具體參數

拖(tuo)泵(beng)制作工藝

刀具選擇

從該(gai)齒(chi)(chi)輪(lun)(lun)(lun)的結構和(he)技(ji)術參數可知(zhi)，該(gai)錐(zhui)齒(chi)(chi)輪(lun)(lun)(lun)屬(shu)于標準(zhun)結構，一(yi)(yi)般情(qing)況下，標準(zhun)直(zhi)齒(chi)(chi)錐(zhui)齒(chi)(chi)輪(lun)(lun)(lun)成(cheng)(cheng)形(xing)銑 刀(dao)的齒(chi)(chi)形(xing)是按大端背錐(zhui)當量(liang)漸開線(xian)齒(chi)(chi)形(xing)設計，而齒(chi)(chi)厚則(ze)按照(zhao)(zhao)小端設計，并考慮留有一(yi)(yi)定精切余(yu)量(liang)。一(yi)(yi) 般情(qing)況下直(zhi)齒(chi)(chi)錐(zhui)齒(chi)(chi)輪(lun)(lun)(lun)成(cheng)(cheng)形(xing)銑刀(dao)有3把(ba)、8把(ba)、15把(ba)、26把(ba)一(yi)(yi)套，刀(dao)號(hao)應按照(zhao)(zhao)錐(zhui)齒(chi)(chi)輪(lun)(lun)(lun)當量(liang)齒(chi)(chi)數來選擇。當 量(liang)齒(chi)(chi)數Zv可按照(zhao)(zhao)下式計算(suan)：

熱處理(li)工藝(yi)方法及過程

如前文所述，機加工(gong)前對齒坯(pi)進(jin)行整(zheng)體(ti)高溫正(zheng)火(huo)處理，正(zheng)火(huo)設備為RT-90-9 箱式爐，具體(ti)工(gong)藝過程是(shi)，爐溫升至裝(zhuang)爐溫度400-650℃時，將(jiang)齒輪放 爐中，裝(zhuang)零(ling)件(jian)時如果需(xu)要疊放，疊放高度不要超過兩層，然后將(jiang)零(ling)件(jian)加熱(re)至920-940℃，使組織完全(quan)發生相(xiang)變，保溫30-50分鐘后，空冷即可(ke)。正(zheng)火(huo)工(gong)藝：

由于該齒(chi)輪精度(du)(du)要求不(bu)(bu)是很(hen)高，為(wei)(wei)(wei)(wei)降低滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)淬(cui)火(huo)成本，可(ke)以采用(yong)(yong)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)后(hou)直接淬(cui)火(huo)的(de)工藝方法，具 體方法是將零(ling)件(jian)裝(zhuang)入滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)筐(kuang)中(zhong)，不(bu)(bu)要疊(die)加，爐(lu)(lu)溫(wen)(wen)升至840℃開(kai)始滴航空煤油，煤油滴速(su)為(wei)(wei)(wei)(wei)60-80d/min， 爐(lu)(lu)溫(wen)(wen)升至930℃時(shi)零(ling)件(jian)開(kai)始裝(zhuang)爐(lu)(lu)。排氣期(qi)(qi)結(jie)束(shu)后(hou)，放(fang)入兩(liang)只(zhi)試(shi)棒，其(qi)中(zhong)一(yi)只(zhi)試(shi)棒在(zai)擴(kuo)散時(shi)間(jian)為(wei)(wei)(wei)(wei)120 min時(shi)取出淬(cui)油冷卻并檢(jian)驗(yan)(yan)淬(cui)硬層(ceng)深度(du)(du)，根(gen)據檢(jian)驗(yan)(yan)結(jie)果決定(ding)(ding)(ding)是否降溫(wen)(wen)，若滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)深度(du)(du)不(bu)(bu)足，擴(kuo)散期(qi)(qi)延長至 150min。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時(shi)可(ke)按照表(biao)1規定(ding)(ding)(ding)參數進(jin)行(xing)(xing)，為(wei)(wei)(wei)(wei)控(kong)(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)時(shi)的(de)碳(tan)(tan)(tan)(tan)勢濃度(du)(du)，可(ke)采用(yong)(yong)在(zai)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)(lu)中(zhong)加裝(zhuang)氧(yang)傳感(gan) 器的(de)方法進(jin)行(xing)(xing)監(jian)測(ce)和(he)控(kong)(kong)制(zhi)，氧(yang)傳感(gan)器通(tong)過(guo)氧(yang)化(hua)鋯(gao)探(tan)頭，將氣氛(fen)狀(zhuang)(zhuang)態轉化(hua)為(wei)(wei)(wei)(wei)電勢差，上述差值通(tong)過(guo)控(kong)(kong)制(zhi) 系統(tong)的(de)比較(jiao)和(he)計(ji)算，確定(ding)(ding)(ding)碳(tan)(tan)(tan)(tan)勢的(de)濃度(du)(du)是否合(he)適并對其(qi)進(jin)行(xing)(xing)自(zi)動(dong)優(you)化(hua)和(he)調整，使碳(tan)(tan)(tan)(tan)勢控(kong)(kong)制(zhi)精度(du)(du)可(ke)以達到 ≤±0.05%C，可(ke)有效控(kong)(kong)制(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)深度(du)(du)并提高滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)層(ceng)的(de)質(zhi)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(she)備采 用(yong)(yong)RQ3-75-9井式滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)爐(lu)(lu)。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)均溫(wen)(wen)期(qi)(qi)結(jie)束(shu)后(hou)，零(ling)件(jian)出爐(lu)(lu)直接淬(cui)火(huo)。淬(cui)火(huo)設(she)備選用(yong)(yong)專(zhuan)(zhuan)用(yong)(yong)恒溫(wen)(wen)油槽(cao)，淬(cui) 火(huo)介質(zhi)為(wei)(wei)(wei)(wei)專(zhuan)(zhuan)用(yong)(yong)等溫(wen)(wen)分級(ji)淬(cui)火(huo)油，介質(zhi)溫(wen)(wen)度(du)(du)恒定(ding)(ding)(ding)在(zai)110-120℃之間(jian)，冷卻30min后(hou)，出爐(lu)(lu)空冷。

為消除淬(cui)火(huo)后(hou)零(ling)件的(de)殘余應力并(bing)防止淬(cui)火(huo)裂紋的(de)產生，應盡快將淬(cui)火(huo)后(hou)的(de)零(ling)件進行低溫(wen)回(hui)火(huo)處理，具(ju)體工(gong)(gong)藝方法是在當爐(lu)(lu)溫(wen)升至160℃左(zuo)右時(shi)零(ling) 件開始(shi)裝(zhuang)爐(lu)(lu)，保(bao)溫(wen)120-150min后(hou)，出爐(lu)(lu)空(kong)冷，回(hui)火(huo)設備為RJJ-36-6回(hui)火(huo)爐(lu)(lu)。淬(cui)火(huo)及(ji)回(hui)火(huo)工(gong)(gong)藝圖見(jian)圖5：

后(hou)序(xu)處理

將熱處理后(hou)的零件(jian)放在(zai)噴(pen)砂(sha)機的轉盤上進行噴(pen)砂(sha)處理，選用(yong)石英(ying)砂(sha)的粒度為10-20目，在(zai)噴(pen)砂(sha)過 程中要經常翻動(dong)零件(jian)使各(ge)面噴(pen)砂(sha)效果均勻。零件(jian)噴(pen)砂(sha)完后(hou)，放入(ru)防銹液中浸泡2-4min后(hou)，在(zai)空氣中干 燥。需要注意(yi)的是，防銹處理必(bi)須在(zai)噴(pen)砂(sha)后(hou)24小時(shi)內(nei)完成。

效(xiao)果(guo)

上述方(fang)法簡(jian)單實用，不需要專(zhuan)用裝備即(ji)可實現(xian)直齒(chi)錐齒(chi)輪的(de)加工(gong)，且經濟性好，成本較(jiao)低(di)。經對 加工(gong)后的(de)錐齒(chi)輪進行(xing)檢測，尺(chi)寸及形位精度(du)(du)均(jun)符合(he)要求(qiu)，滲(shen)碳(tan)層深(shen)度(du)(du)為(wei)1.1-1.3mm，齒(chi)部金相組織(zhi)為(wei) 單一的(de)板條狀回火馬氏體(ti)組織(zhi)，硬度(du)(du)為(wei)HRC58-62。心(xin)部硬度(du)(du)為(wei)HRC36-40，完全可以滿足該零件的(de)質 量要求(qiu)。