CN105081713B - The processing method of integral type bevel gear - Google Patents
The processing method of integral type bevel gear Download PDFInfo
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- CN105081713B CN105081713B CN201410203051.4A CN201410203051A CN105081713B CN 105081713 B CN105081713 B CN 105081713B CN 201410203051 A CN201410203051 A CN 201410203051A CN 105081713 B CN105081713 B CN 105081713B
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Abstract
The invention discloses a kind of processing method of integral type bevel gear, including getting the raw materials ready, blank two ends chamfering bit centre bore, it is rough turn see light, flaw detection, heat treatment, rough turn, blank reinspection, half smart car, rough mill tooth, chamfering, heat treatment, shot-peening, smart car, corase grind, finish-milling tooth, coloring rolling inspection, detection, fine grinding, eventually inspection the step of, it is good it is an object of the invention to provide a kind of structural stability, and the processing method of the high integral type bevel gear of machining accuracy.
Description
Technical field
The present invention relates to the manufacture method of gear, more particularly to a kind of processing method of integral type bevel gear.
Background technology
Bevel gear is also bevel gear, has the advantages that load carrying capacity is strong, noise is low good with lubricity, is widely used in
Industrial drive apparatus, differential for vehicles, locomotive, ship, power plant, steel mill and railroad track detection etc..
Bevel gear was processed on bevel gear special plane in the past, but the problems such as because of cutter (facing cutter and abrasive disc) withdrawing, nothing
Method processes integral type bevel gear, is typically to be fitted together bevel gear and optical axis separate machined, then bevel gear with optical axis baking, but
It is to use to dry the bevel gear that is fitted together with optical axis, compared to the bevel gear of integral type, its integrally-built stability can be by
Influence, meanwhile, it is inevitable there is also trueness error during dress is dried, the overall precision of bevel gear is influenceed, and process relatively complicated,
Greatly reduce its production efficiency.
The content of the invention
It is an object of the invention to overcome the shortcomings of that the above is good there is provided a kind of structural stability, and machining accuracy it is high one
The processing method of body formula bevel gear.
The purpose of the present invention is achieved through the following technical solutions:The processing method of integral type bevel gear, including following step
Suddenly：A, get the raw materials ready：Rough forging, blank normalizing is warming up to after 930 DEG C and is incubated 3 hours, indoor temperature is cooled in atmosphere, then
It is warming up to after 680 DEG C and is incubated 3 hours, gained workpiece is finally cooled to room temperature in atmosphere；
B, by through in step A forge after the completion of blank workpiece two ends chamfering bit centre bore, from B5 centre bores；
C, rough turn see light：By the clamping workpiece after chamfering bit centre bore in step B on lathe, the gear of lathe tool turner part
Body, each step of gear shaft it is cylindrical, car falls workpiece surface oxide skin, remains into full-size, obtain integral type cone tooth
Take turns rough turn body；
D, flaw detection：The rough turn body of integral type bevel gear after will be rough turn in step C carries out carrying out flaw detection with ultrasonic wave, makes flaw detection
Workpiece, defect afterwards allows≤φ 2mm, bottom ripple reduction amount≤6dB, and workpiece does not produce extension defect and close defect area；
E, heat treatment：By detected a flaw in step D it is qualified after the rough turn body of integral type bevel gear carry out normalizing and be warming up to after 930 DEG C
Insulation 3 hours, is cooled to indoor temperature in atmosphere, then is warming up to insulation 3 hours after 680 DEG C, finally by gained workpiece in sky
Room temperature is cooled in gas, its Brinell hardness is reached HB215~HB235；
It is F, rough turn：Centre frame is taken on lathe, the rough turn body clamping of integral type bevel gear after step E is heat-treated is in lathe
On, it is unilateral to stay 5mm surpluses further by the cylindrical and length of turner part gear mass, each step of gear shaft, repair two ends center
Hole, and therefrom cut bulk sample 1 and bulk sample 2；
G, blank are reviewed：Bulk sample 1 after will be rough turn in step F carries out chemical composition, grain size, non-metallic inclusion
Reinspection, while bulk sample 2 to be done to the reinspection of mechanical performance；
H, half smart car：By by reviewed in step G it is qualified after integral type bevel gear blank clamping on lathe, in car
Centre frame is taken on bed, car integral type bevel gear teeth wheel shaft, the cylindrical and length of each step of gear mass are unilateral to stay 3mm surpluses, car face
Cone, back cone, inner cone repair two ends centre bore to finished product, obtain the smart car product of integral type bevel gear half；
I, rough mill tooth：By the smart car product clamping of integral type bevel gear half obtained after half smart car in step H on milling machine, machine
Bed dividing head clamping gear back cone direction axle journal, withstands the centre bore in workpiece face cone direction using frock, and cylindrical bar milling cutter is along advance
The path set carries out rough milling to the smart car product of integral type bevel gear half, and midpoint reference circle chordal tooth thickness is reserved finish-milling tooth amount and arrived
1mm, its bottom of the tooth is with circular arc R transition, and milling, to finished product, tooth root is with circular arc R transition；
J, chamfering：The integral type bevel gear after tooth will be rough milled in step I and carries out chamfering, flank profil is fallen with tooth top respectively
Angle, flank profil chamfering 1.5mm × 45 °, tooth top rounding R1；
K, heat treatment：Integral type tooth surfaces of bevel gears after chamfering in step J is subjected to carburizing and quenching, its remaining part in addition to teeth
Divide and apply antiseepage carbon-coating, the thickness of antiseepage carbon-coating is 0.3mm, at the integral type bevel gear progress high temperature by smearing antiseepage carbon-coating
Reason, temperature is maintained at 920 DEG C~930 DEG C and is incubated 8 hours, 400 DEG C~500 DEG C is then cooled in atmosphere, then be warming up to
820 DEG C~830 DEG C insulations carry out oil quenching after 4 hours, and oil temperature is 60 DEG C so that after carburizing and quenching tooth face hardness be HRC56~
HRC60, core hardness is HRC30~HRC42；
L, shot-peening：The workpiece flank of tooth after being heat-treated in step K is subjected to bead using 2.5mm iron sand, is allowed to spray
Tooth face hardness after ball is HRC58~HRC62；
M, smart car：By the integral bevel gear clamping after shot-peening in step L on lathe, lathe clamp clip back cone axis of orientation
Neck, the top top surface cone direction axle journal centre bore of the staight shank of frock, lathe tool skiving wheel shaft, each step of gear mass it is cylindrical, it is unilateral to stay
0.3mm surpluses, end face stays 0.2mm surpluses, and repaiies two ends centre bore；
N, corase grind：By the clamping workpiece cylindrical grinder after smart car in step M, Double Tops integral type bevel gear centre bore, corase grind
Each step of gear shaft, gear mass it is cylindrical, it is unilateral to stay 0.15mm surpluses, grinding length to finished product；
O, finish-milling tooth:By the integral type bevel gear clamping after being roughly ground in step N, dividing head clamping gear back cone axis of orientation
Neck, the centre bore in workpiece face cone direction is withstood with frock, and the left and right flank of tooth is finished, and midpoint transverse tooth thickness is worked into finished product, tooth
Bottom and tooth root are without processing；
P, coloring rolling inspection：Gear after finish-milling tooth in step O and the gear that matches are coloured so that in underloading
Length direction accounts for the 43%~47% of total facewidth in mesh regional, and short transverse accounts for the 50% of fully teeth height, and contact position is in engagement
The inclined bevel gear small end in middle part in region；
Q, detection：Send gear inspector to detect its teeth portion precision the finished product bevel gear after coloring rolling inspection in step P, go forward side by side
Row magnetic powder inspection, makes linear discontinuities≤0.5mm, circular flaw≤0.1mm after workpiece flaw detection；
R, fine grinding：Workpiece after being detected in step Q is refined, the cylindrical of fine grinding each step of workpiece arrives finished product；
S, eventually inspection：Workpiece after being refined in step R is subjected to whole inspection, each dimensional accuracy is examined, and make a record.
Using above-mentioned technical proposal, in the present invention, oxide skin is that oxidation occurs at high temperature for steel and shape in step C
Into corrosion product, if workpiece quality will be had a strong impact on by not removing；Bulk sample 1 and bulk sample in step F and step G
2 are respectively used to the reinspection of chemical composition, field trash and mechanically stressed performance, meet the reasonability of material test；Step I midpoints point
Degree circle chordal tooth thickness reserves finish-milling tooth amount to 1mm, is that the processing of subsequent fine mill teeth is prepared；In step J, the tooth top rounding of bevel gear
Angle, is avoided that corner angle scratch miscellaneous equipment or personnel, prevents stress concentration and meshing interference；Bead in step L, is improved
Tooth fatigue strength and elimination heat treatment stress；In step P, contact area has size, status requirement, and contact zone ratio is too small, passes
The moment of torsion passed does not reach requirement, and ratio is excessive, and length in meshing interference, easy broken teeth, setting mesh regional occurs after loading
Direction accounts for the 43%~47% of total facewidth, when short transverse accounts for the 50% of fully teeth height, can solve the problem；Contact position, if leaning on
The nearly big end of bevel gear, can extend outside the flank of tooth after loading, it is impossible to meet torsion pass, and engagement place load increases, the easy spot corrosion of the flank of tooth,
Come off, the fixed inclined bevel gear small end in middle part for determining contact position in mesh regional.
It is preferred that, in step O, during assembling, dividing head clamping gear back cone direction axle journal withstands workpiece face cone with frock
The centre bore in direction, centering jitter values≤0.01mm, and its Up Highway UHW of centering and side bus jitter values≤0.01mm, using frock
Top cooperation centre bore is assembled, and clamping is simple, firm, by the way that jitter values are defined to≤0.01mm, can ensure that workpiece clamp
The horizontality held.
It is preferred that, this method uses in step I, M and O and is exclusively used in integral type bevel gear making frock, using the frock
High accuracy, the processing of the integral type bevel gear of efficiency high can be realized, the frock includes top staight shank, tailstock and tip holder；
Described staight shank is top and tip holder is detachable connection, is detachable connection between the tailstock and tip holder；
The staight shank is top including centre head and top body, and the centre head is in cone；The top body is arranged in tip holder；
The tailstock includes upper surface, lower surface, is connected between upper surface and lower surface by support beam, and upper and lower two end faces are flat
OK；The tip holder is arranged on the upper surface of tailstock, the axis of the top axis of staight shank and the bevel gear shaft processed
In same horizontal line, by setting special tooling to be used for the processing of bevel gear, not only convenient mounting and clamping, firmly, and frock
It is simple and reasonable for structure.In use, being together to be fixed on dividing head on platen by the frock so that the machine of dividing head
The axis of body gyroaxis is located in same horizontal line with the top axis of staight shank, and dividing head claw clamps bevel gear back cone direction
Axle journal, the top centre head of staight shank withstands the journal centre hole in bevel gear face cone direction.Cylindrical bar milling cutter is along pre-set path
Bevel gear body is processed.
It is preferred that, the upper surface of its tailstock of technical solutions according to the invention is provided with the cell body of insertion, tip holder base
Rear and front end is provided with the locating slot matched with the cell body, bottom land center line and the top diameter parallel of staight shank of the cell body.
During installation, fastening bolt fixes tip holder on tailstock through locating slot.
It is preferred that, the centre head in the technical program can carry out Integral design with top body, and top body front end is provided with top
Spivot set, the tail end of top body is provided with annular spacing groove, and top body middle-end is provided with slip stopper slot；Top axle sleeve and top body it
Between be provided with some angular contact ball bearings, top axle sleeve front end is fixedly connected with end cap, and Type B skeleton is provided between end cap and top body
Oil sealing.Sliding stopper slot has two effects, first effect be for fixing the top position of staight shank, second act on be in order to
Propulsion and retrogressing to push bolt carry out spacing.
It is preferred that, tip holder includes tip holder base, support frame and top installation portion, set lever, push bolt,
The top installation portion is in integrally cuboid, and positioning hole is located at the both sides of top installation portion, and set lever is arranged on the positioning hole
In, the inside of top installation portion is provided with rear side of the cylindrical cavity matched with the top body phase of staight shank, top installation portion provided with propulsion spiral shell
Bolt mounting hole, push bolt is located in the mounting hole, and the positioning hole is corresponding with the position for sliding stopper slot, push bolt
Land and the annular spacing groove of top body tail end match.By staight shank it is top be arranged on tip holder on when, first by top body
It is inserted into cylindrical cavity, top body is rotated until slip stopper slot is corresponding with positioning hole, with set lever locking top body
Install.
In use, controlling moving forward and backward for bevel gear shaft using push bolt according to cylindrical bar milling cutter path.
It is preferred that, the angular range of acute angle is between 10 degree to 90 degree between the support beam of the tailstock and lower surface.For
On limited platen, the processing of integral type bevel gear can be carried out, and the tailstock support beam of the technical program is with
Acute angle between end face can be sized and dimensioned to different angles according to workbench.So as to complete in a limited space
The processing of integral type bevel gear.The angle of this acute angle can also be between 30 degree to 60 degree.
The present invention has advantages below compared with prior art：Bevel gear is processed with optical axis using integral type, is solved
By bevel gear and optical axis separate machined in existing processing, the problem of bevel gear precision brought is low, structural stability is poor should
Processing technology is easy to operate, improves productivity ratio, it is ensured that the overall precision of bevel gear.
Brief description of the drawings
Fig. 1 is the structural representation of the processing method embodiment of integral type bevel gear of the present invention；
Fig. 2 is the installation diagram in the processing method embodiment of integral type bevel gear of the present invention during work pieces process；
Label in figure：1- dividing heads, 2- platens, 3- face cones, 4- back cones, 5- machine tool control systems, 6- tailstocks,
7- support beams, 8- set levers, 9- push bolt, 10- tip holders, 11- cylindrical bar milling cutters path, 12- staight shanks are top.
Embodiment
In order to deepen the understanding of the present invention, further detailed is made to the present invention below in conjunction with the drawings and specific embodiments
Thin explanation；
The embodiment of the processing method of integral type bevel gear of the present invention, including following step are shown as shown in Figure 1, Figure 2
Suddenly：
A, get the raw materials ready：Rough forging, forging ratio=4 are reported and flaw detection report there is provided material, and blank normalizing is warming up into 930
3 hours are incubated after DEG C, indoor temperature is cooled in atmosphere, then is warming up to insulation 3 hours after 680 DEG C, finally by gained workpiece
Room temperature is cooled in atmosphere；
B, by through in step A forge after the completion of blank workpiece two ends chamfering bit centre bore, from B5 centre bores；
C, rough turn see light：By the clamping workpiece after chamfering bit centre bore in step B on lathe, each step of lathe tool turner part
It is cylindrical, car falls workpiece surface oxide skin, remains into full-size；
D, flaw detection：Workpiece after will be rough turn in step C carries out carrying out flaw detection with ultrasonic wave, is allowed to the workpiece after flaw detection and meets
It is claimed below：
E, heat treatment：Workpiece after being detected a flaw in step D is subjected to normalizing and is warming up to insulation 3 hours after 930 DEG C, in atmosphere
Indoor temperature is cooled to, then is warming up to insulation 3 hours after 680 DEG C, gained workpiece is finally cooled to room temperature in atmosphere, makes it
Brinell hardness reaches HB215~235；
It is F, rough turn：Centre frame is taken on lathe, the clamping workpiece after step E is heat-treated is on lathe, each of turner part
The cylindrical and length of rank, it is unilateral to stay 5mm surpluses, two ends centre bore is repaiied, and therefrom cut φ 30x30 bulk sample 1 and φ
30x180 bulk sample 2；
G, blank are reviewed：Send φ 30x30 bulk sample 1 to carry out chemical analysis, grain size, non-metallic inclusion to answer
Test, while sending φ 30x180 bulk sample 2 to do mechanical performance reinspection, the reinspection result of its workpiece meets claimed below：
Chemical analysis
| Element | C | Si | Mn | Cr | Ni | Mo | P | S |
| Content (%) | 0.15-0.2 | ≤0.4 | 0.4-0.6 | 1.5-1.8 | 1.4-1.7 | 0.25-0.35 | ≤0.035 | ≤0.035 |
Non-metallic inclusion
Mechanical performance after quenching, tempering
H, half smart car：By clamping workpiece lathe of the blank reinspection in step G after qualified, centre frame, turner are taken on lathe
The cylindrical and length of each step of part, unilateral to stay 3mm surpluses, car face cone 3, back cone 4, inner cone repair two ends centre bore to finished product；
I, rough mill tooth：By the clamping workpiece through half smart car in step H, the direction axle journal of 1 clamping gear back cone of dividing head 4 is used
Frock withstands the centre bore in the direction of workpiece face cone 3, carries out rough milling, and midpoint reference circle chordal tooth thickness reserves finish-milling tooth amount to 1mm,
Its bottom of the tooth is with circular arc R transition, and milling, to finished product, tooth root is with circular arc R transition；
J, chamfering：The workpiece after tooth will be rough milled in step I and carries out chamfering, chamfering, flank profil are carried out to flank profil and tooth top respectively
1.5 × 45 ° of chamfering, tooth top rounding R1；
K, heat treatment：The workpiece flank of tooth after chamfering in step J is subjected to carburizing and quenching, 920~930 DEG C are warming up to during carburizing
And 8 hours are incubated, it is cooled to 400~500 DEG C in atmosphere, then oil quenching is carried out after being warming up to 820~830 DEG C of insulations 4 hours, oil
Temperature is 60 DEG C so that tooth face hardness is HRC56~60 after carburizing and quenching, and centre hardness is HRC30~42, its remaining part in addition to teeth
Part applies antiseepage carbon-coating, and the thickness of antiseepage carbon-coating is 0.3mm；
L, shot-peening：The workpiece flank of tooth after being heat-treated in step K is subjected to bead using 2.5mm iron sand, is allowed to spray
Tooth face hardness after ball is HRC58~62, and shot-peening selects 2.5mm iron sand；
M, smart car：By the clamping workpiece lathe after shot-peening in step L, lathe clamp folder left end, the top top of tailstock 6 of frock
Right-hand member centre bore, each step of lathe tool turner part it is cylindrical, unilateral to stay 0.3mm surpluses, end face stays 0.2mm surpluses, and repaiies in two ends
Heart hole；
N, corase grind：By the clamping workpiece cylindrical grinder after smart car in step M, Double Tops centre bore roughly grinds each step of workpiece
It is cylindrical, it is unilateral to stay 0.15mm surpluses, grinding length to finished product；
O:Finish-milling tooth:By the clamping workpiece after being roughly ground in step N, the direction axle journal of 1 clamping gear back cone of dividing head 4, recruitment
Dress withstands the centre bore in the direction of workpiece face cone 3, the left and right flank of tooth is finished, midpoint transverse tooth thickness is worked into finished product, bottom of the tooth and tooth
Root is without processing；
P：Coloring rolling inspection：Gear after finish-milling tooth in step O and the gear that matches are coloured so that in underloading
Length direction accounts for the 43%~47% of total facewidth in mesh regional, and short transverse accounts for the 50% of fully teeth height, and contact position is in engagement
The inclined bevel gear small end in middle part in region；
Q：Detection：Send gear inspector to detect its teeth portion precision the finished product bevel gear after coloring rolling inspection in step P, go forward side by side
Row magnetic powder inspection, is allowed to the workpiece after flaw detection and meets claimed below：
| Defect classification | Scope |
| Linear discontinuities | ≦0.5mm |
| Circular flaw | ≦0.1mm |
| Defect cumulative length in 100mm × 100mm | ≦2.0mm |
R：Fine grinding：Workpiece after being detected in step Q is refined, the cylindrical of fine grinding each step of workpiece arrives finished product；
S：Inspection eventually：Workpiece after being refined in step R is subjected to whole inspection, each dimensional accuracy is examined, and make a record.
In above-mentioned procedure of processing, oxide skin is that steel occurs to corrode production formed by oxidation at high temperature in step C
Thing, if workpiece quality will be had a strong impact on by not removing；Step F is respectively used to the bulk sample 1 in step G and bulk sample 2
Chemical composition, field trash and the reinspection of mechanically stressed performance, meet the reasonability of material test；Step I midpoints reference circle string tooth
The reserved finish-milling tooth amount of thickness, to 1mm, is that the processing of subsequent fine mill teeth is prepared；In step J, the tooth top rounding of bevel gear can be kept away
Exempt from corner angle scratch miscellaneous equipment or personnel, prevent stress concentration and meshing interference；Bead in step L；In step P, connect
There are size, status requirement in tactile region, and contact zone ratio is too small, and the moment of torsion of transmission does not reach requirement, and ratio is excessive, can go out after loading
Length direction accounts for the 43%~47% of total facewidth in existing meshing interference, easy broken teeth, setting mesh regional, and short transverse accounts for full tooth
When high 50%, the problem can be solved；Contact position, if close to the big end of bevel gear, can extend after loading outside the flank of tooth, it is impossible to
Meet torsion pass, load increase in engagement place, comes off at the easy spot corrosion of the flank of tooth, it is fixed to determine contact position and bored partially at the middle part of mesh regional
Gear small end；In step I or O, the cutter that roughing program is used with finishing procedures is hard alloy cylindrical bar milling cutter, by lathe
The control rod cutter path 11 of control system 5, sharp with climb cutting cuts mode, and cylindrical bar milling cutter path 11 is parallel to face cone 3, one tooth
Face is by back cone 4 to inner cone, and another flank of tooth is by inner cone to back cone 4, and whole processing is progressive along the high direction of tooth.
In addition, frock in step I, M and O includes staight shank top 12, tailstock 6 and tip holder 10, staight shank top 12 with
Tip holder 10 is bolt connection, is bolt connection between tailstock 6 and tip holder 10, and staight shank top 12 includes centre head and top
Sharp body, centre head be in cone, top body be arranged on tip holder 10 on, tailstock 6 include upper surface, lower surface, upper surface with
Connected between lower surface by support beam 7, and upper and lower two end faces are parallel, tip holder 10 is arranged on the upper surface of tailstock 6
On, the axis of top 12 axis of staight shank and the bevel gear shaft processed is located in same horizontal line, and the upper surface of tailstock 6, which is provided with, to be passed through
Logical cell body, the base of tip holder 10 is provided with the locating slot matched with the cell body, and the bottom land center line and staight shank of cell body are top
12 diameter parallels, centre head is in Integral design with top body, and top body front end is provided with top axle sleeve, and the tail end of top body is provided with
Annular spacing groove, top body middle-end is provided with some angular contact ball bearings provided with stopper slot is slided between top axle sleeve and top body,
Top axle sleeve front end is fixedly connected with end cap, and Type B outside framework oil seal is provided between end cap and top body, and tip holder 10 includes top
Bracket base, support frame and top installation portion, set lever 8, push bolt 9, top installation portion are in integrally cuboid, positioning hole
Positioned at the both sides of top installation portion, set lever 8 is arranged in the positioning hole, and the inside of top installation portion is provided with top with staight shank
The mounting hole of push bolt 9 is provided with rear side of the cylindrical cavity of 12 body phases matching, top installation portion, push bolt 9 is located at the mounting hole
In, positioning hole is corresponding with the position for sliding stopper slot, the land of push bolt 9 and the annular spacing groove phase of top body tail end
Match somebody with somebody, the angle of acute angle is 45 degree between support beam 7 and lower surface, by rotating push bolt 9 so that staight shank top 12 is transported forward
Dynamic, centre head withstands the centre bore on the direction of face cone 3, then is pinned with set lever 8, by setting special tooling to be used for bevel gear
Processing, not only convenient mounting and clamping, firmly, and tool structure is simple, rationally.
By using the processing method of integral type bevel gear of the present invention, because bevel gear and optical axis use integral type
Process, solve bevel gear and optical axis separate machined in existing processing, the bevel gear precision brought is low, Stability Analysis of Structures
Property difference the problem of, the processing technology is easy to operate, improves productivity ratio, it is ensured that the overall precision of bevel gear.
Above-described is only the preferred embodiment of the present invention, it is noted that for those skilled in the art,
Without departing from the structure of the invention, several modifications and improvements can also be made, these should also be considered as the guarantor of the present invention
Scope is protected, these effects and practical applicability for implementing all without the influence present invention.
Claims (7)
1. the processing method of integral type bevel gear, it is characterised in that comprise the following steps：
A, get the raw materials ready：Rough forging, blank normalizing is warming up to after 930 DEG C and is incubated 3 hours, indoor temperature is cooled in atmosphere,
It is warming up to again after 680 DEG C and is incubated 3 hours, gained workpiece is finally cooled to room temperature in atmosphere；
B, by through in step A forge after the completion of blank workpiece two ends chamfering bit centre bore, from B5 centre bores；
C, rough turn see light：By the clamping workpiece after chamfering bit centre bore in step B on lathe, gear mass, the tooth of lathe tool turner part
Each step of wheel shaft it is cylindrical, car falls workpiece surface oxide skin, remains into full-size, obtains integral type bevel gear rough turn
Body；
D, flaw detection：The rough turn body of integral type bevel gear after will be rough turn in step C carries out carrying out flaw detection with ultrasonic wave, makes after flaw detection
Workpiece, defect allow≤φ 2mm, bottom ripple reduction amount≤6dB, workpiece does not produce extension defect and close defect area；
E, heat treatment：By detected a flaw in step D it is qualified after the rough turn body of integral type bevel gear carry out normalizing and be warming up to after 930 DEG C to be incubated
3 hours, indoor temperature is cooled in atmosphere, then is warming up to insulation 3 hours after 680 DEG C, finally workpiece by gained in atmosphere
Room temperature is cooled to, its Brinell hardness is reached HB215~HB235；
It is F, rough turn：Centre frame is taken on lathe, by the rough turn body clamping of integral type bevel gear after step E heat treatments on lathe,
It is unilateral to stay 5mm surpluses further by the cylindrical and length of turner part gear mass, each step of gear shaft, two ends centre bore is repaiied,
And therefrom cut bulk sample 1 and bulk sample 2；
G, blank are reviewed：Bulk sample 1 after will be rough turn in step F carries out chemical composition, grain size, non-metallic inclusion and answered
Test, while bulk sample 2 to be done to the reinspection of mechanical performance；
H, half smart car：By by reviewed in step G it is qualified after integral type bevel gear blank clamping on lathe, on lathe
Take centre frame, car integral type bevel gear teeth wheel shaft, the cylindrical and length of each step of gear mass are unilateral to stay 3mm surpluses, car face cone,
Back cone, inner cone repair two ends centre bore to finished product, obtain the smart car product of integral type bevel gear half；
I, rough mill tooth：By the smart car product clamping of integral type bevel gear half obtained after half smart car in step H on milling machine, lathe point
Head clamping gear back cone direction axle journal is spent, the centre bore in workpiece face cone direction is withstood using frock, cylindrical bar milling cutter is along presetting
Good path carries out rough milling to the smart car product of integral type bevel gear half, and midpoint reference circle chordal tooth thickness reserves finish-milling tooth amount to 1mm,
Its bottom of the tooth is with circular arc R transition, and milling, to finished product, tooth root is with circular arc R transition；
J, chamfering：The integral type bevel gear after tooth will be rough milled in step I and carries out chamfering, chamfering is carried out to flank profil and tooth top respectively,
Flank profil chamfering 1.5mm × 45 °, tooth top rounding R1；
K, heat treatment：Integral type tooth surfaces of bevel gears after chamfering in step J is subjected to carburizing and quenching, the remainder in addition to teeth
Antiseepage carbon-coating is applied, the thickness of antiseepage carbon-coating is 0.3mm, will be carried out by the integral type bevel gear for smearing antiseepage carbon-coating at high temperature
Reason, temperature is maintained at 920 DEG C~930 DEG C and is incubated 8 hours, 400 DEG C~500 DEG C is then cooled in atmosphere, then be warming up to
820 DEG C~830 DEG C insulations carry out oil quenching after 4 hours, and oil temperature is 60 DEG C so that after carburizing and quenching tooth face hardness be HRC56~
HRC60, core hardness is HRC30~HRC42；
L, shot-peening：The workpiece flank of tooth after being heat-treated in step K is subjected to bead using 2.5mm iron sand, is allowed to after shot-peening
Tooth face hardness be HRC58~HRC62；
M, smart car：By the integral bevel gear clamping after shot-peening in step L on lathe, lathe clamp clip back cone direction axle journal, work
The top top surface cone direction axle journal centre bore of the staight shank of dress, lathe tool skiving wheel shaft, each step of gear mass it is cylindrical, it is unilateral to stay 0.3mm
Surplus, end face stays 0.2mm surpluses, and repaiies two ends centre bore；
N, corase grind：By the clamping workpiece cylindrical grinder after smart car in step M, Double Tops integral type bevel gear centre bore roughly grinds gear
Each step of axle, gear mass it is cylindrical, it is unilateral to stay 0.15mm surpluses, grinding length to finished product；
O, finish-milling tooth:By the integral type bevel gear clamping after being roughly ground in step N, dividing head clamping gear back cone direction axle journal is used
Frock withstands the centre bore in workpiece face cone direction, and the left and right flank of tooth is finished, and midpoint transverse tooth thickness is worked into finished product, bottom of the tooth and tooth
Root is without processing；
P, coloring rolling inspection：Gear after finish-milling tooth in step O and the gear that matches are coloured so that nibbled in underloading
Close length direction in region and account for the 43%~47% of total facewidth, short transverse accounts for the 50% of fully teeth height, and contact position is in mesh regional
The inclined bevel gear small end in middle part；
Q, detection：Send gear inspector to detect its teeth portion precision the finished product bevel gear after coloring rolling inspection in step P, and carry out magnetic
Powder is detected a flaw, and makes linear discontinuities≤0.5mm, circular flaw≤0.1mm after workpiece flaw detection；
R, fine grinding：Workpiece after being detected in step Q is refined, the cylindrical of fine grinding each step of workpiece arrives finished product；
S, eventually inspection：Workpiece after being refined in step R is subjected to whole inspection, each dimensional accuracy is examined, and make a record.
2. the processing method of integral type bevel gear as claimed in claim 1, it is characterised in that in step O, during assembling, point
Head clamping gear back cone direction axle journal is spent, the centre bore in workpiece face cone direction is withstood with frock, centering jitter values≤0.01mm, and
Its Up Highway UHW of centering and side bus jitter values≤0.01mm.
3. the processing method of integral type bevel gear as claimed in claim 1 or 2, it is characterised in that in step I, M and O, institute
Stating frock includes top staight shank, tailstock and tip holder；Described staight shank is top and tip holder is detachable connection, described
It is detachable connection between tailstock and tip holder；The staight shank is top including centre head and top body, and the centre head is in
Cone；The top body is arranged in tip holder；The tailstock includes upper surface, lower surface, upper surface and lower surface it
Between connected by support beam, and upper and lower two end faces are parallel；The tip holder is arranged on the upper surface of tailstock, described straight
The axis of the top axis of handle and the bevel gear shaft processed is located in same horizontal line.
4. the processing method of integral type bevel gear as claimed in claim 3, it is characterised in that the upper surface of the tailstock is provided with
The cell body of insertion, tip holder base is provided with the locating slot matched with the cell body, the bottom land center line and staight shank of the cell body
Top diameter parallel.
5. the processing method of integral type bevel gear as claimed in claim 4, it is characterised in that the centre head is in top body
Integral design, top body front end is provided with top axle sleeve, and the tail end of top body is provided with annular spacing groove, and top body middle-end is provided with cunning
Dynamic stopper slot；Some angular contact ball bearings are provided between the top axle sleeve and top body, top axle sleeve front end is fixedly connected with
End cap, is provided with Type B outside framework oil seal between end cap and top body.
6. the processing method of integral type bevel gear as claimed in claim 5, it is characterised in that the tip holder includes top
Bracket base, support frame and top installation portion, set lever, push bolt, the top installation portion are in integrally cuboid, positioning
Hole position is arranged in the positioning hole in the both sides of top installation portion, set lever, and the inside of top installation portion is provided with and staight shank top
Push bolt mounting hole is provided with rear side of the cylindrical cavity of sharp body phase matching, top installation portion, push bolt is located in the mounting hole,
The positioning hole is corresponding with the position for sliding stopper slot, the land of the push bolt and the annular spacing groove of top body tail end
Match.
7. the processing method of the integral type bevel gear as any one of claim 4-6, it is characterised in that：The support beam
The angular range of acute angle is 10 degree~90 degree between lower surface.
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| CN201410203051.4A CN105081713B (en) | 2014-05-15 | 2014-05-15 | The processing method of integral type bevel gear |
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| CN201410203051.4A CN105081713B (en) | 2014-05-15 | 2014-05-15 | The processing method of integral type bevel gear |
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| CN105081713B true CN105081713B (en) | 2017-10-17 |
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