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具體參數
拖泵制作(zuo)工藝
刀具選擇
從該齒(chi)輪(lun)的結構和技術參數可知(zhi),該錐(zhui)齒(chi)輪(lun)屬于標(biao)準(zhun)結構,一(yi)般情(qing)況下(xia),標(biao)準(zhun)直齒(chi)錐(zhui)齒(chi)輪(lun)成(cheng)形銑(xian) 刀的齒(chi)形是按大端背(bei)錐(zhui)當量漸開線齒(chi)形設計(ji),而齒(chi)厚(hou)則按照小(xiao)端設計(ji),并考慮留有一(yi)定精切余量。一(yi) 般情(qing)況下(xia)直齒(chi)錐(zhui)齒(chi)輪(lun)成(cheng)形銑(xian)刀有3把(ba)(ba)、8把(ba)(ba)、15把(ba)(ba)、26把(ba)(ba)一(yi)套(tao),刀號應(ying)按照錐(zhui)齒(chi)輪(lun)當量齒(chi)數來選(xuan)擇(ze)。當 量齒(chi)數Zv可按照下(xia)式計(ji)算:
熱處理(li)工藝方法及過程(cheng)
如前(qian)文所述,機加工(gong)前(qian)對齒(chi)坯(pi)進行整體高(gao)溫正(zheng)火(huo)處理(li),正(zheng)火(huo)設備為RT-90-9 箱式爐,具體工(gong)藝(yi)過程(cheng)是,爐溫升至(zhi)裝(zhuang)(zhuang)爐溫度(du)400-650℃時(shi),將齒(chi)輪放 爐中,裝(zhuang)(zhuang)零件時(shi)如果需要疊放,疊放高(gao)度(du)不要超過兩層,然(ran)后將零件加熱至(zhi)920-940℃,使組織完全發生相變,保(bao)溫30-50分鐘后,空冷即(ji)可。正(zheng)火(huo)工(gong)藝(yi):
由于該齒輪精度(du)(du)(du)要求不(bu)是很高(gao),為(wei)(wei)降(jiang)(jiang)低滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)淬(cui)(cui)(cui)(cui)火(huo)(huo)(huo)(huo)成本,可(ke)(ke)以采用(yong)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)后(hou)直接(jie)淬(cui)(cui)(cui)(cui)火(huo)(huo)(huo)(huo)的工藝方(fang)(fang)法,具 體方(fang)(fang)法是將零(ling)(ling)件裝(zhuang)入(ru)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)筐中(zhong),不(bu)要疊加,爐(lu)溫(wen)升至(zhi)840℃開(kai)始滴(di)航空(kong)煤(mei)油(you),煤(mei)油(you)滴(di)速為(wei)(wei)60-80d/min, 爐(lu)溫(wen)升至(zhi)930℃時(shi)(shi)零(ling)(ling)件開(kai)始裝(zhuang)爐(lu)。排氣(qi)期結(jie)束后(hou),放入(ru)兩(liang)只試棒,其中(zhong)一只試棒在(zai)(zai)擴散時(shi)(shi)間(jian)為(wei)(wei)120 min時(shi)(shi)取出(chu)淬(cui)(cui)(cui)(cui)油(you)冷卻并檢驗(yan)淬(cui)(cui)(cui)(cui)硬層(ceng)深(shen)度(du)(du)(du),根據檢驗(yan)結(jie)果決定是否降(jiang)(jiang)溫(wen),若(ruo)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)深(shen)度(du)(du)(du)不(bu)足,擴散期延長至(zhi) 150min。滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)(shi)可(ke)(ke)按照表1規定參(can)數進(jin)行(xing),為(wei)(wei)控制(zhi)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)(shi)的碳(tan)(tan)(tan)勢(shi)(shi)濃度(du)(du)(du),可(ke)(ke)采用(yong)在(zai)(zai)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)中(zhong)加裝(zhuang)氧(yang)傳感 器(qi)的方(fang)(fang)法進(jin)行(xing)監(jian)測(ce)和控制(zhi),氧(yang)傳感器(qi)通過氧(yang)化(hua)鋯探頭,將氣(qi)氛狀態轉(zhuan)化(hua)為(wei)(wei)電勢(shi)(shi)差,上述差值通過控制(zhi) 系統的比較和計算,確定碳(tan)(tan)(tan)勢(shi)(shi)的濃度(du)(du)(du)是否合適并對其進(jin)行(xing)自動優化(hua)和調整,使碳(tan)(tan)(tan)勢(shi)(shi)控制(zhi)精度(du)(du)(du)可(ke)(ke)以達到 ≤±0.05%C,可(ke)(ke)有(you)效(xiao)控制(zhi)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)深(shen)度(du)(du)(du)并提高(gao)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)的質(zhi)量(liang),確保無塊狀、網狀滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)物,滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)設備采 用(yong)RQ3-75-9井(jing)式(shi)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)均(jun)溫(wen)期結(jie)束后(hou),零(ling)(ling)件出(chu)爐(lu)直接(jie)淬(cui)(cui)(cui)(cui)火(huo)(huo)(huo)(huo)。淬(cui)(cui)(cui)(cui)火(huo)(huo)(huo)(huo)設備選用(yong)專(zhuan)用(yong)恒溫(wen)油(you)槽,淬(cui)(cui)(cui)(cui) 火(huo)(huo)(huo)(huo)介(jie)質(zhi)為(wei)(wei)專(zhuan)用(yong)等溫(wen)分(fen)級淬(cui)(cui)(cui)(cui)火(huo)(huo)(huo)(huo)油(you),介(jie)質(zhi)溫(wen)度(du)(du)(du)恒定在(zai)(zai)110-120℃之間(jian),冷卻30min后(hou),出(chu)爐(lu)空(kong)冷。
為(wei)消除淬火(huo)后零件的(de)殘余應力并防止淬火(huo)裂(lie)紋的(de)產生(sheng),應盡(jin)快將淬火(huo)后的(de)零件進行低(di)溫(wen)回(hui)火(huo)處理,具體工藝方法(fa)是在(zai)當爐(lu)溫(wen)升至160℃左右(you)時零 件開始裝爐(lu),保溫(wen)120-150min后,出爐(lu)空(kong)冷(leng),回(hui)火(huo)設備為(wei)RJJ-36-6回(hui)火(huo)爐(lu)。淬火(huo)及(ji)回(hui)火(huo)工藝圖見圖5:
后序處理
將熱處(chu)理(li)后(hou)的(de)(de)零(ling)件(jian)放(fang)在噴(pen)砂機(ji)的(de)(de)轉盤上進行噴(pen)砂處(chu)理(li),選用石英砂的(de)(de)粒(li)度為(wei)10-20目(mu),在噴(pen)砂過 程(cheng)中要經常(chang)翻動零(ling)件(jian)使各面噴(pen)砂效果均勻。零(ling)件(jian)噴(pen)砂完后(hou),放(fang)入(ru)防銹液中浸泡2-4min后(hou),在空氣中干 燥。需要注意的(de)(de)是,防銹處(chu)理(li)必(bi)須在噴(pen)砂后(hou)24小時內完成。
效果
上述方法(fa)簡單實(shi)用(yong),不需要(yao)專用(yong)裝(zhuang)備即可實(shi)現(xian)直齒(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)輪的加工,且(qie)經濟性好(hao),成本較低。經對 加工后(hou)的錐(zhui)齒(chi)(chi)(chi)輪進行檢測,尺寸及形(xing)位精度(du)(du)均(jun)符合(he)要(yao)求(qiu),滲碳層深度(du)(du)為(wei)1.1-1.3mm,齒(chi)(chi)(chi)部金相組(zu)織(zhi)為(wei) 單一的板條狀回(hui)火馬氏體組(zu)織(zhi),硬度(du)(du)為(wei)HRC58-62。心部硬度(du)(du)為(wei)HRC36-40,完全可以(yi)滿足(zu)該零件(jian)的質(zhi) 量要(yao)求(qiu)。