具體參數

拖泵制(zhi)作工藝

刀具選(xuan)擇

從該(gai)齒(chi)輪(lun)的結構和技術參數可知，該(gai)錐齒(chi)輪(lun)屬于標準結構，一(yi)般(ban)情況下，標準直(zhi)齒(chi)錐齒(chi)輪(lun)成形銑 刀的齒(chi)形是按大(da)端(duan)背錐當量(liang)漸開線齒(chi)形設計，而(er)齒(chi)厚則(ze)按照(zhao)小端(duan)設計，并考慮留有(you)一(yi)定(ding)精切余(yu)量(liang)。一(yi) 般(ban)情況下直(zhi)齒(chi)錐齒(chi)輪(lun)成形銑刀有(you)3把(ba)、8把(ba)、15把(ba)、26把(ba)一(yi)套，刀號應按照(zhao)錐齒(chi)輪(lun)當量(liang)齒(chi)數來選擇。當 量(liang)齒(chi)數Zv可按照(zhao)下式計算：

熱處理工藝方法及(ji)過程

如前(qian)文所述，機加工(gong)前(qian)對齒坯進行(xing)整(zheng)體(ti)高溫正火處理，正火設備(bei)為(wei)RT-90-9 箱式(shi)爐，具(ju)體(ti)工(gong)藝過(guo)(guo)程是，爐溫升至(zhi)裝(zhuang)爐溫度400-650℃時，將(jiang)齒輪放 爐中，裝(zhuang)零(ling)件時如果需(xu)要疊(die)(die)放，疊(die)(die)放高度不要超(chao)過(guo)(guo)兩層(ceng)，然后將(jiang)零(ling)件加熱至(zhi)920-940℃，使(shi)組織完全發生相變，保溫30-50分鐘(zhong)后，空冷即可。正火工(gong)藝：

由(you)于該齒(chi)輪(lun)精度(du)要(yao)求不(bu)(bu)是(shi)(shi)很高，為(wei)降低滲(shen)(shen)(shen)碳(tan)(tan)(tan)淬(cui)(cui)火成本，可(ke)以采(cai)用(yong)(yong)滲(shen)(shen)(shen)碳(tan)(tan)(tan)后(hou)直接淬(cui)(cui)火的(de)(de)(de)工(gong)藝方(fang)法(fa)，具 體方(fang)法(fa)是(shi)(shi)將零(ling)件(jian)裝(zhuang)入滲(shen)(shen)(shen)碳(tan)(tan)(tan)筐中，不(bu)(bu)要(yao)疊加，爐(lu)(lu)溫(wen)(wen)(wen)升至840℃開始滴(di)(di)航空煤(mei)油(you)(you)，煤(mei)油(you)(you)滴(di)(di)速為(wei)60-80d/min， 爐(lu)(lu)溫(wen)(wen)(wen)升至930℃時(shi)零(ling)件(jian)開始裝(zhuang)爐(lu)(lu)。排氣(qi)期(qi)結束后(hou)，放入兩只(zhi)試棒，其中一只(zhi)試棒在(zai)擴散(san)時(shi)間(jian)為(wei)120 min時(shi)取出淬(cui)(cui)油(you)(you)冷卻并檢(jian)驗(yan)淬(cui)(cui)硬層(ceng)(ceng)深(shen)度(du)，根據檢(jian)驗(yan)結果決定(ding)(ding)是(shi)(shi)否降溫(wen)(wen)(wen)，若滲(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)(ceng)深(shen)度(du)不(bu)(bu)足，擴散(san)期(qi)延長至 150min。滲(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)可(ke)按照表(biao)1規定(ding)(ding)參數進(jin)行(xing)，為(wei)控制(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)的(de)(de)(de)碳(tan)(tan)(tan)勢(shi)濃度(du)，可(ke)采(cai)用(yong)(yong)在(zai)滲(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)(lu)中加裝(zhuang)氧傳(chuan)感 器的(de)(de)(de)方(fang)法(fa)進(jin)行(xing)監測和控制(zhi)(zhi)，氧傳(chuan)感器通(tong)過氧化鋯(gao)探頭，將氣(qi)氛(fen)狀(zhuang)(zhuang)態(tai)轉化為(wei)電勢(shi)差，上述差值(zhi)通(tong)過控制(zhi)(zhi) 系(xi)統的(de)(de)(de)比較和計算，確(que)定(ding)(ding)碳(tan)(tan)(tan)勢(shi)的(de)(de)(de)濃度(du)是(shi)(shi)否合適并對其進(jin)行(xing)自(zi)動優(you)化和調整，使碳(tan)(tan)(tan)勢(shi)控制(zhi)(zhi)精度(du)可(ke)以達到 ≤±0.05%C，可(ke)有效(xiao)控制(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)(ceng)深(shen)度(du)并提高滲(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)(ceng)的(de)(de)(de)質量，確(que)保無塊狀(zhuang)(zhuang)、網狀(zhuang)(zhuang)滲(shen)(shen)(shen)碳(tan)(tan)(tan)物(wu)，滲(shen)(shen)(shen)碳(tan)(tan)(tan)設(she)備(bei)采(cai) 用(yong)(yong)RQ3-75-9井式(shi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)(lu)。滲(shen)(shen)(shen)碳(tan)(tan)(tan)均溫(wen)(wen)(wen)期(qi)結束后(hou)，零(ling)件(jian)出爐(lu)(lu)直接淬(cui)(cui)火。淬(cui)(cui)火設(she)備(bei)選(xuan)用(yong)(yong)專(zhuan)用(yong)(yong)恒溫(wen)(wen)(wen)油(you)(you)槽，淬(cui)(cui) 火介質為(wei)專(zhuan)用(yong)(yong)等溫(wen)(wen)(wen)分(fen)級(ji)淬(cui)(cui)火油(you)(you)，介質溫(wen)(wen)(wen)度(du)恒定(ding)(ding)在(zai)110-120℃之間(jian)，冷卻30min后(hou)，出爐(lu)(lu)空冷。

為(wei)消除淬(cui)火(huo)(huo)(huo)后(hou)零件的殘(can)余應力并防止淬(cui)火(huo)(huo)(huo)裂紋的產生，應盡(jin)快將淬(cui)火(huo)(huo)(huo)后(hou)的零件進行(xing)低溫回(hui)火(huo)(huo)(huo)處(chu)理，具(ju)體(ti)工(gong)(gong)藝(yi)方法是(shi)在當(dang)爐溫升至160℃左右時零 件開(kai)始裝爐，保溫120-150min后(hou)，出爐空冷，回(hui)火(huo)(huo)(huo)設(she)備為(wei)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)(gong)藝(yi)圖見(jian)圖5：

后序處理

將熱處理后(hou)的(de)零件放在(zai)(zai)噴(pen)砂(sha)(sha)機的(de)轉盤上進行噴(pen)砂(sha)(sha)處理，選用石英砂(sha)(sha)的(de)粒度為10-20目(mu)，在(zai)(zai)噴(pen)砂(sha)(sha)過(guo) 程(cheng)中(zhong)(zhong)要(yao)經常翻動零件使(shi)各(ge)面(mian)噴(pen)砂(sha)(sha)效果均(jun)勻。零件噴(pen)砂(sha)(sha)完后(hou)，放入(ru)防銹(xiu)液中(zhong)(zhong)浸泡2-4min后(hou)，在(zai)(zai)空氣中(zhong)(zhong)干 燥(zao)。需要(yao)注意(yi)的(de)是，防銹(xiu)處理必須在(zai)(zai)噴(pen)砂(sha)(sha)后(hou)24小(xiao)時內完成。

效(xiao)果

上述方法簡(jian)單(dan)實用(yong)，不(bu)需(xu)要專用(yong)裝備即可(ke)實現直齒(chi)(chi)錐齒(chi)(chi)輪的加(jia)工(gong)，且經濟性好，成(cheng)本較低。經對 加(jia)工(gong)后(hou)的錐齒(chi)(chi)輪進(jin)行檢(jian)測，尺寸(cun)及形位精度(du)均符(fu)合要求(qiu)(qiu)，滲(shen)碳層深度(du)為(wei)1.1-1.3mm，齒(chi)(chi)部金(jin)相(xiang)組(zu)織為(wei) 單(dan)一的板(ban)條狀回火馬氏(shi)體組(zu)織，硬度(du)為(wei)HRC58-62。心部硬度(du)為(wei)HRC36-40，完全可(ke)以滿足該零件的質 量(liang)要求(qiu)(qiu)。