東(dong)莞(guan)市銳鑫機(ji)電有限公司
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B棟401
具體參數
拖泵制作工藝
刀具選擇
從該齒(chi)(chi)(chi)(chi)輪(lun)的(de)(de)結(jie)構和技術參數(shu)可(ke)知,該錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)屬于標(biao)準結(jie)構,一般(ban)(ban)情況下(xia),標(biao)準直(zhi)齒(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成(cheng)(cheng)形(xing)(xing)銑(xian) 刀的(de)(de)齒(chi)(chi)(chi)(chi)形(xing)(xing)是按大端(duan)(duan)背(bei)錐(zhui)當量(liang)(liang)漸開線(xian)齒(chi)(chi)(chi)(chi)形(xing)(xing)設計(ji)(ji),而齒(chi)(chi)(chi)(chi)厚則按照小端(duan)(duan)設計(ji)(ji),并(bing)考慮留有(you)一定精切余(yu)量(liang)(liang)。一 般(ban)(ban)情況下(xia)直(zhi)齒(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成(cheng)(cheng)形(xing)(xing)銑(xian)刀有(you)3把(ba)(ba)、8把(ba)(ba)、15把(ba)(ba)、26把(ba)(ba)一套,刀號應按照錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)當量(liang)(liang)齒(chi)(chi)(chi)(chi)數(shu)來(lai)選擇。當 量(liang)(liang)齒(chi)(chi)(chi)(chi)數(shu)Zv可(ke)按照下(xia)式(shi)計(ji)(ji)算:
熱處理工藝方(fang)法及過程
如前(qian)文所述(shu),機加(jia)工前(qian)對齒坯(pi)進行整體(ti)高溫(wen)正火處理,正火設備為RT-90-9 箱式爐,具體(ti)工藝(yi)過程是,爐溫(wen)升至(zhi)裝(zhuang)爐溫(wen)度400-650℃時(shi),將(jiang)齒輪放(fang) 爐中,裝(zhuang)零(ling)(ling)件時(shi)如果需(xu)要疊放(fang),疊放(fang)高度不要超過兩層(ceng),然后將(jiang)零(ling)(ling)件加(jia)熱(re)至(zhi)920-940℃,使組織(zhi)完全發生相變,保溫(wen)30-50分鐘后,空(kong)冷即可。正火工藝(yi):
由(you)于(yu)該齒(chi)輪精度(du)(du)要(yao)求不是很高(gao),為(wei)降低滲(shen)(shen)(shen)碳(tan)淬(cui)(cui)(cui)火成本,可(ke)以采用滲(shen)(shen)(shen)碳(tan)后(hou)(hou)直接淬(cui)(cui)(cui)火的(de)工(gong)藝方(fang)法(fa),具 體(ti)方(fang)法(fa)是將(jiang)零(ling)件(jian)裝入滲(shen)(shen)(shen)碳(tan)筐(kuang)中,不要(yao)疊加,爐溫升至840℃開始(shi)(shi)滴(di)(di)航空(kong)煤油(you),煤油(you)滴(di)(di)速為(wei)60-80d/min, 爐溫升至930℃時零(ling)件(jian)開始(shi)(shi)裝爐。排氣期(qi)結(jie)束后(hou)(hou),放入兩(liang)只試棒,其中一只試棒在(zai)擴(kuo)(kuo)散(san)時間(jian)為(wei)120 min時取出淬(cui)(cui)(cui)油(you)冷卻(que)(que)并檢驗(yan)(yan)淬(cui)(cui)(cui)硬(ying)層深度(du)(du),根據檢驗(yan)(yan)結(jie)果決定(ding)是否降溫,若滲(shen)(shen)(shen)碳(tan)層深度(du)(du)不足,擴(kuo)(kuo)散(san)期(qi)延(yan)長至 150min。滲(shen)(shen)(shen)碳(tan)時可(ke)按照表1規定(ding)參數(shu)進(jin)行(xing),為(wei)控制(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)時的(de)碳(tan)勢(shi)濃(nong)度(du)(du),可(ke)采用在(zai)滲(shen)(shen)(shen)碳(tan)爐中加裝氧傳(chuan)感 器(qi)的(de)方(fang)法(fa)進(jin)行(xing)監(jian)測和(he)控制(zhi)(zhi),氧傳(chuan)感器(qi)通過氧化鋯探頭,將(jiang)氣氛狀態轉(zhuan)化為(wei)電勢(shi)差(cha),上述差(cha)值通過控制(zhi)(zhi) 系統的(de)比較和(he)計算(suan),確定(ding)碳(tan)勢(shi)的(de)濃(nong)度(du)(du)是否合適并對其進(jin)行(xing)自(zi)動優化和(he)調整,使(shi)碳(tan)勢(shi)控制(zhi)(zhi)精度(du)(du)可(ke)以達(da)到 ≤±0.05%C,可(ke)有效(xiao)控制(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)層深度(du)(du)并提高(gao)滲(shen)(shen)(shen)碳(tan)層的(de)質量,確保無(wu)塊狀、網狀滲(shen)(shen)(shen)碳(tan)物,滲(shen)(shen)(shen)碳(tan)設備采 用RQ3-75-9井式(shi)滲(shen)(shen)(shen)碳(tan)爐。滲(shen)(shen)(shen)碳(tan)均溫期(qi)結(jie)束后(hou)(hou),零(ling)件(jian)出爐直接淬(cui)(cui)(cui)火。淬(cui)(cui)(cui)火設備選用專用恒溫油(you)槽(cao),淬(cui)(cui)(cui) 火介質為(wei)專用等溫分(fen)級淬(cui)(cui)(cui)火油(you),介質溫度(du)(du)恒定(ding)在(zai)110-120℃之間(jian),冷卻(que)(que)30min后(hou)(hou),出爐空(kong)冷。
為消除(chu)淬(cui)火(huo)(huo)(huo)后零(ling)件(jian)的殘余應(ying)力(li)并防(fang)止淬(cui)火(huo)(huo)(huo)裂(lie)紋的產生,應(ying)盡快將淬(cui)火(huo)(huo)(huo)后的零(ling)件(jian)進行低(di)溫回(hui)(hui)火(huo)(huo)(huo)處理,具體(ti)工(gong)藝方法是在當(dang)爐溫升至160℃左右時零(ling) 件(jian)開始裝爐,保溫120-150min后,出爐空冷(leng),回(hui)(hui)火(huo)(huo)(huo)設(she)備為RJJ-36-6回(hui)(hui)火(huo)(huo)(huo)爐。淬(cui)火(huo)(huo)(huo)及回(hui)(hui)火(huo)(huo)(huo)工(gong)藝圖見圖5:
后(hou)序處理
將熱處(chu)(chu)理(li)后的零(ling)件放在噴(pen)(pen)(pen)砂機的轉盤上進行(xing)噴(pen)(pen)(pen)砂處(chu)(chu)理(li),選用石英(ying)砂的粒度為10-20目,在噴(pen)(pen)(pen)砂過 程中要(yao)(yao)經常翻動(dong)零(ling)件使各面噴(pen)(pen)(pen)砂效果(guo)均(jun)勻。零(ling)件噴(pen)(pen)(pen)砂完后,放入(ru)防銹液中浸泡(pao)2-4min后,在空氣(qi)中干 燥(zao)。需要(yao)(yao)注意的是,防銹處(chu)(chu)理(li)必須在噴(pen)(pen)(pen)砂后24小時內完成。
效果
上(shang)述方法簡單實用,不需要(yao)(yao)專用裝(zhuang)備即可(ke)(ke)實現直齒(chi)錐齒(chi)輪的(de)(de)加(jia)工(gong)(gong),且經(jing)濟性好,成本較低。經(jing)對 加(jia)工(gong)(gong)后的(de)(de)錐齒(chi)輪進行檢測,尺寸(cun)及形位(wei)精度(du)(du)(du)均符(fu)合要(yao)(yao)求(qiu),滲(shen)碳層深(shen)度(du)(du)(du)為1.1-1.3mm,齒(chi)部金相組(zu)織為 單一(yi)的(de)(de)板(ban)條狀回火馬氏體(ti)組(zu)織,硬度(du)(du)(du)為HRC58-62。心部硬度(du)(du)(du)為HRC36-40,完全可(ke)(ke)以(yi)滿足該零件的(de)(de)質 量要(yao)(yao)求(qiu)。