2Broken joint repair of broken parts 2.1 Full-adhesive coating repair method 1 Scope of application For cast iron and cast aluminum alloy shell parts with less stress during work, such as the body of textile equipment, gearbox box, cylinder Cracks, perforations, chipping and corrosion at the cover and the like can be directly repaired by the adhesive method.
2 open V-groove repair process 1-crack; 2r crack-stop hole; V-groove; 4-adhesive.
The crack on the side wall of the diesel engine is taken as an example. The crack on the side of the diesel engine is as an example: the crack length is only 100 mm, and the crack is not long and vertical. Although the part is subjected to a certain load, the stress of the crack is not large. The repairing process is as follows: the crack holes are drilled at both ends of the crack to prevent the crack from further expanding, and the diameter of the crack hole is 3 mm to 5 mm; the V-shaped groove is cut along the crack by a narrow hole, and the length exceeds 5 mm to 10 mm at both ends of the crack, and the depth is regarded as The thickness of the part is determined; the JW-1 epoxy repair adhesive is used to fill the V-groove, and after being fully cured, the surface is trimmed with a trowel and an abrasive cloth.
2.2 Auxiliary reinforcement bonding repair method 1 Scope of application Auxiliary reinforcement bonding repair method is suitable for medium-sized mechanical equipment with a load of about 1.0MPa, such as cracks of various large and medium-sized power machinery, textile machinery cylinders, cylinder heads, beds, etc. , cracked and so on. If it is difficult to ensure the strength requirement by using full-adhesive repair, it is necessary to use an auxiliary reinforcement bonding repair method that combines the cement and some strengthening measures. Commonly used strengthening measures include: reinforced steel plates, metal horse nails, metal wave keys and planted wire mesh. Among these strengthening measures, some are through the bonding area, and some are directly repaired by mechanical connection.
2.2.2 Repair process Initially clean damaged parts, and determine auxiliary reinforcement measures according to the work and stress conditions of the parts. If nail metal nails are used, in addition to the bonding effect of the cement, the mechanical effect of the metal horse nails is used to achieve the repairing effect. The material of the metal horse nail is generally 35~45 steel, the structural size of the round horse nail is seen; the metal horse nail carefully cleans the glue joint, removes oil and performs surface chemical treatment; 2.2.3 repair example due to accident, a certain ship empty Serious cracking occurred on the upper, lower and right side of the press body, which was the damage on the right side. According to the damage, the adhesive is repaired with metal horse nails and glass fiber cloth. The adhesive is made of SW-2 epoxy structural adhesive. After repairing by the above method, the body has been working normally.
1-crack; 2-metal clasp.
The wavy key glue-bonding repair method combines the adhesive with a wavy key made of a high-strength alloy material with a special shape to improve the repair strength.
1 Scope of application ~45mm, repair of cracks and fractures of parts with force below 3MPa. For example, the repair of the cylinder block of a power machine, the casing of a large electric motor, the lathe, and the frame of a press.
2 repair process design to create the shape and size of the wave bond wave button. Flange size d=(1.4~1.6)b flange spacing/=(2~2.2)b, flange thickness t=(1.0~1.2)b. The neck width b of the wave bond is based on the size of the repairing mechanism. Whether the installation possibility and the riveting are convenient or not, generally b=3mm~6mm. The number of flanges of the wave key is generally 5, 7, and 9. In use, the number of flanges should be arranged, so that the machine can be improved. The force of the piece. The material of the wave key is generally selected from low-carbon chrome-nickel stainless steel such as 0Ci.18Ni9, 1Ci.18Ni9Ti, and the steel has good plasticity, and the tensile strength is greatly improved after the riveting and strengthening; the wave key size is designed and processed. There are two main parameters: the groove depth T and the matching clearance with the wave key 5 - T = 2 / 3h, H is the wall thickness of the repair area of ​​the machine; b0.1mm, cleaning the wave keys and the burrs of the wave groove, Oil and oxide layers, then apply a well-adhesive adhesive around the wave bond into the wave groove. Then use a small wind wheel for riveting. After the first wave button is flattened and riveted, continue to embed and rive the second piece in the same way... After each layer is riveted, the chip is removed. The last layer of wave bond riveting should be slightly lower than the plane of the workpiece, and then the groove is filled with adhesive. After the adhesive is completely cured, the surface is ground with a small pneumatic wheel.
2.3.3 Repair example Deep 10mm crack, due to the huge impact load when punching work, the general full glue or auxiliary reinforcement glue can not guarantee the strength requirement. The wave bond is used in the construction to repair and repair. It has been used for more than ten years.
1-crack; 2-strength block; - skin wave bond; 4-stop hole.
2.4 Strengthening the block glue buckle legal reinforcement of the block glue buckle The essence of the law is: machining a certain shape of the cavity in the direction perpendicular to the crack or the fracture section, embedding the high-strength alloy steel block of the corresponding depth and shape , so that the load can be distributed to a larger area and away from cracks and breaks to ensure the quality of repair.
2.4.1 Scope of application For parts with a heavy load wall thickness exceeding 30 mm during operation, such as the bed of a large press, the beam of a hydraulic press, and the main frame of a rolling mill. If the wavy key glue is used only to obtain a reliable repair quality, the reinforcement block glue buckle must be applied as shown.
2.4.2 Design of the reinforcement block The shape of the reinforcement block is designed according to the damaged parts and stress conditions of the machine. The reinforcement blocks of different shapes and sizes are generally used, which are generally rectangular or semi-circular. The material of the reinforcement block is generally selected from 40Cr high-strength alloy inlaid wave keys. Before the wave bond is set, the steel should be carefully cleaned; 1-crack; 2-short pin; 3-rectangular reinforcement block; 4-thick-walled machine.
The processing of the reinforcement block pressing reinforcement block is first drawn on the blank according to the shape of the designed reinforcement block, and then the blank is placed on the part to be repaired, pressed by the pressure plate, drilled at the four corners, and inserted into the positioning pin, and then pressed Draw all the embossed bolt holes. Remove the blank and mill the excess metal by the centerline of the stitching.
Short-sleeve pins with short stitches are made of the same material as the wave keys, such as low-carbon nickel stainless steel such as 1Cr18Ni9, because these materials are easy to rive. The short cylindrical pin size can not be too long, generally 8mm in diameter and 5mm in length, otherwise it is not easy to rive, and the combination is not good.
2.5 Repair of the damaged parts after the damage of the parts 2.5.1 Repair of the broken shaft Drill the matching hole and the exhaust hole at one end of the broken shaft, and the other end of the vehicle with the shaft that fits the hole. The clearance between the journal and the hole is 0.1mm. ~0.2mm, select phosphoric acid-copper oxide inorganic adhesive, see if the length can not be shortened after the broken shaft is repaired, the matching hole and the vent hole can be drilled at both ends of the broken shaft, and another mandrel is used to glue them together. See (b) together; to ensure the length of the shaft, the two ends of the shaft can be small, and then a metal ring is used to bond them together with an adhesive. Finally, the whole shaft is smashed, and the repaired shaft is perfect. For the whole, see (c); if the outer circle of the broken shaft does not match other parts, and does not hinder the appearance and work, a jacket can be prepared at the broken shaft and bonded with an adhesive. This repair is the simplest but the appearance is uneven, see (d).
2.5.2 Broken drill repair is generally repaired with an external steel sleeve. The broken glass fiber and the adhesive are mixed and filled in the cutting groove, and the broken drill which is repaired by the glue is rarely found to have looseness in the bonding part during use, and even if the force is too large and broken, the film portion is not loosened. This fully demonstrates the reliability of the bonding technology (see).
1-glued cullet; 2-break; 3-sleeve.
Drill-repair repair uses a jacket to repair broken drills. Although the process is simple, it affects chip removal during cutting and cannot drill deep holes.
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