U.S. patent application number 11/360416 was filed with the patent office on 2006-09-14 for method and device for hardening the inner surface of holes, in mechanical pieces of cast iron of predominantly ferritic matrix.
This patent application is currently assigned to OGNIBENE S.P.A.. Invention is credited to Claudio Ognibene.
Application Number | 20060201590 11/360416 |
Document ID | / |
Family ID | 36570406 |
Filed Date | 2006-09-14 |
United States Patent
Application |
20060201590 |
Kind Code |
A1 |
Ognibene; Claudio |
September 14, 2006 |
Method and device for hardening the inner surface of holes, in
mechanical pieces of cast iron of predominantly ferritic matrix
Abstract
A method and a device for hardening at least one portion of the
inner surface (12) of a hole (11) made in a mechanical piece (10)
of cast iron of predominantly ferritic matrix, comprising the step
of subjecting said portion of the inner surface (12) to the action
of a laser beam (100), until it causes the melting of its surface
layer. In particular, said method comprises the steps of:
projecting the laser beam (100) in axial direction inside the hole
of the piece (10); deviating the laser beam (100) through a
deviator means (4), so that the same is projected onto the inner
surface of the hole itself, causing the melting of a surface layer;
rotating the deviator means (4) or the piece (10) with respect to
each other, and sliding in axial direction the deviator means (4)
or the piece (10) with respect to each other, until the desired
portion of the inner surface (12) is subjected to the laser beam
(100).
Inventors: |
Ognibene; Claudio; (Reggio
Emilia, IT) |
Correspondence
Address: |
BROWDY AND NEIMARK, P.L.L.C.;624 NINTH STREET, NW
SUITE 300
WASHINGTON
DC
20001-5303
US
|
Assignee: |
OGNIBENE S.P.A.
REGGIO EMILIA
IT
|
Family ID: |
36570406 |
Appl. No.: |
11/360416 |
Filed: |
February 24, 2006 |
Current U.S.
Class: |
148/512 ;
148/565 |
Current CPC
Class: |
C21D 5/00 20130101; C21D
1/09 20130101 |
Class at
Publication: |
148/512 ;
148/565 |
International
Class: |
C21D 1/09 20060101
C21D001/09 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 10, 2005 |
IT |
RE2005A000025 |
Claims
1. Method for hardening at least one portion of the inner surface
(12) of a hole (11) made in a mechanical piece (10) of cast iron of
predominantly ferritic matrix, characterised in that it comprises
the step of subjecting said portion of the inner surface (12) to
the action of a laser beam (100), until it causes the melting of
its surface layer.
2. Method according to claim 1, characterised in that it comprises
the steps of: a) projecting a laser beam (100) in axial direction
inside the hole of the piece (10); b) deviating the laser beam
through a deviator means (4) so that the same is projected onto the
inner surface (12) of the hole itself, causing the melting of a
surface layer; c) rotating the deviator means (4) or the piece (10)
with respect to each other; and d) making the deviator means (4) or
the piece (10) slide in axial direction with respect to each other,
until said portion to be treated of the inner surface (12) is
entirely subjected to the laser beam (100).
3. Method according to claim 1, characterised in that the thickness
of the melted layer of cast iron of predominantly ferritic matrix
is less than 0.5 mm.
4. Method according to claim 1, characterised in that the
wavelength of the laser beam (100) is comprised between 800 nm and
950 nm.
5. Method according to claim 1, characterised in that the power of
the laser beam (100) is comprised between 1500 W and 2200 W.
6. Method according to claim 1, characterised in that the focal
distance of the laser beam (100) is comprised between 66 mm and 500
mm.
7. Method according to claim 1, characterised in that the laser
beam (100) generates on the inner surface (12) a rectangular
luminous spot, with sides comprised between 4 mm and 9 mm.
8. Method according to claim 1, characterised in that the laser
beam (100) generates on the inner surface (12) a luminous spot
which moves, relative to said surface (12), at a speed comprised
between 20 mm/s and 40 mm/s.
9. Device for hardening, by means of laser, at least one portion of
the inner surface (12) of a hole (11) made in a mechanical piece
(10) of cast iron of predominantly ferritic matrix, characterised
in that it comprises: a laser source (2) adapted to generate a
laser beam (100), and project it in axial direction inside the hole
(11) of the piece (10); a deviator means (4) of the laser beam
(100) which, associated with said laser source (2), is adapted to
be inserted in the hole (11) of the piece (10), and to deviate the
beam (100), projecting it onto the inner surface (12); and a
support device (5) of the cast iron piece (10); said support device
(5) and deviator means (4) being adapted to rotate with respect to
each other, and to slide in axial direction with respect to each
other, until said portion to be treated of the inner surface (12)
is entirely subjected to the laser beam (100).
10. Device according to claim 9, characterised in that the support
element (5) comprises a rotating mandrel (52) adapted to hold the
piece (10) so that the axis of the hole (11) coincides with the
rotation axis of the mandrel (52) itself, and to set it in rotation
at a predetermined speed.
11. Device according to claim 9, characterised in that the support
element (5) comprises a motorised carrier (50) adapted to slide
with reciprocating motion along a rectilinear direction, so to
engage the piece (10) to slide in the direction defined by the axis
of the hole (11).
12. Device according to claim 9, characterised in that the deviator
means comprises a faceted body (4), provided with a reflecting
surface (40) which is sloped with respect to the direction of the
laser beam (100) leaving the laser source (2).
13. Device according to claim 12, characterised in that the faceted
body (4) is realised in copper.
14. Device according to claim 12, characterised in that the
reflecting surface (40) is made specular by means of polishing.
15. Device according to claim 9, characterised in that it comprises
means adapted to cool the deviator means (4).
16. Device according to claim 9, characterised in that it comprises
means adapted to convey a flow of protective gas which, leaving a
supply nozzle (6), is adapted to hit the deviator means (4) and the
surface (12).
Description
[0001] The present invention generally refers to a method and
device for the hardening of the inner surface of holes made in
mechanical pieces in iron casting, and mechanically worked. It is
known that for manufacturing these pieces, an easily workable cast
iron is employed, such as the cast iron of predominantly ferritic
matrix. More in particular, the invention regards a method and
device intended to be employed in the process of manufacturing pump
bodies of normal fluid pumps, to harden the surfaces of the
cylindrical cavities adapted to define the reception and guide
seats of members in movement, such as sliding pistons or rotors, so
to avoid seizure.
[0002] As is known, the body pumps are realised by means of a
forming process, which foresees pouring a metallic alloy inside
appropriate dies in order to obtain a rough casting. This is then
subsequently subjected to mechanical working, which confers the
necessary precision to predetermined surfaces and in particular to
the above mentioned surfaces intended to be in contact with the
members in movement.
[0003] For these reasons, the metallic alloy utilised in the
manufacture of the pump bodies is, as said, a cast iron of
predominantly ferritic matrix, easily workable in the machine tool,
but little adapted to being subjected to a thermal hardening
treatment.
[0004] The use of the pump at low ambient temperatures may lead to
drawbacks. This occurs when the inner surfaces of the "cold" pump
are struck with hot oil. The difference in mass between the pump
body and the inner members prevents a homogenous dilation of the
system elements, favouring seizure phenomena, which often
irreparably damages the pump itself. Presently, to overcome this
drawback, an anti-seizure surface treatment is used on the surfaces
intended to be in contact, for example a phosphate treatment.
[0005] Nevertheless, the equipping of a phosphate plant is quite
difficult, and moreover leads to a considerable environmental
impact.
[0006] Object of the present invention is, in general, that of
superficially hardening the surfaces of holes made in mechanical
pieces of cast iron of predominantly ferritic matrix and, more in
particular, hardening the surfaces of the cylindrical cavities of
the pump bodies in contact with the members in movement, so to
effectively avoid the onset of seizure phenomena. Further object of
the invention is to obtain a lasting, reliable hardening which may
be realised in a simple, quick and economic manner on a cast iron
which is highly workable by the tool.
[0007] Such objects are achieved, according to the finding, with a
laser treatment of the relevant surfaces, until it causes the
melting of their surface layer. The treatment may be conveniently
localised, i.e. limited to certain surface portions.
[0008] More precisely, the treatment foresees the steps of:
[0009] a) projecting a laser beam in axial direction inside the
hole of the piece in cast iron of predominantly ferritic
matrix;
[0010] b) deviating the laser beam through a deviator means which
is inserted in the hole, so that the same is projected on the inner
surface of the hole itself, causing the surface melting;
[0011] c) rotating the deviator means or the piece with respect to
each other; and
[0012] d) making the deviator means or the piece slide in axial
direction with respect to each other, so to subject at least one
desired portion of said inner surface of the hole;
[0013] In this manner, a thermal treatment of surface melting of
the cast iron is carried out, obtaining a layer with homogenous and
particularly hard structure.
[0014] Indeed, the melting, which involves a very small thickness
of the material, less than 0.5 mm, and the subsequent quick and
spontaneous cooling, due to the great mass of material surrounding
the melted zone, causes a change of phase in the metallic structure
of the cast iron.
[0015] In particular, the carbon present in the form of graphite is
largely dissolved in the melted metal matrix, which is enriched
with carbon and solidifies with predominantly ledeburitic
structure, characterised by high hardness.
[0016] According to the invention, in particular, the treatment may
be interrupted at the surface portions having edges with specific
roles, for example sealing functions in association with other
components.
[0017] The treatment, in fact, may cause a slight local deformation
of said edges which therefore would not be fit for carrying out
their function.
[0018] According to the invention, moreover, the aforesaid deviator
comprises a faceted body which is realised with a material of high
thermal conductivity, such as copper, whose appropriately prepared
surface possesses a high reflecting power.
[0019] In particular, said surface is made specular by means of a
surface finishing treatment, preferably by means of polishing;
furthermore, during the treatment, it is properly cooled.
[0020] Further and advantageous characteristics of the invention
will be clear from the reading of the following description,
provided as merely exemplifying and not limiting, with the air of
the figures reproduced in the attached drawing tables, in
which:
[0021] FIG. 1 is a side schematic view of a device adapted to carry
out the hardening treatment, in a manner in accordance with the
invention;
[0022] FIG. 2 is a detail of the trace section II-II indicated in
FIG. 1, enlarged and shown during the execution of the
treatment;
[0023] FIG. 3 is the trace section III-III indicated in FIG. 2.
[0024] From the mentioned figures, a device 1 is noted which is
adapted to realise, by means of a laser, a hardening treatment of
the inner surface 12 of a hole 11, realised in a mechanical piece
10 of cast iron of predominantly ferritic matrix (see also FIG.
3).
[0025] Such device 1 comprises a laser source 2, which is provided
with an emission head 20 which projects a laser beam 100 (indicated
with dashed line in FIGS. 2 and 3) along a predetermined
direction.
[0026] The emission head 20 is firmly associated with a support 3,
which supports a faceted copper cylinder 4 arranged along the
emission direction of the laser beam 100 and adapted to deviate the
latter by substantially 90.degree..
[0027] As is visible in FIG. 2, said faceted cylinder 4 has a first
section axially inserted within a containment sleeve 30 of the
frame 3, and a second section which projects from said containment
sleeve 30 from the part of the emission head 20.
[0028] In this manner, the axis of the faceted cylinder 4 lies
substantially in the emission direction of the laser beam 100 (see
also FIG. 3), and the bottom face 40 of the cylinder 4 itself,
which is made specular by means of polishing, acts as a reflecting
surface.
[0029] To avoid that, during the treatment, the faceted surface 4
is melted or damaged when the reflecting surface 40 is struck by
the laser beam 100, means (not shown) are foreseen which are
adapted to cool it; said means may comprise, for example,
channelling made inside the cylinder 4 itself, in which a
refrigerating liquid circulates.
[0030] Furthermore, as illustrated in FIGS. 1 and 2, the device 1
comprises a supply nozzle 6 which is adapted to direct, during the
treatment, a jet of protective gas on the reflecting surface 40 of
the cylinder 4 and on the treated zone, in order to avoid
oxidation; said protective gas being contained in an appropriate
pressure cylinder (not shown), to which the nozzle 6 is
connected.
[0031] As is shown in FIG. 2, the reflecting surface 40 is sloped
450, and is hit by the laser beam 100 so to reflect it with an
angle of deviation equal to 900. In case it is necessary to reach
particular positions, however, the slope of the aforesaid
reflecting surface may also be different from 450.
[0032] The mechanical piece 10 to be treated is mounted on a
support and movement device 5, which comprises a motorised carrier
50, sliding with reciprocating motion on a rectilinear guide
51.
[0033] In particular, said motorised carrier 50 is provided with a
rotating mandrel 52 adapted to support the cast iron piece 10 of
predominantly ferritic matrix, so that the axis of the hole 11 lies
on the rotation axis of the mandrel 52 itself.
[0034] As is illustrated in FIGS. 1 and 3, the light source 2 and
the movement device 5 are mutually positioned so that the rotation
axis of the mandrel 52, and therefore the hole axis 11, is parallel
to the direction of the laser beam 100 leaving the emission head
20, and the mouth of the hole 11 is turned towards the laser source
2.
[0035] With reference to FIG. 2, at the beginning of the treatment,
the carrier 50 is advanced towards the laser source 2, and the
faceted cylinder 4 axially penetrates inside the hole 11, until it
is positioned so to be capable of deviated the laser beam 100 on a
first edge 12' of the cylindrical surface 12 to harden (see also
FIG. 3).
[0036] At this point, the source 2 is activated to generate the
laser beam 100 and, at the same time, the mandrel 52 is placed in
rotation at a predetermined speed, and the carrier 50 is also
driven to slide at a predetermined speed, until the laser beam 100
reaches the second edge 12'' of the cylindrical surface to
harden.
[0037] In this manner, the laser beam 100 eventually hits all the
points of surface 12 of the hole 12, causing the melting of a layer
of cast iron of predominantly ferritic matrix having a very small
thickness, about 0.5 mm.
[0038] Consequently, the metallic structure of said melted layer,
cooling rapidly due to the proximity of a great quantity of
non-melted material, undergoes-a change of state. The carbon in the
form of graphite, present in the cast iron of predominantly
ferritic matrix, is dissolved in the metallic matrix, which is
enriched with carbon and assumes a ledeburitic structure to confer
a very high hardness to the surface layer.
[0039] In order to obtain a quick and effective melting of the
surface 12 of the hole 11, however, the treatment must be conducted
respecting several optimal process parameters.
[0040] In particular, the thickness of the melted layer
substantially depends on the maximum temperature reached by the
surface 12 of the hole 11 during the treatment, which in turn
depends both on the energy of the laser beam 100 which is absorbed
in the time period by the cast iron of predominantly ferritic
matrix of the piece 10 and, of course, by the time of exposure of
the same surface 12 to said laser beam 100.
[0041] Regarding the energy absorbed by the cast iron of
predominantly ferritic matrix, this is determined in particular by
the physical properties of the laser beam 100, and by its
geometrical characteristics.
[0042] Physical properties include: the wavelength of the laser
beam 100, on which the absorption coefficient of the cast iron of
predominantly ferritic matrix depends, that is the percentage of
energy absorbed and utilised in an active manner for the treatment,
with respect to that reflected by the surface 12 to be treated; and
the power of the laser ray 100 itself.
[0043] Geometrical characteristics, on the other hand, include the
focal distance of the laser beam 100 leaving the source 2, and the
dimensions of the "spot", that is the luminous point projected on
the surface 12.
[0044] Regarding the time of exposure to the laser beam 100,
finally, this is a function of the speed with which the luminous
"spot" moves with respect to the surface 12 to be treated, which
depends of course on the rotation speed and translation speed of
the piece 10, with respect to the faceted cylinder 4.
[0045] It should therefore be underlined that, regarding energetic
parameters, optimal results were obtained with a laser beam 100 of
wavelength comprised between 800 nm and 950 nm, and power comprised
between 1500 W and 2200 W.
[0046] This along with a focal distance of the laser beam 100
comprised between 66 mm and 500 mm, and a rectangular luminous
"spot" with sides comprised between 4 mm and 9 mm.
[0047] Regarding the exposure time, optimal results were
demonstrated with a speed of the luminous "spot", with respect to
the surface 12, comprised between 20 mm/s and 40 mm/s.
[0048] Lastly, as merely exemplifying, the process parameters which
permitted obtaining optimal results were reported, in terms of
surface hardness and treatment time, on the inner surface of a
cylindrical cavity of a pump body in cast iron of predominantly
ferritic matrix GS400.
[0049] These parameters, which were compiled in the table placed at
the end of the present description, were obtained during a series
of experiments conducted by the Applicant, in which there were
used: a diode laser source 2 adapted to emit a continuous laser
beam 100; a faceted copper cylinder 4 with 20 mm diameter; a
reflecting surface 40 sloped at 45.degree. and superficially
polished to have a roughness Ra<0.08; and a supply nozzle 6 of
the protective gas which, connected to a pressure cylinder, directs
the jet directly onto a reflecting surface 40, and onto the surface
12 struck by the laser beam 100. TABLE-US-00001 Parameter Value
LASER SOURCE ROFIM DL022 LASER WAVELENGTH 808-940 nm ABSORBED POWER
6680 WATTS POWER SUPPLIED .about.2,000 WATTS FOCAL LENGTH 136 mm
"SPOT" SIZE 4 .times. 9 mm "SPOT" SPEED 25 mm/s PROTECTIVE GAS
NITROGREN
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