東(dong)莞(guan)市銳(rui)鑫(xin)機(ji)電有限公(gong)司
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B棟401
具體參數
拖泵(beng)制作工藝
刀具選(xuan)擇
從該齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)的結構(gou)和技術參數(shu)可(ke)知,該錐(zhui)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)屬于(yu)標(biao)(biao)準結構(gou),一(yi)般(ban)(ban)情(qing)況下(xia),標(biao)(biao)準直齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑(xian)(xian) 刀(dao)的齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)形(xing)是(shi)按大端(duan)背錐(zhui)當量(liang)(liang)漸開線齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)形(xing)設(she)計(ji)(ji),而齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)厚(hou)則(ze)按照(zhao)小端(duan)設(she)計(ji)(ji),并考慮留(liu)有一(yi)定精切余量(liang)(liang)。一(yi) 般(ban)(ban)情(qing)況下(xia)直齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑(xian)(xian)刀(dao)有3把(ba)(ba)、8把(ba)(ba)、15把(ba)(ba)、26把(ba)(ba)一(yi)套(tao),刀(dao)號(hao)應(ying)按照(zhao)錐(zhui)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)當量(liang)(liang)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)數(shu)來選擇(ze)。當 量(liang)(liang)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)(chi)數(shu)Zv可(ke)按照(zhao)下(xia)式計(ji)(ji)算(suan):
熱處理工藝方(fang)法及過程
如(ru)前(qian)文(wen)所述,機加(jia)工前(qian)對(dui)齒坯進行整體高溫(wen)正火(huo)處理,正火(huo)設備為RT-90-9 箱式爐(lu),具體工藝過(guo)程是,爐(lu)溫(wen)升(sheng)至裝(zhuang)爐(lu)溫(wen)度400-650℃時,將齒輪放 爐(lu)中,裝(zhuang)零件(jian)時如(ru)果需要(yao)(yao)疊(die)放,疊(die)放高度不要(yao)(yao)超過(guo)兩層,然后將零件(jian)加(jia)熱至920-940℃,使組織完全發生(sheng)相變,保溫(wen)30-50分(fen)鐘后,空冷即可。正火(huo)工藝:
由于該齒(chi)輪精度(du)要求(qiu)不(bu)是很(hen)高,為降低滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)淬(cui)(cui)火(huo)(huo)成本,可(ke)以采用滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)后(hou)(hou)直接淬(cui)(cui)火(huo)(huo)的(de)(de)工藝方(fang)法,具 體方(fang)法是將零(ling)(ling)(ling)件裝入(ru)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)筐中(zhong),不(bu)要疊加(jia),爐(lu)(lu)溫升至(zhi)840℃開始滴(di)航(hang)空(kong)煤(mei)油(you),煤(mei)油(you)滴(di)速(su)為60-80d/min, 爐(lu)(lu)溫升至(zhi)930℃時零(ling)(ling)(ling)件開始裝爐(lu)(lu)。排(pai)氣期(qi)結束后(hou)(hou),放入(ru)兩只(zhi)試(shi)棒,其中(zhong)一只(zhi)試(shi)棒在擴散時間(jian)為120 min時取出淬(cui)(cui)油(you)冷(leng)卻(que)并(bing)檢(jian)驗淬(cui)(cui)硬層(ceng)(ceng)深度(du),根(gen)據檢(jian)驗結果決定(ding)(ding)是否降溫,若滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)深度(du)不(bu)足,擴散期(qi)延長至(zhi) 150min。滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時可(ke)按照(zhao)表1規定(ding)(ding)參(can)數進行,為控(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時的(de)(de)碳(tan)(tan)(tan)(tan)勢(shi)(shi)濃度(du),可(ke)采用在滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)(lu)中(zhong)加(jia)裝氧(yang)傳感 器(qi)的(de)(de)方(fang)法進行監(jian)測和(he)(he)控(kong)制(zhi)(zhi),氧(yang)傳感器(qi)通(tong)過氧(yang)化(hua)鋯探頭,將氣氛狀態轉化(hua)為電勢(shi)(shi)差(cha)(cha),上述差(cha)(cha)值(zhi)通(tong)過控(kong)制(zhi)(zhi) 系統的(de)(de)比較和(he)(he)計算,確定(ding)(ding)碳(tan)(tan)(tan)(tan)勢(shi)(shi)的(de)(de)濃度(du)是否合適并(bing)對其進行自動優化(hua)和(he)(he)調整,使碳(tan)(tan)(tan)(tan)勢(shi)(shi)控(kong)制(zhi)(zhi)精度(du)可(ke)以達到(dao) ≤±0.05%C,可(ke)有效控(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)深度(du)并(bing)提高滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)的(de)(de)質量,確保(bao)無塊狀、網狀滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)物,滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)設(she)備采 用RQ3-75-9井式滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)(lu)。滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)均溫期(qi)結束后(hou)(hou),零(ling)(ling)(ling)件出爐(lu)(lu)直接淬(cui)(cui)火(huo)(huo)。淬(cui)(cui)火(huo)(huo)設(she)備選用專用恒(heng)(heng)溫油(you)槽,淬(cui)(cui) 火(huo)(huo)介質為專用等溫分級淬(cui)(cui)火(huo)(huo)油(you),介質溫度(du)恒(heng)(heng)定(ding)(ding)在110-120℃之(zhi)間(jian),冷(leng)卻(que)30min后(hou)(hou),出爐(lu)(lu)空(kong)冷(leng)。
為消除(chu)淬(cui)火后(hou)(hou)零(ling)件的(de)殘余應力(li)并防止淬(cui)火裂紋的(de)產生,應盡快將(jiang)淬(cui)火后(hou)(hou)的(de)零(ling)件進(jin)行(xing)低溫回火處理,具體工(gong)藝方法是在當爐(lu)溫升至160℃左右時零(ling) 件開(kai)始(shi)裝爐(lu),保溫120-150min后(hou)(hou),出爐(lu)空冷,回火設備為RJJ-36-6回火爐(lu)。淬(cui)火及(ji)回火工(gong)藝圖(tu)見圖(tu)5:
后(hou)序處理
將(jiang)熱(re)處(chu)(chu)理后的零(ling)件放在(zai)噴(pen)(pen)(pen)砂(sha)機的轉盤上進行噴(pen)(pen)(pen)砂(sha)處(chu)(chu)理,選用(yong)石英(ying)砂(sha)的粒度為10-20目,在(zai)噴(pen)(pen)(pen)砂(sha)過 程中(zhong)要(yao)經常翻動(dong)零(ling)件使各面(mian)噴(pen)(pen)(pen)砂(sha)效果均(jun)勻(yun)。零(ling)件噴(pen)(pen)(pen)砂(sha)完后,放入防銹液中(zhong)浸泡(pao)2-4min后,在(zai)空氣中(zhong)干 燥。需要(yao)注意的是,防銹處(chu)(chu)理必須在(zai)噴(pen)(pen)(pen)砂(sha)后24小(xiao)時內完成(cheng)。
效果
上述方法(fa)簡(jian)單(dan)實用,不需要專用裝備(bei)即(ji)可(ke)實現(xian)直齒(chi)錐齒(chi)輪的(de)加(jia)工,且經濟性(xing)好(hao),成本較低。經對 加(jia)工后的(de)錐齒(chi)輪進行檢(jian)測,尺寸及形位精度(du)均符合要求,滲(shen)碳(tan)層深度(du)為1.1-1.3mm,齒(chi)部金相(xiang)組(zu)織為 單(dan)一的(de)板條狀回火馬氏體組(zu)織,硬度(du)為HRC58-62。心(xin)部硬度(du)為HRC36-40,完(wan)全可(ke)以滿足該零件(jian)的(de)質 量要求。