具體參數

拖(tuo)泵制作(zuo)工藝

刀具選擇

從該齒輪的(de)結構(gou)和(he)技術參數可知(zhi)，該錐(zhui)齒輪屬(shu)于標(biao)準結構(gou)，一(yi)般(ban)情(qing)況下(xia)，標(biao)準直齒錐(zhui)齒輪成形銑 刀(dao)的(de)齒形是按(an)大端背(bei)錐(zhui)當量漸開線齒形設(she)計，而(er)齒厚(hou)則(ze)按(an)照(zhao)(zhao)小(xiao)端設(she)計，并(bing)考(kao)慮留有(you)一(yi)定精(jing)切余量。一(yi) 般(ban)情(qing)況下(xia)直齒錐(zhui)齒輪成形銑刀(dao)有(you)3把、8把、15把、26把一(yi)套，刀(dao)號應按(an)照(zhao)(zhao)錐(zhui)齒輪當量齒數來選(xuan)擇。當 量齒數Zv可按(an)照(zhao)(zhao)下(xia)式計算：

熱處理(li)工藝方(fang)法及(ji)過(guo)程

如(ru)(ru)前文(wen)所述，機加(jia)工(gong)(gong)前對齒(chi)坯(pi)進(jin)行(xing)整(zheng)體(ti)高(gao)溫(wen)正(zheng)火(huo)處理，正(zheng)火(huo)設(she)備(bei)為RT-90-9 箱式爐(lu)，具體(ti)工(gong)(gong)藝過程是，爐(lu)溫(wen)升至(zhi)裝(zhuang)爐(lu)溫(wen)度400-650℃時，將齒(chi)輪放(fang) 爐(lu)中，裝(zhuang)零件(jian)時如(ru)(ru)果(guo)需要疊放(fang)，疊放(fang)高(gao)度不(bu)要超過兩(liang)層，然(ran)后將零件(jian)加(jia)熱至(zhi)920-940℃，使組織完全發生相變，保溫(wen)30-50分鐘后，空冷(leng)即可。正(zheng)火(huo)工(gong)(gong)藝：

由于(yu)該齒輪精度(du)(du)(du)(du)要求(qiu)不是很高，為(wei)(wei)(wei)(wei)降低(di)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)淬(cui)(cui)火成本，可以(yi)采用(yong)(yong)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)后(hou)直接(jie)淬(cui)(cui)火的工(gong)藝(yi)方(fang)(fang)法，具 體方(fang)(fang)法是將(jiang)零件裝入滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)筐中(zhong)，不要疊加，爐(lu)溫(wen)升至840℃開始滴航空煤油(you)(you)，煤油(you)(you)滴速為(wei)(wei)(wei)(wei)60-80d/min， 爐(lu)溫(wen)升至930℃時(shi)零件開始裝爐(lu)。排氣(qi)期(qi)結(jie)束后(hou)，放入兩只(zhi)試棒(bang)，其中(zhong)一(yi)只(zhi)試棒(bang)在擴(kuo)散時(shi)間為(wei)(wei)(wei)(wei)120 min時(shi)取出淬(cui)(cui)油(you)(you)冷(leng)卻(que)并檢驗淬(cui)(cui)硬層(ceng)深(shen)度(du)(du)(du)(du)，根據檢驗結(jie)果決(jue)定(ding)是否(fou)降溫(wen)，若滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)深(shen)度(du)(du)(du)(du)不足，擴(kuo)散期(qi)延(yan)長至 150min。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時(shi)可按照表1規(gui)定(ding)參數進(jin)(jin)行(xing)(xing)，為(wei)(wei)(wei)(wei)控(kong)制(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時(shi)的碳(tan)(tan)(tan)(tan)勢濃度(du)(du)(du)(du)，可采用(yong)(yong)在滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)中(zhong)加裝氧傳(chuan)感 器的方(fang)(fang)法進(jin)(jin)行(xing)(xing)監(jian)測和控(kong)制(zhi)，氧傳(chuan)感器通過(guo)氧化(hua)鋯探頭，將(jiang)氣(qi)氛(fen)狀態轉(zhuan)化(hua)為(wei)(wei)(wei)(wei)電勢差，上述(shu)差值通過(guo)控(kong)制(zhi) 系統的比較和計算，確(que)定(ding)碳(tan)(tan)(tan)(tan)勢的濃度(du)(du)(du)(du)是否(fou)合(he)適并對其進(jin)(jin)行(xing)(xing)自動優化(hua)和調整，使碳(tan)(tan)(tan)(tan)勢控(kong)制(zhi)精度(du)(du)(du)(du)可以(yi)達到 ≤±0.05%C，可有效控(kong)制(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)深(shen)度(du)(du)(du)(du)并提高滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)的質量，確(que)保無塊狀、網(wang)狀滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)物，滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)設(she)備采 用(yong)(yong)RQ3-75-9井(jing)式滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)均溫(wen)期(qi)結(jie)束后(hou)，零件出爐(lu)直接(jie)淬(cui)(cui)火。淬(cui)(cui)火設(she)備選(xuan)用(yong)(yong)專(zhuan)用(yong)(yong)恒(heng)溫(wen)油(you)(you)槽，淬(cui)(cui) 火介質為(wei)(wei)(wei)(wei)專(zhuan)用(yong)(yong)等溫(wen)分(fen)級淬(cui)(cui)火油(you)(you)，介質溫(wen)度(du)(du)(du)(du)恒(heng)定(ding)在110-120℃之間，冷(leng)卻(que)30min后(hou)，出爐(lu)空冷(leng)。

為消除(chu)淬火(huo)后(hou)零(ling)件(jian)(jian)的(de)殘余應力(li)并防止淬火(huo)裂(lie)紋的(de)產生，應盡快將淬火(huo)后(hou)的(de)零(ling)件(jian)(jian)進行低溫(wen)回(hui)火(huo)處理，具體工(gong)藝方法是(shi)在當(dang)爐(lu)溫(wen)升至160℃左右(you)時零(ling) 件(jian)(jian)開始(shi)裝爐(lu)，保溫(wen)120-150min后(hou)，出(chu)爐(lu)空冷，回(hui)火(huo)設備為RJJ-36-6回(hui)火(huo)爐(lu)。淬火(huo)及回(hui)火(huo)工(gong)藝圖見圖5：

后序處理

將熱處(chu)(chu)理后(hou)的(de)(de)零(ling)件放在(zai)(zai)噴(pen)(pen)砂(sha)(sha)(sha)(sha)機的(de)(de)轉盤上(shang)進行噴(pen)(pen)砂(sha)(sha)(sha)(sha)處(chu)(chu)理，選用石英砂(sha)(sha)(sha)(sha)的(de)(de)粒度(du)為10-20目，在(zai)(zai)噴(pen)(pen)砂(sha)(sha)(sha)(sha)過 程中(zhong)要(yao)經常翻動零(ling)件使(shi)各面噴(pen)(pen)砂(sha)(sha)(sha)(sha)效果均勻。零(ling)件噴(pen)(pen)砂(sha)(sha)(sha)(sha)完(wan)(wan)后(hou)，放入防銹液中(zhong)浸泡2-4min后(hou)，在(zai)(zai)空(kong)氣中(zhong)干 燥。需要(yao)注意的(de)(de)是(shi)，防銹處(chu)(chu)理必須(xu)在(zai)(zai)噴(pen)(pen)砂(sha)(sha)(sha)(sha)后(hou)24小時內完(wan)(wan)成。

效果

上述(shu)方法簡(jian)單(dan)實用(yong)，不需要專用(yong)裝備即(ji)可(ke)實現直齒(chi)錐齒(chi)輪的(de)(de)加工，且(qie)經(jing)濟(ji)性好，成(cheng)本(ben)較低。經(jing)對 加工后的(de)(de)錐齒(chi)輪進行檢(jian)測，尺寸及形位精度均符合要求，滲碳層深度為1.1-1.3mm，齒(chi)部金相組織為 單(dan)一的(de)(de)板條(tiao)狀回火馬氏體組織，硬(ying)度為HRC58-62。心部硬(ying)度為HRC36-40，完全可(ke)以(yi)滿(man)足該零(ling)件的(de)(de)質 量要求。