ENDLESS METAL BELT AND MANUFACTURING METHOD THEREFOR

Abstract

An endless metal belt having an excellent abrasion resistance and a method for manufacturing such endless metal belts, capable of sufficiently reducing a tensile stress related to a metal ring in the innermost layer are provided. An endless metal belt includes a belt member formed by laminating a plurality of metal rings; and an element supported by the belt member, in which among the plurality of metal rings, a metal ring in an innermost layer is formed by a maraging steel plate, and another metal ring includes a nitride layer on its surface, and has a specific chemical composition; a tensile strength of the another metal ring is 1,700 MPa or higher; and a surface hardness of the nitride layer is HV800 to HV950.

Claims

1. An endless metal belt comprising: a belt member formed by laminating a plurality of metal rings; and an element supported by the belt member, wherein among the plurality of metal rings, a metal ring in an innermost layer is formed by a maraging steel plate, and another metal ring includes a nitride layer on its surface, contains, in mass %, 0.30 to 0.70% of C, 2.50% or less of Si, 1.00% or less of Mn, 1.00 to 4.00% of Cr, 0.50 to 3.00% of Mo, and 1.00% or less of V, and satisfies an Equation 1:
159C(%)+91Si(%)+68Cr(%)+198Mo(%)+6461000; a remnant of the another metal ring has a chemical composition composed of Fe and an inevitable impurity; a tensile strength of the another metal ring is 1,700 MPa or higher; and a surface hardness of the nitride layer is HV800 to HV950.

2. The endless metal belt according to claim 1, wherein a thickness of the metal ring in the innermost layer is smaller than that of the another metal ring.

3. A method for manufacturing an endless metal belt comprising: manufacturing a metal ring by forming a metal plate into a ring shape and performing a nitriding process, the metal plate containing, in mass %, 0.30 to 0.70% of C, 2.50% or less of Si, 1.00% or less of Mn, 1.00 to 4.00% of Cr, 0.50 to 3.00% of Mo, and 1.00% or less of V, and satisfying an Equation 1:
159C(%)+91Si(%)+68Cr(%)+198Mo(%)+6461000, a remnant of the metal plate having a chemical composition composed of Fe and an inevitable impurity; separately manufacturing a metal ring for an innermost layer by forming a maraging steel plate into a ring shape, a thickness of the maraging steel plate being smaller than that of the metal plate; laminating at least one metal ring on an outer circumference of the metal ring for the innermost layer and thereby forming a belt member; and disposing an element in the belt member.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0024] FIG. 1 is a schematic cross section showing an example of an endless metal belt according to an embodiment;

[0025] FIG. 2 is a schematic partial perspective view showing an example of an endless metal belt according to an embodiment;

[0026] FIG. 3 is a flowchart showing an example of a method for manufacturing an endless metal belt according to an embodiment;

[0027] FIG. 4 is a flowchart showing an example of a process for manufacturing a metal ring;

[0028] FIG. 5 is a flowchart showing an example of a process for manufacturing a metal ring for the innermost layer; and

[0029] FIG. 6 is a graph showing maximum tensile stresses that occur in metal rings according to examples and comparative examples.

DESCRIPTION OF EMBODIMENTS

[0030] Firstly, a structure of an endless metal belt according to an embodiment is described with reference to FIGS. 1 and 2. FIG. 1 is a schematic cross section showing an example of an endless metal belt according to this embodiment, and FIG. 2 is a schematic partial perspective view showing the example of the endless metal belt according to this embodiment.

[0031] An endless metal belt 100 shown in the examples of FIGS. 1 and 2 includes belt members 10 each of which is formed by laminating a plurality of metal rings 1, and an element 20. An appropriate element may be selected from publicly-known elements and used as the element 20. In the example shown in FIG. 1, the element 20 has a base part 11, a head part 12, and a neck part 13 that connects the base part 11 with the head part 12. The head part 12 includes a projecting part 14 and a recessed part (not shown) located on the rear surface (i.e., the opposite surface) of the projecting part 14. In normal use, a side surface 15 of the base part 11 comes into contact with a pulley. Each of the two belt members 10 is disposed in a respective one of gaps formed by the base part 11, the head part 12, and the neck part 13 of the element 20, and they support the element 20. As shown in the example in FIG. 2, the element 20 is usually used with a plurality of other elements and the projecting part 14 of the element 20 is engaged with a recessed part of an adjacent element. FIG. 2 shows a part of the endless metal belt. That is, a plurality of elements 20 are arranged over the circumference of the belt member 10.

[0032] In the above-described endless metal belt 100, a metal ring la in the innermost layer of the belt member 10 comes into contact with a saddle surface 16 of the element 20. Further, the side surface of the belt member 10 comes into contact with the neck part 13 of the element 20.

[0033] In the endless metal belt according to this embodiment, maraging steel having a high strength and a high tenacity is used as the metal ring in the innermost layer of the belt member. Further, a steel that includes a nitride layer having a surface hardness of HV800 to HV950 on its surface, and has the above-specified composition having a tensile strength of 1,700 MPa or higher is used as each of the other metal rings. As a result, a tensile stress related to (i.e., occurring in) the innermost layer is reduced and an abrasion (i.e., wear) caused by the contact between the side part of the belt member and the element is suppressed. Consequently, durability of the endless metal belt is improved. Further, it is also possible to reduce the cost by using the maraging steel only for the innermost layer. Note that in this embodiment, the metal rings other than the metal ring in the innermost layer are referred to as other metal rings.

[0034] The maraging steel, which constitutes the innermost layer of the belt member, is a steel material in which a content of C (carbon) is 0.03% or lower, and a total content of Ni (nickel), Co (cobalt), Ti (titanium), and Al (aluminum) is 30% or higher, and which has a high strength and a high tenacity after undergoing an aging process.

[0035] In this embodiment, a chemical composition of the maraging steel may be selected as desired within a publicly-known range. As an example, the maraging steel may contain, in mass %, 0.03% or less of C, 18 to 19% of Ni, 8.5 to 9.5% of Co, 4.7 to 5.2% of Mo, 0.4 to 0.7% of Ti, 0.05 to 0.15% of Al, 0.5 to 1.5% of Cr (chromium). Further, the remnant of the maraging steel may have, for example, a chemical composition composed of Fe (iron) and inevitable impurities.

[0036] The method for the aging process for the maraging steel is not limited to any particular method. For example, the aging process may be performed for about 90 to 180 minutes at a temperature of about 450 to 500 C. in a nitrogen atmosphere or a reduction atmosphere.

[0037] The maraging steel used in this embodiment is further subjected to a nitriding process. By undergoing the nitri ding process, its surface hardness can be improved. The nitriding process can be performed for about 40 to 120 minutes at a temperature of about 400 to 450 C. in an atmosphere in which: for example, 5 to 15 volume % is an ammonia gas; 1 to 3 volume % is a hydrogen gas; and the remnant is a nitrogen gas. Note that the hydrogen gas in the atmosphere is generated by thermal decomposition of an ammonia gas.

[0038] In this embodiment, a thickness of the metal ring in the innermost layer is not limited to any particular thickness and may be adjusted as appropriate according to the use of the belt member or the like. For example, the thickness of the metal ring may be no smaller than 100 m and no larger than 200 m. In this embodiment, the thickness of the metal ring in the innermost layer is preferably smaller than that of the later-described other metal rings, and more preferably smaller than that of the other metal rings by 5 m or larger. By reducing the thickness of the metal ring in the innermost layer, a bending resistance of the metal ring in the innermost layer can be further improved. Further, by making the thickness of the metal ring in the innermost layer smaller than that of the other metal rings, a ratio of a load that the metal ring in the innermost layer bears can be made smaller compared to the load that the other rings bear. As a result, it is possible to further reduce the stress related to (i.e., occurring in) the metal ring in the innermost layer and thereby improve the overall durability of the endless metal belt. Further, owing to the thickness difference of 5 m or larger, it is also possible to detect a wrong component halfway in the process.

[0039] In this embodiment, each of the metal rings other than the metal ring in the innermost layer includes a nitride layer on its surface, contains, in mass %, 0.30 to 0.70 % of C, 2.50 % or less of Si, 1.00 % or less of Mn, 1.00 to 4.00 % of Cr, 0.50 to 3.00% of Mo, and 1.00% or less of V, and satisfies an Equation 1:

159C(%)+91Si(%)+68Cr(%)+198Mo(%)+6461000.

The remnant of the other metal ring has a chemical composition composed of Fe and inevitable impurities, and a tensile strength of the other metal ring is 1,700 MPa or higher. Further, a surface hardness of the nitride layer is HV800 to HV950. By using the above-described metal rings, it is possible to reduce a stress related to (i.e., occurring in) the metal ring in the innermost layer. Further, side surfaces of the metal rings that come into contact with the element have an excellent abrasion resistance.

[0040] A chemical composition of the above-described other metal rings is described hereinafter.

C: 0.30 to 0.70%

[0041] C needs to be contained in 0.30% or more in order to ensure a strength and a tenacity. However, in order to prevent (or minimize) deterioration in ductility and tenacity due to formation of coarse carbides, a content ratio of C is set to 0.70% or less.

Si: 2.50% or less

[0042] In order to prevent (or minimize) deterioration in ductility and nitriding property, Si (silicon) is set to 2.50% or less. However, Si (silicon) may be contained in 0.10% or more to increase the strength.

Mn: 1.00% or less

[0043] In order to prevent (or minimize) deterioration in ductility, Mn (manganese) is set to 1.00% or less. However, Mn (manganese) may be contained in 0.10% or more to increase the strength.

Cr: 1.00 to 4.00%

[0044] In order to increase the strength and improve the nitriding property, Cr is set to 1.00% or more. However, when a content ratio of Cr increases, the nitriding property is reduced, rather than being increased, thus making the nitriding process difficult. Therefore, Cr is set to 4.00% or less.

Mo: 0.50 to 3.00%

[0045] It is possible to improve the strength and the tenacity without deteriorating the ductility by setting a content radio of Mo (molybdenum) to 0.50% or more. However, 3.00% or less of Mo (molybdenum) sufficiently improves the strength and the tenacity.

V: 1.00% or less

[0046] V (vanadium) may be contained in 0.1% or more in order to refine (or reduce) grain sizes of crystals and improve the strength and the tenacity. However, in order to suppress coarse carbides and thereby prevent (or minimize) deterioration in strength and tenacity, a content ratio of V is set to 1.00% or less.

Ni: 4.00% or less

[0047] The above-described other metal rings may further contain Ni. It is possible to suppress generation of carbides and thereby improve the strength and the tenacity by containing Ni. When Ni is contained, its content ratio is preferably 4.00% or less and more preferably 2.0% or less.

159C(%)+91Si(%)+68Cr(%)+198Mo(%)+6461000 (1)

[0048] When the chemical composition of the above-described other metal rings satisfies the above-shown Equation 1, they become metal rings having an excellent fatigue metal strength characteristic and an excellent fatigue life.

[0049] In the chemical composition of the above-described other metal rings, the remnant other than the above-described elements is composed of Fe and unavoidable impurities. The inevitable impurities are elements that are inevitably mixed in the raw material or mixed during the manufacturing process. They are not limited to any particular elements and examples thereof include S (sulfur), P (phosphorus), N (nitrogen), O (oxygen) Al, Ti, etc.

[0050] A tensile strength of the above-described other metal rings is 1,700 MPa or higher. By using metal rings having a tensile strength of 1,700 MPa or higher in the other layers, a tensile stress related to (i.e., occurring in) the metal ring in the innermost layer can be reduced.

[0051] In this embodiment, the tensile strength was measured by the following tensile test. That is, a target metal ring was looped over a pair of rollers and then the metal ring was pulled through the pair of rollers. Note that a value that was obtained by measuring changes in the load that had occurred just before the metal ring was ruptured in the above-described tensile test and dividing the maximum load obtained by the measurement by a cross-sectional area of the ring member was defined as a tensile strength of the metal ring.

[0052] Further, a surface hardness of the nitride layer of the above-described other metal rings is HV800 to HV950. By adjusting the surface hardness to HV800 or higher, it is possible to prevent (or minimize) an abrasion on the side surface of the metal ring that comes into contact with the element. Further, by adjusting the surface hardness to HV950 or lower, it is possible to prevent the metal ring from becoming brittle and thereby to ensure the strength.

[0053] In this embodiment, a thickness of the other metal rings is not limited to any particular thickness and may be adjusted as appropriate according to the use of the belt member or the like. For example, the thickness of each of the other metal rings may be no smaller than 100 m and no larger than 200 m.

[0054] Further, a thickness of the nitride layer in each of the other metal rings is not limited to any particular thickness, and may be, for example, no smaller than 5 m and no larger than 50 m.

[0055] In this embodiment, the total number of laminated metal rings constituting one belt member, including the metal ring in the innermost layer and the other metal rings, should be at least two. For example, the total number of laminated metal rings may be two to twelve.

[0056] Next, a method for manufacturing an endless metal belt is described with reference to FIG. 3. FIG. 3 is a flowchart showing an example of a method for manufacturing an endless metal belt according to this embodiment. The method for manufacturing an endless metal belt shown in the example in FIG. 3 includes a step of manufacturing a metal ring(s) by using a metal plate(s) having a specific chemical composition (S11), a step of separately manufacturing a metal ring for the innermost layer by using a maraging steel plate (S12), a step of laminating the other metal ring(s) on an outer circumference of the metal ring for the innermost layer and thereby forming a belt member (S13), and a step of disposing an element(s) in the belt member and thereby manufacturing an endless metal belt (S14). According to the manufacturing method in accordance with this embodiment, it is possible to sufficiently reduce a tensile stress related to the metal ring in the innermost layer and suitably manufacture the above-described endless metal belt having an excellent abrasion resistance. Further, in the manufacturing method according to this embodiment, since the maraging steel plate thinner than the metal plate is used, it is possible to prevent an operator or a worker from mistaking the maraging steel plate for the metal plate, and vice versa, which would otherwise be difficult to distinguish one from the other based on their external appearances.

[0057] Details of the step of manufacturing a metal ring(s) (S11) are described hereinafter with reference to FIG. 4. FIG. 4 is a flowchart showing an example of the step of manufacturing a metal ring. As shown in the example in FIG. 4, the step of manufacturing a metal ring includes a metal plate cutting step (S21), a welding step (S22), an annealing step (S23), a ring cutting step (S24), a rolling step (S25), a hardening step (S26), a circumferential-length adjusting step (S27), and a nitriding process step (S28). If necessary, the manufacturing step may include other steps such as a tempering step that is performed after the hardening step (S26).

[0058] The steel material (metal plate) cutting step (S21) is a step of cutting out a metal plate having a predetermined size from a long metal plate such as a rolled metal plate. The cut-out metal plate is bent (or curved) into a tubular shape so that ends of the metal plate are brought together.

[0059] In the welding step (S22), the end parts of the tubular metal plate, which have been brought together, are welded, so that a tubular drum is formed.

[0060] Next, in the annealing step (S23), the drum is annealed to remove distortions caused in the welding process.

[0061] Next, in the ring cutting step (S24), the annealed drum is cut into a predetermined width, so that a plurality of rings are formed. If necessary, barrel polishing or the like may be performed for the obtained rings in order to remove burrs formed in the cutting process.

[0062] In the rolling step (S25), the obtained metal ring is rolled, so that the circumferential length of the metal ring is made closer to a predetermined circumferential length. After the rolling step, the hardening step (S26) is performed and, if necessary, a tempering step is performed after the hardening step.

[0063] In the hardening step (S26), for example, the metal ring is heated to 850 C. to 1,000 C. and then quenched. The tempering step can be performed, for example, at 400 to 500 C., and at or below a temperature of the nitriding process.

[0064] Next, the circumferential length of the metal ring is made equal to a predetermined circumferential length by the circumferential-length adjusting step (S27). In the circumferential-length adjusting step, for example, firstly, two rotatable pulleys, which have rotation shafts parallel to each other and are arranged so that they can be moved in approaching and receding directions, are prepared. Next, the metal ring is looped along the rotatable pulleys. After that, the rotation shafts are gradually moved away from each other while rotating the pulleys, so that the metal ring is expanded and its circumferential length is adjusted.

[0065] The metal ring, whose circumferential length has been adjusted, is subjected to the nitriding process step (S28). The nitriding process can be performed for about 40 to 120 minutes at a temperature of about 400 to 450 C. in an atmosphere in which: for example, 5 to 15 volume % is an ammonia gas; 1 to 3 volume % is a hydrogen gas; and the remnant is a nitrogen gas.

[0066] In this way, it is possible to obtain a metal ring which has a tensile strength of 1,700 MPa or higher and whose nitride layer has a surface hardness of HV800 to HV950.

[0067] Next, the step of manufacturing a metal ring for the innermost layer (S12) is described with reference to FIG. 5. FIG. 5 is a flowchart showing an example of the step of manufacturing a metal ring for the innermost layer. As shown in the example in FIG. 5, a metal ring for the innermost layer can be manufactured, by using the above-described maraging steel, by performing a maraging steel cutting step (S31), a welding step (S32), an annealing step (S33), a ring cutting step (S34), a rolling step (S35), an optional solution step (S36), a circumferential-length adjusting step (S37), an aging step (S38), a nitriding process step (S39).

[0068] Note that by performing the solution step (S36), a processing stresses that has been caused in the rolling step can be removed. Therefore, if necessary, the solution step (S36) is performed after the rolling step. The solution step can be performed, for example, for one to three minutes in a temperature range of 820 to 860 C.

[0069] The aging step (S38) can be performed, for example, for about 90 to 180 minutes at a temperature of about 450 to 500 C. in a nitrogen atmosphere or a reduction atmosphere.

[0070] Further, the nitriding process step (S39) can be performed, for example, for about 40 to 120 minutes at a temperature of about 400 to 450 C. in an atmosphere in which: 5 to 15 volume % is an ammonia gas; 1 to 3 volume % is a hydrogen gas; and the remnant is a nitrogen gas.

EXAMPLE

[0071] The present disclosure is described hereinafter in a concrete manner by using examples and comparative examples. Note that the present disclosure is not limited by the following descriptions.

Manufacturing Example 1: Manufacturing of Metal Ring 1

[0072] A long maraging steel plate was prepared and a metal ring 1 having a thickness of about 180 m and a Young's modulus of 190 GPa was manufactured in accordance with the above-described step of manufacturing a metal ring.

Manufacturing Example 2: Manufacturing of Metal Ring 2

[0073] A long steel plate having the following properties was prepared. That is, the steel plate contained, in mass %, 0.30 to 0.70% of C, 2.50% or less of Si, 1.00% or less of Mn, 1.00 to 4.00% of Cr, 0.50 to 3.00% of Mo, and 1.00% or less of V, and satisfies an Equation 1:

159C(%)+91Si(%)+68Cr(%)+198Mo(%)+6461000.

Further, the remnant of the steel plate was composed of Fe. Then, from the prepared steel plate, a metal ring 2 which had a thickness of about 185 m, a tensile strength of 1,700 MPa or higher, and a Young's modulus of 210 GPa, and included a nitride layer having a thickness of 30 m and a surface hardness of HV800 to HV950 was manufactured in accordance with the above-described step of manufacturing a metal ring.

Example: Manufacturing of Endless Metal Belt

[0074] By using the metal ring 1 in the Manufacturing Example 1 for the innermost layer, eight metal rings each of which was equivalent to the above-described metal ring 2 were laminated on an outer circumference of the metal ring 1, so that a belt member having nine layers was obtained. By using two belt members each of which was obtained as described above, elements were arranged as shown in FIGS. 1 and 2, so that an endless metal belt according to an example was obtained.

Comparative Example: Manufacturing of Endless Metal Belt

[0075] A belt member having nine layers was obtained by using the metal ring 1 for each of the metal rings constituting the belt member. By using two belt members each of which was obtained as described above, elements were arranged as shown in FIGS. 1 and 2, so that an endless metal belt according to a comparative example was obtained.

[0076] Regarding the belt members 1 and 2 used in the example and the comparative example, FIG. 6 shows calculation results of maximum tensile stresses in the innermost layer and the second layer adjacent to the innermost layer. As shown in FIG. 6, it was shown that the maximum tensile stress related to (i.e., occurring in) the innermost layer of the example was reduced from the maximum tensile stress related to (i.e., occurring in) the innermost layer of the comparative example by 6.4%. In the example, the maximum tensile stress in the second layer was increased. From this fact, it is presumed that the tensile stress related to the innermost layer was dispersed into the other layer(s). As described above, according to this embodiment, it is possible to provide an endless metal belt having an excellent abrasion resistance and excellent durability, capable of sufficiently reducing a tensile stress related to (i.e., occurring in) a metal ring in the innermost layer.

[0077] From the disclosure thus described, it will be obvious that the embodiments of the disclosure may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure, and all such modifications as would be obvious to one skilled in the art are intended for inclusion within the scope of the following claims.