具體參數

拖(tuo)泵制作工藝

刀具選擇

從該齒(chi)(chi)(chi)(chi)輪(lun)的結構和(he)技術參數(shu)可(ke)知，該錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)屬于(yu)標準結構，一(yi)般(ban)情況下(xia)，標準直(zhi)齒(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑(xian) 刀(dao)(dao)的齒(chi)(chi)(chi)(chi)形(xing)是(shi)按(an)大端背(bei)錐(zhui)當量(liang)漸開線齒(chi)(chi)(chi)(chi)形(xing)設(she)計，而(er)齒(chi)(chi)(chi)(chi)厚則按(an)照小(xiao)端設(she)計，并考慮(lv)留有一(yi)定精(jing)切(qie)余量(liang)。一(yi) 般(ban)情況下(xia)直(zhi)齒(chi)(chi)(chi)(chi)錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)成形(xing)銑(xian)刀(dao)(dao)有3把、8把、15把、26把一(yi)套(tao)，刀(dao)(dao)號應按(an)照錐(zhui)齒(chi)(chi)(chi)(chi)輪(lun)當量(liang)齒(chi)(chi)(chi)(chi)數(shu)來選擇。當 量(liang)齒(chi)(chi)(chi)(chi)數(shu)Zv可(ke)按(an)照下(xia)式(shi)計算：

熱處理(li)工(gong)藝方法及過程(cheng)

如前文所述，機加工前對齒(chi)坯進行整體高(gao)(gao)溫(wen)正火(huo)處(chu)理，正火(huo)設備為RT-90-9 箱式爐(lu)，具(ju)體工藝過程是，爐(lu)溫(wen)升至裝爐(lu)溫(wen)度400-650℃時，將齒(chi)輪放 爐(lu)中，裝零件(jian)時如果(guo)需要(yao)疊(die)放，疊(die)放高(gao)(gao)度不(bu)要(yao)超過兩層，然后將零件(jian)加熱至920-940℃，使組織完(wan)全發(fa)生(sheng)相變，保溫(wen)30-50分鐘后，空(kong)冷即可。正火(huo)工藝：

由于(yu)該齒輪精度(du)要求不(bu)是(shi)很高，為降低滲(shen)碳(tan)(tan)(tan)(tan)淬(cui)(cui)火(huo)(huo)成本，可(ke)以(yi)采用(yong)(yong)(yong)滲(shen)碳(tan)(tan)(tan)(tan)后直接淬(cui)(cui)火(huo)(huo)的工藝方法(fa)，具 體(ti)方法(fa)是(shi)將(jiang)零件裝(zhuang)入滲(shen)碳(tan)(tan)(tan)(tan)筐中，不(bu)要疊加，爐溫(wen)升至(zhi)840℃開(kai)始滴航空(kong)煤油(you)(you)，煤油(you)(you)滴速為60-80d/min， 爐溫(wen)升至(zhi)930℃時(shi)零件開(kai)始裝(zhuang)爐。排氣期結(jie)束后，放(fang)入兩只試(shi)棒，其中一(yi)只試(shi)棒在擴(kuo)散時(shi)間為120 min時(shi)取(qu)出(chu)淬(cui)(cui)油(you)(you)冷(leng)(leng)卻并(bing)檢驗淬(cui)(cui)硬層(ceng)(ceng)(ceng)深度(du)，根據檢驗結(jie)果(guo)決定(ding)是(shi)否(fou)降溫(wen)，若滲(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)(ceng)深度(du)不(bu)足，擴(kuo)散期延長至(zhi) 150min。滲(shen)碳(tan)(tan)(tan)(tan)時(shi)可(ke)按照表1規(gui)定(ding)參(can)數進(jin)(jin)行(xing)(xing)，為控制(zhi)滲(shen)碳(tan)(tan)(tan)(tan)時(shi)的碳(tan)(tan)(tan)(tan)勢(shi)濃(nong)(nong)度(du)，可(ke)采用(yong)(yong)(yong)在滲(shen)碳(tan)(tan)(tan)(tan)爐中加裝(zhuang)氧(yang)傳感 器的方法(fa)進(jin)(jin)行(xing)(xing)監測(ce)和(he)控制(zhi)，氧(yang)傳感器通(tong)過(guo)氧(yang)化鋯探頭，將(jiang)氣氛狀態轉化為電勢(shi)差，上述(shu)差值通(tong)過(guo)控制(zhi) 系統(tong)的比較和(he)計算，確(que)定(ding)碳(tan)(tan)(tan)(tan)勢(shi)的濃(nong)(nong)度(du)是(shi)否(fou)合適并(bing)對其進(jin)(jin)行(xing)(xing)自(zi)動(dong)優化和(he)調整，使碳(tan)(tan)(tan)(tan)勢(shi)控制(zhi)精度(du)可(ke)以(yi)達到 ≤±0.05%C，可(ke)有(you)效控制(zhi)滲(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)(ceng)深度(du)并(bing)提高滲(shen)碳(tan)(tan)(tan)(tan)層(ceng)(ceng)(ceng)的質(zhi)量，確(que)保(bao)無塊(kuai)狀、網狀滲(shen)碳(tan)(tan)(tan)(tan)物，滲(shen)碳(tan)(tan)(tan)(tan)設備采 用(yong)(yong)(yong)RQ3-75-9井式滲(shen)碳(tan)(tan)(tan)(tan)爐。滲(shen)碳(tan)(tan)(tan)(tan)均溫(wen)期結(jie)束后，零件出(chu)爐直接淬(cui)(cui)火(huo)(huo)。淬(cui)(cui)火(huo)(huo)設備選用(yong)(yong)(yong)專(zhuan)用(yong)(yong)(yong)恒溫(wen)油(you)(you)槽，淬(cui)(cui) 火(huo)(huo)介質(zhi)為專(zhuan)用(yong)(yong)(yong)等溫(wen)分級淬(cui)(cui)火(huo)(huo)油(you)(you)，介質(zhi)溫(wen)度(du)恒定(ding)在110-120℃之間，冷(leng)(leng)卻30min后，出(chu)爐空(kong)冷(leng)(leng)。

為消除淬(cui)火(huo)(huo)后(hou)零(ling)(ling)件(jian)的殘余應力(li)并(bing)防止淬(cui)火(huo)(huo)裂紋的產生(sheng)，應盡快將淬(cui)火(huo)(huo)后(hou)的零(ling)(ling)件(jian)進行低溫(wen)回(hui)火(huo)(huo)處理，具體(ti)工(gong)藝方法是(shi)在當爐(lu)(lu)溫(wen)升(sheng)至160℃左右時(shi)零(ling)(ling) 件(jian)開始裝爐(lu)(lu)，保溫(wen)120-150min后(hou)，出爐(lu)(lu)空(kong)冷(leng)，回(hui)火(huo)(huo)設備為RJJ-36-6回(hui)火(huo)(huo)爐(lu)(lu)。淬(cui)火(huo)(huo)及(ji)回(hui)火(huo)(huo)工(gong)藝圖見圖5：

后序處理(li)

將熱處(chu)理后(hou)的(de)零(ling)件(jian)放在(zai)噴(pen)(pen)砂(sha)(sha)機的(de)轉盤上進行噴(pen)(pen)砂(sha)(sha)處(chu)理，選用石(shi)英砂(sha)(sha)的(de)粒度為10-20目(mu)，在(zai)噴(pen)(pen)砂(sha)(sha)過 程中要(yao)經(jing)常翻(fan)動(dong)零(ling)件(jian)使各面噴(pen)(pen)砂(sha)(sha)效果均勻。零(ling)件(jian)噴(pen)(pen)砂(sha)(sha)完(wan)后(hou)，放入防(fang)銹(xiu)液中浸泡2-4min后(hou)，在(zai)空氣中干(gan) 燥。需要(yao)注意的(de)是，防(fang)銹(xiu)處(chu)理必須在(zai)噴(pen)(pen)砂(sha)(sha)后(hou)24小時內(nei)完(wan)成。

效果

上述(shu)方法簡單(dan)實用，不需要專用裝備即可實現直齒(chi)(chi)錐齒(chi)(chi)輪的(de)加工(gong)，且經(jing)濟性好(hao)，成本較低(di)。經(jing)對(dui) 加工(gong)后的(de)錐齒(chi)(chi)輪進行檢測，尺寸及(ji)形(xing)位精度(du)均符合(he)要求，滲碳層深(shen)度(du)為1.1-1.3mm，齒(chi)(chi)部(bu)金相組(zu)織(zhi)為 單(dan)一的(de)板條狀回火馬氏(shi)體組(zu)織(zhi)，硬(ying)度(du)為HRC58-62。心部(bu)硬(ying)度(du)為HRC36-40，完全可以(yi)滿足該零件的(de)質 量要求。