Self-lubricating rolling bearing and preparation method therefor

Abstract

A self-lubricating rolling bearing is provided. The chemical compositions in the inner rings and the outer rings of bearing are 3.4-3.7% C, 2.7-2.9% Si, 0.3-0.5% Mn, 0.3-0.5% Cr, ≤0.05% S, ≤0.05% P, 0.03-0.045% Residual Mg, and the remainder Fe. The total percent of the chemical compositions is 100%. The material for the inner and outer rings of the rolling bearing introduced in the invention is austempered ductile iron (ADI). In the microstructure of ADI, the diameter of the graphite nodules is less than 0.02 mm, the number of graphite spheres per square millimeter is more than 400, and the microstructure of the metal matrix in the ADI can be showed clearly only when it is observed on the microscope with a magnification more than 500. Eventually, the self-lubricating rolling bearings are made from the ADI.

Claims

1. A self-lubricating rolling bearing comprising: an inner ring; an outer ring; a cage; and balls, wherein the inner ring and the outer ring have a composition comprising: 3.3-3.5 wt. % of C; 2.7-2.9 wt. % of Si; 0.3-0.5 wt. % of Mn; 0.3-0.5 wt. % of Cr; ≤0.05 wt. % of S; ≤0.05 wt. % of P; 0.03-0.045 wt. % of Mg; and a remaining wt. % of Fe, wherein the inner ring and the outer ring have a spheroidization rate ≥93% and a density of graphite nodule ≥500 per mm.sup.2, and wherein a hardness of the balls is HRC 1-2 greater than a hardness of the inner ring and the outer ring.

2. The self-lubricating rolling bearing of claim 1, wherein the cage has a composition comprising: 3.3%-3.5 wt. % of C; 2.8-3.1 wt. % of Si; 0.2-0.3 wt. % of Mn; <0.05 wt. % of S; <0.05 wt. % of P; 0.03-0.045 wt. % of Mg; and a remaining wt. % of Fe.

3. The self-lubricating rolling bearing of claim 1, wherein the inner ring and the outer ring have-a hardness no less than HRC 48.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order to explain more clearly the technical scheme described in the embodiment of the invention, a brief description about the figures used in the embodiment of the invention is presented below. What should be understood is that the figures listed below only presented some embodiments of the invention, and they should not be taken as the limitation of the invention. On the basis of the figures, the ordinary skilled engineers in the art can deduce other interrelated figures without any creative works.

(2) FIG. 1 is the illustration of inner cylinder with two-spiral-continuous water channel, which is a part of crystallizer used in the vertical continuous casting in the invention to produce the self-lubricating rolling bearing.

(3) FIG. 2 is the illustration of assemble diagram for the crystallizer used in the vertical continuous casting to produce the self-lubricating rolling bearing introduced in the invention.

(4) FIG. 3 is a heating curve of the cyclic spheroidizing annealing for the inner rings and the outer rings used to be assembled into the self-lubricating bearing in the invention.

(5) FIG. 4 is the heating curve of the austempering for the inner rings and the outer rings used to be assembled into the self-lubricating bearing in the invention FIG. 5 is the heating curve of the annealing for the cages used to be assembled into the self-lubricating bearing in the invention.

(6) FIG. 6 is pictures of the metallographic microstructure for the inner rings and outer rings used to be assembled into the self-lubricating bearings in the invention.

(7) 1 inner cylinder, 2 outer cylinder, 3 upper flange, 4 lower flange, 5 water inlet tap I, 6 water inlet tap II, 7 water outlet tap I, 8 water outlet tap II, 9 two-spiral-ribbed slab

DETAILED DESCRIPTION

(8) In order to clearly understand the purpose, the technical scheme and the advantage of the embodiment of the invention, a clear and complete description on the technical scheme presented in the embodiment of invention is listed as follows. Some conditions which are not mentioned specifically in the embodiment of invention are carried out according to routines or on suggestions provided by their manufacturers. The reagents or the instruments not mentioned specifically all are conventional products which can be purchased on the market.

(9) The disadvantages of rolling bearings made from the conventional nodular graphite cast iron or from ADI are as follows:

(10) 1) the main factor that causes the rolling bearing failure is the point contact fatigue when they run under ordinary service conditions. The graphite in the nodular graphite cast iron can act as lubricant for the bearing, but because of its low strength, actually, it is a small pit in the metal matrix of cast iron. If the graphite nodules in the cast iron are not round and not small, when a periodic force is applied on them, a great stress will be generated on the edges of graphite nodules, thus the edges will be the initiation areas for fatigue cracks. Actually, the graphite nodules in the cast iron are not round and not small when the cast iron is prepared through conventional casting, thus it is unavoidable that the edges of graphite nodules will be fatigue cracks initiation areas.

(11) 2) lots of casting defects such as blowholes, sand inclusions, slag inclusions, and shrinkage porosity exist in the castings produced through conventional casting, thus the density of the castings is much lower than that of castings made from the forged rolling bearing steel.

(12) 3) the microstructure in the nodular graphite cast iron produced through conventional casting is coarse, thus when the austempering is applied on the casts, the time held at the quenching temperature and the austempered time will become longer (about 1.5 Hour), and then the efficiency of heat treatment will become lower, the cost on the production will increase and the quality of the products will not be the best.

(13) 4) the microstructure in the profiles produced through a horizontal continuous casting is fine, and the casting defects in the profiles are close to zero, but the profiles is solid, not hollow, so the shape of profiles does not meet the need of the shape of bearing ring.

(14) The problems above are all resolved in the invention, thus a self-lubricating rolling bearing which can avoid the problem above is obtained.

(15) The invention will be presented in detail as follow through combining the attached figures with the concrete implementations.

(16) The self-lubricating rolling bearing given in the invention consists of four parts: the inner ring, the outer ring, the cage and the balls. The four parts are assembled into a rolling bearing through a conventional process. The chemical compositions in the cast iron for the inner rings and the outer rings are 3.3-3.5% C, 2.7-2.9% Si, 0.3-0.5% Mn, 0.3-0.5% Cr, ≤0.05% S, ≤0.05% P, 0.03-0.045% Residual Mg, and the remainder Fe. The total percent of the chemical compositions is 100%.

(17) When the self-lubricating rolling bearings given in the invention run under such conditions as low rotating speed, high operating temperature, difficult to lubricate and suffering from the frequent impact, they will not have the problems in the conventional rolling bearings such as the premature failure, poor lubrication and dry-friction.

(18) A new process is also supplied to manufacture the self-lubricating rolling bearing mentioned above. The process is also carried out in the patent of “the equipment for produce hollow metal profiles with low plasticity by continuous casting” (patent no. Zl200710018928.2, Publication no. 101134231, and publication date Mar. 5, 2008). The differences in the equipment between in the invention and in the patent (no. ZL200710018928.2) are the structure of crystallizer. In the invention, the structure of crystallizer is illustrated in the FIG. 1 and FIG. 2. From the figures, it can be seen that the structure of the crystallizer in the invention is of two-spiral water channel, and its detail structure is described as following: the crystallizer is made up of an inner cylinder (marked with “1”) and an outer cylinder (marked with “2”). The inner cylinder is in the outer cylinder and then they are fitted with each other. At the bottom of the two cylinders and at the top of the two cylinders, a ring flange marked with “3” (at the top of cylinder) and “4” (at the bottom of cylinder) are fitted with the cylinder respectively. Moreover, there are two water inlet taps (marked with “I5” or “I16”) in the upper of outer cylinder and two water outlet taps (marked with “I7” or “II8”) in the lower of outer cylinder respectively. Two-spiral-ribbed slabs are obtained in the exterior of the inner cylinder by turning. The two cylinders are fitted together to create a two-spiral-continuous water channel. The two-spiral water channel can supply the crystallizer with a much greater cooling capacity than the water channel in the patent no. Zl200710018928.2. A great cooling capacity can ensure that the number of graphite nodule per square millimeter in the cast iron is greater than 500. A graphite cylinder is inlaid in the inner surface of the inner cylinder, and its inner surface is in contact with the molten iron directly, thus the molten iron can be cooled and solidified on its inner surface to form the hollow profiles. Moreover, the self-lubricating property of the graphite allows the profile to be drawn out of the crystallizer.

(19) A process to prepare the self-lubricating rolling bearing is carried out according to the steps as following.

(20) The first step: the pig iron, steel scraps and ferroalloy are weighted according to the compositions in every part respectively and then are molten together in an induction heating furnace. The chemical compositions in the raw molten iron for the inner rings and the outer rings are 3.4%-3.7% C, 1.5%-1.7% Si, 0.3%-0.5% Mn, 0.3%-0.5% Cr, ≤0.05% S, ≤0.05% P and the remainder Fe. The total percent of the chemical compositions is 100%. Then an inoculation process and a spheroidizing process are applied on the molten iron, thus the final percentage of Si and the residual Mg in the molten iron for the rings are 2.7%-2.9%, 0.03%-0.045% respectively. The chemical compositions for the cages are 3.3%-3.5% C, 2.8%-3.1% Si, 0.2%-0.3% Mn, ≤0.05% S, ≤0.05% P, 0.03%-0.045% Residual Mg and the remainder Fe. The total percent of the chemical compositions is 100%.

(21) The second step: the molten iron above is made into spheroidal graphite cast iron tubes with different diameters and different wall thickness with upward vertical continuous casting process. The inside diameter of the tubes is 4-5 mm smaller than the inside diameter of the inner rings or the outer rings, and the outside diameter of tubes is 3-4 mm larger than that of inner rings or outer rings. The allowance for machining the cage profiles in its internal and external diameters is also 4-5 mm and 3-4 mm respectively

(22) The third step: spheroidizing annealing is carried out on the nodular graphite cast iron tubes, and then the graphite morphology in the tubes is inspected. The graphite morphology must meet the requirements: its nodularity above 90% and the number of graphite nodule per square millimeter greater than 500.

(23) Just as shown in FIG. 3, the spheroidizing annealing is composed of the following steps:

(24) Step a, the spheroidal graphite iron tubes are heated to their eutectoid temperature 780° C., and then kept at the temperature for a time between the range of 55 min and 65 min. After that, the tubes are cooled down to their eutectoid temperature 680° C., and then kept at the temperature for a time between the range of 55 and 65 min.

(25) Step b, repeat the step “a” at least twice.

(26) Step c, after the step b, the tubes are cooled down to a temperature between 595° C. and 605° C. in the furnace, and then the tubes are taken out of the furnace and cooled down to room temperature.

(27) The fourth step: after the spheroidizing annealing, the tubes are made into the inner rings and the outer rings through cutting, turning and grinding. In the machining processes, an austempering process is carried out after the process of turning and before the process of grinding.

(28) As shown in FIG. 4, the austempering process is done according to the following requirements. The inner rings and the outer rings are heated to a temperature between 880° C. and 900° C., and the holding time at the temperature is in the range of 50 min to 60 min when the wall thickness of rings is less than 10 mm. When the wall thickness of rings is larger than 10 mm, as the wall thickness of rings increases by 1 mm, additional 2 min are added to the holding time. When the holding time is over, the rings are taken out of the furnace and then quickly immerged into a hot quench bath with a temperature between 230° C. and 250° C., and kept in the bath for a time between 40 min and 50 min. After that, the rings are taken out of the bath, cooled to room temperature, and subsequently immerged into water to clear off the salt on their surface.

(29) The fifth step: some checks are performed to the rings. The checks include the nodularity of graphite, the number of graphite nodules and the hardness. The nodularity of graphite in the rings is be above 93%, the number of graphite nodule per square millimeter is greater than 500, and the hardness of ferrite in the rings is more than twice that of ferrite in the casts produced by a conventional casting, and the hardness of the tubes is no less than HRC48.

(30) The sixth step: the hollow profiles (tubes) obtained from the second step are annealed as shown in FIG. 5. The detailed processes of annealing are as following: the profiles are heated to their eutectoid temperature 760° C. in a furnace, and then kept at the temperature for 120 min. Subsequently, the profiles are cooled down to 500° C. in the furnace. After that, the profiles are taken out of the furnace and cooled down to room temperature in air. Finally, the profiles are made into cages by machining. The cast iron for the cages is equivalent to QT400-18.

(31) The seventh step: the inner rings and the outer rings resulted from the fifth step, the cages from the sixth step and the balls from purchase are assembled into self-lubricating rolling bearings via conventional process. The hardness of the balls is 1-2HRC higher than that of the inner and outer rings.

(32) Comparing with the technology available to produce the rolling bearing, the advantages of the technology in the invention are that:

(33) The first advantage: the regular, dense and fine graphite nodules not only can supply the lubricant for the running of rolling bearing, but also can avoid the damage resulted from the point-contacting fatigue. As shown in FIG. 6, the nodularity is above 90% in the tubes produced via upwards vertical continuous casting. Moreover, the roundness of the graphite nodules is improved further, thus the probability of fatigue cracks resulted from the edge and the sharp corner of graphite caves is reduced after the tubes are austempered. The number of graphite nodules is so great that it is up to 500-700/mm.sup.2. Such dense and fine graphite nodules make the cross-sectional area of caves coming from the graphite nodules very tiny, and the area of caves is only several tenths of that from the graphite nodules with grade 7 (the number of graphite nodules was 200/mm.sup.2), and also is far smaller than the transient contacting area between the ball and the ring, thus the caves cannot become the initiation of fatigue cracks.

(34) The second advantage: the fine austempering microstructure will supply the inner rings and the outer rings with excellent mechanical properties. The high carbon austenite (whose volume percentage is in the range of 20% to 40% in the microstructure of ring) in the rings will be transformed into martensite when the surface of rings is suffered from the rolling of balls in their working. The transformation of austenite into martensite will increase the hardness of rings and improve their wear resistance. The percent of Si is large in the profiles produced by continuous casting, thus the hardness of the quenched profiles is twice or triple of that of normal ferrite, and then the hardness of rings is improved effectively. Dual-phase microstructure with high-carbon austenite and high-Si ferrite can prevent the crack from propagating quickly, and then increase the impact energy for breaking the parts, and lengthen their serving life.

(35) The third advantage: the ADI materials in the invention consist of nodular graphites and austenite-ferrite microstructure with a high strength and a good toughness. These dense graphite nodules can supply the lubricants for the rolling bearing continuously.

(36) The fourth advantage: low temperature rise. The heat conductivity coefficient of ductile cast iron is about 80 w/(m.Math.k), which is double that of steel (40 w/(m.Math.k)). Thus the heat coming from the friction can be conducted out more quickly. In addition, the resistance of ductile cast iron against tempering is larger than that of steel, and the hardness of ductile cast iron decreases much slower than that of steel when they run at a high temperature. The rolling bearings made from the fine and dense ADI have a low temperature rise, and can run in the circumstance with a temperature no more than that of austempering medium.

(37) The fifth advantage: low noise. The shock absorbing ability of ADI materials is better than that of steel, thus the noise of rolling bearing made from ADI can be cut off intensively.

(38) The sixth advantage: low mass. The mass of ADI with the same volume as that of steel is 10% lighter than that of steel.

(39) The seventh advantage: low allowance for machining. The allowance for machining the casts produced by upwards vertical continuous casting is less than that from forge pieces.

(40) In the invention, the raw materials for the rings of rolling bearing all come from the profiles produced via upwards vertical continuous casting, and all are austempered. Their microstructure is austenite-ferrite with fine and dense nodular graphite in it. Nano-sized austenite and ferrite with rich carbon and silicon will supply high strength, good toughness, great wearing resistance and high compact resistance for the rings of rolling bearing. 20-40% (volume percent) retained austenite in the microstructure not only improve the fatigue performance of rings, but also increase their wear resistance through the deformation hardening of austenite. In the microstructure of rings, the nodularity of graphite is up to 93%, and the number of graphite balls per square millimeter is greater than 500. All of the parameters reach a very high level which is impossible for the conventional ADI. The nodular graphites not only supply the rolling friction with self-lubricant, shock absorption and quick heat-conductivity, but also can avoid initiating the point contacting fatigue crack because of their fine and dense distribution. The bearing balls are made of the traditional bearing steel, and kept their original hardness. The cages are made of the hollow annealed profiles (QT400-18) which are produced by continuous casting. Comparing with the bearing steels, the quenching hardness of ADI in the invention is more than 48 HRC, which is lower than that of quenching bearing steel, thus the bearing made of the ADI cannot run at a great rotating speed. So the application of the self-lubricating rolling bearing is limited for the occasions with a low rotating speed, a higher temperature (but below 200° C.), being difficult to lubricate difficultly and suffering frequent compact.

Exemplary Embodiment 1

(41) The first step: the pig iron, steel scraps and ferroalloy are weighted according to the compositions in every part respectively and then are molten together in an induction heating furnace. The chemical compositions in the raw molten iron for the inner rings and the outer rings are 3.4%-3.7% C, 1.5%-1.7% Si, 0.3%-0.5% Mn, 0.3%-0.5% Cr, ≤0.05% S, ≤0.05% P and the remainder Fe. The total percent of the chemical compositions is 100%. Then an inoculation process and a spheroidizing process are taken on the molten iron, thus the final percentage of Si and the residual Mg in the molten iron for the rings are 2.7%-2.9% Si, 0.03%-0.045% respectively. The chemical compositions for the cages are 3.3%-3.5% C, 2.8%-3.1% Si, 0.2%-0.3% Mn, ≤0.05% S, ≤0.05% P, 0.03%-0.045% Residual Mg and the remainder Fe. The total percent of the chemical compositions is 100%.

(42) The second step: the molten iron above is made into spheroidal graphite cast iron tubes with different diameters and different wall thickness by upward vertical continuous casting respectively. The inside diameter of the tubes is 4-5 mm smaller than the inside diameter of the inner rings or the outer rings, and the outside diameter of tubes is 3-4 mm larger than that of inner rings or outer rings. The allowance for machining the cage profiles in its internal and external diameters is also 4-5 mm and 3-4 mm respectively.

(43) The third step: spheroidizing annealing is carried out on the nodular graphite cast iron tubes, and then the graphite morphology in the tubes is observed. The graphite morphology must be satisfied with the requirement: its nodularity above 90% and the number of graphite nodule per square millimeter greater than 500.

(44) The spheroidizing annealing is composed of the following steps:

(45) Step a, the spheroidal graphite iron tubes are heated to their eutectoid temperature 780° C., and then kept at the temperature for 60 min. After that, the tubes are cooled down to their eutectoid temperature 680° C., and then kept at the temperature for 55 min.

(46) Step b, repeat the step “a” at least twice.

(47) Step c, after the step b, the tubes are cooled down to a temperature 600° C. in the furnace, and then the tubes are taken out of the furnace and cooled down to room temperature.

(48) The fourth step: the spheroidizing-annealed tubes are made into the inner rings and the outer rings through cutting, turning and grinding. In the machining processes, an austempering process was carried out after the process of turning and before the process of grinding.

(49) The austempering process is done according to the following requirements. The inner rings and the outer rings are heated to 880° C., and the holding time at the temperature is 50 min when the wall thickness of rings is less than 10 mm. When the wall thickness of rings is larger than 10 mm, as the wall thickness of rings increases by 1 mm, additional 2 min are added to the holding time. When the holding time is over, the rings are taken out of the furnace and then quickly immerged into a hot quench bath with a temperature of 250° C., and kept in the bath for 40 min. After that, the rings are taken out of the bath, cooled to room temperature, and subsequently immerged into water to clear off the salt on their surface.

(50) The fifth step: some checks are performed to the rings. The checks include the nodularity of graphite, the number of graphite nodules and the hardness. The nodularity of graphite in the rings is above 93%, the number of graphite nodule per square millimeter is greater than 500, and the hardness of ferrite in the rings is more than twice that of ferrite in the casts produced by a conventional casting, and the hardness of the tubes is no less than HRC48.

(51) The sixth step: an annealing is taken on the hollow profiles (tubes) obtained from the second step. The detailed processes of annealing are as following: the profiles are heated to their eutectoid temperature 760° C. in a furnace, and then kept at the temperature for 120 min. Subsequently, the profiles are cooled down to 500° C. in the furnace. After that, the profiles are taken out of the furnace and cooled down to room temperature. Finally, the profiles were made into cages by machining. The cast iron for the cages is equivalent to QT400-18.

(52) The seventh step: the inner rings and the outer rings resulted from the fifth step, the cages from the sixth step and the balls from purchase are assembled into self-lubricating rolling bearings via conventional processes. The hardness of the balls is 1-2HRC higher than that of the inner and outer rings.

Exemplary Embodiment 2

(53) The description of the process supplied in the exemplary embodiment to prepare the self-lubricating rolling bearings is referred to the exemplary embodiment 1. In order to simplify the description, some steps which are not mentioned in the embodiment can be referred to the corresponding steps in the embodiment 1.

(54) In the embodiment, the spheroidizing annealing is composed of the following steps:

(55) Step a, the spheroidal graphite iron tubes are heated to their eutectoid temperature 780° C., and then kept at the temperature for 55 min. After that, the tubes are cooled to their eutectoid temperature 680° C., and then kept at the temperature for 60 min.

(56) Step b, repeat the step “a” at least twice.

(57) Step c, after the step b, the tubes are cooled down to a temperature 595° C. in the furnace, and then the tubes are taken out of the furnace and cooled down to room temperature.

(58) The fourth step: the spheroidizing annealed tubes processed are made into the inner rings and the outer rings through cutting, turning and grinding. In the machining processes, an austempering process is carried out after the process of turning and before the process of grinding.

(59) The austempering process is done according to the following requirements. The inner rings and the outer rings are heated to 900° C., and the holding time at the temperature is 55 min when the wall thickness of rings is less than 10 mm. When the wall thickness of rings is larger than 10 mm, as the wall thickness of rings increases by 1 mm, additional 2 min are added to the holding time. When the holding time is over, the rings are taken out of the furnace and then quickly immerged into a hot quench bath with a temperature of 240° C., and kept in the bath for 45 min. After that, the rings are taken out of the bath, cooled to room temperature, and subsequently immerged into water to clear off the salt on their surface.

(60) The steps not mentioned in the embodiment are same as that in the exemplary embodiment 1.

Exemplary Embodiment 3

(61) The description of the process supplied in the exemplary embodiment to prepare the self-lubricating rolling bearings is referred to the exemplary embodiment 1. In order to simplify the description, some steps which are not mentioned in the embodiment can be referred to the corresponding steps in the embodiment 1.

(62) In the embodiment, the spheroidizing annealing is composed of the following steps:

(63) Step a, the spheroidal graphite iron tubes are heated to their eutectoid temperature 780° C., and then kept at the temperature for 65 min. After that, the tubes are cooled to their eutectoid temperature 680° C., and then kept at the temperature for 65 min.

(64) Step b, repeat the step “a” at least twice.

(65) Step c, after the step b, the tubes are cooled down to a temperature of 605° C. in the furnace, and then the tubes are taken out of the furnace and cooled down to room temperature.

(66) The fourth step: the spheroidizing annealed tubes processed are made into the inner rings and the outer rings through cutting, turning and grinding. In the machining processes, an austempering process is carried out after the process of turning and before the process of grinding.

(67) The austempering process is done according to the following requirements. The inner rings and the outer rings are heated to 890° C., and the holding time at the temperature is 60 min when the wall thickness of rings is less than 10 mm. When the wall thickness of rings is larger than 10 mm, as the wall thickness of rings increases by 1 mm, additional 2 min are added to the holding time. When the holding time is over, the rings are taken out of the furnace and then quickly immerged into a hot quench bath with a temperature of 230° C., and kept in the bath for 50 min. After that, the rings are taken out of the bath, cooled to room temperature, and subsequently immerged into water to clear off the salt on their surface.

(68) The steps not mentioned in the embodiment are same as that in the exemplary embodiment 1.