The heat treatment energy saving aspect is mainly composed of several factors:
1): Whether the heat treatment process is effective to allow the processed workpiece to meet the technical requirements of its design, and at a lower cost.
2): Whether the heat treatment equipment has been effectively and reasonably used in operation, such as continuous production, and the equipment waiting time is reduced. There is no additional heat loss.
3): Heat treatment operators, process technicians, and production management personnel are well communicated, and everyone can be effectively managed and organized.
1. Heat treatment process
In the traditional process calculation time: T = K * A * D in the T is the heating time, K is the furnace loading coefficient, A is the heating coefficient, D is the effective thickness of the workpiece, in fact, in actual production, generally based on past work The experience and the effective thickness of the workpiece to calculate the holding time, in large quantities based on actual experience or to observe the fire color of the workpiece, which is mainly reflected in carbon steel and low alloy steel, because carbon steel has no alloying elements and carbides. It does not need to keep the austenitizing process for a long time. Low alloy steel has a heat transfer coefficient similar to that of carbon steel, so the heat transfer time of the workpiece is mainly determined by its effective size. For a single piece of workpiece in production, when the furnace temperature has reached the process setting value, When the surface of the workpiece has reached the process temperature value, the workpiece has been sterilized. Do not add additional insulation time. This is what we often call “zero†insulation heating. For mass production, we generally heat the furnace first, then put it into the workpiece after the temperature is reached, and when the furnace temperature reaches the process time again, add a certain homogenization time, which can shorten the process cycle relatively, save energy and reduce cost.
Alloy structural steel (40Cr, 35CrMo, 42CrMo), etc., because some alloying elements are added to the material, it takes a certain time to homogenize the carbide during the heating process, so it takes a little more time than carbon steel. Generally, it should be about 60%-80% of the traditional process time. This can shorten the heating time of the steel at high temperature, and the deformation amount is also relatively reduced. The austenite grains are relatively small, and the fine horse can be obtained after quenching. The mechanical properties of the body structure are also improved, which is what the heat treatment workers want to achieve.
2, the parts are loaded
1): In actual production, when the number of workpieces is limited, it is not cost-effective to arrange the furnaces separately. In this case, different workpieces and different materials can be mixed under the same process parameters. Install a furnace, such as Cr12MoV and 8407 or H13, 40Cr and 42CrMo are the same. The quenching temperature is about the same, so that the furnace capacity can be satisfied. Similarly, when the tempering temperature is the same, different parts and different materials can be mixed together, and the tempering time can be based on the longest tempering time. carried out.
2): Heat treatment fixtures, many products are not nearly the same, but the amount is not a lot, but in order to reduce the amount of deformation, sometimes in the heat treatment tooling, many times do not use heat-resistant stainless steel, most have ordinary low-carbon steel instead, mainly materials The price is low, and there are not many.
3. Heat treatment cooling medium
Many mechanical parts are alloy structural steels. Therefore, when considering the quenching medium, the aqueous solution is selected. When the aqueous solution is quenched, the hardness of the large-diameter medium-carbon low-alloy steel may not be reached in the heat treatment, and the water quenching is easy to crack. The water-soluble synthetic quenching liquid is especially suitable for low- and medium-carbon steel induction and large-piece quenching. The water-soluble synthetic quenching liquid is especially suitable for low- and medium-carbon steel induction and large-piece quenching. Different cooling rates can be obtained by adjusting the concentration. The quenched workpiece is bright and has a short-term anti-rust effect. It can be directly tempered without cleaning, and there is no soot. No fumes, no burning, no fire hazard, improve the working environment. It is not easy to age, deteriorate, and has a long service life, compared to oil. The cost is also relatively small.
4, tempering process
The tempering process is to determine the residual heat of the furnace to be used according to the tempering temperature of the part. The general rule is that the tempering temperature of the part is lower than the residual heat temperature of the furnace by about 300 degrees, so that the furnace quickly reaches the tempering process temperature after the workpiece is placed in the furnace. The fixed value, as well as multiple tempering is better than a tempering, so in the mass production, the second tempering results in better tissue performance than a tempering, and the cost is also reduced accordingly.
5, equipment maintenance and maintenance
Regular maintenance of equipment during production should be carried out to check the tightness of the furnace and the door. The instrumentation and instrumentation related to the distribution box should be regularly calibrated and maintained to reduce the loss caused by the shutdown caused by the electrical failure. All relevant operating equipment, such as trolleys, maintenance of the vehicle reduces the inconvenience caused by the inconvenience of entering and leaving the furnace.
6. Control of heat treatment quality
In fact, when the workpiece is heat-treated, it is energy-saving. If a workpiece is not subjected to effective and reasonable heat treatment, the time limit of the part will not be long. It is necessary to manufacture new parts to replace the parts in the early stage. It is necessary to eliminate raw materials and machining time, and other related expenses. Effective and reasonable heat treatment can double the service life of the workpiece. Therefore, the quality of the heat treatment can avoid the early failure of the workpiece, and can avoid a series of procedures such as heat treatment of the workpiece (normalizing, re-quenching, correcting, de-stressing and tempering).
1): Whether the heat treatment process is effective to allow the processed workpiece to meet the technical requirements of its design, and at a lower cost.
2): Whether the heat treatment equipment has been effectively and reasonably used in operation, such as continuous production, and the equipment waiting time is reduced. There is no additional heat loss.
3): Heat treatment operators, process technicians, and production management personnel are well communicated, and everyone can be effectively managed and organized.
1. Heat treatment process
In the traditional process calculation time: T = K * A * D in the T is the heating time, K is the furnace loading coefficient, A is the heating coefficient, D is the effective thickness of the workpiece, in fact, in actual production, generally based on past work The experience and the effective thickness of the workpiece to calculate the holding time, in large quantities based on actual experience or to observe the fire color of the workpiece, which is mainly reflected in carbon steel and low alloy steel, because carbon steel has no alloying elements and carbides. It does not need to keep the austenitizing process for a long time. Low alloy steel has a heat transfer coefficient similar to that of carbon steel, so the heat transfer time of the workpiece is mainly determined by its effective size. For a single piece of workpiece in production, when the furnace temperature has reached the process setting value, When the surface of the workpiece has reached the process temperature value, the workpiece has been sterilized. Do not add additional insulation time. This is what we often call “zero†insulation heating. For mass production, we generally heat the furnace first, then put it into the workpiece after the temperature is reached, and when the furnace temperature reaches the process time again, add a certain homogenization time, which can shorten the process cycle relatively, save energy and reduce cost.
Alloy structural steel (40Cr, 35CrMo, 42CrMo), etc., because some alloying elements are added to the material, it takes a certain time to homogenize the carbide during the heating process, so it takes a little more time than carbon steel. Generally, it should be about 60%-80% of the traditional process time. This can shorten the heating time of the steel at high temperature, and the deformation amount is also relatively reduced. The austenite grains are relatively small, and the fine horse can be obtained after quenching. The mechanical properties of the body structure are also improved, which is what the heat treatment workers want to achieve.
2, the parts are loaded
1): In actual production, when the number of workpieces is limited, it is not cost-effective to arrange the furnaces separately. In this case, different workpieces and different materials can be mixed under the same process parameters. Install a furnace, such as Cr12MoV and 8407 or H13, 40Cr and 42CrMo are the same. The quenching temperature is about the same, so that the furnace capacity can be satisfied. Similarly, when the tempering temperature is the same, different parts and different materials can be mixed together, and the tempering time can be based on the longest tempering time. carried out.
2): Heat treatment fixtures, many products are not nearly the same, but the amount is not a lot, but in order to reduce the amount of deformation, sometimes in the heat treatment tooling, many times do not use heat-resistant stainless steel, most have ordinary low-carbon steel instead, mainly materials The price is low, and there are not many.
3. Heat treatment cooling medium
Many mechanical parts are alloy structural steels. Therefore, when considering the quenching medium, the aqueous solution is selected. When the aqueous solution is quenched, the hardness of the large-diameter medium-carbon low-alloy steel may not be reached in the heat treatment, and the water quenching is easy to crack. The water-soluble synthetic quenching liquid is especially suitable for low- and medium-carbon steel induction and large-piece quenching. The water-soluble synthetic quenching liquid is especially suitable for low- and medium-carbon steel induction and large-piece quenching. Different cooling rates can be obtained by adjusting the concentration. The quenched workpiece is bright and has a short-term anti-rust effect. It can be directly tempered without cleaning, and there is no soot. No fumes, no burning, no fire hazard, improve the working environment. It is not easy to age, deteriorate, and has a long service life, compared to oil. The cost is also relatively small.
4, tempering process
The tempering process is to determine the residual heat of the furnace to be used according to the tempering temperature of the part. The general rule is that the tempering temperature of the part is lower than the residual heat temperature of the furnace by about 300 degrees, so that the furnace quickly reaches the tempering process temperature after the workpiece is placed in the furnace. The fixed value, as well as multiple tempering is better than a tempering, so in the mass production, the second tempering results in better tissue performance than a tempering, and the cost is also reduced accordingly.
5, equipment maintenance and maintenance
Regular maintenance of equipment during production should be carried out to check the tightness of the furnace and the door. The instrumentation and instrumentation related to the distribution box should be regularly calibrated and maintained to reduce the loss caused by the shutdown caused by the electrical failure. All relevant operating equipment, such as trolleys, maintenance of the vehicle reduces the inconvenience caused by the inconvenience of entering and leaving the furnace.
6. Control of heat treatment quality
In fact, when the workpiece is heat-treated, it is energy-saving. If a workpiece is not subjected to effective and reasonable heat treatment, the time limit of the part will not be long. It is necessary to manufacture new parts to replace the parts in the early stage. It is necessary to eliminate raw materials and machining time, and other related expenses. Effective and reasonable heat treatment can double the service life of the workpiece. Therefore, the quality of the heat treatment can avoid the early failure of the workpiece, and can avoid a series of procedures such as heat treatment of the workpiece (normalizing, re-quenching, correcting, de-stressing and tempering).
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