具體參數

拖泵(beng)制(zhi)作工藝

刀具選擇

從該(gai)齒(chi)(chi)(chi)輪(lun)(lun)的(de)結(jie)構(gou)(gou)和技術(shu)參(can)數可(ke)知，該(gai)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)屬于(yu)標準結(jie)構(gou)(gou)，一(yi)般(ban)(ban)情況下，標準直齒(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)成形銑(xian) 刀的(de)齒(chi)(chi)(chi)形是按(an)(an)大端背錐(zhui)(zhui)當量(liang)漸開(kai)線齒(chi)(chi)(chi)形設計(ji)，而齒(chi)(chi)(chi)厚則按(an)(an)照小端設計(ji)，并考慮留有(you)一(yi)定精切(qie)余量(liang)。一(yi) 般(ban)(ban)情況下直齒(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)成形銑(xian)刀有(you)3把、8把、15把、26把一(yi)套(tao)，刀號(hao)應按(an)(an)照錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)當量(liang)齒(chi)(chi)(chi)數來(lai)選擇。當 量(liang)齒(chi)(chi)(chi)數Zv可(ke)按(an)(an)照下式計(ji)算(suan)：

熱(re)處(chu)理工藝方法(fa)及過(guo)程

如前(qian)(qian)文所述，機加工(gong)前(qian)(qian)對齒坯進行整體高(gao)溫正(zheng)火處理，正(zheng)火設備為RT-90-9 箱式爐(lu)，具體工(gong)藝過(guo)程是(shi)，爐(lu)溫升至裝爐(lu)溫度400-650℃時，將(jiang)齒輪放(fang)(fang) 爐(lu)中(zhong)，裝零(ling)件(jian)時如果需要疊放(fang)(fang)，疊放(fang)(fang)高(gao)度不(bu)要超過(guo)兩層，然后將(jiang)零(ling)件(jian)加熱至920-940℃，使(shi)組織完全發生相變，保溫30-50分鐘(zhong)后，空冷即可。正(zheng)火工(gong)藝：

由于該齒輪精度要求不是(shi)(shi)很高(gao)(gao)，為(wei)降(jiang)低(di)滲(shen)(shen)(shen)(shen)碳(tan)(tan)淬(cui)火成(cheng)本，可(ke)以采用滲(shen)(shen)(shen)(shen)碳(tan)(tan)后(hou)直接(jie)淬(cui)火的(de)工藝方法，具 體方法是(shi)(shi)將零(ling)(ling)(ling)件(jian)裝(zhuang)入滲(shen)(shen)(shen)(shen)碳(tan)(tan)筐中，不要疊加，爐溫(wen)(wen)升至(zhi)840℃開始滴航空(kong)煤油(you)，煤油(you)滴速為(wei)60-80d/min， 爐溫(wen)(wen)升至(zhi)930℃時零(ling)(ling)(ling)件(jian)開始裝(zhuang)爐。排氣(qi)期(qi)結束后(hou)，放入兩(liang)只試棒(bang)(bang)，其(qi)中一只試棒(bang)(bang)在(zai)擴散(san)時間(jian)為(wei)120 min時取(qu)出(chu)淬(cui)油(you)冷(leng)卻并檢驗(yan)淬(cui)硬層(ceng)深(shen)度，根據(ju)檢驗(yan)結果(guo)決定(ding)是(shi)(shi)否降(jiang)溫(wen)(wen)，若滲(shen)(shen)(shen)(shen)碳(tan)(tan)層(ceng)深(shen)度不足，擴散(san)期(qi)延長(chang)至(zhi) 150min。滲(shen)(shen)(shen)(shen)碳(tan)(tan)時可(ke)按照表1規(gui)定(ding)參數進行(xing)(xing)，為(wei)控(kong)(kong)(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)時的(de)碳(tan)(tan)勢(shi)(shi)濃(nong)度，可(ke)采用在(zai)滲(shen)(shen)(shen)(shen)碳(tan)(tan)爐中加裝(zhuang)氧(yang)傳(chuan)感(gan) 器的(de)方法進行(xing)(xing)監測和(he)控(kong)(kong)(kong)制(zhi)，氧(yang)傳(chuan)感(gan)器通(tong)過(guo)氧(yang)化(hua)鋯探頭，將氣(qi)氛狀態(tai)轉化(hua)為(wei)電勢(shi)(shi)差(cha)(cha)，上(shang)述差(cha)(cha)值通(tong)過(guo)控(kong)(kong)(kong)制(zhi) 系統的(de)比較(jiao)和(he)計算，確定(ding)碳(tan)(tan)勢(shi)(shi)的(de)濃(nong)度是(shi)(shi)否合適并對其(qi)進行(xing)(xing)自(zi)動優化(hua)和(he)調(diao)整，使(shi)碳(tan)(tan)勢(shi)(shi)控(kong)(kong)(kong)制(zhi)精度可(ke)以達到 ≤±0.05%C，可(ke)有效控(kong)(kong)(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)層(ceng)深(shen)度并提高(gao)(gao)滲(shen)(shen)(shen)(shen)碳(tan)(tan)層(ceng)的(de)質量，確保無塊(kuai)狀、網狀滲(shen)(shen)(shen)(shen)碳(tan)(tan)物，滲(shen)(shen)(shen)(shen)碳(tan)(tan)設備采 用RQ3-75-9井式滲(shen)(shen)(shen)(shen)碳(tan)(tan)爐。滲(shen)(shen)(shen)(shen)碳(tan)(tan)均溫(wen)(wen)期(qi)結束后(hou)，零(ling)(ling)(ling)件(jian)出(chu)爐直接(jie)淬(cui)火。淬(cui)火設備選用專(zhuan)用恒(heng)溫(wen)(wen)油(you)槽，淬(cui) 火介質為(wei)專(zhuan)用等溫(wen)(wen)分(fen)級淬(cui)火油(you)，介質溫(wen)(wen)度恒(heng)定(ding)在(zai)110-120℃之(zhi)間(jian)，冷(leng)卻30min后(hou)，出(chu)爐空(kong)冷(leng)。

為消除淬火(huo)(huo)(huo)后零(ling)件(jian)的(de)殘余應(ying)力(li)并防(fang)止淬火(huo)(huo)(huo)裂紋(wen)的(de)產生，應(ying)盡快(kuai)將淬火(huo)(huo)(huo)后的(de)零(ling)件(jian)進行低溫回火(huo)(huo)(huo)處理，具體工(gong)藝方(fang)法是在當爐(lu)溫升至160℃左右(you)時(shi)零(ling) 件(jian)開始(shi)裝爐(lu)，保(bao)溫120-150min后，出爐(lu)空冷，回火(huo)(huo)(huo)設(she)備為RJJ-36-6回火(huo)(huo)(huo)爐(lu)。淬火(huo)(huo)(huo)及回火(huo)(huo)(huo)工(gong)藝圖(tu)見(jian)圖(tu)5：

后序(xu)處理

將熱處(chu)(chu)理(li)后(hou)的零件(jian)放在(zai)噴(pen)砂(sha)機的轉(zhuan)盤上進行(xing)噴(pen)砂(sha)處(chu)(chu)理(li)，選(xuan)用石(shi)英砂(sha)的粒度為(wei)10-20目，在(zai)噴(pen)砂(sha)過 程中(zhong)(zhong)要(yao)經常(chang)翻動零件(jian)使各面噴(pen)砂(sha)效(xiao)果均勻。零件(jian)噴(pen)砂(sha)完(wan)后(hou)，放入防銹液(ye)中(zhong)(zhong)浸泡2-4min后(hou)，在(zai)空氣中(zhong)(zhong)干 燥。需(xu)要(yao)注意的是，防銹處(chu)(chu)理(li)必須(xu)在(zai)噴(pen)砂(sha)后(hou)24小時(shi)內完(wan)成。

效果

上述方法簡單實用(yong)，不需要(yao)專用(yong)裝備即可實現(xian)直齒(chi)(chi)錐(zhui)齒(chi)(chi)輪的加工，且經濟(ji)性好(hao)，成本較低。經對(dui) 加工后的錐(zhui)齒(chi)(chi)輪進行檢測，尺寸及(ji)形位精度(du)均符合要(yao)求(qiu)，滲碳層(ceng)深(shen)度(du)為(wei)1.1-1.3mm，齒(chi)(chi)部金相組(zu)織為(wei) 單一的板條狀(zhuang)回火馬氏體組(zu)織，硬度(du)為(wei)HRC58-62。心部硬度(du)為(wei)HRC36-40，完全可以滿足(zu)該零件(jian)的質 量要(yao)求(qiu)。