東莞市銳鑫(xin)機電有限公司
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B棟401
具體參數
拖泵制作工藝
刀具選擇
從該齒(chi)(chi)(chi)(chi)輪(lun)的(de)結構(gou)和技術參數可知,該錐齒(chi)(chi)(chi)(chi)輪(lun)屬于(yu)標準結構(gou),一(yi)般情(qing)況(kuang)下,標準直齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成形銑 刀(dao)(dao)的(de)齒(chi)(chi)(chi)(chi)形是按(an)大(da)端(duan)背錐當(dang)量(liang)漸開線齒(chi)(chi)(chi)(chi)形設計,而齒(chi)(chi)(chi)(chi)厚則(ze)按(an)照小端(duan)設計,并考(kao)慮留(liu)有一(yi)定精切余量(liang)。一(yi) 般情(qing)況(kuang)下直齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成形銑刀(dao)(dao)有3把(ba)、8把(ba)、15把(ba)、26把(ba)一(yi)套,刀(dao)(dao)號應按(an)照錐齒(chi)(chi)(chi)(chi)輪(lun)當(dang)量(liang)齒(chi)(chi)(chi)(chi)數來選擇。當(dang) 量(liang)齒(chi)(chi)(chi)(chi)數Zv可按(an)照下式計算:
熱處理(li)工(gong)藝方(fang)法(fa)及過程
如(ru)(ru)前文所述,機加工(gong)前對齒(chi)坯(pi)進行整(zheng)體高溫正火(huo)處理,正火(huo)設備(bei)為RT-90-9 箱式(shi)爐(lu),具體工(gong)藝(yi)過程是,爐(lu)溫升至(zhi)裝(zhuang)(zhuang)爐(lu)溫度400-650℃時,將(jiang)齒(chi)輪放(fang) 爐(lu)中(zhong),裝(zhuang)(zhuang)零件時如(ru)(ru)果需要疊放(fang),疊放(fang)高度不要超過兩(liang)層,然后(hou)(hou)將(jiang)零件加熱至(zhi)920-940℃,使組織完(wan)全發生(sheng)相變(bian),保溫30-50分鐘后(hou)(hou),空冷即(ji)可。正火(huo)工(gong)藝(yi):
由于該齒輪精度(du)要求不是(shi)很高(gao),為(wei)(wei)(wei)降(jiang)低滲(shen)(shen)(shen)碳(tan)淬(cui)(cui)火成本,可(ke)以采用(yong)(yong)滲(shen)(shen)(shen)碳(tan)后(hou)(hou)直接淬(cui)(cui)火的工藝方(fang)法(fa),具 體方(fang)法(fa)是(shi)將零件(jian)(jian)裝(zhuang)入滲(shen)(shen)(shen)碳(tan)筐中(zhong),不要疊加,爐(lu)(lu)溫(wen)(wen)(wen)升(sheng)至(zhi)840℃開始滴航(hang)空煤(mei)油(you),煤(mei)油(you)滴速為(wei)(wei)(wei)60-80d/min, 爐(lu)(lu)溫(wen)(wen)(wen)升(sheng)至(zhi)930℃時(shi)零件(jian)(jian)開始裝(zhuang)爐(lu)(lu)。排氣期(qi)結束后(hou)(hou),放入兩只試棒,其中(zhong)一(yi)只試棒在(zai)擴散(san)時(shi)間為(wei)(wei)(wei)120 min時(shi)取出淬(cui)(cui)油(you)冷(leng)卻(que)并(bing)檢(jian)驗淬(cui)(cui)硬層(ceng)深(shen)度(du),根據檢(jian)驗結果(guo)決定是(shi)否(fou)降(jiang)溫(wen)(wen)(wen),若滲(shen)(shen)(shen)碳(tan)層(ceng)深(shen)度(du)不足,擴散(san)期(qi)延(yan)長至(zhi) 150min。滲(shen)(shen)(shen)碳(tan)時(shi)可(ke)按照(zhao)表1規(gui)定參數進行(xing),為(wei)(wei)(wei)控(kong)(kong)制(zhi)滲(shen)(shen)(shen)碳(tan)時(shi)的碳(tan)勢濃(nong)度(du),可(ke)采用(yong)(yong)在(zai)滲(shen)(shen)(shen)碳(tan)爐(lu)(lu)中(zhong)加裝(zhuang)氧傳感(gan) 器(qi)的方(fang)法(fa)進行(xing)監測和(he)控(kong)(kong)制(zhi),氧傳感(gan)器(qi)通過氧化(hua)鋯(gao)探頭(tou),將氣氛狀(zhuang)態轉(zhuan)化(hua)為(wei)(wei)(wei)電(dian)勢差,上述差值通過控(kong)(kong)制(zhi) 系統的比較(jiao)和(he)計算,確定碳(tan)勢的濃(nong)度(du)是(shi)否(fou)合適并(bing)對其進行(xing)自動優(you)化(hua)和(he)調整,使碳(tan)勢控(kong)(kong)制(zhi)精度(du)可(ke)以達到 ≤±0.05%C,可(ke)有效控(kong)(kong)制(zhi)滲(shen)(shen)(shen)碳(tan)層(ceng)深(shen)度(du)并(bing)提高(gao)滲(shen)(shen)(shen)碳(tan)層(ceng)的質量,確保無塊(kuai)狀(zhuang)、網狀(zhuang)滲(shen)(shen)(shen)碳(tan)物,滲(shen)(shen)(shen)碳(tan)設(she)備(bei)采 用(yong)(yong)RQ3-75-9井式滲(shen)(shen)(shen)碳(tan)爐(lu)(lu)。滲(shen)(shen)(shen)碳(tan)均溫(wen)(wen)(wen)期(qi)結束后(hou)(hou),零件(jian)(jian)出爐(lu)(lu)直接淬(cui)(cui)火。淬(cui)(cui)火設(she)備(bei)選用(yong)(yong)專用(yong)(yong)恒溫(wen)(wen)(wen)油(you)槽,淬(cui)(cui) 火介質為(wei)(wei)(wei)專用(yong)(yong)等溫(wen)(wen)(wen)分級淬(cui)(cui)火油(you),介質溫(wen)(wen)(wen)度(du)恒定在(zai)110-120℃之間,冷(leng)卻(que)30min后(hou)(hou),出爐(lu)(lu)空冷(leng)。
為消除淬火(huo)后(hou)零(ling)件的殘余(yu)應力(li)并(bing)防止淬火(huo)裂紋的產生,應盡快將淬火(huo)后(hou)的零(ling)件進行(xing)低溫回(hui)(hui)火(huo)處(chu)理,具體工(gong)藝(yi)方法是在當(dang)爐溫升至(zhi)160℃左(zuo)右時零(ling) 件開始裝爐,保溫120-150min后(hou),出爐空冷,回(hui)(hui)火(huo)設備為RJJ-36-6回(hui)(hui)火(huo)爐。淬火(huo)及回(hui)(hui)火(huo)工(gong)藝(yi)圖見圖5:
后(hou)序處理
將熱(re)處(chu)理(li)后的(de)零(ling)件(jian)放在(zai)(zai)噴砂機(ji)的(de)轉盤上進行噴砂處(chu)理(li),選(xuan)用(yong)石英砂的(de)粒度為(wei)10-20目,在(zai)(zai)噴砂過 程(cheng)中要(yao)經常翻動零(ling)件(jian)使(shi)各面(mian)噴砂效果均勻。零(ling)件(jian)噴砂完后,放入防(fang)銹液中浸泡2-4min后,在(zai)(zai)空(kong)氣中干 燥。需要(yao)注意的(de)是,防(fang)銹處(chu)理(li)必須在(zai)(zai)噴砂后24小時(shi)內完成。
效果(guo)
上述方法簡單實用(yong),不需要(yao)專(zhuan)用(yong)裝備即可(ke)實現直齒錐齒輪(lun)的(de)(de)加(jia)工,且(qie)經濟性好,成本較低。經對(dui) 加(jia)工后的(de)(de)錐齒輪(lun)進行檢(jian)測,尺寸及形位精度(du)(du)均符合(he)要(yao)求(qiu),滲碳層深度(du)(du)為(wei)1.1-1.3mm,齒部(bu)金相組(zu)織(zhi)為(wei) 單一的(de)(de)板條狀回火馬氏(shi)體(ti)組(zu)織(zhi),硬度(du)(du)為(wei)HRC58-62。心部(bu)硬度(du)(du)為(wei)HRC36-40,完全可(ke)以滿足該(gai)零件的(de)(de)質 量要(yao)求(qiu)。