift the fixture with the workpiece clamped into the box-type heating furnace, and heat the whole body according to the preset quenching process; S6: Segmented cooling: After heating is complete, first cool with water for 4-5 minutes, then switch to oil cooling for 30 minutes; S7: Post-treatment: After degreasing, remove the cover plate fixture and wipe the residual medium off the workpiece surface; S8: Aging and Inspection: Perform low-temperature aging treatment on the workpiece and inspect the surface hardness of the outer diameter of the roller.
8. The method according to claim 7, characterized in that, In step S5, the heating temperature of the preset quenching process is 850-950℃, and the holding time is 1-2 hours.
9. The method according to claim 7, characterized in that, In step S6, water cooling uses flowing clean water at a temperature of 20-30℃; oil cooling uses quenching oil at a temperature of 60-80℃.
10. The method according to claim 7, characterized in that, In step S8, the temperature of the low-temperature aging treatment is 150-200℃, and the holding time is 2-3 hours.