具體參數

拖泵制作工(gong)藝

刀具選擇

從該齒(chi)(chi)(chi)(chi)輪(lun)的(de)結構和技術參數(shu)(shu)可知，該錐齒(chi)(chi)(chi)(chi)輪(lun)屬于標準結構，一般情況下(xia)(xia)，標準直齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成(cheng)形(xing)銑 刀(dao)的(de)齒(chi)(chi)(chi)(chi)形(xing)是按大端(duan)(duan)背錐當量漸開線齒(chi)(chi)(chi)(chi)形(xing)設計(ji)，而齒(chi)(chi)(chi)(chi)厚則按照(zhao)小端(duan)(duan)設計(ji)，并考慮留有一定精切余量。一 般情況下(xia)(xia)直齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成(cheng)形(xing)銑刀(dao)有3把(ba)、8把(ba)、15把(ba)、26把(ba)一套，刀(dao)號應按照(zhao)錐齒(chi)(chi)(chi)(chi)輪(lun)當量齒(chi)(chi)(chi)(chi)數(shu)(shu)來選擇。當 量齒(chi)(chi)(chi)(chi)數(shu)(shu)Zv可按照(zhao)下(xia)(xia)式(shi)計(ji)算：

熱處理工藝方法及過程

如(ru)前(qian)文所述，機加工前(qian)對齒坯進行整體高溫正火(huo)處理(li)，正火(huo)設(she)備為RT-90-9 箱式爐，具體工藝過程是，爐溫升(sheng)至裝(zhuang)爐溫度(du)400-650℃時(shi)，將齒輪放(fang) 爐中，裝(zhuang)零件時(shi)如(ru)果需(xu)要疊(die)放(fang)，疊(die)放(fang)高度(du)不要超過兩層(ceng)，然后將零件加熱至920-940℃，使組織完全發生相變，保(bao)溫30-50分鐘后，空冷即可。正火(huo)工藝：

由于(yu)該(gai)齒輪精(jing)度(du)要求不是很高，為(wei)降低滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)淬火成本(ben)，可(ke)以采(cai)用(yong)(yong)(yong)(yong)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)后直(zhi)(zhi)接淬火的(de)(de)工藝方(fang)法，具 體(ti)方(fang)法是將零件(jian)裝(zhuang)入(ru)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)筐中(zhong)(zhong)，不要疊加(jia)，爐溫(wen)(wen)(wen)升(sheng)至(zhi)(zhi)840℃開(kai)始滴航空煤油(you)(you)(you)，煤油(you)(you)(you)滴速為(wei)60-80d/min， 爐溫(wen)(wen)(wen)升(sheng)至(zhi)(zhi)930℃時零件(jian)開(kai)始裝(zhuang)爐。排氣期結(jie)(jie)束后，放入(ru)兩只試(shi)棒(bang)，其(qi)中(zhong)(zhong)一(yi)只試(shi)棒(bang)在(zai)擴散(san)時間(jian)(jian)為(wei)120 min時取出淬油(you)(you)(you)冷卻并檢(jian)(jian)驗(yan)淬硬(ying)層(ceng)深(shen)度(du)，根據檢(jian)(jian)驗(yan)結(jie)(jie)果決定(ding)(ding)是否降溫(wen)(wen)(wen)，若滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)深(shen)度(du)不足，擴散(san)期延長至(zhi)(zhi) 150min。滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時可(ke)按照(zhao)表1規定(ding)(ding)參數進(jin)(jin)行(xing)，為(wei)控制(zhi)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時的(de)(de)碳(tan)(tan)(tan)勢(shi)濃度(du)，可(ke)采(cai)用(yong)(yong)(yong)(yong)在(zai)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐中(zhong)(zhong)加(jia)裝(zhuang)氧傳(chuan)感(gan)(gan) 器的(de)(de)方(fang)法進(jin)(jin)行(xing)監(jian)測和(he)控制(zhi)，氧傳(chuan)感(gan)(gan)器通(tong)過氧化(hua)(hua)鋯探頭，將氣氛狀(zhuang)態(tai)轉化(hua)(hua)為(wei)電勢(shi)差，上(shang)述(shu)差值通(tong)過控制(zhi) 系統的(de)(de)比較和(he)計算，確(que)定(ding)(ding)碳(tan)(tan)(tan)勢(shi)的(de)(de)濃度(du)是否合適(shi)并對(dui)其(qi)進(jin)(jin)行(xing)自動優化(hua)(hua)和(he)調整，使碳(tan)(tan)(tan)勢(shi)控制(zhi)精(jing)度(du)可(ke)以達到 ≤±0.05%C，可(ke)有(you)效控制(zhi)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)深(shen)度(du)并提高滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)的(de)(de)質(zhi)量，確(que)保無(wu)塊狀(zhuang)、網狀(zhuang)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)物，滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)設備采(cai) 用(yong)(yong)(yong)(yong)RQ3-75-9井(jing)式滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐。滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)均溫(wen)(wen)(wen)期結(jie)(jie)束后，零件(jian)出爐直(zhi)(zhi)接淬火。淬火設備選用(yong)(yong)(yong)(yong)專用(yong)(yong)(yong)(yong)恒(heng)溫(wen)(wen)(wen)油(you)(you)(you)槽(cao)，淬 火介(jie)質(zhi)為(wei)專用(yong)(yong)(yong)(yong)等溫(wen)(wen)(wen)分級(ji)淬火油(you)(you)(you)，介(jie)質(zhi)溫(wen)(wen)(wen)度(du)恒(heng)定(ding)(ding)在(zai)110-120℃之間(jian)(jian)，冷卻30min后，出爐空冷。

為(wei)消除淬火(huo)(huo)(huo)后零件的殘余應(ying)力并防止淬火(huo)(huo)(huo)裂紋的產生，應(ying)盡快將淬火(huo)(huo)(huo)后的零件進行低溫(wen)(wen)(wen)回火(huo)(huo)(huo)處理，具體工(gong)藝方法(fa)是在當爐(lu)(lu)溫(wen)(wen)(wen)升至160℃左右時零 件開始裝爐(lu)(lu)，保溫(wen)(wen)(wen)120-150min后，出爐(lu)(lu)空冷(leng)，回火(huo)(huo)(huo)設備為(wei)RJJ-36-6回火(huo)(huo)(huo)爐(lu)(lu)。淬火(huo)(huo)(huo)及回火(huo)(huo)(huo)工(gong)藝圖見圖5：

后(hou)序處理

將(jiang)熱處理(li)后的零件(jian)放在噴(pen)砂(sha)(sha)機(ji)的轉盤(pan)上(shang)進(jin)行(xing)噴(pen)砂(sha)(sha)處理(li)，選用石英(ying)砂(sha)(sha)的粒(li)度為10-20目，在噴(pen)砂(sha)(sha)過 程中(zhong)要(yao)經常翻動零件(jian)使各(ge)面噴(pen)砂(sha)(sha)效果均勻。零件(jian)噴(pen)砂(sha)(sha)完后，放入(ru)防銹(xiu)液中(zhong)浸泡(pao)2-4min后，在空氣中(zhong)干 燥。需要(yao)注意的是，防銹(xiu)處理(li)必須在噴(pen)砂(sha)(sha)后24小(xiao)時內(nei)完成。

效(xiao)果

上(shang)述方法簡單(dan)實用，不(bu)需要(yao)專用裝(zhuang)備即可(ke)(ke)實現直齒錐齒輪的(de)加(jia)工，且經(jing)濟性好，成本較低。經(jing)對 加(jia)工后的(de)錐齒輪進行檢測，尺寸(cun)及形位精度(du)均符合要(yao)求(qiu)(qiu)，滲碳層深(shen)度(du)為(wei)1.1-1.3mm，齒部(bu)金相組(zu)織為(wei) 單(dan)一的(de)板條狀回火馬氏(shi)體(ti)組(zu)織，硬(ying)度(du)為(wei)HRC58-62。心部(bu)硬(ying)度(du)為(wei)HRC36-40，完全可(ke)(ke)以滿足該零(ling)件的(de)質 量要(yao)求(qiu)(qiu)。