具體參數

拖泵(beng)制作(zuo)工藝

刀具選擇

從該齒(chi)(chi)輪(lun)的(de)結構和技(ji)術(shu)參數可知(zhi)，該錐(zhui)齒(chi)(chi)輪(lun)屬于標準結構，一(yi)般情況下(xia)，標準直(zhi)(zhi)齒(chi)(chi)錐(zhui)齒(chi)(chi)輪(lun)成形銑 刀的(de)齒(chi)(chi)形是(shi)按(an)(an)大(da)端(duan)背錐(zhui)當量(liang)漸開線齒(chi)(chi)形設(she)計，而齒(chi)(chi)厚則按(an)(an)照小端(duan)設(she)計，并(bing)考(kao)慮(lv)留有一(yi)定精切余量(liang)。一(yi) 般情況下(xia)直(zhi)(zhi)齒(chi)(chi)錐(zhui)齒(chi)(chi)輪(lun)成形銑刀有3把、8把、15把、26把一(yi)套，刀號應(ying)按(an)(an)照錐(zhui)齒(chi)(chi)輪(lun)當量(liang)齒(chi)(chi)數來選擇。當 量(liang)齒(chi)(chi)數Zv可按(an)(an)照下(xia)式計算：

熱處理工藝方法及過程

如前文(wen)所述，機加工前對齒坯進行整體高(gao)溫正火處理，正火設備(bei)為RT-90-9 箱式爐，具體工藝過(guo)程是，爐溫升(sheng)至(zhi)裝(zhuang)爐溫度400-650℃時，將齒輪放(fang) 爐中，裝(zhuang)零(ling)件(jian)時如果需要疊放(fang)，疊放(fang)高(gao)度不要超過(guo)兩層，然(ran)后將零(ling)件(jian)加熱(re)至(zhi)920-940℃，使(shi)組織(zhi)完全發(fa)生(sheng)相變，保(bao)溫30-50分(fen)鐘后，空冷(leng)即可。正火工藝：

由于該齒輪精度(du)(du)(du)要求不是很高(gao)，為(wei)降低(di)滲(shen)(shen)(shen)(shen)碳(tan)(tan)淬(cui)(cui)(cui)火(huo)成本，可(ke)以采(cai)用(yong)(yong)(yong)(yong)滲(shen)(shen)(shen)(shen)碳(tan)(tan)后直接(jie)淬(cui)(cui)(cui)火(huo)的工藝方法，具 體方法是將(jiang)零(ling)件裝(zhuang)入滲(shen)(shen)(shen)(shen)碳(tan)(tan)筐中(zhong)，不要疊加，爐(lu)溫(wen)(wen)升至840℃開始滴(di)航(hang)空(kong)煤(mei)油(you)(you)，煤(mei)油(you)(you)滴(di)速為(wei)60-80d/min， 爐(lu)溫(wen)(wen)升至930℃時(shi)零(ling)件開始裝(zhuang)爐(lu)。排氣(qi)期結束后，放(fang)入兩只(zhi)試棒(bang)，其(qi)中(zhong)一(yi)只(zhi)試棒(bang)在(zai)擴(kuo)散(san)(san)時(shi)間為(wei)120 min時(shi)取出(chu)淬(cui)(cui)(cui)油(you)(you)冷(leng)卻(que)并(bing)檢驗淬(cui)(cui)(cui)硬層(ceng)深度(du)(du)(du)，根據檢驗結果決定(ding)(ding)是否(fou)降溫(wen)(wen)，若滲(shen)(shen)(shen)(shen)碳(tan)(tan)層(ceng)深度(du)(du)(du)不足，擴(kuo)散(san)(san)期延長至 150min。滲(shen)(shen)(shen)(shen)碳(tan)(tan)時(shi)可(ke)按照(zhao)表1規定(ding)(ding)參(can)數進(jin)(jin)行，為(wei)控制滲(shen)(shen)(shen)(shen)碳(tan)(tan)時(shi)的碳(tan)(tan)勢(shi)濃度(du)(du)(du)，可(ke)采(cai)用(yong)(yong)(yong)(yong)在(zai)滲(shen)(shen)(shen)(shen)碳(tan)(tan)爐(lu)中(zhong)加裝(zhuang)氧(yang)傳感(gan) 器的方法進(jin)(jin)行監(jian)測和控制，氧(yang)傳感(gan)器通(tong)過氧(yang)化(hua)鋯探頭，將(jiang)氣(qi)氛(fen)狀態轉化(hua)為(wei)電勢(shi)差，上述(shu)差值通(tong)過控制 系(xi)統的比較和計算，確定(ding)(ding)碳(tan)(tan)勢(shi)的濃度(du)(du)(du)是否(fou)合適并(bing)對其(qi)進(jin)(jin)行自動優化(hua)和調整，使(shi)碳(tan)(tan)勢(shi)控制精度(du)(du)(du)可(ke)以達到(dao) ≤±0.05%C，可(ke)有(you)效(xiao)控制滲(shen)(shen)(shen)(shen)碳(tan)(tan)層(ceng)深度(du)(du)(du)并(bing)提(ti)高(gao)滲(shen)(shen)(shen)(shen)碳(tan)(tan)層(ceng)的質(zhi)量(liang)，確保無塊狀、網狀滲(shen)(shen)(shen)(shen)碳(tan)(tan)物，滲(shen)(shen)(shen)(shen)碳(tan)(tan)設備采(cai) 用(yong)(yong)(yong)(yong)RQ3-75-9井式滲(shen)(shen)(shen)(shen)碳(tan)(tan)爐(lu)。滲(shen)(shen)(shen)(shen)碳(tan)(tan)均(jun)溫(wen)(wen)期結束后，零(ling)件出(chu)爐(lu)直接(jie)淬(cui)(cui)(cui)火(huo)。淬(cui)(cui)(cui)火(huo)設備選用(yong)(yong)(yong)(yong)專用(yong)(yong)(yong)(yong)恒溫(wen)(wen)油(you)(you)槽，淬(cui)(cui)(cui) 火(huo)介(jie)質(zhi)為(wei)專用(yong)(yong)(yong)(yong)等溫(wen)(wen)分(fen)級淬(cui)(cui)(cui)火(huo)油(you)(you)，介(jie)質(zhi)溫(wen)(wen)度(du)(du)(du)恒定(ding)(ding)在(zai)110-120℃之間，冷(leng)卻(que)30min后，出(chu)爐(lu)空(kong)冷(leng)。

為消除淬(cui)火(huo)后零(ling)件(jian)的殘余應(ying)力并防止(zhi)淬(cui)火(huo)裂紋的產(chan)生，應(ying)盡快將淬(cui)火(huo)后的零(ling)件(jian)進行低溫(wen)回(hui)火(huo)處理，具體(ti)工(gong)(gong)藝方法是在當(dang)爐(lu)溫(wen)升至(zhi)160℃左右時零(ling) 件(jian)開始裝爐(lu)，保溫(wen)120-150min后，出爐(lu)空(kong)冷(leng)，回(hui)火(huo)設(she)備為RJJ-36-6回(hui)火(huo)爐(lu)。淬(cui)火(huo)及回(hui)火(huo)工(gong)(gong)藝圖(tu)見(jian)圖(tu)5：

后序(xu)處理

將(jiang)熱處(chu)理(li)后(hou)的零(ling)件放(fang)在(zai)噴(pen)(pen)砂(sha)(sha)機的轉盤(pan)上(shang)進行噴(pen)(pen)砂(sha)(sha)處(chu)理(li)，選用(yong)石英砂(sha)(sha)的粒度為10-20目，在(zai)噴(pen)(pen)砂(sha)(sha)過(guo) 程中(zhong)(zhong)要(yao)經常翻動零(ling)件使各面噴(pen)(pen)砂(sha)(sha)效果均勻。零(ling)件噴(pen)(pen)砂(sha)(sha)完后(hou)，放(fang)入防銹(xiu)液中(zhong)(zhong)浸泡2-4min后(hou)，在(zai)空氣中(zhong)(zhong)干 燥。需(xu)要(yao)注意的是(shi)，防銹(xiu)處(chu)理(li)必須在(zai)噴(pen)(pen)砂(sha)(sha)后(hou)24小(xiao)時內(nei)完成。

效果

上述(shu)方法簡單實用(yong)，不需(xu)要專用(yong)裝備即可(ke)實現直齒(chi)(chi)錐(zhui)齒(chi)(chi)輪(lun)的(de)加工，且經濟性好，成本較(jiao)低。經對 加工后的(de)錐(zhui)齒(chi)(chi)輪(lun)進行檢測，尺寸及形位精度(du)(du)均符合要求，滲碳層深度(du)(du)為1.1-1.3mm，齒(chi)(chi)部金(jin)相(xiang)組織為 單一的(de)板條(tiao)狀回火馬氏(shi)體組織，硬度(du)(du)為HRC58-62。心部硬度(du)(du)為HRC36-40，完(wan)全(quan)可(ke)以滿足該零(ling)件的(de)質 量要求。