CN113155444B - Calibration method for detecting grinding burn of carburized and quenched gear by magnetic-elastic method - Google Patents
Calibration method for detecting grinding burn of carburized and quenched gear by magnetic-elastic method Download PDFInfo
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Abstract
The invention discloses a calibration method for detecting grinding burn of a carburized and quenched gear by a magnetic-elastic method, which comprises the steps of preparing a gear burn sample according to process parameters including normal grinding parameters and processing means; carrying out full-tooth grinding burn detection on a plurality of gear burn samples by adopting a magnetic bomb instrument, and marking the mutation position of an MP value; evaluating the burn grade of a grinding burn area of a gear burn sample by adopting one or a combination of at least two of an etching method, a chemical analysis method, a metallographic method, a surface layer microhardness method and a residual stress method, and marking the burn position; and (4) performing comparison and inspection by adopting a magnetic bomb instrument, and taking the MP value at the burn position as a magnetic bomb evaluation standard corresponding to the burn grade. The method has the advantages that the standard for evaluating the burn grade by the magnetic-elastic method is determined by adopting a contrast detection method, so that the problem that the evaluation of the gear grinding burn grade lacks a contrast standard is solved, and the accuracy of burn grade judgment is guaranteed.
Description
Technical Field
The invention relates to a nondestructive technology of materials, in particular to a calibration method for detecting grinding burn of a carburized and quenched gear by a magnetic-elastic method.
Background
Gears are an important basic component of mechanical equipment. The gear product has complete door types and is widely applied to more than twenty fields of wind power, aviation, ships, weapon equipment, machine tool tools, engineering machinery, instruments and meters and the like. With the development of the mechanical industry, higher requirements are put on the gears in terms of high speed, heavy load and high precision. Therefore, the gear is carburized and quenched to ensure the hardness and bearing capacity of the tooth surface, and the finish machining adopts a gear grinding process to improve the surface quality of the precision of the gear. However, in the process of grinding and machining the gear, because the grinding wheel rotates relatively high, the hardness of the surface metal after carburizing and quenching is very high, and the cutting layer is extremely thin, instantaneous high temperature can be generated in a contact area, 60-95% of heat generated by grinding is transmitted to the gear, and only less than 10% of heat is taken away by grinding dust. The heat transferred to the workpiece has no time to spread and accumulates on the gear surface to form local high temperature. Most of the heat is directly transferred to the surface of the gear, and the problem of tooth surface grinding burn is easily caused. The gear grinding burn is difficult to control and avoid, the use performance of the gear cannot be influenced if slight grinding burn occurs, but the rigidity, the strength, the bearing capacity, the fatigue life and the like of the gear can be influenced if the slight grinding burn occurs to a certain degree, and even immeasurable economic loss can be brought.
In order to better control grinding burn, burnt gears are distinguished and screened in time, potential hazards caused by the burnt gears are avoided, and effective detection on the grinding burn of the gears is very important. The existing gear grinding burn control and detection method mainly comprises the steps of pre-prevention and post-inspection, wherein the pre-prevention is to take measures to avoid or reduce the burn before gear grinding, and the post-inspection is to perform burn detection on the gear after the gear grinding. At present, the traditional after-test in the gear industry is mainly carried out by an acid etching method, but the damage test causes the corrosion of the gear by the test solution and also causes environmental pollution and the like. With the progress of scientific technology, nondestructive testing technology is produced. The novel detection method, namely the magnetoelastic detection technology gradually shows unique advantages. The method has the characteristics of simple operation, high efficiency, no damage to workpieces, safety pollution and the like. Because the detection method is novel, is not completely applied and has no relevant standard specification aiming at the method, the instrument can not be checked during actual detection, and the critical value of whether the burn exists or not can be accurately judged and the burn grade evaluation can be carried out.
Disclosure of Invention
The invention aims to provide a calibration method for detecting grinding and burning of a carburized and quenched gear by a magnetic-elastic method, aiming at the defects that when the existing magnetic-elastic method is used for detecting grinding and burning of the carburized and quenched gear, whether a critical value exists or not can not be accurately judged and the burning grade can not be evaluated.
In order to achieve the purpose, the invention adopts the following technical scheme.
A calibration method for detecting grinding burn of a carburized and quenched gear by a magnetic-elastic method comprises the following steps:
first, sample preparation: processing a plurality of grinding gear samples before gear grinding according to a normal production process, and grinding the gear burn samples on a forming gear grinding machine according to a plurality of process parameters including normal grinding parameters;
secondly, determining a burn area by a magnetic-elastic method: carrying out full-tooth grinding burn detection on a plurality of gear burn samples by adopting a magnetic bomb instrument, and marking the mutation position of the MP value;
thirdly, evaluating the burn grade by a non-magnetic bullet method: evaluating the burn grade of a grinding burn area of a gear burn sample by adopting one or a combination of at least two of an etching method, a chemical analysis method, a metallographic method, a surface layer microhardness method and a residual stress method, and marking the burn position;
fourthly, comparing and detecting by a magnetoelastic method: and (3) detecting the gear burn sample with the burn grade evaluated by the non-magnetic bomb method by adopting a magnetic bomb instrument, and taking the MP value at the burn position as the magnetic bomb method evaluation standard corresponding to the burn grade.
According to the invention adopting the technical scheme, the standard of evaluating the burn grade by the magnetic bomb method is determined by sample preparation, determining the burn area by the magnetic bomb method, evaluating the burn grade by the non-magnetic bomb method and comparing and detecting the burn grade by the magnetic bomb method. The problem that the gear grinding burn grade evaluation lacks a comparison standard is solved, and the accuracy of grade judgment is guaranteed. The method comprises the following steps that a plurality of burn qualified and unqualified products for calibration can be obtained through sample preparation, so that a larger coverage range is formed, and samples which are not compared in the actual detection process are avoided; the burn area determined by the magnetic bomb method can quickly and relatively accurately determine the burn range, so that when the non-magnetic bomb method is adopted for judging the burn level, relevant work is pertinently carried out on the burn area of the sample piece, and the judging work efficiency is improved; the non-magnetic-elastic method comprises one or combination of at least two of an etching method, a chemical analysis method, a metallographic method, a surface layer microhardness method and a residual stress method, so that the burn grade can be accurately judged by utilizing the existing mature burn grade judgment method; and multiple methods are combined for use, so that the accuracy of judging the burn grade can be effectively improved.
Preferably, in the step of determining the burn area by using a magnetoelastic method and performing contrast detection, the method comprises the following steps:
the method comprises the following steps that firstly, a gauss meter is adopted to detect tooth surface residual magnetism, and an S1-14-12-02 probe and a matched gauss meter model are selected to carry out detection under the condition that the tooth surface residual magnetism is less than 3 gauss;
secondly, selecting 4 uniformly distributed cross section positions along the tooth width direction of each tooth, respectively carrying out static detection on the positions close to the tooth top and the tooth root, and recording the MP value of each detection position in the comparison detection step;
and a third step of dynamically detecting positions near the tooth crest and near the tooth root in the tooth width direction, respectively, and marking the corresponding positions in the step of determining the burn area when a sudden increase or decrease in the MP value occurs.
The accuracy of the magnetic-elastic method detection is improved, so that the accuracy of the contrast detection is ensured, and the guarantee is provided for accurately obtaining the standard sample.
Preferably, when the burn grade is evaluated by the etching method, the burn test by the acid etching method is carried out on the ground burn gear sample according to the GB/T17879-1999 etching test for surface tempering after gear grinding, and the wiping burn test is carried out according to the solution prepared by the type III etching method, and the burn grade evaluation is carried out according to the test criteria in the standard. The acid etching method is evaluated according to the operation specification, judgment standard and requirement of the acid etching method strictly, and the accuracy of grade evaluation is ensured.
Preferably, when the burn grade is evaluated by the chemical analysis method, the element content of the surface and the shallow surface layer is detected by a spectrometer and an energy spectrometer for burn and non-burn samples taken from the same tooth surface. To ensure the accuracy of chemical analysis to assess the burn grade.
Preferably, when the burning grade is evaluated by the metallographic method, a high-magnification metallographic microscope is adopted to observe the metallographic structure of the superficial layer of the sample, the grade of the nonmetallic inclusion is judged, the difference of the metallographic structure of the burnt part and the metallographic structure of the burnt part is compared, the metallographic structure of the burnt part is mainly observed, and a report is formed. So as to ensure the accuracy of evaluating the burn grade by a metallographic method.
Preferably, when the burn grade is evaluated by the surface microhardness method, a surface hardness test and a core hardness test are included to determine the hardness gradient of the quenching layer in the depth direction. So as to ensure the accuracy of evaluating the burn grade by a metallographic method; when the hardness is detected in the depth direction of the burn injury influence area, the selection of the distance between the adjacent hardness detection points is determined according to the principle that the single detection result is not influenced, and a plurality of detection results can form a reasonable hardness gradient.
Preferably, when the burn grade is evaluated by the residual stress method, the residual stress of the surface of the sample with burn and the residual stress of the surface of the sample without burn are detected by an X-ray diffraction residual stress detector, and are respectively carried out along the tooth width direction and the tooth height direction, and the record and the mark are made. To ensure the accuracy of the residual stress method for assessing the burn grade.
Preferably, the method further comprises the steps of summarizing the test sample detection results of the non-burnt test sample and the burnt test sample respectively, selecting a group of data with a certain gradient and no less than 20 samples according to the summarized results, using the data as calibration sample data for analyzing the grinding burn detected by the magnetic-elastic method, and determining the comparison standard for detecting the grinding burn detected by the magnetic-elastic method through data processing analysis, MP value calibration and verification. The method can effectively avoid the shortage of corresponding calibrated comparison samples when the actual magnetoelastic method is adopted for detection, and ensure that the samples are abundant in quantity and wide in comparison range.
Further preferably, the detection results of the burned sample of the non-burned sample for gathering comprise results of a surface microhardness method, a residual stress method and a magnetic-elastic method, and MP values of the three test results are determined as sample data according to a relatively stable principle; and processing and analyzing the data by adopting a multiple linear regression method. The combination of limited evaluation modes with the screening evaluation result closer to the actual burn effect reduces the data processing amount and improves the calibration efficiency.
Further preferably, in the MP value calibration and verification process, the method comprises the steps of firstly, giving a critical hardness value and a residual stress value, and predicting a discrimination limit for qualified and unqualified grinding burn detection of the magnetic bomb instrument through a multiple linear regression equation; secondly, according to the confidence probability, a prediction interval of the characteristic value MP value is deduced, and the interval is used as a basis for judging whether the burn is qualified or unqualified; thirdly, establishing a grinding burn detection standard; and finally, taking the actually produced gears as the inspection objects of the initial verification, randomly selecting at least 10 gears as one-time verification samples, completing the initial verification within a set time limit, allowing certain relative errors to exist, and adjusting the subsequent verification period according to the initial verification effect after the initial verification is completed. Further ensuring calibration accuracy. The period of the initial verification can be determined as 1 month, and the allowable relative error is controlled within 10%. After one quarter is verified, the calibrated grinding burn detecting instrument is proved to have higher accuracy and stability, and the verification period can be set to be once verified in one quarter. If the verification is still accurate and stable in the quarterly, the verification calibration period can be set to be half a year or once a year.
The method has the advantages that the standard of evaluating the burn grade by the magnetic-elastic method is determined through the steps of sample preparation, determining of the burn area by the magnetic-elastic method, evaluation of the burn grade by the non-magnetic-elastic method and comparison and detection of the magnetic-elastic method, so that the problem that the evaluation of the burn grade by the gear grinding is lack of the comparison standard is solved, and the accuracy of grade judgment is guaranteed. The calibration efficiency is high, and the accuracy is good.
Detailed Description
The present invention is further illustrated but is not to be limited thereby within the scope of the described embodiments.
A magnetic-elastic method for detecting grinding burn calibration of a carburized and quenched gear takes an 18CrNiMo7-6 steel carburized and quenched gear as a calibration sample, and comprises the following steps:
first, sample preparation: processing a plurality of grinding gear samples before gear grinding according to a heat treatment and machining process of normal production, and grinding and processing the gear burn samples on a forming gear grinding machine according to various process parameters including normal grinding parameters and causing the tooth surface to burn when exceeding the normal grinding parameters;
secondly, determining a burn area by a magnetic-elastic method: carrying out full-tooth grinding burn detection on a plurality of gear burn samples by adopting a magnetic bomb instrument, and marking the mutation position of the MP value;
thirdly, evaluating the burn grade by a non-magnetic-elastic method: evaluating the burn grade of a grinding burn area of a gear burn sample by adopting one or a combination of at least two of an etching method, a chemical analysis method, a metallographic method, a surface layer microhardness method and a residual stress method, and marking the burn position;
fourthly, comparing and detecting by a magnetic-elastic method: and (3) detecting the gear burn sample with the burn grade evaluated by the non-magnetic bomb method by adopting a magnetic bomb instrument, and taking the MP value at the burn position as the magnetic bomb method evaluation standard corresponding to the burn grade.
Wherein, in adopting the magnetic-elastic method to confirm the burn area and comparing the detection step, including:
the method comprises the following steps that firstly, a gauss meter is adopted to detect tooth surface residual magnetism, and an S1-14-12-02 probe and a matched gauss meter model are selected to carry out detection under the condition that the tooth surface residual magnetism is less than 3 gauss;
secondly, selecting 4 uniformly distributed cross section positions along the tooth width direction of each tooth, respectively carrying out static detection on the positions close to the tooth top and the tooth root, and recording the MP value of each detection position in the comparison detection step;
and a third step of dynamically detecting positions near the tooth crest and near the tooth root in the tooth width direction, respectively, and marking the corresponding positions in the step of determining the burn area when a sudden increase or decrease in the MP value occurs.
When the burn grade is evaluated by the etching method, according to the GB/T17879-1999 etching test for gear grinding surface tempering, the burn test of the grinding burn gear sample by the acid etching method is carried out, and the wiping burn test is carried out according to the solution prepared by the III type etching method, and the burn grade evaluation is carried out according to the test criteria in the standard. When the chemical analysis method is used for evaluating the burn grade, the element content of the surface and the superficial layer is detected by a spectrometer and an energy spectrometer for burn and non-burn samples taken from the same tooth surface. When the burn grade is evaluated by the metallographic method, a metallographic structure of a sample superficial layer is observed by a high-magnification metallographic microscope, the grade of the nonmetallic inclusion is judged, the difference of the metallographic structures of the burnt part and the burnt part is compared, the metallographic structure of the burnt part is mainly observed, and a report is formed. When the burn grade is evaluated by the surface microhardness method, surface hardness detection and core hardness detection are included to determine the hardness gradient of the quenching layer in the depth direction. When the hardness is detected in the depth direction of the burn injury influence area, the selection of the distance between the adjacent hardness detection points is determined according to the principle that the single detection result is not influenced, and a plurality of detection results can form a reasonable hardness gradient. When the burn grade is evaluated by a residual stress method, an X-ray diffraction residual stress detector is adopted to detect the residual stress of the surfaces of samples with burn and without burn, the detection is respectively carried out along the tooth width direction and the tooth height direction, and the recording and the marking are well carried out.
The method further comprises the steps of summarizing test sample detection results of the non-burnt test samples and the burnt test samples respectively, selecting a group of data with a certain gradient and no less than 20 samples according to the summarized results, using the data as calibration sample data for analyzing the grinding burn detected by the magnetic-elastic method, and determining a comparison standard for detecting the grinding burn detected by the magnetic-elastic method through data processing analysis, MP value calibration and verification.
The method also comprises the steps that the detection results of the burn sample of the non-burn sample for gathering comprise results of a surface microhardness method, a residual stress method and a magnetic-elastic method, and MP values are determined as sample data according to the principle that the three test results are relatively stable; and processing and analyzing the data by adopting a multiple linear regression method. In the MP value calibration and verification process, firstly, giving a critical hardness value and a critical residual stress value, and predicting a discrimination boundary for evaluating whether the grinding burn detected by the magnetoelastic instrument is qualified or unqualified through a multiple linear regression equation; secondly, according to the confidence probability, a prediction interval of the characteristic value MP value is deduced, and the interval is used as a basis for judging whether the burn is qualified or unqualified; thirdly, establishing a grinding burn detection standard; and finally, taking the actually produced gears as the inspection objects of the initial verification, randomly selecting at least 10 gears as one-time verification samples, completing the initial verification within a set time limit, allowing certain relative errors to exist, and adjusting the subsequent verification period according to the initial verification effect after the initial verification is completed.
When the method is adopted, the period of initial verification can be determined to be 1 month, and the allowable relative error is controlled within 10 percent. After one quarter is verified, the calibrated grinding burn detecting instrument is proved to have higher accuracy and stability, and the verification period can be set to be once verified in one quarter. If the verification is still accurate and stable in the quarterly, the verification calibration period can be set to be half a year or once a year.
In the method, in the step of determining the burn area of the sample by adopting the magnetic bomb method, the MP value can also be recorded incidentally, correspondingly, in the step of performing comparison detection by adopting the magnetic bomb method, the difference of the MP values of the two detection results can be compared, the stability of a detection instrument can be determined, and whether the acid corrosion has influence on the burn degree of the sample can be analyzed.
The foregoing shows and describes the general principles and broad features of the present invention and advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are given by way of illustration of the principles of the present invention, but that various changes and modifications may be made without departing from the spirit and scope of the invention, and such changes and modifications are within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. A calibration method for detecting grinding burn of a carburized and quenched gear by a magnetic-elastic method is characterized by comprising the following steps:
first, sample preparation: processing a plurality of grinding gear samples before gear grinding according to a normal production process, and grinding the gear burn samples on a forming gear grinding machine according to a plurality of process parameters including normal grinding parameters;
secondly, determining a burn area by a magnetic-elastic method: carrying out full-tooth grinding burn detection on a plurality of gear burn samples by adopting a magnetic bomb instrument, marking the sudden change position of the MP value and recording the MP value;
thirdly, evaluating the burn grade by a non-magnetic-elastic method: evaluating the burn grade of a grinding burn area of a gear burn sample by adopting one or a combination of at least two of an etching method, a chemical analysis method, a metallographic method, a surface layer microhardness method and a residual stress method, and marking the burn position;
fourthly, comparing and detecting by a magnetic-elastic method: and detecting the gear burn sample with the burn grade evaluated by the non-magnetic bomb method by adopting a magnetic bomb instrument, taking the MP value at the burn position as the evaluation standard of the magnetic bomb method corresponding to the burn grade, and comparing the difference of the MP values of the two detection results.
2. The method of claim 1, wherein in the step of using magnetoelastic contrast detection, the method comprises:
a first small step of detecting tooth surface remanence;
secondly, selecting 4 uniformly distributed cross section positions along the tooth width direction of each tooth, respectively carrying out static detection on the positions close to the tooth top and the tooth root, and recording the MP value of each detection position in the comparison detection step;
and a third step of dynamically detecting positions near the addendum and near the dedendum, respectively, in the tooth width direction, and marking the corresponding positions in the step of determining the burn zone when a sudden increase or decrease in the MP value occurs.
3. A method according to claim 1, wherein when assessing the burn grade by the etching method, the acid etching burn test is performed on a sample of a ground burnt gear according to GB/T17879-1999 test for etching of surface tempering after gear grinding, and wiping burn test is performed by preparing a solution according to type III etching method, and burn grade assessment is performed according to the test criteria in the standard.
4. The method of claim 1, wherein the chemical analysis is used to evaluate the burn grade by detecting the elemental content of the surface and superficial layer by using a spectrometer and an energy spectrometer for both burned and non-burned samples taken from the same tooth surface.
5. The method of claim 1, wherein in the case of evaluating the grade of burn by the metallographic method, the metallographic structure of the superficial layer of the sample is observed by a high-magnification metallographic microscope, the grade of nonmetallic inclusions is judged, the difference between the metallographic structure of the burned part and the metallographic structure of the burned part is compared, the metallographic structure of the burned part is observed with emphasis, and a report is formed.
6. The method of claim 1, wherein the skin microhardness test and the core hardness test are included to determine the hardness gradient in the depth direction of the quenched layer when the burn grade is evaluated by the skin microhardness method.
7. The method according to claim 1, wherein in the evaluation of the burn grade by the residual stress method, the residual stress on the surface of the sample with burn and the sample without burn is detected by an X-ray diffraction residual stress detector and is separately performed in the tooth width and tooth height directions, and recorded and marked.
8. The method according to any one of claims 1 to 7, further comprising summarizing the test results of the non-burnt test samples and the burnt test samples respectively, selecting a group of data with a certain gradient and no less than 20 samples according to the summarized results, using the data as calibration sample data for analyzing the grinding burn of the magnetic bomb method, and determining the comparison standard for detecting the grinding burn of the magnetic bomb method through data processing analysis, MP value calibration and verification.
9. The method according to claim 8, wherein the burn test sample detection results of the non-burn test sample for summarizing include results of three methods of a surface microhardness method, a residual stress method and a magnetoelastic method, and the MP value of the three test samples is determined as sample data according to a principle that the three test results are relatively stable; and processing and analyzing the data by adopting a multiple linear regression method.
10. The method of claim 9, wherein during the MP value calibration and verification process, the critical hardness and residual stress values are given, and the determination limit for the qualification and disqualification of the grinding burn detected by the magnetoelastic instrument is predicted by the multiple linear regression equation; secondly, according to the confidence probability, a prediction interval of the characteristic value MP value is deduced, and the interval is used as a basis for judging whether the burn is qualified or unqualified; thirdly, establishing a grinding burn detection standard; and finally, taking the actually produced gears as an inspection object of initial verification, randomly selecting at least 10 gears as a one-time verification sample, completing the initial verification within a set time limit, allowing certain relative errors to exist, and adjusting a subsequent verification period according to the initial verification effect after the initial verification is completed.
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