CN113063690B - Method for calculating process parameters of cylindrical gear strengthening shot blasting - Google Patents
Method for calculating process parameters of cylindrical gear strengthening shot blasting Download PDFInfo
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Abstract
The invention discloses a method for calculating the technological parameters of cylindrical gear strengthening shot blasting, which belongs to the field of metal surface treatment and comprises the following steps: step S1, determining the preset shot blasting intensity and the preset coverage rate; s2, selecting the diameter of the spray gun to obtain the corresponding relation between the Z-axis moving speed and the rotating speed of the turntable; step S3, determining air pressure, shot blasting flow and spray gun distance through a process test; step S4, calculating a strengthening rate value through a simulation test; s5, obtaining the rotating speed of the turntable, which is the preset peening intensity and the coverage rate of any rotating diameter metal part of which reaches 100%, by the calculation formula of the rotating speed of the turntable, and obtaining the numerical value of the Z-axis moving speed by the calculation formula of the Z-axis moving speed; step S6, determining the shot blasting times according to the requirement of the preset coverage rate; step S7, calculating the numerical value of the shot blasting time by the calculation formula of the shot blasting time; the invention solves the problems that the prior art can not completely eliminate the strong spray blind area, and has long time and unstable quality.
Description
Technical Field
The invention belongs to the technical field of metal surface treatment, and particularly relates to a method for calculating parameters of a cylindrical gear strengthening shot blasting process.
Background
The strengthening shot blasting process is characterized in that shot flow moving at high speed is used for impacting the surface of a metal part to generate a plastic circulating strain layer, so that a residual compressive stress field is introduced into the surface layer of the metal part, the fatigue fracture resistance and the stress corrosion fracture resistance of the metal part are improved, and the performance of the part is improved.
At present, in consideration of reliability, strengthening shot blasting treatment is added after the gear is carburized and quenched, the strength of a metal part after strengthening shot blasting is improved, the strengthening shot blasting treatment does not participate in design and calculation and only plays a role of adding flowers to the metal part, so that the strengthening shot blasting treatment does not give enough attention to the strengthening shot blasting treatment in the gear manufacturing industry, research data of the strengthening shot blasting treatment are less, and the standards including relevant control process parameters are not comprehensive; because the process control parameters related to the shot peening are more, and some parameters are mutually related, if the parameters are not well matched, the quality of the metal part after the shot peening is unstable, the strength or the strengthening coverage rate of each part of the metal part is inconsistent, and even a strong blasting blind area appears, as shown in fig. 2, at this time, the effect of completely eliminating the strong blasting blind area may not be achieved even if the strong blasting time is prolonged, as shown in fig. 3.
Therefore, a calculation method for gear peening process parameters needs to be researched, so that various parameters are in close coordination, a peening blind area is avoided, the consistency of the peening surface quality is improved, and the rationality of process time is set.
Disclosure of Invention
The invention aims to provide a method for calculating the process parameters of the cylindrical gear peening, which solves the problems that the cylindrical gear peening in the prior art can not completely eliminate a strong shot blasting blind area, and the peening has long peening time and unstable quality.
The purpose of the invention can be realized by the following technical scheme:
a method for calculating the parameters of the cylindrical gear strengthening shot blasting process comprises the following steps:
step S1, determining the preset shot blasting intensity A after shot blasting of the metal part according to the design requirement0And a preset coverage rate;
step S2, selecting the diameter d of the spray gun, firstly setting the rotating speed RPM of the turntable, and through a calculation formula of the Z-axis moving speed v:
v＝d×RPM
calculating to obtain a Z-axis moving speed v corresponding to the set rotating speed RPM of the turntable, so that the running tracks of the shot blasting are connected seamlessly, and the aim of eliminating the strong blasting blind area is fulfilled, as shown in FIG. 4;
step S3, determining the numerical values of the air pressure P, the shot blasting flow M and the spray gun distance i through a process test, so as to actually measure the shot blasting intensity ASReach the preset shot blasting intensity A0；
Step S4, selecting a simulation sample with the same material composition and surface hardness as the metal part to be processed, carrying out a shot peening strengthening simulation test under the conditions of the set diameter d of the spray gun, the set air pressure P, the set distance i of the spray gun and the set shot peening flow M, and determining the maximum rotating disc rotating speed RPM when the coverage rate of the simulation sample reaches 100 percentMAXAnd then according to the rotation diameter D of the simulation sampleMAnd part tooth width LMCalculating formula of rotary table rotating speed RPM:
calculating to obtain the preset shot blasting intensity A0The numerical value of the strengthening rate k under the required technological parameters, wherein the strengthening rate k is related to the diameter of the pill, the hardness of the part, the shot blasting strength and the like;
step S5, calculating the preset shot blasting intensity A according to the numerical value of the strengthening rate k calculated in the step S4 and the calculation formula of the rotating speed RPM of the turntable0Under the required technological parameters, the metal part with any rotation diameter D is required to reach the rotating speed RPM of the turntable with the coverage rate of 100%, and then the numerical value of the Z-axis moving speed v is obtained by the calculation formula of the Z-axis moving speed v in the step S2;
step S6, calculating the shot blasting times N according to the preset coverage rate of the metal part divided by 100% so that the actual measurement coverage rate can meet the design requirement without excessive strong blasting;
step S7, obtaining the part tooth width L of the metal part according to the measurement, and calculating the formula according to the shot blasting time t:
and calculating to obtain the numerical value of the shot blasting time t.
Further, the actual turntable speed RPMSTaking the value as an integer part of the theoretical calculation, the actual Z-axis displacement velocity vSThe value is 90-95% of the theoretical calculation value, and the actual shot blasting time tSThe value is taken as a theoretical calculation value, and is accurate to a value one bit behind a decimal point by adopting a further method so as to improve the reliability of the shot blasting strengthening process.
Further, the process test comprises the following steps:
step A1, measuring the tooth width L of the part for clamping the arc height test pieceSAfter the numerical value is obtained, setting numerical values of air pressure P, shot blasting flow M and spray gun distance i;
step a2, shot peening the arc height test piece with the number of shots N of 1, 2, 3, …, N, … and 2N, and measuring the actually measured shot strength a of the arc height test piece after shot peeningSWhen the measured shot strength A is measured for the 2 n-th shot2nWith the n-th actually measured shot peening intensity AnWhen the ratio of the pressure to the flow of the shot blasting to the spray gun is less than 1.1, the n-th shot blasting reaches the shot blasting intensity saturation point under the parameters of the set air pressure P, the set shot blasting flow M and the set spray gun distance i;
step A3, if the actually measured shot peening intensity A of the saturation point of shot peening intensitynPreset shot strength A not meeting design requirements0If the set values of the air pressure P, the shot blasting flow M and the spray gun distance i need to be readjusted, the step A1 and the step A2 are repeated until the actually measured shot blasting intensity A of the saturation point of the shot blasting intensity is reachednPreset shot strength A greater than or equal to design requirement0。
Furthermore, the judgment criterion that the coverage rate reaches 100% is that the actually measured coverage rate is more than or equal to 98%, and the standard specification of HB/Z26-2011 aviation part shot peening strengthening process is met.
Further, the shot blasting times N are integers.
The invention has the beneficial effects that:
the invention determines the preset shot blasting intensity A required by design through the process test of adjusting the air pressure, the shot blasting flow and the spray gun distance0The corresponding partial parameters are subjected to a shot peening simulation test to calculate the material which is the same as that of the metal part to be processed,The surface hardness and the coverage rate under the preset shot blasting intensity just reach the strengthening rate k value of 100 percent, so that the corresponding rotating speed of the turntable and the Z-axis moving speed are calculated, the generation of a strong blasting blind area is effectively avoided, meanwhile, under the strengthening rate k value, the single strong blasting time reaching the coverage rate of 100 percent is shortest, and the strengthening shot blasting efficiency is improved to the maximum extent; adjusting the shot blasting times according to the preset coverage rate required by the design, thereby achieving the purposes of accurately controlling the consistency of the strengthened shot blasting process, improving the stability of the product quality and avoiding the occurrence of over-blasting; and finally, accurately calculating the time of the shot peening strengthening process by combining the part tooth width and shot peening times of the metal part.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a flow chart of a method for calculating parameters of a cylindrical gear peening process according to the present invention;
FIG. 2 is a schematic diagram showing the effect of unreasonable matching between the Z-axis moving speed and the rotating speed of the turntable and one-time forced spraying;
FIG. 3 is a schematic diagram showing the effect of unreasonable matching between the Z-axis moving speed and the rotating speed of the turntable and multiple times of forced spraying;
FIG. 4 is a schematic diagram of the forced spraying effect of the invention with reasonable matching of Z-axis displacement speed and rotating speed of the turntable.
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 derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
Referring to fig. 1, the present invention is a method for calculating parameters of a shot peening process for strengthening a cylindrical gear, and the specific implementation manner is as follows:
step S1, determining the preset shot blasting intensity A according to the design requirement of the selected cylindrical gear00.55A, and the preset coverage rate is more than or equal to 200 percent;
step S2, selecting a spray gun with a spray gun diameter d equal to 10mm, and when performing a process test, selecting a rotary table rotation speed RPM equal to 10r/min, and obtaining the rotation speed according to a calculation formula of a Z-axis moving speed v:
v＝10×10＝100mm/min
step S3, measuring the part tooth width L of the test piece with clamping arc height ASAfter the arc height is 100mm, setting the air pressure P to be 0.40MPa, the shot blasting flow M to be 10kg/min and the spray gun distance i to be 150mm, carrying out 10 times of intensified shot blasting treatment on the arc height A test piece, wherein the shot blasting times N of 10 times of treatment are 1, 2, 3, … and 10, and the process test data are shown in a table 1;
TABLE 1 Process test results
As is clear from the results in Table 1, the 10 th actually measured shot strength A10With the 5 th actually measured shot peening intensity A5If the ratio of (A) to (B) is less than 1.1, the set of process parameters reaches the saturation point of shot strength when shot blasting is cycled for 5 times, but the actually measured shot strength A5Not reaching the preset shot strength A as 0.47A0Adjusting the air pressure and the distance of the spray gun according to the requirement of 0.55A;
example 2
The process test of example 1 was repeated by adjusting the air pressure and the distance between the spray guns, setting the air pressure P to be 0.45MPa, the shot blasting flow M to be 10kg/min, and the distance between the spray guns i to be 120mm, and the process test data is shown in table 2;
TABLE 2 Process test results
As is clear from the results in Table 2, the 8 th actually measured shot strength A8With the 4 th actually measured shot peening intensity A4The ratio of the (A) to the (B) is less than 1.1, the process parameters reach a saturation point when circulating for 4 times, and the shot blasting intensity A is actually measured40.56A, greater than the preset shot strength A0Determining the air pressure P of the process test to be 0.45MPa, the shot blasting flow M to be 10kg/min and the spray gun distance i to be 120 mm;
step S4, selecting the gyration diameter D under the condition of same material, surface hardness and shot blasting intensity as the metal part to be processedM400mm, part tooth width LMThe calculation formula of the rotating speed RPM of the rotary table is as follows:
taking the rotating speed RPM of the rotary table as 1, 2, 3, … and 10 respectively, and carrying out shot peening simulation tests, wherein the test data are shown in a table 3;
TABLE 3 simulation test results of shot peening
From the results in Table 3, it can be seen that the maximum turntable speed RPM ismaxWhen the coverage is 6%, the coverage is exactly 100%, and the diameter of revolution D of the sample is simulatedMThe calculation formula of the rotating speed RPM of the turntable is substituted into the calculation formula of 400mm, the shot blasting flow M is 10kg/min and the diameter d of the spray gun is 10mm, and the calculation formula can be obtained:
calculating to obtain k as 7500;
therefore, the shot strength A is preset at the same material composition and surface hardness as those of the simulation sample0When the peening parameter is corresponding to 0.55A, the calculation formula of the rotating speed RPM of the turntable is as follows:
example 3
In order to verify the accuracy of the calculation method, a metal part with the same material composition and surface hardness as the simulated sample is selected, and the preset shot blasting intensity A is required0The verification is carried out on the metal part with the preset coverage rate of more than or equal to 200% and any rotating diameter, the rotating diameter and the part tooth width are taken as examples and 330 multiplied by 230mm, and the metal part is obtained by substituting the calculation formula of the rotating speed RPM of the rotating disc:
actual turntable speed RPMSTaking the value as an integer part of the theoretical calculation value, and actually taking the rotating speed RPM of the rotating discSWhen the Z-axis displacement v is substituted into 7r/min, the following equation is obtained:
v＝10×7＝70mm/min
practically used Z-axis shift velocity vSTaking the value of 90-95% of the theoretical calculation value, and actually taking the Z-axis moving speed vSThe calculation formula of the shot blasting time t is substituted into 65mm/min to obtain:
actual shot blasting time tSTaking the value as a theoretical calculation value, and adopting a further method to obtain a value which is accurate to one digit after a decimal point, and actually taking the shot blasting time tS＝7.7min；
Similarly, the other three metal parts with the rotation diameter and the part tooth width of 383 multiplied by 150mm, 580 multiplied by 420mm and 780 multiplied by 300mm can be calculated for verification, the forced blasting is firstly carried out for 1 time, the coverage rate can be more than or equal to 98 percent (namely the coverage rate is 100 percent) after detection, then the process is carried out according to the peening frequency N which is 2, and the actually measured peening intensity A of each metal part is detectedSAre all greater than the preset shot blasting intensity A0The coverage was recorded as 200% and the results are shown in table 4.
Table 4 verification of results of calculation methods
The material suitable for the invention mainly comprises alloy steel, titanium alloy and aluminum alloy, and the product suitable for the invention mainly comprises a cylindrical gear or a cylindrical part. The calculation method provided by the invention is used for processing the cylindrical gear or the cylindrical part, the generation of a strong spray blind area can be effectively avoided, the aims of accurately controlling the consistency of the shot blasting strength and the integrity of the coverage rate and avoiding the occurrence of over-spray or under-spray are achieved through the perfect matching of the calculated process parameters, and a basis is provided for establishing the rationality of the process time.
The foregoing is merely exemplary and illustrative of the principles of the present invention and various modifications, additions and substitutions of the specific embodiments described herein may be made by those skilled in the art without departing from the principles of the present invention or exceeding the scope of the claims set forth herein.
Claims (5)
1. A method for calculating the parameters of the cylindrical gear strengthening shot blasting process is characterized by comprising the following steps:
step S1, determining the preset shot blasting intensity A after shot blasting of the metal part according to the design requirement0And a preset coverage rate;
step S2, selecting the diameter d of the spray gun, firstly setting the rotating speed RPM of the turntable, and through a calculation formula of the Z-axis moving speed v:
v＝d×RPM
calculating to obtain a Z-axis moving speed v corresponding to the set rotating speed RPM of the turntable;
step S3, determining the numerical values of the air pressure P, the shot blasting flow M and the spray gun distance i through a process test, so as to actually measure the shot blasting intensity ASReach the preset shot blasting intensityA0；
Step S4, selecting a simulation sample with the same material composition and surface hardness as the metal part to be processed, carrying out a shot peening strengthening simulation test under the conditions of the set diameter d of the spray gun, the set air pressure P, the set distance i of the spray gun and the set shot peening flow M, and determining the maximum rotating disc rotating speed RPM when the coverage rate of the simulation sample reaches 100 percentMAXAnd then according to the rotation diameter D of the simulation sample, calculating the rotation speed RPM of the turntable according to a formula:
calculating to obtain the preset shot blasting intensity A0The value of the strengthening rate k under the required process parameters;
step S5, calculating the preset shot blasting intensity A according to the numerical value of the strengthening rate k calculated in the step S4 and the calculation formula of the rotating speed RPM of the turntable0Under the required technological parameters, the metal part with any rotation diameter D is required to reach the rotating speed RPM of the turntable with the coverage rate of 100%, and then the numerical value of the Z-axis moving speed v is obtained by the calculation formula of the Z-axis moving speed v in the step S2;
step S6, calculating the shot blasting frequency N according to the preset coverage rate of the metal part divided by 100%;
step S7, obtaining the numerical value of the part tooth width L of the metal part according to the measurement, and calculating the formula according to the shot blasting time t:
and calculating to obtain the numerical value of the shot blasting time t.
2. The method for calculating the parameters of the cylindrical gear peening shot blasting process according to claim 1, wherein the method comprises the following steps: actual turntable speed RPMSTaking the value as an integer part of the theoretical calculation, the actual Z-axis displacement velocity vSThe value is 90-95% of the theoretical calculation value, and the actual shot blasting time tSTaking the value as a theoretical calculation value and adopting a further method to accurately calculate the valueTo a value one digit after the decimal point.
3. The method for calculating the parameters of the cylindrical gear peening shot blasting process according to claim 1, wherein the method comprises the following steps: the process test comprises the following steps:
step A1, measuring the tooth width L of the part for clamping the arc height test pieceSAfter the numerical value is obtained, setting numerical values of air pressure P, shot blasting flow M and spray gun distance i;
step a2, shot peening the arc height test piece with the number of shots N of 1, 2, 3, …, N, … and 2N, and measuring the actually measured shot strength a of the arc height test piece after shot peeningSWhen the measured shot strength A is measured for the 2 n-th shot2nWith the n-th actually measured shot peening intensity AnWhen the ratio of the pressure to the flow of the shot blasting to the spray gun is less than 1.1, the n-th shot blasting reaches the shot blasting intensity saturation point under the parameters of the set air pressure P, the set shot blasting flow M and the set spray gun distance i;
step A3, if the actually measured shot peening intensity A of the saturation point of shot peening intensitynPreset shot strength A not meeting design requirements0If the set values of the air pressure P, the shot blasting flow M and the spray gun distance i need to be readjusted, the step A1 and the step A2 are repeated until the actually measured shot blasting intensity A of the saturation point of the shot blasting intensity is reachednPreset shot strength A greater than or equal to design requirement0。
4. The method for calculating the parameters of the cylindrical gear peening shot blasting process according to claim 1, wherein the method comprises the following steps: the judgment criterion that the coverage rate reaches 100% is that the actually measured coverage rate is greater than or equal to 98%.
5. The method for calculating the parameters of the cylindrical gear peening shot blasting process according to claim 1, wherein the method comprises the following steps: the shot blasting times N are integers.
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