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具體參數
拖泵(beng)制作工藝
刀具選擇(ze)
從(cong)該(gai)齒(chi)(chi)(chi)(chi)輪(lun)的結構(gou)和技術參數(shu)可知(zhi),該(gai)錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)屬于標準結構(gou),一(yi)(yi)般(ban)情況下(xia)(xia),標準直齒(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑 刀的齒(chi)(chi)(chi)(chi)形(xing)是按大端背錐(zhui)當量(liang)漸開(kai)線齒(chi)(chi)(chi)(chi)形(xing)設計,而齒(chi)(chi)(chi)(chi)厚則按照小(xiao)端設計,并(bing)考慮(lv)留有(you)一(yi)(yi)定精切余量(liang)。一(yi)(yi) 般(ban)情況下(xia)(xia)直齒(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑刀有(you)3把、8把、15把、26把一(yi)(yi)套,刀號應按照錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)當量(liang)齒(chi)(chi)(chi)(chi)數(shu)來選擇。當 量(liang)齒(chi)(chi)(chi)(chi)數(shu)Zv可按照下(xia)(xia)式計算:
熱處理工藝方法及過(guo)程
如(ru)前文所述,機(ji)加(jia)(jia)工前對齒坯進行(xing)整體(ti)高溫正火(huo)處理,正火(huo)設備(bei)為RT-90-9 箱式爐(lu),具體(ti)工藝過程是(shi),爐(lu)溫升至裝(zhuang)爐(lu)溫度400-650℃時,將齒輪放 爐(lu)中,裝(zhuang)零件(jian)(jian)時如(ru)果需要(yao)疊放,疊放高度不(bu)要(yao)超過兩層,然后將零件(jian)(jian)加(jia)(jia)熱至920-940℃,使(shi)組織完(wan)全發生相變,保溫30-50分鐘后,空冷即可。正火(huo)工藝:
由于(yu)該齒輪精(jing)度要求不(bu)是很高,為(wei)降低(di)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)淬(cui)(cui)火(huo)(huo)成本,可(ke)以采(cai)用滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)后直接淬(cui)(cui)火(huo)(huo)的(de)工藝方(fang)(fang)法,具 體方(fang)(fang)法是將(jiang)零件(jian)裝入滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)筐中(zhong),不(bu)要疊加,爐(lu)(lu)溫(wen)(wen)升至840℃開(kai)始滴航空煤油,煤油滴速為(wei)60-80d/min, 爐(lu)(lu)溫(wen)(wen)升至930℃時(shi)零件(jian)開(kai)始裝爐(lu)(lu)。排氣期(qi)(qi)結(jie)束(shu)(shu)后,放入兩(liang)只(zhi)試棒(bang),其中(zhong)一(yi)只(zhi)試棒(bang)在(zai)擴散(san)時(shi)間(jian)為(wei)120 min時(shi)取(qu)出淬(cui)(cui)油冷(leng)卻并(bing)檢(jian)驗淬(cui)(cui)硬層(ceng)(ceng)深度,根據檢(jian)驗結(jie)果決定(ding)是否(fou)降溫(wen)(wen),若(ruo)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)深度不(bu)足,擴散(san)期(qi)(qi)延長至 150min。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)可(ke)按照表1規定(ding)參數進行,為(wei)控(kong)(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)的(de)碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)濃(nong)度,可(ke)采(cai)用在(zai)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)(lu)中(zhong)加裝氧傳(chuan)感(gan) 器的(de)方(fang)(fang)法進行監測和控(kong)(kong)制(zhi),氧傳(chuan)感(gan)器通過氧化鋯探頭,將(jiang)氣氛狀態轉化為(wei)電勢(shi)差(cha),上(shang)述(shu)差(cha)值通過控(kong)(kong)制(zhi) 系統(tong)的(de)比較和計算,確(que)定(ding)碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)的(de)濃(nong)度是否(fou)合(he)適并(bing)對其進行自動優化和調(diao)整,使(shi)碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)控(kong)(kong)制(zhi)精(jing)度可(ke)以達到 ≤±0.05%C,可(ke)有效控(kong)(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)深度并(bing)提(ti)高滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)的(de)質(zhi)量,確(que)保無(wu)塊狀、網(wang)狀滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)物,滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)設備采(cai) 用RQ3-75-9井式滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)(lu)。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)均(jun)溫(wen)(wen)期(qi)(qi)結(jie)束(shu)(shu)后,零件(jian)出爐(lu)(lu)直接淬(cui)(cui)火(huo)(huo)。淬(cui)(cui)火(huo)(huo)設備選用專用恒(heng)(heng)溫(wen)(wen)油槽,淬(cui)(cui) 火(huo)(huo)介(jie)質(zhi)為(wei)專用等溫(wen)(wen)分級淬(cui)(cui)火(huo)(huo)油,介(jie)質(zhi)溫(wen)(wen)度恒(heng)(heng)定(ding)在(zai)110-120℃之間(jian),冷(leng)卻30min后,出爐(lu)(lu)空冷(leng)。
為消(xiao)除淬火(huo)后(hou)(hou)零(ling)件的殘余應力并防止淬火(huo)裂紋(wen)的產生(sheng),應盡快將(jiang)淬火(huo)后(hou)(hou)的零(ling)件進行低(di)溫回(hui)火(huo)處(chu)理,具體工(gong)藝(yi)方法是在當(dang)爐(lu)溫升至160℃左右時零(ling) 件開始(shi)裝(zhuang)爐(lu),保溫120-150min后(hou)(hou),出爐(lu)空冷(leng),回(hui)火(huo)設備為RJJ-36-6回(hui)火(huo)爐(lu)。淬火(huo)及回(hui)火(huo)工(gong)藝(yi)圖見(jian)圖5:
后序處(chu)理
將熱處(chu)理后(hou)(hou)的零(ling)(ling)件(jian)(jian)放在(zai)噴砂(sha)機的轉盤上進行(xing)噴砂(sha)處(chu)理,選用石(shi)英(ying)砂(sha)的粒度(du)為10-20目,在(zai)噴砂(sha)過 程中要(yao)(yao)經常(chang)翻動零(ling)(ling)件(jian)(jian)使各面噴砂(sha)效(xiao)果均勻。零(ling)(ling)件(jian)(jian)噴砂(sha)完后(hou)(hou),放入防銹(xiu)液中浸泡2-4min后(hou)(hou),在(zai)空氣中干 燥(zao)。需要(yao)(yao)注意的是,防銹(xiu)處(chu)理必須(xu)在(zai)噴砂(sha)后(hou)(hou)24小時(shi)內完成(cheng)。
效果
上述方法(fa)簡單實用(yong),不需要(yao)專用(yong)裝備即可實現直齒錐(zhui)齒輪的(de)(de)加工(gong),且經濟性好,成本較低。經對 加工(gong)后的(de)(de)錐(zhui)齒輪進行檢測(ce),尺寸及形(xing)位精度(du)均符合要(yao)求(qiu),滲(shen)碳層深(shen)度(du)為(wei)1.1-1.3mm,齒部金(jin)相組織為(wei) 單一的(de)(de)板條狀(zhuang)回火(huo)馬氏體組織,硬度(du)為(wei)HRC58-62。心部硬度(du)為(wei)HRC36-40,完全可以(yi)滿足該零件的(de)(de)質 量要(yao)求(qiu)。