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B棟401
具體參數
拖泵制作工藝
刀具(ju)選擇
從(cong)該(gai)齒(chi)(chi)輪(lun)的(de)(de)結構和技術(shu)參數(shu)(shu)可知,該(gai)錐齒(chi)(chi)輪(lun)屬于標(biao)準(zhun)結構,一(yi)(yi)般情況下(xia),標(biao)準(zhun)直齒(chi)(chi)錐齒(chi)(chi)輪(lun)成(cheng)形(xing)銑(xian) 刀的(de)(de)齒(chi)(chi)形(xing)是按大(da)端(duan)背錐當(dang)量(liang)漸開線齒(chi)(chi)形(xing)設(she)計,而齒(chi)(chi)厚則(ze)按照(zhao)小端(duan)設(she)計,并考慮留有(you)(you)一(yi)(yi)定精切余量(liang)。一(yi)(yi) 般情況下(xia)直齒(chi)(chi)錐齒(chi)(chi)輪(lun)成(cheng)形(xing)銑(xian)刀有(you)(you)3把(ba)、8把(ba)、15把(ba)、26把(ba)一(yi)(yi)套,刀號應(ying)按照(zhao)錐齒(chi)(chi)輪(lun)當(dang)量(liang)齒(chi)(chi)數(shu)(shu)來選擇。當(dang) 量(liang)齒(chi)(chi)數(shu)(shu)Zv可按照(zhao)下(xia)式(shi)計算(suan):
熱處理工藝(yi)方法及過程(cheng)
如前(qian)文所述,機加工前(qian)對齒坯進(jin)行整體(ti)高(gao)溫正火(huo)(huo)處理,正火(huo)(huo)設備(bei)為(wei)RT-90-9 箱(xiang)式(shi)爐(lu),具體(ti)工藝過(guo)程(cheng)是,爐(lu)溫升至裝爐(lu)溫度400-650℃時,將(jiang)(jiang)齒輪放(fang) 爐(lu)中,裝零(ling)件(jian)時如果需要(yao)疊(die)放(fang),疊(die)放(fang)高(gao)度不要(yao)超過(guo)兩層,然后(hou)將(jiang)(jiang)零(ling)件(jian)加熱(re)至920-940℃,使組(zu)織(zhi)完全發生相變,保(bao)溫30-50分鐘后(hou),空冷即可。正火(huo)(huo)工藝:
由于該(gai)齒(chi)輪精度(du)要求不(bu)是很高,為(wei)降(jiang)低滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)淬火成本,可(ke)以采用(yong)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)后直(zhi)接淬火的(de)工藝方(fang)法,具 體方(fang)法是將(jiang)零(ling)件裝(zhuang)入滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)筐中(zhong),不(bu)要疊加,爐(lu)(lu)溫(wen)(wen)升至(zhi)840℃開始滴航(hang)空煤油(you)(you),煤油(you)(you)滴速為(wei)60-80d/min, 爐(lu)(lu)溫(wen)(wen)升至(zhi)930℃時(shi)零(ling)件開始裝(zhuang)爐(lu)(lu)。排氣期結束后,放入兩只(zhi)試棒(bang)(bang),其中(zhong)一只(zhi)試棒(bang)(bang)在(zai)(zai)擴散時(shi)間(jian)為(wei)120 min時(shi)取出淬油(you)(you)冷卻(que)并(bing)檢驗淬硬層深度(du),根(gen)據檢驗結果決定(ding)是否降(jiang)溫(wen)(wen),若滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層深度(du)不(bu)足,擴散期延(yan)長至(zhi) 150min。滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)可(ke)按(an)照表1規定(ding)參(can)數(shu)進(jin)行(xing)(xing),為(wei)控(kong)(kong)(kong)制(zhi)(zhi)(zhi)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)的(de)碳(tan)(tan)(tan)勢濃度(du),可(ke)采用(yong)在(zai)(zai)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)(lu)中(zhong)加裝(zhuang)氧(yang)傳(chuan)感 器的(de)方(fang)法進(jin)行(xing)(xing)監測和(he)(he)控(kong)(kong)(kong)制(zhi)(zhi)(zhi),氧(yang)傳(chuan)感器通過(guo)氧(yang)化鋯探頭,將(jiang)氣氛狀態轉化為(wei)電勢差,上(shang)述(shu)差值通過(guo)控(kong)(kong)(kong)制(zhi)(zhi)(zhi) 系統的(de)比較和(he)(he)計(ji)算,確定(ding)碳(tan)(tan)(tan)勢的(de)濃度(du)是否合(he)適并(bing)對其進(jin)行(xing)(xing)自(zi)動優化和(he)(he)調整(zheng),使碳(tan)(tan)(tan)勢控(kong)(kong)(kong)制(zhi)(zhi)(zhi)精度(du)可(ke)以達到 ≤±0.05%C,可(ke)有(you)效控(kong)(kong)(kong)制(zhi)(zhi)(zhi)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層深度(du)并(bing)提(ti)高滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層的(de)質量(liang),確保無塊狀、網狀滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)物,滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)設(she)備采 用(yong)RQ3-75-9井式(shi)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)(lu)。滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)均溫(wen)(wen)期結束后,零(ling)件出爐(lu)(lu)直(zhi)接淬火。淬火設(she)備選用(yong)專用(yong)恒(heng)(heng)溫(wen)(wen)油(you)(you)槽,淬 火介(jie)質為(wei)專用(yong)等溫(wen)(wen)分級淬火油(you)(you),介(jie)質溫(wen)(wen)度(du)恒(heng)(heng)定(ding)在(zai)(zai)110-120℃之間(jian),冷卻(que)30min后,出爐(lu)(lu)空冷。
為(wei)消除淬火后(hou)零(ling)件的殘余(yu)應力并防止淬火裂紋的產生(sheng),應盡(jin)快將淬火后(hou)的零(ling)件進行低(di)溫(wen)回火處理,具(ju)體工(gong)藝方法是在當爐溫(wen)升至160℃左右(you)時零(ling) 件開始裝爐,保溫(wen)120-150min后(hou),出爐空冷(leng),回火設備為(wei)RJJ-36-6回火爐。淬火及回火工(gong)藝圖見圖5:
后序處理
將熱處理后(hou)的(de)(de)零(ling)件(jian)放(fang)在噴(pen)砂(sha)(sha)(sha)機的(de)(de)轉盤上進行噴(pen)砂(sha)(sha)(sha)處理,選(xuan)用(yong)石英砂(sha)(sha)(sha)的(de)(de)粒度為(wei)10-20目,在噴(pen)砂(sha)(sha)(sha)過 程中要經常翻動零(ling)件(jian)使各面噴(pen)砂(sha)(sha)(sha)效果(guo)均勻。零(ling)件(jian)噴(pen)砂(sha)(sha)(sha)完(wan)后(hou),放(fang)入防銹液中浸泡2-4min后(hou),在空(kong)氣(qi)中干 燥。需(xu)要注意的(de)(de)是(shi),防銹處理必須在噴(pen)砂(sha)(sha)(sha)后(hou)24小時內完(wan)成。
效果(guo)
上述方法簡單(dan)實用,不(bu)需要專用裝備即可實現直齒錐齒輪(lun)的(de)加工(gong),且經濟性好(hao),成本(ben)較(jiao)低。經對 加工(gong)后(hou)的(de)錐齒輪(lun)進行檢測(ce),尺(chi)寸及形位精度均符合要求(qiu),滲碳層(ceng)深(shen)度為(wei)1.1-1.3mm,齒部(bu)金相(xiang)組織為(wei) 單(dan)一(yi)的(de)板條狀回火馬氏(shi)體組織,硬度為(wei)HRC58-62。心(xin)部(bu)硬度為(wei)HRC36-40,完(wan)全可以滿足該零件的(de)質 量要求(qiu)。