具體參數

拖泵制(zhi)作工藝

刀具(ju)選擇(ze)

從(cong)該齒(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)的結(jie)構和(he)技術參數可知，該錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)屬(shu)于標準(zhun)結(jie)構，一(yi)般(ban)情(qing)況下(xia)，標準(zhun)直齒(chi)(chi)(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)成形銑 刀的齒(chi)(chi)(chi)(chi)(chi)形是按(an)大(da)端背錐(zhui)(zhui)當量漸(jian)開線齒(chi)(chi)(chi)(chi)(chi)形設計，而齒(chi)(chi)(chi)(chi)(chi)厚(hou)則按(an)照小端設計，并考慮留有(you)一(yi)定(ding)精切余量。一(yi) 般(ban)情(qing)況下(xia)直齒(chi)(chi)(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)成形銑刀有(you)3把、8把、15把、26把一(yi)套(tao)，刀號(hao)應按(an)照錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)當量齒(chi)(chi)(chi)(chi)(chi)數來選擇(ze)。當 量齒(chi)(chi)(chi)(chi)(chi)數Zv可按(an)照下(xia)式計算：

熱處理(li)工藝(yi)方(fang)法及(ji)過程

如前文所(suo)述，機(ji)加工前對齒坯進行整體高溫(wen)(wen)正(zheng)火(huo)處理，正(zheng)火(huo)設備為RT-90-9 箱(xiang)式(shi)爐(lu)，具體工藝過程(cheng)是(shi)，爐(lu)溫(wen)(wen)升(sheng)至裝爐(lu)溫(wen)(wen)度400-650℃時(shi)，將(jiang)齒輪放(fang) 爐(lu)中，裝零(ling)件時(shi)如果需要疊(die)(die)放(fang)，疊(die)(die)放(fang)高度不要超(chao)過兩層，然(ran)后將(jiang)零(ling)件加熱至920-940℃，使組織(zhi)完全發生相變，保溫(wen)(wen)30-50分(fen)鐘后，空冷即可。正(zheng)火(huo)工藝：

由于該齒輪精度(du)要(yao)求不(bu)是很高，為(wei)(wei)(wei)降低滲(shen)(shen)(shen)碳(tan)(tan)(tan)淬(cui)(cui)火(huo)(huo)成本，可(ke)以(yi)采用(yong)(yong)(yong)滲(shen)(shen)(shen)碳(tan)(tan)(tan)后(hou)直(zhi)接(jie)淬(cui)(cui)火(huo)(huo)的工藝方(fang)(fang)法，具 體方(fang)(fang)法是將零件裝入滲(shen)(shen)(shen)碳(tan)(tan)(tan)筐中，不(bu)要(yao)疊加，爐(lu)(lu)溫(wen)(wen)升至(zhi)840℃開始(shi)滴航空煤油，煤油滴速為(wei)(wei)(wei)60-80d/min， 爐(lu)(lu)溫(wen)(wen)升至(zhi)930℃時零件開始(shi)裝爐(lu)(lu)。排氣期結(jie)(jie)束后(hou)，放入兩只試棒，其中一只試棒在擴(kuo)散時間(jian)為(wei)(wei)(wei)120 min時取出(chu)淬(cui)(cui)油冷卻并檢驗淬(cui)(cui)硬層深(shen)度(du)，根據(ju)檢驗結(jie)(jie)果(guo)決定(ding)(ding)是否降溫(wen)(wen)，若(ruo)滲(shen)(shen)(shen)碳(tan)(tan)(tan)層深(shen)度(du)不(bu)足(zu)，擴(kuo)散期延長至(zhi) 150min。滲(shen)(shen)(shen)碳(tan)(tan)(tan)時可(ke)按照表1規定(ding)(ding)參(can)數進行，為(wei)(wei)(wei)控制(zhi)(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)時的碳(tan)(tan)(tan)勢濃度(du)，可(ke)采用(yong)(yong)(yong)在滲(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)(lu)中加裝氧傳(chuan)感 器(qi)的方(fang)(fang)法進行監測(ce)和(he)(he)控制(zhi)(zhi)(zhi)，氧傳(chuan)感器(qi)通(tong)過氧化鋯探頭(tou)，將氣氛狀態轉化為(wei)(wei)(wei)電(dian)勢差(cha)，上述差(cha)值(zhi)通(tong)過控制(zhi)(zhi)(zhi) 系統的比較和(he)(he)計算，確定(ding)(ding)碳(tan)(tan)(tan)勢的濃度(du)是否合(he)適并對其進行自動優(you)化和(he)(he)調(diao)整，使(shi)碳(tan)(tan)(tan)勢控制(zhi)(zhi)(zhi)精度(du)可(ke)以(yi)達到 ≤±0.05%C，可(ke)有效控制(zhi)(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)層深(shen)度(du)并提高滲(shen)(shen)(shen)碳(tan)(tan)(tan)層的質(zhi)量(liang)，確保無塊狀、網狀滲(shen)(shen)(shen)碳(tan)(tan)(tan)物，滲(shen)(shen)(shen)碳(tan)(tan)(tan)設備(bei)采 用(yong)(yong)(yong)RQ3-75-9井式(shi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)(lu)。滲(shen)(shen)(shen)碳(tan)(tan)(tan)均溫(wen)(wen)期結(jie)(jie)束后(hou)，零件出(chu)爐(lu)(lu)直(zhi)接(jie)淬(cui)(cui)火(huo)(huo)。淬(cui)(cui)火(huo)(huo)設備(bei)選(xuan)用(yong)(yong)(yong)專用(yong)(yong)(yong)恒溫(wen)(wen)油槽，淬(cui)(cui) 火(huo)(huo)介質(zhi)為(wei)(wei)(wei)專用(yong)(yong)(yong)等溫(wen)(wen)分級淬(cui)(cui)火(huo)(huo)油，介質(zhi)溫(wen)(wen)度(du)恒定(ding)(ding)在110-120℃之間(jian)，冷卻30min后(hou)，出(chu)爐(lu)(lu)空冷。

為(wei)消(xiao)除淬火后零(ling)(ling)件(jian)的殘(can)余應(ying)力并(bing)防止淬火裂(lie)紋的產(chan)生(sheng)，應(ying)盡快將淬火后的零(ling)(ling)件(jian)進(jin)行(xing)低溫(wen)(wen)回火處(chu)理，具體工(gong)藝(yi)方法是在當爐(lu)(lu)溫(wen)(wen)升至160℃左(zuo)右時零(ling)(ling) 件(jian)開(kai)始(shi)裝(zhuang)爐(lu)(lu)，保溫(wen)(wen)120-150min后，出爐(lu)(lu)空冷，回火設備為(wei)RJJ-36-6回火爐(lu)(lu)。淬火及回火工(gong)藝(yi)圖見圖5：

后序處理

將熱處理后(hou)的(de)(de)零件(jian)放(fang)在(zai)噴(pen)砂機的(de)(de)轉盤上進行噴(pen)砂處理，選用石英砂的(de)(de)粒度為10-20目，在(zai)噴(pen)砂過 程中要經常翻(fan)動(dong)零件(jian)使(shi)各(ge)面噴(pen)砂效果均勻(yun)。零件(jian)噴(pen)砂完(wan)后(hou)，放(fang)入(ru)防(fang)銹(xiu)液中浸泡2-4min后(hou)，在(zai)空氣中干(gan) 燥。需要注意的(de)(de)是(shi)，防(fang)銹(xiu)處理必須在(zai)噴(pen)砂后(hou)24小時內完(wan)成(cheng)。

效果

上述方法簡單實(shi)用(yong)，不需要(yao)(yao)專用(yong)裝備即可(ke)實(shi)現直齒錐(zhui)齒輪的(de)加(jia)工，且經濟性好，成本較(jiao)低。經對(dui) 加(jia)工后的(de)錐(zhui)齒輪進行檢測，尺寸及形位精度(du)均(jun)符合要(yao)(yao)求(qiu)，滲(shen)碳層深(shen)度(du)為1.1-1.3mm，齒部金(jin)相組織為 單一的(de)板條狀回火馬氏(shi)體組織，硬度(du)為HRC58-62。心部硬度(du)為HRC36-40，完全可(ke)以(yi)滿(man)足該零件(jian)的(de)質(zhi) 量要(yao)(yao)求(qiu)。