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B棟401
具體參數
拖泵(beng)制作工藝
刀具(ju)選擇
從該(gai)齒(chi)(chi)(chi)(chi)輪(lun)的(de)結(jie)構和技術參數(shu)可知,該(gai)錐齒(chi)(chi)(chi)(chi)輪(lun)屬于標準結(jie)構,一般(ban)情(qing)況(kuang)下,標準直(zhi)齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成(cheng)(cheng)形銑 刀的(de)齒(chi)(chi)(chi)(chi)形是按(an)大(da)端背錐當量漸開線齒(chi)(chi)(chi)(chi)形設計(ji),而(er)齒(chi)(chi)(chi)(chi)厚則按(an)照(zhao)小端設計(ji),并考慮留有一定精切余量。一 般(ban)情(qing)況(kuang)下直(zhi)齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)成(cheng)(cheng)形銑刀有3把、8把、15把、26把一套,刀號應(ying)按(an)照(zhao)錐齒(chi)(chi)(chi)(chi)輪(lun)當量齒(chi)(chi)(chi)(chi)數(shu)來選擇。當 量齒(chi)(chi)(chi)(chi)數(shu)Zv可按(an)照(zhao)下式計(ji)算:
熱處(chu)理工藝方法及過(guo)程(cheng)
如前文(wen)所述(shu),機(ji)加工(gong)前對(dui)齒坯進行整體高(gao)溫(wen)正(zheng)火處理,正(zheng)火設備為RT-90-9 箱式爐(lu)(lu),具體工(gong)藝(yi)(yi)過程是(shi),爐(lu)(lu)溫(wen)升至裝(zhuang)爐(lu)(lu)溫(wen)度(du)400-650℃時(shi),將齒輪放(fang) 爐(lu)(lu)中,裝(zhuang)零件(jian)時(shi)如果需要疊放(fang),疊放(fang)高(gao)度(du)不要超過兩(liang)層,然后將零件(jian)加熱(re)至920-940℃,使組織(zhi)完(wan)全(quan)發(fa)生相變(bian),保溫(wen)30-50分鐘后,空冷即可(ke)。正(zheng)火工(gong)藝(yi)(yi):
由于該齒(chi)輪(lun)精度(du)(du)要(yao)求不(bu)是(shi)很高(gao),為(wei)降低(di)滲(shen)(shen)(shen)(shen)碳(tan)淬(cui)火(huo)成本,可(ke)以采(cai)用(yong)滲(shen)(shen)(shen)(shen)碳(tan)后直(zhi)(zhi)接(jie)淬(cui)火(huo)的(de)工(gong)藝方法(fa)(fa),具 體方法(fa)(fa)是(shi)將(jiang)零(ling)件(jian)(jian)裝入(ru)滲(shen)(shen)(shen)(shen)碳(tan)筐中(zhong),不(bu)要(yao)疊加(jia),爐(lu)溫(wen)(wen)升(sheng)至(zhi)840℃開(kai)始滴航空煤(mei)油(you)(you),煤(mei)油(you)(you)滴速為(wei)60-80d/min, 爐(lu)溫(wen)(wen)升(sheng)至(zhi)930℃時(shi)零(ling)件(jian)(jian)開(kai)始裝爐(lu)。排氣期(qi)(qi)結(jie)束后,放入(ru)兩只試(shi)棒,其(qi)中(zhong)一只試(shi)棒在擴散(san)時(shi)間為(wei)120 min時(shi)取(qu)出淬(cui)油(you)(you)冷卻并(bing)檢(jian)驗(yan)淬(cui)硬層(ceng)深(shen)度(du)(du),根據檢(jian)驗(yan)結(jie)果決定是(shi)否降溫(wen)(wen),若(ruo)滲(shen)(shen)(shen)(shen)碳(tan)層(ceng)深(shen)度(du)(du)不(bu)足,擴散(san)期(qi)(qi)延長至(zhi) 150min。滲(shen)(shen)(shen)(shen)碳(tan)時(shi)可(ke)按照(zhao)表(biao)1規定參數進(jin)(jin)行(xing),為(wei)控(kong)(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)碳(tan)時(shi)的(de)碳(tan)勢(shi)(shi)濃度(du)(du),可(ke)采(cai)用(yong)在滲(shen)(shen)(shen)(shen)碳(tan)爐(lu)中(zhong)加(jia)裝氧(yang)(yang)傳(chuan)感 器的(de)方法(fa)(fa)進(jin)(jin)行(xing)監(jian)測和(he)控(kong)(kong)制(zhi)(zhi),氧(yang)(yang)傳(chuan)感器通(tong)過氧(yang)(yang)化鋯探(tan)頭(tou),將(jiang)氣氛狀態轉(zhuan)化為(wei)電勢(shi)(shi)差(cha),上述(shu)差(cha)值通(tong)過控(kong)(kong)制(zhi)(zhi) 系統的(de)比(bi)較和(he)計算,確定碳(tan)勢(shi)(shi)的(de)濃度(du)(du)是(shi)否合(he)適并(bing)對其(qi)進(jin)(jin)行(xing)自動優(you)化和(he)調整(zheng),使碳(tan)勢(shi)(shi)控(kong)(kong)制(zhi)(zhi)精度(du)(du)可(ke)以達到 ≤±0.05%C,可(ke)有效控(kong)(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)碳(tan)層(ceng)深(shen)度(du)(du)并(bing)提(ti)高(gao)滲(shen)(shen)(shen)(shen)碳(tan)層(ceng)的(de)質量,確保無塊狀、網狀滲(shen)(shen)(shen)(shen)碳(tan)物,滲(shen)(shen)(shen)(shen)碳(tan)設(she)備采(cai) 用(yong)RQ3-75-9井式滲(shen)(shen)(shen)(shen)碳(tan)爐(lu)。滲(shen)(shen)(shen)(shen)碳(tan)均溫(wen)(wen)期(qi)(qi)結(jie)束后,零(ling)件(jian)(jian)出爐(lu)直(zhi)(zhi)接(jie)淬(cui)火(huo)。淬(cui)火(huo)設(she)備選用(yong)專(zhuan)用(yong)恒溫(wen)(wen)油(you)(you)槽,淬(cui) 火(huo)介(jie)(jie)質為(wei)專(zhuan)用(yong)等溫(wen)(wen)分級(ji)淬(cui)火(huo)油(you)(you),介(jie)(jie)質溫(wen)(wen)度(du)(du)恒定在110-120℃之間,冷卻30min后,出爐(lu)空冷。
為(wei)消除(chu)淬火(huo)(huo)后(hou)(hou)零(ling)件(jian)(jian)的(de)殘余應力并(bing)防止淬火(huo)(huo)裂紋的(de)產生(sheng),應盡快(kuai)將淬火(huo)(huo)后(hou)(hou)的(de)零(ling)件(jian)(jian)進行低溫回火(huo)(huo)處理,具(ju)體工藝方法是在當爐(lu)溫升至160℃左右(you)時零(ling) 件(jian)(jian)開始裝爐(lu),保溫120-150min后(hou)(hou),出爐(lu)空冷,回火(huo)(huo)設備為(wei)RJJ-36-6回火(huo)(huo)爐(lu)。淬火(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(de)零件(jian)放在(zai)(zai)噴砂機的(de)轉盤上(shang)進行(xing)噴砂處(chu)理,選用石英砂的(de)粒度(du)為(wei)10-20目,在(zai)(zai)噴砂過(guo) 程(cheng)中要(yao)經常(chang)翻(fan)動零件(jian)使(shi)各面(mian)噴砂效果均勻。零件(jian)噴砂完后,放入(ru)防銹(xiu)液(ye)中浸泡2-4min后,在(zai)(zai)空氣中干 燥。需要(yao)注意的(de)是(shi),防銹(xiu)處(chu)理必須在(zai)(zai)噴砂后24小(xiao)時內完成。
效果(guo)
上述方法簡單(dan)實用,不需要專用裝備(bei)即可(ke)實現直齒(chi)錐(zhui)齒(chi)輪的(de)加工,且經(jing)濟(ji)性好,成(cheng)本較低。經(jing)對 加工后的(de)錐(zhui)齒(chi)輪進行檢測,尺寸及形位精度(du)均(jun)符(fu)合要求(qiu),滲(shen)碳(tan)層(ceng)深度(du)為(wei)1.1-1.3mm,齒(chi)部金相組(zu)織(zhi)為(wei) 單(dan)一的(de)板條狀回火馬氏體組(zu)織(zhi),硬度(du)為(wei)HRC58-62。心部硬度(du)為(wei)HRC36-40,完全可(ke)以滿足該零件的(de)質 量要求(qiu)。