CN113351846A - Preparation method of amorphous flexible gear for harmonic reducer - Google Patents
Preparation method of amorphous flexible gear for harmonic reducer Download PDFInfo
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- CN113351846A CN113351846A CN202110664248.8A CN202110664248A CN113351846A CN 113351846 A CN113351846 A CN 113351846A CN 202110664248 A CN202110664248 A CN 202110664248A CN 113351846 A CN113351846 A CN 113351846A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/14—Machines with evacuated die cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
- B22D31/002—Cleaning, working on castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H49/00—Other gearings
- F16H49/001—Wave gearings, e.g. harmonic drive transmissions
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
- F16H55/02—Toothed members; Worms
- F16H55/17—Toothed wheels
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2200/00—Crystalline structure
- C22C2200/02—Amorphous
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
Abstract
A preparation method of an amorphous flexible gear for a harmonic reducer belongs to the field of harmonic reducers. The amorphous flexible gear mold is provided with a molding cavity, and the preparation method of the amorphous flexible gear comprises the following steps: injecting the molten amorphous alloy raw material into a forming cavity under a vacuum condition for pressure maintaining to obtain a blank, reserving a machining allowance on the blank, and grinding to remove the machining allowance to obtain the amorphous flexible gear. The amorphous flexible gear prepared by the preparation method has high precision, can avoid crystallization of amorphous alloy materials in the preparation process, and simultaneously improves the utilization rate of materials required for manufacturing the amorphous flexible gear.
Description
Technical Field
The application relates to the field of harmonic reducers, in particular to a preparation method of an amorphous flexible gear for a harmonic reducer.
Background
The harmonic reducer consists of three basic parts: flexible gear, rigid wheel and wave generator. The flexible gear is a flexible thin-wall part with an outer gear ring, and the inner ring of the flexible gear is matched with the outer ring of the flexible bearing and is generally arranged at the output end of the speed reducer; the rigid wheel is a rigid annular part with an inner gear ring, generally has two teeth more than the flexible gear, and is fixed on the reducer body; the wave generator is generally composed of a cam and a flexible bearing, and is used as an input end of harmonic gear transmission, an inner ring of the flexible bearing is fixed with the cam, and an outer ring of the flexible bearing is elastically deformed by a rolling body to be elliptic. It can realize the deceleration or acceleration action, and is convenient for control the mechanical movement. The harmonic reducer is different from a common reducer, has the advantages of large transmission speed ratio, high bearing capacity, small volume, light weight, high transmission precision, high transmission efficiency, simple structure, convenience in installation and the like, and is widely applied to the fields of aerospace, precise medical instruments, industrial robots and the like.
The flexible gear is used as the core of the harmonic reducer and is a key part for transmitting power during the operation of the harmonic reducer, the product performance of the flexible gear is very important, and particularly the strength of the flexible gear is a main factor influencing the transmission life. Due to the effect of the stress, the main form of failure of parts in harmonic gear transmissions is the breakage of the flexspline. The amorphous alloy is a novel metal material with disordered atomic structure arrangement. Due to the disordered structure and the metal bond characteristics, the amorphous alloy has excellent mechanical and chemical properties such as high strength, high hardness, wear resistance, corrosion resistance and the like. Compared with a flexible gear produced by common steel, the flexible gear produced by the amorphous alloy material has insufficient rigidity and short service life, and the flexible gear made of the amorphous alloy material has excellent performances such as high strength, high hardness, high elasticity, high impact fracture energy and the like, can improve the mechanical properties such as strength, elasticity and the like of the flexible gear, and also prolongs the service life of the flexible gear.
However, in the actual processing process, the amorphous alloy material is easily crystallized during the processing process due to the poor thermal conductivity of the amorphous alloy material.
Disclosure of Invention
The application provides a preparation method of an amorphous flexible gear for a harmonic reducer, the prepared amorphous flexible gear is high in precision, crystallization of amorphous alloy materials in the preparation process can be avoided, and meanwhile, the utilization rate of materials required for manufacturing the amorphous flexible gear is improved.
The embodiment of the application is realized as follows:
the application example provides a preparation method of an amorphous flexible gear, wherein an amorphous flexible gear mold is provided with a molding cavity, and the preparation method of the amorphous flexible gear comprises the following steps:
and injecting the molten amorphous alloy raw material into a forming cavity under a vacuum condition for pressure maintaining to obtain a blank.
The blank is provided with a cup-shaped part, a tooth-shaped part and a boss part which are integrally formed, the tooth-shaped part is arranged on the periphery of the cup-shaped part, the tooth-shaped part is provided with a plurality of tooth parts which are arranged along the periphery of the cup-shaped part at equal intervals, each tooth part extends along the axial direction of the cup-shaped part, the boss part protrudes out of one end of the cup-shaped part far away from the opening of the cup-shaped part, and the boss part is provided with a through hole which completely penetrates through the boss part and the cup-shaped part along the axial direction of the cup-shaped part; the inner wall of the cup-shaped part is provided with a machining allowance with the thickness of 0.05-0.1 mm, the outer wall of the tooth-shaped part is provided with a machining allowance with the thickness of 0.01-0.06 mm, the outer wall of the boss is provided with a machining allowance with the thickness of 0.02-0.06 mm, and the inner wall of the through hole is provided with a machining allowance with the thickness of 0.01-0.05 mm.
And respectively grinding and removing the machining allowance of the cup-shaped part, the machining allowance of the tooth-shaped part, the machining allowance of the boss and the machining allowance of the inner wall of the through hole to obtain the amorphous flexible gear.
Firstly, through vacuum die-casting, the metallic glass material is by oxidation when can avoid die-casting to a certain extent, secondly, because the blank has tooth portion and through-hole, consequently, follow-up extra chisel tooth and the step of punching have been avoided, only need polish can, effectively improve machining efficiency, and the inner wall through injecing cup has the machining allowance that thickness is 0.05 ~ 0.1mm, the outer wall of tooth portion has the machining allowance that thickness is 0.01 ~ 0.06mm, the outer wall of boss has the machining allowance that thickness is 0.02 ~ 0.06mm, the inner wall of through-hole has the limited of the machining allowance that thickness is 0.01 ~ 0.05mm, reserve the space that is used for follow-up grinding on the one hand in order to obtain the better finished product of precision, and follow-up thickness of waiting to process the part is little, consequently, still have the reduce processing cost, the benefit of improvement machining efficiency. By adopting a grinding processing mode, the accuracy of the finally obtained amorphous flexible gear can be ensured, the efficiency of preparing the amorphous flexible gear is high, and crystallization can be avoided.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are required to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained from the drawings without inventive effort.
FIG. 1 is a first perspective structural view of a blank for an amorphous flexspline;
FIG. 2 is a second perspective structural view of a blank for an amorphous flexspline;
FIG. 3 is an XRD pattern of the outer wall and bottom wall of the blank made in example 1;
FIG. 4 is an XRD pattern of the outer wall and bottom wall of the amorphous flexspline made in example 1;
FIG. 5 is an XRD pattern of the outer wall and bottom wall of the amorphous flexspline made in comparative example 1;
fig. 6 is an XRD pattern of the outer wall and the bottom wall of the amorphous flexspline prepared in comparative example 2.
Icon: 10-a blank; 100-a cup-shaped portion; 110-a tooth-shaped portion; 111-gear teeth; 120-a boss portion; 121 — a first via; 123-second via.
Detailed Description
Embodiments of the present application will be described in detail below with reference to examples, but those skilled in the art will appreciate that the following examples are only illustrative of the present application and should not be construed as limiting the scope of the present application. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially.
Because the amorphous alloy has high hardness, and the flexible gear for the harmonic reducer has the characteristics of thin wall, small gear modulus and the like, the manufacturing difficulty is high, and the required precision can not be achieved if the flexible gear is directly cast and formed. The way that is usually adopted is therefore: the method comprises the steps of casting each part and then welding, wherein the welding part is easy to crystallize, or a blank (without a gear tooth part and a hole) is obtained by using a die and then is subjected to rough machining and finish machining, so that the processes are multiple, the material is easy to crystallize and crack, meanwhile, the hardness of the amorphous alloy material is high, the tool is seriously abraded by adopting the rough machining and finish machining modes, and the machining cost is increased.
Therefore, the present application is proposed, which obtains a blank composed of a cup-shaped portion, a tooth-shaped portion and a boss portion which are integrally formed after die casting, avoids crystallization caused by welding, and not only avoids crystallization and crack generation of amorphous alloy material, but also ensures processing precision and quality and improves processing efficiency by preparing a blank with a specific processing margin and grinding.
The following specifically describes a method for manufacturing an amorphous flexible gear for a harmonic reducer according to an embodiment of the present application:
the preparation method of the amorphous flexible gear for the harmonic reducer comprises the following steps:
and S1, obtaining the amorphous flexible gear mold.
The amorphous flexible wheel die comprises a vacuum box, a male die core, a female die core, an ejection mechanism and the like, wherein the male die core, the female die core and the ejection mechanism are contained in the vacuum box, a forming cavity is formed in the male die core and the female die core after the male die core and the female die core are attached, the forming cavity is communicated with an injection channel, the ejection mechanism is used for ejecting a blank out of the forming cavity after the male die core and the female die core are separated, and the specific arrangement refers to the related technology.
The applicant has made improvements to the structure of the forming cavity, which comprises a cup-shaped cavity for forming the cup-shaped portion, a tooth-shaped cavity for forming the tooth-shaped portion, and a boss cavity for forming the boss portion; wherein the profile of tooth chamber sets up in the periphery in cup chamber and communicates with cup chamber, and the inner wall that encloses into the profile of tooth chamber has a plurality of tooth's socket that are used for forming the teeth of a cogwheel that arrange along the periphery equidistance interval of cup chamber, and every tooth's socket extends along the axis direction in cup chamber, and the boss chamber is located cup chamber and keeps away from its open-ended one end and communicates with cup chamber, has in the boss chamber to set up and extend to the cylinder in the cup chamber along the axis direction in cup chamber, and the axis of cylinder is parallel with the axis of cup portion, and the cylinder is used for the shaping through-hole.
The forming cavity of the amorphous flexible gear die can be designed according to the size, the dimensional tolerance, the form and position tolerance and the like of the flexible gear, so that the surface of a blank prepared by the amorphous flexible gear die is smooth and the precision is higher.
And S2, injecting the molten amorphous alloy raw material into a forming cavity under a vacuum condition for pressure maintaining to obtain a blank to be fused.
The molding cavity under the vacuum condition can prevent the amorphous alloy from being oxidized in the die-casting process.
Optionally, the vacuum degree of the vacuum is 2 × 10-3～2×10-2pa, e.g. vacuum degree of 2X 10-3、4×10-3、5×10-3pa、8×10-3pa、1×10-2pa、1.5×10-2pa、2×10-2pa, etc., or between any two values.
It should be noted that, in order to make the molding cavity of the amorphous flexible gear mold in a vacuum condition, the region where the amorphous flexible gear mold is opened may be vacuumized in advance, that is, the amorphous flexible gear mold that is opened is in a vacuum environment, and then the mold closing is performed, where the molding cavity is in a vacuum environment at this time, or the molding cavity that is closed may be vacuumized.
The amorphous alloy includes, but is not limited to, zirconium-based amorphous alloy, and it may also be iron-based amorphous alloy, aluminum-based amorphous alloy, lanthanum-based amorphous alloy, or the like.
The amorphous alloy based on zirconium is easy to mold and has low melting temperature, and optionally, the amorphous alloy is the amorphous alloy based on zirconium.
The zirconium-based amorphous alloy includes, but is not limited to, Zr-Al-Ni-Cu system, Zr-Ti-Al-Ni-Cu-Be system or Zr-Nb-Cu-Ni-Al system, etc., and can Be selected by those skilled in the art according to actual needs.
Alternatively, the zirconium-based amorphous alloy is a Zr-Nb-Cu-Ni-Al system, which may include Zr57Nb5Cu15.4Ni12.6Al10。
Optionally, when a zirconium-based amorphous alloy system is adopted, the molten amorphous alloy raw material is obtained by heating the amorphous alloy to 800-1000 ℃, and the molten amorphous alloy raw material heated to 800-1000 ℃ is easy to form. In order to avoid oxidation, the molten amorphous alloy raw material can also be melted in vacuum or inert atmosphere to avoid oxidation.
Since the filling speed of the molten amorphous alloy raw material in the forming cavity, the flowability of the molten amorphous alloy raw material, the compactness of the blank, the definition of the blank and the roughness of the surface of the blank are influenced by the height of the injection specific pressure, the filling speed can also be directly related to the internal quality and the appearance quality of the die casting. And different injection specific pressures and filling speeds can cause different scouring degrees of molten alloy on the surface of the die cavity, so that the problems of die sticking or influence on the service life of the die-casting die and the like are caused.
Therefore, alternatively, the injection step of injecting the molten amorphous alloy raw material into the molding cavity of the amorphous flexible mold includes: under the condition that the injection specific pressure is 52-56 MPa, for example, any one of 52MPa, 53MPa, 54MPa, 55MPa or 56MPa or between any two of the injection specific pressure values, the molten amorphous alloy raw material is filled into the forming cavity under the condition that the injection speed is 5-7 m/s, for example, any one of 5m/s, 5.5m/s, 6m/s, 6.5m/s or 7m/s or between any two of the injection speed values, and the filling time is 0.04-0.06 s.
The selection of the injection specific pressure avoids the problems of die sticking and the like caused by strong scouring of molten amorphous alloy on the premise of ensuring the blank quality and the use requirement, and is matched with a vacuum environment for use, so that the problem that the die is expanded due to overlarge injection specific pressure in the use process is effectively avoided. Filling speed undersize can make the outline of blank unclear, can not take shape even, and filling speed is too big and makes the blank glue the mould or make the inside porosity of blank increase, reduces mechanical properties, and the clear and fine and close of blank outline can be guaranteed to above-mentioned injection speed, is convenient for obtain accurate process allowance, and the follow-up grinding of being convenient for is got rid of and is guaranteed final off-the-shelf precision.
Because the amorphous alloy has poor thermal conductivity, in order to maintain the stability of the temperature of the die and improve the die-casting forming quality and the surface quality, optionally, before injecting the molten amorphous alloy raw material into the forming cavity, the preparation method further comprises the following steps: preheating the die to 150-180 ℃.
Optionally, the pressure maintaining step comprises: and maintaining the pressure for 4-7 s at 52-56 MPa after filling, for example, maintaining the pressure for 4s, 5s, 6s or 7s at any one or between any two injection specific pressure values of 52MPa, 53MPa, 54MPa, 55MPa or 56MPa, wherein the reasonable pressure maintaining setting can further ensure the tissue compactness of the blank.
And after the pressure maintaining step, cooling for 9-15 s to obtain a blank.
It should be noted that, when the mold is not opened after pressure holding, that is, the blank is still in the mold, the mold may be cooled by a water cooling method to indirectly cool the blank, and when the mold is opened after pressure holding, that is, the blank is taken out of the mold, the mold is directly cooled by an air cooling method. That is, in the cooling process, if the cooled fluid is liquid, the blank does not contact with the liquid, and the blank is prevented from being polluted.
In summary, referring to fig. 1 and 2, the blank 10 obtained through the above steps has the cup-shaped portion 100, the tooth-shaped portion 110, and the boss portion 120, which are integrally formed.
The tooth-shaped portion 110 is disposed at an outer periphery of the cup-shaped portion 100, the tooth-shaped portion 110 has a plurality of teeth 111 spaced at equal intervals along the outer periphery of the cup-shaped portion 100, each of the teeth 111 extends along an axial direction of the cup-shaped portion 100, the boss portion 120 protrudes from an end of the cup-shaped portion 100 away from an opening thereof, and the boss portion 120 is provided with a through hole completely penetrating the boss portion 120 and the cup-shaped portion 100 along the axial direction of the cup-shaped portion 100. Through the setting, follow-up need not additionally punch and processing obtains the teeth of a cogwheel 111, only need follow-up carry on the grinding can, effectively overcome the difficult problem of processing of amorphous alloy because of characteristics such as high rigidity, heat conductivity difference and improved, when improving machining efficiency, avoided the waste of amorphous alloy raw materials.
The axis of the through hole is parallel to or coincides with the axis of the cup-shaped portion 100, for example, the through hole includes a first through hole 121 and a second through hole 123, wherein the axis of the first through hole 121 coincides with the axis of the cup-shaped portion 100, the number of the second through holes 123 is multiple, the multiple second through holes 123 are arranged around the periphery of the first through hole 121, and each second through hole 123 is arranged at an interval with the first through hole 121 and the adjacent second through hole 123. The sizes of the second through holes 123 may be the same or different, and as shown in fig. 2, the sizes of the second through holes 123 are partially the same and partially different, which is not limited herein.
The inner wall of the cup-shaped portion 100 is provided with a machining allowance with the thickness of 0.05-0.1 mm, the outer wall of the tooth-shaped portion 110 (including the surface of the gear teeth 111) is provided with a machining allowance with the thickness of 0.01-0.06 mm, the outer wall of the boss is provided with a machining allowance with the thickness of 0.02-0.06 mm, and the inner wall of the through hole is provided with a machining allowance with the thickness of 0.01-0.05 mm.
The limitation of the machining allowance is characterized in that a space for subsequent grinding is reserved and a finished product with better precision is obtained, on the other hand, the specific limitation of the machining allowance is used for effectively preventing the crystallization phenomenon caused by overhigh local temperature in the machining process, and meanwhile, the limitation of the machining allowance is used for enabling the blank 10 to be subjected to subsequent slight grinding, so that the problem that the amorphous alloy material is difficult to machine due to the characteristics of high hardness, poor heat conductivity and the like is solved, the machining efficiency and the machining precision are improved, the machining cost is reduced, and the machining efficiency is improved.
And S3, fixing the blank 10 on a fixture, grinding the blank 10 by using a numerical control grinding machine according to the processing drawing of the amorphous alloy flexible gear, and respectively grinding and removing the machining allowance of the cup-shaped part 100, the machining allowance of the tooth-shaped part 110, the machining allowance of the boss and the machining allowance of the inner wall of the through hole to obtain the amorphous flexible gear.
Compared with other machining modes such as turning and the like, the machining precision of the grinding machining mode is higher, and the amorphous alloy crystallization is effectively avoided and the production efficiency is improved by limiting specific machining allowance and specific grinding parameters.
Alternatively, the step of grinding to remove the machining allowance of the tooth-shaped portion 110 may be performed using a numerically controlled precision gear grinding machine, wherein the step of grinding to remove the machining allowance of the tooth-shaped portion 110 includes: the first grinding wheel is used for grinding under the condition that the feeding speed is 0.001-0.003 mm/s, for example, the linear speed of the first grinding wheel is 200-300 mm/min, wherein the material of the first grinding wheel comprises silicon carbide, the silicon carbide has good heat conductivity, a part of processing temperature can be taken away in the grinding process, crystallization is avoided, on the other hand, the hardness is high, the grinding wheel is sharp, the processing excess material is easy to remove by grinding, the grinding wheel is durable, and the processing cost is reduced.
Alternatively, the step of grinding and removing the machining allowance of the cup-shaped portion 100 and the machining allowance of the boss may be performed by using a numerically controlled vertical grinder, wherein the step of grinding and removing the machining allowance of the cup-shaped portion 100 and the machining allowance of the boss includes: and grinding by adopting a second grinding wheel under the conditions that the feeding speed is 0.002-0.005 mm/s and the linear speed of the second grinding wheel is 200-300 mm/min, wherein the second grinding wheel is a cylinder for better grinding effect.
The material of the second grinding wheel comprises silicon carbide. Wherein the material of second emery wheel includes carborundum, and wherein carborundum heat conductivity is good, can take away partly processing temperature at the grinding in-process, avoids the crystallization, and on the other hand hardness is big, and the emery wheel is sharp, easily the grinding gets rid of the processing clout, and is durable, reduces the processing cost.
Alternatively, the step of grinding and removing the machining allowance of the inner wall of the through hole is performed by using a numerically controlled centerless grinder, and since the number of the through holes can be plural and non-coaxial, and each through hole is not coaxial with the cup-shaped portion 100, a vertical grinder cannot be used here, and a centerless grinder is used for difference compensation.
Wherein, the step of grinding and removing the machining allowance of the inner wall of the through hole comprises the following steps: adopt the third emery wheel to grind under the condition that feed rate is 0.003 ~ 0.006mm/s, third emery wheel linear velocity is 200 ~ 300mm/min, and the material of third emery wheel includes silicon carbide, and the silicon carbide heat conductivity is good, can take away partly processing temperature in grinding process, avoids the crystallization, and on the other hand hardness is big, and the emery wheel is sharp, easily the grinding gets rid of the processing clout, and is durable, reduces the processing cost.
The following describes the method for manufacturing the amorphous flexspline for the harmonic reducer according to the present invention in further detail with reference to the following examples.
In the following examples and comparative examples, Vit106 (Zr) of a zirconium-based system from the same source was used for the amorphous alloys57Nb5Cu15.4Ni12.6Al10)。
Example 1
(1) And putting the amorphous alloy into a crucible, and heating the amorphous alloy to 900 ℃ by using an induction coil to obtain the amorphous alloy in a molten state.
(2) Installing the amorphous flexible gear mold on a die casting machine, vacuumizing and preheating the amorphous flexible gear mold to ensure that the vacuum degree of a forming cavity of the amorphous flexible gear mold is 1 multiplied by 10-3pa, the temperature of the die is 170 ℃, the amorphous alloy in the molten state in the step (1) is poured into a charging basket of a die casting machine, then the molten amorphous alloy raw material is filled into a forming cavity at the filling speed of 6m/s by using a high-pressure injection rod of the die casting machine under the condition that the injection specific pressure is 55MPa, the filling time is 0.05s, the pressure is maintained for 6s under the condition of 4MPa, and then water cooling is carried out for 15 s.
(3) And opening the die, and ejecting the blank by using an ejection mechanism.
The blank is provided with a cup-shaped part, a tooth-shaped part and a boss part which are integrally formed, the tooth-shaped part is arranged on the periphery of the cup-shaped part, the tooth-shaped part is provided with a plurality of gear teeth which are arranged along the periphery of the cup-shaped part at equal intervals, each gear tooth extends along the axial direction of the cup-shaped part, the boss part protrudes out of one end of the cup-shaped part far away from the opening of the cup-shaped part, and the boss part is provided with a through hole which completely penetrates through the boss part and the cup-shaped part along the axial direction of the cup-shaped part; the inner wall of the cup-shaped portion has a machining allowance of 0.1mm in thickness, the outer wall of the tooth-shaped portion has a machining allowance of 0.05mm in thickness, the outer wall of the boss has a machining allowance of 0.05mm in thickness, and the inner wall of the through hole has a machining allowance of 0.03mm in thickness.
(4) Fixing the blank by using a clamp, and then removing the machining allowance of the tooth-shaped part of the blank by using a numerical control precision gear grinding machine, wherein a first grinding wheel is adopted for grinding under the conditions that the feeding speed is 0.002mm/s and the linear speed of the first grinding wheel is 250mm/min, and the material of the first grinding wheel is silicon carbide. And then, grinding and removing the machining allowance of the cup-shaped part and the machining allowance of the boss by using a numerical control vertical grinding machine, wherein a cylindrical second grinding wheel is adopted for grinding under the conditions that the feeding speed is 0.003mm/s and the linear speed of the second grinding wheel is 250mm/min, and the material of the second grinding wheel is silicon carbide. And finally, removing the machining allowance of the inner wall of the through hole by using a numerical control centerless grinding machine, specifically grinding by using a third grinding wheel under the conditions that the feeding speed is 0.004mm/s and the linear speed of the third grinding wheel is 250mm/min, wherein the third grinding wheel is made of silicon carbide.
Example 2
(1) And putting the amorphous alloy into a crucible, and heating the amorphous alloy to 1000 ℃ by using an induction coil to obtain the amorphous alloy in a molten state.
(2) Installing the amorphous flexible gear mold on a die casting machine, vacuumizing and preheating the amorphous flexible gear mold to ensure that the vacuum degree of a forming cavity of the amorphous flexible gear mold is 2 multiplied by 10-3And the temperature of the die is 173 ℃, the amorphous alloy in the molten state in the step (1) is poured into a charging basket of a die casting machine, then the molten amorphous alloy raw material is filled into a forming cavity at the filling speed of 5m/s by using a high-pressure injection rod of the die casting machine under the condition that the injection specific pressure is 52MPa, the filling time is 0.06s, the pressure is maintained for 5s under the condition of 5MPa, and then the water cooling is carried out for 9 s.
(3) And opening the die, and ejecting the blank by using an ejection mechanism.
The blank is provided with a cup-shaped part, a tooth-shaped part and a boss part which are integrally formed, the tooth-shaped part is arranged on the periphery of the cup-shaped part and is provided with a plurality of gear teeth which are arranged at equal intervals along the periphery of the cup-shaped part, each gear tooth extends along the axial direction of the cup-shaped part, the boss part protrudes out of one end of the cup-shaped part, which is far away from the opening of the cup-shaped part, the boss part is provided with a through hole which completely penetrates through the boss part and the cup-shaped part along the axial direction of the cup-shaped part, and the axial line of the through hole is parallel to the axial line of the cup-shaped part; the inner wall of the cup-shaped part has a machining allowance of 0.08mm in thickness, the outer wall of the tooth-shaped part has a machining allowance of 0.06mm in thickness, the outer wall of the boss has a machining allowance of 0.02mm in thickness, and the inner wall of the through hole has a machining allowance of 0.05mm in thickness.
(4) The method comprises the steps of fixing a blank by using a clamp, then removing machining allowance of a tooth-shaped part of the blank by using a numerical control precision gear grinding machine, and specifically grinding by using a first grinding wheel under the conditions that the feeding speed is 0.001mm/s and the linear speed of the first grinding wheel is 220mm/min, wherein the first grinding wheel is made of silicon carbide. And then, grinding and removing the machining allowance of the cup-shaped part and the machining allowance of the boss by using a numerical control vertical grinding machine, wherein a cylindrical second grinding wheel is adopted for grinding under the conditions that the feeding speed is 0.005mm/s and the linear speed of the second grinding wheel is 300mm/min, and the second grinding wheel is made of silicon carbide. And finally, removing the machining allowance of the inner wall of the through hole by using a numerical control centerless grinding machine, wherein the grinding is carried out by adopting a third grinding wheel under the conditions that the feeding speed is 0.003mm/s and the linear speed of the third grinding wheel is 300mm/min, and the third grinding wheel is made of silicon carbide.
Comparative example 1
It differs from example 1 only in that: the outer wall of the cup-shaped part has a machining allowance of 0.2mm in thickness, and the outer wall of the boss has a machining allowance of 0.1mm in thickness.
Comparative example 2
The finished product obtained in comparative example 2 has the same specifications as the finished product of example 1, and comparative example 2 differs from example 1 only in that: the amorphous flexible gear mold is characterized in that cavities of the amorphous flexible gear mold are different, a manufactured blank is provided with a cup-shaped portion, a gear ring portion and a boss portion which are integrally formed, the gear ring portion is free of teeth, the boss portion is free of holes, the machining allowance of the outer wall of the cup-shaped portion is 0.3mm, the machining allowance of the inner wall is 0.25mm, the machining allowance of the outer wall of the boss portion is 0.25mm, the internal machining allowance of the boss is 0.25mm, the outer wall of the inner wall of the cup-shaped portion of the gear and the outer wall of the inner wall of the boss portion are turned according to a drawing, and then gear hobbing is performed.
Comparative example 3
It differs from example 1 only in that: the turning mode is adopted, and the result shows that the blank adopted by the method has high precision and small machining allowance with a finished product, so that the precision required by a drawing can not be achieved in the turning process, and a high-quality product can not be obtained.
Test example 1
XRD patterns of the wall surface and the bottom wall of the blank obtained in example 1 and the amorphous flexible spline obtained in comparative examples 1-2 were obtained in the same manner, and the results are shown in fig. 3 to 6. The wall surface of the blank is the outer wall of the cup-shaped portion, the bottom wall of the blank is the outer wall of the boss portion, the wall surface of the amorphous flexible gear is the outer wall of the cup-shaped portion corresponding to the finished amorphous flexible gear after machining allowance is removed, and the bottom wall of the amorphous flexible gear is the outer wall of the boss portion corresponding to the finished amorphous flexible gear after machining allowance is removed.
Figure 3 is an XRD pattern of the outer wall and bottom wall of the blank made in example 1. FIG. 4 is an XRD pattern of the outer wall and bottom wall of the amorphous flexspline made in example 1; FIG. 5 is an XRD pattern of the outer wall and bottom wall of the amorphous flexspline made in comparative example 1; fig. 6 is an XRD pattern of the outer wall and the bottom wall of the amorphous flexspline prepared in comparative example 2.
Fig. 3 has a typical amorphous diffuse scattering peak, illustrating that it is an amorphous alloy. In contrast, in example 1, comparative example 1 and comparative example 2, crystallization occurred to some extent. However, fig. 4 shows a small change from fig. 3, indicating that the degree of crystallization of example 1 is low, whereas fig. 5 and 6 show a large change from fig. 3, indicating that the degree of crystallization is severe, and that the degree of crystallization of comparative example 2 is higher than that of comparative example 1.
That is to say, the mode that this application adopted can effectively reduce the crystallization that the amorphous flexspline for the harmonic speed reducer leads to in the course of working.
In addition to the above change in the degree of crystallization, in both example 1 and example 2, the processing time from the start of preparation to the obtainment of the amorphous flexspline is significantly shorter than that in comparative example 1 and comparative example 2, and the processing efficiency is effectively improved.
In summary, the embodiment of the present application provides a method for manufacturing an amorphous flexible gear for a harmonic reducer, and the manufactured amorphous flexible gear has high precision, and can avoid crystallization of an amorphous alloy material in a manufacturing process, ensure good performance of the amorphous flexible gear, improve utilization rate and processing efficiency of materials required for manufacturing the amorphous flexible gear, and effectively reduce production cost.
The foregoing is merely exemplary of the present application and is not intended to limit the present application, which may be modified or varied by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims (10)
1. A preparation method of an amorphous flexible gear for a harmonic reducer is characterized in that an amorphous flexible gear mold is provided with a molding cavity, and the preparation method comprises the following steps:
injecting the molten amorphous alloy raw material into a forming cavity under a vacuum condition for pressure maintaining to obtain a blank;
the blank is provided with a cup-shaped part, a tooth-shaped part and a boss part which are integrally formed, the tooth-shaped part is arranged on the periphery of the cup-shaped part, the tooth-shaped part is provided with a plurality of gear teeth which are arranged along the periphery of the cup-shaped part at equal intervals, each gear tooth extends along the axial direction of the cup-shaped part, the boss part protrudes out of one end of the cup-shaped part far away from the opening of the cup-shaped part, and the boss part is provided with a through hole which completely penetrates through the boss part and the cup-shaped part along the axial direction of the cup-shaped part; the inner wall of the cup-shaped part is provided with a machining allowance with the thickness of 0.05-0.1 mm, the outer wall of the tooth-shaped part is provided with a machining allowance with the thickness of 0.01-0.06 mm, the outer wall of the boss is provided with a machining allowance with the thickness of 0.02-0.06 mm, and the inner wall of the through hole is provided with a machining allowance with the thickness of 0.01-0.05 mm;
and respectively grinding and removing the machining allowance of the cup-shaped part, the machining allowance of the tooth-shaped part, the machining allowance of the boss and the machining allowance of the inner wall of the through hole to obtain the amorphous flexible gear.
2. The manufacturing method according to claim 1, wherein the step of grinding to remove the machining allowance of the tooth portion includes: grinding by using a first grinding wheel under the conditions that the feeding speed is 0.001-0.003 mm/s and the linear speed of the first grinding wheel is 200-300 mm/min, wherein the material of the first grinding wheel comprises silicon carbide.
3. The manufacturing method according to claim 1, wherein the step of grinding to remove the machining allowance of the cup-shaped portion and the machining allowance of the boss includes: grinding by using a second grinding wheel under the conditions that the feeding speed is 0.002-0.005 mm/s and the linear speed of the second grinding wheel is 200-300 mm/min, wherein the material of the second grinding wheel comprises silicon carbide.
4. The production method according to claim 1, wherein the step of grinding to remove the machining allowance of the inner wall of the through-hole includes: grinding by using a third grinding wheel under the conditions that the feeding speed is 0.003-0.006 mm/s and the linear speed of the third grinding wheel is 200-300 mm/min, wherein the third grinding wheel is made of silicon carbide.
5. A method of making as defined in claim 1 wherein said step of injecting comprises: and filling the molten amorphous alloy raw material into the molding cavity at a filling speed of 5-7 m/s under the condition that the injection pressure is 52-56 MPa, wherein the filling time is 0.04-0.06 s.
6. The production method according to any one of claims 1 to 5, characterized in that the step of holding pressure comprises: maintaining the pressure at 0.9-5 MPa for 4-7 s.
7. A production method according to any one of claims 1 to 5, wherein before injecting the molten amorphous alloy raw material into the molding cavity, the production method further comprises: preheating the mold to 150-180 ℃.
8. The method according to any one of claims 1 to 5, wherein the degree of vacuum of the vacuum condition is 2X 10-3～2×10-2pa。
9. The method according to any one of claims 1 to 5, wherein the amorphous alloy comprises a zirconium-based amorphous alloy;
optionally, the zirconium-based amorphous alloy comprises a Zr-Nb-Cu-Ni-Al system;
optionally, the zirconium-based amorphous alloy comprises Zr57Nb5Cu15.4Ni12.6Al10。
10. The method according to claim 9, wherein the molten amorphous alloy raw material is obtained by heating the amorphous alloy to 800 to 1000 ℃.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113969967A (en) * | 2021-10-26 | 2022-01-25 | 松山湖材料实验室 | Rigid wheel and preparation method thereof, harmonic reducer and application thereof |
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