東莞市銳鑫機電有限公司
聯(lian)系人:劉(liu)君燕/13539086677
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地址(zhi):東(dong)(dong)莞市虎門鎮捷(jie)東(dong)(dong)南路(lu)9號
B棟(dong)401
具體參數
拖泵制作(zuo)工藝
刀具選擇
從該(gai)齒(chi)(chi)(chi)輪的結構(gou)和技術參(can)數(shu)可知,該(gai)錐(zhui)齒(chi)(chi)(chi)輪屬于標準(zhun)結構(gou),一般(ban)(ban)情(qing)況下(xia),標準(zhun)直齒(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)輪成形銑 刀的齒(chi)(chi)(chi)形是按大端背錐(zhui)當量(liang)(liang)漸開線(xian)齒(chi)(chi)(chi)形設(she)計,而齒(chi)(chi)(chi)厚則(ze)按照小端設(she)計,并考慮留有(you)一定(ding)精切余(yu)量(liang)(liang)。一 般(ban)(ban)情(qing)況下(xia)直齒(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)輪成形銑刀有(you)3把(ba)(ba)(ba)、8把(ba)(ba)(ba)、15把(ba)(ba)(ba)、26把(ba)(ba)(ba)一套,刀號應(ying)按照錐(zhui)齒(chi)(chi)(chi)輪當量(liang)(liang)齒(chi)(chi)(chi)數(shu)來選擇。當 量(liang)(liang)齒(chi)(chi)(chi)數(shu)Zv可按照下(xia)式計算:
熱處理工藝方法(fa)及過程
如(ru)前文(wen)所述,機加工(gong)前對(dui)齒(chi)坯進行整體高(gao)溫(wen)正火(huo)(huo)處理,正火(huo)(huo)設(she)備為RT-90-9 箱式爐,具體工(gong)藝過(guo)程是,爐溫(wen)升至(zhi)裝(zhuang)爐溫(wen)度400-650℃時,將齒(chi)輪放(fang)(fang)(fang) 爐中,裝(zhuang)零(ling)件時如(ru)果需要(yao)疊放(fang)(fang)(fang),疊放(fang)(fang)(fang)高(gao)度不要(yao)超過(guo)兩(liang)層,然后將零(ling)件加熱至(zhi)920-940℃,使組織完全發生相變,保(bao)溫(wen)30-50分鐘后,空冷(leng)即可。正火(huo)(huo)工(gong)藝:
由于該齒輪精度(du)要求不是(shi)很(hen)高,為(wei)(wei)降低滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)淬(cui)(cui)(cui)火(huo)(huo)(huo)成本,可(ke)(ke)以采(cai)用(yong)滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)后直(zhi)接淬(cui)(cui)(cui)火(huo)(huo)(huo)的(de)工藝(yi)方法,具(ju) 體(ti)方法是(shi)將零(ling)件(jian)裝(zhuang)入滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)筐中(zhong),不要疊(die)加(jia),爐(lu)(lu)(lu)溫(wen)(wen)(wen)(wen)升至(zhi)840℃開(kai)(kai)始(shi)滴航空煤油,煤油滴速為(wei)(wei)60-80d/min, 爐(lu)(lu)(lu)溫(wen)(wen)(wen)(wen)升至(zhi)930℃時(shi)(shi)零(ling)件(jian)開(kai)(kai)始(shi)裝(zhuang)爐(lu)(lu)(lu)。排氣(qi)期結束后,放入兩(liang)只試棒,其(qi)中(zhong)一只試棒在擴散(san)時(shi)(shi)間(jian)為(wei)(wei)120 min時(shi)(shi)取出淬(cui)(cui)(cui)油冷卻并檢驗淬(cui)(cui)(cui)硬層(ceng)深度(du),根據檢驗結果決定(ding)是(shi)否(fou)降溫(wen)(wen)(wen)(wen),若滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層(ceng)深度(du)不足,擴散(san)期延(yan)長至(zhi) 150min。滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)時(shi)(shi)可(ke)(ke)按照表1規定(ding)參數進行,為(wei)(wei)控(kong)制滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)時(shi)(shi)的(de)碳(tan)(tan)(tan)(tan)(tan)勢濃度(du),可(ke)(ke)采(cai)用(yong)在滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)爐(lu)(lu)(lu)中(zhong)加(jia)裝(zhuang)氧傳(chuan)感 器的(de)方法進行監測(ce)和控(kong)制,氧傳(chuan)感器通(tong)過氧化鋯探頭(tou),將氣(qi)氛狀(zhuang)態轉化為(wei)(wei)電勢差(cha),上(shang)述差(cha)值(zhi)通(tong)過控(kong)制 系統的(de)比(bi)較和計算,確定(ding)碳(tan)(tan)(tan)(tan)(tan)勢的(de)濃度(du)是(shi)否(fou)合適并對其(qi)進行自動優化和調整,使(shi)碳(tan)(tan)(tan)(tan)(tan)勢控(kong)制精度(du)可(ke)(ke)以達到(dao) ≤±0.05%C,可(ke)(ke)有效控(kong)制滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層(ceng)深度(du)并提高滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層(ceng)的(de)質量(liang),確保無(wu)塊(kuai)狀(zhuang)、網狀(zhuang)滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)物,滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)設備采(cai) 用(yong)RQ3-75-9井(jing)式滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)爐(lu)(lu)(lu)。滲(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)均溫(wen)(wen)(wen)(wen)期結束后,零(ling)件(jian)出爐(lu)(lu)(lu)直(zhi)接淬(cui)(cui)(cui)火(huo)(huo)(huo)。淬(cui)(cui)(cui)火(huo)(huo)(huo)設備選(xuan)用(yong)專(zhuan)用(yong)恒溫(wen)(wen)(wen)(wen)油槽(cao),淬(cui)(cui)(cui) 火(huo)(huo)(huo)介(jie)質為(wei)(wei)專(zhuan)用(yong)等溫(wen)(wen)(wen)(wen)分級淬(cui)(cui)(cui)火(huo)(huo)(huo)油,介(jie)質溫(wen)(wen)(wen)(wen)度(du)恒定(ding)在110-120℃之間(jian),冷卻30min后,出爐(lu)(lu)(lu)空冷。
為(wei)消(xiao)除淬(cui)火(huo)(huo)(huo)后零件(jian)的(de)(de)(de)殘余應力并(bing)防(fang)止淬(cui)火(huo)(huo)(huo)裂紋的(de)(de)(de)產生,應盡快將(jiang)淬(cui)火(huo)(huo)(huo)后的(de)(de)(de)零件(jian)進(jin)行低溫回火(huo)(huo)(huo)處理,具體工(gong)藝方法是在(zai)當爐(lu)溫升至(zhi)160℃左右時(shi)零 件(jian)開始(shi)裝爐(lu),保溫120-150min后,出爐(lu)空冷(leng),回火(huo)(huo)(huo)設備為(wei)RJJ-36-6回火(huo)(huo)(huo)爐(lu)。淬(cui)火(huo)(huo)(huo)及回火(huo)(huo)(huo)工(gong)藝圖見(jian)圖5:
后序處理
將熱處理后(hou)(hou)的零件(jian)(jian)放(fang)在(zai)噴砂機的轉盤上(shang)進行(xing)噴砂處理,選用石(shi)英砂的粒度為10-20目,在(zai)噴砂過 程中(zhong)要經常翻動(dong)零件(jian)(jian)使各(ge)面噴砂效果均勻。零件(jian)(jian)噴砂完后(hou)(hou),放(fang)入(ru)防銹液中(zhong)浸泡2-4min后(hou)(hou),在(zai)空氣中(zhong)干(gan) 燥。需(xu)要注(zhu)意(yi)的是,防銹處理必須(xu)在(zai)噴砂后(hou)(hou)24小(xiao)時內完成。
效果
上述方法簡(jian)單實(shi)用(yong),不需要專(zhuan)用(yong)裝備即可實(shi)現直齒(chi)(chi)錐(zhui)齒(chi)(chi)輪的(de)加(jia)工,且經濟性好,成本較低。經對 加(jia)工后的(de)錐(zhui)齒(chi)(chi)輪進行檢測,尺(chi)寸及形位精度(du)均符合要求,滲碳層深度(du)為(wei)1.1-1.3mm,齒(chi)(chi)部金相組織(zhi)為(wei) 單一(yi)的(de)板(ban)條(tiao)狀回火(huo)馬氏體組織(zhi),硬度(du)為(wei)HRC58-62。心部硬度(du)為(wei)HRC36-40,完(wan)全可以(yi)滿足該(gai)零件(jian)的(de)質 量(liang)要求。