基于热喷涂的轴类零件再制造工艺及其残余应力分析

Analysis of Remanufacturing Process and Residual Stress of Axis Parts Based on Thermal Spraying

热喷涂技术是再制造工程的关键支撑技术之一,是实现损伤零部件表面尺寸快速恢复、性能大幅提升以及服役寿命延长的重要技术手段。热喷涂制备的涂层系统内过大的残余应力对再制造零件的质量和可靠性有着重要的影响。以某废旧滚齿机主轴为例,采用等离子喷涂技术对磨损的外锥面进行了修复,基于有限元法对涂层/基体系统在冷却过程中产生的残余应力及其分布情况进行了分析和预测,并用X射线衍射法检测验证了所建立的分析模型的合理性以及模拟结果的可信度。涂层系统残余应力的模拟结果和检测结果具有很好的一致性。

As one of the key supporting technologies of remanufacturing engineering,thermal spraying was an important technical means to achieve surface size recovered rapidly,to improve performance significantly and to extend service life of the damaged parts.But the excessive residual stresses in the coating system had an important influence on the quality and reliability of remanufactured parts.A case of used hobbing machine spindle was analyzed,and air plasma spraying was adopted to remanufacture the abraded outer taper surface.The residual stresses generated in coating/substrate system during the cooling process and also the distribution were simulated by using finite element method,and Xray diffraction method was applied to verify the rationality of the established model and the credibility of the simulation results.Simulation results have good consistency with the test ones.