Rolling bearing condition monitoring and fault diagnosis
2023-08-06 05:08:59
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Rolling bearing condition monitoring and fault diagnosis
Source: Bearing network time: 2014-10-05
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1. Surfacing correction of gear shaft broken teeth:
Modulus m=30mm Number of teeth z=24 Tooth width b = 300mm Maximum diameter of outer circle is φ 914mm Total length is 2. 75m Single weight 7.722t The uniform service life of this gear shaft is 11. 5 years; medium plate mill reducer The heavy-duty herringbone gear shaft data is 50SiMnMoB steel. The damage method is wear, peeling, broken teeth, etc. At that time, as long as a small number of manufacturers in the country can produce and produce. The factory used the surfacing method to correct a broken tooth; the maximum break The dimensions are 200mm 40mm 45mm and the gear shaft is scrapped; the detailed correction process is as follows:
1 Do not allow any cracks to heat the workpiece before welding; use the hand-held grinding wheel to grind the bottom surface of the broken tooth. Use the far-infrared radiant electric heater 24 pieces to evenly fit on the top surface of all the teeth; wrap it with asbestos cloth. Heat about 6h The workpiece temperature is controlled at around 300 °C.
2 Before welding, the electrode should be carefully dried. Replace the surfacing with φ 4mm E308-16 A102 electrode and φ 4mm E8515-G J857 electrode.
3 Thickness is about 4mm and then surfacing with E8515-G welding rod is 16 20mm thick; first use E308-16 welding rod to make bottom welding. Then use E308-16 welding rod to weld about 3mm buffer layer; finally use E8515-G welding rod to pile the tooth After welding, during the surfacing process, the workpiece should be kept in a heating state; and placed in a sheltered place; the interlayer temperature is maintained at about 300 °C; each layer is welded; (hot) the hammer is used to strike the welds. More than 30 times. The entire surfacing process should be carried out in succession;
4 After surfacing, it should be kept for 4 hours and then slowly cooled.
5 Manual grinding should be carried out with a careful grinding wheel. In order to obtain better tooth shape accuracy.
All meet the quality requirements. Ultrasonic flaw detection and hardness inspection of the gear shaft corrected by surfacing.
Second, the inner ring gear repair welding correction:
The inner ring gear outer diameter φ 1400mm thick 135mm when making teeth; 50t crawler crane walking and the upper channel are connected with reverse support. Because of the machine tool malfunction; the tooth thickness of one of the teeth is milled half; Surfacing correction. The internal ring gear is 5CrMnMo steel; the weldability is poor. The inner ring gear is treated by quenching and tempering, and the disadvantageous tooth is not allowed to be subjected to corresponding heat treatment after surfacing; therefore, it is required to select the hardness and its appropriate electrode. And the selection of the surfacing process that does not present cracks in the heat-affected zone. The detailed surfacing process is as follows:
1 and around the windshield to be settled. Carefully remove the oil, dirt, etc. on the workpiece. Use oxyacetylene flame to preheat the teeth to be welded and their surroundings to about 300 °C. Surfacing should be carried out in the workshop.
2 The electrode is baked at 400 °C for 1h. When welding, the DC is reversed. Use φ 3. 2mm E8015-G J807 welding rod welding.
3 Place the tooth surface to be welded in the vertical welding direction. Start from the root of the tooth; place the ring gear on the bracket. Use multi-layer multi-layer up-welding; the welding direction of each weld is opposite. After the thickness; change the ring gear; make the end face of the tooth in the vertical welding direction; the end face of the welding tooth and the two side faces; until all the welding is completed. After each welding seam; the slag should be carefully arranged; during the surfacing process; The temperature is maintained at 180 220 °C.
4 Then cover with asbestos cloth; immediately after surfacing, heat the surfacing to about 300 °C with oxyacetylene flame. Slowly cool to room temperature.
5 Then machine the tooth shape on the bed. Use a hand-held grinding wheel to smooth the two sides of the welding tooth.
Both meet the quality requirements of the ring gear. Magnetic flaw detection and hardness inspection of the surfacing parts after processing.
Third, the sprocket broken teeth surfacing correction:
It was found that the sprocket in the walking transmission organization had two teeth broken from the root. Because there is no milling cutter, it can't be made from the head; when a crane is overhauled, the resolution is corrected by surfacing.
The wear-resistant surfacing electrode is used for the surfacing of the toothed surface. The surfacing process is as follows: The chemical composition of the sprocket data is 0. 35% C 1.12% Mn 0. 51% Si 0. 32% Cr 0. %Cu tooth surface hardness is greater than 50HRC. When surfacing, the general low alloy steel electrode is first formed into a tooth shape.
1 It is convenient to check the tooth shape frequently. Put the broken teeth of the sprocket side up slightly; Before the welding, make a sample which can measure two teeth according to the tooth shape. Brush the surface to be welded and the adjacent rust with a wire brush; Finishing clean. Slowly heat the surfacing part with oxyacetylene flame; preheating temperature is about 200 °C; to avoid cracking during surfacing. Surfacing should be carried out indoors without wind.
2 Before welding, the electrode is dried at 400 °C for 2h. φ 5mm EDPCrMo-A 4-03 D212 electrode is used to weld the outer surface layer; φ 4mm E6016-D1 J606 electrode is used to weld the toothed part. Before welding, the electrode is dried at 150 °C for 1h. Welding uses a communication welder.
3 Re-welding four weeks; firstly use E6016-D1 welding rod to weld on the broken tooth surface. First weld the center. This way the welding heat of the center will anneaize the external quenching layer of the original tooth; then reduce the tendency of cracking. Select Short arc welding; after finishing one layer of cleaning slag; and control the interlayer temperature between 150 200 ° C. The surface of the surfacing layer should be as smooth as possible; the crater should be filled; to avoid the occurrence of micro-cracks in the crater. Time; 2 3mm thick surfacing should be reserved according to the tooth shape; in order to weld the wear layer.
4 Continuous surfacing is completed. The surface of the tooth after welding should be avoided. Next, the toothed shape is welded with EDPCrMo-A 4-03 electrode to reduce the workload of grinding the tooth profile.
5 Let it cool slowly. Cover the weld with asbestos cloth immediately after welding.
6 After inspection with the sample plate; use the hand-held grinding wheel to grind and trim the teeth of the surfacing. The sprocket can be used.
After the installation test, it proves that the application is outstanding; the sprocket with the surfacing correction has no shortcomings such as cracking and cracking in the use of the surfacing; it has been used normally for more than two years.
4. Surfacing correction of large cast iron gear broken teeth:
The gear data is HT200. The slotted pile tooth method is used to correct the broken teeth; the root of the large cast iron gear teeth is cracked. Winning. This method does not need to disassemble the gear; it has simple process, convenient operation and high quality of weld quality. The detailed practice is 1 Clean with a wire brush. Open the U-shaped groove; Remove the outer surface of the broken tooth with gasoline. Groove depth 8 15mm Width 5 10mm The number of slots depends on the thickness of the root. Preheat the broken surface with oxyacetylene flame; When the dark red color is present, the heating is stopped; the surfacing is carried out.
2 A layer of transition layer is deposited on the entire surface of the broken tooth; after preheating, the groove is filled with EZNiFe-1 electrode. Finally, the E4303 J422 electrode is used for surfacing welding. The communication and DC welding machine can be used. If necessary, the electrode is dried according to the rules.
3 After grinding the tooth shape with a trowel; the weld-formed gear teeth can be put into operation.
The use of more than one year is still intact; the gears modified by the slotted pile method do not exhibit tooth deformation and crack; and the wear resistance of the surfacing is better than the original teeth.
5. Welding repair of the rack of the planer table:
The rack data is Ht200 to ensure the common service requirements of the rack and post-weld deformation. The B2152 type planer workbench breaks 8 teeth in the middle of the rack. It is welded by cold welding.
1 Make the oil-slip transition of the surfacing. Clean the oil on the rack with gasoline and abrasive cloth before welding. Trim the damaged tooth with a flat spatula.
2 The electrode is welded at 200 °C and 2h before use, and φ3.2mm EZNiFe-1 Z408 electrode is used for welding and drying.
3 For each welding, it is necessary to carry out cleaning and hammering; when welding, the DC is reversed. The workpiece is not preheated. The straight line method is adopted. The interlayer temperature must be kept below 100 °C. The welding teeth should have a machining allowance.
4 The rack is not deformed at all; After welding, it is still in the scope of the original rack. No defects such as slag inclusion, pores and cracks are found after processing; it has been proved to be very effective through application; it has reached the technical requirements of equipment.
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