東莞市銳鑫機電有(you)限公司
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B棟401
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。