High-wear-resistance scraper chain wheel and manufacturing method thereof

Abstract

The manufacturing method of the high-abrasion-resistance scraper chain wheel comprises the following steps that according to the size requirement of the chain wheel, a forged raw material is cut into a chain wheel blank, and accurate machining allowance reservation is conducted on key parts of the chain wheel; quenching and tempering heat treatment is conducted on the chain wheel blank; carrying out shot blasting treatment on the chain wheel blank subjected to quenching and tempering treatment; rough machining is conducted on the chain wheel blank, and corresponding machining allowance is reserved for the end face, the inner hole and the tooth shape strictly according to the deformation control technical requirement; carburizing and quenching the chain wheel blank; finish machining is conducted on the carburized and quenched chain wheel blank, then gear shaping machining is conducted, manufacturing of the chain wheel tooth shape is completed, and the chain wheel tooth shape meets the actual use requirement; according to the actual use requirement of the chain wheel, the part, needing to be locally softened, of the chain wheel is softened. The deformation of the chain wheel in the carburizing and quenching process is reduced, the dimensional precision of the chain wheel is guaranteed, the surface hardness of the chain wheel reaches HRC58-62, the wear resistance is obviously improved, and the service life is prolonged by 10% compared with that of a traditional chain wheel.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of scraper conveyor, in particular to a high-wear-resistance scraper conveyor chain wheel and a manufacturing method thereof. BACKGROUND

[0002] In the coal mining industry, as the core equipment for coal conveying, the chain wheel component of the scraper conveyor bears the key power transmission task. The chain wheel is installed at the head and tail of the scraper conveyor, and the tooth groove of the chain wheel is continuously engaged with the round link chain during long-term operation, continuously bearing strong alternating stress and sudden impact load. Such a harsh working environment makes the chain wheel prone to wear and tear. Once the wear and tear is excessive, the chain wheel will fail, and the scraper conveyor will also stop running. This not only causes the interruption of coal mining operations and increases equipment maintenance costs, but also seriously affects the overall production efficiency of the coal mine. Especially in the thin coal seam mining environment, due to the narrow space and complex geological conditions, the durability of the chain wheel is required to be more stringent. SUMMARY

[0003] In order to solve the above technical problems, it is necessary to provide a high-wear-resistance scraper conveyor chain wheel manufacturing method.

[0004] A high-wear-resistance scraper conveyor chain wheel manufacturing method, comprising the following steps,

[0005] Step S1: according to the size requirements of the chain wheel, the raw material after forging processing is cut into chain wheel blanks, and the key parts of the chain wheel are accurately processed with a processing allowance;

[0006] Step S2: quenching and tempering heat treatment is performed on the chain wheel blank;

[0007] Step S3: shot blasting treatment is performed on the chain wheel blank after quenching and tempering treatment to remove the surface oxide scale and impurities;

[0008] Step S4: rough machining is performed on the chain wheel blank, and the corresponding machining allowance is strictly reserved for the end face, inner hole and tooth shape according to the deformation control technical requirements;

[0009] Step S5: carburizing and quenching treatment is performed on the chain wheel blank;

[0010] Step S6: finish machining is performed on the chain wheel blank after carburizing and quenching to remove the reserved machining allowance and accurately control the size accuracy of the chain wheel, and then gear cutting is performed to complete the manufacture of the chain wheel tooth shape, so that it meets the actual use requirements;

[0011] Step S7: according to the actual use requirements of the chain wheel, the parts that need to be locally softened are softened.

[0012] Preferably, in step S2, the quenching and tempering heat treatment adopts the following manner,

[0013] The sprocket blank is heated to 830±10℃ and kept at this temperature for 3-4h;

[0014] The sprocket blank is oil-cooled after being discharged from the furnace;

[0015] The sprocket blank is immediately tempered when it is cooled to 260-310℃.

[0016] Preferably, the sprocket blank is oil-cooled in the following way,

[0017] The sprocket blank is rapidly first oil-cooled after being discharged from the furnace, and the oil-cooling time is 35-45s;

[0018] After the first oil-cooling is completed, the sprocket blank is taken out and reheated to 320-360℃, and then oil-cooled for 25-35s again;

[0019] The above operation is repeated until the sprocket blank is cooled to a temperature of 260-310℃.

[0020] Preferably, the sprocket blank is tempered in the following way,

[0021] The tempering temperature is set to 620±10℃, and the holding time is 3-4h;

[0022] The sprocket blank is naturally cooled to room temperature in air after being discharged from the furnace.

[0023] Preferably, in step S5, the sprocket blank is carburized and quenched in the following way,

[0024] The rough machined sprocket blank is placed in a cleaning basket in layers, and cleaned in water at a temperature of 75-85℃ for 1-1.5h using a professional cleaning device to ensure that the surface of the sprocket blank is free of oil stains and impurities;

[0025] After cleaning, the sprocket blank is dried, and then the parts that need to be protected from carburization are brushed with a carburization-resistant coating, and the coating thickness is controlled to be 0.12-0.15mm;

[0026] After brushing, the dried sprocket blank is prepared for loading into the basket, and when loading into the basket, enough space should be ensured between the teeth of adjacent sprocket blanks, and then the sprocket blank is loaded into a carburizing furnace for carburizing and quenching, so as to ensure that the carburized layer thickness is 3.2mm, the minimum carbon content of the carburized layer is 0.38%C, and the maximum content of carbide is 85%Ac.

[0027] Preferably, the carburizing and quenching are performed in the following specific way,

[0028] Furnace loading: temperature 930℃, carbon potential 0.45;

[0029] Temperature rise: temperature 930℃, carbon potential 0.65;

[0030] Propane make-up: temperature 930°C, carbon potential 1.1;

[0031] Strong permeation: temperature 930°C, carbon potential 1.1;

[0032] Diffusion: temperature 930°C, carbon potential 0.7;

[0033] Cooling: temperature 860°C, carbon potential 0.7;

[0034] Soaking: temperature 860°C, carbon potential 0.7;

[0035] Unloading: when rapid cooling is used, the cooling oil is required to flow rapidly to reduce the temperature to 55°C in 25 minutes; when slow cooling is used, the cooling oil is required to flow rapidly to reduce the temperature to 55°C in 30 minutes;

[0036] Oil control - out of the furnace.

[0037] Preferably, the sprocket blank is dried in the following manner,

[0038] If room temperature drying is used, it is required to be placed at a temperature above 20°C for not less than 3 hours;

[0039] If drying equipment is used, it is required to be dried at a temperature of 170-180°C for not less than 40 minutes.

[0040] Preferably, in step S7, the softening treatment is performed in the following manner, according to the performance requirements of different parts of the sprocket, a local annealing process using high-frequency induction heating is used, a specially designed induction coil is used to rapidly heat the part to be softened to 560-580°C, and then the induction coil is quickly removed, so that the part is naturally cooled to room temperature at room temperature.

[0041] Preferably, the raw material uses a specially designed alloy steel as the material for manufacturing the sprocket, and the chemical composition (mass percentage) is as follows: carbon 0.38-0.43, silicon 0.25-0.45, manganese 0.60-0.75, phosphorus content not more than 0.012, sulfur content not more than 0.003, chromium 1.90-2.10, nickel 1.75-1.90, molybdenum 0.40-0.70, vanadium 0.15-0.25, and the rest is iron; at the same time, the gas content in the material is strictly limited, the hydrogen (H) content is not more than 1.5 ppm, the oxygen (O) content is not more than 20 ppm, and the nitrogen (N) content is not more than 80 ppm.

[0042] It is also necessary to provide a high-wear-resistance scraper chain sprocket.

[0043] A high-wear-resistance scraper chain sprocket is manufactured by the high-wear-resistance scraper chain sprocket manufacturing method described above.

[0044] Compared with the prior art, the high-wear-resistance scraper machine sprocket and the manufacturing method thereof provided by the application have the following technical advantages:

[0045] 1. By carefully designing the material composition of the sprocket and combining the innovative carburizing and quenching process, the surface hardness of the manufactured sprocket can reach HRC 58-62, which is comparable to the hardness of imported high-quality sprockets, significantly improves the wear resistance of the sprocket, and effectively prolongs the service life thereof;

[0046] 2. The strict deformation control technology greatly reduces the deformation amount of the sprocket in the carburizing and quenching process, ensures the dimensional accuracy of the sprocket, which not only reduces the difficulty and cost of subsequent processing, but also improves the assembly accuracy and use performance of the sprocket, and ensures that the sprocket can stably and efficiently operate in the scraper conveyor;

[0047] 3. The local softening process for improving the comprehensive performance can be targeted according to the functional requirements of different parts of the sprocket, further improves the comprehensive performance of the sprocket, so that the sprocket can maintain good working condition when bearing different loads, and better adapt to the complex working conditions of thin coal seam mining.

[0048] 4. Through performance detection of the sprocket manufactured by the technical solution of the application, the results show that the surface hardness of the sprocket reaches HRC 58-62, and the wear resistance is significantly improved; in the test of simulating the working condition of thin coal seam, the service life of the sprocket is prolonged by 10% compared with the sprocket prepared by the traditional process. DETAILED DESCRIPTION

[0049] The technical solutions in the embodiments of the application will be described clearly and completely below in conjunction with the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0050] Embodiment 1

[0051] The application provides a high-wear-resistance scraper machine sprocket manufacturing method, which adopts the following method to manufacture the sprocket,

[0052] (1) The special alloy steel is used as the material for manufacturing the sprocket, and the chemical composition (mass percentage) is as follows: carbon 0.38, silicon 0.25, manganese 0.60, phosphorus 0.01, sulfur 0.002, chromium 1.90, nickel 1.75, molybdenum 0.40, vanadium 0.15, and the rest is iron. Meanwhile, the gas content in the material is strictly limited, the hydrogen (H) content is not more than 1.5 ppm, the oxygen (O) content is not higher than 20 ppm, and the nitrogen (N) content is not more than 80 ppm. The material composition design can make the sprocket have excellent comprehensive mechanical properties, and provide strong guarantee for subsequent carburizing treatment and realization of high wear resistance.

[0053] (2) The raw material is forged to improve the internal structure of the material and improve its mechanical properties. After forging, the sprocket is cut into a rough shape by gas cutting process to provide a blank for subsequent machining. It should be emphasized that the key parts of the sprocket are accurately machined with a machining allowance; the front end face is reserved with a machining allowance of 2.5-3.5 mm, the inner hole is reserved with a machining allowance of 2.5-3.5 mm, and the tooth shape is controlled within 0.03-0.05 mm. At the same time, the end face and the inner hole are subjected to special protection treatment and reserved allowance, and then subjected to finish machining after carburizing and quenching. In this way, the deformation generated during carburizing and quenching can be effectively controlled, the dimensional accuracy of the sprocket can be ensured, and the product quality can be improved.

[0054] (3) Heat treatment process - quenching and tempering treatment:

[0055] The sprocket blank is heated to 820℃ and kept at this temperature for 4h;

[0056] After the sprocket blank is taken out of the furnace, it is quickly subjected to first oil cooling for 35s; after the first oil cooling is completed, the sprocket blank is taken out and reheated to 320℃, and then subjected to oil cooling for 25s again; the above operation is repeated until the final cooling temperature of the sprocket blank reaches 260℃;

[0057] After the sprocket blank is cooled to 260℃, the sprocket blank is immediately subjected to tempering treatment, and the tempering temperature is set to 620℃, and the temperature is kept for 4h; after the sprocket blank is taken out of the furnace, it is naturally cooled to room temperature in the air.

[0058] (4) The sprocket blank after quenching and tempering treatment is subjected to shot blasting treatment to remove the surface scale and impurities and improve the surface quality. Then the sprocket blank is subjected to rough machining, and the machining allowance is strictly reserved for the end face, inner hole and tooth shape according to the deformation control technical requirements.

[0059] (5) Carburizing and quenching treatment of the sprocket blank:

[0060] The rough machined sprocket blank is placed in a cleaning basket in layers, and a professional cleaning device is used to clean it at a water temperature of 75℃ for 1.5h to ensure that the sprocket blank surface is free of oil stains and impurities;

[0061] After cleaning, the sprocket blank is dried, and then the anti-carburizing paint is applied to the parts that need to be protected from carburization, with the coating thickness controlled at 0.125 mm;

[0062] After the painting is completed, the sprocket blank needs to be dried. If room temperature drying is used, it needs to be placed at a temperature above 20℃ for not less than 3h; if drying equipment is used, it needs to be dried at a temperature of 170℃ for 50min;

[0063] The dried sprocket blank is then loaded into a basket for preparation, and when loading the basket, enough space should be ensured between the teeth of adjacent sprocket blanks, and then loaded into a carburizing furnace for carburizing and quenching, to ensure that the carburized layer thickness is 3.2mm, the minimum carbon content of the carburized layer is 0.38%C, and the maximum carbide content is 85%Ac;

[0064] The specific method of carburizing and quenching is as follows,

[0065] Loading: temperature 930℃, carbon potential 0.45;

[0066] Temperature rise: temperature 930℃, carbon potential 0.65;

[0067] Propane supplement: temperature 930℃, carbon potential 1.1;

[0068] Strong penetration: temperature 930℃, carbon potential 1.1;

[0069] Diffusion: temperature 930℃, carbon potential 0.7;

[0070] Temperature drop: temperature 860℃, carbon potential 0.7;

[0071] Temperature holding: temperature 860℃, carbon potential 0.7;

[0072] Unloading: when rapid cooling is used, the cooling oil needs to flow rapidly to reduce the temperature to 55℃, and the time is 25min; when slow cooling is used, the cooling oil needs to flow rapidly to reduce the temperature to 55℃, and the time is 30min;

[0073] Oil control-out of the furnace.

[0074] (6) The sprocket blank after carburizing and quenching is subjected to finishing machining to remove the reserved machining allowance, and the size accuracy of the sprocket is accurately controlled, and then the gear cutting machining is performed to complete the manufacture of the sprocket tooth profile, so as to meet the actual use requirements.

[0075] (7) According to the performance requirements of different parts of the sprocket, a local annealing process using high-frequency induction heating is adopted, and a specially designed induction coil is used to quickly heat the part that needs to be softened to 570℃, and then the induction coil is quickly removed, so that the part is naturally cooled to room temperature at room temperature.

[0076] Example 2

[0077] The present application provides a high wear-resisting scraper chain wheel manufacturing method, which adopts the following method to manufacture the chain wheel,

[0078] (1) A special alloy steel is used as the material for manufacturing the chain wheel, and the chemical composition (mass percentage) is as follows: carbon 0.43, silicon 0.45, manganese 0.75, phosphorus 0.01, sulfur 0.002, chromium 2.10, nickel 1.90, molybdenum 0.70, vanadium 0.25, and the rest is iron; at the same time, the gas content in the material is strictly limited, the hydrogen (H) content is not more than 1.5 ppm, the oxygen (O) content is not higher than 20 ppm, and the nitrogen (N) content is not more than 80 ppm. The material composition design can make the chain wheel have excellent comprehensive mechanical properties, and provide strong guarantee for the subsequent carburizing treatment and realization of high wear resistance.

[0079] (2) The raw material is forged to improve the internal structure of the material and improve its mechanical properties. After forging, the chain wheel is cut into the approximate shape by gas cutting process to provide the blank for subsequent processing. It should be emphasized that the key parts of the chain wheel are accurately processed with a processing allowance; the front end face is reserved with a processing allowance of 2.5-3.5 mm, the inner hole is reserved with a processing allowance of 2.5-3.5 mm, and the tooth shape is reserved with a processing allowance of 0.03-0.05 mm. At the same time, the end face and the inner hole are subjected to special protection treatment and reserved allowance, and then subjected to finish machining after carburizing and quenching. In this way, the deformation generated during carburizing and quenching can be effectively controlled, the dimensional accuracy of the chain wheel can be ensured, and the product quality can be improved.

[0080] (3) Heat treatment process-quenching and tempering treatment:

[0081] The chain wheel blank is heated to 840℃ and kept at this temperature for 4h;

[0082] After the chain wheel blank is taken out of the furnace, it is rapidly subjected to first oil cooling for 45s; after the first oil cooling is completed, the chain wheel blank is taken out and reheated to 360℃, and then subjected to oil cooling for 35s again; the above operation is repeated until the final cooling temperature of the chain wheel blank reaches 310℃;

[0083] After the chain wheel blank is cooled to 310℃, the chain wheel blank is immediately subjected to tempering treatment, and the tempering temperature is set to 630℃, and the temperature is kept for 4h; after the chain wheel blank is taken out of the furnace, it is naturally cooled to room temperature in the air.

[0084] (4) The chain wheel blank after quenching and tempering treatment is subjected to shot blasting treatment to remove the surface scale and impurities and improve the surface quality. Then the chain wheel blank is subjected to rough machining, and the corresponding machining allowance is reserved for the end face, the inner hole and the tooth shape according to the deformation control technical requirements.

[0085] (5) Carburizing and quenching treatment is performed on the sprocket blank:

[0086] After rough machining, the sprocket blank is placed in a cleaning basket in layers, and is cleaned for 1.5 h at a water temperature of 85°C using a professional cleaning device to ensure that the sprocket blank surface is free of oil stains and impurities;

[0087] After cleaning, the sprocket blank is dried, and then the parts that need to be prevented from carburizing are painted with a carburizing-resistant paint, with a coating thickness controlled at 0.15 mm;

[0088] After painting, the sprocket blank needs to be dried. If room temperature drying is used, it needs to be placed at a temperature of 20°C or higher for not less than 3 h; if drying equipment is used, it needs to be dried at a temperature of 180°C for 40 min;

[0089] The dried sprocket blank is prepared for loading into a basket, and when loading into the basket, enough space between the teeth of adjacent sprocket blanks needs to be ensured, and then the sprocket blank is loaded into a carburizing furnace for carburizing and quenching, to ensure that the carburized layer thickness is 3.2 mm, the minimum carbon content of the carburized layer is 0.38% C, and the maximum content of carbide is 85% Ac;

[0090] The specific method of carburizing and quenching is as follows,

[0091] Loading into the furnace: temperature 930°C, carbon potential 0.45;

[0092] Temperature rise: temperature 930°C, carbon potential 0.65;

[0093] Propane supplement: temperature 930°C, carbon potential 1.1;

[0094] Strong carburizing: temperature 930°C, carbon potential 1.1;

[0095] Diffusion: temperature 930°C, carbon potential 0.7;

[0096] Temperature drop: temperature 860°C, carbon potential 0.7;

[0097] Temperature holding: temperature 860°C, carbon potential 0.7;

[0098] Unloading: when rapid cooling is used, the cooling oil needs to flow rapidly to reduce the temperature to 55°C, and the time is 25 min; when slow cooling is used, the cooling oil needs to flow rapidly to reduce the temperature to 55°C, and the time is 30 min;

[0099] Oil control-out of the furnace.

[0100] (6) After the carburizing and quenching of the sprocket blank, finish machining is performed to remove the reserved machining allowance, and the size accuracy of the sprocket is accurately controlled, and then gear cutting is performed to complete the manufacture of the sprocket tooth shape, so that it meets the actual use requirements.

[0101] (7) According to the performance requirements of different parts of the chain wheel, a local annealing process of high-frequency induction heating is adopted, a special induction coil is used to quickly heat the part to be softened to 560℃, and then the induction coil is quickly removed, so that the part is naturally cooled to room temperature at room temperature.

[0102] Example 3

[0103] The application provides a high-wear-resistance scraper chain wheel manufacturing method, and the chain wheel is manufactured in the following manner,

[0104] (1) A special alloy steel is used as the material for manufacturing the chain wheel, and the chemical composition (mass percentage) of the alloy steel is as follows: carbon 0.4, silicon 0.35, manganese 0.68, phosphorus 0.01, sulfur 0.002, chromium 2.00, nickel 1.80, molybdenum 0.55, vanadium 0.20, and the rest is iron; meanwhile, the gas content in the material is strictly limited, the hydrogen (H) content is not more than 1.5 ppm, the oxygen (O) content is not higher than 20 ppm, and the nitrogen (N) content is not more than 80 ppm. The material composition design can enable the chain wheel to have excellent comprehensive mechanical properties, and provide a strong guarantee for subsequent carburizing treatment and realization of high wear resistance.

[0105] (2) The raw material is subjected to forging processing to improve the internal organizational structure of the material and improve the mechanical properties. After forging, the chain wheel is cut into a rough shape through a gas cutting process to provide a blank for subsequent processing. It should be noted that the key parts of the chain wheel are accurately processed with a processing allowance; the front end face is reserved with a processing allowance of 2.5-3.5 mm, the inner hole is reserved with a processing allowance of 2.5-3.5 mm, and the tooth shape is reserved with a processing allowance of 0.03-0.05 mm. At the same time, the end face and the inner hole are subjected to special protection treatment and are reserved with an allowance, and then are subjected to finish machining after carburizing and quenching are completed. In this way, the deformation generated in the carburizing and quenching process can be effectively controlled, the dimensional accuracy of the chain wheel can be ensured, and the product quality can be improved.

[0106] (3) Heat treatment process-quenching and tempering treatment:

[0107] The chain wheel blank is heated to 830℃ and is kept at this temperature for 3.5h;

[0108] After the chain wheel blank is taken out of the furnace, the first oil cooling is quickly performed, and the oil cooling time is 40s; after the first oil cooling is completed, the chain wheel blank is taken out and reheated to 340℃, and then is oil cooled for 25s again; the above operation is repeated until the final cooling temperature of the chain wheel blank reaches 280℃;

[0109] After the chain wheel blank is cooled to 280℃, the chain wheel blank is immediately subjected to tempering treatment, the tempering temperature is set to 620℃, and the tempering is kept for 3.5h; after the chain wheel blank is taken out of the furnace, the chain wheel blank is naturally cooled to room temperature in the air.

[0110] (4) The quenched and tempered chain wheel blank is subjected to shot blasting treatment to remove the surface scale and impurities and improve the surface quality. Then the chain wheel blank is subjected to rough machining, and the machining allowance is reserved for the end face, inner hole and tooth profile according to the deformation control technical requirements.

[0111] (5) The chain wheel blank is subjected to carburizing and quenching treatment:

[0112] The rough machined chain wheel blank is placed in a cleaning basket in layers, and is cleaned at 80℃ for 1h using a professional cleaning device to ensure that the chain wheel blank surface is free of oil stains and impurities;

[0113] After cleaning, the chain wheel blank is dried, and then the parts that need to be prevented from carburizing are brushed with a carburizing-resistant coating, and the coating thickness is controlled at 0.15mm;

[0114] After brushing, the chain wheel blank needs to be dried. If room temperature drying is used, it needs to be placed at a temperature above 20℃ for not less than 3h; if drying equipment is used, it needs to be dried at a temperature of 180℃ for 40min;

[0115] The dried chain wheel blank is prepared for loading into a basket, and when loading into a basket, enough space should be ensured between the teeth of adjacent chain wheel blanks, and then loaded into a carburizing furnace for carburizing and quenching to ensure that the carburizing layer thickness is 3.2mm, the minimum carbon content of the carburizing layer is 0.38%C, and the maximum content of carbide is 85%Ac;

[0116] The specific method of carburizing and quenching is as follows,

[0117] Loading: temperature 930℃, carbon potential 0.45;

[0118] Temperature rise: temperature 930℃, carbon potential 0.65;

[0119] Propane supplement: temperature 930℃, carbon potential 1.1;

[0120] Strong carburizing: temperature 930℃, carbon potential 1.1;

[0121] Diffusion: temperature 930℃, carbon potential 0.7;

[0122] Temperature drop: temperature 860℃, carbon potential 0.7;

[0123] Temperature holding: temperature 860℃, carbon potential 0.7;

[0124] Unloading: when rapid cooling is used, the cooling oil needs to flow rapidly to reduce the temperature to 55℃, and the time is 25min; when slow cooling is used, the cooling oil needs to flow rapidly to reduce the temperature to 55℃, and the time is 30min;

[0125] Oil control-out of the furnace.

[0126] (6) The chain wheel blank after carburizing and quenching is finished to remove the reserved machining allowance, the size precision of the chain wheel is accurately controlled, then the gear cutting is carried out, the tooth shape of the chain wheel is completed, and the actual use requirement is met.

[0127] (7) According to the performance requirement of different parts of the chain wheel, a local annealing process of high-frequency induction heating is adopted, the part needing to be softened is rapidly heated to 560 DEG C by using a special induction coil, then the induction coil is quickly removed, and the part is naturally cooled to room temperature.

[0128] The above only discloses the preferred embodiments of the present application, of course, cannot be limited by this to limit the scope of the present application, those skilled in the art can understand that the whole or part of the above-mentioned embodiments are implemented, and the equivalent changes made according to the claims of the present application still belong to the scope covered by the present application.

Claims

1. A method of manufacturing a high wear scraper chain wheel, characterized by: The method comprises the following steps, Step S1: according to the size requirement of the sprocket, the raw material after forging processing is cut into a sprocket blank, and an accurate machining allowance is reserved for the key parts of the sprocket; Step S2: the sprocket blank is subjected to quenching and tempering heat treatment; Step S3: the sprocket blank after the quenching and tempering treatment is subjected to shot blasting treatment to remove the surface oxide scale and impurities; Step S4: the sprocket blank is subjected to rough machining, and the machining allowance is strictly reserved for the end face, the inner hole and the tooth shape according to the deformation control technical requirement; Step S5: the sprocket blank is subjected to carburizing and quenching treatment; Step S6: the sprocket blank after the carburizing and quenching treatment is subjected to finish machining to remove the reserved machining allowance, the size precision of the sprocket is accurately controlled, then the gear cutting processing is carried out, and the tooth shape of the sprocket is completed to meet the actual use requirement; Step S7: according to the actual use requirement of the sprocket, the softening treatment is carried out on the part of the sprocket which needs to be locally softened.

2. The method of claim 1, wherein: In step S2, the quenching and tempering heat treatment is carried out in the following manner, The sprocket blank is heated to 830±10℃ and kept at this temperature for 3-4h; After the sprocket blank is taken out of the furnace, oil cooling is carried out; When the sprocket blank is cooled to 260-310℃, the sprocket blank is immediately subjected to tempering treatment.

3. The method of claim 2, wherein: When the sprocket blank is oil cooled, the following manner is adopted, After the sprocket blank is taken out of the furnace, the first oil cooling is carried out immediately, and the oil cooling time is 35-45s; After the first oil cooling is completed, the sprocket blank is taken out and reheated to 320-360℃, and then oil cooled for 25-35s again; The above operation is repeated until the sprocket blank is cooled to the final temperature of 260-310℃.

4. The method of claim 3, wherein: When the sprocket blank is subjected to tempering treatment, the following manner is adopted, The tempering temperature is set to 620±10℃, and the temperature is kept for 3-4h; After the sprocket blank is taken out of the furnace, it is naturally cooled to room temperature in the air.

5. The method of claim 4, wherein: In step S5, when the sprocket blank is subjected to carburizing and quenching treatment, the following manner is adopted, The sprocket blank after rough machining is placed in a cleaning basket in layers, and professional cleaning equipment is used to clean the sprocket blank at a water temperature of 75-85℃ for 1-1.5h to ensure that the surface of the sprocket blank is free of oil stains and impurities; After cleaning, the sprocket blank is dried, then the parts needing to be prevented from carburizing are brushed with anti-carburizing paint, and the thickness of the coating is controlled to be 0.12-0.15mm; After brushing, the dried sprocket blank is prepared for loading into the basket, and when loading into the basket, enough space should be ensured between the teeth of adjacent sprocket blanks, and then the sprocket blank is loaded into a carburizing and quenching furnace to ensure that the thickness of the carburized layer is 3.2mm, the minimum carbon content of the carburized layer is 0.38%C, and the maximum content of carbide is 85%Ac.

6. The method of claim 5, wherein: The specific manner of carburizing and quenching is as follows, Furnace loading: temperature 930℃, carbon potential 0.45; Temperature rise: temperature 930℃, carbon potential 0.65; Propane supplement: temperature 930℃, carbon potential 1.1; Strong carburizing: temperature 930℃, carbon potential 1.1; Diffusion: temperature 930℃, carbon potential 0.7; Temperature reduction: temperature 860℃, carbon potential 0.7; Temperature keeping: temperature 860℃, carbon potential 0.7; Unloading: when rapid cooling is adopted, the cooling oil should be made to flow rapidly to reduce the temperature to 55℃ in 25 minutes; when slow cooling is adopted, the cooling oil should be made to flow rapidly to reduce the temperature to 55℃ in 30 minutes; Oil control-out of the furnace.

7. The method of claim 6, wherein: When the sprocket blank is dried, the following method is adopted, If room temperature drying is adopted, it should be kept at a temperature above 20℃ for not less than 3 hours; If drying equipment is adopted, it should be dried at a temperature of 170-180℃ for not less than 40 minutes.

8. The method of claim 7, wherein: In step S7, the following method is adopted for softening treatment: according to the performance requirements of different parts of the sprocket, a local annealing process of high-frequency induction heating is adopted, a special induction coil is used to rapidly heat the part to be softened to 560-580℃, then the induction coil is removed quickly, and the part is naturally cooled to room temperature at room temperature.

9. The method of claim 8, wherein: The raw material adopts a special alloy steel as the material for manufacturing the sprocket, and the chemical composition (mass percentage) is as follows: carbon 0.38-0.43, silicon 0.25-0.45, manganese 0.60-0.75, phosphorus content not more than 0.012, sulfur content not more than 0.003, chromium 1.90-2.10, nickel 1.75-1.90, molybdenum 0.40-0.70, vanadium 0.15-0.25, and the rest is iron; at the same time, the gas content in the material is strictly limited, the hydrogen (H) content is not more than 1.5ppm, the oxygen (O) content is not more than 20ppm, and the nitrogen (N) content is not more than 80ppm.

10. A high wear scraper chain wheel characterized by: The high-wear-resistance sprocket manufacturing method of any one of claims 1-9 is adopted. The high-wear-resistance sprocket manufacturing method of any one of claims 1-9 is adopted.