具體參數

拖泵制作工藝

刀(dao)具(ju)選擇

從該齒(chi)(chi)輪(lun)的(de)結構(gou)和(he)技術參數可知，該錐齒(chi)(chi)輪(lun)屬于標準結構(gou)，一般(ban)情況(kuang)下(xia)，標準直(zhi)齒(chi)(chi)錐齒(chi)(chi)輪(lun)成(cheng)形銑 刀的(de)齒(chi)(chi)形是按(an)大端(duan)背錐當量漸(jian)開線齒(chi)(chi)形設(she)計，而(er)齒(chi)(chi)厚則按(an)照小(xiao)端(duan)設(she)計，并考慮留有一定(ding)精切余量。一 般(ban)情況(kuang)下(xia)直(zhi)齒(chi)(chi)錐齒(chi)(chi)輪(lun)成(cheng)形銑刀有3把(ba)、8把(ba)、15把(ba)、26把(ba)一套，刀號(hao)應按(an)照錐齒(chi)(chi)輪(lun)當量齒(chi)(chi)數來(lai)選擇。當 量齒(chi)(chi)數Zv可按(an)照下(xia)式(shi)計算(suan)：

熱處理工藝方法(fa)及過程

如(ru)前文所述(shu)，機加(jia)工(gong)前對齒坯(pi)進行整(zheng)體高溫(wen)正火(huo)處理，正火(huo)設備為RT-90-9 箱式爐，具體工(gong)藝(yi)過程是(shi)，爐溫(wen)升(sheng)至(zhi)裝(zhuang)爐溫(wen)度(du)400-650℃時(shi)，將(jiang)齒輪(lun)放(fang) 爐中，裝(zhuang)零件(jian)時(shi)如(ru)果(guo)需(xu)要疊放(fang)，疊放(fang)高度(du)不要超過兩層，然后將(jiang)零件(jian)加(jia)熱(re)至(zhi)920-940℃，使組織完全發(fa)生相變，保溫(wen)30-50分鐘后，空(kong)冷即可。正火(huo)工(gong)藝(yi)：

由(you)于該齒輪(lun)精度要(yao)求(qiu)不(bu)是(shi)(shi)很高(gao)，為(wei)(wei)降(jiang)低滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)淬(cui)(cui)火(huo)成本(ben)，可(ke)以采用(yong)(yong)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)后直接(jie)淬(cui)(cui)火(huo)的(de)工(gong)藝方(fang)法(fa)，具 體方(fang)法(fa)是(shi)(shi)將(jiang)零件裝入(ru)(ru)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)筐中，不(bu)要(yao)疊加，爐(lu)溫(wen)(wen)(wen)升至(zhi)840℃開始(shi)滴(di)航空煤(mei)油，煤(mei)油滴(di)速為(wei)(wei)60-80d/min， 爐(lu)溫(wen)(wen)(wen)升至(zhi)930℃時(shi)零件開始(shi)裝爐(lu)。排氣期(qi)結(jie)(jie)束(shu)后，放入(ru)(ru)兩只試棒(bang)，其中一只試棒(bang)在(zai)擴散(san)時(shi)間為(wei)(wei)120 min時(shi)取(qu)出淬(cui)(cui)油冷卻并檢驗淬(cui)(cui)硬層(ceng)深(shen)度，根據(ju)檢驗結(jie)(jie)果決(jue)定(ding)是(shi)(shi)否降(jiang)溫(wen)(wen)(wen)，若滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)深(shen)度不(bu)足，擴散(san)期(qi)延長至(zhi) 150min。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)可(ke)按照表1規定(ding)參數進(jin)行，為(wei)(wei)控(kong)(kong)(kong)制(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)時(shi)的(de)碳(tan)(tan)(tan)(tan)(tan)(tan)勢濃(nong)度，可(ke)采用(yong)(yong)在(zai)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)中加裝氧傳(chuan)(chuan)感 器的(de)方(fang)法(fa)進(jin)行監測(ce)和(he)控(kong)(kong)(kong)制(zhi)(zhi)，氧傳(chuan)(chuan)感器通(tong)(tong)過(guo)氧化(hua)鋯探(tan)頭，將(jiang)氣氛(fen)狀態轉化(hua)為(wei)(wei)電勢差，上述差值通(tong)(tong)過(guo)控(kong)(kong)(kong)制(zhi)(zhi) 系統的(de)比較(jiao)和(he)計算，確定(ding)碳(tan)(tan)(tan)(tan)(tan)(tan)勢的(de)濃(nong)度是(shi)(shi)否合適并對其進(jin)行自動優化(hua)和(he)調整(zheng)，使(shi)碳(tan)(tan)(tan)(tan)(tan)(tan)勢控(kong)(kong)(kong)制(zhi)(zhi)精度可(ke)以達(da)到(dao) ≤±0.05%C，可(ke)有效控(kong)(kong)(kong)制(zhi)(zhi)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)深(shen)度并提高(gao)滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)層(ceng)的(de)質(zhi)量，確保無塊狀、網狀滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)物，滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)設備采 用(yong)(yong)RQ3-75-9井式滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)爐(lu)。滲(shen)(shen)(shen)碳(tan)(tan)(tan)(tan)(tan)(tan)均溫(wen)(wen)(wen)期(qi)結(jie)(jie)束(shu)后，零件出爐(lu)直接(jie)淬(cui)(cui)火(huo)。淬(cui)(cui)火(huo)設備選用(yong)(yong)專用(yong)(yong)恒溫(wen)(wen)(wen)油槽(cao)，淬(cui)(cui) 火(huo)介質(zhi)為(wei)(wei)專用(yong)(yong)等溫(wen)(wen)(wen)分級淬(cui)(cui)火(huo)油，介質(zhi)溫(wen)(wen)(wen)度恒定(ding)在(zai)110-120℃之間，冷卻30min后，出爐(lu)空冷。

為消除淬(cui)火(huo)(huo)后(hou)零件的(de)殘余應力(li)并(bing)防止淬(cui)火(huo)(huo)裂紋(wen)的(de)產生(sheng)，應盡快將淬(cui)火(huo)(huo)后(hou)的(de)零件進行低溫回(hui)(hui)火(huo)(huo)處理(li)，具體工(gong)藝(yi)方(fang)法是在(zai)當爐(lu)溫升至160℃左右時(shi)零 件開始(shi)裝爐(lu)，保溫120-150min后(hou)，出爐(lu)空冷，回(hui)(hui)火(huo)(huo)設備為RJJ-36-6回(hui)(hui)火(huo)(huo)爐(lu)。淬(cui)火(huo)(huo)及回(hui)(hui)火(huo)(huo)工(gong)藝(yi)圖見圖5：

后(hou)序處(chu)理

將熱處理(li)后的(de)零件放在(zai)噴(pen)(pen)(pen)(pen)砂機的(de)轉盤上進行(xing)噴(pen)(pen)(pen)(pen)砂處理(li)，選用石英砂的(de)粒(li)度為10-20目，在(zai)噴(pen)(pen)(pen)(pen)砂過 程(cheng)中(zhong)要經常翻動零件使各(ge)面噴(pen)(pen)(pen)(pen)砂效果均勻(yun)。零件噴(pen)(pen)(pen)(pen)砂完后，放入(ru)防(fang)銹(xiu)液中(zhong)浸泡2-4min后，在(zai)空氣中(zhong)干 燥。需(xu)要注意的(de)是，防(fang)銹(xiu)處理(li)必須在(zai)噴(pen)(pen)(pen)(pen)砂后24小時內完成。

效果

上述方法簡(jian)單(dan)實用(yong)，不需要專用(yong)裝備(bei)即可實現直(zhi)齒(chi)(chi)錐齒(chi)(chi)輪的加工(gong)，且經(jing)濟性(xing)好(hao)，成本(ben)較低。經(jing)對 加工(gong)后的錐齒(chi)(chi)輪進(jin)行(xing)檢測(ce)，尺寸及形位(wei)精度均(jun)符合要求，滲(shen)碳層深(shen)度為1.1-1.3mm，齒(chi)(chi)部金相(xiang)組織為 單(dan)一的板條狀回火(huo)馬氏體組織，硬度為HRC58-62。心部硬度為HRC36-40，完全(quan)可以滿足該零件(jian)的質 量要求。