東莞市銳鑫機(ji)電(dian)有限公司
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B棟401
具體參數
拖(tuo)泵(beng)制作(zuo)工藝
刀具選擇
從該齒(chi)(chi)(chi)(chi)輪(lun)的結構(gou)和技(ji)術參數可知,該錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)輪(lun)屬于標準結構(gou),一般(ban)情況(kuang)(kuang)下(xia)(xia),標準直齒(chi)(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成形銑 刀的齒(chi)(chi)(chi)(chi)形是按(an)大端背錐(zhui)(zhui)當(dang)量(liang)漸開(kai)線齒(chi)(chi)(chi)(chi)形設(she)計,而齒(chi)(chi)(chi)(chi)厚(hou)則(ze)按(an)照小端設(she)計,并考慮留有一定精切余量(liang)。一 般(ban)情況(kuang)(kuang)下(xia)(xia)直齒(chi)(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成形銑刀有3把、8把、15把、26把一套,刀號應按(an)照錐(zhui)(zhui)齒(chi)(chi)(chi)(chi)輪(lun)當(dang)量(liang)齒(chi)(chi)(chi)(chi)數來選擇(ze)。當(dang) 量(liang)齒(chi)(chi)(chi)(chi)數Zv可按(an)照下(xia)(xia)式計算:
熱處理工藝方法及過程
如(ru)前(qian)文所述,機加工(gong)前(qian)對齒(chi)坯(pi)進(jin)行(xing)整體高溫(wen)正火處(chu)理,正火設備為RT-90-9 箱式爐(lu),具(ju)體工(gong)藝過程是(shi),爐(lu)溫(wen)升至裝爐(lu)溫(wen)度(du)400-650℃時,將(jiang)齒(chi)輪放 爐(lu)中,裝零(ling)件時如(ru)果需要疊放,疊放高度(du)不要超過兩層(ceng),然后將(jiang)零(ling)件加熱至920-940℃,使組織完全發(fa)生相變,保溫(wen)30-50分鐘后,空冷(leng)即(ji)可。正火工(gong)藝:
由于(yu)該(gai)齒輪精(jing)度要(yao)求不是很高(gao),為(wei)降低滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)淬(cui)火成本,可以(yi)采用(yong)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)后直接淬(cui)火的工藝方(fang)法,具 體(ti)方(fang)法是將(jiang)零件裝入(ru)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)筐(kuang)中,不要(yao)疊加,爐(lu)溫(wen)(wen)升至(zhi)840℃開始(shi)滴(di)航(hang)空煤油(you),煤油(you)滴(di)速為(wei)60-80d/min, 爐(lu)溫(wen)(wen)升至(zhi)930℃時零件開始(shi)裝爐(lu)。排氣期(qi)(qi)結束后,放入(ru)兩(liang)只試棒,其中一只試棒在(zai)擴散時間為(wei)120 min時取出淬(cui)油(you)冷卻(que)并(bing)檢驗(yan)(yan)淬(cui)硬層深度,根據檢驗(yan)(yan)結果決(jue)定(ding)(ding)是否降溫(wen)(wen),若滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層深度不足,擴散期(qi)(qi)延長至(zhi) 150min。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)時可按照表1規(gui)定(ding)(ding)參數進行(xing),為(wei)控制滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)時的碳(tan)(tan)(tan)(tan)(tan)勢(shi)(shi)濃度,可采用(yong)在(zai)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)爐(lu)中加裝氧(yang)傳(chuan)感(gan) 器(qi)的方(fang)法進行(xing)監測和(he)(he)控制,氧(yang)傳(chuan)感(gan)器(qi)通過氧(yang)化鋯探(tan)頭,將(jiang)氣氛狀態轉化為(wei)電勢(shi)(shi)差,上述差值(zhi)通過控制 系統的比較和(he)(he)計算,確(que)定(ding)(ding)碳(tan)(tan)(tan)(tan)(tan)勢(shi)(shi)的濃度是否合適(shi)并(bing)對其進行(xing)自(zi)動優化和(he)(he)調整,使碳(tan)(tan)(tan)(tan)(tan)勢(shi)(shi)控制精(jing)度可以(yi)達到 ≤±0.05%C,可有效(xiao)控制滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層深度并(bing)提高(gao)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層的質(zhi)(zhi)量(liang),確(que)保(bao)無塊狀、網(wang)狀滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)物,滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)設備(bei)采 用(yong)RQ3-75-9井式(shi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)均(jun)溫(wen)(wen)期(qi)(qi)結束后,零件出爐(lu)直接淬(cui)火。淬(cui)火設備(bei)選用(yong)專用(yong)恒溫(wen)(wen)油(you)槽,淬(cui) 火介質(zhi)(zhi)為(wei)專用(yong)等溫(wen)(wen)分級淬(cui)火油(you),介質(zhi)(zhi)溫(wen)(wen)度恒定(ding)(ding)在(zai)110-120℃之間,冷卻(que)30min后,出爐(lu)空冷。
為(wei)消除淬(cui)火(huo)后零件(jian)的殘余應力(li)并防止淬(cui)火(huo)裂(lie)紋的產生(sheng),應盡快將淬(cui)火(huo)后的零件(jian)進行低溫(wen)回(hui)(hui)火(huo)處理(li),具體工藝(yi)方(fang)法是在當(dang)爐溫(wen)升至160℃左右時(shi)零 件(jian)開始裝(zhuang)爐,保溫(wen)120-150min后,出爐空冷(leng),回(hui)(hui)火(huo)設備(bei)為(wei)RJJ-36-6回(hui)(hui)火(huo)爐。淬(cui)火(huo)及回(hui)(hui)火(huo)工藝(yi)圖(tu)見圖(tu)5:
后序處理(li)
將熱處(chu)理后(hou)的(de)(de)零件(jian)(jian)放在(zai)噴(pen)(pen)砂機(ji)的(de)(de)轉盤上進(jin)行(xing)噴(pen)(pen)砂處(chu)理,選用石(shi)英砂的(de)(de)粒度為10-20目,在(zai)噴(pen)(pen)砂過 程(cheng)中要經常翻動零件(jian)(jian)使各面(mian)噴(pen)(pen)砂效(xiao)果(guo)均勻(yun)。零件(jian)(jian)噴(pen)(pen)砂完后(hou),放入防銹液中浸(jin)泡2-4min后(hou),在(zai)空氣中干 燥(zao)。需要注(zhu)意的(de)(de)是,防銹處(chu)理必須在(zai)噴(pen)(pen)砂后(hou)24小時內(nei)完成。
效果
上述方(fang)法簡單(dan)(dan)實用(yong),不(bu)需要專用(yong)裝備即可實現直齒錐(zhui)齒輪的(de)加工,且經濟性好,成本較(jiao)低(di)。經對(dui) 加工后(hou)的(de)錐(zhui)齒輪進行檢(jian)測,尺寸(cun)及形位精(jing)度均符合(he)要求,滲碳層深度為(wei)(wei)1.1-1.3mm,齒部金相組織為(wei)(wei) 單(dan)(dan)一的(de)板(ban)條狀回火馬氏體組織,硬度為(wei)(wei)HRC58-62。心(xin)部硬度為(wei)(wei)HRC36-40,完全可以滿足該零件的(de)質 量(liang)要求。