CN107366735A - 一种螺旋齿轮及其制备方法 - Google Patents
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Abstract
本发明涉及一种螺旋齿轮。该装置包括柱状的基体,所述基体的中心开设有沿基体轴线方向的贯穿槽,所述的贯穿槽用于穿插轴,所述基体外侧面上设有呈螺旋状的齿,位于贯穿槽内壁的基体上设有用于存储润滑剂的凹槽,所述齿的各齿根处开设有与凹槽接通的针孔通道。由于针孔通道与存储润滑剂的凹槽相配合,针孔通道可有效地为工作状态下的齿轮啮合面润滑,从而降低啮合面的温度,延缓啮合面达到疲劳强度。
Description
技术领域
本发明涉及齿轮技术领域,尤其涉及一种螺旋齿轮及其制备方法。
背景技术
现有的中国专利数据库中公开了名称为一种广角布编造机组螺旋齿轮的专利,其专利申请号为:201010597502.9,申请日为:2010.12.21,申请公布号为:CN102537278A,申请公布日为:2012.07.04,该装置包括齿轮杆和一体成型在齿轮杆上的轴套,齿轮杆的外侧面上具有呈螺旋状的齿,所述的轴套呈筒状,所述的齿的螺旋角为20°~25°。其不足之处在于:由于该螺旋齿轮自身不具有润滑部件,设置在空气中的该螺旋齿轮长时间工作,很容易因高温和疲劳而损坏,从而影响整个机器的正常运转。
发明内容
本发明的目的是针对现有技术存在的不足,即缺少润滑机构,长时间工作很容易损坏,提供一种自身具有润滑功能的螺旋齿轮。
为了实现上述发明的目的,本发明所采取的技术方案:
一种螺旋齿轮,包括柱状的基体,所述基体的中心开设有沿基体轴线方向的贯穿槽,所述的贯穿槽用于穿插轴,所述基体外侧面上设有呈螺旋状的齿,位于贯穿槽内壁的基体上设有用于存储润滑剂的凹槽,所述齿的各齿根处开设有与凹槽接通的针孔通道。
本发明工作时,先将凹槽内填塞润滑剂,然后将轴穿插到贯穿槽内,将螺旋齿轮安装在机械装置上,当螺旋齿轮工作时,由于离心力和高温,促使润滑剂顺着针孔通道流向齿轮的吃根外表面,从而润滑齿轮的啮合面。
为了保证轴上的力有效地传递到螺旋齿轮上,位于贯穿槽内壁的基体上开设有沿轴线方向的键槽。
为了保证轴上的力有效地传递到螺旋齿轮上,所述的键槽开设有多个,键槽沿贯穿槽内壁外周呈放射状设置。
进一步地,所述齿的螺旋角为25.1°~30.1°。
为了保证各针孔通道都能释放润滑剂,所述的凹槽设置有多个,各针孔通道对应的凹槽经贯穿槽内壁上的导流通道接通。
与现有技术相比,本发明的有益效果为:由于针孔通道与存储润滑剂的凹槽相配合,针孔通道可有效地为工作状态下的齿轮啮合面润滑,从而降低啮合面的温度,延缓啮合面达到疲劳强度。
本发明还提供了一种螺旋齿轮的制备方法,该方法所采取的技术方案:
一种螺旋齿轮的制备方法,该方法包括以下步骤:
步骤一:搅拌:将金属粉末按配比搅拌,均匀混合;
步骤二:成形:将均匀混合的金属粉末填充到成型模具内,通过成型模具压制出生胚,所述的生胚具有盲孔的锻胚,所述锻胚的轴向长度为1.1~1.3的齿轮宽度,所述锻胚的直径为1.5~1.8的齿轮的分度圆直径;
步骤三:烧结:将步骤二中的生胚摆放在碳板上输送至烧结炉内,生胚在烧结炉内烧结4.5~6h,烧结炉温为770℃~1300℃,将生胚烧结成基体;
步骤四:一次油浸:将烧结后冷却的基体进行油浸,去除基体表面铁削、毛刺,将基体与空气隔开;
步骤五:粗加工:使用钻孔机沿所述基体外侧面向基体中心加工出若干针孔通道,使用车刀,对步骤四中的基体外柱面车削,便于外柱面滚齿;使用镗刀去除步骤四中基体盲孔剩余的实心锻胚部分,形成一贯穿槽,使用镗刀对贯穿槽内壁的基体进行加工,形成用于储存润滑剂的凹槽,同时使用镗刀对基体加工,形成键槽;
步骤六:一次外检:对基体的外柱面、贯穿槽内壁以及凹槽内壁的平整度、同轴度均进行检验,看检验是否合格,如果不合格基体报废,如果检验合格,对基体进行步骤七的处理;
步骤七:滚齿:依据贯穿槽进行定位,用滚刀对基体的外柱面进行加工,滚出齿槽,在齿槽两侧留出适当的精加工余量,再用滚刀对齿槽进行精加工,在基体外柱面滚出齿;
步骤八:二次外检:对步骤七中加工出的基体进行几何精度检验,如果基体精度合格,执行步骤九,如果不合格基体报废;
步骤九:热处理:将检验合格的基体放置在热处理网带上,通过热处理炉加热,热处理温度900℃,热处理时间1~3小时,然后进入油槽淬火,油温50℃以下,使该螺旋齿轮硬度达到HRA50度,最后送入回火炉1~2小时,回火温度200℃,使该螺旋齿轮抗压强度达到2400N以上;
步骤十:黑化:将成品的螺旋齿轮清洗干净,然后将成品暴露在等离子体焰炬中,向等离子体焰炬中注入重量百分比为80%氧气和重量百分比为20%四氟化碳,等离子体焰炬内的放电装置将气体诱发成等离子态,所述等离子体焰炬内的温度为800℃,成品送入等离子体焰炬内5~8小时,成品表面产生一个金属氧化物层;
步骤十一:二次油浸、包装:将成品的螺旋齿轮清洗油浸,包装。
与现有技术相比,本发明的有益效果为:由于针孔通道与存储润滑剂的凹槽相配合,针孔通道可有效地为工作状态下的齿轮啮合面润滑,从而降低啮合面的温度,延缓啮合面达到疲劳强度。
附图说明
图1为本发明的结构示意图。
图2为图1沿A-A处的剖视图。
其中,1基体,101贯穿槽,102凹槽,103针孔通道,104键槽,105导流通道,2齿。
具体实施方式
下面结合具体实施例对本发明作进一步地说明:
如图1-2所述,为一种螺旋齿轮,包括柱状的基体1,基体1的中心开设有沿基体1轴线方向的贯穿槽101,贯穿槽101用于穿插轴,位于贯穿槽101内壁的基体1上开设有沿轴线方向的键槽104,键槽104开设有多个,键槽104沿贯穿槽101内壁外周呈放射状设置,基体1外侧面上设有呈螺旋状的齿2,齿2的螺旋角为25.1°~30.1°,位于贯穿槽101内壁的基体1上设有用于存储润滑剂的凹槽102,齿2的各齿2根处开设有与凹槽102接通的针孔通道103,凹槽102设置有多个,各针孔通道103对应的凹槽102经贯穿槽101内壁上的导流通道105接通。
工作时,先将凹槽102内填塞润滑剂,然后将轴穿插到贯穿槽101内,将螺旋齿2轮安装在机械装置上,当螺旋齿2轮工作时,由于离心力和高温,促使润滑剂顺着针孔通道103流向齿2轮的吃根外表面,从而润滑齿2轮的啮合面。
与上述一种螺旋齿轮相对应,本发明还提供一种螺旋齿轮的制备方法,该方法包括下列步骤:步骤一:搅拌:将金属粉末按配比搅拌,均匀混合;
步骤二:成形:将均匀混合的金属粉末填充到成型模具内,通过成型模具压制出生胚,所述的生胚具有盲孔的锻胚,所述锻胚的轴向长度为1.1~1.3的齿轮宽度,所述锻胚的直径为1.5~1.8的齿轮的分度圆直径;
步骤三:烧结:将步骤二中的生胚摆放在碳板上输送至烧结炉内,生胚在烧结炉内烧结4.5~6h,烧结炉温为770℃~1300℃,将生胚烧结成基体1;
步骤四:一次油浸:将烧结后冷却的基体1进行油浸,去除基体1表面铁削、毛刺,将基体1与空气隔开;
步骤五:粗加工:使用钻孔机沿基体1外侧面向基体1中心加工出若干针孔通道103,使用车刀,对步骤四中的基体1外柱面车削,便于外柱面滚齿2;使用镗刀去除步骤四中基体1盲孔剩余的实心锻胚部分,形成一贯穿槽101,使用镗刀对贯穿槽101内壁的基体1进行加工,形成用于储存润滑剂的凹槽102,同时使用镗刀对基体1加工,形成键槽104;
步骤六:一次外检:对基体1的外柱面、贯穿槽101内壁以及凹槽102内壁的平整度、同轴度均进行检验,看检验是否合格,如果不合格基体1报废,如果检验合格,对基体1进行步骤七的处理;
步骤七:滚齿2:依据贯穿槽101进行定位,用滚刀对基体1的外柱面进行加工,滚出齿槽,在齿槽两侧留出适当的精加工余量,再用滚刀对齿槽进行精加工,在基体1外柱面滚出齿2;
步骤八:二次外检:对步骤七中加工出的基体1进行几何精度检验,如果基体1精度合格,执行步骤九,如果不合格基体1报废;
步骤九:热处理:将检验合格的基体1放置在热处理网带上,通过热处理炉加热,热处理温度900℃,热处理时间1~3小时,然后进入油槽淬火,油温50℃以下,使该螺旋齿轮硬度达到HRA50度,最后送入回火炉1~2小时,回火温度200℃,使该螺旋齿轮抗压强度达到2400N以上;
步骤十:黑化:将成品的螺旋齿轮清洗干净,然后将成品暴露在等离子体焰炬中,向等离子体焰炬中注入重量百分比为80%氧气和重量百分比为20%四氟化碳,等离子体焰炬内的放电装置将气体诱发成等离子态,所述等离子体焰炬内的温度为800℃,成品送入等离子体焰炬内5~8小时,成品表面产生一个金属氧化物层;
步骤十一:二次油浸、包装:将成品的螺旋齿轮清洗油浸,包装。
本发明并不局限于上述实施例,在本发明公开的技术方案的基础上,本领域的技术人员根据所公开的技术内容,不需要创造性的劳动就可以对其中的一些技术特征作出一些替换和变形,这些替换和变形均在本发明的保护范围内。
Claims (6)
1.一种螺旋齿轮,包括柱状的基体,所述基体的中心开设有沿基体轴线方向的贯穿槽,所述的贯穿槽用于穿插轴,所述基体外侧面上设有呈螺旋状的齿,其特征在于:位于贯穿槽内壁的基体上设有用于存储润滑剂的凹槽,所述齿的各齿根处开设有与凹槽接通的针孔通道。
2.根据权利要求1所述的一种螺旋齿轮,其特征在于:位于贯穿槽内壁的基体上开设有沿轴线方向的键槽。
3.根据权利要求2所述的一种螺旋齿轮,其特征在于:所述的键槽开设有多个,键槽沿贯穿槽内壁外周呈放射状设置。
4.根据权利要求1-3中任一权利要求所述的一种螺旋齿轮,其特征在于:所述齿的螺旋角为25.1°~30.1°。
5.根据权利要求4的一种螺旋齿轮,其特征在于:所述的凹槽设置有多个,各针孔通道对应的凹槽经贯穿槽内壁上的导流通道接通。
6.根据权利要求5所述的一种螺旋齿轮的制备方法,其特征在于,该方法包括以下步骤:
步骤一:搅拌:将金属粉末按配比搅拌,均匀混合;
步骤二:成形:将均匀混合的金属粉末填充到成型模具内,通过成型模具压制出生胚,所述的生胚具有盲孔的锻胚,所述锻胚的轴向长度为1.1~1.3的齿轮宽度,所述锻胚的直径为1.5~1.8的齿轮的分度圆直径;
步骤三:烧结:将步骤二中的生胚摆放在碳板上输送至烧结炉内,生胚在烧结炉内烧结4.5~6h,烧结炉温为770℃~1300℃,将生胚烧结成基体;
步骤四:一次油浸:将烧结后冷却的基体进行油浸,去除基体表面铁削、毛刺,将基体与空气隔开;
步骤五:粗加工:使用钻孔机沿所述基体外侧面向基体中心加工出若干针孔通道,使用车刀,对步骤四中的基体外柱面车削,便于外柱面滚齿;使用镗刀去除步骤四中基体盲孔剩余的实心锻胚部分,形成一贯穿槽,使用镗刀对贯穿槽内壁的基体进行加工,形成用于储存润滑剂的凹槽,同时使用镗刀对基体加工,形成键槽;
步骤六:一次外检:对基体的外柱面、贯穿槽内壁以及凹槽内壁的平整度、同轴度均进行检验,看检验是否合格,如果不合格基体报废,如果检验合格,对基体进行步骤七的处理;
步骤七:滚齿:依据贯穿槽进行定位,用滚刀对基体的外柱面进行加工,滚出齿槽,在齿槽两侧留出适当的精加工余量,再用滚刀对齿槽进行精加工,在基体外柱面滚出齿;
步骤八:二次外检:对步骤七中加工出的基体进行几何精度检验,如果基体精度合格,执行步骤九,如果不合格基体报废;
步骤九:热处理:将检验合格的基体放置在热处理网带上,通过热处理炉加热,热处理温度900℃,热处理时间1~3小时,然后进入油槽淬火,油温50℃以下,使该螺旋齿轮硬度达到HRA50度,最后送入回火炉1~2小时,回火温度200℃,使该螺旋齿轮抗压强度达到2400N以上;
步骤十:黑化:将成品的螺旋齿轮清洗干净,然后将成品暴露在等离子体焰炬中,向等离子体焰炬中注入重量百分比为80%氧气和重量百分比为20%四氟化碳,等离子体焰炬内的放电装置将气体诱发成等离子态,所述等离子体焰炬内的温度为800℃,成品送入等离子体焰炬内5~8小时,成品表面产生一个金属氧化物层;
步骤十一:二次油浸、包装:将成品的螺旋齿轮清洗油浸,包装。
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