A method for manufacturing a steel wheel of a wear-resistant composite plate

Abstract

The present application belongs to the technical field of steel wheel manufacturing, and relates to a steel wheel manufacturing method of wear-resistant composite plate. The method comprises the following steps: S1: using a coiling machine pressure head at a position 80-120 mm away from the head and tail of a steel plate, pre-coiling an arc, processing an X-shaped groove, coiling according to the actual length of the cut-out, and spot welding at the closing position; S2: welding 3-5 layers on the inner side of the roller and 2-5 layers on the outer side of the roller, and using a segmented back-welding process on the outer side; S3: covering ceramic heating sheets within a range of 500 mm of the longitudinal seam of the roller for heating, the heating temperature is 150-300 DEG C, the temperature is kept for 2 h, and the roller is slowly cooled to room temperature, and the roller is subjected to flaw detection after more than 48 h; S4: using ceramic heating sheets or installing a gas exhaust heating device to heat the area to be coiled, and the temperature of the coiled part is not less than 200-350 DEG C; S5: performing appearance inspection on the roller body, and performing near-surface and internal flaw detection on the welded seam area. The hardness of the wear-resistant layer of the coiled roller is greater than or equal to 370 HB, and a longer continuous working time and lower maintenance cost can be obtained.

Description

Technical Field

[0001] This invention belongs to the field of steel wheel manufacturing technology, and specifically relates to a method for manufacturing a wear-resistant composite plate steel wheel. Background Technology

[0002] Road rollers are core equipment in road construction machinery clusters. Their wheels, as the working parts that directly contact the compacted material, are subjected to continuous impact and friction with the material under long-term, high-frequency, and large-amplitude conditions. This places stringent requirements on the manufacturing precision, wear resistance, and structural reliability of the wheels. The manufacturing cost of steel wheels often accounts for a large proportion of the overall machine cost, with cost differences primarily determined by the manufacturing processes used. Due to the limitations of road roller wheel structure and the high requirements for weldability, low-carbon steel is commonly used domestically and internationally to fasten to the surface of road roller wheels. However, low-carbon steel itself has poor wear resistance, while road rollers operate under diverse conditions, requiring a certain level of wear resistance from the wheels. Traditionally, quenching is used to improve wear resistance, but quenching results in poor weldability, and the large size of road roller wheels prevents them from fitting into typical heat treatment furnaces. Currently, advanced engineering practices employ thick plate rolling processes. By calculating and analyzing key parameters such as bending force and circumference change rate, the elongation, roundness, and angularity during the rolling process are effectively controlled. However, equipment capacity often becomes a limiting factor. Furthermore, research indicates that improper rolling processes can lead to strain aging and grain growth, affecting component quality. Therefore, achieving longer continuous working hours and low-maintenance steel wheels has become a primary requirement for manufacturers.

[0003] Document CN109666776B discloses a hardening process for the surface of low-carbon steel wheel bodies in road rollers. This method uses a laser to rapidly heat the wheel surface to form a hardened layer, thereby improving surface hardness and solving the problem of insufficient hardness improvement during quenching of low-carbon steel. However, the processing efficiency of lasers is relatively slow, and the labor cost is high.

[0004] Document CN120041820A discloses a method for improving wheel wear resistance based on laser cladding technology. This method uses cobalt-based composite powder to uniformly clad onto the wheel body under the action of laser to form a high-hardness composite layer, ensuring wear resistance and improving wheel lifespan. However, the alloy used is an expensive alloy, and the equipment cost is also high. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides a method for manufacturing steel wheels of wear-resistant composite plates. The steel wheels produced have a wall thickness of 18-42mm. After the steel plate is pressed and rolled, preheating welding is not required. The flaw detection of the rolled roller after recirculation meets the Class I requirements of NB / T47013.3 standard, with an ellipticity error ≤2mm and a wear-resistant layer hardness ≥370HB. This method can achieve a longer continuous working time and lower maintenance costs.

[0006] The technical solution adopted in this invention is a method for manufacturing steel wheels from wear-resistant composite plates, comprising the following steps: S1: Cutting process. Cut the wear-resistant composite plate according to the process requirements. Use a plate rolling machine to press the plate at a distance of 80-120mm from the beginning and end of the plate to pre-form an arc. Use a semi-automatic cutting machine to process the bevel into an X shape. Perform magnetic particle or penetrant testing on the bevel surface. Roll the plate into a circle according to the actual cutting length and spot weld the end. S2: Welding process: Weld 3-5 layers on the inside of the drum, grind the outside with an angle grinder until the root is smooth, weld 2-5 layers on the outside of the drum, and use a segmented back welding process on the outside. S3: Post-weld hydrogen removal treatment, cover the longitudinal seam of the roller with ceramic heating plates and heat at 150-300℃, keep warm for 2 hours and slowly cool to room temperature, and perform flaw detection after more than 48 hours; S4: Rounding process, ceramic heating elements and / or air exhaust heating devices are used to heat the area to be rolled, ensuring that the temperature of the rolled part is not lower than 200-350℃; S5: Inspection process, conduct an external inspection of the cylinder, and perform near-surface and internal flaw detection on the weld area.

[0007] Furthermore, the steel plate has a thickness of 18-42mm, a bevel angle of 45-65°, and a blunt edge of 2-5mm.

[0008] Furthermore, the segmented back-welding process specifically involves welding from the middle to both sides, and then switching to high-strength wear-resistant welding wire when the weld reaches 2-3mm from the joint surface. This allows the residual heat from the base material welding to be used for continuous welding to the outer cover surface of the roller, ensuring that the roller temperature reaches above 100℃.

[0009] Furthermore, the roundness error of the steel wheel after recirculation is ≤2mm, and the hardness of the wear-resistant layer is ≥370HB.

[0010] The beneficial effects of this invention are as follows: The heated rounding process proposed in this invention for wear-resistant composite steel wheels utilizes the enhanced atomic activity during low-temperature heating, which reduces the deformation resistance of the material. At the same time, by using the thermo-elastic-plastic stress deformation generated by local heating, high-strength wear-resistant steel can be bent into a perfect circle under relatively small external force. This solves the problems of limited high-strength wear-resistant steel coils and roller roundness. After rounding, the roundness error is ≤2mm, and the hardness of the wear-resistant layer is ≥370HB. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0012] Figure 1 This is a schematic diagram of the bevel structure at the splicing point; Figure 2 This is a comparison of the cracking situation of the steel wheel. Detailed Implementation

[0013] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention.

[0014] This invention provides a method for manufacturing steel wheels from wear-resistant composite plates, employing a process path including blanking, rolling, welding, post-weld hydrogen removal, and warm-rolling. The composite plate is made by composite rolling of low-carbon steel and wear-resistant plate. Key process steps are as follows: (1) Cutting: Cut the wear-resistant composite plate according to the drawings and process requirements to ensure smooth butt welding of the longitudinal seam after rolling into a cylinder. Use a semi-automatic cutting machine to process the bevel into an X shape, with a bevel angle of 45-65° and a blunt edge of 2-5mm. Figure 1 As shown; perform magnetic particle or penetrant testing on the bevel surface, roll it into a circle according to the actual cutting length, and spot weld the end.

[0015] (2) Welding: Select appropriate welding materials according to the base material and the cover material. Weld 3-5 layers on the inner side of the roller and grind the outer side with an angle grinder until the root is smooth. Weld 2-5 layers on the outer side of the roller. Use a segmented back welding process on the outer side, welding from the middle to both sides. Weld to 2-3mm away from the joint surface and then use high-strength wear-resistant welding wire for welding. This is beneficial for the residual heat of the base material welding to continuously weld to the outer cover surface of the roller. During this period, ensure that the roller temperature reaches above 100℃.

[0016] (3) Post-weld hydrogen removal treatment: Cover the longitudinal seam of the roller with a ceramic heating plate and heat it at a temperature of 150-300℃. Keep it warm for 2 hours and then slowly cool it to room temperature to avoid the generation of delayed cracks on the bonding surface of the wear-resistant composite plate and the high-strength coating material. After more than 48 hours, perform flaw detection.

[0017] (4) Rounding: Ceramic heating plates are used to ensure that the temperature of the rolling part is not lower than 200-350℃. At the same time, an air exhaust heating device is installed to heat the area to be rolled. The air exhaust heating device covers the axial length of the roller to maintain the temperature of the extrusion part.

[0018] (5) Inspection: Inspect the appearance of the cylinder and perform near-surface and internal flaw detection on the weld area.

[0019] The following examples provide further details.

[0020] Example 1: This embodiment involves a composite of Q235B and NM400 steel plates with a thickness of 40mm.

[0021] The key process steps are: (1) The beveling is symmetrical X-shaped with an angle of 60°, a blunt edge of 3mm, and an assembly gap of 1mm. After cutting, the workpiece is ground and assembled to form the workpiece to be welded. Remove water, oil, rust and other dirt from the beveling position, and grind the beveling surface and the 50mm area to be welded with an angle grinder until the metal luster is exposed. Preheat to 100℃, spot weld the two ends of the workpiece and install the arc-starting plate and arc-extinguishing plate, roll it into a circle according to the actual cutting length, spot weld the end, measure and record the circumference of the opening and the middle outer circle. (2) Welding: Weld 4-5 layers on the inner side of the drum using 1.2mm ER50-6 welding wire. Grind the outer side with an angle grinder until the root is smooth. Weld about two layers with 1.2mm ER50-6 welding wire to fill the gap. Use a segmented back welding process on the outer side, welding from the middle to both sides. The interlayer temperature is below 120℃. Weld to 2-3mm away from the joint surface. Use the residual heat of the base material welding to control the drum temperature above 100℃. Use 1.2mm ER120S-6 welding wire to weld the transition layer and the cover layer. Use a current of 220-240A and a voltage of 26-30V for the low carbon steel welding wire. The welding speed is 50cm / min. Use a current of 240-280A and a voltage of 26-30V for the transition layer welding wire. The welding heat input is ≤15kJ / cm. (3) Post-weld hydrogen removal treatment: Cover the longitudinal seam of the roller with ceramic heating plates and heat at a temperature of 150-300℃. Keep it warm for 2 hours and slowly cool it to room temperature to avoid the generation of delayed cracks on the bonding surface of the wear-resistant composite plate and the high-strength coating material. After more than 48 hours, perform flaw detection. (4) Rounding: Cover the extrusion part with a ceramic heating plate, heat the part to 250-300℃, and install an air exhaust heating device to slow down the cooling rate and keep the temperature of the extrusion part at about 260 degrees Celsius for pressing and rounding. (5) Inspection: The roller has a good appearance, no defects are found during flaw detection, the roundness error is 2mm, and the wear-resistant layer hardness is 400HB.

[0022] Example 2: This embodiment involves a Q960E high-strength steel plate with a thickness of 40mm.

[0023] The key process steps are: (1) The blanking size is 40 2170 5315, with 50mm added to both ends, the unfolded mid-diameter of the component is 5215mm. A plate rolling machine pressure head is used at a distance of 100mm from the beginning and end of the steel plate to pre-form an arc, ensuring a smooth transition at the longitudinal seam weld of the roller. A semi-automatic cutting machine is used to process an X-shaped bevel with a 60° bevel angle and a 2mm blunt edge. After magnetic particle inspection of the bevel surface, it is rolled into a circle according to the actual cutting length. A Φ1620 template is used to measure the inner diameter, and spot welding is performed at the closing point.

[0024] (2) Welding: GM120 gas-shielded welding wire from Bole was used for welding. The preheating temperature was 180-200℃. A ceramic heating element was used to cover the perimeter of the longitudinal seam for 500mm. Welding parameters: current 240-280A, voltage 26-30V, welding heat input ≤15kJ / cm. Welding was performed alternately on the inner and outer sides. First, three layers were welded on the inner side, leaving a 7-8mm gap. Then, two to three layers were welded on the outer side, leaving a 10mm gap. The deformation of the roller was measured during this process. The inner weld was then welded until the cover was completed, and finally, the outer side was welded. The entire longitudinal seam was welded in one pass. The interpass temperature was controlled between 150-250℃.

[0025] (3) Post-weld hydrogen removal treatment: Cover the longitudinal seam of the roller with a ceramic heating plate and heat it at 230℃. Keep it at the temperature for 2 hours and slowly cool it to room temperature. After more than 48 hours, perform flaw detection.

[0026] (4) Rewinding: The rolling part is heated to 250°C by using ceramic heating plates, and an air exhaust heating device is installed to heat the area to be rolled, covering the axial length of the roller and maintaining the temperature when entering the rolling machine.

[0027] (5) Inspection: The roller has a good appearance, no defects are found during flaw detection, the roundness error is 1.5mm, and the wear-resistant layer hardness is 380HB.

[0028] Comparative Example 1: The difference between Comparative Example 1 and Example 2 is that the heated rounding process was not used after the hydrogen removal treatment following welding, which led to cracking of the cylinder. Figure 2 As shown.

[0029] In summary, the heated rounding process of this invention solves the problems of limited high-strength wear-resistant steel coils and roller roundness. After rounding, the roundness error is ≤2mm and the wear-resistant layer hardness is ≥370HB.

[0030] The above embodiments are preferred implementations of the present invention. In addition, the present invention can be implemented in other ways. Any obvious substitutions without departing from the concept of the present technical solution are within the protection scope of the present invention.

[0031] To facilitate understanding by those skilled in the art of the improvements of this invention over the prior art, some of the accompanying drawings and descriptions have been simplified, and for clarity, some other elements have been omitted from this application. Those skilled in the art should realize that these omitted elements may also constitute the content of this invention.

Claims

1. A method for manufacturing a steel wheel from a wear-resistant composite plate, characterized in that, Includes the following steps: S1: Cutting process. Cut the wear-resistant composite plate according to the process requirements. Use a plate rolling machine to press the plate at a distance of 80-120mm from the beginning and end of the plate to pre-form an arc. Use a semi-automatic cutting machine to process the bevel into an X shape. Perform magnetic particle or penetrant testing on the bevel surface. Roll the plate into a circle according to the actual cutting length and spot weld the end. S2: Welding process: Weld 3-5 layers on the inside of the drum, grind the outside with an angle grinder until the root is smooth, weld 2-5 layers on the outside of the drum, and use a segmented back welding process on the outside. S3: Post-weld hydrogen removal treatment, cover the longitudinal seam of the roller with ceramic heating plates and heat at 150-300℃, keep warm for 2 hours and slowly cool to room temperature, and perform flaw detection after more than 48 hours; S4: Rounding process, ceramic heating elements and / or air exhaust heating devices are used to heat the area to be rolled, ensuring that the temperature of the rolled part is not lower than 200-350℃; S5: Inspection process, conduct an external inspection of the cylinder, and perform near-surface and internal flaw detection on the weld area.

2. The method for manufacturing a steel wheel for a wear-resistant composite plate as described in claim 1, characterized in that, The steel plate has a thickness of 18-42mm, a bevel angle of 45-65°, and a blunt edge of 2-5mm.

3. The method for manufacturing a steel wheel for a wear-resistant composite plate as described in claim 2, characterized in that, The segmented back-welding process is as follows: weld from the middle to both sides, and when the weld reaches 2-3mm from the joint surface, use high-strength wear-resistant welding wire for welding. This allows the residual heat from the base material welding to be used for continuous welding to the outer cover surface of the roller, ensuring that the roller temperature reaches above 100℃.

4. The method for manufacturing a steel wheel for a wear-resistant composite plate as described in claim 3, characterized in that, The roundness error of the steel wheel after recirculation is ≤2mm, and the hardness of the wear-resistant layer is ≥370HB.

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