具體參數

拖泵(beng)制作工藝

刀具選擇

從該齒(chi)(chi)(chi)輪(lun)(lun)的(de)(de)結構和技術參(can)數(shu)可知，該錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)屬于(yu)標(biao)準結構，一(yi)般情況下(xia)(xia)，標(biao)準直齒(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)成(cheng)形(xing)銑(xian) 刀(dao)的(de)(de)齒(chi)(chi)(chi)形(xing)是按大端(duan)背(bei)錐(zhui)(zhui)當量漸開線齒(chi)(chi)(chi)形(xing)設計(ji)，而齒(chi)(chi)(chi)厚則按照小端(duan)設計(ji)，并(bing)考慮(lv)留有(you)一(yi)定精切余量。一(yi) 般情況下(xia)(xia)直齒(chi)(chi)(chi)錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)成(cheng)形(xing)銑(xian)刀(dao)有(you)3把(ba)(ba)、8把(ba)(ba)、15把(ba)(ba)、26把(ba)(ba)一(yi)套，刀(dao)號(hao)應按照錐(zhui)(zhui)齒(chi)(chi)(chi)輪(lun)(lun)當量齒(chi)(chi)(chi)數(shu)來選擇(ze)。當 量齒(chi)(chi)(chi)數(shu)Zv可按照下(xia)(xia)式(shi)計(ji)算(suan)：

熱處理(li)工藝方(fang)法及(ji)過程

如前文(wen)所(suo)述，機加工前對齒坯進行整體高溫(wen)正(zheng)火(huo)處理，正(zheng)火(huo)設備為(wei)RT-90-9 箱式爐，具體工藝過(guo)程是，爐溫(wen)升至裝爐溫(wen)度400-650℃時，將齒輪放 爐中(zhong)，裝零件時如果需要疊放，疊放高度不要超(chao)過(guo)兩層(ceng)，然后將零件加熱至920-940℃，使組織完(wan)全發生相變，保溫(wen)30-50分(fen)鐘(zhong)后，空冷即可(ke)。正(zheng)火(huo)工藝：

由于該齒輪精(jing)度(du)(du)(du)要求不(bu)是很高，為(wei)降低(di)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)淬(cui)(cui)火成本，可(ke)以(yi)采用(yong)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)后(hou)直(zhi)接淬(cui)(cui)火的(de)(de)(de)工(gong)藝方法，具 體方法是將零件裝(zhuang)入(ru)(ru)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)筐中(zhong)，不(bu)要疊加，爐(lu)溫升(sheng)至840℃開(kai)始(shi)滴航空煤(mei)油(you)(you)，煤(mei)油(you)(you)滴速為(wei)60-80d/min， 爐(lu)溫升(sheng)至930℃時(shi)零件開(kai)始(shi)裝(zhuang)爐(lu)。排氣(qi)期結(jie)(jie)束后(hou)，放(fang)入(ru)(ru)兩只(zhi)試棒，其中(zhong)一只(zhi)試棒在(zai)擴散時(shi)間(jian)為(wei)120 min時(shi)取出淬(cui)(cui)油(you)(you)冷(leng)卻并檢驗淬(cui)(cui)硬層(ceng)(ceng)深度(du)(du)(du)，根據檢驗結(jie)(jie)果決定(ding)是否降溫，若滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)(ceng)深度(du)(du)(du)不(bu)足，擴散期延長至 150min。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)可(ke)按照(zhao)表1規定(ding)參(can)數進行(xing)(xing)，為(wei)控(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)時(shi)的(de)(de)(de)碳(tan)(tan)(tan)勢(shi)濃度(du)(du)(du)，可(ke)采用(yong)在(zai)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)中(zhong)加裝(zhuang)氧傳(chuan)感(gan) 器(qi)(qi)的(de)(de)(de)方法進行(xing)(xing)監測和控(kong)制(zhi)(zhi)，氧傳(chuan)感(gan)器(qi)(qi)通過氧化鋯探頭，將氣(qi)氛狀(zhuang)態轉化為(wei)電勢(shi)差，上述差值通過控(kong)制(zhi)(zhi) 系統(tong)的(de)(de)(de)比較(jiao)和計算，確(que)定(ding)碳(tan)(tan)(tan)勢(shi)的(de)(de)(de)濃度(du)(du)(du)是否合適(shi)并對其進行(xing)(xing)自動優化和調(diao)整，使(shi)碳(tan)(tan)(tan)勢(shi)控(kong)制(zhi)(zhi)精(jing)度(du)(du)(du)可(ke)以(yi)達到(dao) ≤±0.05%C，可(ke)有效控(kong)制(zhi)(zhi)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)(ceng)深度(du)(du)(du)并提高滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)層(ceng)(ceng)的(de)(de)(de)質量，確(que)保無塊狀(zhuang)、網狀(zhuang)滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)物(wu)，滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)設備采 用(yong)RQ3-75-9井式滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)(shen)碳(tan)(tan)(tan)均溫期結(jie)(jie)束后(hou)，零件出爐(lu)直(zhi)接淬(cui)(cui)火。淬(cui)(cui)火設備選用(yong)專用(yong)恒溫油(you)(you)槽，淬(cui)(cui) 火介質為(wei)專用(yong)等(deng)溫分級淬(cui)(cui)火油(you)(you)，介質溫度(du)(du)(du)恒定(ding)在(zai)110-120℃之(zhi)間(jian)，冷(leng)卻30min后(hou)，出爐(lu)空冷(leng)。

為(wei)消除淬(cui)火(huo)后(hou)零(ling)件(jian)的殘余(yu)應力并防止淬(cui)火(huo)裂(lie)紋的產生，應盡快將淬(cui)火(huo)后(hou)的零(ling)件(jian)進行(xing)低溫回火(huo)處(chu)理，具體工(gong)(gong)藝方法是在當爐溫升至160℃左右時零(ling) 件(jian)開(kai)始裝爐，保溫120-150min后(hou)，出爐空(kong)冷(leng)，回火(huo)設(she)備為(wei)RJJ-36-6回火(huo)爐。淬(cui)火(huo)及(ji)回火(huo)工(gong)(gong)藝圖見(jian)圖5：

后序處理(li)

將熱處理(li)后的零(ling)件放在(zai)(zai)噴(pen)(pen)砂(sha)機的轉(zhuan)盤上進行(xing)噴(pen)(pen)砂(sha)處理(li)，選用石英砂(sha)的粒度為10-20目(mu)，在(zai)(zai)噴(pen)(pen)砂(sha)過(guo) 程(cheng)中要經常翻動零(ling)件使(shi)各(ge)面噴(pen)(pen)砂(sha)效果均勻。零(ling)件噴(pen)(pen)砂(sha)完(wan)后，放入防銹液中浸泡2-4min后，在(zai)(zai)空氣(qi)中干 燥。需(xu)要注意(yi)的是(shi)，防銹處理(li)必須在(zai)(zai)噴(pen)(pen)砂(sha)后24小(xiao)時內(nei)完(wan)成。

效果

上述方法簡單實用，不需要(yao)專用裝備即可(ke)實現直齒(chi)錐齒(chi)輪(lun)的(de)加工(gong)，且經(jing)濟性好，成本(ben)較低。經(jing)對 加工(gong)后(hou)的(de)錐齒(chi)輪(lun)進行(xing)檢(jian)測，尺寸及(ji)形位精度(du)均符合要(yao)求(qiu)，滲(shen)碳層深度(du)為(wei)1.1-1.3mm，齒(chi)部金相組織(zhi)為(wei) 單一的(de)板條(tiao)狀回火馬氏(shi)體(ti)組織(zhi)，硬(ying)(ying)度(du)為(wei)HRC58-62。心部硬(ying)(ying)度(du)為(wei)HRC36-40，完(wan)全(quan)可(ke)以滿足該零件的(de)質(zhi) 量要(yao)求(qiu)。