CN114055103A - Gear machining process - Google Patents
Gear machining process Download PDFInfo
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- CN114055103A CN114055103A CN202111319544.0A CN202111319544A CN114055103A CN 114055103 A CN114055103 A CN 114055103A CN 202111319544 A CN202111319544 A CN 202111319544A CN 114055103 A CN114055103 A CN 114055103A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
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Abstract
The invention relates to the technical field of gears, and discloses a gear machining process, which comprises the following steps of forging and blank making and also comprises the following steps of: the selection of the gear positioning reference is different due to different structural shapes of the gears, the gear with the shaft is mainly positioned by adopting a tip, when the aperture is large, the conical plug is adopted, the precision of the tip positioning is high, the reference can be unified, and the following two positioning and clamping modes are often adopted when the gear surface of the gear with the hole is machined. According to the gear machining process, the gear teeth can be directly cast for large-size and low-precision gears by reducing the machining amount; for small-size and complex-shape gears, the gear blank with gear teeth can be manufactured by new processes such as precision casting, pressure casting, precision forging, powder metallurgy, hot rolling, cold extrusion and the like, so that the labor productivity is improved, and raw materials are saved.
Description
Technical Field
The invention relates to the technical field of gears, in particular to a gear machining process.
Background
A gear is a mechanical element with teeth on a rim that can continuously mesh to transmit motion and power. The gear transmission is widely applied to mechanical equipment in various industries such as industry, agriculture, national defense, aerospace, transportation and the like, motion and energy are transmitted through mutual meshing of a driving gear and a driven gear in the gear transmission process, mechanical vibration in a certain form is generated in the process, and the mechanical vibration state is easy to change due to abrasion, pitting corrosion, manufacturing errors, assembly errors and the like, so that the gear is also one of mechanical parts easy to damage.
The prior art has the following defects and shortcomings: the workpiece is subjected to heat treatment such as carburizing after a model for machining the gear is machined, but the core hardness of some blank pieces cannot meet the hardness requirement of the gear, so that the product has high failure rate due to the fact that the gear is machined firstly and then the heat treatment is carried out.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a gear processing technology, which can solve the problem of the existing gear processing technology; the device manufactures the gear blank with the gear teeth by the new processes of forging blank making, hot rolling, cold extrusion and the like, so that the labor productivity is improved, and the raw materials are saved to effectively solve the problems.
In order to achieve the purpose of the gear machining process, the invention provides the following technical scheme: a gear machining process comprises the following steps:
the method comprises the following steps: forging and blank making: the blank form of the gear mainly comprises a bar, a forging and a casting, wherein the bar is used for the gear which is small in size, simple in structure and low in strength requirement, when the gear requires high strength, wear resistance and impact resistance, the forging is multipurpose, the gear with the diameter larger than 400-600 mm is commonly used for casting the blank;
step two: normalizing: isothermal normalizing, arranging preheating normalizing or quenching and tempering before and after the gear blank processing, and mainly aiming at eliminating residual stress caused by forging and rough processing, improving the machinability of materials and improving the comprehensive mechanical property;
step three: turning: the processing of the gear blank is completely realized by adopting a numerical control lathe, and a mechanically clamped non-regrinding lathe tool is used, so that the processing of the aperture, the end surface and the outer diameter is synchronously finished under one clamping, the verticality requirement of an inner hole and the end surface is ensured, and the size dispersion of the large-batch gear blank production is small, so that the gear blank precision is improved, the processing quality of a subsequent gear is ensured, in addition, the high efficiency of the numerical control lathe processing is also greatly reduced, the equipment quantity is greatly reduced, and the economical efficiency is good;
step four: rolling and gear shaping:
1) 8-grade precision gears: the gear hobbing or gear shaping for the hardened and tempered gear can meet the requirements, and the hardened gear can be formed by the following steps: the machining scheme of gear hobbing, gear end machining, quenching and hole correction is adopted, but the tooth shape machining precision before quenching is improved by one step;
2)6-7 grade precision gear: for hardened gears, the following can be used: rough gear hobbing, fine gear hobbing, gear end machining, fine gear shaving, surface quenching, benchmark correction and gear honing;
3) gear with 5-grade precision or higher: the following are generally adopted: rough gear hobbing, fine gear hobbing, gear end machining, quenching, benchmark correction, rough gear grinding and fine gear grinding, wherein gear grinding is the machining method with highest precision and smallest surface roughness value in the existing gear shape machining, and the highest precision can reach 3-4 levels;
step five: gear shaving: the radial shaving technology is widely applied to the production of large-batch automobile gears due to the advantages of high efficiency, easy realization of the modification requirements of designed tooth shape and tooth direction and the like;
step six: and (3) heat treatment: after the tooth profile is processed, in order to improve the hardness and the wear resistance of the tooth surface, heat treatment procedures such as carburizing and quenching, high-frequency induction heating and quenching, carbonitriding, nitriding and the like are often carried out;
step seven: grinding: and performing finish machining on parts such as the inner hole, the end face and the outer diameter of the shaft of the gear subjected to heat treatment so as to improve the dimensional accuracy and reduce form and position tolerance.
Preferably, the forging blank further comprises the selection of a positioning reference: the selection of the gear positioning reference is different due to different structural shapes of the gears, the gears with shafts are mainly positioned by tips, when the hole diameter is large, the tips are plugged, the precision of the tip positioning is high, the reference is uniform, and the gears with holes are always positioned and clamped in the following two modes:
1) the gear center and the axial position are determined by positioning the inner hole and the end face, namely jointly positioning the inner hole and the end face of the workpiece, and a clamping mode facing the positioning end face is adopted, so that the positioning reference, the design reference, the assembly reference and the measurement reference are superposed, the positioning precision is high, the gear is suitable for batch production, and the requirement on the manufacturing precision of a clamp is high;
2) the fit clearance between the workpiece and the fixture mandrel is larger by positioning the excircle and the end face, the excircle is corrected by a dial indicator to determine the position of the center, and the workpiece and the fixture mandrel are positioned by the end face; clamping is performed from the other end face, and the mode is low in production efficiency because each workpiece needs to be corrected; it has high requirement for coaxiality of inner and outer circles of the gear blank and low requirement for precision of the clamp, so that it is suitable for single-piece and small-batch production.
Preferably, the forging blank is made of medium carbon steel and low and medium carbon alloy steel, such as 20Cr, 40Cr, 20CrMnTi and the like, important gears with higher requirements can be made of 38CrMoAlA nitriding steel, and non-force-transmission gears can also be made of cast iron, cloth-sandwiched bakelite, nylon and the like.
Preferably, the tooth blanks of the shaft gear and the sleeve gear mainly depend on the wheel body structure and the production type of the gear:
1) when a large amount of medium-sized gear blanks are processed in a large scale, the process scheme of drilling, pulling and turning multiple tools is adopted: positioning the outer circle and the end face of the blank to drill or expand the hole;
hole drawing;
roughly and finely turning the excircle, the end face, the cutting groove, the chamfer and the like on a multi-cutter semi-automatic lathe by positioning the hole;
2) when the gear blanks are produced in batches, a process scheme of turning and pulling one gear is adopted:
positioning by using the excircle or hub of the gear blank, and finely turning the excircle, the end face and the inner hole;
with end-face bearing pull-out or splined bore
And (5) positioning and finely turning the excircle, the end face and the like by using the hole.
Preferably, the selection of the processing schemes of the rolling and the gear shaping tooth profiles mainly depends on the precision grade, the structural shape, the production type and the production conditions of the gear, and the common processing schemes of the tooth profiles for the gears with different precision grades are as follows:
milling teeth: gear precision grade: grade 9 or below;
tooth surface roughness Ra: 6.3-3.2 μm;
the application range is as follows: in single piece repairing production, processing low-precision external cylindrical gears, racks, bevel gears and worm gears;
tooth broaching: gear precision grade: stage 7
Tooth surface roughness Ra: 1.6 to 0.4 μm
The application range is as follows: the 7-grade internal gears are produced in a large scale, and the external gear broach is complex to manufacture, so that the use is less;
gear hobbing, gear precision grade: 8 to 7 grades
Tooth surface roughness Ra: 3.2 to 1.6 μm
The application range is as follows: in various mass production, medium-quality external cylindrical gears and worm gears are processed;
gear shaping, gear precision grade: 8 to 7 grades
Tooth surface roughness Ra: 1.6 μm
The application range is as follows: in various mass production, processing medium-quality inner and outer cylindrical gears, multiple gears and small racks;
gear rolling (or gear inserting), quenching and gear honing, wherein the gear precision grade is as follows: 8 to 7 grades
Tooth surface roughness Ra: 0.8 to 0.4 μm
The application range is as follows: gears for tooth surface quenching;
gear hobbing-gear shaving, wherein the gear precision grade is as follows: 7 to 6 grades
Tooth surface roughness Ra: 0.8 to 0.4 μm
The application range is as follows: the method is mainly used for mass production;
gear hobbing, gear shaving, quenching and gear honing, wherein the gear precision grade is as follows: 7 to 6 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the method is mainly used for mass production;
gear hobbing, quenching and gear grinding, wherein the gear precision grade is as follows: 6 to 3 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the gear machining device is used for machining the gear surface of a high-precision gear, and is low in production efficiency and high in cost;
gear hobbing-gear grinding: gear precision grade: 6 to 3 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the gear surface machining method is used for machining the gear surface of the high-precision gear, and is low in productivity and high in cost.
Preferably, the grinding processing also comprises finishing the positioning reference surface, and both the inner hole and the end surface of the gear are deformed after quenching, so that if the tooth profile finish machining is directly carried out by using the hole and the end surface as references after quenching, the requirement on the precision of the gear is difficult to meet, and the tooth profile finish machining is carried out by positioning the finished reference surface, so that the positioning is accurate and reliable, the allowance distribution is uniform, and the purpose of finish machining is achieved.
Preferably, the machining of the gear blank before forging and blanking takes a very important position in the whole gear machining process, because the datum for tooth surface machining and detection must be machined at this stage.
Compared with the prior art, the invention provides a gear machining process, which has the following beneficial effects:
1. a gear processing technology reduces the machining amount by arranging a forging blank, and can directly cast gear teeth for large-size and low-precision gears; for the gears with small size and complex shape, the gear blank with gear teeth can be manufactured by new processes of precision casting, pressure casting, precision forging, powder metallurgy, hot rolling, cold extrusion and the like, so that the labor productivity is improved, and raw materials are saved;
2. a gear machining process is characterized in that gears are arranged, when a large number of medium-sized gear blanks are machined in a large scale, a production line or an automatic line can be formed by adopting an efficient machine tool, so that the production efficiency is high, and when the gear blanks are produced in batches, the gear blanks are machined by a horizontal lathe or a turret lathe and a broaching machine. It is characterized by stable processing quality and higher production efficiency;
3. a gear machining process is characterized in that a positioning reference is selected, and the selection of the positioning reference of a gear is different due to different structural shapes of the gear. The gear with the shaft is mainly positioned by a tip, and when the aperture is large, a conical plug is adopted. The precision of top location is high, and can accomplish the benchmark unified.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
A gear machining process comprises the following steps:
the method comprises the following steps: forging and blank making: the blank form of the gear mainly comprises a bar, a forging and a casting, wherein the bar is used for the gear which is small in size, simple in structure and low in strength requirement, when the gear requires high strength, wear resistance and impact resistance, the forging is multipurpose, the gear with the diameter larger than 400-600 mm is commonly used for casting the blank;
step two: normalizing: isothermal normalizing, arranging preheating normalizing or quenching and tempering before and after the gear blank processing, and mainly aiming at eliminating residual stress caused by forging and rough processing, improving the machinability of materials and improving the comprehensive mechanical property;
step three: turning: the processing of the gear blank is completely realized by adopting a numerical control lathe, and a mechanically clamped non-regrinding lathe tool is used, so that the processing of the aperture, the end surface and the outer diameter is synchronously finished under one clamping, the verticality requirement of an inner hole and the end surface is ensured, and the size dispersion of the large-batch gear blank production is small, so that the gear blank precision is improved, the processing quality of a subsequent gear is ensured, in addition, the high efficiency of the numerical control lathe processing is also greatly reduced, the equipment quantity is greatly reduced, and the economical efficiency is good;
step four: rolling and gear shaping:
1) 8-grade precision gears: the gear hobbing or gear shaping for the hardened and tempered gear can meet the requirements, and the hardened gear can be formed by the following steps: the machining scheme of gear hobbing, gear end machining, quenching and hole correction is adopted, but the tooth shape machining precision before quenching is improved by one step;
2)6-7 grade precision gear: for hardened gears, the following can be used: rough gear hobbing, fine gear hobbing, gear end machining, fine gear shaving, surface quenching, benchmark correction and gear honing;
3) gear with 5-grade precision or higher: the following are generally adopted: rough gear hobbing, fine gear hobbing, gear end machining, quenching, benchmark correction, rough gear grinding and fine gear grinding, wherein gear grinding is the machining method with highest precision and smallest surface roughness value in the existing gear shape machining, and the highest precision can reach 3-4 levels;
step five: gear shaving: the radial shaving technology is widely applied to the production of large-batch automobile gears due to the advantages of high efficiency, easy realization of the modification requirements of designed tooth shape and tooth direction and the like;
step six: and (3) heat treatment: after the tooth profile is processed, in order to improve the hardness and the wear resistance of the tooth surface, heat treatment procedures such as carburizing and quenching, high-frequency induction heating and quenching, carbonitriding, nitriding and the like are often carried out;
step seven: grinding: and performing finish machining on parts such as the inner hole, the end face and the outer diameter of the shaft of the gear subjected to heat treatment so as to improve the dimensional accuracy and reduce form and position tolerance.
Forging and blank making also comprises the selection of positioning references: the selection of the gear positioning reference is different due to different structural shapes of the gears, the gears with shafts are mainly positioned by tips, when the hole diameter is large, the tips are plugged, the precision of the tip positioning is high, the reference is uniform, and the gears with holes are always positioned and clamped in the following two modes:
1) the gear center and the axial position are determined by positioning the inner hole and the end face, namely jointly positioning the inner hole and the end face of the workpiece, and a clamping mode facing the positioning end face is adopted, so that the positioning reference, the design reference, the assembly reference and the measurement reference are superposed, the positioning precision is high, the gear is suitable for batch production, and the requirement on the manufacturing precision of a clamp is high;
2) the fit clearance between the workpiece and the fixture mandrel is larger by positioning the excircle and the end face, the excircle is corrected by a dial indicator to determine the position of the center, and the workpiece and the fixture mandrel are positioned by the end face; clamping is performed from the other end face, and the mode is low in production efficiency because each workpiece needs to be corrected; it has high requirement for coaxiality of inner and outer circles of the gear blank and low requirement for precision of the clamp, so that it is suitable for single-piece and small-batch production.
The material for forging blank is medium carbon steel and low and medium carbon alloy steel, such as 20Cr, 40Cr, 20CrMnTi, etc. for general gear, 38CrMoAlA nitrided steel can be used for important gear with higher requirement, and cast iron, cloth-sandwiched bakelite or nylon, etc. can be used for non-force-transmission gear.
The tooth blanks for shaft and sleeve gears depend mainly on the body structure and production type of the gear:
1) when a large amount of medium-sized gear blanks are processed in a large scale, the process scheme of drilling, pulling and turning multiple tools is adopted: positioning the outer circle and the end face of the blank to drill or expand the hole;
hole drawing;
roughly and finely turning the excircle, the end face, the cutting groove, the chamfer and the like on a multi-cutter semi-automatic lathe by positioning the hole;
2) when the gear blanks are produced in batches, a process scheme of turning and pulling one gear is adopted:
positioning by using the excircle or hub of the gear blank, and finely turning the excircle, the end face and the inner hole;
with end-face bearing pull-out or splined bore
And (5) positioning and finely turning the excircle, the end face and the like by using the hole.
The selection of the processing schemes of the rolling gear and the gear shaping gear mainly depends on the precision grade, the structural shape, the production type and the production conditions of the gear, and the common processing schemes of the gear with different precision grades are as follows:
milling teeth: gear precision grade: grade 9 or below;
tooth surface roughness Ra: 6.3-3.2 μm;
the application range is as follows: in single piece repairing production, processing low-precision external cylindrical gears, racks, bevel gears and worm gears;
tooth broaching: gear precision grade: stage 7
Tooth surface roughness Ra: 1.6 to 0.4 μm
The application range is as follows: the 7-grade internal gears are produced in a large scale, and the external gear broach is complex to manufacture, so that the use is less;
gear hobbing, gear precision grade: 8 to 7 grades
Tooth surface roughness Ra: 3.2 to 1.6 μm
The application range is as follows: in various mass production, medium-quality external cylindrical gears and worm gears are processed;
gear shaping, gear precision grade: 8 to 7 grades
Tooth surface roughness Ra: 1.6 μm
The application range is as follows: in various mass production, processing medium-quality inner and outer cylindrical gears, multiple gears and small racks;
gear rolling (or gear inserting), quenching and gear honing, wherein the gear precision grade is as follows: 8 to 7 grades
Tooth surface roughness Ra: 0.8 to 0.4 μm
The application range is as follows: gears for tooth surface quenching;
gear hobbing-gear shaving, wherein the gear precision grade is as follows: 7 to 6 grades
Tooth surface roughness Ra: 0.8 to 0.4 μm
The application range is as follows: the method is mainly used for mass production;
gear hobbing, gear shaving, quenching and gear honing, wherein the gear precision grade is as follows: 7 to 6 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the method is mainly used for mass production;
gear hobbing, quenching and gear grinding, wherein the gear precision grade is as follows: 6 to 3 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the gear machining device is used for machining the gear surface of a high-precision gear, and is low in production efficiency and high in cost;
gear hobbing-gear grinding: gear precision grade: 6 to 3 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the gear surface machining method is used for machining the gear surface of the high-precision gear, and is low in productivity and high in cost.
The grinding processing also comprises the step of finishing the positioning reference surface, the inner hole and the end surface of the gear can deform after quenching, if the gear profile finish machining is carried out by directly adopting the hole and the end surface as the reference after quenching, the requirement of the gear precision is difficult to achieve, the gear profile finish machining is carried out by positioning the finished reference surface, the positioning is accurate and reliable, the allowance distribution is uniform, and the purpose of finish machining is achieved.
The machining of gear blanks prior to forging and blanking is important during the entire gear machining process, as the datum for tooth flank machining and inspection must be machined at this stage.
In conclusion, the machining amount is reduced, and gear teeth can be directly cast for large-size and low-precision gears; for the gears with small size and complex shape, the gear blank with gear teeth can be manufactured by new processes of precision casting, pressure casting, precision forging, powder metallurgy, hot rolling, cold extrusion and the like, so that the labor productivity is improved, and raw materials are saved; when a large amount of medium-sized gear blanks are machined in a large scale, a production line or an automatic line can be formed by adopting an efficient machine tool, so that the production efficiency is high, and the gear blanks are produced in batches by using a horizontal lathe or a turret lathe and a broaching machine. It is characterized by stable processing quality and higher production efficiency; the selection of the gear positioning reference is different due to the different structural shapes of the gears. The gear with the shaft is mainly positioned by a tip, and when the aperture is large, a conical plug is adopted. The precision of top location is high, and can accomplish the benchmark unified.
The working use flow and the installation method of the invention are that when the gear machining process is used, the blank form of the gear mainly comprises a bar stock, a forging piece and a casting piece, the bar stock is used for the gear with small size, simple structure and low strength requirement, when the gear requires high strength, wear resistance and impact resistance, the forging piece is used for multiple purposes, the gear with the diameter larger than 400-600 mm is used for casting the blank in common use; isothermal normalizing, arranging preheating normalizing or quenching and tempering before and after the gear blank processing, and mainly aiming at eliminating residual stress caused by forging and rough processing, improving the machinability of materials and improving the comprehensive mechanical property; the processing of the gear blank is completely realized by adopting a numerical control lathe, and a mechanically clamped non-regrinding lathe tool is used, so that the processing of the aperture, the end surface and the outer diameter is synchronously finished under one clamping, the verticality requirement of an inner hole and the end surface is ensured, and the size dispersion of the large-batch gear blank production is small, so that the gear blank precision is improved, the processing quality of a subsequent gear is ensured, in addition, the high efficiency of the numerical control lathe processing is also greatly reduced, the equipment quantity is greatly reduced, and the economical efficiency is good; the radial shaving technology is widely applied to the production of large-batch automobile gears due to the advantages of high efficiency, easy realization of the modification requirements of designed tooth shape and tooth direction and the like; after the tooth profile is processed, in order to improve the hardness and the wear resistance of the tooth surface, heat treatment procedures such as carburizing and quenching, high-frequency induction heating and quenching, carbonitriding, nitriding and the like are often carried out; and performing finish machining on parts such as the inner hole, the end face and the outer diameter of the shaft of the gear subjected to heat treatment so as to improve the dimensional accuracy and reduce form and position tolerance.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (7)
1. A gear machining process is characterized in that: the method comprises the following steps:
the method comprises the following steps: forging and blank making: the blank form of the gear mainly comprises a bar, a forging and a casting, wherein the bar is used for the gear which is small in size, simple in structure and low in strength requirement, when the gear requires high strength, wear resistance and impact resistance, the forging is multipurpose, the gear with the diameter larger than 400-600 mm is commonly used for casting the blank;
step two: normalizing: isothermal normalizing, arranging preheating normalizing or quenching and tempering before and after the gear blank processing, and mainly aiming at eliminating residual stress caused by forging and rough processing, improving the machinability of materials and improving the comprehensive mechanical property;
step three: turning: the processing of the gear blank is completely realized by adopting a numerical control lathe, and a mechanically clamped non-regrinding lathe tool is used, so that the processing of the aperture, the end surface and the outer diameter is synchronously finished under one clamping, the verticality requirement of an inner hole and the end surface is ensured, and the size dispersion of the large-batch gear blank production is small, so that the gear blank precision is improved, the processing quality of a subsequent gear is ensured, in addition, the high efficiency of the numerical control lathe processing is also greatly reduced, the equipment quantity is greatly reduced, and the economical efficiency is good;
step four: rolling and gear shaping:
1) 8-grade precision gears: the gear hobbing or gear shaping for the hardened and tempered gear can meet the requirements, and the hardened gear can be formed by the following steps: the machining scheme of gear hobbing, gear end machining, quenching and hole correction is adopted, but the tooth shape machining precision before quenching is improved by one step;
2)6-7 grade precision gear: for hardened gears, the following can be used: rough gear hobbing, fine gear hobbing, gear end machining, fine gear shaving, surface quenching, benchmark correction and gear honing;
3) gear with 5-grade precision or higher: the following are generally adopted: rough gear hobbing, fine gear hobbing, gear end machining, quenching, benchmark correction, rough gear grinding and fine gear grinding, wherein gear grinding is the machining method with highest precision and smallest surface roughness value in the existing gear shape machining, and the highest precision can reach 3-4 levels;
step five: gear shaving: the radial shaving technology is widely applied to the production of large-batch automobile gears due to the advantages of high efficiency, easy realization of the modification requirements of designed tooth shape and tooth direction and the like;
step six: and (3) heat treatment: after the tooth profile is processed, in order to improve the hardness and the wear resistance of the tooth surface, heat treatment procedures such as carburizing and quenching, high-frequency induction heating and quenching, carbonitriding, nitriding and the like are often carried out;
step seven: grinding: and performing finish machining on parts such as the inner hole, the end face and the outer diameter of the shaft of the gear subjected to heat treatment so as to improve the dimensional accuracy and reduce form and position tolerance.
2. A gear machining process according to claim 1, characterized in that: the forging blank also comprises the following steps of selecting a positioning datum: the selection of the gear positioning reference is different due to different structural shapes of the gears, the gears with shafts are mainly positioned by tips, when the hole diameter is large, the tips are plugged, the precision of the tip positioning is high, the reference is uniform, and the gears with holes are always positioned and clamped in the following two modes:
1) the gear center and the axial position are determined by positioning the inner hole and the end face, namely jointly positioning the inner hole and the end face of the workpiece, and a clamping mode facing the positioning end face is adopted, so that the positioning reference, the design reference, the assembly reference and the measurement reference are superposed, the positioning precision is high, the gear is suitable for batch production, and the requirement on the manufacturing precision of a clamp is high;
2) the fit clearance between the workpiece and the fixture mandrel is larger by positioning the excircle and the end face, the excircle is corrected by a dial indicator to determine the position of the center, and the workpiece and the fixture mandrel are positioned by the end face; clamping is performed from the other end face, and the mode is low in production efficiency because each workpiece needs to be corrected; it has high requirement for coaxiality of inner and outer circles of the gear blank and low requirement for precision of the clamp, so that it is suitable for single-piece and small-batch production.
3. A gear machining process according to claim 1, characterized in that: the forging blank is made of medium carbon steel and low and medium carbon alloy steel, such as 20Cr, 40Cr, 20CrMnTi, etc. for general gears, 38CrMoAlA nitrided steel can be used for important gears with higher requirements, and cast iron, cloth-sandwiched bakelite or nylon, etc. can be used for non-force-transmission gears.
4. A gear machining process according to claim 1, characterized in that: the tooth blanks for shaft and sleeve gears depend mainly on the body structure and production type of the gear:
1) when a large amount of medium-sized gear blanks are processed in a large scale, the process scheme of drilling, pulling and turning multiple tools is adopted: positioning the outer circle and the end face of the blank to drill or expand the hole;
hole drawing;
roughly and finely turning the excircle, the end face, the cutting groove, the chamfer and the like on a multi-cutter semi-automatic lathe by positioning the hole;
2) when the gear blanks are produced in batches, a process scheme of turning and pulling one gear is adopted:
positioning by using the excircle or hub of the gear blank, and finely turning the excircle, the end face and the inner hole;
with end-face bearing pull-out or splined bore
And (5) positioning and finely turning the excircle, the end face and the like by using the hole.
5. A gear machining process according to claim 1, characterized in that: the selection of the processing schemes of the rolling gear and the gear shaping gear mainly depends on the precision grade, the structural shape, the production type and the production conditions of the gear, and the common processing schemes of the gear with different precision grades are as follows:
milling teeth: gear precision grade: grade 9 or below;
tooth surface roughness Ra: 6.3-3.2 μm;
the application range is as follows: in single piece repairing production, processing low-precision external cylindrical gears, racks, bevel gears and worm gears;
tooth broaching: gear precision grade: stage 7
Tooth surface roughness Ra: 1.6 to 0.4 μm
The application range is as follows: the 7-grade internal gears are produced in a large scale, and the external gear broach is complex to manufacture, so that the use is less;
gear hobbing, gear precision grade: 8 to 7 grades
Tooth surface roughness Ra: 3.2 to 1.6 μm
The application range is as follows: in various mass production, medium-quality external cylindrical gears and worm gears are processed;
gear shaping, gear precision grade: 8 to 7 grades
Tooth surface roughness Ra: 1.6 μm
The application range is as follows: in various mass production, processing medium-quality inner and outer cylindrical gears, multiple gears and small racks;
gear rolling (or gear inserting), quenching and gear honing, wherein the gear precision grade is as follows: 8 to 7 grades
Tooth surface roughness Ra: 0.8 to 0.4 μm
The application range is as follows: gears for tooth surface quenching;
gear hobbing-gear shaving, wherein the gear precision grade is as follows: 7 to 6 grades
Tooth surface roughness Ra: 0.8 to 0.4 μm
The application range is as follows: the method is mainly used for mass production;
gear hobbing, gear shaving, quenching and gear honing, wherein the gear precision grade is as follows: 7 to 6 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the method is mainly used for mass production;
gear hobbing, quenching and gear grinding, wherein the gear precision grade is as follows: 6 to 3 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the gear machining device is used for machining the gear surface of a high-precision gear, and is low in production efficiency and high in cost;
gear hobbing-gear grinding: gear precision grade: 6 to 3 grades
Tooth surface roughness Ra: 0.4 to 0.2 μm
The application range is as follows: the gear surface machining method is used for machining the gear surface of the high-precision gear, and is low in productivity and high in cost.
6. A gear machining process according to claim 1, characterized in that: the grinding processing also comprises the step of finishing the positioning reference surface, the inner hole and the end surface of the gear can deform after quenching, if the hole and the end surface are directly adopted as references to perform tooth profile finish machining after quenching, the requirement of the gear precision is difficult to achieve, the tooth profile finish machining is performed by positioning the finished reference surface, the positioning is accurate and reliable, the allowance distribution is uniform, and the purpose of finish machining is achieved.
7. A gear machining process according to claim 1, characterized in that: the machining of the gear blank before forging and blanking plays an important role in the whole gear machining process, because the datum for tooth surface machining and detection must be machined at this stage.
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| CN114669976A (en) * | 2022-03-31 | 2022-06-28 | 盛瑞传动股份有限公司 | Machining process of gear ring of planet row for transmission |
| CN114891991A (en) * | 2022-04-19 | 2022-08-12 | 杭州正元齿轮制造有限公司 | Heat treatment process for conical bearing |
| CN114905235A (en) * | 2022-04-19 | 2022-08-16 | 杭州正元齿轮制造有限公司 | Forging forming process for triple gear |
| CN115519323A (en) * | 2022-10-13 | 2022-12-27 | 四川普什宁江机床有限公司 | Multi-tooth probe processing method |
| CN118268824A (en) * | 2024-06-03 | 2024-07-02 | 山东磁浮列车轨道工程有限公司 | Manufacturing method of high-precision mountain toothed rail |
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| CN114669976A (en) * | 2022-03-31 | 2022-06-28 | 盛瑞传动股份有限公司 | Machining process of gear ring of planet row for transmission |
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| CN114905235A (en) * | 2022-04-19 | 2022-08-16 | 杭州正元齿轮制造有限公司 | Forging forming process for triple gear |
| CN115519323A (en) * | 2022-10-13 | 2022-12-27 | 四川普什宁江机床有限公司 | Multi-tooth probe processing method |
| CN118268824A (en) * | 2024-06-03 | 2024-07-02 | 山东磁浮列车轨道工程有限公司 | Manufacturing method of high-precision mountain toothed rail |
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