具體參數

拖泵(beng)制作工(gong)藝

刀(dao)具(ju)選擇

從(cong)該齒(chi)(chi)(chi)(chi)輪(lun)的結構(gou)和技術參數可(ke)知，該錐齒(chi)(chi)(chi)(chi)輪(lun)屬于標準結構(gou)，一(yi)般情況下，標準直(zhi)齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑 刀的齒(chi)(chi)(chi)(chi)形(xing)是(shi)按大(da)端(duan)背錐當(dang)量(liang)(liang)漸(jian)開(kai)線齒(chi)(chi)(chi)(chi)形(xing)設計(ji)(ji)，而(er)齒(chi)(chi)(chi)(chi)厚則按照(zhao)小端(duan)設計(ji)(ji)，并考慮留有一(yi)定精(jing)切余量(liang)(liang)。一(yi) 般情況下直(zhi)齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑刀有3把(ba)(ba)、8把(ba)(ba)、15把(ba)(ba)、26把(ba)(ba)一(yi)套，刀號應按照(zhao)錐齒(chi)(chi)(chi)(chi)輪(lun)當(dang)量(liang)(liang)齒(chi)(chi)(chi)(chi)數來選擇。當(dang) 量(liang)(liang)齒(chi)(chi)(chi)(chi)數Zv可(ke)按照(zhao)下式(shi)計(ji)(ji)算：

熱處(chu)理工藝方法及過程

如前文所述，機加(jia)工前對齒坯進(jin)行(xing)整體(ti)高溫正(zheng)火(huo)處(chu)理，正(zheng)火(huo)設備(bei)為RT-90-9 箱式爐(lu)，具體(ti)工藝過程是，爐(lu)溫升至(zhi)裝(zhuang)爐(lu)溫度(du)400-650℃時，將齒輪放 爐(lu)中(zhong)，裝(zhuang)零件時如果需要(yao)疊放，疊放高度(du)不(bu)要(yao)超過兩層(ceng)，然后將零件加(jia)熱至(zhi)920-940℃，使組織完全(quan)發生相變，保溫30-50分鐘后，空冷即可。正(zheng)火(huo)工藝：

由于該齒輪精(jing)度(du)要(yao)求不(bu)(bu)是(shi)(shi)(shi)很高，為(wei)降低滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)淬(cui)(cui)(cui)火(huo)(huo)(huo)成本，可(ke)以采用(yong)(yong)(yong)(yong)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)后直(zhi)接(jie)淬(cui)(cui)(cui)火(huo)(huo)(huo)的(de)工藝(yi)方法，具 體方法是(shi)(shi)(shi)將(jiang)零(ling)件裝(zhuang)入滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)筐中，不(bu)(bu)要(yao)疊(die)加，爐(lu)溫升(sheng)至840℃開始滴航空煤油(you)(you)，煤油(you)(you)滴速(su)為(wei)60-80d/min， 爐(lu)溫升(sheng)至930℃時(shi)(shi)(shi)零(ling)件開始裝(zhuang)爐(lu)。排氣(qi)期(qi)結束后，放入兩(liang)只(zhi)試(shi)棒(bang)，其中一只(zhi)試(shi)棒(bang)在擴(kuo)散時(shi)(shi)(shi)間(jian)為(wei)120 min時(shi)(shi)(shi)取出淬(cui)(cui)(cui)油(you)(you)冷(leng)卻并(bing)檢驗(yan)淬(cui)(cui)(cui)硬層(ceng)(ceng)深度(du)，根據檢驗(yan)結果決定(ding)是(shi)(shi)(shi)否降溫，若滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)深度(du)不(bu)(bu)足，擴(kuo)散期(qi)延長至 150min。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)(shi)(shi)可(ke)按照(zhao)表1規定(ding)參數進行，為(wei)控(kong)(kong)(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)(shi)(shi)的(de)碳(tan)(tan)(tan)(tan)(tan)(tan)勢濃(nong)度(du)，可(ke)采用(yong)(yong)(yong)(yong)在滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)中加裝(zhuang)氧傳感(gan)(gan) 器的(de)方法進行監測和(he)(he)控(kong)(kong)(kong)制(zhi)(zhi)，氧傳感(gan)(gan)器通(tong)過氧化鋯(gao)探頭，將(jiang)氣(qi)氛狀態(tai)轉(zhuan)化為(wei)電勢差，上述(shu)差值(zhi)通(tong)過控(kong)(kong)(kong)制(zhi)(zhi) 系統(tong)的(de)比較和(he)(he)計(ji)算，確定(ding)碳(tan)(tan)(tan)(tan)(tan)(tan)勢的(de)濃(nong)度(du)是(shi)(shi)(shi)否合適并(bing)對其進行自(zi)動優化和(he)(he)調(diao)整，使碳(tan)(tan)(tan)(tan)(tan)(tan)勢控(kong)(kong)(kong)制(zhi)(zhi)精(jing)度(du)可(ke)以達到(dao) ≤±0.05%C，可(ke)有(you)效控(kong)(kong)(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)深度(du)并(bing)提(ti)高滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)(ceng)的(de)質量，確保無(wu)塊(kuai)狀、網狀滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)物，滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)設備(bei)采 用(yong)(yong)(yong)(yong)RQ3-75-9井式(shi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)均溫期(qi)結束后，零(ling)件出爐(lu)直(zhi)接(jie)淬(cui)(cui)(cui)火(huo)(huo)(huo)。淬(cui)(cui)(cui)火(huo)(huo)(huo)設備(bei)選(xuan)用(yong)(yong)(yong)(yong)專(zhuan)用(yong)(yong)(yong)(yong)恒(heng)溫油(you)(you)槽，淬(cui)(cui)(cui) 火(huo)(huo)(huo)介質為(wei)專(zhuan)用(yong)(yong)(yong)(yong)等溫分級淬(cui)(cui)(cui)火(huo)(huo)(huo)油(you)(you)，介質溫度(du)恒(heng)定(ding)在110-120℃之間(jian)，冷(leng)卻30min后，出爐(lu)空冷(leng)。

為消除淬火(huo)(huo)后零件的(de)殘余應力并(bing)防止(zhi)淬火(huo)(huo)裂紋的(de)產生(sheng)，應盡快將淬火(huo)(huo)后的(de)零件進行低溫回(hui)火(huo)(huo)處理，具體工藝方法是(shi)在(zai)當爐溫升至160℃左右時零 件開(kai)始裝爐，保溫120-150min后，出爐空(kong)冷，回(hui)火(huo)(huo)設備為RJJ-36-6回(hui)火(huo)(huo)爐。淬火(huo)(huo)及回(hui)火(huo)(huo)工藝圖(tu)見圖(tu)5：

后(hou)序處理

將熱處(chu)理(li)后的零件(jian)放在噴砂(sha)(sha)(sha)(sha)機的轉盤上進行噴砂(sha)(sha)(sha)(sha)處(chu)理(li)，選(xuan)用(yong)石(shi)英(ying)砂(sha)(sha)(sha)(sha)的粒度(du)為(wei)10-20目，在噴砂(sha)(sha)(sha)(sha)過 程中(zhong)要經常翻動零件(jian)使各面噴砂(sha)(sha)(sha)(sha)效果均(jun)勻。零件(jian)噴砂(sha)(sha)(sha)(sha)完(wan)后，放入(ru)防銹(xiu)液(ye)中(zhong)浸泡(pao)2-4min后，在空氣中(zhong)干 燥。需要注意的是(shi)，防銹(xiu)處(chu)理(li)必須在噴砂(sha)(sha)(sha)(sha)后24小(xiao)時內完(wan)成。

效果

上(shang)述方法(fa)簡(jian)單實(shi)用(yong)，不需要(yao)專用(yong)裝備(bei)即可實(shi)現直齒(chi)錐齒(chi)輪的(de)加(jia)工，且經(jing)濟性好，成本較低。經(jing)對 加(jia)工后的(de)錐齒(chi)輪進行檢測(ce)，尺寸及形(xing)位(wei)精度均符(fu)合(he)要(yao)求，滲碳(tan)層深度為1.1-1.3mm，齒(chi)部金相(xiang)組織為 單一的(de)板條狀回火(huo)馬氏體(ti)組織，硬度為HRC58-62。心部硬度為HRC36-40，完全可以滿足該零件的(de)質 量要(yao)求。