A Mesh belt carburizing (quenching and tempering) production line is a continuous - type heat - treatment equipment mainly used for the carburizing, quenching, and tempering of small - and medium - sized mechanical parts. Here is an introduction to its composition, working principle, characteristics, and application scope:

Composition

Automatic loading machine: It is set at the front end of the production line and consists of a hopper flipping device and a feeder, which automatically supply the parts to be processed to the continuous furnace production line.

Carburizing furnace: It includes the furnace body, furnace lining, mesh belt driving device, mesh belt, heating element, in - furnace atmosphere mixer, smoke - exhaust device, and other components, which is used for carburizing, carbonitriding, and quenching.

Quenching oil tank: It is composed of the tank body, jet device, oil - cooling device, transmission mesh belt device, tubular heater, oil - removal device, liquid - level detection alarm, etc. After the parts are carburized, they are rapidly cooled in oil to obtain the required hardness and strength.

Cleaning machine: It is composed of a cleaning tank, a spray device arranged along the conveyor rack, a cleaning liquid temperature - control device, a hot - air blower, and a hot - air blowing grid. It is used to soak, clean, and dry the workpiece to remove oil stains and other impurities on the surface of the workpiece.

Tempering furnace: It consists of the furnace body, heater, in - furnace mixer, furnace bed plate, mesh belt, mesh belt driving device, and mesh belt tensioning device. After quenching, the parts are tempered in the tempering furnace to eliminate quenching stress, stabilize the structure, and improve toughness and plasticity.

Cooling machine: It is composed of a steel - plate - welded and profiled - steel - reinforced body, a spray pump, and nozzles, which is used for the final cooling of the parts to room temperature.

Electrical control panel: It controls the entire production line, including temperature control, atmosphere control, mesh belt speed adjustment, and the start - up, shutdown, and operation sequence of each device.

Working Principle

Carburizing principle: The carburizing furnace heats the parts to the set carburizing temperature, usually between 900°C and 950°C. At the same time, a carbon - containing medium, such as kerosene or propane, is introduced. The hydrocarbon compounds in the medium decompose into active carbon atoms at high temperatures. In an atmosphere with high temperature and a certain carbon potential, the carbon atoms diffuse to the surface of the workpiece and gradually penetrate into the interior, forming a carburized layer with a certain depth.

Quenching principle: After carburizing, the parts are rapidly cooled in the quenching oil tank to make the microstructure of the parts transform, thereby improving the hardness, strength, and wear resistance of the parts.

Tempering principle: The parts after quenching are heated to a certain temperature in the tempering furnace, generally between 150°C and 650°C, and held for a certain period. This can eliminate the internal stress generated during quenching, improve the toughness and plasticity of the parts, and make the performance of the parts more stable.

Characteristics

High automation: The entire production line is controlled by a PLC, which can automatically complete processes such as loading, carburizing, quenching, cleaning, tempering, and unloading. This reduces manual operation errors and labor intensity and improves production efficiency and product quality consistency.

Accurate process control: The temperature control adopts a multi - point SCR/PID control system, and the atmosphere control uses a high - precision, high - temperature - resistant oxygen probe and an atmosphere controller. This ensures high - precision control of the furnace temperature and atmosphere, with good temperature uniformity, which is beneficial for ensuring the quality of Heat treatment. The carbon potential control accuracy can reach ±0.05% C, and the temperature control accuracy can reach ±1°C.

Good product quality: The parts are evenly heated in the furnace and there is no collision between the parts during the heat - treatment process. Coupled with the protection of the controllable atmosphere, the surface of the treated parts is bright and clean, without decarburization, with uniform hardness, small deformation, and high quality.

Energy saving and high efficiency: The furnace uses high - quality insulation materials, such as lightweight and high - strength ceramic fiber insulation materials, which have good heat - insulation performance and can reduce heat loss. At the same time, the use of silicon - controlled regulators and other components can improve the electro - thermal efficiency and save energy.

Application scope

This production line is suitable for the heat treatment of various small - and medium - sized mechanical parts, such as screws, nuts, washers, and other standard parts in the hardware industry; gears, shafts, and other parts in the automotive and motorcycle industries; and bearings, chains, and other parts in the mechanical manufacturing industry. It can improve the surface hardness, wear resistance, and fatigue resistance of these parts, thereby prolonging the service life of the parts and improving the reliability and performance of the products.

The mesh belt carburizing (quenching and tempering) production line is a highly efficient and automated solution that revolutionizes the Heat treatment process for a wide range of metal components. Combining the essential processes of carburizing, quenching, and tempering into an integrated system, this production line offers unparalleled precision, productivity, and consistency, making it a cornerstone in modern manufacturing across multiple industries.

At the heart of the production line is its innovative mesh belt design. The continuously moving mesh belt serves as the conveyor, transporting workpieces through each stage of the heat treatment process. This design ensures even exposure of components to heat and treatment media, facilitating uniform carburization, quenching, and tempering. During the carburizing stage, the workpieces are placed in a controlled atmosphere furnace filled with carburizing gas. The mesh belt slowly moves the components through the furnace, allowing carbon atoms to diffuse into the surface of the metal, increasing its hardness and wear resistance. This is especially crucial for parts like gears and shafts in the automotive industry, where high surface hardness is required to withstand heavy loads and friction.

Following carburization, the workpieces are seamlessly transferred to the quenching zone. Here, the rapid cooling process solidifies the carburized layer, locking in the enhanced mechanical properties. The production line is equipped with advanced quenching systems, such as oil or polymer quenching tanks, which can be precisely controlled to achieve the desired cooling rate. This level of control is essential for preventing issues like cracking and distortion, ensuring the dimensional accuracy of the components. For example, in the manufacturing of precision - engineered parts for the aerospace sector, the accurate quenching process enabled by the mesh belt production line guarantees that components meet strict quality standards.

The final tempering stage on the production line relieves internal stress and improves the toughness of the workpieces. By carefully controlling the temperature and time in the tempering furnace, the production line optimizes the balance between hardness and ductility of the components. This is vital for applications where components need to withstand both impact and wear, such as in the production of tools and dies.

The mesh belt carburizing (quenching and tempering) production line is also equipped with state - of - the - art control systems. Advanced temperature sensors, gas flow meters, and programmable logic controllers (PLCs) work in tandem to monitor and adjust process parameters in real - time. Operators can easily set and modify parameters like furnace temperature, gas composition, and belt speed through an intuitive human - machine interface. Some models even feature intelligent control algorithms that can optimize the production process based on the type and size of the workpieces, ensuring maximum efficiency and minimal energy consumption.

This production line finds extensive applications across various industries. In the automotive industry, it is widely used for processing engine components, transmission parts, and suspension systems, enhancing their performance and durability. The electronics industry benefits from the production line's ability to treat small - scale precision components with high accuracy, ensuring the reliability of electronic devices. In the machinery manufacturing sector, the mesh belt production line plays a key role in producing high - quality parts for industrial equipment, reducing maintenance costs and increasing equipment lifespan.

From a productivity and cost - management perspective, the mesh belt carburizing (quenching and tempering) production line offers significant advantages. Its automated and continuous operation reduces manual labor requirements and increases production throughput. The consistent quality of heat - treated components minimizes rework and scrap rates, saving both time and resources. Additionally, the energy - efficient design of the production line, including optimized furnace insulation and intelligent power management, helps reduce operational costs while also contributing to environmental sustainability.