CN101954574A - Method for machining output shaft assembly - Google Patents
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Abstract
Description
技术领域technical field
本发明涉及一种输出轴组件的加工方法,尤其涉及一种汽车起动电机输出轴组件的加工方法。The present invention relates to a processing method of an output shaft assembly, in particular to a processing method of an output shaft assembly of an automobile starter motor.
背景技术Background technique
目前,汽车行业应用最广泛的起动电机是减速传动型起动电机,而其中占比最大是行星齿轮式减速传动型起动电机,其在轿车的应用达到70~80%,在整个汽车行业的应用达到60%以上。At present, the most widely used starter motor in the automotive industry is the reduction transmission starter motor, and the planetary gear reduction transmission starter motor accounts for the largest proportion. Its application in cars reaches 70-80%, and its application in the entire automotive industry reaches More than 60%.
汽车起动电机输出轴组件是行星齿轮式减速传动型起动电机最重要的零部件之一,其加工的质量好坏和精度高低,直接决定了整个起动电机的装配、传动、振动噪音、耐久,以及起动等诸多关键性能。The output shaft assembly of the automobile starter motor is one of the most important parts of the planetary gear reduction transmission type starter motor. The quality and precision of its processing directly determine the assembly, transmission, vibration, noise, durability, and Starting and many other key performances.
图1所示为一种典型的汽车起动电机输出轴组件。汽车起动电机输出轴组件是由输出轴、齿轮轴及含油轴承组装而成,其加工过程包括输出轴的加工及齿轮轴、输出轴与所述输出轴的组装,所述输出轴的加工工序包括坯料准备、制坯、机械加工和特种加工等,所述制坯包括采用温热锻造技术制坯,该加工方法不仅消耗能源,污染环境,而且加工余量大,精度低,加工效率低。Figure 1 shows a typical automotive starter motor output shaft assembly. The output shaft assembly of the automobile starter motor is assembled from an output shaft, a gear shaft and an oil-impregnated bearing. The processing process includes the processing of the output shaft and the assembly of the gear shaft, the output shaft and the output shaft. The processing steps of the output shaft include Billet preparation, billet making, mechanical processing and special processing, etc. The billet making includes using warm forging technology to make billets. This processing method not only consumes energy, pollutes the environment, but also has large processing allowance, low precision and low processing efficiency.
发明内容Contents of the invention
本发明的目的在于提供一种加工精度高和加工效率高的输出轴组件的加工方法。The purpose of the present invention is to provide a processing method of an output shaft assembly with high processing precision and high processing efficiency.
本发明的目的是这样实现的,一种输出轴组件的加工方法,包括输出轴的加工及齿轮轴、含油轴承与所述输出轴的组装,所述输出轴的加工流程包括坯料准备、制坯、机械加工、特种加工及辅助处理,其特征在于,所述制坯包括采用冷挤压成形技术预制坯和制坯。The purpose of the present invention is achieved in this way, a processing method of the output shaft assembly, including the processing of the output shaft and the assembly of the gear shaft, the oil bearing and the output shaft, the processing flow of the output shaft includes blank preparation, blank making . Mechanical processing, special processing and auxiliary treatment, characterized in that the billet making includes prefabricated billet and billet made by adopting cold extrusion forming technology.
为了提高加工效率及螺旋花键的综合质量,解决无退刀槽渐开线齿形零件无法滚铣机械加工的难题,上述特种加工包括渐开线螺旋花键的加工,所述渐开线螺旋花键的加工为采用冷滚轧成形技术。采用冷滚轧成形技术,加工出的螺旋花键的齿面粗糙度较高,可达Ra0.4以上;因为齿形部分金属纤维是完整、连续的,不像机械加工齿形的金属纤维被切断,以及齿形表面的金属颗粒变小、细化,因此冷滚轧齿形具有较高的抗疲劳应力和抗弯强度,综合强度可提高15~20%;滚轧成形模具寿命长,可达十多万至数十万件;另外,采用冷滚轧工艺可以节省大量机床设备、厂房面积及生产操作人员,且便于生产管理,易于实现生产过程自动化;因而应用冷滚轧成形技术可以大幅度降低生产制造成本。In order to improve the processing efficiency and the overall quality of the helical spline, and solve the problem that the involute tooth-shaped parts without undercuts cannot be machined by hobbing, the above-mentioned special processing includes the processing of the involute helical spline, and the involute helical The splines are processed by cold rolling forming technology. Using the cold rolling forming technology, the processed helical spline has a high roughness of the tooth surface, which can reach above Ra0.4; because the metal fibers of the tooth shape are complete and continuous, unlike the metal fibers of the mechanically processed tooth shape Cutting off, and the metal particles on the surface of the tooth profile become smaller and more refined, so the cold rolled tooth profile has higher fatigue resistance and bending strength, and the overall strength can be increased by 15-20%; the roll forming die has a long life and can In addition, the use of cold rolling technology can save a lot of machine tools, plant area and production operators, and is convenient for production management and easy to realize the automation of the production process; therefore, the application of cold rolling forming technology can be large Significantly reduce manufacturing costs.
上述特种加工还包括冲孔,为了提高齿轮轴底孔的冲孔合格率,所述冲孔为使用申请号为201020055240.9的专利公开的冲孔模具在上述输出轴上冲压出三个齿轮轴底孔,冲孔时以上述含油轴承座孔作为定位基准,所述三个齿轮轴底孔的尺寸误差≤0.02,且相对于两个基准小端中心孔和含油轴承座孔的位置误差≤0.03。较普通冲孔技术产品合格率提高15~20%,冲孔模具寿命达到30000件以上。The above-mentioned special processing also includes punching. In order to improve the punching pass rate of the bottom hole of the gear shaft, the punching is to punch out three bottom holes of the gear shaft on the output shaft using the punching die disclosed in the patent application number 201020055240.9. When punching, the above-mentioned oil-impregnated bearing seat hole is used as a positioning reference, the size error of the three gear shaft bottom holes is ≤0.02, and the position error relative to the two reference small end center holes and the oil-impregnated bearing seat hole is ≤0.03. Compared with ordinary punching technology, the qualified rate of products is increased by 15-20%, and the life of punching dies reaches more than 30,000 pieces.
为了保持基准的一致性和进一步提高输出轴的加工质量,上述机械加工的工艺过程均是以所述小端中心孔和大端60°锥孔作为定位基准。In order to maintain the consistency of the benchmarks and further improve the processing quality of the output shaft, the above-mentioned machining processes all use the central hole at the small end and the 60° taper hole at the big end as positioning benchmarks.
为了提高加工精度,上述机械加工包括粗车、半精车和精车,所述粗车、半精车和精车均采用数控车床。In order to improve machining accuracy, the above-mentioned mechanical processing includes rough turning, semi-finishing turning and finishing turning, and the rough turning, semi-finishing turning and finishing turning all adopt numerical control lathes.
为了提高输出轴组件的装配合格率,降低生产成本,上述齿轮轴、含油轴承与上述输出轴的组装为使用申请号为201020055282.2的专利公开的铆挤装配模具在液压机床上一次将含油轴承和三根齿轮轴铆挤装配到所述输出轴,所述三根齿轮轴相对于两个基准小端中心孔和含油轴承内孔的位置误差≤0.04。产品合格率提高20%以上,降低制造成本15~20%,铆挤装配模具寿命达到30000~50000件。In order to improve the assembly qualification rate of the output shaft assembly and reduce the production cost, the assembly of the above-mentioned gear shaft, the oil-impregnated bearing and the above-mentioned output shaft is to use the riveting assembly die disclosed in the patent application number 201020055282. The shaft is riveted and assembled to the output shaft, and the position error of the three gear shafts relative to the center holes of the two reference small ends and the inner hole of the oil-impregnated bearing is ≤0.04. The pass rate of the product is increased by more than 20%, the manufacturing cost is reduced by 15-20%, and the life of the riveting assembly die reaches 30,000-50,000 pieces.
为了提高产品的综合质量、成品率和加工效率,本发明输出轴采用以下加工步骤:In order to improve the overall quality, yield and processing efficiency of the product, the output shaft of the present invention adopts the following processing steps:
上述坯料准备具体包括The above blank preparation specifically includes
(1)下料:热轧棒料采用剪切或锯割的工艺方法下料; (1) Cutting: hot-rolled bars are cut by cutting or sawing;
(2)抛丸:去除所下材料表面的氧化皮; (2) Shot blasting: remove the oxide skin on the surface of the material;
(3)车坯:车去下料时材料两端所形成的塌角并倒角,提高冷挤压预制坯时的工艺稳定性;(3) Car billet: the collapse and chamfering formed at both ends of the material when the car is removed for blanking, which improves the process stability of the cold extrusion preform;
(4)表面处理:通过表面磷化皂化处理,在坯料表面均匀覆盖一层磷化皂化膜,从而减小冷挤压预制坯时的摩擦阻力和成形抗力,提高工艺稳定性。(4) Surface treatment: Through surface phosphating and saponification treatment, a layer of phosphating and saponification film is uniformly covered on the billet surface, thereby reducing frictional resistance and forming resistance during cold extrusion of preforms, and improving process stability.
上述制坯具体包括The above blanks specifically include
(1)预制坯:采用冷挤压成形技术预制坯,为下一步成形出最终坯件做准备; (1) Prefabricated billet: Prefabricated billet using cold extrusion forming technology to prepare for the final billet formed in the next step;
(2)表面处理:通过表面磷化皂化处理,在预制坯件表面均匀覆盖一层磷化皂化膜,从而减小冷挤压成形时的摩擦阻力和成形抗力,提高工艺稳定性; (2) Surface treatment: Through surface phosphating and saponification treatment, a layer of phosphating and saponification film is evenly covered on the surface of the preform, thereby reducing friction resistance and forming resistance during cold extrusion forming, and improving process stability;
(3)预镦坯:采用冷挤压成形技术来预镦坯,为下一步成形出最终坯件做进一步准备; (3) Pre-upsetting billet: use cold extrusion forming technology to pre-upset the billet, and make further preparations for the next step of forming the final billet;
(4)退火;通过退火处理降低之前预制坯和预镦坯件因加工硬化所产生的硬度提高与去除应力,从而使冷挤压成形力大幅度降低,减小设备吨位,同时提高后续冷挤压成形的工艺稳定性;(4) Annealing: through annealing treatment, the hardness increase and stress removal of the preform and pre-heading blank due to work hardening are reduced, so that the cold extrusion forming force is greatly reduced, the tonnage of the equipment is reduced, and the subsequent cold extrusion is improved. Process stability of press forming;
(5)抛丸:去除之前退火坯件表面的氧化皮; (5) Shot blasting: remove the scale on the surface of the previously annealed blank;
(6)表面处理:通过表面磷化皂化处理,在预镦坯件表面均匀覆盖一层磷化皂化膜,从而减小冷挤压成形时的摩擦阻力和成形抗力,提高工艺稳定性; (6) Surface treatment: Through surface phosphating and saponification treatment, a layer of phosphating and saponification film is uniformly covered on the surface of pre-heading blanks, thereby reducing friction resistance and forming resistance during cold extrusion forming, and improving process stability;
(7)冷挤压:采用冷挤压成形技术,成形出和输出轴很接近的最终坯件,提高金属材料利用率,将后续机械加工的金属余量减小到较低水平,提高加工效率; (7) Cold extrusion: adopt cold extrusion forming technology to form the final blank that is very close to the output shaft, improve the utilization rate of metal materials, reduce the metal allowance for subsequent machining to a lower level, and improve processing efficiency ;
(8)正火;正火处理的目的是降低冷挤压成形坯件因加工硬化所产生的较高硬度,去除因加工硬化所产生的应力,同时提高后续机械加工工艺的稳定性;(8) Normalizing: The purpose of normalizing is to reduce the high hardness of the cold extrusion forming blank due to work hardening, remove the stress caused by work hardening, and improve the stability of the subsequent machining process;
(9)校直;如果正火坯件出现过度弯曲,则需要通过校直工艺校正,为后续机械加工工序做准备; (9) Straightening; if there is excessive bending of the normalizing blank, it needs to be corrected by the straightening process to prepare for the subsequent machining process;
上述机械加工包括粗车、半精车和精车,所述粗车、半精车和精车均采用数控车床且均是以小端中心孔(1)和大端60°锥孔(12)作为定位基准,上述机械加工和特种加工具体包括The above-mentioned mechanical processing includes rough turning, semi-finishing turning and finishing turning. The rough turning, semi-finishing turning and finishing turning all adopt CNC lathes and are all centered on the small end center hole (1) and the big end 60° tapered hole (12). As a positioning reference, the above-mentioned mechanical processing and special processing specifically include
(1)车大端面:去除大端面两端以及大端外圆的多余金属材料,为后续机械加工工序做准备; (1) Turning the large end face: remove the excess metal material at both ends of the large end face and the outer circle of the large end to prepare for the subsequent machining process;
(2)车小端面:加工去除小端面的多余材料,为后续机械加工工序做准备; (2) Turning small end face: processing to remove excess material on the small end face to prepare for the subsequent machining process;
(3)加工大端中心孔:加工大端中心孔,作为后续机械加工工序的过渡基准,最终会被加工去掉; (3) Machining the center hole of the big end: machining the center hole of the big end, as the transition benchmark of the subsequent machining process, will eventually be removed by machining;
(4)加工小端中心孔:加工小端中心孔,作为后续机械加工工序的基准之一; (4) Machining the center hole of the small end: machining the center hole of the small end as one of the benchmarks for the subsequent machining process;
(5)粗车基准面:粗加工后续机械加工工序的夹持基准,去除多余材料;(5) Rough turning datum surface: the clamping datum of the subsequent machining process of rough machining to remove excess material;
(6)精车基准面:加工出后续机械加工工序的夹持基准;(6) Finishing datum plane: the clamping datum for the subsequent machining process;
(7)车大端面及含油轴承座孔:加工大端面两端、外圆,去除多余材料,加工含油轴承座孔及60°锥孔,以此作为后续机械加工、冷滚轧渐开线螺旋花键、冲压齿轮轴底孔、以及铆挤装配等工序的多重定位基准;(7) Turning the large end face and oil bearing seat hole: process both ends of the large end face and the outer circle, remove excess material, process the oil bearing seat hole and 60° tapered hole, and use it as a follow-up machining, cold rolling involute spiral Multiple positioning datums for processes such as splines, stamping gear shaft bottom holes, and riveting assembly;
(8)粗车外圆:粗加工各外圆以及渐开线螺旋花键(6)滚轧前的外圆,去除多余材料;(8) Rough turning outer circle: rough machining of each outer circle and involute helical spline (6) The outer circle before rolling to remove excess material;
(9)半精车外圆:进一步加工各外圆,去除多余材料,加工渐开线螺旋花键滚轧成形段坯料形状和尺寸,包括倒角、斜角和渐开线螺旋花键滚轧前的外圆直径,以及卡簧槽和退刀槽;(9) Semi-finishing outer circle: further processing each outer circle, removing excess material, processing the shape and size of the blank of the involute spiral spline rolling forming section, including chamfering, bevel and involute spiral spline rolling The outer diameter of the front, as well as the ring groove and the relief groove;
(10)冷滚轧:应用冷滚轧成形技术加工制造渐开线螺旋花键,解决了无退刀槽齿形零件无法机械加工的难题,减少机械加工工序,加工效率大幅度提高20倍以上;(10) Cold rolling: apply cold rolling forming technology to process and manufacture involute spiral splines, which solves the problem that tooth-shaped parts without undercut grooves cannot be machined, reduces machining processes, and greatly improves processing efficiency by more than 20 times ;
(11)精车外圆:精加工各外圆以及渐开线螺旋花键齿顶圆,去除多余材料,只留热处理后的磨削余量;(11) Finishing outer circle: finishing each outer circle and involute spiral spline tooth tip circle, removing excess material, leaving only the grinding allowance after heat treatment;
(12)冲孔:使用申请号为201020055240.9的专利公开的冲孔模具在输出轴上冲压出三个齿轮轴底孔,冲孔时以上述含油轴承座孔作为定位基准,所述三个齿轮轴底孔的尺寸误差≤0.02,且相对于两个基准小端中心孔和含油轴承座孔的位置误差≤0.03;(12) Punching: use the punching die disclosed in the patent application number 201020055240.9 to punch out three gear shaft bottom holes on the output shaft. The size error of the bottom hole is ≤0.02, and the position error relative to the center hole of the two datum small ends and the oil bearing seat hole is ≤0.03;
(13)精车大端两面:加工大端面两侧以及大端外圆,去除多余材料和冲孔塌角,保证盘厚尺寸及形位公差要求; (13) Finish turning both sides of the big end: process both sides of the big end face and the outer circle of the big end, remove excess material and punching slump, and ensure the disc thickness and shape tolerance requirements;
(14)车总长:加工去除小端面的多余材料,保证总长尺寸; (14) The overall length of the vehicle: processing and removing the excess material on the small end face to ensure the overall length;
(15)加工含油轴承座孔:加工含油轴承座孔,保证孔深尺寸;(15) Process the oil-impregnated bearing seat hole: process the oil-impregnated bearing seat hole to ensure the hole depth;
(16)孔口倒角:孔口倒角去除毛刺,以利于齿轮轴铆挤装配,保证总成装配的质量;(16) Orifice chamfering: the orifice is chamfered to remove burrs, so as to facilitate the riveting assembly of the gear shaft and ensure the quality of the assembly assembly;
(17)打标记:打上要求的标机;(17) Marking: mark the required marking machine;
(18)渗碳淬火;通过渗碳淬火处理提高输出轴心部和表面的硬度,改善组织,使表面的有效渗碳层深度达到要求;(18) Carburizing and quenching: through carburizing and quenching treatment, the hardness of the output shaft center and surface can be improved, the structure can be improved, and the effective carburized layer depth on the surface can meet the requirements;
(19)研磨基准孔:研磨用以提高基准孔表面粗糙度,清除孔内沙石等杂物;(19) Grinding reference hole: Grinding is used to improve the surface roughness of the reference hole and remove debris such as sand and stones in the hole;
(20)磨外圆:磨削使各外圆的尺寸、表面粗糙度、以及形位公差均达到要求;(20) Grinding the outer circle: Grinding to make the size, surface roughness, and shape tolerance of each outer circle meet the requirements;
上述辅助处理包括对已磨削产品进行清洗除污和防锈处理。The above-mentioned auxiliary treatment includes cleaning, decontamination and anti-rust treatment of the ground product.
本发明具有如下有益效果,本发明采用冷挤压成形技术制坯,采用冷滚轧成形技术加工渐开线螺旋花键,采用数控车床进行机械加工,采用专用的冲孔模具和铆挤装配模具进行冲孔和组装,并采用特有的加工步骤和方法,不仅提高了输出轴组件的制造精度和加工效率,提高了产品综合质量和成品率,而且降低了原材料和能源消耗,减少了环境污染。The present invention has the following beneficial effects: the present invention adopts cold extrusion forming technology to make blank, adopts cold rolling forming technology to process involute spiral spline, adopts numerical control lathe for machining, and adopts special punching die and riveting assembly die Punching and assembly, and the use of unique processing steps and methods, not only improve the manufacturing accuracy and processing efficiency of the output shaft assembly, improve the overall quality and yield of products, but also reduce raw materials and energy consumption, and reduce environmental pollution.
the
附图说明Description of drawings
图1为本发明输出轴组件结构示意图;Fig. 1 is a structural schematic diagram of the output shaft assembly of the present invention;
图2为图1的侧视图。FIG. 2 is a side view of FIG. 1 .
具体实施方式Detailed ways
实施例1,一种输出轴组件的加工方法,包括输出轴19的加工及齿轮轴17、含油轴承18与输出轴19的组装,输出轴19的加工流程包括坯料准备、制坯、机械加工、特种加工及辅助处理;Embodiment 1, a processing method of the output shaft assembly, including the processing of the
制坯包括采用冷挤压成形技术预制坯和制坯;Billet making includes preform and billet making by cold extrusion forming technology;
特种加工包括渐开线螺旋花键6的加工,渐开线螺旋花键6的加工为采用冷滚轧成形技术;Special processing includes the processing of involute helical spline 6, and the processing of involute helical spline 6 adopts cold rolling forming technology;
特种加工还包括冲孔,该冲孔为使用申请号为201020055240.9的专利公开的冲孔模具在上述输出轴上冲压出三个齿轮轴底孔,冲孔时以含油轴承座孔作为定位基准,该三个齿轮轴底孔的尺寸误差≤0.02,且相对于作为基准的小端中心孔和含有轴承座孔的位置误差≤0.03;The special processing also includes punching. The punching is to use the punching die disclosed in the patent application number 201020055240.9 to punch out three bottom holes of the gear shaft on the output shaft. The size error of the bottom holes of the three gear shafts is ≤0.02, and the position error of the center hole of the small end and the hole containing the bearing seat is ≤0.03;
机械加工的工艺过程均是以小端中心孔1和大端60°锥孔12作为定位基准;The machining process is based on the central hole 1 at the small end and the 60°
机械加工包括粗车、半精车和精车,所述粗车、半精车和精车均采用数控车床;Mechanical processing includes rough turning, semi-finishing turning and finishing turning, and the rough turning, semi-finishing turning and finishing turning all adopt numerical control lathe;
辅助处理包括为已磨削产品进行清洗除污和防锈处理;Auxiliary treatment includes cleaning, decontamination and anti-rust treatment for ground products;
齿轮轴17、含油轴承18与输出轴19的组装为使用申请号为201020055282.2的专利公开的铆挤装配模具在液压机床上一次将含油轴承18和三根齿轮轴17铆挤装配到输出轴19上,三根齿轮轴17相对于两个作为基准的小端中心孔和含油轴承内孔的位置误差≤0.04。The
实施例2,一种输出轴组件的加工方法,包括输出轴19的加工及齿轮轴17、含油轴承18与输出轴19的组装,输出轴19的加工流程包括坯料准备、制坯、机械加工和特种加工及辅助处理;Embodiment 2, a processing method of the output shaft assembly, including the processing of the
输出轴19的加工具体操作步骤如下:The specific operation steps of the machining of the
坯料准备包括Billet preparation includes
(1)下料:热轧棒料采用剪切或锯割的工艺方法下料; (1) Cutting: hot-rolled bars are cut by cutting or sawing;
(2)抛丸:去除所下材料表面的氧化皮; (2) Shot blasting: remove the oxide skin on the surface of the material;
(3)车坯:车去下料时材料两端所形成的塌角并倒角,提高冷挤压预制坯时的工艺稳定性;(3) Car billet: the collapse and chamfering formed at both ends of the material when the car is removed for blanking, which improves the process stability of the cold extrusion preform;
(4)表面处理:通过表面磷化皂化处理,在坯料表面均匀覆盖一层磷化皂化膜;(4) Surface treatment: Through surface phosphating and saponification treatment, a layer of phosphating and saponification film is evenly covered on the surface of the billet;
制坯包括Billets include
(1)预制坯:采用冷挤压成形技术预制坯; (1) Prefabricated billets: prefabricated billets using cold extrusion forming technology;
(2)表面处理:通过表面磷化皂化处理,在预制坯件表面均匀覆盖一层磷化皂化膜; (2) Surface treatment: Through surface phosphating and saponification treatment, a layer of phosphating and saponification film is evenly covered on the surface of the prefabricated blank;
(3)预镦坯:采用冷挤压成形技术来预镦坯; (3) Pre-upset billet: adopt cold extrusion forming technology to pre-upset billet;
(4)退火;(4) Annealing;
(5)抛丸:去除之前退火坯件表面的氧化皮; (5) Shot blasting: remove the scale on the surface of the previously annealed blank;
(6)表面处理:通过表面磷化皂化处理,在预镦坯件表面均匀覆盖一层磷化皂化膜; (6) Surface treatment: Through surface phosphating and saponification treatment, a layer of phosphating and saponification film is evenly covered on the surface of the pre-heading blank;
(7)冷挤压:采用冷挤压成形技术,成形出和输出轴19很接近的最终坯件; (7) Cold extrusion: using cold extrusion forming technology to form a final blank that is very close to the
(8)正火;(8) normalizing;
(9)校直; (9) straightening;
机械加工包括粗车、半精车和精车,所述粗车、半精车和精车均采用数控车床且均是以小端中心孔1和大端60°锥孔12作为定位基准,机械加工和特种加工具体包括Machining includes rough turning, semi-finishing turning and finishing turning, and described rough turning, semi-finishing turning and finishing turning all adopt numerical control lathe and all take the small end central hole 1 and the big end 60°
(1)车大端面:去除大端面两端13、15以及大端外圆14的多余金属材料; (1) Turning the large end face: remove the excess metal material at both ends 13 and 15 of the large end face and the
(2)车小端面:加工去除小端面16的多余材料; (2) Car small end face: process to remove excess material of
(3)加工大端中心孔:加工大端中心孔,作为后续机械加工工序的过渡基准,最终会被加工去掉; (3) Machining the center hole of the big end: machining the center hole of the big end, as the transition benchmark of the subsequent machining process, will eventually be removed by machining;
(4)加工小端中心孔:加工小端中心孔1,作为后续机械加工工序的基准之一; (4) Machining the center hole of the small end: machining the center hole 1 of the small end as one of the benchmarks of the subsequent machining process;
(5)粗车基准面:粗加工后续机械加工工序的夹持基准,去除多余材料;(5) Rough turning datum surface: the clamping datum of the subsequent machining process of rough machining to remove excess material;
(6)精车基准面:加工出后续机械加工工序的夹持基准;(6) Finishing datum plane: the clamping datum for the subsequent machining process;
(7)车大端面及含油轴承座孔:加工大端面两端13、15及外圆14,去除多余材料,加工含油轴承座孔8和大端60°锥孔12,以此作为后续机械加工、冷滚轧渐开线螺旋花键6、冲压齿轮轴底孔、以及铆挤装配等工序的多重定位基准;(7) Turn the big end face and oil bearing seat hole: process the two ends of the
(8)粗车外圆:粗加工各外圆2、4、9以及渐开线螺旋花键6滚轧前的外圆,去除多余材料;(8) Rough turning outer circle: rough machining each
(9)半精车外圆:进一步加工各外圆2、4、9,去除多余材料,加工渐开线螺旋花键6滚轧成形段坯料形状和尺寸,包括倒角5、斜角7和渐开线螺旋花键6滚轧前的外圆直径,以及卡簧槽3和退刀槽10;(9) Semi-finished outer circle: further process each
(10)冷滚轧:应用冷滚轧成形技术加工制造渐开线螺旋花键6;(10) Cold rolling: apply cold rolling forming technology to process and manufacture involute helical spline 6;
(11)精车外圆:精加工各外圆2、4、9以及渐开线螺旋花键6齿顶圆,去除多余材料,只留热处理后的磨削余量;(11) Finishing outer circle: finish machining each
(12)冲孔:使用申请号为201020055240.9的专利公开的冲孔模具在输出轴19上冲压出三个齿轮轴底孔11;冲孔时以含油轴承座孔作为定位基准,该三个齿轮轴底孔的尺寸误差≤0.02,且相对于作为基准的小端中心孔和含有轴承座孔的位置误差≤0.03;(12) Punching: Use the punching die disclosed in the patent application number 201020055240.9 to punch out three gear shaft bottom holes 11 on the
(13)精车大端两面:加工大端面两侧13、15以及大端外圆14,去除多余材料和冲孔塌角,保证盘厚尺寸及形位公差要求; (13) Finish turning both sides of the big end: process the two
(14)车总长:加工去除小端面16的多余材料,保证总长尺寸; (14) The overall length of the car: machining and removing the excess material on the
(15)加工含油轴承座孔:加工含油轴承座孔8,保证孔深尺寸;(15) Process the oil-impregnated bearing seat hole: process oil-impregnated bearing seat hole 8 to ensure the hole depth;
(16)孔口倒角:孔口倒角去除毛刺,以利于齿轮轴17铆挤装配,保证总成装配的质量;(16) Orifice chamfering: the orifice is chamfered to remove burrs, so as to facilitate the riveting assembly of the
(17)打标记:打上要求的标机;(17) Marking: mark the required marking machine;
(18)渗碳淬火;(18) Carburizing and quenching;
(19)研磨基准孔:研磨用以提高基准孔表面粗糙度,清除孔内沙石等杂物;(19) Grinding reference hole: Grinding is used to improve the surface roughness of the reference hole and remove debris such as sand and stones in the hole;
(20)磨外圆:磨削使各外圆2、4、9的尺寸、表面粗糙度、以及形位公差均达到要求;(20) Grinding the outer circle: Grinding to make the size, surface roughness, and shape and position tolerance of each
辅助处理包括为已磨削产品进行清洗除污和防锈处理;Auxiliary treatment includes cleaning, decontamination and anti-rust treatment for ground products;
齿轮轴17、含油轴承18与输出轴19的组装为使用申请号为201020055282.2的专利公开的铆挤装配模具在液压机床上一次将含油轴承18和三根齿轮轴17铆挤装配到输出轴19上,三根齿轮轴17相对于两个作为基准的小端中心孔和含油轴承内孔的位置误差≤0.04。The
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