【摘要】：本文針對當(dāng)前砂型鑄造球磨機襯板存在收縮缺陷、組織粗大、使用壽命較短的問題,提出了以液態(tài)模鍛工藝制造襯板的技術(shù)思路,研究了典型襯板材料組織性能特點,并設(shè)計了成套液鍛襯板技術(shù)方案。首先,選取球磨機襯板的兩種典型材料中低合金耐磨鋼ZG60Cr4MnMoCu和高錳鋼改進材料ZGMn1 3Cr2,利用SEM、EDS、XRD、MLD-10B沖擊磨料磨損試驗機及其他檢測設(shè)備,研究了液態(tài)模鍛球磨機襯板材料的組織、耐磨性及其他力學(xué)性能的特點,得到了比壓對液態(tài)模鍛球磨機襯板材料組織與性能的影響規(guī)律,分析了與砂型、金屬型重力鑄造相比,液態(tài)模鍛球磨機襯板的極大優(yōu)越性。其次,進行了球磨機襯板液態(tài)模鍛工藝方案設(shè)計,得到了成套液鍛球磨機襯板工藝,設(shè)計了一套專用液鍛模具、一臺液態(tài)模鍛機以及液鍛球磨機襯板生產(chǎn)所需相關(guān)附屬設(shè)備。最后,利用PROCAST對液鍛球磨機襯板工藝進行了數(shù)值模擬和虛擬正交試驗,利用ANSYS對液鍛球磨機襯板模具進行了校核和優(yōu)化。得到的主要結(jié)論如下:(1)液態(tài)模鍛ZG60Cr4MnMoCu的沖擊磨料磨損耐磨性明顯優(yōu)于金屬型重力鑄造,其磨損速率僅為金屬型鑄造的74%。液態(tài)模鍛ZG60Cr4MnMoCu的耐磨性隨比壓的增大呈非線性規(guī)律增加,當(dāng)比壓較低時,隨著比壓增大,抗磨性顯著提高;當(dāng)比壓高于130MPa后,再提高比壓,抗磨性提高不明顯;(2)液態(tài)模鍛ZG60Cr4MnMOCu磨損機理為一開始以粘著磨損、磨料磨損為主,然后逐漸發(fā)展成只有磨料磨損為主,最后發(fā)展成磨料磨損和表面疲勞磨損共同存在、相互促進的過程;(3)鑄態(tài)時,液態(tài)模鍛ZGMn13Cr2試樣耐磨性比砂型鑄造試樣提高14.8%,比金屬型鑄造試樣提高15.3%;經(jīng)熱處理后,液態(tài)模鍛試樣耐磨性比砂型鑄造試樣提高8%,比金屬型鑄造試樣提高14.8%;(4)比壓對于改善ZGMn13Cr2晶粒尺寸有顯著作用。比壓越大,晶粒越細,但是隨著比壓增大,細化作用將逐漸減弱,當(dāng)比壓增大到228MPa時,繼續(xù)增大比壓將不會繼續(xù)細化晶粒;(5)比壓對于碳化物析出有抑制作用,比壓越大,析出碳化物越細越少。比壓能夠改變析出碳化物類型,當(dāng)比壓增大到140MPa后,M3C碳化物將不再出現(xiàn),此時只出現(xiàn)M7C3碳化物,主要分布在晶界;(6)球磨機襯板液態(tài)模鍛的澆注方案為有擋渣功能的翻轉(zhuǎn)包+流槽過濾網(wǎng)+圓形緩沖澆注室,加壓方案為主缸加壓鎖模+下缸和補壓缸局部增壓補縮,出件方案為下壓頭帶動頂桿快速出件;(7)經(jīng)過虛擬正交試驗得出,球磨機襯板液態(tài)模鍛生產(chǎn)最優(yōu)工藝參數(shù)為補壓壓頭比壓230MPa,充型速度46.167mm/s,澆注溫度1500℃,模具預(yù)熱溫度600℃。通過對兩種典型的球磨機襯板材料的組織性能研究,證明了用液態(tài)模鍛工藝制造球磨機襯板在提高其耐磨性和減少凝固缺陷、延長使用壽命方面的巨大優(yōu)勢。同時通過對球磨機襯板的工藝方案設(shè)計和數(shù)值模擬分析,明確了球磨機襯板液態(tài)模鍛技術(shù)方案是切實可行的,擴大了液態(tài)模鍛工藝在黑色金屬產(chǎn)品的應(yīng)用范圍,對于推廣液態(tài)模鍛在工業(yè)生產(chǎn)中的運用起到了一定的積極作用。
[Abstract]:Aiming at the problems of shrinkage defect, coarse structure and short service life of lining plate of sand mold casting ball mill at present, this paper puts forward the technical thought of manufacturing lining plate by liquid forging technology, studies the characteristics of typical lining material and designs a set of technical scheme of liquid forging lining plate. Firstly, two typical lining plates of ball mill are selected. ZG60Cr4MnMoCu and ZGMn1 3Cr2 were used to study the microstructure, wear resistance and other mechanical properties of the lining material of liquid die forging ball mill. The effect of specific pressure on the structure and properties of the lining material of liquid die forging ball mill were obtained by means of SEM, EDS, XRD, MLD-10B impact abrasive wear tester and other testing equipment. Secondly, the design of the lining plate of the ball mill by liquid forging is carried out, and the lining plate technology of the ball mill by liquid forging is obtained. A set of special liquid forging die, a liquid forging machine and the lining of the ball mill by liquid forging are designed. Finally, the numerical simulation and virtual orthogonal test of the lining plate technology of the liquid forging ball mill are carried out by using PROCAST. The lining plate die of the liquid forging ball mill is checked and optimized by using ANSYS. The main conclusions are as follows: (1) The impact abrasive wear resistance of the liquid forging ZG60Cr4MnMoCu is obviously better than that of the metal. The wear rate of mold gravity casting is only 74% of that of metal mold casting. The wear resistance of liquid die forging ZG60Cr4MnMoCu increases nonlinearly with the increase of specific pressure. When the specific pressure is low, the wear resistance increases significantly with the increase of specific pressure; when the specific pressure is higher than 130MPa, the wear resistance of liquid die forging ZG60Cr4MnMOCu increases slightly with the increase of specific pressure. The wear resistance of liquid die forged ZGMn13Cr2 specimens is 14.8% higher than that of sand mold cast specimens and 15.3% higher than that of metal mold cast specimens. After heat treatment, the wear resistance of liquid die forging sample is 8% higher than that of sand casting sample and 14.8% higher than that of metal casting sample. (4) Specific pressure has significant effect on improving the grain size of ZGMn13Cr2. The specific pressure can change the type of carbide precipitated, when the specific pressure increases to 140 MPa, M3C carbide will not appear, at this time only M7C3 carbide, mainly distributed in the grain boundary; (6) ball mill liner liquid die forging pouring square The case is a turning-over package with slag-stopping function, a flow channel filter net and a circular buffer pouring chamber. The pressurization scheme is a main cylinder pressurized die-locking, a lower cylinder and a supplementary cylinder pressurized and fed, and the output scheme is a lower pressure head driven the rapid ejection of the ejector rod. (7) Through the virtual orthogonal test, the optimum technological parameter of the liquid die forging production of the ball mill liner is the specific pressure of the supplementary pressure head 2. 30 MPa, filling speed 46.167 mm/s, pouring temperature 1500 C, mold preheating temperature 600 C. By studying the microstructure and properties of two typical ball mill liner materials, it is proved that the liquid die forging process has great advantages in improving its wear resistance, reducing solidification defects and prolonging its service life. The process scheme design and numerical simulation analysis of the liner show that the liquid forging technology scheme of the liner plate of the ball mill is feasible, and the application range of the liquid forging technology in ferrous metal products is enlarged.
【學(xué)位授予單位】：北京交通大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG242;TG316.3

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