Composite material wire passing porcelain eye and preparation process thereof

Abstract

The invention discloses a composite material wire passing porcelain eye and a preparation process thereof, the composite material wire passing porcelain eye comprises a mold core and an outer sleeve, the mold core is provided with a wire passing hole in a penetrating mode, the outer sleeve wraps the outer surface of the mold core through interference assembly, the mold core is made of a hard material with the hardness larger than or equal to HRA80, and the outer sleeve is made of a metal material with the toughness larger than or equal to 100 J / cm. The mold core is made of one or more of hard alloy, artificial diamond, diamond, aluminum oxide ceramic, zirconium oxide ceramic, silicon carbide or silicon nitride. The material with higher hardness and high wear resistance is adopted as the material of the threading porcelain eye, so that the hardness and the wear resistance of the threading porcelain eye can be remarkably improved, the threading porcelain eye is prevented from being deformed in the use process, the service life can be further prolonged, frequent replacement in the production process is reduced, the purpose of improving the production efficiency is achieved, and meanwhile, the production cost is reduced. And by performing multi-wheel superfine grinding on the wire passing porcelain eye wire hole, the roughness of the wire passing porcelain eye wire hole can be reduced, and the problems of wire damage or wire breakage and the like and the occurrence of loss are reduced.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of wire passing porcelain eyes, and particularly relates to a composite material wire passing porcelain eye and a preparation process thereof. BACKGROUND

[0002] In the production of various wire drawing, rewinding and other wire related industries in some fields, wire passing porcelain eyes are needed to achieve the functions of connection, wire guiding and protection. The wire passing porcelain eye is a single material wire passing component made of various ceramics and carbon steel, which has the characteristics of high hardness and smoothness, and the Mohs hardness reaches 8 levels, and the surface roughness can reach Ra0.2 levels, which can effectively reduce the friction damage of the wire, and is widely used in the transmission path of the enameled wire of the winding machine, textile machinery and other equipment.

[0003] However, with the development of metal / non-metal wire to ultra-fine and high performance, the traditional single material wire passing porcelain eye cannot meet the use requirements, and mainly has the following shortcomings: ① insufficient hardness, leading to easy deformation of the die hole; ② poor wear resistance: single material cannot balance hardness and toughness; ③ short service life: frequent replacement leads to low production efficiency; ④ high wire breakage rate: rough hole wall and sharp edges easily increase the wire breakage rate. Although there are related patents on the market that use zirconium oxide, titanium carbide and other composite formulations to further improve the acid and alkali resistance and wear resistance, the use effect is not ideal, and there are still the shortcomings of short service life, poor protection and low production efficiency.

[0004] Therefore, in view of the above technical problems, it is necessary to provide a composite material wire passing porcelain eye and a preparation process thereof.

[0005] The information disclosed in this Background section is intended only to increase an understanding of the general background of the application, and is not admitted to be prior art against the application. SUMMARY

[0006] The purpose of the present application is to provide a composite material wire passing porcelain eye and a preparation process thereof, which can solve the problems in the background art.

[0007] In order to achieve the above purpose, the technical scheme provided by an embodiment of the present application is as follows:

[0008] A composite material wire passing porcelain eye, comprising a die core and an outer sleeve, the die core is provided with a wire passing hole, the outer sleeve is assembled by interference to cover the outer surface of the die core, the die core is made of a hard material with a hardness greater than or equal to HRA80, and the outer sleeve is made of a metal material with a toughness greater than or equal to 100J / cm².

[0009] In one or more embodiments of the present application, the mold core is one or more combinations of cemented carbide, synthetic diamond, diamond, alumina ceramic, zirconia ceramic, silicon carbide or silicon nitride, and the material of the outer sleeve is one or more combinations of stainless steel, carbon steel or alloy steel. In this way, the material combination of the wire passing ceramic eye can be optimized, and the stress distribution of the wire passing ceramic eye can be optimized, thereby avoiding brittle fracture.

[0010] In one or more embodiments of the present application, the inner surface roughness Ra of the wire passing hole is less than or equal to 0.08, and the straightness deviation is less than or equal to 0.005 mm. In this way, the hole wall of the wire passing hole can be optimized to reduce wire friction damage, thereby greatly reducing the wire breakage rate.

[0011] In one or more embodiments of the present application, the wire inlet and outlet ends of the wire passing hole are each provided with a curved transition area, the curvature radius R of the curved transition area is 0.1-0.5 mm, and the surface roughness is consistent with that of the wire passing hole, which can eliminate sharp angle contact and prevent wire scratching.

[0012] In one or more embodiments of the present application, the outer surface of the outer sleeve is circular, square or special-shaped structure, which can adapt to the needs of diversified equipment installation to expand the overall application range of the wire passing ceramic eye. The outer sleeve side surface is optionally provided with a stress release groove, which can reduce assembly residual stress.

[0013] A preparation process of a composite material wire passing ceramic eye, comprising the following steps:

[0014] S1, mold core blank processing: tungsten steel mold core blank is prepared by powder metallurgy;

[0015] S2, precision hole processing: the wire passing hole is polished by diamond grinding needle in multiple rounds, and the granularity of abrasive decreases by 10 μm each round, so that the final granularity is less than or equal to 0.5 μm;

[0016] S3, curved chamfering: three-dimensional curved surface polishing is performed on the edge of the wire inlet and outlet hole by using a ball head grinding needle;

[0017] S4, hot-pressing sleeve insertion: the mold core is heated to 300-400 ℃ and then pressed into the outer sleeve at room temperature to form an interference fit composite.

[0018] In one or more embodiments of the present application, the polishing speed in S2 is greater than or equal to 20,000 rpm, and the axial feed speed is less than or equal to 0.01 mm / s, which can ensure the polishing effect.

[0019] In one or more embodiments of the present application, the multiple rounds of polishing in S2 include three stages of rough polishing, semi-fine polishing and fine polishing, and the step-by-step polishing can ensure the consistency of the hole wall precision of the wire passing hole.

[0020] In one or more embodiments of the present application, the curved surface polishing in S3 adopts a five-axis linkage machining center, the grinding head inclination angle of which is 30-45°, to ensure the polishing effect of the through-hole.

[0021] In one or more embodiments of the present application, the interference amount in S4 is 0.02-0.05mm, and the composite is subjected to aging treatment at 150-200℃ after assembly, which can offset the brittle stress of the mold core.

[0022] Compared with the prior art, the composite material through-hole ceramic eye and the preparation process thereof can significantly improve the hardness and wear resistance of the through-hole ceramic eye by using a material with higher hardness and high wear resistance as the material of the through-hole ceramic eye, thereby avoiding deformation of the through-hole ceramic eye during use, prolonging the service life, reducing the frequent replacement during production to improve the production efficiency, and reducing the occurrence of problems such as thread damage or thread breakage and losses by multiple rounds of ultra-fine polishing of the through-hole ceramic eye. BRIEF DESCRIPTION OF DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiments or prior art description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments described in the present application, and other drawings can be obtained by those skilled in the art without creative labor on the basis of these drawings.

[0024] Fig. 1 It is a perspective view of a composite material through-hole ceramic eye in an embodiment of the present application.

[0025] Fig. 2 It is a side view of a composite material through-hole ceramic eye in an embodiment of the present application.

[0026] Fig. 3 It is a flowchart of a preparation process of a composite material through-hole ceramic eye in an embodiment of the present application.

[0027] MAIN REFERENCE NUMERALS:

[0028] 1-mold core, 101-through-hole, 1011-curved transition zone, 2-outer sleeve, 201-stress release groove. DETAILED DESCRIPTION

[0029] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0030] like Figs. 1-2 As shown, a composite material wire guide eye in one embodiment of the present invention includes a core 1 and an outer sleeve 2. The core 1 has a through wire guide hole 101. The outer sleeve 2 covers the outer surface of the core 1 by interference fit. The core 1 is made of a hard material with a hardness greater than or equal to HRA80, and the outer sleeve 2 is made of a metal material with a toughness greater than or equal to 100J / cm².

[0031] The thread guide ceramic eye in this invention is formed by an interference fit between a high-hardness and high-wear-resistance mold core 1 and a high-toughness outer sleeve 2. This not only significantly improves the hardness and wear resistance of the thread guide ceramic eye, but also enhances its impact resistance. Furthermore, the thermal expansion coefficients of the two components are well-matched, such as Δα being less than or equal to 5 × 10⁻⁶. -6 / K can prevent thermal stress cracking, thereby extending the service life of the ceramic eye and reducing the need for frequent replacements during production, thus improving production efficiency.

[0032] Optionally, the core 1 is made of one or more of cemented carbide, synthetic diamond, diamond, alumina ceramic, zirconia ceramic, silicon carbide, or silicon nitride, and the outer sleeve 2 is made of one or more of stainless steel, carbon steel, or alloy steel. This configuration optimizes the material combination of the wire guide eye, thereby optimizing the stress distribution of the wire guide eye and preventing brittle fracture.

[0033] In addition, the surface roughness Ra of the inner surface of the wire guide hole 101 is less than or equal to 0.08, and the straightness deviation is less than or equal to 0.005 mm. This setting optimizes the hole wall of the wire guide hole 101 to reduce wire friction damage, thereby significantly reducing the wire breakage rate.

[0034] In the embodiment, both the inlet and outlet ends of the wire passage hole 101 are provided with curved transition areas 1011. The radius of curvature R of the curved transition area 1011 is 0.1-0.5mm, and the surface roughness is consistent with that of the wire passage hole 101, which can eliminate sharp angle contact and prevent the wire from being scratched.

[0035] like Figs. 1-2As shown, the outer surface of the sleeve 2 is circular, square or irregular in shape, which can meet the needs of various equipment installation to improve the overall application range of the threading porcelain eye. The sleeve 2 can be optionally provided with a stress release groove 201, which can reduce the assembly residual stress.

[0036] As shown, the preparation process of the composite material threading porcelain eye in an embodiment of the present application comprises the following steps: Fig. 3

[0037] S1, mold core blank processing: tungsten steel mold core blank is prepared by powder metallurgy;

[0038] S2, precision hole processing: the threading hole 101 is polished by diamond grinding needle in multiple rounds, and the granularity of abrasive decreases by 10 μm each round, so that the final granularity is less than or equal to 0.5 μm;

[0039] S3, curved chamfering: three-dimensional curved surface polishing is performed on the edge of the threading hole by using a ball head grinding needle;

[0040] S4, hot-pressing sleeve insertion: the mold core is heated to 300-400℃ and then pressed into the normal temperature sleeve to form an interference fit composite.

[0041] In S2, the polishing speed is greater than or equal to 20000 rpm, and the axial feed speed is less than or equal to 0.01 mm / s, which can ensure the polishing effect.

[0042] In addition, the multiple rounds of polishing in S2 include coarse grinding, semi-fine grinding and fine grinding, and the step-by-step polishing can ensure the consistency of the hole wall precision of the threading hole 101.

[0043] Preferably, the abrasive granularity of coarse grinding is 20-40 μm, the speed is 5000 rpm, and the feed speed is 0.05 mm / s; the abrasive granularity of semi-fine grinding is 5-10 μm, the speed is 10000 rpm, and the feed speed is 0.02 mm / s; the abrasive granularity of fine grinding is 1-3 μm, the speed is 15000 rpm, and the feed speed is 0.01 mm / s.

[0044] In the example, S2 further comprises a polishing process, the abrasive granularity of polishing is less than or equal to 0.5 μm, the speed is 25000 rpm, and the feed speed is 0.005 mm / s.

[0045] The present application can reduce the roughness of the threading hole 101 by multiple rounds of polishing, and in combination with the material properties of high hardness and high wear resistance, it can play a role in protecting the wire quality including ultra-fine wire with a diameter less than 20 μm and high-performance wire, and also protect the threading porcelain eye itself, prolong its service life, and reduce frequent replacement in the production process to improve production efficiency.

[0046] ​Specifically, the curved surface polishing in S3 adopts a five-axis linkage machining center, and the grinding head angle is 30-45°, which ensures the polishing effect of the through-hole 101.

[0047] In addition, the interference amount in S4 is 0.02-0.05mm, and the composite is subjected to aging treatment at 150-200℃ after assembly, which can offset the brittle stress of the mold core.

[0048] Example One

[0049] The material of the mold core 1 is YG8 tungsten steel (hardness HRA91)

[0050] The material of the outer sleeve 2 is 316 stainless steel (tensile strength ≥620MPa)

[0051] The interference amount of the mold core 1 and the outer sleeve 2 is 0.03mm

[0052] Surface treatment: the inner surface roughness of the through-hole 101 is Ra=0.03, and the curvature radius of the curved surface transition area 1011 is R=0.3mm

[0053] Through use test, the through-hole ceramic eye in example one can work continuously for 500 hours without wear and tear, and the breakage rate is 0.008‰

[0054] Example Two

[0055] The material of the mold core 1 is Al2O3-TiC ceramic alloy (hardness HRA94)

[0056] The material of the outer sleeve 2 is TC4 titanium alloy (wall thickness 1.5mm)

[0057] Surface treatment: after the S4 step, magnetorheological polishing is added, so that the inner surface roughness of the through-hole 101 is Ra=0.01, and the curvature radius of the curved surface transition area 1011 is R=0.2mm

[0058] Through use test, the through-hole ceramic eye in example two is suitable for 0.005mm ultra-fine molybdenum wire, and the service life can reach 1200 hours.

[0059] It is obvious to those skilled in the art that the present disclosure is not limited to the details of the above exemplary embodiments, and the present disclosure can be implemented in other specific forms without departing from the spirit or essential characteristics of the present disclosure. Therefore, the embodiments should be regarded as exemplary and non-limiting, and the scope of the present disclosure is defined by the appended claims rather than the above description, and therefore all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present disclosure. Any reference signs in the claims should not be regarded as limiting the claims involved.

[0060] Furthermore, it should be understood that although the specification is described in terms of embodiments, not every embodiment includes every feature or implementation described herein. The specification can include implicit combinations of explicitly mentioned features and / or implicit combinations of implicitly mentioned features. Such combinations are also expressly included within the scope of the specification and an embodiment.

Claims

1. A composite material thread guide eye, characterized in that, include: The mold core and the outer sleeve are provided. The mold core has a through hole, and the outer sleeve covers the outer surface of the mold core by interference fit. The mold core is made of a hard material with a hardness greater than or equal to HRA80, and the outer sleeve is made of a metal material with a toughness greater than or equal to 100J / cm².

2. The composite material wire guide eye according to claim 1, characterized in that, The core material is one or more of the following: cemented carbide, synthetic diamond, diamond, alumina ceramic, zirconia ceramic, silicon carbide, or silicon nitride; the outer casing material is one or more of the following: stainless steel, carbon steel, or alloy steel.

3. The composite material wire guide eye according to claim 1, characterized in that, The surface roughness Ra of the inner surface of the wire hole is less than or equal to 0.08, and the straightness deviation is less than or equal to 0.005 mm.

4. The composite material wire guide eye according to claim 1, characterized in that, Both the inlet and outlet ends of the wire-passing hole are provided with curved transition areas. The radius of curvature R of the curved transition areas is 0.1-0.5mm, and the surface roughness is consistent with that of the wire-passing hole.

5. The composite material wire guide eye according to claim 1, characterized in that, The outer surface of the jacket is circular, square, or irregularly shaped, and a stress relief groove may be provided on the side of the jacket.

6. A preparation process for a composite material through-hole ceramic eye as described in any one of claims 1-5, characterized in that, Includes the following steps: S1. Mold core blank processing: Tungsten steel mold core blanks are prepared using powder metallurgy; S2. Precision hole machining: The wire hole is polished by diamond grinding needles in multiple rounds, with the abrasive particle size decreasing by 10μm in each round, so that the final particle size is less than or equal to 0.5μm. S3. Surface chamfering: The edges of the inlet and outlet holes are polished in three dimensions using a ball head grinder. S4. Hot-pressed insert: The mold core is heated to 300-400℃ and then pressed into the room-temperature outer sleeve. After cooling, an interference fit composite is formed.

7. The preparation process of a composite material through-hole ceramic eye according to claim 6, characterized in that, In S2, the grinding speed is greater than or equal to 20,000 rpm, and the axial feed speed is less than or equal to 0.01 mm / s.

8. The preparation process of a composite material wire-passing ceramic eye according to claim 6, characterized in that, The multi-round grinding process in S2 includes three stages: rough grinding, semi-fine grinding, and fine grinding.

9. The preparation process of a composite material wire-passing ceramic eye according to claim 6, characterized in that, The surface grinding in S3 uses a five-axis linkage machining center with a grinding head tilt angle of 30-45°.

10. The preparation process of a composite material through-hole ceramic eye according to claim 6, characterized in that, The interference fit in S4 is 0.02-0.05 mm, and the composite is subjected to aging treatment at 150-200℃ after assembly.

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