CN108274208B - Machining process of large-modulus gear with small tooth number - Google Patents
Machining process of large-modulus gear with small tooth number Download PDFInfo
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- CN108274208B CN108274208B CN201810358582.9A CN201810358582A CN108274208B CN 108274208 B CN108274208 B CN 108274208B CN 201810358582 A CN201810358582 A CN 201810358582A CN 108274208 B CN108274208 B CN 108274208B
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Abstract
The invention discloses a machining process of a large-modulus small-tooth-number gear, which comprises the following steps of: firstly, modeling; drawing a gear three-dimensional model diagram according to the given parameters of the gear; secondly, according to the gear three-dimensional model diagram generated in the first step, generating a rough machining track, a semi-finishing track and a finishing track of the tooth profile in sequence; step three, processing; and generating machining codes by using a CAM technology according to the rough machining track, the semi-finish machining track and the finish machining track, introducing the machining codes into a four-axis machining center, and performing rough machining, semi-finish machining and finish machining on the tooth profile of the gear in sequence to obtain a finished product. The invention has the characteristic of reducing the production cost.
Description
Technical Field
The invention relates to a gear machining process, in particular to a large-modulus small-tooth-number gear machining process.
Background
The rubber asphalt pump is an external gear pump, and is characterized by that two external gears are meshed to transfer liquid, and its structure is simple, weight is light, operation is reliable, and it is mainly used for transferring rubber powder modified asphalt containing solid small particles. According to the external meshing structure, the design of large module and less teeth is adopted, the displacement is larger than that of the design of small module and more teeth, and the large module and less teeth make the volume of the pump smaller for the gear with certain displacement. Meanwhile, the small addendum circle is beneficial to reducing radial unbalanced force, the number of teeth is small, the noise is lower, and the pulsation is small. However, the processing of the gear with large modulus and few teeth is difficult, the existing gear processing mainly comprises a forming method and a generating method, wherein the forming method mainly comprises a disc-shaped milling cutter processing cutter and a finger-shaped milling cutter processing cutter, for the gear with the same modulus, as long as the tooth number is different, the tooth profile shapes are different, different forming cutters are required, and the manufacturing cost of the cutters is very high; the generating method mainly comprises a gear type and a rack type machining cutter, can generate serious 'undercut' when machining a gear with few teeth, is rarely used for machining gears with less than 10 teeth, and has high cutter manufacturing cost. Therefore, the prior art has the problem of high production cost.
Disclosure of Invention
The invention aims to provide a machining process for a gear with a large modulus and a small tooth number. The invention has the characteristic of reducing the production cost.
The technical scheme of the invention is as follows: a machining process for a large-modulus small-tooth-number gear comprises the following steps:
firstly, modeling; drawing a gear three-dimensional model diagram according to the given parameters of the gear;
secondly, according to the gear three-dimensional model diagram generated in the first step, generating a rough machining track, a semi-finishing track and a finishing track of the tooth profile in sequence;
step three, processing; generating machining codes by using a CAM technology according to a rough machining track, a semi-finish machining track and a finish machining track, introducing the machining codes into a four-axis machining center, and performing rough machining, semi-finish machining and finish machining on the tooth profile of the gear in sequence to obtain a finished product;
the process of rough machining of the tooth profile is that a milling cutter performs slotting cutting operation along the axial direction of the tooth profile from the middle of a tooth slot to finish the rough machining of the tooth profile of the gear;
the semi-finishing process of the tooth profile comprises the following steps: the flat milling cutter performs cutting operation along the tooth profile surface after rough machining is completed, and the whole process ensures that the flat milling cutter is vertical to the tooth profile molded line;
the process of finishing the tooth profile comprises the following steps: and the spherical milling cutter performs cutting operation along the tooth profile surface after the semi-finishing operation is completed, and the whole process ensures that the spherical milling cutter is vertical to the tooth profile molded line.
In the machining process of the gear with large modulus and few teeth, the specific process of the grooving and cutting operation in the rough machining of the tooth profile is as follows: firstly, selecting a milling cutter with proper size according to the width of a tooth groove, slotting the milling cutter from the middle of the tooth groove along the axial direction of a tooth profile, lifting the milling cutter after cutting is finished, and finishing first cutting; then, the milling cutter moves leftwards according to the tooth profile and performs slotting along the axial direction of the tooth profile, the distance of left movement does not exceed the diameter of the milling cutter, and the milling cutter is reset to the initial position of left movement of the milling cutter to finish the cutting of a second cutter; then, the milling cutter is rightwards moved to be grooved along the axial direction of the tooth profile, and the rightwards movement distance is the same as the leftwards movement distance in the cutting process of the second cutter; so as to finish the rough machining of the tooth profile.
In the machining process of the gear with the large modulus and the small tooth number, the tooth profile after rough machining is left with 1-2mm of machining allowance.
In the machining process of the large-modulus small-tooth-number gear, after rough machining of the tooth profile of the gear is finished, quenching and tempering are required; the quenching and tempering process comprises the following steps: firstly, placing the gear subjected to the rough processing of the tooth profile into a quenching furnace, and linearly heating the temperature of the quenching furnace from room temperature to 180-200 ℃ within 13-16 minutes; then the furnace temperature is continuously linearly increased to 500-550 ℃ within 40-50 minutes; then, the furnace temperature is continuously linearly increased to 610 ℃ at the temperature of 600-; after the heat preservation is finished, opening a furnace door of the quenching furnace to enable the product A to fall into cooling oil for quenching treatment to obtain a product B; then, the B product is put into a tempering furnace, the furnace temperature is linearly increased to 650 ℃ for 50-60 minutes, the temperature is kept for 30-40 minutes, then the temperature of the tempering furnace is continuously linearly increased to 720 ℃ for 700-80 minutes, the temperature is kept for 50-60 minutes, and finally the furnace temperature is naturally cooled to the normal temperature, thus finishing the tempering treatment.
In the machining process of the gear with large modulus and small tooth number, the flat milling cutter adopted in the semi-finishing process of the tooth profile is a hard flat milling cutter; and after the semi-finishing is finished, the shape of the tooth profile is reserved with a machining allowance of 0.1-0.2 mm.
In the machining process of the gear with large modulus and small tooth number, the spherical milling cutter in the finish machining process of the tooth profile adopts a high-precision hard spherical milling cutter; after the spherical milling cutter finishes cutting along the tooth profile surface, the spherical milling cutter still needs to walk idle for one time according to the original walking track.
In the machining process of the gear with large modulus and small tooth number, micro-deformation heat treatment is needed after finishing the finish machining operation of the tooth profile; the micro-deformation heat treatment is ion nitriding treatment or QPQ salt bath composite treatment.
In the machining process of the large-modulus small-tooth-number gear, the specific process of the QPQ salt bath composite treatment is as follows: 1) cleaning the gear to obtain a product a; 2) preheating the product a at the temperature of 450-500 ℃ for 10-13min to obtain a product b; 3) performing salt bath nitriding treatment on the product b, namely putting the product b into a salt bath nitriding furnace, keeping the temperature of the salt bath nitriding furnace within 550-580 ℃, preserving the heat for 30-40min, then increasing the temperature of the salt bath nitriding furnace to 640 ℃ at a linear temperature rise speed of 5-8 ℃/min, and preserving the heat for 20-30min to obtain a product c; 4) performing salt bath oxidation treatment on the product c, namely putting the product c into a salt bath oxidation furnace, firstly keeping the temperature of the salt bath oxidation furnace at 520 ℃ for 10-15min, then reducing the temperature of the salt bath oxidation furnace to 480 ℃ at a linear cooling speed of 2-3 ℃/min, and keeping the temperature for 5-15min to obtain a product d; 5) cooling product d in cold water, soaking in hot water, washing with cold water, and oven drying to obtain product e; 6) and polishing the product e to obtain a finished product.
In the machining process of the gear with the large modulus and the small tooth number, the polishing treatment is carried out by using the carborundum grinding wheel, and the polishing thickness is 0.01 mm.
Compared with the prior art, the invention adopts a rough machining track for grooving and cutting from the middle of a tooth socket along the axial direction of a tooth profile, and adopts a moving track for semi-finishing and finishing the cutter and the tooth profile, which is vertical to the tooth profile, so as to replace the traditional machining track, and the invention can machine gears with different parameters such as various modules, tooth numbers, pressure angles, involutes, cycloids, arcs, envelope lines and the like, large modules and few tooth numbers by adopting a common milling cutter, a hard flat milling cutter and a hard ball cutter, does not need a specific machining cutter, has strong universality of the machining method, and greatly reduces the production cost; and through the mutual cooperation between the processing method and the processing cutter, the smoothness and the precision of the tooth surface can be effectively improved, so that the precision of the processed gear can reach 6-grade precision, and the smoothness of the tooth surface reaches Ra0.4. Meanwhile, after the machining code is generated by the CAM technology, the machining code is input into a four-axis machining center, complex tooth profile generating enveloping machining can be completed, special equipment requirements and operator skill requirements are avoided, the machining technical requirements are low, and the machining precision can be effectively improved. In addition, the gear is subjected to quenching and tempering after rough machining, and then is subjected to micro-deformation heat treatment after finish machining, and the hardness of the tooth surface is enabled to reach more than 60HRC by strictly controlling each process parameter of quenching and tempering and micro-deformation heat treatment, so that the performance of the gear is greatly improved.
Drawings
FIG. 1 is a schematic trace of roughing;
FIG. 2 is a schematic diagram of the trajectory of the semi-finishing;
fig. 3 is a schematic diagram of a trajectory of the finishing.
Detailed Description
The invention is further illustrated by the following figures and examples, which are not to be construed as limiting the invention.
Example 1. A machining process for a large-modulus gear with few teeth comprises the following steps as shown in figures 1 to 3:
firstly, modeling; drawing a gear three-dimensional model diagram according to the given parameters of the gear;
secondly, according to the gear three-dimensional model diagram generated in the first step, generating a rough machining track, a semi-finishing track and a finishing track of the tooth profile in sequence;
step three, processing; generating machining codes by using a CAM technology according to a rough machining track, a semi-finish machining track and a finish machining track, introducing the machining codes into a four-axis machining center, and performing rough machining, semi-finish machining and finish machining on the tooth profile of the gear in sequence to obtain a finished product;
the process of rough machining of the tooth profile is that a milling cutter performs slotting cutting operation along the axial direction of the tooth profile from the middle of a tooth slot to finish the rough machining of the tooth profile of the gear;
the semi-finishing process of the tooth profile comprises the following steps: the flat milling cutter carries out cutting operation along the tooth profile surface after rough machining is finished, and the whole semi-finish machining process ensures that the flat milling cutter is vertical to the tooth profile molded line;
the process of finishing the tooth profile comprises the following steps: and the spherical milling cutter performs cutting operation along the tooth profile surface after the semi-finishing operation is completed, and the whole finishing process ensures that the spherical milling cutter is vertical to the tooth profile molded line.
The specific process of the grooving cutting operation in the rough machining of the tooth profile comprises the following steps: firstly, selecting a milling cutter with proper size according to the width of a tooth groove, slotting the milling cutter from the middle of the tooth groove along the axial direction of a tooth profile, and lifting the milling cutter for a certain distance after cutting is finished to finish first cutting; then, the milling cutter moves leftwards according to the tooth profile and performs slotting along the axial direction of the tooth profile, the distance of left movement does not exceed the diameter of the milling cutter, and the milling cutter is reset to the initial position of left movement of the milling cutter to finish the cutting of a second cutter; then, the milling cutter is rightwards moved to be grooved along the axial direction of the tooth profile, and the rightwards movement distance is the same as the leftwards movement distance in the cutting process of the second cutter; so as to finish the rough machining of the tooth profile.
And (4) reserving 1-2mm of machining allowance for the tooth profile after rough machining.
After the rough machining of the tooth profile of the gear is finished, quenching and tempering are needed; the quenching and tempering process comprises the following steps: firstly, placing the gear subjected to the rough processing of the tooth profile into a quenching furnace, and linearly heating the temperature of the quenching furnace from room temperature to 180-200 ℃ within 13-16 minutes; then the furnace temperature is continuously linearly increased to 500-550 ℃ within 40-50 minutes; then, the furnace temperature is continuously linearly increased to 610 ℃ at the temperature of 600-; after the heat preservation is finished, opening a furnace door of the quenching furnace to enable the product A to fall into cooling oil for quenching treatment to obtain a product B; then, the B product is put into a tempering furnace, the furnace temperature is linearly increased to 650 ℃ for 50-60 minutes, the temperature is kept for 30-40 minutes, then the temperature of the tempering furnace is continuously linearly increased to 720 ℃ for 700-80 minutes, the temperature is kept for 50-60 minutes, and finally the furnace temperature is naturally cooled to the normal temperature, thus finishing the tempering treatment.
The flat milling cutter adopted in the semi-finishing process of the tooth profile is a hard flat milling cutter; and after the semi-finishing is finished, the shape of the tooth profile is reserved with a machining allowance of 0.1-0.2 mm.
The spherical milling cutter in the finish machining process of the tooth profile adopts a high-precision hard spherical milling cutter; after the spherical milling cutter finishes cutting along the tooth profile surface, the spherical milling cutter still needs to walk idle for one time according to the original walking track.
After finishing the tooth profile, carrying out micro-deformation heat treatment; the micro-deformation heat treatment is ion nitriding treatment or QPQ salt bath composite treatment.
The specific process of QPQ salt bath composite treatment is as follows: 1) cleaning the gear to obtain a product a; 2) preheating the product a at the temperature of 450-500 ℃ for 10-13min to obtain a product b; 3) performing salt bath nitriding treatment on the product b, namely putting the product b into a salt bath nitriding furnace, keeping the temperature of the salt bath nitriding furnace within 550-580 ℃, preserving the heat for 30-40min, then increasing the temperature of the salt bath nitriding furnace to 640 ℃ at a linear temperature rise speed of 5-8 ℃/min, and preserving the heat for 20-30min to obtain a product c; 4) performing salt bath oxidation treatment on the product c, namely putting the product c into a salt bath oxidation furnace, firstly keeping the temperature of the salt bath oxidation furnace at 520 ℃ for 10-15min, then reducing the temperature of the salt bath oxidation furnace to 480 ℃ at a linear cooling speed of 2-3 ℃/min, and keeping the temperature for 5-15min to obtain a product d; 5) cooling product d in cold water, soaking in hot water, washing with cold water, and oven drying to obtain product e; 6) and polishing the product e to obtain a finished product.
The polishing treatment is carried out by adopting a carborundum grinding wheel, and the polishing thickness is 0.01 mm.
And the rough machining track, the semi-finishing track and the finishing track of the modeling and generating tooth profile are all completed by adopting a CAM technology. Such as UG NX, Pro/NC, CATIA, etc.
Example 2. A machining process for a large-modulus gear with few teeth comprises the following steps as shown in figures 1 to 3:
firstly, modeling; drawing a gear three-dimensional model diagram according to the given parameters of the gear;
secondly, according to the gear three-dimensional model diagram generated in the first step, generating a rough machining track, a semi-finishing track and a finishing track of the tooth profile in sequence;
step three, processing; generating machining codes by using a CAM technology according to a rough machining track, a semi-finish machining track and a finish machining track, introducing the machining codes into a four-axis machining center, and performing rough machining, semi-finish machining and finish machining on the tooth profile of the gear in sequence to obtain a finished product;
the process of rough machining of the tooth profile is that a milling cutter performs slotting cutting operation along the axial direction of the tooth profile from the middle of a tooth slot to finish the rough machining of the tooth profile of the gear;
the semi-finishing process of the tooth profile comprises the following steps: the flat milling cutter carries out cutting operation along the tooth profile surface after rough machining is finished, and the whole semi-finish machining process ensures that the flat milling cutter is vertical to the tooth profile molded line;
the process of finishing the tooth profile comprises the following steps: and the spherical milling cutter performs cutting operation along the tooth profile surface after the semi-finishing operation is completed, and the whole finishing process ensures that the spherical milling cutter is vertical to the tooth profile molded line.
The specific process of the grooving cutting operation in the rough machining of the tooth profile comprises the following steps: firstly, selecting a milling cutter with proper size according to the width of a tooth groove, slotting the milling cutter from the middle of the tooth groove along the axial direction of a tooth profile, and lifting the milling cutter for a certain distance after cutting is finished to finish first cutting; then, the milling cutter moves leftwards according to the tooth profile and performs slotting along the axial direction of the tooth profile, the distance of left movement does not exceed the diameter of the milling cutter, and the milling cutter is reset to the initial position of left movement of the milling cutter to finish the cutting of a second cutter; then, the milling cutter is rightwards moved to be grooved along the axial direction of the tooth profile, and the rightwards movement distance is the same as the leftwards movement distance in the cutting process of the second cutter; so as to finish the rough machining of the tooth profile.
And the tooth profile after the rough machining leaves 1mm of machining allowance.
After the rough machining of the tooth profile of the gear is finished, quenching and tempering are needed; the quenching and tempering process comprises the following steps: firstly, placing the gear subjected to tooth profile rough machining into a quenching furnace, and linearly heating the temperature of the quenching furnace from room temperature to 180 ℃ within 13 minutes; then the furnace temperature is continuously linearly increased to 500 ℃ within 40 minutes; then, the furnace temperature is continuously linearly increased to 600 ℃ within 50 minutes, the temperature is increased, and then the temperature is maintained for 170 minutes to obtain a product A; after the heat preservation is finished, opening a furnace door of the quenching furnace to enable the product A to fall into cooling oil for quenching treatment to obtain a product B; and then, putting the B product into a tempering furnace, linearly raising the temperature of the tempering furnace to 600 ℃ within 50 minutes, preserving the temperature for 30 minutes, continuously linearly raising the temperature of the tempering furnace to 700 ℃ within 70 minutes, preserving the temperature for 50 minutes, and finally naturally cooling the furnace to normal temperature to finish tempering treatment.
The flat milling cutter adopted in the semi-finishing process of the tooth profile is a hard flat milling cutter; and after the semi-finishing is finished, the shape of the tooth profile is reserved with a machining allowance of 0.1 mm.
The spherical milling cutter in the finish machining process of the tooth profile adopts a high-precision hard spherical milling cutter; after the spherical milling cutter finishes cutting along the tooth profile surface, the spherical milling cutter still needs to walk idle for one time according to the original walking track.
After finishing the tooth profile, carrying out micro-deformation heat treatment; the micro-deformation heat treatment is ion nitriding treatment or QPQ salt bath composite treatment.
The specific process of QPQ salt bath composite treatment is as follows: 1) cleaning the gear to obtain a product a; 2) preheating the product a at 450 ℃ for 10min to obtain a product b; 3) performing salt bath nitriding treatment on the product b, namely putting the product b into a salt bath nitriding furnace, keeping the temperature of the salt bath nitriding furnace within 550 ℃, preserving the temperature for 30min, then increasing the temperature of the salt bath nitriding furnace to 620 ℃ at a linear temperature-increasing speed of 5 ℃/min, and preserving the temperature for 20min to obtain a product c; 4) performing salt bath oxidation treatment on the product c, namely putting the product c into a salt bath oxidation furnace, firstly keeping the temperature of the salt bath oxidation furnace at 500 ℃, preserving the temperature for 10min, then reducing the temperature of the salt bath oxidation furnace to 470 ℃ at a linear cooling speed of 2 ℃/min, and preserving the temperature for 5min to obtain a product d; 5) cooling product d in cold water, soaking in hot water, washing with cold water, and oven drying to obtain product e; 6) and polishing the product e to obtain a finished product.
The polishing treatment is carried out by adopting a carborundum grinding wheel, and the polishing thickness is 0.01 mm.
And the rough machining track, the semi-finishing track and the finishing track of the modeling and generating tooth profile are all completed by adopting a CAM technology. Such as UG NX, Pro/NC, CATIA, etc.
Example 3. A machining process for a large-modulus gear with few teeth comprises the following steps as shown in figures 1 to 3:
firstly, modeling; drawing a gear three-dimensional model diagram according to the given parameters of the gear;
secondly, according to the gear three-dimensional model diagram generated in the first step, generating a rough machining track, a semi-finishing track and a finishing track of the tooth profile in sequence;
step three, processing; generating machining codes by using a CAM technology according to a rough machining track, a semi-finish machining track and a finish machining track, introducing the machining codes into a four-axis machining center, and performing rough machining, semi-finish machining and finish machining on the tooth profile of the gear in sequence to obtain a finished product;
the process of rough machining of the tooth profile is that a milling cutter performs slotting cutting operation along the axial direction of the tooth profile from the middle of a tooth slot to finish the rough machining of the tooth profile of the gear;
the semi-finishing process of the tooth profile comprises the following steps: the flat milling cutter carries out cutting operation along the tooth profile surface after rough machining is finished, and the whole semi-finish machining process ensures that the flat milling cutter is vertical to the tooth profile molded line;
the process of finishing the tooth profile comprises the following steps: and the spherical milling cutter performs cutting operation along the tooth profile surface after the semi-finishing operation is completed, and the whole finishing process ensures that the spherical milling cutter is vertical to the tooth profile molded line.
The specific process of the grooving cutting operation in the rough machining of the tooth profile comprises the following steps: firstly, selecting a milling cutter with proper size according to the width of a tooth groove, slotting the milling cutter from the middle of the tooth groove along the axial direction of a tooth profile, and lifting the milling cutter for a certain distance after cutting is finished to finish first cutting; then, the milling cutter moves leftwards according to the tooth profile and performs slotting along the axial direction of the tooth profile, the distance of left movement does not exceed the diameter of the milling cutter, and the milling cutter is reset to the initial position of left movement of the milling cutter to finish the cutting of a second cutter; then, the milling cutter is rightwards moved to be grooved along the axial direction of the tooth profile, and the rightwards movement distance is the same as the leftwards movement distance in the cutting process of the second cutter; so as to finish the rough machining of the tooth profile.
The tooth profile after the rough machining leaves 1.5mm of machining allowance.
After the rough machining of the tooth profile of the gear is finished, quenching and tempering are needed; the quenching and tempering process comprises the following steps: firstly, placing the gear subjected to tooth profile rough machining into a quenching furnace, and linearly heating the temperature of the quenching furnace from room temperature to 190 ℃ within 14 minutes; then the furnace temperature is continuously linearly increased to 525 ℃ within 45 minutes; then, the furnace temperature is continuously linearly increased to 605 ℃ within 55 minutes, the temperature is increased, and then the temperature is maintained for 180 minutes to obtain a product A; after the heat preservation is finished, opening a furnace door of the quenching furnace to enable the product A to fall into cooling oil for quenching treatment to obtain a product B; and then, putting the B product into a tempering furnace, linearly raising the temperature of the tempering furnace to 625 ℃ within 55 minutes, preserving the temperature for 35 minutes, continuously linearly raising the temperature of the tempering furnace to 710 ℃ within 75 minutes, preserving the temperature for 55 minutes, and finally naturally cooling the furnace to normal temperature to finish tempering treatment.
The flat milling cutter adopted in the semi-finishing process of the tooth profile is a hard flat milling cutter; and after the semi-finishing is finished, the shape of the tooth profile is reserved with a machining allowance of 0.15 mm.
The spherical milling cutter in the finish machining process of the tooth profile adopts a high-precision hard spherical milling cutter; after the spherical milling cutter finishes cutting along the tooth profile surface, the spherical milling cutter still needs to walk idle for one time according to the original walking track.
After finishing the tooth profile, carrying out micro-deformation heat treatment; the micro-deformation heat treatment is ion nitriding treatment or QPQ salt bath composite treatment.
The specific process of QPQ salt bath composite treatment is as follows: 1) cleaning the gear to obtain a product a; 2) preheating the product a at 475 ℃ for 12min to obtain a product b; 3) performing salt bath nitriding treatment on the product b, namely putting the product b into a salt bath nitriding furnace, keeping the temperature of the salt bath nitriding furnace within 565 ℃, preserving the heat for 35min, then increasing the temperature of the salt bath nitriding furnace to 630 ℃ at a linear heating rate of 7 ℃/min, and preserving the heat for 25min to obtain a product c; 4) performing salt bath oxidation treatment on the product c, namely putting the product c into a salt bath oxidation furnace, firstly keeping the temperature of the salt bath oxidation furnace at 510 ℃, preserving the heat for 12.5min, then reducing the temperature of the salt bath oxidation furnace to 475 ℃ at a linear cooling speed of 2.5 ℃/min, and preserving the heat for 10min to obtain a product d; 5) cooling product d in cold water, soaking in hot water, washing with cold water, and oven drying to obtain product e; 6) and polishing the product e to obtain a finished product.
The polishing treatment is carried out by adopting a carborundum grinding wheel, and the polishing thickness is 0.01 mm.
And the rough machining track, the semi-finishing track and the finishing track of the modeling and generating tooth profile are all completed by adopting a CAM technology. Such as UG NX, Pro/NC, CATIA, etc.
Example 4. A machining process for a large-modulus gear with few teeth comprises the following steps as shown in figures 1 to 3:
firstly, modeling; drawing a gear three-dimensional model diagram according to the given parameters of the gear;
secondly, according to the gear three-dimensional model diagram generated in the first step, generating a rough machining track, a semi-finishing track and a finishing track of the tooth profile in sequence;
step three, processing; generating machining codes by using a CAM technology according to a rough machining track, a semi-finish machining track and a finish machining track, introducing the machining codes into a four-axis machining center, and performing rough machining, semi-finish machining and finish machining on the tooth profile of the gear in sequence to obtain a finished product;
the process of rough machining of the tooth profile is that a milling cutter performs slotting cutting operation along the axial direction of the tooth profile from the middle of a tooth slot to finish the rough machining of the tooth profile of the gear;
the semi-finishing process of the tooth profile comprises the following steps: the flat milling cutter carries out cutting operation along the tooth profile surface after rough machining is finished, and the whole semi-finish machining process ensures that the flat milling cutter is vertical to the tooth profile molded line;
the process of finishing the tooth profile comprises the following steps: and the spherical milling cutter performs cutting operation along the tooth profile surface after the semi-finishing operation is completed, and the whole finishing process ensures that the spherical milling cutter is vertical to the tooth profile molded line.
The specific process of the grooving cutting operation in the rough machining of the tooth profile comprises the following steps: firstly, selecting a milling cutter with proper size according to the width of a tooth groove, slotting the milling cutter from the middle of the tooth groove along the axial direction of a tooth profile, and lifting the milling cutter for a certain distance after cutting is finished to finish first cutting; then, the milling cutter moves leftwards according to the tooth profile and performs slotting along the axial direction of the tooth profile, the distance of left movement does not exceed the diameter of the milling cutter, and the milling cutter is reset to the initial position of left movement of the milling cutter to finish the cutting of a second cutter; then, the milling cutter is rightwards moved to be grooved along the axial direction of the tooth profile, and the rightwards movement distance is the same as the leftwards movement distance in the cutting process of the second cutter; so as to finish the rough machining of the tooth profile.
And 2mm of machining allowance is left for the tooth profile after rough machining.
After the rough machining of the tooth profile of the gear is finished, quenching and tempering are needed; the quenching and tempering process comprises the following steps: firstly, placing the gear subjected to tooth profile rough machining into a quenching furnace, and linearly heating the furnace temperature of the quenching furnace from room temperature to 200 ℃ within 16 minutes; then the furnace temperature is continuously and linearly increased to 550 ℃ within 50 minutes; then, the furnace temperature is continuously linearly increased to 610 ℃ within 60 minutes, the temperature is increased, and then the temperature is maintained for 190 minutes to obtain a product A; after the heat preservation is finished, opening a furnace door of the quenching furnace to enable the product A to fall into cooling oil for quenching treatment to obtain a product B; and then, putting the B product into a tempering furnace, linearly raising the temperature of the tempering furnace to 650 ℃ within 60 minutes, preserving the temperature for 40 minutes, continuously linearly raising the temperature of the tempering furnace to 720 ℃ within 80 minutes, preserving the temperature for 60 minutes, and finally naturally cooling the furnace to normal temperature to finish tempering treatment.
The flat milling cutter adopted in the semi-finishing process of the tooth profile is a hard flat milling cutter; and after the semi-finishing is finished, the shape of the tooth profile is reserved with a machining allowance of 0.2 mm.
The spherical milling cutter in the finish machining process of the tooth profile adopts a high-precision hard spherical milling cutter; after the spherical milling cutter finishes cutting along the tooth profile surface, the spherical milling cutter still needs to walk idle for one time according to the original walking track.
After finishing the tooth profile, carrying out micro-deformation heat treatment; the micro-deformation heat treatment is ion nitriding treatment or QPQ salt bath composite treatment.
The specific process of QPQ salt bath composite treatment is as follows: 1) cleaning the gear to obtain a product a; 2) preheating the product a at 500 ℃ for 13min to obtain a product b; 3) performing salt bath nitriding treatment on the product b, namely putting the product b into a salt bath nitriding furnace, keeping the temperature of the salt bath nitriding furnace within 580 ℃, preserving the heat for 40min, then increasing the temperature of the salt bath nitriding furnace to 640 ℃ at a linear heating rate of 8 ℃/min, and preserving the heat for 30min to obtain a product c; 4) performing salt bath oxidation treatment on the product c, namely putting the product c into a salt bath oxidation furnace, firstly keeping the temperature of the salt bath oxidation furnace at 520 ℃, preserving the temperature for 15min, then reducing the temperature of the salt bath oxidation furnace to 480 ℃ at a linear cooling speed of 3 ℃/min, and preserving the temperature for 15min to obtain a product d; 5) cooling product d in cold water, soaking in hot water, washing with cold water, and oven drying to obtain product e; 6) and polishing the product e to obtain a finished product.
The polishing treatment is carried out by adopting a carborundum grinding wheel, and the polishing thickness is 0.01 mm.
And the rough machining track, the semi-finishing track and the finishing track of the modeling and generating tooth profile are all completed by adopting a CAM technology. Such as UG NX, Pro/NC, CATIA, etc.
Claims (7)
1. A machining process for a large-modulus small-tooth-number gear is characterized by comprising the following steps of:
firstly, modeling; drawing a gear three-dimensional model diagram according to the given parameters of the gear;
secondly, according to the gear three-dimensional model diagram generated in the first step, generating a rough machining track, a semi-finishing track and a finishing track of the tooth profile in sequence;
step three, processing; generating machining codes by using a CAM technology according to a rough machining track, a semi-finish machining track and a finish machining track, introducing the machining codes into a four-axis machining center, and performing rough machining, semi-finish machining and finish machining on the tooth profile of the gear in sequence to obtain a finished product;
the process of rough machining of the tooth profile is that a milling cutter performs slotting cutting operation along the axial direction of the tooth profile from the middle of a tooth slot to finish the rough machining of the tooth profile of the gear;
the semi-finishing process of the tooth profile comprises the following steps: the flat milling cutter performs cutting operation along the tooth profile surface after rough machining is completed, and the whole process ensures that the flat milling cutter is vertical to the tooth profile molded line;
the process of finishing the tooth profile comprises the following steps: the spherical milling cutter performs cutting operation along the tooth profile surface after the semi-finishing operation is completed, and the spherical milling cutter is ensured to be vertical to the tooth profile molded line in the whole process;
the specific process of the grooving cutting operation in the rough machining of the tooth profile comprises the following steps: firstly, selecting a milling cutter with proper size according to the width of a tooth groove, slotting the milling cutter from the middle of the tooth groove along the axial direction of a tooth profile, lifting the milling cutter after cutting is finished, and finishing first cutting; then, the milling cutter moves leftwards according to the tooth profile and performs slotting along the axial direction of the tooth profile, the distance of left movement does not exceed the diameter of the milling cutter, and the milling cutter is reset to the initial position of left movement of the milling cutter to finish the cutting of a second cutter; then, the milling cutter is rightwards moved to be grooved along the axial direction of the tooth profile, and the rightwards movement distance is the same as the leftwards movement distance in the cutting process of the second cutter; the rough machining of the tooth profile is finished in such a reciprocating way;
after the rough machining of the tooth profile of the gear is finished, quenching and tempering are needed; the quenching and tempering process comprises the following steps: firstly, placing the gear subjected to the rough processing of the tooth profile into a quenching furnace, and linearly heating the temperature of the quenching furnace from room temperature to 180-200 ℃ within 13-16 minutes; then the furnace temperature is continuously linearly increased to 500-550 ℃ within 40-50 minutes; then, the furnace temperature is continuously linearly increased to 610 ℃ at the temperature of 600-; after the heat preservation is finished, opening a furnace door of the quenching furnace to enable the product A to fall into cooling oil for quenching treatment to obtain a product B; then, the B product is put into a tempering furnace, the furnace temperature is linearly increased to 650 ℃ for 50-60 minutes, the temperature is kept for 30-40 minutes, then the temperature of the tempering furnace is continuously linearly increased to 720 ℃ for 700-80 minutes, the temperature is kept for 50-60 minutes, and finally the furnace temperature is naturally cooled to the normal temperature, thus finishing the tempering treatment.
2. The machining process of the gear with the large modulus and the small tooth number as claimed in claim 1, wherein the machining process comprises the following steps: and (4) reserving 1-2mm of machining allowance for the tooth profile after rough machining.
3. The machining process of the gear with the large modulus and the small tooth number as claimed in claim 1, wherein the machining process comprises the following steps: the flat milling cutter adopted in the semi-finishing process of the tooth profile is a hard flat milling cutter; and after the semi-finishing is finished, the shape of the tooth profile is reserved with a machining allowance of 0.1-0.2 mm.
4. The machining process of the gear with the large modulus and the small tooth number as claimed in claim 1, wherein the machining process comprises the following steps: the spherical milling cutter in the finish machining process of the tooth profile adopts a high-precision hard spherical milling cutter; after the spherical milling cutter finishes cutting along the tooth profile surface, the spherical milling cutter still needs to walk idle for one time according to the original walking track.
5. The machining process of the gear with the large modulus and the small tooth number as claimed in claim 1, wherein the machining process comprises the following steps: after finishing the tooth profile, carrying out micro-deformation heat treatment; the micro-deformation heat treatment is ion nitriding treatment or QPQ salt bath composite treatment.
6. The machining process of the gear with the large modulus and the small tooth number as claimed in claim 5, wherein the machining process comprises the following steps: the specific process of QPQ salt bath composite treatment is as follows: 1) cleaning the gear to obtain a product a; 2) preheating the product a at the temperature of 450-500 ℃ for 10-13min to obtain a product b; 3) performing salt bath nitriding treatment on the product b, namely putting the product b into a salt bath nitriding furnace, keeping the temperature of the salt bath nitriding furnace within 550-580 ℃, preserving the heat for 30-40min, then increasing the temperature of the salt bath nitriding furnace to 640 ℃ at a linear temperature rise speed of 5-8 ℃/min, and preserving the heat for 20-30min to obtain a product c; 4) performing salt bath oxidation treatment on the product c, namely putting the product c into a salt bath oxidation furnace, firstly keeping the temperature of the salt bath oxidation furnace at 520 ℃ for 10-15min, then reducing the temperature of the salt bath oxidation furnace to 480 ℃ at a linear cooling speed of 2-3 ℃/min, and keeping the temperature for 5-15min to obtain a product d; 5) cooling product d in cold water, soaking in hot water, washing with cold water, and oven drying to obtain product e; 6) and polishing the product e to obtain a finished product.
7. The machining process of the gear with the large module and the small tooth number as claimed in claim 6, wherein the machining process comprises the following steps: the polishing treatment is carried out by adopting a carborundum grinding wheel, and the polishing thickness is 0.01 mm.
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| CN111915975A (en) * | 2020-05-13 | 2020-11-10 | 衢州职业技术学院 | Design method of novel gear generating machining virtual prototype based on UG NX |
| CN114769737A (en) * | 2022-05-09 | 2022-07-22 | 陕西理工大学 | Forming and grinding processing method for gear with small number of teeth |
| CN116571819B (en) * | 2023-07-12 | 2023-12-08 | 陕西法士特齿轮有限责任公司 | Processing method for improving fatigue strength and gluing bearing capacity of gear |
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| DE502006003095D1 (en) * | 2006-06-06 | 2009-04-23 | Klingelnberg Gmbh | Apparatus and method for soft machining of bevel gears and use of the apparatus |
| CN101913067A (en) * | 2010-08-20 | 2010-12-15 | 重庆齿轮箱有限责任公司 | Forming and machining method of large-modulus gear |
| CN103480919B (en) * | 2013-09-24 | 2015-09-23 | 二重集团（德阳）重型装备股份有限公司 | Large modulus Hardened gear face tooth bar profile of tooth method for fine finishing |
| CN105441867A (en) * | 2015-12-23 | 2016-03-30 | 四川全丰新材料科技有限公司 | QPQ (Quench-Polish-Quench) salt bath treatment method applicable to surface of iron casting |
| CN105499712B (en) * | 2016-01-08 | 2017-07-18 | 南京工大数控科技有限公司 | A kind of few number of teeth roller gear processing method of super-modulus |
| CN106774167B (en) * | 2017-02-07 | 2019-06-07 | 陕西理工学院 | A kind of gear with little teeth number numerical-control processing method |
| CN107511647B (en) * | 2017-09-30 | 2019-07-12 | 中信重工机械股份有限公司 | A kind of fine module gear tooth Profile Machining method |
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Denomination of invention: A Machining Technology for Large Module Gear with Small Number of Teeth Effective date of registration: 20221129 Granted publication date: 20200327 Pledgee: CITIC Bank Limited by Share Ltd. Lishui branch Pledgor: ZHEJIANG WEIKENTE INTELLIGENT MACHINERY CO.,LTD. Registration number: Y2022330003330 |