具體參數

拖泵制(zhi)作工藝

刀具選擇

從該齒(chi)(chi)(chi)(chi)(chi)輪的(de)結構(gou)和技術(shu)參數(shu)可知(zhi)，該錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪屬(shu)于(yu)標(biao)準(zhun)結構(gou)，一般(ban)情(qing)況(kuang)下，標(biao)準(zhun)直齒(chi)(chi)(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪成(cheng)形(xing)(xing)(xing)銑 刀(dao)的(de)齒(chi)(chi)(chi)(chi)(chi)形(xing)(xing)(xing)是按大端背錐(zhui)(zhui)當(dang)量(liang)漸開(kai)線齒(chi)(chi)(chi)(chi)(chi)形(xing)(xing)(xing)設(she)計(ji)(ji)，而齒(chi)(chi)(chi)(chi)(chi)厚則按照小(xiao)端設(she)計(ji)(ji)，并考慮(lv)留有一定精(jing)切余量(liang)。一 般(ban)情(qing)況(kuang)下直齒(chi)(chi)(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪成(cheng)形(xing)(xing)(xing)銑刀(dao)有3把(ba)、8把(ba)、15把(ba)、26把(ba)一套(tao)，刀(dao)號應按照錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪當(dang)量(liang)齒(chi)(chi)(chi)(chi)(chi)數(shu)來選擇。當(dang) 量(liang)齒(chi)(chi)(chi)(chi)(chi)數(shu)Zv可按照下式計(ji)(ji)算：

熱(re)處理工藝方法(fa)及過程

如前文(wen)所述，機加(jia)工(gong)(gong)前對齒坯進(jin)行整體(ti)高(gao)溫(wen)正火處(chu)理，正火設備為RT-90-9 箱式(shi)爐，具體(ti)工(gong)(gong)藝(yi)過(guo)程是，爐溫(wen)升至裝爐溫(wen)度400-650℃時，將(jiang)齒輪放(fang)(fang) 爐中，裝零件時如果需(xu)要疊放(fang)(fang)，疊放(fang)(fang)高(gao)度不要超過(guo)兩層(ceng)，然后將(jiang)零件加(jia)熱至920-940℃，使組(zu)織(zhi)完全發生相(xiang)變，保溫(wen)30-50分鐘后，空冷即可。正火工(gong)(gong)藝(yi)：

由于(yu)該齒輪精度(du)(du)(du)要求不是很高(gao)，為降(jiang)低滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)淬(cui)(cui)(cui)(cui)火(huo)成本(ben)，可(ke)以(yi)采(cai)用(yong)(yong)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)后(hou)直接淬(cui)(cui)(cui)(cui)火(huo)的工(gong)藝(yi)方(fang)法，具 體(ti)方(fang)法是將(jiang)零(ling)件(jian)(jian)裝(zhuang)入滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)筐中(zhong)，不要疊(die)加，爐溫(wen)升至(zhi)840℃開始(shi)滴(di)航空(kong)煤(mei)油(you)，煤(mei)油(you)滴(di)速為60-80d/min， 爐溫(wen)升至(zhi)930℃時(shi)零(ling)件(jian)(jian)開始(shi)裝(zhuang)爐。排氣期結(jie)(jie)束后(hou)，放入兩(liang)只(zhi)試棒，其(qi)中(zhong)一只(zhi)試棒在擴散時(shi)間為120 min時(shi)取出淬(cui)(cui)(cui)(cui)油(you)冷(leng)(leng)卻(que)并(bing)檢(jian)驗淬(cui)(cui)(cui)(cui)硬層(ceng)深(shen)度(du)(du)(du)，根據檢(jian)驗結(jie)(jie)果決定(ding)(ding)是否(fou)(fou)降(jiang)溫(wen)，若滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)深(shen)度(du)(du)(du)不足，擴散期延長(chang)至(zhi) 150min。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)可(ke)按照表1規定(ding)(ding)參(can)數進行(xing)(xing)(xing)，為控(kong)制滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)的碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)濃度(du)(du)(du)，可(ke)采(cai)用(yong)(yong)在滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐中(zhong)加裝(zhuang)氧(yang)(yang)傳感 器的方(fang)法進行(xing)(xing)(xing)監(jian)測和(he)(he)控(kong)制，氧(yang)(yang)傳感器通過氧(yang)(yang)化鋯(gao)探(tan)頭(tou)，將(jiang)氣氛狀態(tai)轉化為電勢(shi)差，上(shang)述差值通過控(kong)制 系(xi)統的比較和(he)(he)計算，確定(ding)(ding)碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)的濃度(du)(du)(du)是否(fou)(fou)合適(shi)并(bing)對其(qi)進行(xing)(xing)(xing)自動優(you)化和(he)(he)調整，使碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)控(kong)制精度(du)(du)(du)可(ke)以(yi)達到 ≤±0.05%C，可(ke)有效控(kong)制滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)深(shen)度(du)(du)(du)并(bing)提(ti)高(gao)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)的質量，確保無塊(kuai)狀、網狀滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)物，滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)設備采(cai) 用(yong)(yong)RQ3-75-9井式滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)均溫(wen)期結(jie)(jie)束后(hou)，零(ling)件(jian)(jian)出爐直接淬(cui)(cui)(cui)(cui)火(huo)。淬(cui)(cui)(cui)(cui)火(huo)設備選(xuan)用(yong)(yong)專用(yong)(yong)恒溫(wen)油(you)槽，淬(cui)(cui)(cui)(cui) 火(huo)介質為專用(yong)(yong)等溫(wen)分級淬(cui)(cui)(cui)(cui)火(huo)油(you)，介質溫(wen)度(du)(du)(du)恒定(ding)(ding)在110-120℃之間，冷(leng)(leng)卻(que)30min后(hou)，出爐空(kong)冷(leng)(leng)。

為消(xiao)除淬火(huo)后(hou)零(ling)件(jian)(jian)的(de)(de)殘余應力并(bing)防止淬火(huo)裂紋的(de)(de)產生，應盡快將(jiang)淬火(huo)后(hou)的(de)(de)零(ling)件(jian)(jian)進行低溫(wen)(wen)回火(huo)處理(li)，具體工(gong)藝方法是在當(dang)爐溫(wen)(wen)升至(zhi)160℃左(zuo)右時零(ling) 件(jian)(jian)開(kai)始(shi)裝爐，保(bao)溫(wen)(wen)120-150min后(hou)，出爐空冷，回火(huo)設備為RJJ-36-6回火(huo)爐。淬火(huo)及回火(huo)工(gong)藝圖見圖5：

后序處理

將熱處理(li)后(hou)的(de)零(ling)(ling)(ling)件(jian)放在(zai)噴(pen)(pen)砂(sha)(sha)機的(de)轉盤上進行噴(pen)(pen)砂(sha)(sha)處理(li)，選(xuan)用石英(ying)砂(sha)(sha)的(de)粒度為10-20目，在(zai)噴(pen)(pen)砂(sha)(sha)過 程中(zhong)(zhong)要經常翻(fan)動零(ling)(ling)(ling)件(jian)使(shi)各(ge)面(mian)噴(pen)(pen)砂(sha)(sha)效果均勻。零(ling)(ling)(ling)件(jian)噴(pen)(pen)砂(sha)(sha)完后(hou)，放入防銹(xiu)(xiu)液(ye)中(zhong)(zhong)浸泡2-4min后(hou)，在(zai)空氣中(zhong)(zhong)干 燥。需要注意的(de)是(shi)，防銹(xiu)(xiu)處理(li)必須在(zai)噴(pen)(pen)砂(sha)(sha)后(hou)24小時內完成。

效果

上述方法簡(jian)單(dan)實(shi)用(yong)，不(bu)需(xu)要專用(yong)裝備即(ji)可實(shi)現直齒(chi)錐(zhui)齒(chi)輪的加工，且(qie)經濟性好，成本較(jiao)低。經對 加工后的錐(zhui)齒(chi)輪進行檢測，尺寸及形位精度(du)均符合要求，滲碳(tan)層深度(du)為(wei)(wei)1.1-1.3mm，齒(chi)部金相組織(zhi)為(wei)(wei) 單(dan)一的板(ban)條(tiao)狀回火(huo)馬氏體(ti)組織(zhi)，硬(ying)度(du)為(wei)(wei)HRC58-62。心(xin)部硬(ying)度(du)為(wei)(wei)HRC36-40，完全可以滿足該零件的質 量要求。