工序号 Number | 工序内容 Process | 相关照片 Photos | 检测设备 Test |
1-1 | 检查工件表面是否有震纹，斜纹，磕碰、砂眼、孔洞等。 Check whether the roll surface has shock, twill, bump, sand hole, hole, etc. |
| 目测 Visual measurement |
1-2 | 检查工件尺寸等是否符合技术要求？ Check whether the size of the roll meets the technical requirements in drawing? |
| 卡尺、外径千分尺 Calipers and Micrometer |
工序号
| 工序内容 Process | 相关照片 Photos | 检测设备 TEST |
2-1 | 1.工件吊装至专用旋转工装上，进行除湿去油处理。 2.除湿时工件必须旋转进行。 1. Lift the roll to the special rotary tooling for dehumidification and oil removal. 2. The roll must be rotated during dehumidification. 设备型号 ；JP5000不送粉 | ||
2-2 | 工件转数 ；:查转速表 烘烤时间； 自动走一个来回 烘烤温度；去除水份，表面干燥。 清洗剂种类；专用清洗剂 Revolution: check the tachometer Baking time: automatic walk back and forth Baking temperature: remove moisture and dry the surface. Cleaning agent type: special cleaning agent |
序号
| 工序内容 Process | 相关照片 Photos | 检测设备 TEST |
3-1 |
喷砂使用的空气由压缩机出来需要经过冷凝器与滤清器过滤。每次使用前需用白纸进行检测（方法：压缩空气对白纸吹1分钟，距离100~150mm，观察是否有水分或油污）。
| The air used for sandblasting is filtered by condenser and filter when it comes out of compressor. White paper shall be used for detection before each use. The method is as follows: blow white paper with compressed air for 1 minute, with a distance of 100-150 mm, and observe whether there is water or oil stain. | |
3-2 | 喷砂设备：压力式全自动喷砂机 喷枪：1把 喷砂角度：60°-90°
喷嘴直径：6-7㎜ 喷枪距离：200-250㎜ 喷砂空气压力0.45~0.75Mpa。
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Sandblasting equipment: pressure type automatic sandblasting machine Spray gun: 1 Sandblasting angle: 60 ° - 90 ° Sandblasting material: white corundum Nozzle diameter: 6-7mm Spray gun distance: 200-250mm Sand blasting air pressure is 0.45 ~ 0.75mpa
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3-3 |
喷砂后的检验： 1. 使用压缩空气吹干净工件表面。 2. 喷砂后表面清洁度达到ISO 8501 Sa3。 3. 按照技术要求使用粗糙度仪进行测量，满足辊面成品决定粗糙度大小。 Inspection after sandblasting: 1. Use compressed air to blow clean the workpiece surface. 2. The surface cleanliness after sandblasting shall reach ISO 8501 SA3. 3. Use roughness meter to measure according to the technical requirements, to meet the requirement that the roughness of the finished roll surface is determined. |
| ISO 8501 Sa3 清洁度图片 粗糙度仪 Roughness tester |
序号
| 工序内容 Process | 相关照片 Photos | 检测设备 TEST |
5-1 | 1.喷涂后的辊筒吊装至专用大型抛磨机床上进行去峰处理。 2.抛加工时必须使用专用抛光带进行处理。 3.满足图纸粗糙度要求。 4.进行粗糙度的测量及记录。
| 1. After spraying, the roller is hoisted to the special large grinding machine for peak removal. 2. Special polishing belt must be used for polishing. 3. Meet the roughness requirements of drawings. 4. Measure and record the roughness. | 千分表、粗糙度仪 Dial indicator and Roughness tester |
5-2 |
粗糙度仪型号： Roughness tester: MITUTOYO SJ-301 | |
5-3 | 喷涂完成后，必须确保涂层面无污染。 采用专用封孔剂对无污染的涂层面进行封孔处理。 待漆膜干固后进行二次封孔处理。 After spraying, the coating surface must be free of contamination. Special sealing agent is used to seal the non polluted coating surface. After the paint film is dry and solid, the secondary hole sealing treatment shall be carried out. | | 目测 VM |
序号 6 | 工序内容
| 相关照片
| 检测设备
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6-1 | 1.采用专用包覆材料对已检测合格的辊筒进行包装。 2.包装好的辊筒堆放时必须有摆放在防震垫上。 3.工件必须离地存放，不得存放在有潮湿以及腐蚀液体的环境下。 1. The qualified roller shall be packed with special wrapping materials. 2. The packed roller must be placed on the shockproof pad when stacking. 3. the workpieces must be stored off the ground, and shall not be stored in the environment with damp and corrosive liquid. |
| 目测 VM |
6-2 | 张贴所需的合格标识。 Post the required qualification mark | Finished |
辊子喷涂碳化钨操作流程 Operation Flow of Spraying Tungsten Carbide on Rollers YATAI |
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辊子图号 Drawing No. | XXXX | 零件名称 Roll Name | 镀锌钢板辊 Roll |
喷涂设备 Spraying Equipment | 进口普莱克斯 PRAXAIR from America | 设备型号 Equipment Model | JP-5000 |
热喷涂类型Spraying type | 超音速喷涂Supersonic spraying | 技术负责technician | 陈国利 Chen Guoli |
序号
| 工序内容 Process | 相关照片 Photos | 检测设备 TEST |
4-1 | 喷涂必须在前道工序结束后2小时内完成，如超出2小时后还未喷涂，工件必须重新喷砂处理。 The spraying must be completed within 2 hours after the end of the previous process. If the spraying is not finished after 2 hours, the roll srface must be sandblasted again. |
| 时钟 Clock |
4-2 | 喷涂前使用压缩空气吹干净工件表面Use compressed air to blow the surface of roll before spraying.
| 目测 VM | |
4-3 | 1.材料种类：根据图纸要求选用材料 Material for spraying: Praxair 1375/H.C STARCK558 or H.C STARCK 519 2.材料规格：Size 15-53μm | 目测 VM | |
4-4 | 超音速喷涂参数： Supersonic spraying parameters 设备型号Unit type：JP5000 载气量Air carrying capacity：29 氧气量Oxygen quantity：1950 煤油量Kerosene quantity：6-6.2 喷涂距离distance:300-350mm 送粉powder feeding rate：65g/min |
| 超音速喷涂设备（JP-5000） HVOF spraying equipment（JP-5000） |
4-5 | 1.使用美国普莱克斯公司生产的JP-5000喷涂设备操作施工。 2.喷涂前再次检查喷涂工装是否安装到位。 3.按规定喷涂参数进行施工。 4.喷涂结束后使用压缩空气对工件表面进行清理，去除残留的灰尘（辊筒两端点焊配带试块留备用和检测专用）。 1. Use jp-5000 spraying equipment produced by Praxair company to operate and construct. 2. Check whether the spraying tooling is installed in place again before spraying. 3. Carry out the construction according to the specified spraying parameters. 4. After spraying, use compressed air to clean the surface of the roll and remove the residual dust (spot welding at both ends of the roller with test block reserved for standby and testing) | | |
4-6 | 涂层检验： 1.涂层厚度要求：根据图纸用测厚仪检测。2.涂层表面无飞溅物、无剥落、无开裂。3.涂层厚度均匀。 Coating inspection: 1. Coating thickness requirements: test with thickness gauge according to the drawing. 2. The coating surface shall be free of splashes, peeling and cracking. 3. The coating thickness is uniform. |
| 北京时代T200涂层测厚仪 thickness meter |
