Profiling sensor for quenching surface of chain wheel

Abstract

The utility model provides a profiling inductor for chain wheel surface quenching, which comprises a profiling inductor main body, the section of the profiling inductor main body is spoon-shaped, the profiling inductor main body comprises a middle arc section, two ends of the middle arc section respectively extend to form a handle part, the tail end of each handle part is welded with a circular tube, a liquid spraying hole is processed at the corner angle of the lower side of the outer circle of the middle arc section, and the liquid spraying hole is communicated with the middle arc section. The handle portions at the two ends of the middle arc section are retracted and then welded to an inductor base connecting plate, the inductor base connecting plate is connected with frequency induction heating equipment, and a round pipe at the tail end of each handle portion is connected with a water inlet pipe of the frequency induction heating equipment. The profiling sensor for quenching the surface of the chain wheel solves the problem that the temperature difference of each part of a part is difficult to control in the existing chain wheel quenching process.

Description

Technical Field

[0001] The utility model belongs to the technical field of surface induction hardening devices, and particularly relates to a profiling inductor for surface hardening of a sprocket wheel. Background Art

[0002] For a sprocket wheel on a tool changing device of a fixed-length shearing product, the conventional surface hardening process for such structural parts is the simultaneous heating and quenching method. However, due to the fact that 6 - Φ120 through holes are evenly distributed on the thickness surface of the sprocket wheel, and the holes are only 19 mm away from the bottom of the sprocket wheel groove near the tooth part, the structural strength is low. During the simultaneous heating and immersion quenching process, it is extremely easy to be cracked, and the risk of quenching cracking is large.

[0003] Generally, for the surface hardening treatment of such structural parts, the internal magnetic field simultaneous heating induction quenching method is often adopted. The inductor generally adopts an annular structure and heats at the largest outer diameter of the sprocket wheel. Due to the unique magnetic field direction of induction heating, the temperature at the bottom of the sprocket wheel groove and the edges and corners of the sprocket wheel reaches the austenitizing temperature first in a short time, while the temperature rising speed of the two side surfaces of the teeth is slower. In order to make the temperatures of all parts of the tooth surface reach the quenching temperature, continuous heating is required. This leads to the continuous diffusion of the temperature at the bottom of the tooth groove towards the inside, and finally the transition position between the 6 - Φ120 holes and the tooth groove reaches the austenitizing temperature, and the temperature of the tooth edges and corners will be too high. During the quenching lifting process, the temperature of the edges and corners will be pre-cooled and reduced, and it has little impact after entering the cooling medium. However, the thermal stress and tissue stress are relatively large at the transition position between the holes and the tooth groove during the cooling process. Coupled with the low structural strength at this place, it is extremely easy to crack and produce waste products. Therefore, it is urgent to develop a new inductor and adopt a new surface hardening process method to apply to the surface hardening process of the above components. Summary of the Utility Model

[0004] The purpose of the utility model is to provide a profiling inductor for surface hardening of a sprocket wheel, which solves the problem that it is difficult to control the temperature difference of each part of the part in the existing sprocket wheel quenching process.

[0005] The technical solution adopted by the utility model is: a profiling inductor for surface hardening of a sprocket wheel, including a profiling inductor main body. The cross-sectional shape of the profiling inductor main body is like a spoon shape. The profiling inductor main body includes an intermediate arc section. Both ends of the intermediate arc section extend with handle parts, and a circular tube is welded at the end of the handle part. A liquid spraying hole is processed at the edge of the lower side of the outer circle of the intermediate arc section, and a Π-shaped magnetic conductor is attached. The handle parts at both ends of the intermediate arc section are retracted and then welded on the inductor base connecting plate. The inductor base connecting plate is connected with a frequency induction heating device. The circular tube at the end of the handle part is connected with the water inlet pipe of the frequency induction heating device.

[0006] The characteristics of the technical solution adopted by the utility model also lie in:

[0007] Furthermore, the intermediate arc section is a profiling structure, with a smaller gap in the middle section, and the two free ends near the edges and corners are retracted to form handle parts after that.

[0008] Furthermore, the profiling inductor body is fixed and fastened to the inductor base through bakelite washers, copper bolts.

[0009] Furthermore, the included angle between the center line of the liquid spraying hole and the axis line of the workpiece is selected as the lower limit of the conventional angle, i.e., 30°, to avoid the water backflow phenomenon.

[0010] Furthermore, the handles at both ends of the middle arc section are fixedly connected to the connecting plate of the inductor base. The connecting plate of the inductor base is L-shaped, and an insulating bakelite board is clamped in the middle.

[0011] The beneficial effects of the present utility model are as follows:

[0012] The profiling inductor of the present utility model is manufactured according to the characteristics of induction heating, which can reduce the temperature difference at various parts of the part, achieve uniform heating, rapid quenching, avoid the risk of quenching cracks at the transition part between the bottom of the groove and the hole, realize the high-efficiency and high-quality local surface quenching of the sprocket with this special structure, achieve zero scrap of the product, have low manufacturing cost, long service life, convenient operation, safety and reliability, and can be reused for batch parts. The surface quenching of the rope groove of a rope pulley with a similar structure can also design the inductor according to this method, and the application range is wide. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 FIG. 1 is a schematic structural diagram of the profiling inductor for surface quenching of the sprocket of the present utility model and a top view of its installation position with the sprocket in the working state;

[0014] Figure 2 FIG. 2 is a side view of the profiling inductor for surface quenching of the sprocket of the present utility model;

[0015] Figure 3 FIG. 3 is a schematic diagram of the relative position of the profiling inductor for surface quenching of the sprocket of the present utility model and the sprocket in the working state and the connection position of the intermediate frequency induction heating equipment;

[0016] Figure 4 FIG. Figure 3 is an enlarged view of the circled part in FIG.

[0017] Figure 5 FIG. 4 is a schematic structural diagram of the working object (sprocket) of the profiling inductor of the present utility model.

[0018] In the figures: 1. Profiling inductor body, 101. Middle arc section, 102. Handle, 103. Round tube, 104. Liquid spraying hole;

[0019] 2. Sprocket, 3. Π-shaped magnetic conductor, 4. Connecting plate of inductor base, 5. Insulating bakelite board, 6. Intermediate frequency induction heating equipment. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] The present utility model will be described in detail below with reference to the drawings and specific embodiments.

[0021] The utility model discloses a profiling inductor for surface quenching of a sprocket, as Figure 1 shown, which includes a profiling inductor body 1. The profiling inductor body 1 is fixedly clamped through a bakelite washer, copper bolts and an inductor base connecting plate 4. The cross-sectional shape of the profiling inductor body 1 is like a spoon shape. The profiling inductor body 1 includes an intermediate arc section 101, and the intermediate arc section 101 is a profiling structure. The gap in the middle section is relatively small. After the two free ends near the edges are retracted, a handle part 102 is formed. The two ends of the intermediate arc section 101 respectively extend with a handle part 102, and a round tube 103 is welded at the end of the handle part 102.

[0022] As Figure 2 and Figure 4 shown, a liquid spraying hole 104 is machined at the edge of the lower side of the outer circle of the intermediate arc section 101. The included angle between the center line of the liquid spraying hole 104 and the axis line of the workpiece is selected as the lower limit of the conventional angle, which is 30°, to avoid the phenomenon of water backflow. And a Π-shaped magnetic conductor 3 is attached. The handle parts 102 at both ends of the intermediate arc section 101 are retracted and then welded on the inductor base connecting plate 4. The inductor base connecting plate 4 is connected with a frequency induction heating device 6. The round tube 103 at the end of the handle part 102 is connected with the water inlet pipe of the frequency induction heating device 6.

[0023] The handle parts 102 at both ends of the intermediate arc section 101 are fixedly connected to the inductor base connecting plate 4. The inductor base connecting plate 4 is L-shaped, and an insulating bakelite board 5 is clamped in the middle.

[0024] Embodiment 1

[0025] Referring to Figure 1 、 Figure 2 and Figure 5 , for the technical requirements of the drawing for tooth surface quenching, its material is 35#, and the required hardness is HRC45 - 50. According to the special structure of the quenching part of the sprocket 2, its tooth shape is relatively deep, and the transition connection part between the tooth groove part and the hole part is only 19 mm. If the conventional treatment method, that is, the internal magnetic field simultaneous heating induction quenching method, is adopted, it takes a long time to heat to make the whole tooth part reach the austenitizing temperature, which will cause the penetration layer of the sprocket to be too deep, and the transition part between the tooth groove and the hole part reaches the quenching temperature, and it is extremely easy to crack during the cooling process. Therefore, it is necessary to consider local single-tooth quenching, design and manufacture a self-spraying tooth profiling inductor, and adopt the external magnetic field single-tooth continuous spraying quenching method for tooth quenching.

[0026] When designing the inductor, it is necessary to consider conforming to the tooth profile of the tooth part. According to the characteristics of induction heating, and since the design principle is the external magnetic field induction heating method with low heating efficiency, it is necessary to add a Π-shaped magnetic conductor 3 for magnetic driving and magnetic focusing to concentrate the current at the notch surface, thereby improving the magnetic coupling efficiency (the curvature of the middle arc section is relatively large, and it is difficult to place the Π-shaped magnetic conductor 3. After grinding and shaping it, it is installed). Considering the edge effect, the gap in the middle arc part is controlled at 1.0 - 1.5 mm, and the gaps at both side edges are slightly larger, controlled at 1.5 - 2.0 mm. A single-tooth continuous spray quenching profiling inductor is made, called profiling inductor 1. Profiling inductor 1 selects a 10x10 mm rectangular copper pipe, the outer diameter of the arc section is φ78 mm, and the gap at both edge parts is controlled at 1.5 - 2.0 mm to ensure that the temperature at this place does not become too high during heating, and the temperatures at all parts of the quenching surface are close to being uniform. Finally, the two free ends are bent and retracted. After the bending is completed, the spray holes are processed. Generally, for a self-spraying inductor, the required spray hole diameter is Φ1.8 - 2.2 mm, and the included angle between the center line of the spray hole and the axis line of the workpiece is 30 - 50°. The selected spray hole diameter for this design is Φ2.0 mm, and the hole pitch is 4 mm. In view of the large curvature of the tooth surface of the quenching surface, water will flow back when the water line hits the workpiece, affecting the heating efficiency and resulting in soft bands or unhardened areas on the quenched workpiece. Therefore, the lower limit of 30° is selected for the included angle between the center line of the spray hole and the axis line of the workpiece to delay cooling. Finally, the processed copper pipe is welded to the inductor base connecting plate 4, and circular copper pipes are welded to the upper ends of the two free ends, which are connected to the water inlet hose during operation.

[0027] Based on the above considerations, the structure of the present utility model is that the cross-sectional shape of the main body of the profiling inductor 1 is like a spoon shape, including a middle arc section, a handle part, and circular pipes welded at both ends. Spray holes are processed on the lower side edges of the outer circle of the arc section, and a Π-shaped magnetic conductor 3 is attached for magnetic driving. Among them, the arc section is a profiling structure. After the two free ends are retracted, they are welded to the inductor base connecting plate 4, and an insulating phenolic resin board 5 is used for insulation in the middle to form an electric current loop, and the profiling inductor 1 and the inductor base connecting plate 4 are fixed and clamped with phenolic resin washers and copper bolts, and are connected to the intermediate frequency induction heating equipment 6 during operation. Circular copper pipes are respectively welded and connected to the ends of the handle part of the profiling inductor 1, and the ends of the two copper pipes are connected to the water inlet pipe of the intermediate frequency induction heating equipment 6.

[0028] All connections of the profiling inductor 1 are brazed connections. After manufacturing, it is required to file down all the welded arcs. Welding deformation is inevitable. A wooden hammer can be used to correct the flatness and conduct a pressure test to check the angular flatness of the spray water line to ensure that the water line is unobstructed and the angles are consistent, and there is no leakage at the welded joints of the inductor.

[0029] The usage method of the inductor of the present utility model is as follows:

[0030] 1) Firmly mount the profiling inductor 1 of the present utility model with the Π-shaped magnetic conductor 3 on the wiring board of the intermediate frequency induction heating equipment 6. Connect the two water inlet ends to the water inlet hose and lock them with a bayonet to prevent them from falling off during use;

[0031] 2) As Figure 3 shown, mount the sprocket 2 on the workbench of the intermediate frequency quenching machine tool. Start the intermediate frequency quenching machine tool, adjust the installation position and clearance between the profiling inductor 1 and the sprocket 2, check whether the clearance between the sprocket and the profiling inductor 1 is appropriate, adjust the clearance to 1 - 1.5 mm, and perform an idle run according to the quenching requirements to check whether the quenching machine tool is normal;

[0032] 3) Check the water cooling system of the equipment, confirm that the water pressure meets the requirements and there is no water leakage. Check that the water line of the profiling inductor 1 is uniform and the angles are consistent. Start the intermediate frequency equipment and perform parameter debugging;

[0033] 4) Adjust the working parameters of the intermediate frequency induction heating equipment 6 to a DC voltage of 560 V, an output current of 300 A, an output power of 55 KW, and a resonance frequency of 7900 HZ; set the moving speed of the quenching machine tool to 10 V and perform continuous spray quenching induction hardening. During heating, it is strictly prohibited for the profiling inductor 1 to contact the sprocket 2 to avoid short - circuiting and burning the parts.

[0034] 5) When the inductor is about to run to the upper surface of the tooth part, reduce the power, then cut off the power. The profiling inductor 1 continues to run until the water line falls on the upper end of the quenching part of the part, and continue to cool for 3 - 5 min to enhance the quenching effect. After one tooth surface is quenched, perform coloring flaw detection to check that there are no cracks on the edges, and perform hardness testing, with HRC48 - 49, meeting the expectations. Then perform the quenching of the remaining tooth surfaces according to the above process. After all tooth surfaces are quenched, promptly perform tempering. Arrange tempering at 180 °C for 6 h, check the hardness, and the detected hardness is HRC47 - 49, achieving the expected effect.

[0035] Example 2

[0036] Surface hardening example of a similar structural part rope pulley. In this embodiment, the part name is rope pulley, the material is Q345D, its maximum outer dimension is Φ1120x105mm, the rope groove part is an R21 groove, the groove depth is 60mm, the groove opening width is 80mm, and the technical requirement is that the surface hardening hardness of the rope groove part is HB300 - 350, and the depth is 2 - 3mm. According to the manufacturing method of the profiling inductor of the present utility model, the profiling inductor for the rope groove part is manufactured. The inductor selects a 10x10mm rectangular copper pipe, the outer diameter of the arc section is φ40mm, the gap at both edge parts is controlled at 2.0mm, and finally the two free ends are bent and retracted. The spray hole diameter is selected as Φ2.0mm, the hole pitch is 4mm, and the included angle between the center line of the liquid spray hole and the axis line of the workpiece is selected as the lower limit of 30° to achieve the effect of delayed cooling. Finally, the processed copper pipe is welded to the connecting plate of the inductor base, and circular copper pipes are welded to the upper ends of the two free ends, which are connected to the water inlet hose during work.

[0037] In this embodiment, a 65 quenching machine tool is used to realize the uniform rotation of the workpiece. The workpiece is clamped, and the position of the inductor is adjusted (a Π-shaped magnetic conductor is installed on the arc section of the inductor). The water pressure is adjusted and tested to be controlled at 0.1MPa. Power is supplied (the working parameters are adjusted to a DC voltage of 556V, an output current of 318A, an output power of 70KW, and a resonance frequency of 8207Hz); the rotation speed of the quenching machine tool is 130mm / min, the quenching temperature is controlled at 900°C, and continuous spray quenching induction hardening is carried out. Finally, a 10mm welding soft band is left at the starting part. The power is cut off, the quenching machine tool is stopped, and the water is stopped after 3 - 5 minutes of cold storage. The quenching hardness is detected as HRC48 - 52, and then tempering treatment is carried out at 350°C for 6 hours. After waiting until room temperature, the hardness is detected as HB340 - 350, and it is completed.

[0038] Example 3

[0039] Surface hardening example of a similar structural part sprocket. In this embodiment, the part name is sprocket, the material is 35CrMo, its maximum outer dimension is Φ1144x65mm, the tooth part is an R45 groove, the groove depth is 40mm, the groove opening width is 95mm, and the technical requirement is that the surface hardening hardness of the sprocket tooth part is HRC40 - 45, and the depth is 2 - 3mm. According to the manufacturing method of the profiling inductor of the present utility model, the profiling inductor for the tooth part is manufactured. The inductor selects a 10x10mm rectangular copper pipe, the outer diameter of the arc section is φ88mm, the gap at both edge parts is controlled at 2.0mm, and finally the two free ends are bent and retracted. The spray hole diameter is selected as Φ2.0mm, the hole pitch is 4mm, and the included angle between the center line of the liquid spray hole and the axis line of the workpiece is selected as the lower limit of 30° to achieve the effect of delayed cooling. Finally, the processed copper pipe is welded to the connecting plate of the inductor base, and circular copper pipes are welded to the upper ends of the two free ends, which are connected to the water inlet hose during work.

[0040] In this embodiment, a common vertical medium-frequency quenching machine tool is used. The profiling inductor equipped with a Π-shaped magnetic conductor is clamped on the wiring board of the medium-frequency induction heating equipment. The two water inlet ends are connected to the water inlet hose and locked with a bayonet to prevent detachment. The sprocket is clamped on the workbench of the medium-frequency quenching machine tool. The medium-frequency quenching machine tool is started, and the position and gap between the profiling inductor and the sprocket are adjusted appropriately. The test water pressure is adjusted and controlled at 0.1 MPa. Power is supplied (the working parameters are adjusted to a DC voltage of 565 V, an output current of 308 A, an output power of 60 KW, and a resonance frequency of 7980 Hz). The moving speed of the quenching machine tool is 120 mm / min, and the quenching temperature is controlled at 880 °C for continuous spray quenching induction hardening. When the inductor is about to run to the upper surface of the tooth part, the power is reduced, and then the power is cut off. The inductor continues to run. When the water line falls on the upper end of the quenching part of the part, the water supply is stopped after continuous cooling for 3 - 5 min. The quenching hardness is detected to be HRC51 - 53, and then tempering treatment is carried out at 320 °C for 6 h. After the workpiece is cooled to room temperature, its hardness is detected to be HRC43 - 45, and it is completed.

Claims

1. A profile sensor for sprocket surface hardening, characterized in that: The invention comprises a profile sensor body (1), wherein the cross-section of the profile sensor body (1) is spoon-shaped, the profile sensor body (1) comprises a middle circular arc section (101), the two ends of the middle circular arc section (101) are respectively extended with handles (102), and the ends of the handles (102) are welded with round tubes (103), the lower edges of the outer circle of the middle circular arc section (101) are processed with liquid spray holes (104), and a Π-shaped magnetic conductor (3) is attached, the handles (102) at the two ends of the middle circular arc section (101) are retracted and welded to a sensor base connecting plate (4), the sensor base connecting plate (4) is connected to a high-frequency induction heating device (6), and the round tube (103) at the end of the handle (102) is connected to a water inlet pipe of the high-frequency induction heating device (6).

2. The profiling sensor for sprocket surface hardening according to claim 1, characterized in that: The middle circular arc section (101) is a contoured structure, wherein the gap between the middle sections is relatively small, and the free ends at both ends near the corners are retracted to form a handle (102).

3. The profiling sensor for sprocket surface hardening according to claim 2, characterized in that: The contour sensor body (1) is fixedly connected to the sensor base connecting plate (4) by means of bakelite washers and copper bolts.

4. The profiling sensor for sprocket surface hardening according to claim 2, characterized in that: The intersection angle between the center line of the liquid spray hole (104) and the axis line of the workpiece is selected to have a conventional lower limit of 30° to avoid backflow.

5. The profiling sensor for sprocket surface hardening according to claim 1, characterized in that: The handles (102) at both ends of the middle arc segment (101) are fixedly connected to the sensor base connecting plate (4); the sensor base connecting plate (4) is L-shaped, with an insulating bakelite board (5) sandwiched in the middle.

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