高速电弧喷涂再制造曲轴弯曲疲劳寿命及再制造效益评估

Bending Fatigue Life and Remanufacturing Benefit Evaluation of High Velocity Arc Spraying Remanufacturing Crankshaft

摘要:

针对重载汽车发动机曲轴的再制造需求，基于六自由度机器人自动化高速电弧喷涂系统，采用研制的FeNiCrAl涂层及设计的“环形”、“Z”字型喷涂路径对磨损失效曲轴进行了再制造应用。并与采用常规3Cr13涂层性能对比，采用“Z”字形路径喷涂FeNiCrAl涂层后的残余应力状态与新品曲轴表面应力状态分布较为接近。依照国标QC-T637-2000对喷涂再制造后的曲轴进行弯曲疲劳性能考核，实验弯矩在2305.38 N.m，加载系数1.2时，其疲劳寿命通过1×107次，达到国标要求。结果表明：采用研制FeNiCrAl喷涂再制造曲轴弯曲疲劳寿命高于采用常规3Cr13涂层喷涂后曲轴。经济性分析表明：采用FeNiCrAl材料喷涂曲轴消耗的粉芯丝材重量仅为制造新品曲轴所需材料的3%左右，单根曲轴再制造成本相比制造新品下降了93.8%，再制造过程耗时相比制造新品曲轴节省了18%。该技术的节能、节材及环保效果非常明显，应用前景广阔。

Abstract:

According to the demand of remanufacturing engine crankshaft, use the automatic high velocity arc spraying system based on the six degree freedom robot, employed the self-design FeNiCrAl wire and ‘circular’, ‘Z’ spraying path for remanufacturing the worn failure crankshaft. Compared with the conventional 3Cr13 coating performance, the residual stress of FeNiCrAl coating was the agreement of the results with the new crankshaft, the bend fatigue performance of spraying FeNiCrAl coated crankshaft conducted accordance with the national standard QC-T637-2000 (test bending moment was 2305.38 N.m, load factor was 1.2, the fatigue life was exceeded 1×107) meet the demand of national standard. The results show that the bend fatigue of FeNiCrAl coated crankshaft was higher than that sprayed by 3Cr13. The remanufacture benefit show that the weights exhaust of FeNiCrAl spraying cored wire was not less than 3% to that product a new crankshaft. The cost of remanufactured a single crankshaft was fell by 90% compared with products a new one. The remanufacturing process saves time about 18% compared to the manufacture a new one. Therefore, the energy saving and environmental protection of the technology is obvious, and the application prospect is broad.