CN114001142B - High-load gear with low transmission noise and preparation method thereof - Google Patents

High-load gear with low transmission noise and preparation method thereof Download PDF

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Publication number
CN114001142B
CN114001142B CN202111249640.2A CN202111249640A CN114001142B CN 114001142 B CN114001142 B CN 114001142B CN 202111249640 A CN202111249640 A CN 202111249640A CN 114001142 B CN114001142 B CN 114001142B
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gear
deposition layer
silver
noise
hydrogen
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CN114001142A (en
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樊晓光
赵俊平
汪连英
李剑平
吴永强
王祖勇
牛恩来
余金科
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Dongfeng Commercial Vehicle Co Ltd
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Dongfeng Commercial Vehicle Co Ltd
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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
    • F16H55/06—Use of materials; Use of treatments of toothed members or worms to affect their intrinsic material properties
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/0021—Reactive sputtering or evaporation
    • C23C14/0036—Reactive sputtering
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/02—Pretreatment of the material to be coated
    • C23C14/028—Physical treatment to alter the texture of the substrate surface, e.g. grinding, polishing
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/0605—Carbon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/0641—Nitrides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24—Vacuum evaporation
    • C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
    • C23C14/325—Electric arc evaporation
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/34—Sputtering
    • C23C14/35—Sputtering by application of a magnetic field, e.g. magnetron sputtering
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/54—Controlling or regulating the coating process
    • 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
    • F16H55/14—Construction providing resilience or vibration-damping
    • 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
    • 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
    • F16H57/00—General details of gearing
    • F16H57/04—Features relating to lubrication or cooling or heating
    • F16H57/041—Coatings or solid lubricants, e.g. antiseize layers or pastes
    • 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
    • F16H57/00—General details of gearing
    • F16H57/04—Features relating to lubrication or cooling or heating
    • F16H57/0467—Elements of gearings to be lubricated, cooled or heated

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Thermal Sciences (AREA)
  • Gears, Cams (AREA)

Abstract

The invention relates to a high-load gear with low transmission noise and a preparation method thereof. According to the invention, the silver-doped nano-crystalline hydrogen-free diamond-like carbon deposition layer is prepared on the finished gear, silver atoms can be separated out after friction extrusion of the silver-doped nano-crystalline hydrogen-free diamond-like carbon deposition layer, nano holes with sound absorption effect are formed in the original positions of the silver nano-crystalline, and the silver lubrication layer is formed on the multi-nano-hole hydrogen-free diamond-like carbon deposition layer, so that the friction coefficient of the gear can be reduced, and the friction noise is reduced. Compared with a gearbox adopting a common gear, the noise of the gearbox adopting the high-load gear with low transmission noise can be reduced by 4.1 dB at maximum, and the noise reduction effect is obvious.

Description

High-load gear with low transmission noise and preparation method thereof
Technical Field
The invention relates to the technical field of transmission parts in the automobile manufacturing industry, in particular to a high-load gear with low transmission noise and a preparation method thereof.
Background
Noise not only reduces the comfort experience of people and even causes serious harm to human health, but also is more and more valued in recent years, so that the effort of reducing the noise of the whole commercial vehicle and each large assembly becomes one of key targets of truck design and manufacture. Gears are important in heavy truck engines, gearboxes and drive axles, friction and touch generated by various gears during transmission can form transmission noise, and the transmission noise greatly contributes to total noise generated by commercial vehicles, so that it is very important to find a reasonable method for reducing gear transmission noise.
The noise is generated by the gears for several reasons: (1) the running vibration speed of the gear is too high: the vibration speed is high, so that the vibration frequency is influenced, and noise is generated; (2) load impact: when the gears are subjected to loads of different degrees, the vibration frequency and the torsion direction are different, most of vibration force in the circumferential direction can be formed, and the problems of noise treatment of the gears can form smooth and uncrushed noise; (3) resonance-generated noise: when resonance is brought by gear transmission, the vibration generated by the rigidity difference of the gears and the vibration generated by friction between the gears are in the same vibration frequency, so that resonance is easy to occur due to interaction of the gears, and noise brought by resonance occurs; (4) partial gear surface smoothness is insufficient: many gears have large friction surfaces due to too rough surfaces, high vibration frequency and high generated noise when being rubbed with each other; (5) The lack of proper lubrication support results in no reduction in friction and thus no noise reduction.
The conventional ways of reducing noise generated by gear transmission mainly include: (1) The gear adopts fine high teeth in design, so that the contact ratio is increased; (2) performing precise shaping on the tooth surface to reduce friction; (3) improving the precision grade of the gear. The application of the method reduces noise generated in the gear transmission process to a certain extent, and improves user experience. However, the use of a slim high tooth design reduces the load carrying capacity of the gears to some extent for high load heavy duty commercial vehicle gearboxes, which is unacceptable and difficult to achieve; secondly, as the design of the gearbox of the heavy commercial vehicle needs to deal with more complicated working conditions, a pair of gears need to bear various working loads, and the tooth surface modification aiming at one working condition is difficult to take on the same effect under the other working condition, so that the tooth surface modification work has no small challenge; finally, increasing gear accuracy means higher and even multiplied manufacturing and machining costs, which are difficult to fully realize for current mass-produced automobile manufacturers in face of the intense price competition of various opponents.
Disclosure of Invention
In order to solve the problem of large transmission noise of a high-load gear, the invention provides the high-load gear with low transmission noise and the preparation method thereof, firstly, a hydrogen-free diamond-like carbon deposition layer (Diamond Like Carbon, DLC) doped with silver nanocrystals is prepared on a finished gear, silver atoms can be separated out from the hydrogen-free diamond-like carbon deposition layer doped with silver nanocrystals after friction extrusion, nanopores with sound absorption function are formed at the original positions of the silver nanocrystals, and a silver lubricating layer is formed on the hydrogen-free diamond-like carbon deposition layer with multiple nanopores, so that the friction coefficient of the gear can be reduced, and the friction noise is reduced.
The technical scheme provided by the invention is as follows:
in a first aspect, the present invention provides a high load gear with low transmission noise comprising:
the base body is a finished gear; and
the noise reduction coating at least can cover the transmission stress surface of the matrix, and at least comprises a silver-nanocrystalline-doped hydrogen-free diamond-like carbon deposition layer as an outermost layer.
Based on the technical scheme, the silver-nanocrystalline-doped hydrogen-free diamond-like carbon deposition layer is tougher and more wear-resistant than the matrix material, and the wear resistance of the gear can be improved after the stress surface of the coated gear is formed; the hydrogen-free diamond-like carbon deposition layer doped with silver nanocrystals can be rubbed for dozens of times to separate out silver nanocrystals, and a plurality of nanopores with sound absorption effect are formed on the hydrogen-free diamond-like carbon deposition layer, so that the vibration frequency of a matrix material is changed; the silver lubrication layer is formed on the surface of the multi-nano-hole hydrogen-free diamond-like carbon deposition layer after the precipitated silver particles are extruded under high load, so that the friction coefficient of the gear is reduced, and the friction noise is reduced.
On the basis of the high-load gear with low transmission noise, as a preferable technical scheme of the invention, the size of the silver nanocrystalline doped in the hydrogen-free diamond-like carbon deposition layer is 6nm-14nm. After silver nanocrystalline is separated out, micropores with the size slightly smaller than 6nm-14nm are left in the hydrogen-free diamond-like carbon deposition layer, and the sizes of the nano holes in the hydrogen-free diamond-like carbon deposition layer are controlled by controlling the sizes of doped nano silver particles.
On the basis of the high-load gear with low transmission noise, as a preferable technical scheme of the invention, the ratio of the silver nanocrystals in the hydrogen-free diamond-like carbon deposition layer doped with the silver nanocrystals is 3at% to 12at%. The invention controls the porosity of the hydrogen-free diamond-like carbon deposition layer in this way.
On the basis of the high-load gear with low transmission noise, which is provided by the invention, as a preferable technical scheme of the invention, the noise reduction coating sequentially comprises a pure chromium deposition layer, a CrN deposition layer and a silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer from inside to outside. The invention controls the compressive strength of the noise reduction coating and the bonding strength with the matrix in this way.
On the basis of the high-load gear with low transmission noise, as a preferable technical scheme of the invention, the thickness of the pure chromium deposition layer is 1-2 mu m; the thickness of the CrN deposition layer is 0.6 mu m-1 mu m; the thickness of the non-hydrogen diamond-like carbon deposition layer is 2-3 mu m. The total thickness of the noise reduction coating is not too thick due to the limitation of the accuracy requirement of the gear, and the total thickness of the noise reduction coating is controlled in the mode.
On the basis of the high-load gear with low transmission noise, which is provided by the invention, as a preferable technical scheme of the invention, the non-hydrogen diamond-like carbon deposition layer contains 6at% to 8at% of Cr atoms, and the hardness of the non-hydrogen diamond-like carbon deposition layer is controlled in the mode.
On the basis of the high-load gear with low transmission noise, as an optimal technical scheme, the noise reduction coating is only arranged on the transmission stress surface positioned on the outer surface of the gear, and the noise reduction coating is not arranged at other parts, for example, the inner ring of the outer gear does not participate in transmission, does not contribute to transmission noise, and is not arranged. As shown in fig. 1, the transmission stress surface of the gear comprises all tooth surfaces and upper and lower end surfaces of the gear.
On the basis of the high-load gear with low transmission noise, the finishing mode is one or more of shaving, grinding, extruding, lapping and honing.
On the basis of the high-load gear with low transmission noise, which is provided by the invention, the gear is used for a gearbox and a drive axle of a high-load heavy-duty commercial vehicle.
In a second aspect, the present invention provides a method for preparing the high load gear with low transmission noise, comprising the steps of:
providing a substrate;
and preparing the noise reduction coating serving as the outermost layer of the matrix transmission stress surface by adopting an unbalanced magnetron sputtering technology.
On the basis of the preparation method of the high-load gear with low transmission noise, which is provided by the invention, as a preferable technical scheme of the invention, before preparing the silver-nanocrystalline-doped hydrogen-free diamond-like carbon deposition layer, the preparation method further comprises the following steps:
blasting and cleaning the region to be coated of the substrate;
depositing metal Cr in a sand blasting area by adopting a multi-arc ion plating process technology to obtain a pure chromium deposition layer;
and depositing a CrN deposition layer on the pure chromium deposition layer sequentially by adopting an unbalanced magnetron sputtering technology.
On the basis of providing a method for preparing the high-load gear with low transmission noise, as a preferable technical scheme of the invention, after adopting an unbalanced magnetron sputtering technology to prepare the silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer as the outermost layer of the transmission stress surface of the matrix, the method further comprises the following steps:
taking 1/2 design bearing torque as running-in load, running for a period of time sequentially at 1/3, 2/3 and 1 of design rotating speed, and pre-running the gear.
On the basis of the method for preparing the high-load gear with low transmission noise, the method for depositing the silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer is as follows: the hydrogen-free diamond-like composite coating containing Cr element and Ag element is formed by controlling the current control coating components of the graphite target and the silver metal target by the unbalanced magnetron sputtering technology.
The invention has the following advantages and beneficial effects:
according to the noise reduction coating on the high-load gear with low transmission noise, provided by the invention, through friction induction generated by running-in of the gear in the initial stage, silver nanocrystals are separated out from the surface of the noise reduction coating, and separated silver particles form a very soft solid lubrication layer on the surface of a gear friction pair under the action of friction extrusion, so that the operation under the boundary lubrication condition of the high-load heavy-duty gear is fully lubricated, the friction coefficient between the gear friction pairs is effectively reduced, the transmission efficiency is improved, and meanwhile, the noise caused by friction shear is effectively reduced. The friction coefficient is effectively reduced by the formation of the solid lubricating layer, so that tangential force born by the surface of the heavy-duty gear is reduced, the risk of pitting caused by the tangential force of the heavy-duty gear is reduced, the bearing capacity of the gear is effectively improved, and the contact fatigue strength of the gear is improved.
Compared with a gearbox adopting a common gear, the noise of the gearbox adopting the high-load gear with low transmission noise can be reduced by 4.1 dB at maximum, and the noise reduction effect is obvious.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for the description of the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic diagram for explaining a covered portion of a noise reduction coating according to an embodiment of the present invention.
Fig. 2 is a schematic view for explaining the structure of a noise reduction coating according to an embodiment of the present invention; wherein, the alloy comprises a 1-substrate, a 2-pure chromium deposition layer, a 3-CrN deposition layer and a 4-doped silver nanocrystalline hydrogen-free diamond-like carbon deposition layer.
FIG. 3 illustrates the noise reduction effect of a high load gear with low transmission noise compared to a conventional gear in a transmission assembly; wherein # 5 represents a normal gear and # 2 represents a high load gear with low transmission noise.
Fig. 4 is an SEM photograph of silver particles precipitated on the surface of the hydrogen-free diamond-like carbon deposition layer doped with silver nanocrystals.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Hereinafter, "layer", "coating" and "deposited layer" are used as the same meaning concept. Such "layers" are uninterrupted, tightly bonded to the substrate or underlying deposited layer, and are not prone to flaking off in the same coating area. Each deposited layer is required to be uniform in thickness to meet the requirements of being unlikely to fall off, break, and crack under gear design loads.
The invention relates to a noise reduction coating which is designed for gears of a gearbox of a high-load heavy commercial vehicle. The coating object is a finished gear after machining, carburizing and quenching and finishing, and the finishing mode is one or any combination of more than two of shaving, grinding, extruding, lapping and honing.
The noise reduction coating can fully cover the whole outer surface of the finish machining gear, so that the cost is reduced, the noise reduction coating can only cover a transmission stress surface outside the gear, other parts which are not stressed or are less stressed are not covered with the noise reduction coating, for example, the inner ring of the outer gear does not participate in transmission, the transmission noise is not contributed, and the noise reduction coating is not arranged. As shown in fig. 1, the transmission stress surface of the gear comprises all the tooth surfaces, the upper end surface and the lower end surface of the gear and other parts with larger loads.
In order to meet the requirement that the noise reduction coating is not easy to fall off from a transmission stress surface, the noise reduction coating is a compact deposition layer and is prepared by adopting one or more of a multi-arc ion plating process technology and an unbalanced magnetron sputtering technology, and preferably, the noise reduction coating is preparedBefore the noise reduction coating, sand blasting is carried out on the area to be coated so as to activate the surface of the substrate and form micro pits on the surface of the substrate; and cleaning the substrate after sand blasting to remove sand blasting residues. Preferably, the sand blasting adopts white corundum sand, the main component of which is Al 2 O 3 。
The noise reduction coating disclosed by the invention is required to reduce the friction coefficient of a gear after forming the stressed surface of the coated gear, so that the surface of the noise reduction coating is required to be smooth or lubricated.
The noise reduction coating provided by the invention has a certain buffer effect after forming the stress surface of the coated gear, silver nanocrystals in the noise reduction coating are separated out, and nanometer holes are formed in the noise reduction coating, so that the noise reduction coating has a porous structure. In the running process, the porous structure can effectively relieve impact, so that noise generated by the impact is reduced, the risk of damage of the gear caused by the impact is also reduced, and the service life of the gear is prolonged. Preferably, the particle size of the silver nanocrystals is less than or equal to 100nm, more preferably, the particle size of the silver nanocrystals is less than or equal to 50nm, more preferably, the particle size of the silver nanocrystals is less than or equal to 20nm, and particularly preferably, the particle size of the silver nanocrystals is from 6nm to 14nm. Preferably, the content of silver nanocrystals is preferably 1at% to 20at%, more preferably, the content of silver nanocrystals is preferably 2at% to 16at%, particularly preferably, the content of silver nanocrystals is preferably 4at% to 12at%, particularly preferably, the content of silver nanocrystals is preferably 6at% to 10at%.
After the noise reduction coating is formed on the stressed surface of the coated gear, the wear resistance and compression resistance of the gear are required to be improved, so that the hardness of the noise reduction coating is required to be at least higher than that of a matrix material of the gear, and preferably, the noise reduction coating is a hydrogen-free diamond-like carbon deposition layer doped with silver nanocrystals. In order to improve the hardness of the non-hydrogen diamond-like carbon deposition layer, as a preferable technical scheme of the invention, the non-hydrogen diamond-like carbon deposition layer contains 6at% to 8at% of Cr atoms. The hardness of the noise reduction coating prepared by the method is between 1600HV and 2100HV, and is higher than that of the matrix material of the gear; the toughness of the silver-nano-crystal-doped hydrogen-free diamond-like carbon deposition layer is superior to that of a conventional hydrogen-free diamond-like carbon deposition layer, the service life is longer, and the silver-nano-crystal-doped hydrogen-free diamond-like carbon deposition layer is more suitable for the working condition of gears.
The noise reduction coating disclosed by the invention is required to have stronger binding force with a matrix after forming the stressed surface of the coated gear, and has higher compression resistance, so that a pure chromium deposition layer is directly deposited on the matrix to serve as a binding layer, a CrN deposition layer is deposited on the surface of the pure chromium deposition layer to serve as a supporting layer, and a silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer is deposited on the CrN deposition layer to serve as a porous layer and a wear-resistant layer. The total thickness of the noise reduction coating is not too thick due to the limitation of the precision requirement of the gear, and the thickness of the pure chromium deposition layer is preferably 1-2 mu m for controlling the total thickness of the noise reduction coating; the thickness of the CrN deposition layer is 0.6 mu m-1 mu m; the thickness of the non-hydrogen diamond-like carbon deposition layer is 2-3 μm.
To the extent that the effect of the invention is not impaired, the noise reduction coating can dope silver nanocrystalline in the CrN deposition layer and the pure chromium deposition layer so as to increase the doping amount of silver, on one hand, more silver simple substances can be separated out, and silver particles which fall off due to friction are supplemented; on the other hand, more nanometer holes are formed in the noise reduction coating, and the buffer performance of the noise reduction coating is improved.
The high-load gear with low transmission noise can be arranged in a gearbox assembly according to a normal assembly process, so that a silver simple substance solid lubricating layer can be automatically formed after friction for a period of time; it is also possible to carry out sufficient running-in beforehand, and install gears in the gearbox assembly where a solid lubrication layer has already been present. Preferably, it is ensured that at least one of the two friction pairs of the gearbox has a solid lubrication layer already present when mounted. The pre-grinding process comprises the following steps: half of the designed bearing torque is taken as running-in load, and the running-in load runs for 25min at 1/3, 2/3 and 1 of the designed rotating speed respectively.
The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to the specific details of the above embodiments, and various simple modifications can be made to the technical solution of the present invention within the scope of the technical concept of the present invention, and all the simple modifications belong to the protection scope of the present invention.
In addition, the specific features described in the above embodiments may be combined in any suitable manner, and in order to avoid unnecessary repetition, various possible combinations are not described further.
Moreover, any combination of the various embodiments of the invention can be made without departing from the spirit of the invention, which should also be considered as disclosed herein.
The present invention will be specifically described below with reference to examples, but the scope of the present invention is not limited thereto.
Example 1:
the preparation method of the high-load gear with low transmission noise provided by the embodiment comprises the following steps:
step (1): selecting one gear with smaller diameter of all gear friction pairs of a certain gearbox, machining, carburizing, quenching and gear grinding, and cleaning and drying the gears;
step (2): adopting white corundum sand with the particle size of 36-40 meshes to carry out sand blasting treatment on the surfaces of the gears; sand blasting parameters: the pressure of the compressed air is 0.6MPa, and the sand blasting time is 8-10 minutes;
step (3): carrying out ultrasonic cleaning on the gear after sand blasting;
step (4): the gears are put into a vacuum chamber of vacuum coating equipment, metal Cr is uniformly deposited on the tooth surface and the upper and lower end surfaces of the gears by adopting a multi-arc ion plating process technology, and the thickness of a formed pure chromium deposition layer is 1.3 mu m; the temperature of the gear is controlled to be lower than 180 ℃ in the deposition process. The main technological parameters are as follows: ar gas flow is 70sccm, vacuum chamber pressure is 0.1Pa, bias voltage is 60V, pure Cr target current is 50A, and pure Cr metal layer is deposited for about 40min;
step (5): the tooth surface and the upper and lower ends of the gears on which the pure chromium layers are deposited are formed by adopting an unbalanced magnetron sputtering technologyUniformly depositing a CrN deposition layer with the thickness of 0.8 mu m on the surface; the specific process parameters are as follows: ar gas flow rate was 30sccm, N 2 The gas flow is 90sccm, the bias voltage is 80V, the Cr target current is 40A, and a pure CrN deposition layer is deposited for about 30min;
step (6): and uniformly depositing a layer of silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer on the tooth surface and the upper and lower end surfaces of the gears on which the CrN deposition layer is deposited by adopting an unbalanced magnetron sputtering process technology, wherein the thickness is controlled to be 2 mu m. The content of Cr in the hydrogen-free diamond-like carbon deposition layer doped with silver nano-crystals is controlled to be 6at%, and the content of Ag is controlled to be 6at%.
Step (7): the gears are assembled into a certain gearbox assembly according to a normal assembly process, so that one gear in two friction pairs of the gearbox is guaranteed to have a noise reduction coating. Half of the designed bearing torque is taken as running-in load, and the running-in load runs for 25min at 1/3, 2/3 and 1 of the designed rotating speed respectively.
Step (8): and (3) installing the gearbox assembly provided with the gear processed in the step (7) on a standard test bed, firstly running in according to a standard test procedure, then testing noise data according to a standard noise test method, and comparing the noise data with the gearbox assembly provided with the common gear and of the same model.
The data obtained by the test are shown in fig. 3, and under different working conditions, the noise of the gearbox adopting the high-load gear with low transmission noise is reduced by 4.1 db at maximum and 2.2 db at average. The noise reduction coating prepared by the embodiment has uniform thickness, and is not easy to fall off, break and crack in the noise reduction test.
Example 2:
the preparation method of the high-load gear with low transmission noise provided by the embodiment comprises the following steps:
step (1): selecting one gear with smaller diameter of all gear friction pairs of a certain gearbox, machining, carburizing, quenching and gear grinding, and cleaning and drying the gears;
step (2): adopting white corundum sand with the particle size of 36-40 meshes to carry out sand blasting treatment on the surfaces of the gears; sand blasting parameters: the pressure of the compressed air is 0.6MPa, and the sand blasting time is 8-10 minutes;
step (3): carrying out ultrasonic cleaning on the gear after sand blasting;
step (4): the gears are put into a vacuum chamber of vacuum coating equipment, metal Cr is uniformly deposited on the tooth surfaces and the upper and lower end surfaces of the gears by adopting a multi-arc ion plating process technology, and the thickness of a formed pure chromium deposition layer is 2 mu m; the temperature of the gear is controlled to be lower than 180 ℃ in the deposition process. The main technological parameters are as follows: ar gas flow is 70sccm, vacuum chamber pressure is 0.1Pa, bias voltage is 60V, pure Cr target current is 60A, and pure Cr metal layer is deposited for about 60min;
step (5): uniformly depositing a CrN deposition layer with the thickness of 1 mu m on the tooth surfaces and the upper and lower end surfaces of the gears on which the pure chromium layers are deposited by adopting an unbalanced magnetron sputtering technology; the specific process parameters are as follows: ar gas flow rate was 30sccm, N 2 The gas flow is 90sccm, the bias voltage is 80V, the Cr target current is 40A, and a pure CrN deposition layer is deposited for about 45min;
step (6): and uniformly depositing a layer of silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer on the tooth surface and the upper and lower end surfaces of the gears on which the CrN deposition layer is deposited by adopting an unbalanced magnetron sputtering process technology, wherein the thickness is controlled to be 3 mu m. The Cr content in DLC is controlled to be 8at%, the Ag content is 12at%, and the size of silver nanocrystalline is controlled to be 9-14nm.
Step (7): the gears are assembled into a certain gearbox assembly according to a normal assembly process, so that one gear in two friction pairs of the gearbox is guaranteed to have a noise reduction coating. Half of the designed bearing torque is taken as running-in load, and the running-in load runs for 25min at 1/3, 2/3 and 1 of the designed rotating speed respectively.
Step (8): and (3) installing the gearbox assembly provided with the gear processed in the step (7) on a standard test bed, firstly running in according to a standard test procedure, then testing noise data according to a standard noise test method, and comparing the noise data with the gearbox assembly provided with the common gear and of the same model.
Under different working conditions, the noise of the gearbox adopting the high-load gear with low transmission noise is reduced by 4 dB at maximum and is reduced by 2.8 dB on average. The noise reduction coating prepared by the embodiment has uniform thickness, and is not easy to fall off, break and crack in the noise reduction test.
Comparative example 1:
the present comparative example provides a method of preparing a high load gear with low transmission noise without depositing a CrN support layer, comprising the steps of:
step (1): selecting one gear with smaller diameter of all gear friction pairs of a certain gearbox, machining, carburizing, quenching and gear grinding, and cleaning and drying the gears;
step (2): adopting white corundum sand with the particle size of 36-40 meshes to carry out sand blasting treatment on the surfaces of the gears; sand blasting parameters: the pressure of the compressed air is 0.6MPa, and the sand blasting time is 8-10 minutes;
step (3): carrying out ultrasonic cleaning on the gear after sand blasting;
step (4): the gears are put into a vacuum chamber of vacuum coating equipment, metal Cr is uniformly deposited on the tooth surfaces and the upper and lower end surfaces of the gears by adopting a multi-arc ion plating process technology, and the thickness of a formed pure chromium deposition layer is 2 mu m; the temperature of the gear is controlled to be lower than 180 ℃ in the deposition process. The main technological parameters are as follows: ar gas flow is 70sccm, vacuum chamber pressure is 0.1Pa, bias voltage is 60V, pure Cr target current is 60A, and pure Cr metal layer is deposited for about 60min;
step (5): and uniformly depositing a layer of silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer on the tooth surface and the upper and lower end surfaces of the gears on which the Cr deposition layer is deposited by adopting an unbalanced magnetron sputtering process technology, wherein the thickness is controlled to be 2 mu m. The Cr content in DLC is controlled to be 6at%, the Ag content is 12at%, and the size of silver nanocrystalline is controlled to be 9-12nm.
Step (6): and (3) installing the gearbox assembly provided with the gears processed in the step (5) on a standard test bench, firstly running in according to a standard test procedure, then testing noise data according to a standard noise test method, and comparing the noise data with the gearbox assembly provided with the common gears and of the same model.
The test shows that under different working conditions, the noise of the gearbox of the gear adopting the coating of the embodiment is slightly reduced, the maximum reduction is 2 db, and the average reduction is 1.5 db. Disassembly found localized flaking of the coating, thus resulting in poor noise reduction.
Comparative example 2:
the present comparative example provides a method for manufacturing a high load gear with low transmission noise without depositing Cr transition layer, comprising the steps of:
step (1): selecting one gear with smaller diameter of all gear friction pairs of a certain gearbox, machining, carburizing, quenching and gear grinding, and cleaning and drying the gears;
step (2): adopting white corundum sand with the particle size of 36-40 meshes to carry out sand blasting treatment on the surfaces of the gears; sand blasting parameters: the pressure of the compressed air is 0.6MPa, and the sand blasting time is 8-10 minutes;
step (3): carrying out ultrasonic cleaning on the gear after sand blasting;
step (4): loading gears into vacuum equipment, and uniformly depositing a CrN deposition layer with the thickness of 1 mu m on the tooth surfaces and the upper and lower end surfaces of the gears by adopting an unbalanced magnetron sputtering technology; the specific process parameters are as follows: ar gas flow rate was 30sccm, N 2 The gas flow is 90sccm, the bias voltage is 80V, the Cr target current is 40A, and a pure CrN deposition layer is deposited for about 45min;
step (5): and uniformly depositing a layer of silver-doped nano-crystalline hydrogen-free diamond-like carbon deposition layer on the tooth surface and the upper and lower end surfaces of the gears on which the CrN deposition layer is deposited by adopting an unbalanced magnetron sputtering process technology, wherein the thickness is controlled to be 2 mu m. The Cr content in DLC is controlled to be 6at%, the Ag content is 12at%, and the size of silver nanocrystalline is controlled to be 9-12nm.
Step (6): the gears are assembled into a certain gearbox assembly according to a normal assembly process, so that one gear in two friction pairs of the gearbox is guaranteed to have a noise reduction coating. Half of the designed bearing torque is taken as running-in load, and the running-in load runs for 25min at 1/3, 2/3 and 1 of the designed rotating speed respectively.
Step (7): and (3) installing the gearbox assembly provided with the gear processed in the step (6) on a standard test bed, firstly running in according to a standard test procedure, then testing noise data according to a standard noise test method, and comparing the noise data with the gearbox assembly provided with the common gear and of the same model.
The test shows that under different conditions, the noise of the gearbox of the gear adopting the coating of the embodiment has little change. Disassembly found that the coating had large areas of localized flaking, thus resulting in poor noise reduction.
The foregoing is only a specific embodiment of the invention to enable those skilled in the art to understand or practice the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims (1)

1. A method of manufacturing a high load gear with low transmission noise, the high load gear with low transmission noise comprising:
the base body is a finished gear; and
the noise reduction coating can at least cover a transmission stress surface of the matrix, and the transmission stress surface comprises a tooth surface and upper and lower end surfaces of the gear; the noise reduction coating at least comprises a hydrogen-free diamond-like carbon deposition layer doped with silver nanocrystals as an outermost layer; the size of the silver nanocrystalline is 6nm-14nm;
the noise reduction coating comprises a pure chromium deposition layer, a CrN deposition layer and a silver-nanocrystalline-doped hydrogen-free diamond-like carbon deposition layer from inside to outside in sequence;
the hydrogen-free diamond-like carbon deposition layer doped with the silver nanocrystals can separate out the silver nanocrystals after friction extrusion, nanopores with a plurality of sound absorption effects are formed at the original positions of the silver nanocrystals, and a silver lubrication layer is formed on the hydrogen-free diamond-like carbon deposition layer with the plurality of nanopores;
the preparation method of the high-load gear with low transmission noise comprises the following steps:
step (1): selecting one gear with smaller diameter of all gear friction pairs of a certain gearbox, machining, carburizing, quenching and gear grinding, and cleaning and drying the gears;
step (2): adopting white corundum sand with the particle size of 36-40 meshes to carry out sand blasting treatment on the surface of the gear; sand blasting parameters: the pressure of the compressed air is 0.6MPa, and the sand blasting time is 8-10 minutes;
step (3): carrying out ultrasonic cleaning on the gear after sand blasting;
step (4): loading the gear into a vacuum chamber of vacuum coating equipment, and uniformly depositing metal Cr on the tooth surface and the upper and lower end surfaces of the gear by adopting a multi-arc ion plating process technology, wherein the thickness of a formed pure chromium deposition layer is 1.3 mu m; controlling the temperature of the gear to be lower than 180 ℃ in the deposition process; the main technological parameters are as follows: ar gas flow is 70sccm, vacuum chamber pressure is 0.1Pa, bias voltage is 60V, pure Cr target current is 50A, and pure Cr metal layer is deposited for about 40min;
step (5): uniformly depositing a CrN deposition layer with the thickness of 0.8 mu m on the tooth surface and the upper and lower end surfaces of the gear on which the pure chromium layer is deposited by adopting an unbalanced magnetron sputtering technology; the specific process parameters are as follows: ar gas flow rate was 30sccm, N 2 The gas flow is 90sccm, the bias voltage is 80V, the Cr target current is 40A, and a pure CrN deposition layer is deposited for about 30min;
step (6): uniformly depositing a layer of silver-doped nanocrystalline hydrogen-free diamond-like carbon deposition layer on the tooth surface and the upper and lower end surfaces of the gear on which the CrN deposition layer is deposited by adopting an unbalanced magnetron sputtering process technology, wherein the thickness is controlled to be 2 mu m; the content of Cr in the hydrogen-free diamond-like carbon deposition layer doped with silver nano-crystals is controlled to be 6at%, and the content of Ag is controlled to be 6at%;
step (7): and (3) loading the gears into a certain gearbox assembly according to a normal assembly process, ensuring that one gear in two friction pairs of the gearbox is provided with a noise reduction coating, taking half of the designed bearing torque as running-in load, and respectively running at 1/3, 2/3 and 1 of the designed rotating speed for 25min.
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