具體參數

拖泵制作工藝

刀(dao)具(ju)選擇

從該齒(chi)(chi)(chi)(chi)輪(lun)(lun)的結構和技(ji)術(shu)參數(shu)可(ke)知，該錐齒(chi)(chi)(chi)(chi)輪(lun)(lun)屬于標準(zhun)結構，一(yi)般情況下(xia)，標準(zhun)直(zhi)齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)(lun)成形(xing)銑 刀的齒(chi)(chi)(chi)(chi)形(xing)是按(an)大端背錐當(dang)量(liang)漸開線齒(chi)(chi)(chi)(chi)形(xing)設計(ji)，而齒(chi)(chi)(chi)(chi)厚則(ze)按(an)照(zhao)小(xiao)端設計(ji)，并考慮留有一(yi)定精切余量(liang)。一(yi) 般情況下(xia)直(zhi)齒(chi)(chi)(chi)(chi)錐齒(chi)(chi)(chi)(chi)輪(lun)(lun)成形(xing)銑刀有3把(ba)、8把(ba)、15把(ba)、26把(ba)一(yi)套，刀號應按(an)照(zhao)錐齒(chi)(chi)(chi)(chi)輪(lun)(lun)當(dang)量(liang)齒(chi)(chi)(chi)(chi)數(shu)來選(xuan)擇(ze)。當(dang) 量(liang)齒(chi)(chi)(chi)(chi)數(shu)Zv可(ke)按(an)照(zhao)下(xia)式計(ji)算(suan)：

熱處理工藝方(fang)法(fa)及過程

如(ru)前文所述，機加(jia)工(gong)(gong)前對齒坯進行整體高溫(wen)正(zheng)火(huo)(huo)處理，正(zheng)火(huo)(huo)設備為RT-90-9 箱式爐(lu)，具體工(gong)(gong)藝(yi)過(guo)(guo)程是，爐(lu)溫(wen)升至(zhi)裝(zhuang)爐(lu)溫(wen)度400-650℃時(shi)，將齒輪放 爐(lu)中，裝(zhuang)零件(jian)(jian)時(shi)如(ru)果需要疊放，疊放高度不(bu)要超過(guo)(guo)兩層(ceng)，然后(hou)將零件(jian)(jian)加(jia)熱(re)至(zhi)920-940℃，使組織完全發生相變(bian)，保溫(wen)30-50分鐘(zhong)后(hou)，空冷即(ji)可。正(zheng)火(huo)(huo)工(gong)(gong)藝(yi)：

由(you)于該(gai)齒輪精(jing)度(du)(du)要(yao)求不(bu)(bu)是(shi)很高，為(wei)(wei)降低(di)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)淬(cui)(cui)(cui)火(huo)(huo)(huo)成本(ben)，可以(yi)采(cai)用(yong)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)后直(zhi)接淬(cui)(cui)(cui)火(huo)(huo)(huo)的(de)工藝方法(fa)，具 體方法(fa)是(shi)將(jiang)零(ling)件裝(zhuang)入滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)筐中，不(bu)(bu)要(yao)疊加(jia)(jia)，爐(lu)溫(wen)(wen)升至(zhi)840℃開(kai)始(shi)滴(di)航空煤油(you)(you)(you)，煤油(you)(you)(you)滴(di)速為(wei)(wei)60-80d/min， 爐(lu)溫(wen)(wen)升至(zhi)930℃時零(ling)件開(kai)始(shi)裝(zhuang)爐(lu)。排氣(qi)期結(jie)束(shu)后，放入兩只(zhi)試棒，其中一(yi)只(zhi)試棒在擴散時間(jian)為(wei)(wei)120 min時取(qu)出(chu)淬(cui)(cui)(cui)油(you)(you)(you)冷(leng)卻并(bing)(bing)檢(jian)驗(yan)淬(cui)(cui)(cui)硬(ying)層(ceng)(ceng)(ceng)深度(du)(du)，根據檢(jian)驗(yan)結(jie)果(guo)決定(ding)是(shi)否降溫(wen)(wen)，若滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)(ceng)深度(du)(du)不(bu)(bu)足，擴散期延(yan)長至(zhi) 150min。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時可按照表1規(gui)定(ding)參數進(jin)行，為(wei)(wei)控(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時的(de)碳(tan)(tan)(tan)(tan)勢(shi)濃(nong)度(du)(du)，可采(cai)用(yong)在滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)中加(jia)(jia)裝(zhuang)氧(yang)傳感 器(qi)的(de)方法(fa)進(jin)行監測(ce)和控(kong)制(zhi)，氧(yang)傳感器(qi)通過(guo)氧(yang)化鋯探(tan)頭，將(jiang)氣(qi)氛(fen)狀(zhuang)(zhuang)態轉化為(wei)(wei)電(dian)勢(shi)差，上述(shu)差值通過(guo)控(kong)制(zhi) 系統的(de)比較(jiao)和計算，確定(ding)碳(tan)(tan)(tan)(tan)勢(shi)的(de)濃(nong)度(du)(du)是(shi)否合適并(bing)(bing)對其進(jin)行自動優化和調整，使碳(tan)(tan)(tan)(tan)勢(shi)控(kong)制(zhi)精(jing)度(du)(du)可以(yi)達到 ≤±0.05%C，可有(you)效控(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)(ceng)深度(du)(du)并(bing)(bing)提高滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)(ceng)的(de)質量，確保無(wu)塊狀(zhuang)(zhuang)、網狀(zhuang)(zhuang)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)物，滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)設備采(cai) 用(yong)RQ3-75-9井式(shi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)均(jun)溫(wen)(wen)期結(jie)束(shu)后，零(ling)件出(chu)爐(lu)直(zhi)接淬(cui)(cui)(cui)火(huo)(huo)(huo)。淬(cui)(cui)(cui)火(huo)(huo)(huo)設備選(xuan)用(yong)專(zhuan)用(yong)恒溫(wen)(wen)油(you)(you)(you)槽，淬(cui)(cui)(cui) 火(huo)(huo)(huo)介(jie)質為(wei)(wei)專(zhuan)用(yong)等溫(wen)(wen)分(fen)級淬(cui)(cui)(cui)火(huo)(huo)(huo)油(you)(you)(you)，介(jie)質溫(wen)(wen)度(du)(du)恒定(ding)在110-120℃之間(jian)，冷(leng)卻30min后，出(chu)爐(lu)空冷(leng)。

為消(xiao)除淬(cui)火(huo)(huo)(huo)后零(ling)件的(de)殘(can)余(yu)應(ying)力并防止淬(cui)火(huo)(huo)(huo)裂紋的(de)產生，應(ying)盡(jin)快將(jiang)淬(cui)火(huo)(huo)(huo)后的(de)零(ling)件進(jin)行(xing)低溫回(hui)火(huo)(huo)(huo)處理(li)，具體工(gong)藝方法是在當爐溫升至160℃左右時(shi)零(ling) 件開始裝爐，保(bao)溫120-150min后，出爐空(kong)冷，回(hui)火(huo)(huo)(huo)設備為RJJ-36-6回(hui)火(huo)(huo)(huo)爐。淬(cui)火(huo)(huo)(huo)及回(hui)火(huo)(huo)(huo)工(gong)藝圖見(jian)圖5：

后序處理

將(jiang)熱處理后(hou)的(de)零件(jian)放在(zai)噴(pen)(pen)(pen)砂(sha)機的(de)轉盤上進行噴(pen)(pen)(pen)砂(sha)處理，選用石英砂(sha)的(de)粒度為(wei)10-20目，在(zai)噴(pen)(pen)(pen)砂(sha)過 程中(zhong)(zhong)要經常翻動零件(jian)使各(ge)面噴(pen)(pen)(pen)砂(sha)效果均勻。零件(jian)噴(pen)(pen)(pen)砂(sha)完(wan)后(hou)，放入(ru)防銹(xiu)液中(zhong)(zhong)浸泡(pao)2-4min后(hou)，在(zai)空氣(qi)中(zhong)(zhong)干(gan) 燥。需要注意的(de)是，防銹(xiu)處理必須在(zai)噴(pen)(pen)(pen)砂(sha)后(hou)24小時(shi)內完(wan)成。

效果

上(shang)述方(fang)法(fa)簡單(dan)實用(yong)，不需要(yao)專用(yong)裝備即可實現(xian)直齒(chi)錐齒(chi)輪的加工，且經濟性(xing)好，成本較(jiao)低。經對 加工后的錐齒(chi)輪進行檢測，尺寸(cun)及形位(wei)精度均符合要(yao)求(qiu)，滲碳層深度為1.1-1.3mm，齒(chi)部金相組織為 單(dan)一(yi)的板(ban)條狀回火馬氏體組織，硬度為HRC58-62。心部硬度為HRC36-40，完全可以(yi)滿足該零件的質 量要(yao)求(qiu)。