CN114889040B - Method for manufacturing composite gear - Google Patents

Method for manufacturing composite gear Download PDF

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Publication number
CN114889040B
CN114889040B CN202210517094.4A CN202210517094A CN114889040B CN 114889040 B CN114889040 B CN 114889040B CN 202210517094 A CN202210517094 A CN 202210517094A CN 114889040 B CN114889040 B CN 114889040B
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gear blank
gear
blank
treatment
manufacturing
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CN114889040A (en
Inventor
吴镝
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Shenzhen Baidi Technology Co ltd
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Shenzhen Baidi Technology Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/08—Cleaning involving contact with liquid the liquid having chemical or dissolving effect
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
    • B08B3/12—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/1753—Cleaning or purging, e.g. of the injection unit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • B29C45/78—Measuring, controlling or regulating of temperature
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76494—Controlled parameter
    • B29C2945/76531—Temperature

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Thermal Sciences (AREA)
  • Gears, Cams (AREA)

Abstract

The invention discloses a manufacturing method of a composite gear, which comprises the following steps: providing a gear blank with sulphonates on the surface, which is obtained by pretreatment; providing a plastic mould, and placing the gear blank into the plastic mould; injecting PEEK material into the plastic mold through a screw barrel according to preset injection molding conditions so as to combine the PEEK material and the sulfonated to obtain the composite gear with the injection molding layer with the preset thickness on the surface. In the insert injection molding process, the invention can improve the binding force between the gear blank and the injection molding layer, reduce the stress concentration point of the binding surface, and improve the integral stress and fatigue resistance, so that the stress fatigue resistance of the gear surface is higher, and the gear transmission noise is smaller.

Description

Method for manufacturing composite gear
Technical Field
The invention relates to the technical field of gear manufacturing, in particular to a manufacturing method of a composite gear.
Background
The gear is a mechanical element with a gear on a rim for continuously meshing and transmitting motion and power, the special engineering plastic is a kind of engineering plastic with higher comprehensive performance and long-term use temperature of more than 150 ℃, the special engineering plastic has unique and excellent physical properties and is mainly applied to the high-tech fields of electronics and electric, special industry and the like, in the related technology, the inertia quantity of a metal gear in the transmission process is large, the tolerance moment of the gear in the transmission process is small, the insert injection molding of the existing gear is easy to cause insufficient binding force, the stress concentration point is easy to form on a binding surface, the stress and fatigue resistance of the whole piece are reduced, the stress fatigue resistance performance of the surface of the gear is lower, and the gear transmission noise is large.
Disclosure of Invention
The present invention aims to solve at least one of the technical problems in the related art to some extent. To this end, an object of the present invention is to propose a method for manufacturing a composite gear, comprising:
Providing a gear blank with sulphonates on the surface, which is obtained by pretreatment;
Providing a plastic mould, and placing the gear blank into the plastic mould;
Injecting PEEK material into the plastic mold through a screw barrel according to preset injection molding conditions so as to combine the PEEK material and the sulfonated to obtain the composite gear with the injection molding layer with the preset thickness on the surface.
Optionally, the pre-treatment of the gear blank comprises:
Providing a pretreated gear blank;
placing the gear blank in an acidic corrosive liquid, and carrying out anodic oxidation treatment on the gear blank under a preset condition to form the gear blank with an oxide layer;
After ultrasonic washing treatment is carried out on the gear blank with the oxide layer, the gear blank is placed into dimethyl sulfoxide solution with sulfonate under the preset condition for electrophoresis treatment;
carrying out ultrasonic washing treatment on the gear blank again, and carrying out constant-temperature drying to obtain a gear blank with the sulfonate on the surface; wherein the roughness of the gear blank is Ra3.2-Ra50.
Optionally, the pretreatment of the gear blank comprises:
Sand blasting and polishing the gear blank through sand materials with preset particle sizes so as to remove the surface oxide layer of the gear blank;
Placing the gear blank with the surface oxide layer removed into deionized water solution for degreasing treatment; wherein the temperature of the deoiling treatment is 50-75 ℃, and the treatment time is 5-10 minutes;
And carrying out ultrasonic washing treatment on the gear blank subjected to the degreasing treatment to finish the pretreatment operation on the gear blank.
Optionally, the deionized water solution comprises 3-5% of sodium carbonate, 3-5% of trisodium phosphate and 1-3% of sodium silicate.
Optionally, the ultrasonic washing is performed for 3-4 times, the washing time is 2-3 minutes, and the frequency of ultrasonic waves is 100kHz.
Optionally, the acidic corrosive liquid comprises hydrochloric acid, sulfuric acid and oxalic acid, wherein the ratio of the hydrochloric acid to the sulfuric acid to the oxalic acid is 3-3.5:2-2.5:0.5-1 percent, and the total mass percentage of the acid corrosive liquid is 2-10 percent.
Alternatively, the predetermined condition is a temperature of 30.+ -. 5 ℃, a current density of 500.+ -.50 mA/cm2, and ultrasonic treatment with ultrasonic waves of 50.+ -.25 kHz, and the ultrasonic treatment time is 3 to 10 minutes.
Optionally, the concentration of the dimethyl sulfoxide solution is 1-10wt%, and the sulfonate is one or more of sulfonated polysulfone (S-PSU), sulfonated polyether sulfone (S-PES), sulfonated polyphenylene sulfone (S-PPSU), sulfonated polyether ether ketone (S-PEEK), sulfonated polyether ketone (S-PEK), sulfonated polyether ketone (S-PEKK) and sulfonated polyether ketone ether ketone (S-PEKEKK).
Optionally, the thickness of the oxide layer is 10-50um.
Optionally, the predetermined injection molding conditions include: the temperature of the screw cylinder is 385+/-20 ℃, 395+/-20 ℃, 400+/-20 ℃ or 410+/-20 ℃, the temperature of the plastic mold is 190+/-20 ℃, the injection pressure is more than 80Mpa, and the injection period is less than 0.9s.
Optionally, the viscosity of the PEEK material is 300-800 Pa.s, and the preset thickness is 1-10mm.
The invention provides a manufacturing method of a composite gear, which comprises the steps of providing a gear blank with sulphonates on the surface, wherein the gear blank is obtained by pretreatment; providing a plastic mould, and placing the gear blank into the plastic mould; injecting PEEK material into the plastic mold through a screw barrel according to preset injection molding conditions so as to combine the PEEK material and the sulfonated to obtain the composite gear with the injection molding layer with the preset thickness on the surface. Therefore, in the insert injection molding process, the binding force between the gear blank and the injection molding layer can be improved, the stress concentration point of the binding surface is reduced, the integral stress and fatigue resistance are improved, the stress fatigue resistance of the gear surface is higher, and the gear transmission noise is smaller.
Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to the structures shown in these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of a method of manufacturing a composite gear according to an embodiment of the present invention;
FIG. 2 is a schematic view of a gear provided in an embodiment of the present invention;
Fig. 3 is an enlarged view of a portion a shown in fig. 2.
FIG. 4 is a partial schematic view of a gear blank provided in an embodiment of the invention;
Fig. 5 is an enlarged view of the portion B shown in fig. 4.
The achievement of the objects, functional features and advantages of the present invention will be further described with reference to the accompanying drawings, in conjunction with the embodiments.
Detailed Description
Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below are exemplary and intended to illustrate the present invention and should not be construed as limiting the invention, and all other embodiments, based on the embodiments of the present invention, which may be obtained by persons of ordinary skill in the art without inventive effort, are within the scope of the present invention.
The method of manufacturing a composite gear according to an embodiment of the present invention is described in detail below with reference to the accompanying drawings.
Referring to fig. 1, a method for manufacturing a composite gear according to an embodiment of the present invention includes:
s10, providing a gear blank with sulphonates on the surface, which is obtained by pretreatment;
S20, providing a plastic mould, and placing the gear blank into the plastic mould;
S30, injecting PEEK material into a plastic mold through a screw barrel according to preset injection molding conditions so as to combine the PEEK material with the sulfonated to obtain the composite gear with the injection molding layer with the preset thickness on the surface.
Wherein, the temperature of the screw cylinder can be 385+/-20 ℃, the temperature of the plastic mould can be controlled at 190+/-20 ℃, the injection pressure can be controlled to be more than 120Mpa in the injection molding process, the holding pressure can be kept at 60-95% of the injection pressure after the PEEK material and the sulfonated are combined, more preferably the holding pressure is 80-90%, and the holding pressure rate can be 50-95% of the injection molding rate, more preferably 75-85%; therefore, the overall binding force can be improved in the injection molding pressure maintaining process, and the injection molding efficiency is higher.
In the embodiment, the roughness of the gear blank is Ra3.2-Ra50, and the gear blank can be made of an aluminum alloy material or a special aluminum alloy material, and the sulfonate is sulfonated polysulfone (S-PSU), sulfonated polyethersulfone (S-PES), sulfonated polyphenylene sulfone (S-PPSU), sulfonated polyetheretherketone (S-PEEK), sulfonated polyetherketone (S-PEK), sulfonated polyetheretherketone (S-PEKK) or sulfonated polyetheretherketone (S-PEKEKK); wherein the predetermined injection molding conditions include: the temperature of the screw cylinder is 385+/-20 ℃, 395+/-20 ℃, 400+/-20 ℃ or 410+/-20 ℃, the temperature of the plastic mold is 190+/-20 ℃, the injection pressure is more than 80Mpa, and the injection period is less than 0.9s; the viscosity of the PEEK material is 300-800 Pa.s, and the preset thickness is 1-10mm.
In summary, after injection molding is completed, an injection molding layer with a predetermined thickness can be formed on the surface of the gear blank, so in this embodiment, gears corresponding to injection molding layers with different predetermined thicknesses are tested, and the testing conditions of the gears are as follows: the diameter of the gear is 100mm, the rotation torque is 50N.m, the rotation speed is 1000rpm, the lubricating medium adopts the total synthetic engine oil of a Mobil speed motor 2000W-40, the temperature of the lubricating oil is controlled to be 50+/-2 ℃, the machine is stopped every 4 hours to check the state of the gear, the test machine is returned to the initial state, the test is continued, and the conclusion obtained after the test is regulated and tested by the test is shown in the following table:
Gear parameters Pure aluminum alloy 1mm 2mm 5mm 20mm
Noise generation 45db 40db 37db 36db 36db
Time to pitting 60h 96h 150h 160h 140h
As can be seen from the above table, when the injection layer is not formed on the gear surface, the generated noise is 45db, the pitting time is 60h, when the injection layer is formed on the gear surface is 1mm, the generated noise is 40db, the pitting time is 96h, when the injection layer is formed on the gear surface is 2mm, the generated noise is 37db, the pitting time is 150h, when the injection layer is formed on the gear surface is 5mm, the generated noise is 36db, the pitting time is 160h, and when the injection layer is formed on the gear surface is 20mm, the generated noise is 36db, the pitting time is 140h, therefore, when the injection layer is formed on the gear surface is 5mm, the noise of the gear is minimum, and the pitting time is longest, the required PEEK material is reasonable, that is, the preferable preset thickness of the injection layer can be set to be 5mm in the injection process, so that the stress fatigue resistance performance of the gear surface can be higher, and the gear transmission noise is smaller.
The invention provides a manufacturing method of a composite gear, which comprises the steps of providing a gear blank with sulphonates on the surface, wherein the gear blank is obtained by pretreatment; providing a plastic mould, and placing the gear blank into the plastic mould; injecting PEEK material into the plastic mold through a screw barrel according to preset injection molding conditions so as to combine the PEEK material and the sulfonated to obtain the composite gear with the injection molding layer with the preset thickness on the surface. Therefore, in the insert injection molding process, the binding force between the gear blank and the injection molding layer can be improved, the stress concentration point of the binding surface is reduced, the integral stress and fatigue resistance are improved, the stress fatigue resistance of the gear surface is higher, and the gear transmission noise is smaller.
In an alternative embodiment, the pretreatment of the gear blank provided in the embodiments of the present invention includes: a pretreated gear blank is provided.
Specifically, the pretreatment of the gear blank includes:
Step one, sand blasting polishing is carried out on a gear blank through sand materials with preset particle sizes so as to remove a surface oxide layer of the gear blank;
Step two, putting the gear blank with the surface oxide layer removed into deionized water solution for degreasing treatment; wherein the temperature of the deoiling treatment is 50-75 ℃, and the treatment time is 5-10 minutes;
and thirdly, carrying out ultrasonic washing treatment on the gear blank subjected to the degreasing treatment so as to finish the pretreatment operation on the gear blank.
The gear blank can be made of an aluminum alloy material with a flat and smooth surface, for example, a 2-series, 5-series, 6-series and 7-series aluminum alloy material with high strength or high strength and fatigue resistance can be adopted, and because the aluminum alloy can generate a surface oxide layer under the air, the gear blank can be subjected to sand blasting polishing through a sand blasting polishing machine, so that the surface oxide layer of the gear blank is polished and removed, after the surface oxide layer is removed, the gear blank can be placed into deionized water solution for degreasing treatment, the degreasing treatment can be carried out for 8 minutes at 65 ℃, and after the degreasing treatment, the gear blank can be repeatedly washed for 3 times through an ultrasonic cleaner, wherein the washing time can be 3 minutes, so that the gear blank with a clean surface and no oxide layer is obtained.
Optionally, the deionized water solution comprises 3-5% of sodium carbonate, 3-5% of trisodium phosphate and 1-3% of sodium silicate; and the ultrasonic washing times are 3-4 times, the washing time is 2-3 minutes, the frequency of ultrasonic wave is 100kHz, the ultrasonic washing can be performed by adopting deionized water, and the deionized water is the pure water from which the impurities in the form of ions are removed.
Referring to fig. 3 and 4, according to the method for manufacturing a composite gear provided by the present invention, the following first to sixth embodiments use gear blanks having sulphonates on the surfaces thereof obtained by treatment under different conditions, and the overall treatment process is comprehensively analyzed.
First embodiment
The pretreatment of the gear blank provided in the first embodiment of the present invention includes:
taking a gear blank as an anode and graphite as a cathode, and placing the gear blank in a ratio of hydrochloric acid, sulfuric acid and oxalic acid of 3:2:0.5, and carrying out anodic oxidation treatment on the gear blank at the temperature of 25 ℃ and the current density of 450mA/cm < 2 >, and adopting ultrasonic waves of 35kHz to form an oxide layer with the thickness of 45um, wherein nano micropores are formed on the surface of the gear blank;
Placing the gear blank with the thickness of 45um of the oxide layer into an ultrasonic cleaner with the thickness of 100kHz to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is 2 minutes;
after the cleaning is completed, putting the gear blank into a dimethyl sulfoxide solution with sulfonate and the concentration of 1.5wt%, taking the gear blank as an anode, taking graphite as a cathode, and carrying out electrophoresis treatment at the temperature of 25 ℃ under the current density of 450mA/cm < 2 >, and adopting ultrasonic waves of 35 kHz;
Putting the gear blank into an ultrasonic cleaner with the frequency of 100kHz again to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is2 minutes;
After the completion of the washing, the gear blank was placed in a drying oven to be dried at a constant temperature of 200 ℃ for 20 minutes, to obtain a gear blank having a sulfonate on the surface.
Second embodiment
The pretreatment of the gear blank provided in the second embodiment of the present invention includes:
Taking a gear blank as an anode and graphite as a cathode, and placing the gear blank in a ratio of hydrochloric acid, sulfuric acid and oxalic acid of 3.2:2.4:0.7, and carrying out anodic oxidation treatment on the gear blank at the temperature of 25 ℃ and the current density of 450mA/cm <2 >, and adopting ultrasonic waves of 35kHz to form an oxide layer with the thickness of 32um, wherein nano micropores are formed on the surface of the gear blank;
placing the gear blank with the thickness of 32um of the oxide layer into an ultrasonic cleaner with the thickness of 100kHz to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is 2 minutes;
after the cleaning is finished, putting the gear blank into a dimethyl sulfoxide solution with a sulfonate and a concentration of 2.8wt%, taking the gear blank as an anode, taking graphite as a cathode, and carrying out electrophoresis treatment at a temperature of 35 ℃ and a current density of 550mA/cm < 2 >, and adopting ultrasonic waves of 75 kHz;
Putting the gear blank into an ultrasonic cleaner with the frequency of 100kHz again to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is2 minutes;
After the completion of the washing, the gear blank was placed in a drying oven to be dried at a constant temperature of 200 ℃ for 20 minutes, to obtain a gear blank having a sulfonate on the surface.
Third embodiment
The pretreatment of the gear blank provided in the third embodiment of the present invention includes:
taking a gear blank as an anode and graphite as a cathode, and placing the gear blank in a ratio of hydrochloric acid, sulfuric acid and oxalic acid of 3.5:2.6:0.6, and carrying out anodic oxidation treatment on the gear blank at the temperature of 35 ℃ and the current density of 550mA/cm <2 >, and adopting ultrasonic waves of 55kHz to form an oxide layer with the thickness of 27um, wherein nano micropores are formed on the surface of the gear blank;
Placing the gear blank with the thickness of 27um of the oxide layer into an ultrasonic cleaner with the thickness of 100kHz to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is 2 minutes;
After the cleaning is finished, putting the gear blank into a dimethyl sulfoxide solution with sulfonate and the concentration of 3.7wt%, taking the gear blank as an anode, taking graphite as a cathode, and carrying out electrophoresis treatment at the temperature of 35 ℃ and the current density of 550mA/cm < 2 >, and adopting ultrasonic waves of 55 kHz;
Putting the gear blank into an ultrasonic cleaner with the frequency of 100kHz again to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is2 minutes;
After the completion of the washing, the gear blank was placed in a drying oven to be dried at a constant temperature of 200 ℃ for 20 minutes, to obtain a gear blank having a sulfonate on the surface.
Fourth embodiment
The pretreatment of the gear blank provided in the fourth embodiment of the present invention includes:
taking a gear blank as an anode and graphite as a cathode, and placing the gear blank in a ratio of hydrochloric acid, sulfuric acid and oxalic acid of 3.3:2.1:0.8, and carrying out anodic oxidation treatment on the gear blank at the temperature of 25 ℃ and the current density of 450mA/cm <2 >, and adopting ultrasonic waves of 35kHz to form an oxide layer with the thickness of 25um, wherein nano micropores are formed on the surface of the gear blank;
placing the gear blank with the thickness of 25um of the oxide layer into an ultrasonic cleaner with the thickness of 100kHz to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is 2 minutes;
After the cleaning is completed, putting the gear blank into a dimethyl sulfoxide solution with sulfonate and concentration of 4wt%, taking the gear blank as an anode, taking graphite as a cathode, and carrying out electrophoresis treatment at the temperature of 25 ℃ under the current density of 450mA/cm < 2 >, and adopting ultrasonic waves of 35 kHz;
Putting the gear blank into an ultrasonic cleaner with the frequency of 100kHz again to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is2 minutes;
After the completion of the washing, the gear blank was placed in a drying oven to be dried at a constant temperature of 200 ℃ for 20 minutes, to obtain a gear blank having a sulfonate on the surface.
Fifth embodiment
The pretreatment of the gear blank provided in the fifth embodiment of the present invention includes:
Taking a gear blank as an anode and graphite as a cathode, and placing the gear blank in a ratio of hydrochloric acid, sulfuric acid and oxalic acid of 3.1:2.3:0.9, and carrying out anodic oxidation treatment on the gear blank at the temperature of 35 ℃ and the current density of 550mA/cm <2 >, and adopting ultrasonic waves of 75kHz to form an oxide layer with the thickness of 18um, wherein nano micropores are formed on the surface of the gear blank;
Placing the gear blank with the thickness of 18um of the oxide layer into an ultrasonic cleaner with the thickness of 100kHz to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is 2 minutes;
after the cleaning is completed, putting the gear blank into a dimethyl sulfoxide solution with sulfonate and the concentration of 4wt%, taking the gear blank as an anode, taking graphite as a cathode, and carrying out electrophoresis treatment at the temperature of 35 ℃ and the current density of 550mA/cm < 2 >, and adopting ultrasonic waves of 75 kHz;
Putting the gear blank into an ultrasonic cleaner with the frequency of 100kHz again to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is2 minutes;
After the completion of the washing, the gear blank was placed in a drying oven to be dried at a constant temperature of 200 ℃ for 20 minutes, to obtain a gear blank having a sulfonate on the surface.
Sixth embodiment
The pretreatment of the gear blank provided in the sixth embodiment of the present invention includes:
Taking a gear blank as an anode and graphite as a cathode, and placing the gear blank in a ratio of hydrochloric acid, sulfuric acid and oxalic acid of 3.5:2.5:1, and carrying out anodic oxidation treatment on the gear blank at the temperature of 35 ℃ and the current density of 550mA/cm < 2 >, and adopting ultrasonic waves of 75kHz to form an oxide layer with the thickness of 13um, wherein nano micropores are formed on the surface of the gear blank;
Placing the gear blank with the thickness of 13um of the oxide layer into an ultrasonic cleaner with the thickness of 100kHz to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is 2 minutes;
after the cleaning is completed, placing the gear blank into a dimethyl sulfoxide solution with sulfonate and concentration of 2wt%, taking the gear blank as an anode, taking graphite as a cathode, and carrying out electrophoresis treatment at the temperature of 35 ℃ and the current density of 550mA/cm < 2 >, and adopting ultrasonic waves of 75 kHz;
Putting the gear blank into an ultrasonic cleaner with the frequency of 100kHz again to carry out ultrasonic water washing for 3 times through deionized water, wherein the time for each washing is2 minutes;
After the completion of the washing, the gear blank was placed in a drying oven to be dried at a constant temperature of 200 ℃ for 20 minutes, to obtain a gear blank having a sulfonate on the surface.
As is clear from the above-described first to sixth embodiments, the thinner the oxide layer is formed and the larger the nano-micropores are formed when the proportion of the acidic etching solution is higher, and the thicker the oxide layer is formed and the smaller the nano-micropores are formed when the proportion of the acidic etching solution is lower; and when the concentration of the dimethyl sulfoxide solution of the sulfonate is higher, the binding force of the sulfonate permeated in the nanometer micropores of the gear blank is firmer, and when the sulfonate is used for carrying out insert injection molding on the PEEK material and the gear blank, the binding force is tighter.
In the description of the present specification, a description referring to terms "one embodiment," "some embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, the different embodiments or examples described in this specification and the features of the different embodiments or examples may be combined and combined by those skilled in the art without contradiction.
The foregoing description is only of the preferred embodiments of the present invention and is not intended to limit the scope of the invention, and all equivalent structural changes made by the description of the present invention and the accompanying drawings or direct/indirect application in other related technical fields are included in the scope of the invention.

Claims (8)

1.A method of manufacturing a composite gear, comprising:
Providing a gear blank with sulphonates on the surface, which is obtained by pretreatment;
Providing a plastic mold, and placing the gear blank into the plastic mold;
Injecting PEEK material into the plastic mold through a screw barrel according to preset injection molding conditions so as to combine the PEEK material and the sulfonated to obtain a composite gear with an injection molding layer with a preset thickness on the surface;
Providing a pretreated gear blank;
Placing the gear blank in an acidic corrosive liquid, and carrying out anodic oxidation treatment on the gear blank under a preset condition to form the gear blank with an oxide layer and nano-scale micropores formed on the surface;
After ultrasonic washing treatment is carried out on the gear blank with the oxide layer, the gear blank is placed into dimethyl sulfoxide solution with sulfonate under the preset condition for electrophoresis treatment;
carrying out ultrasonic washing treatment on the gear blank again, and carrying out constant-temperature drying to obtain a gear blank with the sulfonate on the surface; wherein the gear blank has a roughness of Ra3.2-Ra50;
The concentration of the dimethyl sulfoxide solution is 1-10wt%, and the sulfonate is one or more of sulfonated polysulfone (S-PSU), sulfonated polyether sulfone (S-PES), sulfonated polyphenylene sulfone (S-PPSU), sulfonated polyether ether ketone (S-PEEK), sulfonated polyether ketone (S-PEK), sulfonated polyether ketone (S-PEKK) and sulfonated polyether ketone ether ketone (S-PEKEKK).
2. The method of manufacturing a composite gear according to claim 1, wherein the pretreatment of the gear blank comprises:
Sand blasting and polishing the gear blank through sand materials with preset particle sizes so as to remove the surface oxide layer of the gear blank;
Placing the gear blank with the surface oxide layer removed into deionized water solution for degreasing treatment; wherein the temperature of the deoiling treatment is 50-75 ℃, and the treatment time is 5-10 minutes;
And carrying out ultrasonic washing treatment on the gear blank subjected to the degreasing treatment to finish the pretreatment operation on the gear blank.
3. The method of manufacturing a composite gear according to claim 2, wherein the deionized water solution comprises 3-5% sodium carbonate, 3-5% trisodium phosphate, and 1-3% sodium silicate.
4. The method for manufacturing a composite gear according to claim 1, wherein the acidic corrosive liquid comprises hydrochloric acid, sulfuric acid and oxalic acid, and wherein the ratio of the hydrochloric acid, sulfuric acid and oxalic acid is 3 to 3.5:2-2.5:0.5-1 percent, and the total mass percentage of the acid corrosive liquid is 2-10 percent.
5. The method of manufacturing a composite gear according to claim 1, wherein the predetermined condition is a temperature of 30±5 ℃, a current density of 500±50mA/cm2, and ultrasonic treatment is performed using ultrasonic waves of 50±25kHz for 3 to 10 minutes.
6. The method of manufacturing a composite gear according to claim 1, wherein the oxide layer has a thickness of 10 to 50um.
7. The method of manufacturing a composite gear according to claim 1, wherein the predetermined injection molding conditions include: the temperature of the screw cylinder is 385+/-20 ℃, 395+/-20 ℃, 400+/-20 ℃ or 410+/-20 ℃, the temperature of the plastic mold is 190+/-20 ℃, the injection pressure is more than 80Mpa, and the injection period is less than 0.9s.
8. The method of manufacturing a composite gear according to claim 1, wherein the viscosity of the PEEK material is 300 to 800pa.s, and the predetermined thickness is 1 to 10mm.
CN202210517094.4A 2022-01-18 2022-05-12 Method for manufacturing composite gear Active CN114889040B (en)

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