CN111719108B - Heat treatment process and machining method for high-speed rail reducer gear - Google Patents
Heat treatment process and machining method for high-speed rail reducer gear Download PDFInfo
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- CN111719108B CN111719108B CN202010418412.2A CN202010418412A CN111719108B CN 111719108 B CN111719108 B CN 111719108B CN 202010418412 A CN202010418412 A CN 202010418412A CN 111719108 B CN111719108 B CN 111719108B
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/20—Carburising
- C23C8/22—Carburising of ferrous surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23F—MAKING GEARS OR TOOTHED RACKS
- B23F17/00—Special methods or machines for making gear teeth, not covered by the preceding groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/32—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for gear wheels, worm wheels, or the like
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Abstract
The invention provides a heat treatment process and a processing method of a high-speed rail reducer gear, wherein the heat treatment process comprises pretreatment, a heating first region, an initial carburizing carbon region, a strong carburizing three region, a diffusion carburizing four region and a quenching carburizing five region, and optimizes processing steps and processing tools.
Description
Technical Field
The invention relates to the technical field of gear machining of speed reducers, in particular to a heat treatment process and a machining method of a high-speed rail speed reducer gear.
Background
The high-speed rail speed reducer gear is mainly applied to a main speed reducer of a bridge body of a high-speed rail locomotive and is a main component for reducing the rotating speed and increasing the torque in a locomotive transmission system. High-speed railway locomotive pontic main reducer realizes slowing down and the direction of transfer of variation force through a set of gear pair, and the gear pair includes initiative bevel gear and driven bevel gear, and initiative bevel gear is helical gear axle etc. and driven bevel gear is helical gear, and both mesh mutually and transmit power, need use a plurality of gears among the whole speed reducer structure assembly, use through mutually supporting between them. The heat treatment process of the gear directly influences the surface hardness, the core hardness and the metallographic structure of the gear and has important influence on various performances of the gear,
the 30CrMnTi steel is used for processing gears, the process step design of the gear processing process and the gear carburizing heat treatment process have important influence on the surface hardness, the core hardness and various metallographic phases of the gears, and the parameters influence the impact toughness, the wear resistance and the like of the gears. The stress of the speed reducer gear of the railway locomotive is large in the transmission process, particularly the transmission of the speed reducer gear of the high-speed rail drive axle body is long in service time, the load impact and the abrasion on the gear are serious, so that the service performance of the whole speed reducer of the railway locomotive can be influenced, and the early failure of the high-speed rail speed reducer gear is easy to occur under the action of strong torque.
Disclosure of Invention
The invention provides a heat treatment process and a processing method of a high-speed rail speed reducer gear, which can eliminate the non-contact surface interference phenomenon in the gear transmission process, improve the shape and the position of a contact patch, reduce the transmission noise of a gear pair, realize high-precision, high-strength and stable transmission and solve the early failure of the high-speed rail speed reducer gear under the action of strong torque.
The technical scheme of the invention is realized as follows: a heat treatment process of a high-speed rail reducer gear adopts a double-row continuous furnace to carry out carburization treatment, the period is double rows of 80 +/-5 min, and the heat treatment process comprises the following steps:
(1) pretreatment: conveying the gears to a pretreatment furnace, wherein the temperature of the pretreatment furnace is 460 +/-10 ℃, and the material level of material racks of the pretreatment furnace is 3;
(2) heating a first zone: the gear enters a first heating area, the temperature of the first heating area is 870 +/-5 ℃, the flow rate of methanol is 20 +/-5 ml/min, and the material level of the material rack in the first heating area is 10;
(3) initial carburization carbon region: the gear enters a carburizing secondary zone, the temperature of the carburizing secondary zone is 890 +/-5 ℃, the carbon potential is 0.9 +/-0.05 percent, the flow rate of methanol is 25 +/-5 ml/min, the flow rate of acetone is 20 +/-3 ml/min, and the material level of a material rack in the carburizing secondary zone is 6;
(4) a strong carburization three-zone: the gear enters a three carburizing zone, the temperature of the three carburizing zone is 910 +/-5 ℃, the carbon potential is 1.05 +/-0.05%, the flow rate of methanol is 30 +/-5 ml/min, the flow rate of acetone is 20 +/-3 ml/min, and the material level of a material rack in the carbon carburizing zone is 10;
(5) four zones of diffusion carburization: the gear enters a four carburizing zone, the temperature of the four carburizing zone is 890 +/-5 ℃, and carbon is addedPotential is 0.8 + -0.05%, methanol flow is 25 + -5 ml/min, acetone flow is 0-10ml/min, and air flow is 0-1m3The material level of the material rack in the four carburizing zones is 10;
(6) a quenching and carburizing five zone: the gear enters a five carburization zone, the temperature of the five carburization zone is 790 +/-5 ℃, the carbon potential is 0.75 +/-0.05 percent, the flow rate of methanol is 20 +/-5 ml/min, the flow rate of acetone is 0-10ml/min, and the air flow rate is 0-1m3And h, the material level of the material rack in the five carburization areas is 6.
Further, after the carburization in the step (6) is finished, the driven bevel gear is subjected to quenching and tempering treatment, and the method comprises the following steps:
1) quenching: the medium is Y15-II rapid quenching oil, the temperature is 80 +/-10 ℃, and the quenching time is 30 min;
2) cleaning: after quenching, the gear enters an alkaline water tank, the temperature of the alkaline water tank is 80 +/-10 ℃, the gear is soaked and washed for 10min, and then the gear enters a clear water tank, the temperature of the clear water tank is 80 +/-10 ℃, and the gear is sprayed for 8 min;
3) tempering: the temperature is 180 +/-5 ℃, the tempering time is 12 hours, and the tempering is carried out for 2 times;
4) shot blasting: and performing shot blasting treatment after tempering.
A method for processing a high-speed rail reducer gear comprises the steps of dividing the gear into a driving bevel gear and a driven bevel gear, wherein the driven bevel gear needs to be subjected to processes of inner hole driving, face turning, tooth cutting, rough tooth grinding, hot front inspection, tooth end chamfering/tooth top chamfering and hot front cleaning before the heat treatment process is carried out, and the driven bevel gear is subjected to processes of hot rear hard turning, tooth grinding, pairing, hot rear cleaning, magnetic powder inspection and packaging and warehousing after the heat treatment process is finished.
Further, the tip chamfer/tip chamfer: chamfering the large end and the small end of the gear tooth of the driven bevel gear by 2 multiplied by 45 degrees respectively by using an angle grinder, wherein the chamfering depth is up to the tooth root, and removing burrs at the tooth end; and (3) using an angle grinder to grind and chamfer the tooth tops of the concave-convex surfaces of the gear teeth of the driven bevel gear by 1.1-1.5 multiplied by 45 degrees along the direction of the tooth-wise spiral line, and ensuring that the chamfer line is smooth and has no distortion.
Further, gear cutting, rough grinding and gear grinding process all adopt the elastic fixture to fix driven bevel gear, the elastic fixture includes body and connecting axle, the coaxial slip of tip of connecting axle passes the body, and be provided with the connecting seat, the coaxial cover in the outside of connecting seat is equipped with collet chuck and position sleeve, the position sleeve is located collet chuck and keeps away from one side of body, the one end of body links to each other with the lathe, the other end is the toper cover, and arrange in between connecting seat and the collet chuck, collet chuck's inside wall is for the conical surface with the cooperation of collet chuck pressfitting, collet chuck includes hollow annular chuck, be provided with a plurality of flutings along the axial on annular chuck's the lateral wall.
Furthermore, the outer side wall of the conical sleeve is symmetrically provided with first guide posts, and the spring chuck is provided with first guide grooves matched with the first guide posts; the outer side of the connecting shaft is slidably sleeved with a coaxial guide sleeve, a second guide post is arranged on the guide sleeve, a second guide groove matched with the second guide post is formed in the connecting shaft, a third guide post is arranged on the body, and a third guide groove matched with the third guide post is formed in the connecting seat.
A method for processing a high-speed rail reducer gear comprises the steps that the gear is divided into a driving bevel gear and a driven bevel gear, the driving bevel gear needs to be subjected to center hole drilling on the end face of a small end of a traveling crane, center hole drilling on the end face of a large end of the traveling crane, fine turning of a rod part, fine turning of a face cone, coarse grinding of a shaft neck, tapping, gear milling, coarse grinding of a gear, tooth top grinding of a gear, chamfering of a tooth end grinding of the gear and hot pre-cleaning before the heat treatment process is carried out, and after the heat treatment process is completed, the driving bevel gear is subjected to fine grinding of the shaft neck, gear grinding, taper matching grinding, magnetic powder inspection, packaging and warehousing.
Further, the addendum grinding rib is: the two sides of the tooth crest of the driving bevel gear are chamfered by 0.7-1.0 multiplied by 35 degrees.
Further, the tooth end is subjected to edge grinding and chamfering: adjusting the screwing distance of a pull rod of the angle grinder to ensure the set tension; and installing a cutter, adjusting a chamfering arm, inclining the grinding wheel according to the tooth form inclination angle to enable the grinding edge to be parallel to the edge of the tooth end, chamfering the large end and the small end of the tooth of the driving bevel gear by 1.8 multiplied by 45 degrees respectively, and chamfering to the tooth root.
The invention has the beneficial effects that:
1. the invention improves the strength of the product and the high hardenability of the heat treatment, improves the impact toughness, can be cooled and directly quenched after carburization, has higher bending strength and good wear resistance, and is suitable for heavy-load carburized parts with larger sections and speed reducer gears with larger stress;
2. by using the high-precision positioning tool elastic clamp, the conical sleeve of the body is matched with the taper of the inner side wall of the spring chuck in a compression joint manner, the conical sleeve extrudes the spring chuck to realize fixed clamping on the basin teeth, so that the stability and the coaxiality of clamping a workpiece are ensured, and the technical requirement of high-precision machining is realized in tooth profile machining;
3. the non-contact surface interference phenomenon in the gear transmission process is eliminated, the shape and the position of a contact trace are improved, the transmission noise of a gear pair is reduced, high-precision, high-strength and stable transmission is realized, and the early failure of a high-speed rail speed reducer gear under the action of strong torque is solved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic view of a driven bevel gear;
FIG. 2 is a schematic structural view of an elastic clamp;
FIG. 3 is a schematic structural view of a collet chuck;
FIG. 4 is a schematic structural view of a drive bevel gear;
FIG. 5 is a schematic view of the driven bevel gear teeth;
FIG. 6 is a schematic structural view of a concave surface of a big tooth;
FIG. 7 is a schematic structural view of a convex surface of a large tooth;
fig. 8 is an analysis diagram (scale 22 x 41) of the gear contact surface ATCA;
fig. 9 is a tooth surface mismatch topology analysis (scale 22 x 41);
FIG. 10 is a tooth flank overlap ratio analysis plot for finite element loading (loading torque 30000 N.m);
FIG. 11 is a tooth contact orthogonal shear stress analysis plot of finite element loading (loading torque 30000 N.m);
FIG. 12 is a tooth surface skin shear stress analysis plot for finite element loading (loading torque 30000 N.m);
FIG. 13 is a graph of finite element loaded large gear tooth face contact stress analysis (load torque 30000N m).
The connecting device comprises a body 1, a connecting shaft 2, a connecting seat 3, a spring chuck 4, a positioning sleeve 5, a conical sleeve 6, a conical surface 7, a first guide post 8, a first guide groove 9, an annular chuck 10, a groove 11, a guide sleeve 12, a second guide post 13, a second guide groove 14, a third guide post 15 and a third guide groove 16.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
The high-speed reducer gear is prepared from the raw materials of 30CrMnTi, and the chemical components of the 30CrMnTi comprise the following components in percentage by mass: 0.24 to 0.29 percent of C, 0.24 to 0.35 percent of Si, 0.80 to 1.10 percent of Mn, 1.00 to 1.30 percent of Cr, 0.04 to 0.10 percent of Ti, less than or equal to 0.02 percent of P, less than or equal to 0.02 percent of S, less than or equal to 0.1 percent of Cu, and less than or equal to 15ppm of O. End hardenability of 30 CrMnTi: j9: 36-45HRC, J15:35-41 HRC.
Non-metallic inclusion of 30 CrMnTi:
the 30CrMnTi has austenite grain size of 7 grades or less, a banded structure grade of 0-2 grades, and a macrostructure grade as follows:
| center porosity | Generally loose | Segregation of | Other low power defects | |
| Rank of | ≤1.0 | ≤1.0 | ≤1.0 | Is free of |
The method comprises the steps of reasonably proportioning related alloy elements of 30CrMnTi low-carbon alloy steel, strictly controlling an end quenching interval value of the steel, forging and isothermal normalizing, controlling a standard interval value of a belt-shaped and metallographic structure of the steel, carrying out mechanical processing and tooth profile processing, and carrying out carburizing quenching and tempering tests to ensure the surface hardness, the core hardness and various metallographic standards of the gear teeth of the product so as to meet various performance test standards of the railway locomotive.
The following description will be given with reference to specific examples.
Example one
The 30CrMnTi comes from Dazhu special steel member Co Ltd, and the 30CrMnTi comprises the following chemical components in percentage by mass: 0.28% of C, 0.24% of Si, 0.96% of Mn, 1.15% of Cr, 0.065% of Ti, 0.013% of P, 0.012% of S, 0.009% of Cu and 0.006% of Ni.
Grade of non-metallic inclusions: a is 1.0 in fine and 0 in coarse; b is 1.0 in the fine line and 0 in the coarse line; c is 0 in fine system and 0 in coarse system; d is 0.5 fine and 0.5 coarse.
The grain size grade is 8.0-7.0 grade. Macroscopic tissue grade: generally, the porosity is 1.0 grade, the center porosity is 0.5 grade, the ingot type segregation is 0.5 grade, the edge spot segregation is 0, and generally the spot segregation is 0.
The 30CrMnTi has the tensile strength of 1474MPa, the elongation after fracture of 10.0 percent and the reduction of area of 42 percent, and adopts GB/T229-2007 metallic material Charpy pendulum impact test method, impact absorption energy KU254.99J。
A method for processing a high-speed rail reducer gear comprises the following steps of:
1. turning an inner hole: selecting an excircle jaw to ensure that no collision, flash or burr exists on a jaw working surface, installing and turning the jaw in a matched manner, ensuring that the fit clearance of the jaw and a working excircle is less than or equal to 2-3 in a free state, and respectively turning an inner hole, an inner hole chamfer, a large end face, a step end face fillet and a back cone;
2. turning a face cone: selecting an inner hole clamping jaw, ensuring that a working surface of the clamping jaw has no collision, flash and burr, installing and matching and turning the clamping jaw, ensuring that a matching clearance between the clamping jaw and a working excircle is less than or equal to 0.20 in a free state, and turning the excircle, a face cone, a front cone and a back cone (local part) respectively;
3. gear cutting: the end jump and the diameter jump of the gear cutting tool are less than 0.015mm, and the T value of the gear teeth is
The midpoint chord tooth thickness (Sh is 5.99) is 13 +/-0.05 mm;
4. rough gear grinding: the end jump and the diameter jump of the rough grinding tooth are less than 0.015mm, the roughness is Ra1.6, no knifing exists, and the thickness of the middle point chord tooth (Sh is 5.99) is 12 +/-0.05 mm;
5. checking before heating: stability is involved, and no abnormal sound is required to be stable; the position of the contact area requires the middle of the front vehicle surface to be slightly smaller (2-3mm), the middle of the reverse vehicle surface and the top weight to be 0.2; contact zone shape, required to be free of bad contact; the length of the contact zone is required to be 55-65% of the tooth length, the width of the contact zone is required to be 60-70% of the tooth height, the distance between the contact zone and the tooth top is required to be 1.2-1.5mm, and the variation of the backlash is less than or equal to 0.06;
6. tip chamfering/tip grinding: chamfering the large end and the small end of the gear tooth of the driven bevel gear by 2 multiplied by 45 degrees respectively by using an angle grinder, wherein the chamfering depth is up to the tooth root, and removing burrs at the tooth end; and (3) using an angle grinder to grind and chamfer the tooth tops of the concave-convex surfaces of the gear teeth of the driven bevel gear by 1.1-1.5 multiplied by 45 degrees along the direction of the tooth-wise spiral line, ensuring that the chamfer line is smooth and has no distortion, and strictly preventing the tooth surfaces from being damaged.
7. Cleaning before heating: putting the product at a feeding port of a transmission belt, controlling the speed of the transmission belt at 29-32Hz, the cleaning pressure at 0.45-0.55MPa, and the cleaning temperature: and cleaning by adopting a cleaning antirust agent at the temperature of between 50 and 80 ℃.
8. And (3) heat treatment: the method comprises the steps of inner hole seepage prevention, disc loading, pretreatment, heating, carburizing, diffusion, precooling, quenching, cleaning, tempering and shot blasting, specifically adopts a double-row continuous furnace to carry out carburizing treatment, and the period is double rows of 80 +/-5 min, and comprises the following steps:
(1) pretreatment: conveying the gears to a pretreatment furnace, wherein the temperature of the pretreatment furnace is 460 +/-10 ℃, and the material level of material racks of the pretreatment furnace is 3;
(2) heating a first zone: the gear enters a first heating area, the temperature of the first heating area is 870 +/-5 ℃, the flow rate of methanol is 20 +/-5 ml/min, and the material level of the material rack in the first heating area is 10;
(3) initial carburization carbon region: the gear enters a carburizing secondary zone, the temperature of the carburizing secondary zone is 890 +/-5 ℃, the carbon potential is 0.9 +/-0.05 percent, the flow rate of methanol is 25 +/-5 ml/min, the flow rate of acetone is 20 +/-3 ml/min, and the material level of a material rack in the carburizing secondary zone is 6;
(4) a strong carburization three-zone: the gear enters a three carburizing zone, the temperature of the three carburizing zone is 910 +/-5 ℃, the carbon potential is 1.05 +/-0.05%, the flow rate of methanol is 30 +/-5 ml/min, the flow rate of acetone is 20 +/-3 ml/min, and the material level of a material rack in the carbon carburizing zone is 10;
(5) four zones of diffusion carburization: the gear enters a four-carburizing zone, the temperature of the four-carburizing zone is 890 plus and minus 5 ℃, the carbon potential is 0.8 plus or minus 0.05 percent, the flow rate of the methanol is 25 plus or minus 5ml/min, the flow rate of the acetone is 0-10ml/min, and the air flow rate is 0-1m3The material level of the material rack in the four carburizing zones is 10;
(6) a quenching and carburizing five zone: the gear enters a five carburization zone, the temperature of the five carburization zone is 790 +/-5 ℃, the carbon potential is 0.75 +/-0.05 percent, the flow rate of methanol is 20 +/-5 ml/min, the flow rate of acetone is 0-10ml/min, and air is introducedThe flow rate is 0-1m3And h, the material level of the material rack in the five carburization areas is 6.
And (6) processing time of each stage is the number of the material levels of the material rack multiplied by the period time.
After the carburization in the step (6) is finished, the driven bevel gear is quenched and tempered, and the method comprises the following steps:
1) quenching: the medium is Y15-II rapid quenching oil, the temperature is 80 +/-10 ℃, and the quenching time is 30 min;
2) cleaning: after quenching, the gear enters an alkaline water tank, the temperature of the alkaline water tank is 80 +/-10 ℃, the gear is soaked and washed for 10min, and then the gear enters a clear water tank, the temperature of the clear water tank is 80 +/-10 ℃, and the gear is sprayed for 8 min;
3) tempering: the temperature is 180 +/-5 ℃, the tempering time is 12 hours, and the tempering is carried out for 2 times;
4) shot blasting: performing shot blasting treatment after tempering;
9. hard turning after heating: correcting pitch circle positioning tooling, ensuring that the radial jump and the end jump of the tooling are less than or equal to 0.02, and finely turning an inner hole and a large end face;
10. grinding teeth, pairing, cleaning after heating, magnetic powder inspection and packaging and warehousing.
After the heat treatment process of the step 8 is adopted, the results of the metallographic structure and the hardness of the gear are as follows:
after the heat treatment process of the step 8 is adopted, the inner hole of the gear is divided into an upper part, a middle part and a lower part, the roundness error of the upper part is 0.02-0.08mm, the roundness error of the middle part is 0.02-0.12mm, the roundness error of the lower part is 0.03-0.12mm, and the axial taper error of the inner hole is 0.06-0.12 mm.
Example two
Gear cutting, rough grinding and gear grinding process all adopt elastic fixture to fix driven bevel gear, as shown in fig. 3 and 4, elastic fixture includes body 1 and connecting axle 2, and the coaxial slip of tip of connecting axle 2 passes body 1, and threaded fixation has connecting seat 3, and the coaxial cover in the outside of connecting seat 3 is equipped with collet chuck 4 and position sleeve 5, and collet chuck 4 and position sleeve 5 are fixed continuous with the one end that connecting axle 2 was kept away from to connecting seat 3, and position sleeve 5 is located collet chuck 4 and keeps away from one side of body 1.
One end of the body 1 is fixedly connected with a machine tool bolt, the other end of the body is a conical sleeve 6 and is arranged between the connecting seat 3 and the spring chuck 4, and the inner side wall of the spring chuck 4 is a conical surface 7 which is in compression joint with the conical sleeve 6. Two first guide posts 8 perpendicular to the axial direction are symmetrically fixed on the outer side wall of the conical sleeve 6 through threads, a first guide groove 9 matched with the first guide posts 8 is formed in the collet chuck 4, and the first guide groove 9 is located at one end, close to the body 1, of the collet chuck 4 and is an open groove along the axial direction. The conical sleeve 6 is axially inserted into the spring clamp by the cooperation of the first guide post 8 and the first guide groove 9.
The collet chuck 4 comprises a hollow annular chuck 10, and a plurality of slots 11 are axially formed on a side wall of the annular chuck 10. The collet chuck 4 is made of spring steel and has elasticity, and the slot 11 is provided for bearing the elastic deformation of the conical sleeve 6 under pressure.
The outer side of the connecting shaft 2 is slidably sleeved with a coaxial guide sleeve 12, a second guide post 13 is fixedly connected to the guide sleeve 12 through threads, a second guide groove 14 matched with the second guide post 13 is formed in the connecting shaft 2, a third guide post 15 is fixedly connected to the body 1 through threads, and a third guide groove 16 matched with the third guide post 15 is formed in the connecting seat 3. The second guide post 13 and the third guide post 15 are perpendicular to the axial direction, and the second guide groove 14 and the third guide groove 16 are parallel to the axial direction. Through the cooperation of second guide post 13 and second guide way 14, the coaxial removal of connecting axle 2, connecting seat 3, collet chuck 4 and position sleeve 5 is guaranteed in the cooperation of third guide post 15 and third guide way 16 to guarantee the axiality when basin tooth adds man-hour.
The application method of the embodiment comprises the following steps: the body 1 and the guide sleeve 12 are fixedly connected with a machine tool through bolts, the connecting shaft 2 is connected with a telescopic mechanism of the machine tool, the positioning sleeve 5 and the spring chuck 4 are placed in a shaft hole of the basin tooth, the telescopic mechanism drives the connecting shaft 2 to move towards the body 1, the conical sleeve 6 enters between the connecting seat 3 and the spring chuck 4, the outer side wall of the conical sleeve 6 is in taper compression fit with the inner side wall of the spring chuck 4, and therefore stable clamping of the spring chuck 4 on the basin tooth is achieved; when the basin teeth need to be taken down, the telescopic mechanism drives the connecting shaft 2 to move towards the direction far away from the body 1, the conical sleeve 6 is separated from the spring chuck 4, and the locating sleeve 5 and the spring chuck 4 can be taken down.
EXAMPLE III
This embodiment is substantially the same as the first embodiment, except that: a method for processing a high-speed rail reducer gear comprises the following steps:
1. and (3) drilling a central hole on the end face of the small end: starting the machine tool, keeping idle running for 10 minutes, operating the machine tool after the machine tool is stable, selecting a machining lathe tool and a C12 center drill, and correcting the diameter of a small-end shaft to ensure that the diameter jump is less than or equal to 0.1; the end face of the small end is turned to ensure that the set distance from the large end face is met and the end face runout is less than or equal to 0.08;
2. and (3) drilling a central hole on the end face of the large end: starting the machine tool, keeping idle running for 10 minutes, operating the machine tool after the machine tool is stable, selecting a machining lathe tool, adjusting a central support, and ensuring that the radial jump of the shaft diameter I is less than or equal to 0.1; turning the end face of a large end to ensure the total length, drilling a C30 center hole on the large end face, and using a 60-degree chamfer drill to grind the center hole to ensure that the contact area of the center hole and a standard 60-degree center is not less than 90%;
3. finely turning a rod part: starting the machine tool, keeping idle running for 10 minutes, operating the machine tool after the machine tool is stable, selecting a machining lathe tool, namely a YBC251P10-P30 hard alloy blade, fixing the small-end shaft neck by using a chicken heart chuck, and finely turning the excircle, the large end face step, the back cone and the tool withdrawal groove of the rod part;
4. finish turning of a face cone: starting the machine tool, keeping idle running for 10 minutes, operating the machine tool after the machine tool is stable, and selecting a machining lathe cutter, namely a YBC251P10-P30 hard alloy blade, and finely turning a face cone, a small end shaft diameter, a small end face, a clamp spring groove and a tool withdrawal groove;
5. and (3) rough grinding of the shaft neck: starting the machine tool, keeping idle running for 10 minutes, operating the machine tool after the machine tool is stable, selecting a P600X 75X 305 brown corundum grinding wheel, grinding the front shaft diameter end face and the excircle, grinding the rear shaft diameter end face and the excircle, and enabling the end face and the grinding excircle to jump less than or equal to 0.02;
6. tapping: starting the machine tool, keeping idle running for 10 minutes, operating the machine tool after the machine tool is stable, correcting the tool, ensuring that the coaxiality of the center of the bottom tip of the tool and the center of the top V-shaped block is less than or equal to 0.03, and tapping at the large end and the small end respectively;
7. gear milling: starting the machine tool, keeping idle running for 10 minutes, and enabling the machine tool to be operable after being stable; correcting the gear cutting tool, wherein the end jump and the diameter jump are required to be less than 0.015mm, checking the theoretical mounting distance position of a machine tool and a standard small wheel used for checking, determining the parking position of the machine tool, confirming the position when the tool is set every time, controlling the total allowance of rough grinding bilateral sides to be 0.8-0.9mm, controlling the depth of rough grinding full teeth to be less than the depth of rough cutting full teeth to be 0.05-0.1mm, checking the use condition of the tool at any time, mainly checking the use condition and the cooling condition of the rough cutting tool, roughly milling convex and concave surfaces, and removing burrs of the flash at the gear ends;
8. rough gear grinding: starting the machine tool, keeping idle running for 10 minutes, and enabling the machine tool to be operable after being stable; checking the gear grinding tool by using a mandrel, ensuring that end run-out and diameter run-out are less than 0.01mm, adjusting card input gear grinding parameters according to theory, installing a corresponding grinding wheel, setting the rotating speed of the grinding wheel to 1600r/min, grinding the convex surface and the concave surface of the small wheel respectively, determining the final contact area position under the theoretical installation position, and meeting the requirements of gear grinding.
9. Grinding the crest of the tooth: a workpiece is placed into a positioning sleeve, a grinding head with the diameter phi of 50 is selected, the outer circle of the grinding head is ground according to the tooth-shaped spiral angle, the end face of the grinding head is always perpendicular to the spiral tooth groove, the edge trimming of the tooth tops at two ends of the gear tooth is ensured to be consistent, and chamfers are arranged on two sides of the tooth top of the gear tooth of the driving bevel gear at an angle of 0.7-1.0 multiplied by 35 degrees;
10. grinding edges and chamfering at the tooth ends: adjusting the screwing distance of a pull rod of the angle grinder to ensure the set tension; installing a cutter, adjusting a chamfering arm, inclining a grinding wheel according to the tooth form inclination angle to enable a grinding edge to be parallel to the edge of a tooth end, chamfering the large end and the small end of the tooth of the driving bevel gear by 1.8 multiplied by 45 degrees respectively, and chamfering the depth to the tooth root;
11. cleaning before heating: starting the machine tool, keeping the idle running for 10 minutes, operating the machine tool after the machine tool is stable, placing the product at a conveying belt feeding port, controlling the speed of the conveying belt to be 29-32Hz, and controlling the cleaning pressure to be 0.45-0.55MPa, so as to ensure that oil stains and red lead powder on the gear at the discharging port are cleaned;
12. and (3) heat treatment: a heat treatment step according to example one;
13. and carrying out fine grinding on the shaft neck, grinding the gear, matching and grinding the taper, carrying out magnetic powder inspection, packaging and warehousing.
The precision of the driven bevel gear processed by the first embodiment and the precision of the drive bevel gear processed by the third embodiment meet the 7-grade precision requirement of GB11365-89 & lt & gt precision of bevel gears and hypoid gears, and the specific test results are as follows:
gear precision testing result:
gear roughness test results:
the drive bevel gear and the driven bevel gear of the invention: noise is 1450 rpm, Db is 76-76.5; the length of the contact mark tooth is 57-60%, and the height of the contact mark tooth is 65-68%.
As can be seen from the figures 8-13, the heat treatment process and the processing method of the invention ensure high-precision meshing transmission of the gear, improve the strength of the gear, have uniform stress in a bearing state, ensure that a contact area during meshing of the tooth surface reaches an ideal state and is in an inner diagonal direction, ensure that the contact points of the tooth surface are uniformly distributed, and prevent tooth top disengagement and poor contact to cause tooth striking when the bearing torque is 30000 N.m, thereby reducing the abrasion of the gear, eliminating the interference phenomenon of a non-contact surface in the gear transmission process, improving the shape and the position of a contact mark, effectively ensuring that the gear plays a better role in the transmission process, and solving the early failure of the high-speed reducer gear under the action of strong torque.
Wherein, in FIG. 8, the Gear Convex Gear is Convex; gear Concave surface; mean tooth length; the Toe small end; the Heel big end; root roots; topland tooth tip; transmission Error; micro-Radians micro Radians; the Pitch Position engagement Position.
In FIG. 10, LOAD SHARING RATIO of LOAD SHARING RAW-RAW vs. SMOOTHED DATA LOAD SHARING is greater than RAW DATA versus SMOOTHED DATA; TOTAL CONTACT RATIO of TOTAL CONTACT; a PITCH POSITION engagement POSITION.
In FIG. 11, ORTHOGONAL SHEAR STRESS vs DEPTH normal SHEAR stress and DEPTH, MAXIMUM DEPTH OF ORTHOGONAL SHEAR normal SHEAR MAXIMUM DEPTH, ORTHOGONAL SHEAR STRESS normal SHEAR stress.
In FIG. 12, SUBSURFACE SHEAR STRESS vs DEPTH skin shear stress versus DEPTH; MAXIMUM DEPTH OF skin SHEAR stress OF lateral SHEAR; SHEAR STRESS shear stress.
In FIG. 13, the GEAR contact stress surface contact stress; MAX PITCH LINE STRESS maximum pitch line stress.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (7)
1. A processing method of a high-speed rail speed reducer gear is characterized in that the gear is divided into a driving bevel gear and a driven bevel gear, and the processing method is characterized in that: before the driven bevel gear is subjected to a heat treatment process, the working procedures of inner holes of a traveling crane, face turning cone, gear cutting, rough gear grinding, hot front inspection, chamfering of a gear end/grinding of a gear top and hot front cleaning are required to be carried out, and after the heat treatment process is finished, the driven bevel gear is subjected to hot rear hard turning, gear grinding, pairing, hot rear cleaning, magnetic powder inspection and packaging warehousing;
the heat treatment process adopts a double-row continuous furnace to carry out carburization treatment, and the period is double-row 80
5min, comprising the following steps:
(1) pretreatment: the gear is sent to a pre-treatment furnace, the temperature of which is 460
The material level of the material rack of the pretreatment furnace is 3 at 10 ℃;
(2) heating a first zone: the gear enters a first heating area, and the temperature of the first heating area is 870 DEG
Methanol flow rate of 20 at 5 deg.C
5ml/min, wherein the material level of the material rack in the first heating area is 10;
(3) initial carburization carbon region: the gear enters a carburizing two-stage zone, and the temperature of the carburizing two-stage zone is 890
Carbon potential of 0.9 at 5 DEG C
0.05% and a methanol flow of 25
5ml/min, acetone flow 20
3ml/min, and 6 material levels of the material racks in the carbon infiltration and carbonization area;
(4) a strong carburization three-zone: the gear enters a three-zone carburizing region, and the temperature of the three-zone carburizing region is 910
Carbon potential of 1.05 ℃ at 5 DEG C
0.05% and a methanol flow of 30
5ml/min, acetone flow 20
3ml/min, and the material level of the material rack in the carbon infiltration and carbonization area is 10;
(5) four zones of diffusion carburization: the gear enters a four-carburizing zone, and the temperature of the four-carburizing zone is 890
At 5 ℃ and a carbon potential of 0.8
0.05% and a methanol flow of 25
5ml/min, acetone flow of 0-10ml/min, and air flow of 0-1m3The material level of the material rack in the four carburizing zones is 10;
(6) a quenching carburization five area: the gear enters a five carburization zone, and the temperature of the five carburization zones is 790
Carbon potential of 0.75 at 5 DEG C
0.05% and a methanol flow of 20
5ml/min, acetone flow of 0-10ml/min, and air flow of 0-1m3The material level of the material rack in the five carburization areas is 6;
gear cutting, rough grinding tooth and gear grinding process all adopt elastic fixture to fix driven bevel gear, elastic fixture includes body and connecting axle, the coaxial slip of tip of connecting axle passes the body, and be provided with the connecting seat, the coaxial cover in the outside of connecting seat is equipped with collet chuck and position sleeve, the position sleeve is located collet chuck and keeps away from one side of body, the one end of body links to each other with the lathe, the other end is the toper cover, and arrange in between connecting seat and the collet chuck, collet chuck's inside wall is for the bell face with toper cover pressfitting complex, collet chuck includes hollow annular chuck, be provided with a plurality of flutings along the axial on annular chuck's the lateral wall.
2. The method for processing the gear of the high-speed rail reducer according to claim 1, wherein: after the carburization in the step (6) is finished, the driven bevel gear is quenched and tempered, and the method comprises the following steps:
1) quenching: the medium is Y15-II rapid quenching oil with the temperature of 80 DEG C
Quenching time is 30min at 10 ℃;
2) cleaning: after quenching, the gear enters an alkaline water tank, and the temperature of the alkaline water tank is 80 DEG
Soaking and washing at 10 deg.C for 10min, and introducing into clear water tank at 80 deg.C
Spraying at 10 deg.C for 8 min;
3) tempering: temperature 180 deg.C
Tempering for 12 hours at 5 ℃ for 2 times;
4) shot blasting: and performing shot blasting treatment after tempering.
3. The method for processing the gear of the high-speed rail reducer according to claim 1, wherein: and the tooth end chamfer/tooth top grinding edge: chamfering the large end and the small end of the gear tooth of the driven bevel gear by 2 multiplied by 45 degrees respectively by using an angle grinder, wherein the chamfering depth is up to the tooth root, and removing burrs at the tooth end; and (3) using an angle grinder to grind and chamfer the tooth tops of the concave-convex surfaces of the gear teeth of the driven bevel gear by 1.1-1.5 multiplied by 45 degrees along the direction of the tooth-wise spiral line, and ensuring that the chamfer line is smooth and has no distortion.
4. The method for processing the gear of the high-speed rail reducer according to claim 1, wherein: the outer side wall of the conical sleeve is symmetrically provided with first guide posts, and the spring chuck is provided with first guide grooves matched with the first guide posts; the outer side of the connecting shaft is slidably sleeved with a coaxial guide sleeve, a second guide post is arranged on the guide sleeve, a second guide groove matched with the second guide post is formed in the connecting shaft, a third guide post is arranged on the body, and a third guide groove matched with the third guide post is formed in the connecting seat.
5. The method for processing the gear of the high-speed rail reducer according to claim 1, wherein: before the heat treatment process, the driving bevel gear is characterized in that: the method comprises the steps of firstly driving a small end face to punch a central hole, driving a large end face to punch a central hole, finely turning a rod part, finely turning a face cone, roughly grinding a shaft neck, tapping, milling teeth, roughly grinding teeth, grinding tooth tops, grinding tooth edges and chamfering the tooth ends, and cleaning before heating, wherein after a heat treatment process is completed on a driving bevel gear, the shaft neck is finely ground, the teeth are ground, the taper is matched, magnetic powder inspection is performed, and the driving bevel gear is packaged and put in storage.
6. The method for processing the gear of the high-speed rail reducer according to claim 5, wherein: and (3) grinding the tooth crest: the two sides of the tooth crest of the driving bevel gear are chamfered by 0.7-1.0 multiplied by 35 degrees.
7. The method of processing a high-speed reduction gear according to claim 5 or 6, characterized in that: and (3) grinding and chamfering the tooth end: adjusting the screwing distance of a pull rod of the angle grinder to ensure the set tension; and installing a cutter, adjusting a chamfering arm, inclining the grinding wheel according to the tooth form inclination angle to enable the grinding edge to be parallel to the edge of the tooth end, chamfering the large end and the small end of the tooth of the driving bevel gear by 1.8 multiplied by 45 degrees respectively, and chamfering to the tooth root.
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| JP2002327237A (en) * | 2001-04-27 | 2002-11-15 | Nippon Steel Corp | Gear with long dedendum life and contact fatigue life, and manufacturing method therefor |
| CN103834953A (en) * | 2014-02-24 | 2014-06-04 | 浙江浦江齿轮有限公司 | Carburizing and quenching process of internal spline gear |
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| US5806373A (en) * | 1995-05-05 | 1998-09-15 | Dana Corporation | Gear and method for manufacturing same |
| CN102373400B (en) * | 2011-10-25 | 2013-08-07 | 哈尔滨汇隆汽车箱桥有限公司 | Heat treatment method of spiral bevel gear of cargo truck on double-row rare earth carburization equipment |
| CN202715907U (en) * | 2012-05-22 | 2013-02-06 | 綦江重配齿轮有限公司 | Clamp for finish milling axle driving double bevel gear |
| US9597743B2 (en) * | 2014-01-17 | 2017-03-21 | Sikorsky Aircraft Corporation | Machine for machining gear teeth and gear teeth machining method |
| FR3016819B1 (en) * | 2014-01-24 | 2016-02-12 | Snecma | INERTIAL FRICTION WELDING PROCESS OF TWO PARTS OF A TURBOMACHINE ROTATING SUBASSEMBLY |
| CN206530671U (en) * | 2016-12-26 | 2017-09-29 | 重庆凯瑞车辆传动制造有限公司 | Rail traffic gear box uses single track bevel gear |
| DE102017003648A1 (en) * | 2017-04-13 | 2018-10-18 | Liebherr-Verzahntechnik Gmbh | Method for tooth machining a workpiece |
| CN208408768U (en) * | 2018-05-11 | 2019-01-22 | 南阳浩帆车辆部件有限公司 | A kind of drive bevel gear tooth Profile Machining bipyramid positioning tool |
| CN108500403B (en) * | 2018-06-07 | 2024-07-02 | 北京北方车辆集团有限公司 | Spiral bevel gear grinding clamp |
| CN209598348U (en) * | 2019-03-13 | 2019-11-08 | 定州市新华机械制造有限公司 | Gear grinding machines workpiece positioning clamp |
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| JP2002327237A (en) * | 2001-04-27 | 2002-11-15 | Nippon Steel Corp | Gear with long dedendum life and contact fatigue life, and manufacturing method therefor |
| CN103834953A (en) * | 2014-02-24 | 2014-06-04 | 浙江浦江齿轮有限公司 | Carburizing and quenching process of internal spline gear |
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Denomination of invention: Heat treatment process and processing method of a high-speed railway reducer gear Effective date of registration: 20230713 Granted publication date: 20220510 Pledgee: Henan Xichuan Rural Commercial Bank Co.,Ltd. Pledgor: NANYANG HAOFAN AUTO PART CO.,LTD. Registration number: Y2023980048217 |
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