具體參數

拖泵制作工(gong)藝

刀具選擇

從該齒(chi)(chi)(chi)輪的結(jie)構和技術參數可(ke)知，該錐(zhui)齒(chi)(chi)(chi)輪屬于(yu)標(biao)準結(jie)構，一般情(qing)況(kuang)下，標(biao)準直(zhi)齒(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)輪成形銑 刀(dao)的齒(chi)(chi)(chi)形是按(an)大端背錐(zhui)當量(liang)漸開線(xian)齒(chi)(chi)(chi)形設(she)(she)計(ji)(ji)，而(er)齒(chi)(chi)(chi)厚則按(an)照小端設(she)(she)計(ji)(ji)，并考慮留有(you)一定精切余量(liang)。一 般情(qing)況(kuang)下直(zhi)齒(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)輪成形銑刀(dao)有(you)3把、8把、15把、26把一套，刀(dao)號(hao)應按(an)照錐(zhui)齒(chi)(chi)(chi)輪當量(liang)齒(chi)(chi)(chi)數來選(xuan)擇(ze)。當 量(liang)齒(chi)(chi)(chi)數Zv可(ke)按(an)照下式計(ji)(ji)算：

熱(re)處理(li)工藝方法(fa)及(ji)過程(cheng)

如前文所述，機加(jia)工前對齒坯(pi)進行(xing)整體高(gao)溫(wen)正(zheng)火(huo)處(chu)理，正(zheng)火(huo)設(she)備為RT-90-9 箱(xiang)式爐(lu)，具體工藝(yi)過程是，爐(lu)溫(wen)升至裝爐(lu)溫(wen)度400-650℃時，將齒輪(lun)放 爐(lu)中，裝零件時如果需要疊放，疊放高(gao)度不要超(chao)過兩層，然(ran)后(hou)將零件加(jia)熱至920-940℃，使組織完(wan)全發生相(xiang)變，保(bao)溫(wen)30-50分鐘(zhong)后(hou)，空冷即可(ke)。正(zheng)火(huo)工藝(yi)：

由于(yu)該齒輪精(jing)度要(yao)求不(bu)是(shi)(shi)很高，為(wei)降低滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)淬(cui)火(huo)(huo)成本，可(ke)以采用(yong)(yong)(yong)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)后直(zhi)接(jie)淬(cui)火(huo)(huo)的(de)(de)工藝方(fang)(fang)法(fa)(fa)，具 體方(fang)(fang)法(fa)(fa)是(shi)(shi)將(jiang)(jiang)零件(jian)(jian)裝入滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)筐中，不(bu)要(yao)疊加，爐(lu)溫(wen)升至(zhi)840℃開始滴航空(kong)煤(mei)油(you)，煤(mei)油(you)滴速為(wei)60-80d/min， 爐(lu)溫(wen)升至(zhi)930℃時(shi)零件(jian)(jian)開始裝爐(lu)。排氣期結(jie)束(shu)后，放(fang)入兩只(zhi)試棒(bang)，其中一只(zhi)試棒(bang)在擴散時(shi)間為(wei)120 min時(shi)取出淬(cui)油(you)冷卻并(bing)檢(jian)驗淬(cui)硬層(ceng)深(shen)度，根據檢(jian)驗結(jie)果決定(ding)是(shi)(shi)否(fou)降溫(wen)，若滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)深(shen)度不(bu)足，擴散期延長至(zhi) 150min。滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)可(ke)按(an)照表1規定(ding)參數進行，為(wei)控制(zhi)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)的(de)(de)碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)濃度，可(ke)采用(yong)(yong)(yong)在滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)中加裝氧傳感 器(qi)(qi)的(de)(de)方(fang)(fang)法(fa)(fa)進行監測和(he)控制(zhi)，氧傳感器(qi)(qi)通(tong)(tong)過氧化鋯(gao)探頭，將(jiang)(jiang)氣氛狀態轉(zhuan)化為(wei)電勢(shi)差，上述(shu)差值通(tong)(tong)過控制(zhi) 系統的(de)(de)比較和(he)計算，確定(ding)碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)的(de)(de)濃度是(shi)(shi)否(fou)合(he)適并(bing)對(dui)其進行自(zi)動優化和(he)調(diao)整，使碳(tan)(tan)(tan)(tan)(tan)(tan)勢(shi)控制(zhi)精(jing)度可(ke)以達到(dao) ≤±0.05%C，可(ke)有效控制(zhi)滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)深(shen)度并(bing)提高滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)的(de)(de)質(zhi)量(liang)，確保無塊狀、網(wang)狀滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)物，滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)設(she)(she)備采 用(yong)(yong)(yong)RQ3-75-9井式滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)均溫(wen)期結(jie)束(shu)后，零件(jian)(jian)出爐(lu)直(zhi)接(jie)淬(cui)火(huo)(huo)。淬(cui)火(huo)(huo)設(she)(she)備選用(yong)(yong)(yong)專(zhuan)用(yong)(yong)(yong)恒溫(wen)油(you)槽，淬(cui) 火(huo)(huo)介(jie)(jie)質(zhi)為(wei)專(zhuan)用(yong)(yong)(yong)等(deng)溫(wen)分級(ji)淬(cui)火(huo)(huo)油(you)，介(jie)(jie)質(zhi)溫(wen)度恒定(ding)在110-120℃之間，冷卻30min后，出爐(lu)空(kong)冷。

為消除淬火后零件(jian)的殘余應力并防止淬火裂(lie)紋的產生，應盡快將淬火后的零件(jian)進行低溫回(hui)火處理，具體工藝方(fang)法是(shi)在當爐(lu)溫升至160℃左右時零 件(jian)開(kai)始裝(zhuang)爐(lu)，保溫120-150min后，出爐(lu)空(kong)冷，回(hui)火設備為RJJ-36-6回(hui)火爐(lu)。淬火及回(hui)火工藝圖見圖5：

后序處理(li)

將熱處(chu)理(li)后(hou)(hou)的(de)零(ling)件(jian)放在(zai)噴(pen)(pen)(pen)砂(sha)(sha)機的(de)轉盤上進行噴(pen)(pen)(pen)砂(sha)(sha)處(chu)理(li)，選用石英砂(sha)(sha)的(de)粒度為10-20目，在(zai)噴(pen)(pen)(pen)砂(sha)(sha)過 程中要(yao)經常(chang)翻(fan)動零(ling)件(jian)使(shi)各面噴(pen)(pen)(pen)砂(sha)(sha)效果(guo)均勻。零(ling)件(jian)噴(pen)(pen)(pen)砂(sha)(sha)完(wan)后(hou)(hou)，放入防(fang)銹(xiu)液中浸泡2-4min后(hou)(hou)，在(zai)空氣中干 燥(zao)。需(xu)要(yao)注意的(de)是，防(fang)銹(xiu)處(chu)理(li)必須在(zai)噴(pen)(pen)(pen)砂(sha)(sha)后(hou)(hou)24小(xiao)時內(nei)完(wan)成。

效果

上(shang)述方法簡單(dan)實用，不需要(yao)專用裝備即可實現直(zhi)齒(chi)錐齒(chi)輪的加工，且經濟(ji)性好，成本較低。經對 加工后的錐齒(chi)輪進(jin)行檢(jian)測，尺寸(cun)及形位精度均符合要(yao)求(qiu)，滲(shen)碳層深(shen)度為(wei)(wei)(wei)1.1-1.3mm，齒(chi)部金相組(zu)織為(wei)(wei)(wei) 單(dan)一(yi)的板(ban)條狀回火馬(ma)氏體組(zu)織，硬(ying)度為(wei)(wei)(wei)HRC58-62。心部硬(ying)度為(wei)(wei)(wei)HRC36-40，完全(quan)可以滿(man)足(zu)該零件的質 量要(yao)求(qiu)。