CN114058827B - Method for controlling hardness of spline after gear carburization integral quenching - Google Patents
Method for controlling hardness of spline after gear carburization integral quenching Download PDFInfo
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- CN114058827B CN114058827B CN202111421466.5A CN202111421466A CN114058827B CN 114058827 B CN114058827 B CN 114058827B CN 202111421466 A CN202111421466 A CN 202111421466A CN 114058827 B CN114058827 B CN 114058827B
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- C—CHEMISTRY; METALLURGY
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/32—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for gear wheels, worm wheels, or the like
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- 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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- C21D1/18—Hardening; Quenching with or without subsequent tempering
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- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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- C23C8/20—Carburising
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- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
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Abstract
The invention discloses a method for controlling the hardness of a spline after gear carburization integral quenching, which comprises the following steps: 1. gear die forging; 2. normalizing and high-temperature tempering, and processing three, hobbing and contours; 4. carburizing; 5. tempering at high temperature; 6. turning and spline machining; 7. protection of the anti-carburizing paint; 8. quenching; 9. tempering at low temperature; 10. and (5) finishing. According to the invention, the allowance design is carried out on the gear spline before gear carburization, so that the problem that the hardness of the spline after integral quenching is improved due to the fact that the carbon content of a carburized layer transition zone at the gear spline is increased is solved, the gear spline is protected by adopting anti-carburizing paint before quenching, the carbon potential protection of the carburized gear atmosphere is prevented from promoting the surface layer of the spline to be carburized, the problem that the surface hardness of the spline is higher due to the surface layer carburization at the spline is solved, and the problem that the spline hardness is higher due to the upper limit of chemical components of raw materials is prevented by accurately controlling the tempering temperature by utilizing a local surface induction tempering treatment method after low-temperature tempering.
Description
Technical Field
The invention belongs to the technical field of low-carbon alloy steel heat treatment, and particularly relates to a method for controlling spline hardness after gear carburization integral quenching.
Background
Gears are key parts in a transmission system of the coal mining machine, and the quality of the gears is critical to the running reliability of the coal mining machine. In recent years, the heat treatment mode of the heavy-duty gear tends to a carburized integral quenching mode, and the carburized, quenched and tempered and surface quenched modes have the problems that the contact fatigue strength and bending fatigue strength of gear teeth are insufficient due to incomplete quenching of tooth root parts and tooth core parts, so that the gear is in early failure; however, the gear carburization integral quenching also has the problem of higher spline hardness, and the product quality is difficult to ensure.
The defects of the prior art are as follows: 1. because of the adoption of the national standard material with high hardenability, the fluctuation of chemical components is large, so that the hardness of the chemical components to the upper limit gear spline exceeds the technical requirement range; 2. because the turning allowance of the gear spline before carburization is less than the carburetion depth of the spline, the hardness of the quenched spline exceeds the technical requirement range; 3. because the furnace atmosphere carbon potential is protected (0.85 percent Cp) in the integral quenching process of the carburized gear, the gear spline is carburised in the heat preservation process, and the hardness of the spline after integral quenching exceeds the technical requirement range.
There is therefore a need for a method of controlling the hardness of the spline after carburization of the gear and overall quenching.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for controlling the hardness of the spline after gear carburization integral quenching aiming at the defects of the prior art. According to the method, the rest design of the gear spline is carried out before gear carburization, so that the problem that the hardness of the spline is improved after integral quenching due to the fact that the carbon content of a carburized layer transition zone of the gear spline is increased is solved, the gear spline is protected by adopting anti-carburizing paint before quenching, the carbon potential protection of the carburized gear atmosphere is prevented from promoting the surface layer of the spline to be carburized, the problem that the surface hardness of the spline is higher due to the surface layer carburization of the spline is solved, and the problem that the spline hardness is higher due to the upper limit of chemical components of raw materials is prevented by accurately controlling the tempering temperature by utilizing a local surface induction tempering treatment method after low-temperature tempering.
In order to solve the technical problems, the invention adopts the following technical scheme: the method for controlling the hardness of the spline after the integral quenching of the gear carburization is characterized by comprising the following steps of:
step one, heating a cylindrical steel raw material, and then performing die forging to obtain a gear piece forging stock;
step two, normalizing and high-temperature tempering are sequentially carried out on the gear piece forging stock obtained in the step one, so as to obtain a blank;
step three, hobbing and contour machining are carried out on the blank obtained in the step two, and a blank body is obtained; reserving machining allowance at a spline in the machining process of the hobbing and the profile;
step four, carburizing the blank obtained in the step three to obtain a carburized gear blank;
step five, carrying out high-temperature tempering on the carburized gear blank obtained in the step four for two times to obtain a high-temperature tempered blank;
step six, turning a carburized layer at the spline part and processing the spline to the high-temperature tempered blank obtained in the step five to obtain a processed spline gear blank;
step seven, the processed spline gear blank obtained in the step six is subjected to anti-carbon seepage coating protection at the spline to obtain a gear blank subjected to anti-carbon seepage coating protection;
step eight, carrying out integral quenching on the gear blank which is protected by the spline anti-carbon seepage coating obtained in the step seven, so as to obtain an integral quenching gear blank;
step nine, carrying out low-temperature tempering on the gear integral quenching blank obtained in the step eight to obtain a gear low-temperature tempering blank; when the spline hardness of the gear low-temperature tempering blank body is greater than 42HRC, carrying out local surface induction tempering treatment on the spline part;
step ten, carrying out finish machining on the gear low-temperature tempering blank obtained in the step nine to obtain a gear part; the spline hardness of the gear part is 36 HRC-42 HRC, the precision grade is 8-9, and the surface finish is Ra3.2-6.3.
The gear part is manufactured by die forging to manufacture the preliminary shape of the gear, hobbing and contour machining to manufacture the outer contour of the position of the pre-machined spline into a round shape, facilitating the subsequent spline manufacture, leaving a certain margin, turning away the reserved margin at the spline by turning a carburized layer at the spline, manufacturing the spline by the spline, and finally finishing.
The method for controlling the hardness of the spline after the gear carburization integral quenching is characterized in that in the first step, the cylindrical steel raw material is 17Cr2Ni2MoA, 18CrMnNiMoA, 18Cr2Ni4WA or 20Cr2Ni4A low-carbon alloy steel; the initial forging temperature in the die forging process is 1120-1180 ℃, and the final forging temperature is 860-900 ℃. The invention adopts the material which is mainly formed by changing the temperature as the steel raw material, and has the advantages of high alloy content, good hardenability, excellent carburization and quenching performances and the like. The invention controls the initial forging temperature and the final forging temperature in the die forging process to ensure that the temperature of the cylindrical steel raw material is uniform and the tissue is transformed for a sufficient time, thereby improving the plasticity, reducing the high-temperature deformation resistance, improving the production efficiency and improving the internal quality of the cylindrical forging stock.
The method for controlling the hardness of the spline after the integral quenching of the gear carburization is characterized in that the normalizing temperature in the second step is 920-950 ℃, and the high-temperature tempering temperature is 630-670 ℃. The invention eliminates defects generated in the forging process by controlling the temperature of normalizing and high-temperature tempering, refines grains, reduces hardness, improves plasticity, removes internal stress, controls the temperature of normalizing to 920-950 ℃, ensures complete austenitization of a workpiece, adopts air cooling or air cooling to room temperature for cooling, aims at eliminating defects, refining grains, ensures the grain size to be more than 6 grade, ensures the temperature of high-temperature tempering to be 630-670 ℃, and is convenient for cutting processing due to the fact that raw materials are high-hardenability materials, the blank is subjected to martensite or bainite transformation and generates residual austenite structure due to air cooling or air cooling, and the blank is of an unbalanced structure, and the structure is stabilized by high-temperature tempering, the internal stress is removed and the hardness is controlled.
The method for controlling the hardness of the spline after the gear carburization integral quenching is characterized in that the reserved machining allowance at the spline part in the third step meets the following conditions: when the depth of the carburized layer is more than 0.6mm and less than 1.2mm, the thickness of the machining allowance is 2.0mm, when the depth of the carburized layer is more than or equal to 1.2mm and less than 2.0mm, the thickness of the machining allowance is 2.9mm, when the depth of the carburized layer is more than or equal to 2.0mm and less than 2.5mm, the thickness of the machining allowance is 3.8mm, when the depth of the carburized layer is more than or equal to 2.5mm and less than 3.0mm, the thickness of the machining allowance is 4.9mm, when the depth of the carburized layer is more than or equal to 3.0mm and less than 4.0mm, the thickness of the machining allowance is 6.3mm, and when the depth of the carburized layer is more than or equal to 4.0mm and less than 5.0mm, the thickness of the machining allowance is 7.6mm. According to the invention, the allowance of the carburized layer is turned at the position of the gear spline, the allowance of the carburized layer is not only the allowance of the depth of the carburized layer, but is generally considered to be consistent with the depth of the carburized layer by cold working, the recognition is not scientific, the depth of the carburized layer is the effective depth of the hardened layer, namely the depth from the surface to 0.35 percent of carbon content, but the hardness of the spline is controlled to be about 0.18-0.19 percent of the carbon content of the body, so that the problem of overhigh hardness of the spline is caused by the increase of the carbon content in the range of 0.35-0.20 percent, the design of the machining amount of the carburized layer is reserved at the position of the spline before carburized, the machining allowance is required to be designed in combination with the depth of the carburized layer of the gear tooth surface, namely the machining allowance is larger than the carburised depth at the position of the spline, namely the depth of the machining allowance exceeds the upper limit of the carbon content chemical composition of the carburized material, the main reason is that the material is high-hardenability material, the hardness of the spline is increased by 3-5 HRC after the integral quenching is slightly, the hardness of the spline is controlled according to the difference of the depth of the carburized layer, the machining allowance is ensured to be larger than the depth of the carburized layer, the hardness of the spline is adjusted, and the hardness of the gear is controlled to meet the requirement of the spline is met after the integral quenching is achieved.
The method for controlling the hardness of the spline after the integral quenching of gear carburization is characterized in that in the fourth step, the carburization adopts a nitrogen-methanol carburization atmosphere, the carburization temperature is 900-930 ℃, and the carbon potential Cp is 1.15-1.25%. The invention adopts the nitrogen-methanol atmosphere to carry out carburization processing, has the advantages of low cost and easy operation, and the finally obtained effective hardening layer can meet the use requirement by controlling the carburization temperature and carbon potential, and the thickness of the effective hardening layer is reduced by carrying out finish machining in the subsequent process, so that a thick carburized layer is required to be obtained for leaving enough processing allowance, and the tooth surface is provided with higher carbon content.
The method for controlling the hardness of the spline after the gear carburization integral quenching is characterized in that the temperature of the high-temperature tempering in the fifth step is 650-670 ℃ and the time is 4-6 h. According to the invention, carbide aggregation of a carburized layer structure is promoted by carrying out high-temperature tempering twice, the residual austenite amount is reduced, the residual austenite is completely converted, the hardness is reduced, a foundation is laid for subsequent processing, the problem that the residual austenite structure of the carburized layer is decomposed insufficiently and the subsequent overall quenching hardness is low due to the fact that the high-temperature tempering temperature is too low is avoided, the defect that the surface carburized layer is converted into austenite and the residual austenite content is increased due to the fact that the carbon concentration of the carburized layer is higher due to the fact that the high-temperature tempering temperature is too high is avoided, the problems that the high-temperature tempering is insufficient and the residual austenite conversion is insufficient due to the fact that the high-temperature tempering time is short are avoided, and the problems that the economic benefit is poor and unnecessary due to the long high-temperature tempering time are avoided.
The method for controlling the hardness of the spline after the gear carburization integral quenching is characterized in that the spline in the step six is processed into an inserted spline or a rolling spline. According to the invention, the spline is subjected to semi-finishing by inserting the spline or rolling the spline, so that the reserved allowance of the gear spline is removed.
The method for controlling the hardness of the spline after the gear carburization integral quenching is characterized in that the protection of the anti-carbon coating at the spline in the step seven comprises the following steps: cleaning the processed spline gear blank, then coating anti-carbon coating on the spline part by adopting a brushing method, and then drying; the thickness of the anti-carburizing paint is 1 mm-2 mm, the drying is manual drying or normal temperature airing for 1 h-2 h, and the brushing is one or two times; the quenching temperature is 790-810 ℃, quenching oil is adopted for quenching, the temperature of the quenching oil is 40-80 ℃, and the quenching time is 40-60 min. According to the invention, the anti-carburizing coating is protected at the spline, and the reason is that when the gear is integrally quenched, the carbon potential protection of the atmosphere in the quenching furnace leads to local carburetion of the spline, so that the gear spline has higher hardness, and the anti-carburizing coating is coated at the spline part with a certain thickness through strict process control to standardize the use points of the anti-carburizing coating, so that the carburetion of the spline part is prevented from being caused in the quenching heat preservation process; the invention thoroughly removes oil and rust on the surface of a workpiece through cleaning, so that the paint is firmly adsorbed on the anti-seepage surface of the workpiece, before the paint is applied, paint powder and a proper amount of water agent are poured into a plastic vessel for proportioning and blending, a stainless steel rod is used for stirring uniformly, the paint at a spline is coated by adopting a normal-temperature brushing method, the brushing method is adopted, the brushing is uniform, the brushing is preferably carried out for two times, when the first coating is slightly hard, the second coating is carried out, the drying of the coating is the most important ring in the whole coating process, the use effect is directly related, the drying speed is related to the thickness of the coating, the temperature, the humidity, ventilation and other conditions, and manual drying or normal-temperature airing can be selected for about 1h for drying; the invention combines the hardness of the gear surface and the core hardness by controlling the quenching temperature, the quenching oil temperature and the quenching time, improves the performance of the gear, avoids the defect of reduced surface carburized layer hardness caused by overhigh quenching temperature, and avoids the defect of lower core hardness and core ferrite grade more than 4 caused by low quenching temperature.
The method for controlling the hardness of the spline after the integral quenching of the gear carburization is characterized in that the low-temperature tempering temperature in the step eight is 180-200 ℃ and the time is 8-12 h. The invention promotes the quenched martensitic structure in the precursor of the quenched thin-wall part to be converted into a tempered martensitic structure by controlling the temperature and time of low-temperature tempering, and aims to enable the supersaturated martensitic structure to precipitate carbide in the low-temperature tempering process, eliminate residual stress generated by quenching, stabilize the structure, reduce brittleness and maintain high hardness, avoid the defect that quenched martensite only generates partial aggregation of carbon atoms due to the excessively low temperature tempering temperature, eliminate incomplete quenching internal stress, reduce surface hardness due to the excessively high low temperature tempering temperature and influence the abrasion resistance of the thin-wall part.
The method for controlling the hardness of the spline after the gear carburization integral quenching is characterized in that the condition of the local surface induction tempering treatment of the spline in the step nine is as follows: the intermediate frequency induction quenching machine tool is adopted, the output power of a power supply is 2.0 KHz-2.3 KHz, the gap of an induction coil is 8 mm-12 mm, the power factor is 50% -75%, the lifting speed of the coil is 15 mm/s-20 mm/s, the heating temperature is 450-520 ℃, an infrared temperature detection device is adopted to monitor the temperature in the process, and the cooling mode is air cooling or furnace cooling. The invention must remove the dirt, rust spot, impervious carbon coating on the surface of the part before the local induction tempering of the spline, the invention selects the medium frequency induction quenching machine tool by controlling the local induction tempering condition of the spline, adjusts the turn ratio of the transformer, controls the reasonable power output frequency, selects the proper induction coil according to the size of the spline of the workpiece before the induction heating, properly increases the clearance between the coil and the local tempering surface of the part, reduces the power output specific power, increases the temperature at a slower speed, determines the tempering heating temperature, strictly controls the production operating temperature, must pay attention to the control of the local tempering heating temperature of the gear spline, strictly adjusts the power output of the medium frequency quenching machine tool and the lifting speed of the coil according to the real-time temperature fed back by the novel double-color comparison infrared temperature detection device, and precisely controls the local tempering heating temperature of the spline, thereby ensuring the hardness after the spline tempering to meet the requirements. In order to reduce spline deformation, the cooling method needs to adopt an air cooling mode or slow descent in a furnace.
Compared with the prior art, the invention has the following advantages:
1. according to the invention, the gear spline is scientifically designed before carburization, so that the problem of hardness improvement of the spline after integral quenching caused by the increase of carbon content in a carburized layer transition region of the gear spline is prevented, and the spline hardness of the gear part is ensured to meet the use requirement.
2. According to the invention, the anti-carburizing coating is adopted to protect the spline of the gear before the gear is integrally quenched, so that the carbon potential protection of the atmosphere of the carburized gear is prevented from promoting the surface layer of the spline to be carburized, the problem of higher surface hardness of the spline caused by the surface layer carburization of the spline is solved, and the spline hardness is ensured to meet the requirement.
3. According to the method, aiming at the problem that the hardness of the spline of the gear with the upper limit of the chemical composition exceeds the technical requirement range due to the fact that the chemical composition of the national standard material with high hardenability fluctuates greatly, the local surface induction tempering treatment method is utilized for the spline with the hardness exceeding the standard after low-temperature tempering, the problem that the hardness of the spline is high due to the fact that the chemical composition of the raw material is higher than the upper limit is prevented by accurately controlling the tempering temperature, the quality of a gear product is improved, and the finish machining difficulty is reduced.
4. According to the invention, a novel bicolor contrast infrared temperature detection device is introduced in the local induction tempering treatment to monitor the temperature in real time, so that the final spline hardness is ensured to meet the technical requirements.
The technical scheme of the invention is further described in detail through the drawings and the embodiments.
Drawings
Fig. 1 is a schematic structural view of a blank of the present invention.
Fig. 2 is a schematic diagram of the structure of a gear blank protected by spline anti-carbon coating according to the invention.
Reference numerals illustrate:
1-spline contour; 2-machining allowance; 3-a machined spline gear blank;
4-anti-seepage carbon paint.
Detailed Description
As shown in fig. 1, in the gear hobbing and contour machining process, the outer contour of a spline is machined, the outer contour of the spline is machined into a round shape, a certain machining allowance 2 is reserved, a spline contour line 1 in the figure represents the position of the spline after subsequent machining, and a black part in the figure represents the reserved machining allowance 2.
As shown in fig. 2, the gear blank body protected by the spline anti-carbon coating according to the invention is formed by brushing a layer of anti-carbon coating 4 on the surface 3 of the gear blank body with the processed spline, and black thick lines in the figure indicate the anti-carbon coating 4.
Example 1
The embodiment comprises the following steps:
step one, heating a cylindrical steel raw material, and then performing die forging to obtain a gear piece forging stock; the cylindrical steel raw material is 17Cr2Ni2MoA low-carbon alloy steel; the initial forging temperature in the die forging process is 1160 ℃, and the final forging temperature is 880 ℃;
step two, normalizing and high-temperature tempering are sequentially carried out on the gear piece forging stock obtained in the step one, so as to obtain a blank; the normalizing temperature is 930 ℃, and the high-temperature tempering temperature is 650 ℃;
step three, hobbing and contour machining are carried out on the blank obtained in the step two, and a blank body is obtained; reserving machining allowance at a spline in the machining process of the hobbing and the profile; the reserved machining allowance at the spline part meets the following conditions: the thickness of the machining allowance is 3.8mm;
step four, carburizing the blank obtained in the step three to obtain a carburized gear blank; the carburization adopts a nitrogen-methanol carburization atmosphere, the carburization temperature is 920 ℃, and the carbon potential Cp is 1.20%; the depth of a carburized layer in the carburized gear blank is 2.3mm;
step five, carrying out high-temperature tempering on the carburized gear blank obtained in the step four for two times to obtain a high-temperature tempered blank; the temperature of the two high-temperature tempering is 660 ℃ and the time is 5 hours;
step six, turning a carburized layer at the spline part and processing the spline to the high-temperature tempered blank obtained in the step five to obtain a processed spline gear blank; the spline is processed into a spline;
step seven, the processed spline gear blank obtained in the step six is subjected to anti-carbon seepage coating protection at the spline to obtain a gear blank subjected to anti-carbon seepage coating protection; the anti-carbon coating protection at the spline comprises the following steps: cleaning the processed spline gear blank, then coating anti-carbon coating on the spline part by adopting a brushing method, and then drying; the thickness of the anti-carburizing paint is 1.5mm, the drying is manual drying, and the brushing is performed twice; the quenching temperature is 800 ℃, the quenching adopts Futon quick quenching oil, the Futon quick quenching oil temperature is 60 ℃, and the quenching time is 50min;
step eight, carrying out integral quenching on the spline anti-carbon seepage coating protection gear blank obtained in the step seven to obtain an integral quenching gear blank; the low-temperature tempering temperature is 190 ℃ and the time is 10 hours;
step nine, carrying out low-temperature tempering on the gear integral quenching blank obtained in the step eight to obtain a gear low-temperature tempering blank; the spline hardness of the low-temperature tempering blank of the gear is greater than 42HRC, and the low-temperature tempering blank of the gear is subjected to local surface induction tempering treatment at the spline position; the local surface induction tempering treatment conditions of the spline are as follows: adopting an intermediate frequency induction quenching machine tool, wherein the output power of a power supply is 2.2KHz, the power factor is 60%, the gap of an induction coil is 10mm, the lifting speed of the coil is 18mm/s, the heating temperature is 500 ℃, and the temperature is monitored by adopting a novel bicolor contrast infrared temperature detection device in the process, and the cooling mode is air cooling;
and step ten, carrying out finish machining on the gear low-temperature tempering blank obtained in the step nine to obtain a gear part.
Through detection, the spline hardness of the gear part prepared by the embodiment is 40HRC, the precision grade is 9, and the surface finish is Ra6.0.
Example 2
The embodiment comprises the following steps:
step one, heating a cylindrical steel raw material, and then performing die forging to obtain a gear piece forging stock; the cylindrical steel raw material is 18CrMnNiMoA low-carbon alloy steel; the initial forging temperature in the die forging process is 1120 ℃, and the final forging temperature is 900 ℃;
step two, normalizing and high-temperature tempering are sequentially carried out on the gear piece forging stock obtained in the step one, so as to obtain a blank; the normalizing temperature is 920 ℃, and the high-temperature tempering temperature is 670 ℃;
step three, hobbing and contour machining are carried out on the blank obtained in the step two, and a blank body is obtained; reserving machining allowance at a spline in the machining process of the hobbing and the profile; the reserved machining allowance at the spline part meets the following conditions: the thickness of the machining allowance is 4.9mm;
step four, carburizing the blank obtained in the step three to obtain a carburized gear blank; the carburization adopts a nitrogen-methanol carburization atmosphere, the carburization temperature is 900 ℃, and the carbon potential Cp is 1.25%; the depth of a carburized layer in the carburized gear blank is 2.8mm;
step five, carrying out high-temperature tempering on the carburized gear blank obtained in the step four for two times to obtain a high-temperature tempered blank; the temperature of the two high-temperature tempering is 650 ℃ and the time is 6 hours;
step six, turning a carburized layer at the spline part and processing the spline to the high-temperature tempered blank obtained in the step five to obtain a processed spline gear blank; the spline is processed into a rolling spline;
step seven, the processed spline gear blank obtained in the step six is subjected to anti-carbon seepage coating protection at the spline to obtain a gear blank subjected to anti-carbon seepage coating protection; the anti-carbon coating protection at the spline comprises the following steps: cleaning the processed spline gear blank, then coating anti-carbon coating on the spline part by adopting a brushing method, and then drying; the thickness of the anti-carburizing paint is 1mm, the drying is carried out at normal temperature for 2 hours, and the brushing is carried out twice; the quenching temperature is 790 ℃, the quenching adopts Futon quick quenching oil, the temperature of the Futon quick quenching oil is 80 ℃, and the quenching time is 40min;
step eight, carrying out integral quenching on the spline anti-carbon seepage coating protection gear blank obtained in the step seven to obtain an integral quenching gear blank; the low-temperature tempering temperature is 180 ℃ and the time is 12 hours;
step nine, carrying out low-temperature tempering on the gear integral quenching blank obtained in the step eight to obtain a gear low-temperature tempering blank; the spline hardness of the low-temperature tempering blank of the gear is greater than 42HRC, and the low-temperature tempering blank of the gear is subjected to local surface induction tempering treatment at the spline position; the local surface induction tempering treatment conditions of the spline are as follows: adopting an intermediate frequency induction quenching machine tool, wherein the output power of a power supply is 2.0KHz, the power factor is 75%, the gap of an induction coil is 8mm, the lifting speed of the coil is 20mm/s, the heating temperature is 450 ℃, and the temperature is monitored by adopting a novel bicolor contrast infrared temperature detection device in the process, and the cooling mode is furnace cooling;
and step ten, carrying out finish machining on the gear low-temperature tempering blank obtained in the step nine to obtain a gear part.
Through detection, the spline hardness of the gear part prepared by the embodiment is 36HRC, the precision grade is 8, and the surface finish is Ra6.3.
Example 3
The embodiment comprises the following steps:
step one, heating a cylindrical steel raw material, and then performing die forging to obtain a gear piece forging stock; the cylindrical steel raw material is 18Cr2Ni4WA low-carbon alloy steel; the initial forging temperature in the die forging process is 1180 ℃, and the final forging temperature is 860 ℃;
step two, normalizing and high-temperature tempering are sequentially carried out on the gear piece forging stock obtained in the step one, so as to obtain a blank; the normalizing temperature is 950 ℃, and the high-temperature tempering temperature is 630 ℃;
step three, hobbing and contour machining are carried out on the blank obtained in the step two, and a blank body is obtained; reserving machining allowance at a spline in the machining process of the hobbing and the profile; the reserved machining allowance at the spline part meets the following conditions: the thickness of the machining allowance is 2.9 mm;
step four, carburizing the blank obtained in the step three to obtain a carburized gear blank; the carburization adopts a nitrogen-methanol carburization atmosphere, the carburization temperature is 930 ℃, and the carbon potential Cp is 1.15%; the depth of a carburized layer in the carburized gear blank is 1.8mm;
step five, carrying out high-temperature tempering on the carburized gear blank obtained in the step four for two times to obtain a high-temperature tempered blank; the temperature of the two high-temperature tempering is 670 ℃ and the time is 4 hours;
step six, turning a carburized layer at the spline part and processing the spline to the high-temperature tempered blank obtained in the step five to obtain a processed spline gear blank; the spline is processed into a spline;
step seven, the processed spline gear blank obtained in the step six is subjected to anti-carbon seepage coating protection at the spline to obtain a gear blank subjected to anti-carbon seepage coating protection; the anti-carbon coating protection at the spline comprises the following steps: cleaning the processed spline gear blank, then coating anti-carbon coating on the spline part by adopting a brushing method, and then drying; the thickness of the anti-carburizing paint is 2mm, the drying is carried out at normal temperature for 1h, and the brushing is carried out twice; the quenching temperature is 810 ℃, the quenching adopts Futon quick quenching oil, the Futon quick quenching oil temperature is 40 ℃, and the quenching time is 60min;
step eight, carrying out integral quenching on the spline anti-carbon seepage coating protection gear blank obtained in the step seven to obtain an integral quenching gear blank; the low-temperature tempering temperature is 200 ℃ and the time is 8 hours;
step nine, carrying out low-temperature tempering on the gear integral quenching blank obtained in the step eight to obtain a gear low-temperature tempering blank; the spline hardness of the low-temperature tempering blank of the gear is greater than 42HRC, and the low-temperature tempering blank of the gear is subjected to local surface induction tempering treatment at the spline position; the local surface induction tempering treatment conditions of the spline are as follows: adopting an intermediate frequency induction quenching machine tool, wherein the output power of a power supply is 2.3KHz, the power factor is 50%, the gap of an induction coil is 12mm, the lifting speed of the coil is 15mm/s, the heating temperature is 520 ℃, and the temperature is monitored by adopting a novel bicolor contrast infrared temperature detection device in the process, and the cooling mode is furnace cooling;
and step ten, carrying out finish machining on the gear low-temperature tempering blank obtained in the step nine to obtain a gear part.
Through detection, the spline hardness of the gear part prepared by the embodiment is 42HRC, the precision grade is 8, and the surface finish is Ra5.5.
Example 4
The embodiment comprises the following steps:
step one, heating a cylindrical steel raw material, and then performing die forging to obtain a gear piece forging stock; the cylindrical steel raw material is 20Cr2Ni4A low-carbon alloy steel; the initial forging temperature in the die forging process is 1140 ℃, and the final forging temperature is 890 ℃;
step two, normalizing and high-temperature tempering are sequentially carried out on the gear piece forging stock obtained in the step one, so as to obtain a blank; the normalizing temperature is 930 ℃, and the high-temperature tempering temperature is 640 ℃;
step three, hobbing and contour machining are carried out on the blank obtained in the step two, and a blank body is obtained; reserving machining allowance at a spline in the machining process of the hobbing and the profile; the reserved machining allowance at the spline part meets the following conditions: the thickness of the machining allowance is 6.3mm;
step four, carburizing the blank obtained in the step three to obtain a carburized gear blank; the carburization adopts a nitrogen-methanol carburization atmosphere, the carburization temperature is 910 ℃, and the carbon potential Cp is 1.20%; the depth of a carburized layer in the carburized gear blank is 3.5mm;
step five, carrying out high-temperature tempering on the carburized gear blank obtained in the step four for two times to obtain a high-temperature tempered blank; the temperature of the two high-temperature tempering is 660 ℃ and the time is 5 hours;
step six, turning a carburized layer at the spline part and processing the spline to the high-temperature tempered blank obtained in the step five to obtain a processed spline gear blank; the spline is processed into an inserting spline or a rolling spline;
step seven, the processed spline gear blank obtained in the step six is subjected to anti-carbon seepage coating protection at the spline to obtain a gear blank subjected to anti-carbon seepage coating protection; the anti-carbon coating protection at the spline comprises the following steps: cleaning the processed spline gear blank, then coating anti-carbon coating on the spline part by adopting a brushing method, and then drying; the thickness of the anti-carburizing paint is 1.5mm, the drying is carried out at normal temperature for 1.5h, and the brushing is carried out once or twice; the quenching temperature is 800 ℃, the quenching adopts Fudun quick quenching oil, the Fudun quick quenching oil is 50 ℃, and the quenching time is 40-60 min;
step eight, carrying out integral quenching on the spline anti-carbon seepage coating protection gear blank obtained in the step seven to obtain an integral quenching gear blank; the low-temperature tempering temperature is 190 ℃ and the time is 9 hours;
step nine, carrying out low-temperature tempering on the gear integral quenching blank obtained in the step eight to obtain a gear low-temperature tempering blank; the spline hardness of the low-temperature tempering blank of the gear is greater than 42HRC, and the low-temperature tempering blank of the gear is subjected to local surface induction tempering treatment at the spline position; the local surface induction tempering treatment conditions of the spline are as follows: adopting an intermediate frequency induction quenching machine tool, wherein the output power of a power supply is 2.2KHz, the power factor is 70%, the gap of an induction coil is 11mm, the lifting speed of the coil is 18mm/s, the heating temperature is 500 ℃, and the temperature is monitored by adopting a novel bicolor contrast infrared temperature detection device in the process, and the cooling mode is air cooling;
and step ten, carrying out finish machining on the gear low-temperature tempering blank obtained in the step nine to obtain a gear part.
Through detection, the spline hardness of the gear part prepared by the embodiment is 40HRC, the precision grade is 9, and the surface finish is Ra4.8.
The above description is only of the preferred embodiments of the present invention, and is not intended to limit the present invention. Any simple modification, variation and equivalent variation of the above embodiments according to the technical substance of the invention still fall within the scope of the technical solution of the invention.
Claims (9)
1. The method for controlling the hardness of the spline after the integral quenching of the gear carburization is characterized by comprising the following steps of:
step one, heating a cylindrical steel raw material, and then performing die forging to obtain a gear piece forging stock;
step two, normalizing and high-temperature tempering are sequentially carried out on the gear piece forging stock obtained in the step one, so as to obtain a blank;
step three, hobbing and contour machining are carried out on the blank obtained in the step two, and a blank body is obtained; reserving machining allowance at a spline in the machining process of the hobbing and the profile; the reserved machining allowance at the spline part meets the following conditions: when the depth of the carburized layer is more than 0.6mm and less than 1.2mm, the thickness of the machining allowance is 2.0mm, when the depth of the carburized layer is more than or equal to 1.2mm and less than 2.0mm, the thickness of the machining allowance is 2.9mm, when the depth of the carburized layer is more than or equal to 2.0mm and less than 2.5mm, the thickness of the machining allowance is 3.8mm, when the depth of the carburized layer is more than or equal to 2.5mm and less than 3.0mm, the thickness of the machining allowance is 4.9mm, when the depth of the carburized layer is more than or equal to 3.0mm and less than 4.0mm, the thickness of the machining allowance is 6.3mm, and when the depth of the carburized layer is more than or equal to 4.0mm and less than 5.0mm, the thickness of the machining allowance is 7.6mm;
step four, carburizing the blank obtained in the step three to obtain a carburized gear blank;
step five, carrying out high-temperature tempering on the carburized gear blank obtained in the step four for two times to obtain a high-temperature tempered blank;
step six, turning a carburized layer at the spline part and processing the spline to the high-temperature tempered blank obtained in the step five to obtain a processed spline gear blank;
step seven, the processed spline gear blank obtained in the step six is subjected to anti-carbon seepage coating protection at the spline to obtain a gear blank subjected to anti-carbon seepage coating protection;
step eight, carrying out integral quenching on the gear blank which is protected by the spline anti-carbon seepage coating obtained in the step seven, so as to obtain an integral quenching gear blank;
step nine, carrying out low-temperature tempering on the gear integral quenching blank obtained in the step eight to obtain a gear low-temperature tempering blank; when the spline hardness of the gear low-temperature tempering blank body is greater than 42HRC, carrying out local surface induction tempering treatment on the spline part;
step ten, carrying out finish machining on the gear low-temperature tempering blank obtained in the step nine to obtain a gear part; the spline hardness of the gear part is 36 HRC-42 HRC, the precision grade is 8-9, and the surface finish is Ra3.2-6.3.
2. The method for controlling spline hardness after gear carburization integral quenching according to claim 1, wherein in the first step, the cylindrical steel raw material is 17Cr2Ni2MoA, 18CrMnNiMoA, 18Cr2Ni4WA or 20Cr2Ni4A low-carbon alloy steel; the initial forging temperature in the die forging process is 1120-1180 ℃, and the final forging temperature is 860-900 ℃.
3. The method for controlling the hardness of the spline after gear carburization integral quenching according to claim 1, wherein the normalizing temperature in the second step is 920-950 ℃, and the high-temperature tempering temperature is 630-670 ℃.
4. The method for controlling the hardness of the spline after gear carburization integral quenching according to claim 1, wherein in the fourth step, a nitrogen-methanol carburization atmosphere is adopted for carburization, the carburization temperature is 900-930 ℃, and the carbon potential Cp is 1.15-1.25%.
5. The method for controlling the hardness of the spline after gear carburization integral quenching according to claim 1, wherein the temperature of the high-temperature tempering in the fifth step is 650-670 ℃ for 4-6 h.
6. The method for controlling the hardness of a spline after gear carburization and integral quenching according to claim 1, wherein in the sixth step, the spline is processed into an insert spline or a rolling spline.
7. The method for controlling the hardness of the spline after gear carburization and integral quenching according to claim 1, wherein the protection of the anti-carburizing paint at the spline in the step seven comprises the following steps: cleaning the processed spline gear blank, then coating anti-carbon coating on the spline part by adopting a brushing method, and then drying; the thickness of the anti-carburizing paint is 1 mm-2 mm, the drying is manual drying or normal temperature airing for 1 h-2 h, and the brushing is one or two times; the quenching temperature is 790-810 ℃, quenching oil is adopted for quenching, the temperature of the quenching oil is 40-80 ℃, and the quenching time is 40-60 min.
8. The method for controlling the hardness of the spline after gear carburization integral quenching according to claim 1, wherein the low-temperature tempering temperature in the step eight is 180-200 ℃ and the time is 8-12 h.
9. The method for controlling hardness of a spline after gear carburization and integral quenching as claimed in claim 1, wherein the condition of the local surface induction tempering treatment at the spline in step nine is: an intermediate frequency induction quenching machine tool is adopted, the output power of a power supply is 2.0 KHz-2.3 KHz, the power factor is 50% -75%, the gap of an induction coil is 8 mm-12 mm, the lifting speed of the coil is 15 mm/s-20 mm/s, the heating temperature is 450-520 ℃, an infrared temperature detection device is adopted to monitor the temperature in the process, and the cooling mode is air cooling or furnace cooling.
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| CN114850809B (en) * | 2022-04-21 | 2023-05-09 | 新昌县金鹰齿轮箱有限公司 | Manufacturing method of internal spline gear for engineering vehicle |
| CN115283945B (en) * | 2022-07-19 | 2024-04-09 | 陕西法士特齿轮有限责任公司 | High-hardness synchronizer riveting locking pin and processing method thereof |
| CN115679242A (en) * | 2022-10-18 | 2023-02-03 | 河南柴油机重工有限责任公司 | Machining process for reducing deformation of low-carbon alloy steel gear |
| CN118028735B (en) * | 2024-02-20 | 2024-08-02 | 西安煤矿机械有限公司 | One-step carburization method for same piece and different layer of driving wheel of mining machine |
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