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Precision GCr15, Hard Chrome Plated, HRC55-63 Textile Conveyor Shaft Assemblies
Header include
This process describes a complete manufacturing solution for the key moving parts of textile machinery - the conveyor shaft and its assembly of complete sets of products. It takes GCr15 bearing steel as the base material and, through precision mechanical processing, high-frequency surface quenching (HRC55-63), and functional hard chromium plating surface treatment, ultimately achieves the technical requirement of a working surface roughness of Ra0.4. The core lies in integrating the core toughness of the material, extremely high surface hardness and wear resistance, excellent anti-corrosion and low friction properties, aiming to meet the requirements of textile equipment for the ultra-long service life and operational stability of transmission components under high-speed, continuous, high-load and certain temperature and humidity environments.
ManufacturingObjects
This object specifically refers to the core precision shaft components in the textile industry (such as carding machines, roving machines, looms, etc.) that undertake the functions of conveying, pulling and tensioning yarns or fabrics. It is not only an independent transmission shaft, but usually also includes bearing positions, gear installation positions, threaded connection parts and key fiber contact working surfaces that precisely fit with it. As a complete set of products, it needs to work in coordination with bearings, seals, etc. Its performance directly determines the production efficiency of textile equipment, product quality (such as reducing yarn fuzz and breakage rate) and maintenance cycle.
Core features and requirements
The core features of this type of product are the combination of "rigidity and flexibility" and "refinement both inside and out". The specific requirements are as follows: Firstly, the material GCr15 needs to achieve a scientific performance gradient distribution through heat treatment, that is, the core should maintain good strength and toughness to withstand torsional loads, while the working surface should have extremely high hardness (HRC55-63) to resist the long-term wear of fibers and micro-friction. Secondly, the hard chromium plating layer not only needs to further enhance the surface wear resistance and anti-corrosion ability, but also must ensure a firm bond with the substrate and no risk of peeling. Finally, all key mating surfaces and working surfaces (especially the areas in direct contact with the fibers) must achieve a smoothness of Ra0.4 to minimize running resistance and prevent fiber adhesion and dust accumulation. The entire component requires extremely high dimensional stability and positional accuracy to ensure dynamic balance during high-speed operation.
Key processes and technologies
To achieve the above requirements, a rigorous and orderly composite process chain is needed:
1、Precision matrix processing: Firstly, rough machining and quenching and tempering pretreatment are carried out on GCr15 steel to lay the microstructure foundation for subsequent quenching. Leave a reasonable allowance after semi-finishing.
2、Selective heat treatment: The key technology of high-frequency induction hardening is adopted. By precisely controlling the parameters of the induction coil and the scanning speed, the shaft surface (especially the working surface) is rapidly heated and immediately quenched to obtain a martensitic hardened layer of a predetermined depth and high hardness, while the microstructure and properties of the core remain basically unchanged. Subsequently, low-temperature tempering is carried out to stabilize the structure and relieve stress.
3、Finishing and superfinishing: After heat treatment, the slight deformations produced are finely ground to restore dimensional and positional accuracy. Then, through precise grinding or polishing processes, the key surface roughness is increased to Ra0.4.
4、Surface strengthening treatment: Electroplating hard chromium on the surface that meets the requirements of size and smoothness. Strictly control the composition of the plating solution, current density and temperature to ensure that the chromium layer is dense and uniform, with a thickness usually ranging from 0.01 to 0.03mm and a hardness of over HV800. Low-temperature dehydrogenation treatment may be required after plating to prevent hydrogen embrittlement.
5、Integration and Inspection: 100% inspection is conducted on all finished product dimensions, hardness gradients (which can be tested by combining Rockwell and Vickers hardness testers), coating adhesion, and surface roughness to ensure that they meet assembly and usage requirements as complete sets of products.
Conclusion
In conclusion, the manufacturing of high-wear-resistant conveyor shaft components in the textile industry is a systematic technology that integrates materials science, heat treatment engineering and surface engineering. Through a series of interlocking processes including "precision machining - selective high-frequency quenching - ultra-fine surface finishing - functional electroplating", excellent comprehensive mechanical properties and surface characteristics have been successfully integrated on a single part. This product not only demonstrates a profound understanding and response to the extreme working conditions of textile machinery, but also represents a classic example of traditional mechanical manufacturing achieving high performance, high reliability and long service life of key components through compound process innovation. It is an important cornerstone for ensuring the efficient and high-quality operation of modern textile industry.
Precision GCr15, Hard Chrome Plated, HRC55-63 Textile Conveyor Shaft Assemblies
Header include
This process describes a complete manufacturing solution for the key moving parts of textile machinery - the conveyor shaft and its assembly of complete sets of products. It takes GCr15 bearing steel as the base material and, through precision mechanical processing, high-frequency surface quenching (HRC55-63), and functional hard chromium plating surface treatment, ultimately achieves the technical requirement of a working surface roughness of Ra0.4. The core lies in integrating the core toughness of the material, extremely high surface hardness and wear resistance, excellent anti-corrosion and low friction properties, aiming to meet the requirements of textile equipment for the ultra-long service life and operational stability of transmission components under high-speed, continuous, high-load and certain temperature and humidity environments.
ManufacturingObjects
This object specifically refers to the core precision shaft components in the textile industry (such as carding machines, roving machines, looms, etc.) that undertake the functions of conveying, pulling and tensioning yarns or fabrics. It is not only an independent transmission shaft, but usually also includes bearing positions, gear installation positions, threaded connection parts and key fiber contact working surfaces that precisely fit with it. As a complete set of products, it needs to work in coordination with bearings, seals, etc. Its performance directly determines the production efficiency of textile equipment, product quality (such as reducing yarn fuzz and breakage rate) and maintenance cycle.
Core features and requirements
The core features of this type of product are the combination of "rigidity and flexibility" and "refinement both inside and out". The specific requirements are as follows: Firstly, the material GCr15 needs to achieve a scientific performance gradient distribution through heat treatment, that is, the core should maintain good strength and toughness to withstand torsional loads, while the working surface should have extremely high hardness (HRC55-63) to resist the long-term wear of fibers and micro-friction. Secondly, the hard chromium plating layer not only needs to further enhance the surface wear resistance and anti-corrosion ability, but also must ensure a firm bond with the substrate and no risk of peeling. Finally, all key mating surfaces and working surfaces (especially the areas in direct contact with the fibers) must achieve a smoothness of Ra0.4 to minimize running resistance and prevent fiber adhesion and dust accumulation. The entire component requires extremely high dimensional stability and positional accuracy to ensure dynamic balance during high-speed operation.
Key processes and technologies
To achieve the above requirements, a rigorous and orderly composite process chain is needed:
1、Precision matrix processing: Firstly, rough machining and quenching and tempering pretreatment are carried out on GCr15 steel to lay the microstructure foundation for subsequent quenching. Leave a reasonable allowance after semi-finishing.
2、Selective heat treatment: The key technology of high-frequency induction hardening is adopted. By precisely controlling the parameters of the induction coil and the scanning speed, the shaft surface (especially the working surface) is rapidly heated and immediately quenched to obtain a martensitic hardened layer of a predetermined depth and high hardness, while the microstructure and properties of the core remain basically unchanged. Subsequently, low-temperature tempering is carried out to stabilize the structure and relieve stress.
3、Finishing and superfinishing: After heat treatment, the slight deformations produced are finely ground to restore dimensional and positional accuracy. Then, through precise grinding or polishing processes, the key surface roughness is increased to Ra0.4.
4、Surface strengthening treatment: Electroplating hard chromium on the surface that meets the requirements of size and smoothness. Strictly control the composition of the plating solution, current density and temperature to ensure that the chromium layer is dense and uniform, with a thickness usually ranging from 0.01 to 0.03mm and a hardness of over HV800. Low-temperature dehydrogenation treatment may be required after plating to prevent hydrogen embrittlement.
5、Integration and Inspection: 100% inspection is conducted on all finished product dimensions, hardness gradients (which can be tested by combining Rockwell and Vickers hardness testers), coating adhesion, and surface roughness to ensure that they meet assembly and usage requirements as complete sets of products.
Conclusion
In conclusion, the manufacturing of high-wear-resistant conveyor shaft components in the textile industry is a systematic technology that integrates materials science, heat treatment engineering and surface engineering. Through a series of interlocking processes including "precision machining - selective high-frequency quenching - ultra-fine surface finishing - functional electroplating", excellent comprehensive mechanical properties and surface characteristics have been successfully integrated on a single part. This product not only demonstrates a profound understanding and response to the extreme working conditions of textile machinery, but also represents a classic example of traditional mechanical manufacturing achieving high performance, high reliability and long service life of key components through compound process innovation. It is an important cornerstone for ensuring the efficient and high-quality operation of modern textile industry.
