CN112917111B - Method for machining split crankshaft gear for diesel engine - Google Patents
Method for machining split crankshaft gear for diesel engine Download PDFInfo
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- CN112917111B CN112917111B CN202110245472.3A CN202110245472A CN112917111B CN 112917111 B CN112917111 B CN 112917111B CN 202110245472 A CN202110245472 A CN 202110245472A CN 112917111 B CN112917111 B CN 112917111B
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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- 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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Abstract
A method for processing a split crankshaft gear for a diesel engine belongs to the technical field of split gear processing. The method comprises the following steps: step 1) cutting the machined workpiece along the diameter of the workpiece to cut the workpiece into two semicircular workpieces; step 2) hobbing the two semicircular workpieces respectively, wherein the actual central position of the workpiece during hobbing deviates to the inner side of the semicircular workpiece relative to a cutting plane; step 3) carrying out carburizing quenching and tempering treatment on the semi-circular workpiece after gear hobbing; step 4), drilling connecting holes (2) in the two semicircular workpieces, and combining the two semicircular workpieces; step 5) machining the combined workpieces, and grinding the teeth of the workpieces; and 6) splitting the workpiece into two semicircular workpieces, removing burrs, and combining the workpieces to form the split gear (1). In the invention, machining allowance is left at the cutting surface during gear hobbing, so that the carburized layer of the tooth surface is ensured to be uniform, the performance of the gear is greatly improved, and the service life is greatly prolonged.
Description
Technical Field
A method for processing a split crankshaft gear for a diesel engine belongs to the technical field of split gear processing.
Background
A crankshaft gear of a marine diesel engine is designed into two halves for being easily assembled on a crankshaft, and is positioned through a pin and a pin hole of a joint surface and connected through a bolt; the gear material is low-carbon alloy steel, the heat treatment mode is carburizing and quenching, the surface hardness requirement is HRC 58-62, and the precision grade DIN 6 of the carburized layer depth is 1.0-1.4 mm; the gear design structure is compact, the wall is thin, the gear is provided with an end surface hole, a combination surface hole and an outer circular hole, and the heat treatment and machining processes are easy to deform, so that the size tolerance and the precision grade cannot be achieved. And the carburized layer of the tooth surface is not uniform according to the conventional method, the conditions of exceeding the lower limit and the upper limit occur, the performance and the service life of the gear are influenced, and the hidden quality danger is caused.
The conventional machining method of the crankshaft gear comprises the following two methods:
(1) After semi-finish turning, sequentially performing gear hobbing, heat treatment, linear cutting (molybdenum wire is 0.18 mm), drilling and milling a junction surface (each surface is processed by about 0.3mm due to the deformation of a semi-circle after cutting), assembling, finish turning, grinding a top circle of a tooth, grinding the tooth, drilling and milling an end face and drilling and tapping an outer circle;
(2) After semi-finish turning, gear hobbing, linear cutting (molybdenum wire is 0.18 mm), heat treatment, drilling and milling of a joint surface (the heat treatment is more in deformation and each surface is processed by about 0.85 mm), assembling, finish turning, gear grinding of a top circle, gear grinding, end face drilling and milling and outer circle drilling and tapping are sequentially carried out.
The two methods have the following technical problems:
firstly, drilling and milling a joint surface, finish turning and gear grinding are finished at one time, and due to the fact that various holes are machined and even the end surface holes are machined asymmetrically, the machined gear is oval due to the influence of internal stress changes, deformation is severe, and the gear grinding precision grade is seriously influenced.
Secondly, materials are removed by processing a joint surface, so that the gear is elliptical after combination, in a final gear grinding process, the allowance distribution of a tooth surface is influenced by the ellipse, the grinding allowance at the joint surface is the largest, an effective carburized layer after gear grinding is shallow and is easily lower than 1.0mm, in a direction perpendicular to the joint surface, the grinding allowance is small, and the effective carburized layer after gear grinding is deep and is easily larger than 1.4mm; in particular, the effective carburized layer is more different in the second method.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the defects in the prior art are overcome, and the split crankshaft gear machining method for the diesel engine can ensure that the carburized layer is uniform, the performance of the split gear is ensured, and the service life of the split gear is prolonged.
The technical scheme adopted by the invention for solving the technical problem is as follows: the processing method of the split crankshaft gear for the diesel engine is characterized by comprising the following steps of: the method comprises the following steps:
step 1) cutting the machined workpiece along the diameter of the workpiece to cut the workpiece into two semicircular workpieces;
step 2) hobbing the two semicircular workpieces respectively, wherein the actual central position during hobbing deviates to the inner side of the semicircular workpieces relative to the cutting surface, and a machining allowance is reserved on the cutting surface of the semicircular workpieces;
step 3) carrying out carburizing quenching and tempering treatment on the semi-circular workpiece after hobbing;
step 4) drilling connecting holes in the two semicircular workpieces, and combining the two semicircular workpieces;
step 5) machining the combined workpieces, and grinding the teeth of the workpieces;
and 6) splitting the workpiece into two semicircular workpieces, removing burrs, and combining the workpieces to form the split gear.
Preferably, the machining in step 1) includes rough turning and semi-finish turning, and the workpiece is subjected to normalizing treatment after the rough turning.
Preferably, the workpiece in the step 1) is cut by using wire cutting, and the diameter of a molybdenum wire used for wire cutting is 0.18mm. The diameter of the molybdenum wire adopted by the wire cutting is 0.18mm, so that the cutting seam can be ensured to be small, and the loss of the workpiece during cutting is ensured to be small.
Preferably, the semicircular workpiece in the step 2) is clamped on a hobbing die for hobbing.
Preferably, the hobbing die comprises a positioning disc, a pressing disc and a pressing screw rod, wherein one side of the top of the positioning disc is concave inwards to form a clamping part for accommodating a semicircular workpiece, the pressing disc is arranged on the upper side of the positioning disc, the upper end of the pressing screw rod penetrates through the pressing disc and is connected with a pressing nut, the pressing disc is pressed on the positioning disc, and the pressing part for pressing the semicircular workpiece is arranged on the pressing disc. The position of the semicircular workpiece can be conveniently adjusted through the positioning disc, so that enough machining allowance is reserved on one side of a cutting surface of the semicircular workpiece, and after the two semicircular workpieces are spliced after gear hobbing, gear teeth of the two semicircular workpieces can be spliced into a complete gear.
Preferably, both sides of the pressing disc are in threaded connection with a plurality of vertical pressing bolts to form the pressing part. The semi-circular workpiece is compressed through the compressing part, and the compressing part is in point contact with the semi-circular workpiece, so that the semi-circular workpiece is reliably compressed.
Preferably, after the cut surface of the semicircular workpiece in the step 3) is coated with the impermeable coating, the gear tooth part of the semicircular workpiece is carburized. The anti-seepage coating is coated on the cutting surface of the semicircular workpiece, so that a carburized layer can be prevented from being formed on the cutting surface of the semicircular workpiece, and the cutting surface can be conveniently ground and drilled.
Preferably, the semicircular workpieces in the step 4) are combined after being ground. The semi-circular workpieces are assembled after being ground, and the gear teeth of the assembled semi-circular workpieces can be spliced into a complete gear.
Preferably, the two semicircular workpieces in the step 4) are connected through a connecting bolt, and the two semicircular workpieces in the step 6) are combined by using a new connecting bolt. And (3) combining the two semicircular workpieces in the step 6) by adopting a new connecting bolt, so that the metal fatigue of the connecting bolt is avoided.
Compared with the prior art, the invention has the following beneficial effects:
the processing method of the split crankshaft gear for the diesel engine directly cuts the workpiece into the two semicircular workpieces through the middle of the workpiece, hobbing is respectively carried out on the two semicircular workpieces, in addition, a processing allowance is reserved at the cutting surface during hobbing, the subsequent processing of a processing surface is convenient, the carburization quenching and tempering treatment are carried out on the semicircular workpieces after hobbing, the thickness of a carburization layer of a tooth surface cannot be influenced when the processing surface is ground, in addition, the grinding amount of the tooth surface does not need to be very large, the two semicircular workpieces after combination can be ensured to be spliced into a complete tooth shape, the uniformity of the carburization layer of the tooth surface is ensured, the good wear resistance of the gear is further ensured, the performance of the gear is greatly improved, the service life is greatly prolonged, and the potential safety hazard of the gear is eliminated.
Drawings
Fig. 1 is a top view of a split gear.
FIG. 2 is a front cross-sectional view of a split gear connection.
Fig. 3 is a front cross-sectional view of the hobbing die.
In the figure: 1. the split gear comprises a split gear 2, a connecting hole 3, a counter bore 4, a base 5, a compression screw 6, a positioning disc 601, a clamping part 7, a compression nut 8, a compression disc 9, a compression bolt 10, an upper cushion plate 11 and a lower cushion plate.
Detailed Description
FIGS. 1 to 3 show preferred embodiments of the present invention, and the present invention will be further described with reference to FIGS. 1 to 3.
As shown in FIGS. 1 to 2: a method for processing a split crankshaft gear for a diesel engine comprises the following steps:
and 1) cutting the machined workpiece along the diameter of the workpiece, and cutting the workpiece into two semicircular workpieces.
The workpiece is produced in a forging mode, machining is carried out on the forged workpiece, in the embodiment, rough turning and semi-finish turning are carried out on the forged workpiece in sequence, normalizing treatment needs to be carried out on the workpiece after rough turning, and then semi-finish turning is carried out.
And after the semi-finish turning is finished, cutting the workpiece along the diameter of the workpiece to cut the workpiece into two semicircular workpieces. In this example, the workpiece was cut by wire cutting using a molybdenum wire having a diameter of 0.18mm.
And 2) hobbing the two semicircular workpieces respectively, wherein the actual central position during hobbing deviates towards the inner side of the semicircular workpiece relative to the cutting surface, and a machining allowance is reserved on the cutting surface of the semicircular workpiece.
The two semicircular workpieces are respectively clamped on a gear hobbing die, the gear hobbing die is installed on a gear hobbing machine, and gear hobbing is respectively carried out on the two semicircular workpieces through the gear hobbing machine. When the semicircular workpiece is clamped and hobbed, the actual central position of the hobbed is deviated to the inner side of the semicircular workpiece relative to the cutting surface, and in the embodiment, the reserved machining allowance on the cutting surface of the semicircular workpiece is 1mm.
And 3) carrying out carburizing quenching and tempering treatment on the semi-circular workpiece after hobbing.
After gear hobbing, coating an anti-seepage coating on a joint surface, namely the cutting surface, performing carburization treatment on the two semicircular workpieces, and performing heat treatment on the two semicircular workpieces. The depth of a tooth surface hardening layer of the semicircular workpiece is 1.0-1.4 mm, the allowance single side is 0.3mm, and the surface hardness of the tooth surface is 58-62HRC.
And 4) drilling connecting holes 2 in the two semicircular workpieces, and combining the two semicircular workpieces.
Grinding the end faces of the two semicircular workpieces, drilling connecting holes 2 on a joint surface, wherein the connecting holes 2 are formed in one side of the diameter of each semicircular workpiece, the connecting holes 2 are perpendicular to the joint surface, two connecting holes 2 are symmetrically formed in two sides of each semicircular workpiece, and the corresponding connecting holes 2 in the two semicircular workpieces can be spliced into a complete through hole. The connecting hole 2 of any one semicircular workpiece is provided with a counter bore 3, the counter bore 3 is arranged at one end of the connecting hole 2 far away from the combining surface, and the diameter of the counter bore 3 is larger than that of the connecting hole 2.
And milling the joint surfaces of the two semicircular workpieces after the drilling is finished, wherein the milling amount is 0.85mm. And grinding the joint surface after milling is finished, wherein the grinding amount is 0.1mm. And then the two semicircular workpieces are combined at one time through the connecting bolt penetrating through the connecting hole 2.
And 5) machining the combined workpieces, and grinding the teeth of the workpieces.
The workpiece is machined after the combination, in the embodiment, the machining sequentially comprises primary finish turning and primary gear grinding, wherein the turning allowance after the primary finish turning is 0.3mm, and the grinding allowance after the primary gear grinding is 0.3mm. And after the grinding is finished, aligning the tooth sockets, drilling end face holes and round holes, and after the drilling is finished, splitting the workpiece once and removing burrs. And then, carrying out secondary grinding on the combined surface, wherein the grinding amount is 0.05mm, and carrying out secondary assembly on the workpiece after the grinding is finished.
And 6) splitting the workpiece into two semicircular workpieces, removing burrs, and combining the workpieces to form the split gear 1.
After the secondary combination, the workpiece is subjected to secondary finish turning, gear grinding and tooth top rounding and secondary gear grinding in sequence, and then the workpiece is subjected to secondary splitting and burr removal. After the burrs are removed, a new connecting bolt is replaced, the two semicircular workpieces are combined for three times through the new connecting bolt, metal fatigue of the old connecting bolt is avoided, and the split gear 1 is formed.
As shown in fig. 3: the gear hobbing die comprises a base 4, a positioning disc 6, a pressing disc 8 and a pressing screw rod 5. The bottom of base 4 is installed on the gear hobbing machine and is continuous with the gear hobbing machine, and positioning disk 6 is installed at the top of base 4, and positioning disk 6 is vertical to be set up, and the left side indent of positioning disk 6 forms semicircular clamping part 601. The pressing plate 8 is coaxially arranged on the upper side of the positioning plate 6, and the diameter of the pressing plate 8 is the same as that of the positioning plate 6 or slightly larger than that of the positioning plate 6 and smaller than that of the workpiece. The hold-down screw 5 is vertically arranged, and the diameter of the lower end of the hold-down screw 5 is larger than that of the middle part, so that a blocking part is formed. The upper end of the compression screw rod 5 sequentially penetrates through the upper part of the base 4, the positioning disc 6 and the compression disc 8 from bottom to top and then extends upwards, the upper end of the compression screw rod 5 is in threaded connection with the compression nut 7, the compression disc 8 can be compressed through the compression nut 7, and then the semicircular workpiece placed on the clamping part 601 is clamped tightly. Be provided with a plurality of clamp bolts 9 on the pressure disk 8, the vertical setting of clamp bolt 9, clamp bolt 9 and pressure disk 8 threaded connection to form a plurality of portions that compress tightly at the downside that compresses tightly disk 8. The clamp bolt 9 encircles 8 interval equipartitions of clamp plate, and clamp bolt 9 can enough compress tightly the work piece, can guarantee the atress balance of 8 both sides of clamp plate again through the right side that compresses tightly positioning disk 6, avoids clamp plate 8 to take place to warp.
The lower backing plate 11 is arranged on the lower side of the semicircular workpiece, and the upper backing plate 10 is arranged on the upper side of the semicircular workpiece, so that the position of the semicircular workpiece can be ensured, and the damage to the end face of the semicircular workpiece can be avoided. The diameter of the semicircular workpiece is larger than that of the positioning disc 6, so that the outer edge of the semicircular workpiece can be smoothly subjected to gear hobbing, and the actual central position of the semicircular workpiece during gear hobbing is conveniently adjusted due to the clamping part 601.
The foregoing is directed to preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. However, any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention will still fall within the protection scope of the technical solution of the present invention.
Claims (7)
1. A processing method of a split crankshaft gear for a diesel engine is characterized by comprising the following steps: the method comprises the following steps:
step 1) cutting the machined workpiece along the diameter of the workpiece to cut the workpiece into two semicircular workpieces;
step 2) hobbing the two semicircular workpieces respectively, wherein the actual central position of the workpiece during hobbing deviates to the inner side of the semicircular workpiece relative to the cutting surface, and a machining allowance is reserved on the cutting surface of the semicircular workpiece;
step 3) carrying out carburizing quenching and tempering treatment on the semi-circular workpiece after gear hobbing;
step 4), drilling connecting holes (2) in the two semicircular workpieces, and combining the two semicircular workpieces;
step 5) machining the combined workpieces, and grinding the teeth of the workpieces;
step 6) splitting the workpiece into two semicircular workpieces, removing burrs, and then combining the workpieces to form the split gear (1);
clamping the semicircular workpiece on a hobbing die for hobbing in the step 2); the hobbing die comprises a positioning disc (6), a pressing disc (8) and a pressing screw (5), wherein one side of the top of the positioning disc (6) is concave inwards to form a clamping part (601) for accommodating a semicircular workpiece, the pressing disc (8) is arranged on the upper side of the positioning disc (6), the upper end of the pressing screw (5) penetrates through the pressing disc (8) and then is connected with a pressing nut (7), the pressing disc (8) is pressed on the positioning disc (6), and a pressing part for pressing the semicircular workpiece is arranged on the pressing disc (8).
2. The method of processing a split crankshaft gear for a diesel engine according to claim 1, wherein: the machining in the step 1) comprises rough turning and semi-finish turning, and the workpiece is subjected to normalizing treatment after rough turning.
3. The method of processing a split crankshaft gear for a diesel engine according to claim 1, wherein: cutting the workpiece in the step 1) by adopting wire cutting, wherein the diameter of a molybdenum wire adopted in the wire cutting is 0.18mm.
4. The method of processing a split crankshaft gear for a diesel engine according to claim 1, wherein: both sides of the pressing disc (8) are in threaded connection with a plurality of vertical pressing bolts (9) to form the pressing part.
5. The method of processing a split crankshaft gear for a diesel engine according to claim 1, wherein: and (3) after the cut surface of the semicircular workpiece is coated with the impermeable coating in the step 3), performing carburization treatment on the gear teeth of the semicircular workpiece.
6. The method of processing a split crankshaft gear for a diesel engine according to claim 1, wherein: grinding the semicircular workpieces in the step 4), and then combining the semicircular workpieces.
7. The method of processing a split crankshaft gear for a diesel engine according to claim 1, wherein: the two semicircular workpieces in the step 4) are connected through connecting bolts, and the two semicircular workpieces in the step 6) are combined by adopting new connecting bolts.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110245472.3A CN112917111B (en) | 2021-03-05 | 2021-03-05 | Method for machining split crankshaft gear for diesel engine |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110245472.3A CN112917111B (en) | 2021-03-05 | 2021-03-05 | Method for machining split crankshaft gear for diesel engine |
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| CN112917111A CN112917111A (en) | 2021-06-08 |
| CN112917111B true CN112917111B (en) | 2022-10-14 |
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Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3034761C2 (en) * | 1980-09-15 | 1984-06-20 | Kraftwerk Union AG, 4330 Mülheim | Process for the production and assembly of a split externally toothed spur gear on a shaft |
| CN101900196B (en) * | 2009-05-27 | 2012-03-07 | 华新水泥股份有限公司 | Large welded gear and process method for manufacturing same |
| CN101898297B (en) * | 2010-04-15 | 2011-09-07 | 南通振华重型装备制造有限公司 | Manufacturing method of large-size welding type carburizing and quenching gear |
| CN102152087B (en) * | 2011-01-30 | 2013-01-02 | 吴敬 | Technique for processing 9,000-millimeter-diameter dissection gear of rotary kiln, and special hobbing machine |
| CN104668919B (en) * | 2015-01-12 | 2017-02-22 | 广东华力通变压器有限公司 | Process for machining special winding gears for transformers with roll iron cores |
| CN109826936A (en) * | 2017-11-22 | 2019-05-31 | 四川名齿齿轮制造股份有限公司 | A kind of Combined herringbone gear structure |
| CN207723624U (en) * | 2017-12-21 | 2018-08-14 | 株洲高精齿轮有限公司 | The laborsaving pressing device of the more bolts of the long torque of gear-hobbing clamp |
| CN209503149U (en) * | 2018-12-17 | 2019-10-18 | 河北宣化工程机械股份有限公司 | A kind of gear teeth clamp |
| CN110039270B (en) * | 2019-04-11 | 2021-02-26 | 苏州科峰英诺传动技术有限公司 | Method for manufacturing combined duplicate gear |
| CN110421326A (en) * | 2019-07-23 | 2019-11-08 | 重庆申耀机械工业有限责任公司 | A kind of processing technology of nutating gear |
| CN110961876A (en) * | 2020-01-03 | 2020-04-07 | 重庆齿轮箱有限责任公司 | Machining method of two half type gear rings |
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