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B棟401
具體參數
拖泵制作工藝(yi)
刀具(ju)選擇
從(cong)該(gai)齒(chi)(chi)(chi)輪(lun)(lun)的結構(gou)和技術參(can)數(shu)(shu)可知,該(gai)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)屬(shu)于標準(zhun)結構(gou),一般(ban)情況下(xia),標準(zhun)直齒(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)成形銑 刀的齒(chi)(chi)(chi)形是按大端背錐(zhui)(zhui)當(dang)量(liang)漸開線齒(chi)(chi)(chi)形設計(ji),而齒(chi)(chi)(chi)厚(hou)則(ze)按照(zhao)小端設計(ji),并(bing)考慮留有(you)一定(ding)精(jing)切余量(liang)。一 般(ban)情況下(xia)直齒(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)成形銑刀有(you)3把、8把、15把、26把一套,刀號應按照(zhao)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)當(dang)量(liang)齒(chi)(chi)(chi)數(shu)(shu)來選擇。當(dang) 量(liang)齒(chi)(chi)(chi)數(shu)(shu)Zv可按照(zhao)下(xia)式計(ji)算(suan):
熱處理工藝(yi)方法及過程
如前(qian)文所述,機加工前(qian)對齒(chi)坯(pi)進行整體高溫(wen)(wen)正(zheng)火處理(li),正(zheng)火設(she)備為RT-90-9 箱式爐,具(ju)體工藝過(guo)程是,爐溫(wen)(wen)升至(zhi)裝爐溫(wen)(wen)度(du)400-650℃時,將齒(chi)輪(lun)放 爐中,裝零件時如果(guo)需要疊(die)放,疊(die)放高度(du)不(bu)要超(chao)過(guo)兩(liang)層(ceng),然后(hou)將零件加熱(re)至(zhi)920-940℃,使組(zu)織(zhi)完全發生相變,保溫(wen)(wen)30-50分鐘(zhong)后(hou),空冷即可。正(zheng)火工藝:
由于(yu)該齒輪精度(du)要求(qiu)不是很高,為(wei)(wei)降低滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)淬火(huo)成本(ben),可(ke)以采用(yong)(yong)(yong)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)后直接(jie)淬火(huo)的(de)(de)(de)(de)工藝方(fang)(fang)法,具(ju) 體方(fang)(fang)法是將零(ling)件裝(zhuang)入(ru)(ru)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)筐(kuang)中(zhong),不要疊(die)加,爐(lu)(lu)溫(wen)升至(zhi)840℃開(kai)始滴航空煤油(you)(you),煤油(you)(you)滴速為(wei)(wei)60-80d/min, 爐(lu)(lu)溫(wen)升至(zhi)930℃時(shi)(shi)零(ling)件開(kai)始裝(zhuang)爐(lu)(lu)。排(pai)氣期結(jie)束后,放(fang)入(ru)(ru)兩(liang)只試棒,其中(zhong)一只試棒在擴散(san)時(shi)(shi)間為(wei)(wei)120 min時(shi)(shi)取出淬油(you)(you)冷卻(que)并檢驗淬硬層(ceng)(ceng)深(shen)度(du),根據檢驗結(jie)果決定(ding)是否(fou)降溫(wen),若滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)深(shen)度(du)不足,擴散(san)期延長至(zhi) 150min。滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)時(shi)(shi)可(ke)按(an)照表1規定(ding)參數進(jin)行,為(wei)(wei)控(kong)制滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)時(shi)(shi)的(de)(de)(de)(de)碳(tan)(tan)(tan)(tan)(tan)勢(shi)(shi)濃度(du),可(ke)采用(yong)(yong)(yong)在滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)爐(lu)(lu)中(zhong)加裝(zhuang)氧傳感 器的(de)(de)(de)(de)方(fang)(fang)法進(jin)行監測和控(kong)制,氧傳感器通(tong)過氧化(hua)鋯探頭,將氣氛狀態轉化(hua)為(wei)(wei)電(dian)勢(shi)(shi)差,上述差值通(tong)過控(kong)制 系統的(de)(de)(de)(de)比較和計算(suan),確定(ding)碳(tan)(tan)(tan)(tan)(tan)勢(shi)(shi)的(de)(de)(de)(de)濃度(du)是否(fou)合(he)適(shi)并對其進(jin)行自動(dong)優化(hua)和調整,使(shi)碳(tan)(tan)(tan)(tan)(tan)勢(shi)(shi)控(kong)制精度(du)可(ke)以達到 ≤±0.05%C,可(ke)有效控(kong)制滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)深(shen)度(du)并提高滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)的(de)(de)(de)(de)質(zhi)量,確保無(wu)塊狀、網狀滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)物,滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)設備采 用(yong)(yong)(yong)RQ3-75-9井式(shi)滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)爐(lu)(lu)。滲(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)均(jun)溫(wen)期結(jie)束后,零(ling)件出爐(lu)(lu)直接(jie)淬火(huo)。淬火(huo)設備選用(yong)(yong)(yong)專用(yong)(yong)(yong)恒溫(wen)油(you)(you)槽,淬 火(huo)介質(zhi)為(wei)(wei)專用(yong)(yong)(yong)等溫(wen)分(fen)級淬火(huo)油(you)(you),介質(zhi)溫(wen)度(du)恒定(ding)在110-120℃之間,冷卻(que)30min后,出爐(lu)(lu)空冷。
為(wei)消除淬(cui)(cui)火(huo)(huo)后零件(jian)的(de)殘余應力并防止淬(cui)(cui)火(huo)(huo)裂(lie)紋的(de)產(chan)生,應盡快將(jiang)淬(cui)(cui)火(huo)(huo)后的(de)零件(jian)進行低溫(wen)回火(huo)(huo)處理,具體工藝方法(fa)是在當(dang)爐溫(wen)升至160℃左右時零 件(jian)開始裝爐,保溫(wen)120-150min后,出爐空冷,回火(huo)(huo)設備為(wei)RJJ-36-6回火(huo)(huo)爐。淬(cui)(cui)火(huo)(huo)及回火(huo)(huo)工藝圖見圖5:
后序處理(li)
將熱處(chu)理后的零件放(fang)在(zai)(zai)噴(pen)(pen)(pen)砂(sha)(sha)機的轉(zhuan)盤上(shang)進行噴(pen)(pen)(pen)砂(sha)(sha)處(chu)理,選用石(shi)英(ying)砂(sha)(sha)的粒度(du)為10-20目,在(zai)(zai)噴(pen)(pen)(pen)砂(sha)(sha)過 程中(zhong)要經常翻動零件使(shi)各面噴(pen)(pen)(pen)砂(sha)(sha)效果均勻。零件噴(pen)(pen)(pen)砂(sha)(sha)完(wan)后,放(fang)入防銹液中(zhong)浸泡2-4min后,在(zai)(zai)空氣(qi)中(zhong)干(gan) 燥。需要注(zhu)意的是,防銹處(chu)理必須在(zai)(zai)噴(pen)(pen)(pen)砂(sha)(sha)后24小時內(nei)完(wan)成。
效果
上述方法簡單實用,不需要專用裝備即可實現直齒(chi)錐齒(chi)輪的(de)(de)加工,且經濟性好,成本較低(di)。經對 加工后的(de)(de)錐齒(chi)輪進行檢測,尺寸(cun)及形(xing)位(wei)精(jing)度(du)(du)均符合要求(qiu),滲(shen)碳(tan)層深度(du)(du)為1.1-1.3mm,齒(chi)部金相(xiang)組織為 單一的(de)(de)板條狀回火馬(ma)氏體組織,硬度(du)(du)為HRC58-62。心部硬度(du)(du)為HRC36-40,完全(quan)可以滿足該零件的(de)(de)質(zhi) 量要求(qiu)。