CN117260201A - Prime number helical gear processing method and gear hobbing tool - Google Patents
Prime number helical gear processing method and gear hobbing tool Download PDFInfo
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- CN117260201A CN117260201A CN202311250901.1A CN202311250901A CN117260201A CN 117260201 A CN117260201 A CN 117260201A CN 202311250901 A CN202311250901 A CN 202311250901A CN 117260201 A CN117260201 A CN 117260201A
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- 238000003672 processing method Methods 0.000 title claims abstract description 23
- 238000005266 casting Methods 0.000 claims abstract description 28
- 238000007514 turning Methods 0.000 claims abstract description 11
- 238000012216 screening Methods 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 22
- 238000005096 rolling process Methods 0.000 claims description 15
- 238000010438 heat treatment Methods 0.000 claims description 13
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 238000001816 cooling Methods 0.000 claims description 9
- 238000003825 pressing Methods 0.000 claims description 7
- 230000007547 defect Effects 0.000 claims description 5
- 229910000859 α-Fe Inorganic materials 0.000 claims description 4
- 230000003746 surface roughness Effects 0.000 abstract description 6
- 230000008569 process Effects 0.000 description 6
- 239000000463 material Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000005242 forging Methods 0.000 description 3
- 238000003754 machining Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 239000002826 coolant Substances 0.000 description 2
- 238000002372 labelling Methods 0.000 description 2
- 238000011179 visual inspection Methods 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 229910001141 Ductile iron Inorganic materials 0.000 description 1
- 208000010641 Tooth disease Diseases 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23F—MAKING GEARS OR TOOTHED RACKS
- B23F23/00—Accessories or equipment combined with or arranged in, or specially designed to form part of, gear-cutting machines
- B23F23/02—Loading, unloading or chucking arrangements for workpieces
- B23F23/06—Chucking arrangements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23F—MAKING GEARS OR TOOTHED RACKS
- B23F9/00—Making gears having teeth curved in their longitudinal direction
- B23F9/08—Making gears having teeth curved in their longitudinal direction by milling, e.g. with helicoidal hob
- B23F9/082—Making gears having teeth curved in their longitudinal direction by milling, e.g. with helicoidal hob with a hob
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Gear Processing (AREA)
Abstract
The application provides a prime number helical gear processing method and a gear hobbing tool, wherein the prime number helical gear processing method comprises the following steps: casting to obtain a tooth blank of a prime helical gear; checking casting quality, and screening out tooth blanks meeting casting quality requirements; roughly turning the end face, the inner hole and the top circle of a tooth blank, wherein the unilateral margin of the tooth blank is 2mm; heat treating the tooth blank to a surface hardness of greater than or equal to HB229 and less than or equal to HB302; finish turning the end face, the inner hole and the top circle of the gear blank; the gear blank is mounted to a gear hobbing tool; the common normal line of the tooth shape is unilaterally left for 0.3mm to 0.4mm; and (3) the tooth shape of the gear hobbing blank is finished. The prime helical gear processing method improves the surface hardness of the cast tooth blank by checking, screening and removing bad tooth blank, improves the surface processing precision of the tooth blank by step turning and step hobbing, and can improve the strength of the manufactured prime helical gear and reduce the surface roughness of the prime helical gear.
Description
Technical Field
The application relates to the field of processing of prime bevel gears, in particular to a prime bevel gear processing method and a gear rolling tool.
Background
The intermediate gear and the crank gear are important parts of the marine medium-speed diesel engine, the intermediate gear and the crank gear are prime helical gears with the tooth number more than 100, and the requirements on the gear strength and the gear profile surface roughness are high.
In the related art, most intermediate gears of medium-speed diesel engines and tooth blanks of crankshaft gears are made of forged alloy steel, and the forged gears are compact in internal structure and high in strength, and can be used in working conditions with strict requirements.
The cast gear has the advantages of simple processing technology, low production cost and the like, but compared with forging, the cast gear has the advantages of low internal structure performance deviation, low strength and high surface roughness, is only suitable for being used under the common working condition, and is difficult to be applied to marine diesel engines.
Disclosure of Invention
The present application aims to solve at least one of the technical problems existing in the prior art. Therefore, the prime number bevel gear machining method and the gear rolling tool are provided, and prime number bevel gears are manufactured through a forging process.
According to the prime number bevel gear processing method provided by the application, the method comprises the following steps of: casting to obtain a tooth blank of a prime helical gear; checking casting quality, and screening out the tooth blank meeting casting quality requirements; roughly turning the end face, the inner hole and the top circle of the tooth blank, wherein the single side of the tooth blank is left for 2mm; heat treating the tooth blank to a surface hardness of greater than or equal to HB229 and less than or equal to HB302; finely turning the end face, the inner hole and the top circle of the tooth blank; the gear blank is mounted to a gear hobbing tool; roughly rolling the tooth shape of the tooth blank, wherein the unilateral margin of the common normal line of the tooth shape is 0.3 mm-0.4 mm; and finely rolling the tooth shape of the tooth blank.
According to the prime number helical gear processing method provided by the application, the method has at least the following technical effects: the prime helical gear processing method improves the surface hardness of the cast tooth blank through checking and screening the poor tooth blank, improves the surface processing precision of the tooth blank through step turning and step hobbing, can improve the strength of the manufactured prime helical gear, reduces the surface roughness of the prime helical gear, and is beneficial to manufacturing the prime helical gear suitable for a marine diesel engine.
According to some embodiments of the present application, meeting casting quality requirements includes that the surface of the tooth blank is free of casting defects including cracks, porosity, inclusions, and foreign inclusions under 10 x magnification.
According to some embodiments of the present application, meeting casting quality requirements includes a spheroidization grade of the metallographic structure of the tooth blank that is greater than or equal to grade 1 and less than or equal to grade 3, the ferrite content of the metallographic structure of the tooth blank being no greater than 25%.
According to some embodiments of the present application, the heat treatment step comprises: heating the tooth blank to 920 ℃ and maintaining; the tooth blank is rapidly cooled to normal temperature; heating the tooth blank to 560 ℃ and maintaining; and naturally cooling the tooth blank to room temperature.
According to some embodiments of the present application, the tooth blank is maintained at 920 ℃ for 3 hours and the tooth blank is maintained at 560 ℃ for 4 hours.
According to some embodiments of the present application, the tooth blank is rapidly cooled using air cooling.
According to some embodiments of the present application, the prime bevel gear has a number of teeth greater than 100, and the gear blank is rough rolled and finish rolled by a gear hobbing machine, and before the rough rolling step, the method further includes: manufacturing a prime straight tooth gear with the same tooth number as the prime helical gear; manufacturing a large prime number split gear plate matched with the prime number straight gear, wherein the large prime number split gear plate comprises an avoidance groove, and the avoidance groove is used for avoiding a gear set of the gear hobbing machine; and replacing the original tooth dividing and lapping gear in the gear hobbing machine with the prime straight-tooth gear, and replacing the original tooth dividing and lapping gear in the gear hobbing machine with the large prime tooth dividing and lapping gear.
According to the gear hobbing tool, the prime number bevel gear processing method is used for implementing.
According to some embodiments of the present application, the gear hobbing frock includes base, clamp plate and dabber, the mounting hole has been seted up to the base, the dabber is inserted and is established in the mounting hole, the dabber is used for the location the hole of tooth base, the clamp plate is installed on the base, the base includes first terminal surface, the clamp plate include with the second terminal surface that first terminal surface is relative, the second terminal surface will along the axial the tooth base compress tightly in first terminal surface.
According to some embodiments of the present application, the gear hobbing tool comprises a backing ring on which the base is mounted.
The gear hobbing tool is used for implementing the prime number bevel gear processing method provided by the application, so that the gear hobbing tool has the beneficial effects provided by the prime number bevel gear processing method correspondingly and is not described in detail herein.
Drawings
The foregoing and/or additional aspects and advantages of the present application will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a flow diagram of a prime number bevel gear processing method according to an embodiment of the present application;
FIG. 2 is an internal schematic view of a gear hobbing machine used in the prime number helical gear processing method of the embodiment of the present application;
FIG. 3 is an internal schematic view of a gear hobbing machine used in the prime number helical gear processing method of the embodiment of the present application;
fig. 4 is a schematic structural view of a jig unit provided in an embodiment of the present application;
FIG. 5 is a schematic structural view of a base provided by an embodiment of the present application, with exemplary labeling of preferred tolerances;
FIG. 6 is a schematic structural view of a mandrel provided by an embodiment of the present application, with exemplary labeling of preferred tolerances;
FIG. 7 is a schematic diagram of a backing ring provided in an embodiment of the present application, wherein preferred tolerances are illustratively noted.
Reference numerals:
a large prime number gear dividing plate 110, a gear dividing and taking gear 120, a gear dividing and taking gear plate 130, a carrier gear 140, a base 210, a first end surface 211, a fourth end surface 212, a mounting hole 213, a mandrel 220, a first shaft section 221, a second shaft section 222, a third end surface 223, a pressing plate 230, a backing ring 240, a fifth end surface 241, a sixth end surface 242, and a gear blank 310.
Detailed Description
Embodiments of the present application are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are exemplary only for the purpose of explaining the present application and are not to be construed as limiting the present application.
In the description of the present application, it should be understood that references to orientation descriptions such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc., are based on the orientation or positional relationship shown in the drawings, are for convenience of description and simplicity of description only, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be configured and operated in a particular orientation, and therefore should not be construed as limiting the present application.
In the description of the present application, the meaning of a number is one or more, the meaning of a number is two or more, greater than, less than, exceeding, etc. are understood to not include the present number, and the meaning of a number above, below, within, etc. are understood to include the present number. The description of the first and second is for the purpose of distinguishing between technical features only and should not be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated or implicitly indicating the precedence of the technical features indicated.
In the description of the present application, unless explicitly defined otherwise, terms such as arrangement, installation, connection, etc. should be construed broadly and the specific meaning of the terms in the present application can be reasonably determined by a person skilled in the art in combination with the specific contents of the technical solution.
The casting process is low in cost, and the related technology is often used for manufacturing parts instead of the forging process so as to reduce the production cost.
However, the quality of the blanks obtained by casting is generally such that the parts obtained by machining are difficult to meet the performance requirements of severe operating conditions (for example, gears of gearboxes of marine diesel engines). When a gear is manufactured by using a casting process, one of the problems is that the surface roughness of the cast is large, the engagement and transmission of the gear are affected, and the other is that the strength of the cast is insufficient, the life of the gear is low when used in a diesel engine with a large load, and tooth breakage easily occurs.
In order to improve the product quality, so that the gear based on the manufacturing process can meet the requirements, the application provides a prime helical gear processing method, and referring to fig. 1, the prime helical gear processing method comprises the following steps:
casting to obtain a tooth blank 310 of a prime helical gear;
checking casting quality, and screening out tooth blanks 310 meeting casting quality requirements;
roughly turning the end face, inner hole and top circle of the tooth blank 310, and leaving 2mm on one side of the tooth blank 310;
heat treating the tooth blank 310 to a surface hardness of the tooth blank 310 greater than or equal to HB229 and less than or equal to HB302;
finish turning the end face, inner hole and top circle of the tooth blank 310;
the gear blank 310 is mounted to a gear hobbing tool;
the single side of the common normal line of the tooth shape 310 remains 0.3mm to 0.4mm;
the tooth form of the fine hobbing blank 310.
According to the prime number bevel gear processing method provided by the application, the poor tooth blank 310 is removed through inspection and screening, the surface hardness of the tooth blank 310 obtained through casting is improved through a heat treatment process, the surface processing precision of the tooth blank 310 is improved through step turning and step hobbing, the strength of the manufactured prime number bevel gear can be improved, the surface roughness of the prime number bevel gear is reduced, and the prime number bevel gear suitable for a marine diesel engine is manufactured.
On the basis, further clear screening standards are needed, so that the situation that the casting yield is too low due to too tight standards on one hand and the production cost is too high is avoided, and on the other hand, the situation that the performance of a prime helical gear finished product cannot meet requirements due to too loose standards is avoided.
Specifically, the tooth blank 310 may first be inspected for macroscopic defects. Illustratively, meeting the casting quality requirements may first include that the surface of the tooth blank 310 is free of casting defects including cracks, porosity, inclusions, and foreign inclusions under 10 x magnification. The visual inspection can conveniently and quickly perform primary screening on the tooth blank 310, and remove the tooth blank 310 with obviously substandard quality.
Next, the microstructure of the tooth blank 310 may be further inspected to more finely evaluate casting quality. Illustratively, satisfying the casting quality requirements after visual inspection may further include a spheroidization grade of the metallographic structure of the tooth blank 310 of greater than or equal to grade 1 and less than or equal to grade 3, the ferrite content of the metallographic structure of the tooth blank being no greater than 25%.
The calculation method of the ferrite ratio and the demarcation basis of the grade can refer to the existing standard of the industry, for example, refer to the related content of GB/T9441 'ductile iron metallographic examination', and the description is omitted here.
The tooth blank 310 may be brought to a desired surface hardness by different heat treatment processes, illustratively, heat treatment steps including: the tooth blank 310 is heated to 920 ℃ and maintained; the tooth blank 310 is rapidly cooled to normal temperature; the tooth blank 310 is heated to 560 ℃ and maintained; the tooth blank 310 naturally cools to room temperature.
Specifically, in order to secure the heat treatment effect, it may be designed that the tooth blank 310 is maintained at 920 ℃ for 3 hours and the tooth blank 310 is maintained at 560 ℃ for 4 hours. The heating may be performed in a special heat treatment furnace, such as an air furnace.
In addition, in the present application, it is preferable to use air-cooled rapid cooling of the tooth blank 310, for example, rapid cooling may be achieved by means of blowing heat dissipation using an industrial fan. It will be appreciated that the use of water-cooled cooling may result in a tooth blank 310 that cools too quickly, and that excessive stress or even cracking may occur during cooling of the tooth blank 310. The use of oil or coolant as the water-cooled medium may reduce the cooling rate to some extent as compared to conventional water, but at a higher cost and with a lower amplitude than desired, and the oil and coolant may also alter the metallurgical structure of the tooth blank 310.
The gear hobbing machine is used for rough rolling and finish rolling of the gear hobbing blank 310, rough rolling is used for rough rolling, finish rolling is used for finish rolling of the gear hobbing cutter, when prime helical gears are machined by the gear hobbing machine, generating motion exists between the hob cutter and the gear blank 310, and in a gear transmission chain used for generating the generating motion in the gear hobbing machine, the number of teeth of a gear (namely, a gear dividing and lapping change gear 120 in the gear hobbing machine) is an integer multiple of the number of teeth of the prime helical gears to be machined (the situation that the number of teeth is equal is also included).
Some marine prime bevel gears have a number of teeth Z greater than 100 (called large prime bevel gears), and in general, a gear hobbing machine manufacturer only provides a tooth dividing gear with a number of teeth corresponding to a prime bevel gear with a Z of 100 or less, so that there is no suitable tooth dividing gear as the tooth dividing gear 120 for generating the generating motion.
In the related art, a differential compensation method is often used to machine a prime bevel gear with a Z greater than 100, that is, the gear 120 is selected according to the virtual number of teeth (z+Δz) instead of the actual number of teeth Z. The disadvantage of the differential compensation method for processing the large-prime bevel gear is that after the hob starts to roll the gear to the end point from the start point, the hob cannot return to the original point quickly, the hob must reverse and move reversely to return to the original point, so that the time for processing the large-prime bevel gear is slower than that for processing the non-prime bevel gear by about one time theoretically; the compensating tooth dividing error DeltaZ generated by the differential compensation method is overlapped in the differential motion in the motion process, so that dislocation and tooth disorder are caused, and the gear machining precision is affected. For further technical details of the differential compensation method, reference is made to the prior art, and no further description is given here.
In order to overcome the drawbacks of the differential compensation method, the rough rolling step in the present application further includes making a prime straight-tooth gear with the same number of teeth as the prime helical gear, and replacing the original split-and-lap gear 120 in the gear hobbing machine with the prime straight-tooth gear. That is, the present application self-prepares a prime number spur gear that matches a large prime number helical gear to be processed, and uses the prime number spur gear as a tooth dividing and lapping gear 120, so that the gear hobbing machine can directly process a required large prime number helical gear without using a differential compensation method for fitting, when the hob starts to roll the gear to the end point from the start point, the hob can quickly return to the original point without reversing and backing back, and the compensation tooth dividing error Δz cannot be generated.
It should be noted that, since the structure inside the gear hobbing machine is not adapted to the prime number spur gear having the number of teeth greater than 100, after the prime number spur gear is mounted as the split-teeth gear shift 120, the gear set inside the gear hobbing machine interferes with the split-teeth gear shift plate 130 on which the split-teeth gear shift 120 is mounted, resulting in the gear hobbing machine not being operated.
For this reason, the prime helical gear processing method further includes manufacturing a large prime split gear plate 110 adapted to the prime straight gear, wherein the large prime split gear plate 110 includes an avoidance groove for avoiding a gear set of the gear hobbing machine; the original gear plate in the gear hobbing machine is replaced with a large prime number gear plate 110.
Fig. 2 and 3 exemplarily show a part of gears of a gear set inside a gear hobbing machine, and referring to fig. 2 and 3, fig. 2 is a case where a prime number spur gear is mounted but the original gear plate 130 is not replaced, and it is seen that the gear plate 130 interferes with the gear set. Specifically, the gear wheel plate 130 is provided with a carrier gear 140 in addition to the gear wheel 120, the gear wheel 120 is meshed with the carrier gear 140, the carrier gear 140 is meshed with a differential gear wheel in the gear box through a gear set, the diameter of the gear wheel 120 is correspondingly increased due to the increase of the number of teeth, the carrier gear 140 needs to be correspondingly reduced, and the gear meshed with the carrier gear 140 interferes with the gear wheel plate 130.
Fig. 3 shows the situation after the large prime number split gear plate 110 is installed, and it can be seen that by adding the avoiding groove, it is ensured that no interference occurs, so that the gear hobbing machine operates normally.
In addition, in order to ensure the reliability and the service life of the large prime number gear plate 110, and to compensate for the weakening effect of the avoidance groove on the strength of the large prime number gear plate 110, the material of the large prime number gear plate 110 may be designed to be 40Cr (the material of the original gear plate of the gear hobbing machine is mostly HT 250), and heat treatment is performed to make the hardness of the large prime number gear plate 110 reach HB292 to HB320.
The application also provides a gear hobbing tool, which is used for implementing the prime number helical gear processing method.
The gear hobbing tool comprises a base 210, a pressing plate 230 and a mandrel 220, wherein the base 210 is provided with a mounting hole 213, the mandrel 220 is inserted into the mounting hole 213, the mandrel 220 is used for positioning an inner hole of a tooth blank 310, the pressing plate 230 is arranged on the base 210, the base 210 comprises a first end surface 211, the pressing plate 230 comprises a second end surface opposite to the first end surface 211, and the second end surface axially presses the tooth blank 310 on the first end surface 211.
Illustratively, referring to fig. 4 and 5, the base 210 includes a receiving chamber with a mounting hole 213 centrally located therein and coaxial therewith, the receiving chamber having an upwardly facing opening with a first end face surrounding the opening, and a platen 230 mounted in the open position by a stud to press against the tooth blank 310.
With continued reference to fig. 4, the gear hobbing tool may further comprise a backing ring 240, with the base 210 mounted on the backing ring 240.
In order to ensure the assembly effect and improve the processing quality, further restrictions on the assembly tolerance are required.
Illustratively, referring to fig. 6, the mandrel 220 has a first shaft section 221 that mates with the mounting hole 213 and a second shaft section 222 that mates with the inner bore of the tooth blank 310, the mandrel 220 includes a third end surface 223 perpendicular to the axial direction, the third end surface 223 contacts the base 210 to position the mandrel 220, the first shaft section 221 and the second shaft section 222 should have a coaxiality error (based on the second shaft section 222) of less than or equal to 0.015mm, and the third end surface 223 should have a perpendicularity error (based on the axis of the second shaft section 222) of less than or equal to 0.020mm.
Referring to fig. 5, the base includes a fourth end surface 212, the fourth end surface 212 is in contact with the backing ring 240, and a perpendicularity error (based on an axis of the mounting hole 213) of the fourth end surface 212 should be less than or equal to 0.020mm.
Referring to fig. 7, the backing ring 240 includes a fifth end surface 241 and a sixth end surface 242, the fifth end surface 241 is configured to contact the fourth end surface 212, the sixth end surface 242 is opposite to the fifth end surface 241, and a parallelism error (based on the fifth end surface 241) of the fifth end surface 241 and the sixth end surface 242 should be less than or equal to 0.020mm.
In the description of the present specification, reference to the terms "one embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
In some alternative embodiments, the functions/acts noted in the block diagrams may occur out of the order noted in the operational illustrations. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Furthermore, the embodiments presented and described in the flowcharts of this application are provided by way of example in order to provide a more thorough understanding of the technology. The disclosed methods are not limited to the operations and logic flows presented herein. Alternative embodiments are contemplated in which the order of various operations is changed, and in which sub-operations described as part of a larger operation are performed independently.
While embodiments of the present application have been shown and described, it will be understood by those of ordinary skill in the art that: many changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the application, the scope of which is defined by the claims and their equivalents.
Claims (10)
1. The prime number bevel gear processing method is characterized by comprising the following steps of:
casting to obtain a tooth blank of a prime helical gear;
checking casting quality, and screening out the tooth blank meeting casting quality requirements;
roughly turning the end face, the inner hole and the top circle of the tooth blank, wherein the single side of the tooth blank is left for 2mm;
heat treating the tooth blank to a surface hardness of greater than or equal to HB229 and less than or equal to HB302;
finely turning the end face, the inner hole and the top circle of the tooth blank;
the gear blank is mounted to a gear hobbing tool;
roughly rolling the tooth shape of the tooth blank, wherein the unilateral margin of the common normal line of the tooth shape is 0.3 mm-0.4 mm;
and finely rolling the tooth shape of the tooth blank.
2. The method of claim 1, wherein meeting casting quality requirements includes no casting defects on the surface of the tooth blank under 10 x magnification, the casting defects including cracks, porosity, inclusions, and foreign inclusions.
3. The method of claim 2, wherein meeting casting quality requirements includes a spheroidization grade of the metallurgical structure of the tooth blank of greater than or equal to grade 1 and less than or equal to grade 3, wherein the ferrite content of the metallurgical structure of the tooth blank is no greater than 25%.
4. The prime number bevel gear processing method of claim 1, wherein the heat treatment step comprises:
heating the tooth blank to 920 ℃ and maintaining;
the tooth blank is rapidly cooled to normal temperature;
heating the tooth blank to 560 ℃ and maintaining;
and naturally cooling the tooth blank to room temperature.
5. The method of claim 4, wherein the tooth blank is maintained at 920 ℃ for 3 hours and at 560 ℃ for 4 hours.
6. The method of claim 4, wherein said tooth blank is rapidly cooled using air cooling.
7. The method of claim 1, wherein the prime number bevel gear has a number of teeth greater than 100, the gear blank is rough rolled and finish rolled using a gear hobbing machine, and further comprising, prior to the rough rolling step:
manufacturing a prime straight tooth gear with the same tooth number as the prime helical gear;
manufacturing a large prime number split gear plate matched with the prime number straight gear, wherein the large prime number split gear plate comprises an avoidance groove, and the avoidance groove is used for avoiding a gear set of the gear hobbing machine;
and replacing the original tooth dividing and lapping gear in the gear hobbing machine with the prime straight-tooth gear, and replacing the original tooth dividing and lapping gear in the gear hobbing machine with the large prime tooth dividing and lapping gear.
8. A gear hobbing tool for carrying out the prime number bevel gear processing method of any one of claims 1 to 7.
9. The gear hobbing tool according to claim 8, wherein the gear hobbing tool comprises a base, a pressing plate and a mandrel, wherein the base is provided with a mounting hole, the mandrel is inserted into the mounting hole, the mandrel is used for positioning an inner hole of the tooth blank, the pressing plate is mounted on the base, the base comprises a first end face, the pressing plate comprises a second end face opposite to the first end face, and the second end face axially presses the tooth blank to the first end face.
10. The gear hobbing tool according to claim 9, wherein said gear hobbing tool comprises a backing ring, said base being mounted on said backing ring.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311250901.1A CN117260201A (en) | 2023-09-25 | 2023-09-25 | Prime number helical gear processing method and gear hobbing tool |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311250901.1A CN117260201A (en) | 2023-09-25 | 2023-09-25 | Prime number helical gear processing method and gear hobbing tool |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117260201A true CN117260201A (en) | 2023-12-22 |
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ID=89217346
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311250901.1A Pending CN117260201A (en) | 2023-09-25 | 2023-09-25 | Prime number helical gear processing method and gear hobbing tool |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117260201A (en) |
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2023
- 2023-09-25 CN CN202311250901.1A patent/CN117260201A/en active Pending
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