CN117161701A - Gear forming process - Google Patents

Gear forming process Download PDF

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Publication number
CN117161701A
CN117161701A CN202311323447.8A CN202311323447A CN117161701A CN 117161701 A CN117161701 A CN 117161701A CN 202311323447 A CN202311323447 A CN 202311323447A CN 117161701 A CN117161701 A CN 117161701A
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gear
forming
hardness
cutter
requirements
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CN202311323447.8A
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Chinese (zh)
Inventor
钟文
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DONGGUAN SILENT INDUSTRIAL CO LTD
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DONGGUAN SILENT INDUSTRIAL CO LTD
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Priority to CN202311323447.8A priority Critical patent/CN117161701A/en
Publication of CN117161701A publication Critical patent/CN117161701A/en
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Abstract

The application relates to a forming process of a gear, which comprises the following steps: s1: determining parameters such as the size, the tooth number, the modulus, the tooth profile and the like of the gear according to engineering requirements and use conditions; s2: selecting proper forming materials according to the load requirement of the gear; s3: heat treating the selected material; s4: turning the outer diameter of the gear by using tools such as a lathe and the like; s5: grinding the turned gear; s6: coarse hobbing is carried out on the tooth blank by using a coarse hobbing cutter; s7: treating the surface of the gear; s8: the micro-convex part of the metal surface is flattened by utilizing the action of vibration force and abrasive, so that the smooth effect is achieved; s9: cutting the gear on a lathe by using a cutter; s10: carrying out finish rolling processing on the gear; s11: removing the flash; s12: cleaning; s13: and (5) warehousing. The application can improve the strength, hardness and wear resistance of the gear.

Description

Gear forming process
Technical Field
The application relates to a gear forming method, in particular to a gear forming process.
Background
The gear is a mechanical element with teeth on the rim and can continuously transmit motion and power, and the service life of the gear is closely related to the strength of the gear in the use process of the gear.
The related art discloses a processing method for improving the fatigue strength and the gluing bearing capacity of a gear, which can also be called as a forming process of the gear, and comprises the following steps of S1, adopting a near-net forming process to perform rough machining on a gear blank; s2, adopting a gear grinding process to finish the gear part of the gear after rough machining; s3, performing heat treatment on the gear subjected to finish machining by adopting a QPQ salt bath composite heat treatment process, and forming a composite reinforcing layer on the surface of the gear; s4, carrying out residual compressive stress lifting treatment on the surface of the gear subjected to heat treatment by adopting a shot blasting process; and S5, carrying out roughness treatment on the gear surface subjected to residual compressive stress lifting treatment to enable the roughness to reach the preset requirement, and finishing gear machining.
In carrying out the present application, the inventors have found that at least the following problems exist in this technique: in the gear production process, the gear can generate casting defects such as cracks, sand holes, looseness, slag inclusion, bubbles and the like, so that the strength, the hardness and the wear resistance of the gear are not strong enough.
Disclosure of Invention
In order to improve the strength, hardness and wear resistance of the gear, the application provides a forming process of the gear.
The forming process of the gear adopts the following technical scheme:
a forming process of a gear comprises the following steps:
s1: determining parameters such as the size, the tooth number, the modulus, the tooth profile and the like of the gear according to engineering requirements and use conditions;
s2: selecting proper forming materials according to the using conditions and load requirements of the gears;
s3: heat treating the selected material;
s4: turning the outer diameter of the gear according to design requirements by using tools such as a lathe and the like;
s5: grinding the turned gear;
s6: coarse hobbing is carried out on the tooth blank by using a coarse hobbing cutter;
s7: treating the surface of the gear;
s8: grinding the tiny convex part of the metal surface by utilizing the action of vibration force and abrasive;
s9: cutting the gear on a lathe by using a cutter;
s10: carrying out finish rolling processing on the gear;
s11: removing the flash;
s12: cleaning;
s13: and (5) warehousing.
By adopting the technical scheme, parameters such as the size, the number of teeth, the modulus, the tooth profile and the like of the gear are determined according to engineering requirements and use conditions, so that the molded gear is ensured to meet the use conditions; according to the using conditions and the load requirements of the gears, proper forming materials are selected, so that the load of the gears can be ensured to meet the using conditions, and the cost can be saved; the strength and hardness of the material are improved by heat treatment of the material; turning the outer diameter of the gear according to design requirements by using tools such as a lathe and the like so as to ensure the precision and the surface quality of the gear; the gear is ground, so that the accuracy and the surface quality of the gear are improved; the gear hobbing cutter is used for rough hobbing of the gear blank, preparation is made for subsequent finish hobbing, the subsequent processing process is faster and more convenient, and the efficiency of finish hobbing is improved; the wear resistance and corrosion resistance of the gear are improved by treating the surface of the gear; the micro-convex part of the metal surface is flattened by utilizing the action of vibration force and abrasive, so that the smooth effect is achieved; cutting the gear on a lathe by utilizing a cutter, thereby realizing finish machining of the gear; performing fine hobbing on the gear to correct tooth shape, and improving machining precision and tooth surface quality to obtain a finished gear; the smoothness of the gear surface is further increased by removing the burrs; the cleaning degree of the surface of the gear is increased by cleaning the gear; the gears are put in storage, so that the gears can be conveniently collected.
Preferably, the molding material in S2 includes steel, cast iron, copper alloy, and the like.
By adopting the technical scheme, the steel material provides high strength-to-weight ratio, high wear resistance and enhances the physical properties of the gear through heat treatment; the cast iron material has excellent mechanical properties, high strength and rigidity, and particularly better wear resistance and heat resistance; the cast iron has the advantages of easily available raw materials, relatively low cost, simple manufacturing process and no need of complex processing and manufacturing process; the cast iron material contains chromium and nickel in a certain proportion, can effectively resist corrosion and oxidation, and has stronger corrosion resistance; the heat shrinkage coefficient of the cast iron material is smaller, the problems of dimensional deformation, thinning and the like are not easy to occur, and the dimensional stability of the product is good; the strength of the copper alloy is higher than that of a common copper material, and the corrosion resistance of the copper alloy is very strong, so that the copper alloy is an advantage of the physical properties of copper, and the corrosion resistance of the copper alloy is improved after other elements are added. After elements such as zinc, nickel, aluminum and the like are added in the alloy, the corrosion resistance of the alloy can be improved, and surface oxidation or corrosion caused by the influence of external environment or chemical substances is avoided; the copper alloy has relatively good performance in machining, and the natural toughness and elasticity of the copper material can enable the copper alloy to be easier to form in the machining processes of stamping, milling and the like.
Preferably, the heat treatment in S3 includes quenching, carburizing, tempering, and the like.
By adopting the technical scheme, the mechanical property of the gear is improved by quenching, the hardness and the wear resistance of the gear are improved, and the comprehensive mechanical property of the gear is improved; carburization gives the surface layer of the gear a high hardness and wear resistance, while the central part of the gear still maintains the toughness and plasticity of the low carbon steel; tempering improves the stability of the gear structure, so that the gear is not transformed in the use process, and the geometric dimension and performance of the gear are kept stable; meanwhile, tempering can also eliminate internal stress of the gear, so that the service performance of the gear is improved and the geometric dimension of the gear is stabilized; the mechanical properties of the gear are adjusted to meet the use requirements, the corrosion resistance of the gear is improved, the permanent magnetism of the gear is increased, and the like.
Preferably, the surface treatment in S7 includes chrome plating or nitriding.
By adopting the technical scheme, the chromium plating can make the automobile have better color and obviously improve the strength, hardness and wear resistance; nitriding improves the surface properties of the gear, such as surface hardness, wear resistance, fatigue strength, seizure resistance, corrosion resistance, tempering softening resistance and the like, so that the service life of the gear is further prolonged.
Preferably, in S10, the specific steps of the finish rolling process are as follows:
step one: checking parameters such as the size, hardness, surface quality and the like of the gear, ensuring that the gear meets the machining requirements, and confirming a machining machine tool and a cutter;
step two: clamping the gear, and placing the gear on a processing table and clamping;
step three: the machine tool is adjusted, and the positions of rollers, supports, guide rails and the like of the machine tool are adjusted according to the machining requirements;
step four: gear hobbing, starting processing equipment, and rolling the surface of the gear through a roller to finish the processing of the gear;
step five: the measuring tool is used for measuring parameters such as the size, the hardness, the surface roughness and the like of the gear.
By adopting the technical scheme, the high-hardness smooth roller is in rolling contact with the metal surface, so that the surface layer of the roller is subjected to local micro plastic deformation to improve the surface roughness, and the processing quality of the gear is further improved.
Preferably, the machine tool, the cutter and other parts in the first step are strictly required to be processed.
By adopting the technical scheme, the machine tool and the cutter are operated according to the processing requirements, so that the processing precision of the gear is further improved.
Preferably, in the fourth step, the rolling pressure and the rolling speed should be set reasonably according to the hardness, the material and other parameters of the gear.
Through adopting above-mentioned technical scheme, through reasonable setting rolling pressure and rolling speed to avoid excessive rolling, thereby avoid the gear to warp or damage, further promote the processingquality of gear.
Preferably, the tool is cleaned and replaced periodically.
By adopting the technical scheme, the processing cutter is easy to generate cuttings and abrasion in the processing process, and the processing cutter is periodically cleaned and replaced, so that the forming quality of the gear is further improved.
Preferably, the material of the gear is 20CrMnTi.
By adopting the technical scheme, the 20CrMnTi is carburizing steel with good performance, has higher hardenability, has a hard and wear-resistant surface and a tough core after carburizing and quenching, has higher low-temperature impact toughness, has medium weldability and good machinability after normalizing.
Preferably, the hardness of the gear is HRC58-62 °.
By adopting the technical scheme, the hardness of the gear is HRC58-62 degrees, so that the gear is ensured to be suitable for being used under specific working conditions, the production efficiency of the gear is improved, and the durability of the gear is also improved.
In summary, the present application includes at least one of the following beneficial technical effects:
1. determining parameters such as the size, the number of teeth, the modulus, the tooth profile and the like of the gear according to engineering requirements and use conditions, so as to ensure that the molded gear meets the use conditions; according to the using conditions and the load requirements of the gears, proper forming materials are selected, so that the load of the gears can be ensured to meet the using conditions, and the cost can be saved; the strength and hardness of the material are improved by heat treatment of the material; turning the outer diameter of the gear according to design requirements by using tools such as a lathe and the like so as to ensure the precision and the surface quality of the gear; the gear is ground, so that the accuracy and the surface quality of the gear are improved; the gear hobbing cutter is used for rough hobbing of the gear blank, preparation is made for subsequent finish hobbing, the subsequent processing process is faster and more convenient, and the efficiency of finish hobbing is improved; the wear resistance and corrosion resistance of the gear are improved by treating the surface of the gear; the micro-convex part of the metal surface is flattened by utilizing the action of vibration force and abrasive, so that the smooth effect is achieved; cutting the gear on a lathe by utilizing a cutter, thereby realizing finish machining of the gear; performing fine hobbing on the gear to correct tooth shape, and improving machining precision and tooth surface quality to obtain a finished gear; the smoothness of the gear surface is further increased by removing the burrs; the cleaning degree of the surface of the gear is increased by cleaning the gear; the gears are put in storage, so that the gears can be conveniently collected;
2. the steel material provides a high strength to weight ratio, high wear resistance, physical properties of the gear enhanced by heat treatment; the cast iron material has excellent mechanical properties, high strength and rigidity, and particularly better wear resistance and heat resistance; the cast iron has the advantages of easily available raw materials, relatively low cost, simple manufacturing process and no need of complex processing and manufacturing process; the cast iron material contains chromium and nickel in a certain proportion, can effectively resist corrosion and oxidation, and has stronger corrosion resistance; the heat shrinkage coefficient of the cast iron material is smaller, the problems of dimensional deformation, thinning and the like are not easy to occur, and the dimensional stability of the product is good; the strength of the copper alloy is higher than that of a common copper material, and the corrosion resistance of the copper alloy is very strong, so that the copper alloy is an advantage of the physical properties of copper, and the corrosion resistance of the copper alloy is improved after other elements are added. After elements such as zinc, nickel, aluminum and the like are added in the alloy, the corrosion resistance of the alloy can be improved, and surface oxidation or corrosion caused by the influence of external environment or chemical substances is avoided; the copper alloy has relatively good performance in machining, and the natural toughness and elasticity of the copper material can enable the copper alloy to be easier to form in the machining processes of stamping, milling and the like;
3. the quenching improves the mechanical property of the gear, simultaneously improves the hardness and the wear resistance of the gear, and improves the comprehensive mechanical property of the gear; carburization gives the surface layer of the gear a high hardness and wear resistance, while the central part of the gear still maintains the toughness and plasticity of the low carbon steel; tempering improves the stability of the gear structure, so that the gear is not transformed in the use process, and the geometric dimension and performance of the gear are kept stable; meanwhile, tempering can also eliminate internal stress of the gear, so that the service performance of the gear is improved and the geometric dimension of the gear is stabilized; the mechanical properties of the gear are adjusted to meet the use requirements, the corrosion resistance of the gear is improved, the permanent magnetism of the gear is increased, and the like.
Drawings
Fig. 1 is a flowchart of a gear molding process according to an embodiment of the present application.
Detailed Description
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. Unless defined otherwise, technical or scientific terms used herein should be given the ordinary meaning as understood by one of ordinary skill in the art to which this application belongs. The terms "first," "second," and the like, as used herein, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.
A forming process of a gear comprises the following steps:
s1: determining parameters such as the size, the tooth number, the modulus, the tooth profile and the like of the gear according to engineering requirements and use conditions;
s2: selecting proper forming materials according to the using conditions and load requirements of the gears;
s3: heat treating the selected material;
s4: turning the outer diameter of the gear according to design requirements by using tools such as a lathe and the like;
s5: grinding the turned gear;
s6: coarse hobbing is carried out on the tooth blank by using a coarse hobbing cutter;
s7: treating the surface of the gear;
s8: grinding the tiny convex part of the metal surface by utilizing the action of vibration force and abrasive;
s9: cutting the gear on a lathe by using a cutter;
s10: carrying out finish rolling processing on the gear;
s11: removing the flash;
s12: cleaning;
s13: and (5) warehousing.
Wherein the molding material in S2 includes steel, cast iron, copper alloy, and the like. When the gear is formed from a steel material, the steel material provides a high strength to weight ratio, high wear resistance, and enhanced physical properties of the gear by heat treatment.
When the gear is formed by using the cast iron material, the cast iron material has excellent mechanical properties, and has higher strength and rigidity, and particularly better wear resistance and heat resistance. Meanwhile, the cast iron has the advantages of easily available raw materials, relatively low cost, simple manufacturing process and no need of complex processing and manufacturing process; meanwhile, the cast iron material contains chromium and nickel in a certain proportion, so that the cast iron material can effectively resist corrosion and oxidation and has stronger corrosion resistance; meanwhile, the cast iron material has smaller heat shrinkage coefficient, is not easy to generate the problems of size deformation, thinning and the like, and has good size stability.
When the copper alloy is used for forming the gear, the strength of the copper alloy is higher than that of a common copper material, and the corrosion resistance of the copper alloy is very strong, so that the corrosion resistance of the copper alloy is improved after other elements are added. After elements such as zinc, nickel, aluminum and the like are added in the alloy, the corrosion resistance of the alloy can be improved, and surface oxidation or corrosion caused by the influence of external environment or chemical substances is avoided; the copper alloy has relatively good performance in machining, and the natural toughness and elasticity of the copper material can enable the copper alloy to be easier to form in the machining processes of stamping, milling and the like.
In the embodiment, the gear is made of 20CrMnTi,20CrMnTi is carburizing steel with good performance, has higher hardenability, has a hard and wear-resistant surface and a tough core after carburizing and quenching, has higher low-temperature impact toughness, has moderate weldability and has good machinability after normalizing.
In the embodiment, the hardness of the gear is HRC58-62 degrees, so that the gear is ensured to adapt to the use under specific working conditions, the production efficiency of the gear is improved, and the durability of the gear is also improved.
The heat treatment method in S3 includes quenching, carburizing, tempering, and the like. The quenching improves the mechanical property of the gear, simultaneously improves the hardness and the wear resistance of the gear, and improves the comprehensive mechanical property of the gear; carburization gives the surface layer of the gear a high hardness and wear resistance, while the central part of the gear still maintains the toughness and plasticity of the low carbon steel; tempering improves the stability of the gear structure, so that the gear is not transformed in the use process, and the geometric dimension and performance of the gear are kept stable; meanwhile, tempering can also eliminate internal stress of the gear, so that the service performance of the gear is improved and the geometric dimension of the gear is stabilized; the mechanical properties of the gear are adjusted to meet the use requirements, the corrosion resistance of the gear is improved, the permanent magnetism of the gear is increased, and the like.
Wherein, the surface treatment mode in S7 comprises chrome plating or nitriding. The chromium plating has the functions of ensuring better automobile color and remarkably improving the strength, hardness and wear resistance; nitriding improves the surface properties of the gear, such as surface hardness, wear resistance, fatigue strength, seizure resistance, corrosion resistance, tempering softening resistance and the like, so that the service life of the gear is further prolonged.
Determining parameters such as the size, the number of teeth, the modulus, the tooth profile and the like of the gear according to engineering requirements and use conditions, so as to ensure that the molded gear meets the use conditions; according to the using conditions and the load requirements of the gears, proper forming materials are selected, so that the load of the gears can be ensured to meet the using conditions, and the cost can be saved; the strength and hardness of the material are improved by heat treatment of the material; turning the outer diameter of the gear according to design requirements by using tools such as a lathe and the like so as to ensure the precision and the surface quality of the gear; the gear is ground, so that the accuracy and the surface quality of the gear are improved; the gear hobbing cutter is used for rough hobbing of the gear blank, preparation is made for subsequent finish hobbing, the subsequent processing process is faster and more convenient, and the efficiency of finish hobbing is improved; the wear resistance and corrosion resistance of the gear are improved by treating the surface of the gear; the micro-convex part of the metal surface is flattened by utilizing the action of vibration force and abrasive, so that the smooth effect is achieved; cutting the gear on a lathe by utilizing a cutter, thereby realizing finish machining of the gear; performing fine hobbing on the gear to correct tooth shape, and improving machining precision and tooth surface quality to obtain a finished gear; the smoothness of the gear surface is further increased by removing the burrs; the cleaning degree of the surface of the gear is increased by cleaning the gear; the gears are put in storage, so that the gears can be conveniently collected.
In S10, the finish rolling process specifically includes the steps of:
step one: checking parameters such as the size, hardness, surface quality and the like of the gear, ensuring that the gear meets the machining requirements, and confirming a machining machine tool and a cutter;
step two: clamping the gear, and placing the gear on a processing table and clamping;
step three: the machine tool is adjusted, and the positions of rollers, supports, guide rails and the like of the machine tool are adjusted according to the machining requirements;
step four: gear hobbing, starting processing equipment, and rolling the surface of the gear through a roller to finish the processing of the gear;
step five: the measuring tool is used for measuring parameters such as the size, the hardness, the surface roughness and the like of the gear.
In a specific machining process, a machine tool and a cutter are operated according to machining requirements, so that the machining precision of the gear is further improved; the machining cutter is easy to generate cutting scraps and abrasion in the machining process, and the forming quality of the gear is further improved by periodically cleaning and replacing the machining cutter; by reasonably setting the rolling pressure and the rolling speed, excessive rolling is avoided, so that deformation or damage of the gear is avoided, and the processing quality of the gear is further improved; thereby avoiding excessive rolling, avoiding deformation or damage of the gear and further improving the processing quality of the gear; the high-hardness smooth roller is in rolling contact with the metal surface, so that the surface layer of the roller is subjected to local micro plastic deformation to improve the surface roughness, and the processing quality of the gear is further improved.
In S11, the specific gear deburring method may be:
1. manual deburring: many gear machining enterprises can use files, sand papers and grinding heads as auxiliary tools in this way. This approach, which is not technically demanding, can be used for spur-small gears.
2. Deburring by a die: the punch die is matched with the punch press for deburring. This approach is suitable for gears with simpler parting surfaces.
3. Grinding and deburring: the deburring method comprises vibration, sand blasting, road roller and the like, and is adopted by more enterprises at present, and the defect is that the deburring is not very clean. Is suitable for large-batch pinions.
4. Freezing and deburring, namely removing the burrs which become brittle after cooling by using a spraying mode. Gears with a small burr wall thickness are suitable in this way.
5. And (3) thermal explosion deburring, namely putting some easy gas into the equipment furnace, and removing burrs by using the energy of explosion under the action of some mediums and conditions. Mainly used for some high-precision gears.
6. Deburring by an engraving machine: the equipment is low in price, and the gear with simple structural design is suitable for use.
7. Electrolytic deburring, namely an electrochemical machining method for deburring metal parts by electrolysis. Is suitable for gear deburring.
8. High-pressure water jet deburring: the flash and burr generated after processing can be removed by using the instant impact force of the water as a medium, and meanwhile, the aim of cleaning data can be achieved.
9. Ultrasonic deburring: the ultrasonic wave generates instantaneous high pressure to remove burrs of the gear.
The above embodiments are not intended to limit the scope of the present application, so: all equivalent changes in structure, shape and principle of the application should be covered in the scope of protection of the application.

Claims (10)

1. The forming process of the gear is characterized by comprising the following steps of:
s1: determining parameters such as the size, the tooth number, the modulus, the tooth profile and the like of the gear according to engineering requirements and use conditions;
s2: selecting proper forming materials according to the using conditions and load requirements of the gears;
s3: heat treating the selected material;
s4: turning the outer diameter of the gear according to design requirements by using tools such as a lathe and the like;
s5: grinding the turned gear;
s6: coarse hobbing is carried out on the tooth blank by using a coarse hobbing cutter;
s7: treating the surface of the gear;
s8: grinding the tiny convex part of the metal surface by utilizing the action of vibration force and abrasive;
s9: cutting the gear on a lathe by using a cutter;
s10: carrying out finish rolling processing on the gear;
s11: removing the flash;
s12: cleaning;
s13: and (5) warehousing.
2. A process for forming a gear according to claim 1, wherein: the molding material in S2 includes steel, cast iron, copper alloy, and the like.
3. A process for forming a gear according to claim 1, wherein: the heat treatment mode in S3 comprises quenching, carburizing, tempering and the like.
4. A process for forming a gear according to claim 1, wherein: the surface treatment in S7 includes chrome plating or nitriding.
5. A process for forming a gear according to claim 1, wherein: in S10, the finish rolling process specifically includes the steps of:
step one: checking parameters such as the size, hardness, surface quality and the like of the gear, ensuring that the gear meets the machining requirements, and confirming a machining machine tool and a cutter;
step two: clamping the gear, and placing the gear on a processing table and clamping;
step three: the machine tool is adjusted, and the positions of rollers, supports, guide rails and the like of the machine tool are adjusted according to the machining requirements;
step four: gear hobbing, starting processing equipment, and rolling the surface of the gear through a roller to finish the processing of the gear;
step five: the measuring tool is used for measuring parameters such as the size, the hardness, the surface roughness and the like of the gear.
6. A process for forming a gear according to claim 1, wherein: the machine tool, the cutter and other parts in the first step are strictly carried out according to the processing requirements.
7. A process for forming a gear according to claim 1, wherein: in the fourth step, the rolling pressure and rolling speed should be set reasonably according to the hardness, material and other parameters of the gears.
8. A process for forming a gear according to claim 1, wherein: the rolling cutters are prone to chipping and wear during machining and require periodic cleaning and replacement.
9. A process for forming a gear according to claim 1, wherein: the material of the gear is preferably 20CrMnTi.
10. A process for forming a gear according to claim 1, wherein: the hardness of the gear is HRC58-62 degrees.
CN202311323447.8A 2023-10-12 2023-10-12 Gear forming process Pending CN117161701A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202311323447.8A CN117161701A (en) 2023-10-12 2023-10-12 Gear forming process

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202311323447.8A CN117161701A (en) 2023-10-12 2023-10-12 Gear forming process

Publications (1)

Publication Number Publication Date
CN117161701A true CN117161701A (en) 2023-12-05

Family

ID=88943282

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202311323447.8A Pending CN117161701A (en) 2023-10-12 2023-10-12 Gear forming process

Country Status (1)

Country Link
CN (1) CN117161701A (en)

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