CN117506348A - Anti-fatigue manufacturing method of bowl-shaped conical gear with internal spline - Google Patents
Anti-fatigue manufacturing method of bowl-shaped conical gear with internal spline Download PDFInfo
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- CN117506348A CN117506348A CN202311689490.6A CN202311689490A CN117506348A CN 117506348 A CN117506348 A CN 117506348A CN 202311689490 A CN202311689490 A CN 202311689490A CN 117506348 A CN117506348 A CN 117506348A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 25
- 230000002929 anti-fatigue Effects 0.000 title claims abstract description 15
- 238000000227 grinding Methods 0.000 claims abstract description 80
- 238000000034 method Methods 0.000 claims abstract description 52
- 238000005498 polishing Methods 0.000 claims abstract description 50
- 238000012545 processing Methods 0.000 claims abstract description 35
- 238000003754 machining Methods 0.000 claims abstract description 18
- 238000007514 turning Methods 0.000 claims abstract description 18
- 238000001514 detection method Methods 0.000 claims abstract description 12
- 238000005553 drilling Methods 0.000 claims abstract description 11
- 238000013461 design Methods 0.000 claims abstract description 7
- 238000010438 heat treatment Methods 0.000 claims abstract description 6
- 238000004040 coloring Methods 0.000 claims description 26
- 238000005496 tempering Methods 0.000 claims description 13
- 230000007547 defect Effects 0.000 claims description 9
- 238000005242 forging Methods 0.000 claims description 7
- 230000008439 repair process Effects 0.000 claims description 7
- 239000004576 sand Substances 0.000 claims description 7
- 238000007689 inspection Methods 0.000 claims description 6
- 230000003746 surface roughness Effects 0.000 claims description 5
- 229920000742 Cotton Polymers 0.000 claims description 4
- 238000007664 blowing Methods 0.000 claims description 4
- 206010006514 bruxism Diseases 0.000 claims description 4
- 238000005255 carburizing Methods 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 238000007333 cyanation reaction Methods 0.000 claims description 3
- 238000003801 milling Methods 0.000 claims description 3
- 238000007517 polishing process Methods 0.000 claims 1
- 238000010923 batch production Methods 0.000 abstract description 3
- 238000005516 engineering process Methods 0.000 description 7
- 230000009286 beneficial effect Effects 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 230000003111 delayed effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000007790 scraping Methods 0.000 description 2
- XFXPMWWXUTWYJX-UHFFFAOYSA-N Cyanide Chemical compound N#[C-] XFXPMWWXUTWYJX-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
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- 239000000463 material Substances 0.000 description 1
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Abstract
The invention discloses an anti-fatigue manufacturing method of a bowl-shaped conical gear with an internal spline, which relates to the technical field of gear machining and comprises the following steps: s1, roughly turning the outer contour; s2, grinding an outer circle, an end face and an addendum circle; s3, turning conical surfaces; s4, rough machining of tooth shapes; s5, rounding and polishing the sharp edge; s6, heat treatment; s7, benchmark restoration; s8, a vehicle inner cavity, a boring hole and a center hole; s9, processing internal splines; s10, drilling and rounding; s11, cyaniding; s12, magnetic flaw detection; s13, grinding a spline and polishing; s14, grinding two outer circles and end faces of the two outer circles; s15, tooth form finish machining; s16, magnetic flaw detection. The anti-fatigue manufacturing method of the bowl-shaped conical gear with the internal spline is mainly carried out from two aspects of a process route design of the bowl-shaped conical gear with the internal spline and an anti-fatigue manufacturing design method of two outer circles and tooth shapes, and can meet the requirements of high precision, stable state and good anti-fatigue performance, and is suitable for batch production.
Description
Technical Field
The invention relates to the technical field of gear machining, in particular to an anti-fatigue manufacturing method of a bowl-shaped conical gear with an internal spline.
Background
The conical gear is used as an important transmission part, plays a role in transmitting motion and power between two intersecting shafts in a machine, is widely applied in the whole mechanical field, and is important in running stability and fatigue resistance of the gear along with the development of technology and the increase of the rotating speed of the gear, and meanwhile, the structural requirement on the gear is more and more stringent.
The bowl-shaped conical gear with the internal spline (bowl-shaped conical gear for short, see figure 1) is characterized in that two ends of the bowl-shaped conical gear are respectively provided with an outer circle (for bearing installation), the material 12Cr2Ni4A is used for the whole cyanide of the part, the depth is 0.1-0.3mm, the hardness HR15N is more than or equal to 88, the angular position of the internal spline and the conical gear is arbitrary, the coaxiality of the two outer circle surfaces is 0.02mm, the runout of the internal spline to the two outer circle surfaces and the end surface of the internal spline is 0.02mm, the runout of teeth to the two outer circles is 0.05mm, the web of the conical surface is 8mm, the part is extremely easy to deform in the processing process, the tooth part is twisted, and the reliability and the stability of the part are affected.
The bevel gear is a common pattern in mechanical gears, is generally used as a main transmission part of a component, and has the advantages of high stress, high rotating speed and severe requirements on fatigue resistance. Therefore, the processing technology is particularly important for the anti-fatigue manufacturing technology of the bowl-shaped conical gear with high hardness, and the stable processing technology is proved to be needed in the manufacturing process of the bowl-shaped conical gear, the processing of the two outer circles and the tooth shape is performed in an accurate positioning mode, and the production efficiency is improved while the anti-fatigue performance of the part is ensured.
Therefore, we propose a method for manufacturing a bowl-shaped bevel gear with an internal spline to resist fatigue.
Disclosure of Invention
The invention aims to overcome the existing defects, and provides an anti-fatigue manufacturing method of a bowl-shaped conical gear with an internal spline, which mainly meets the requirements of high precision, stable state and good anti-fatigue performance in two aspects of process route design and two-excircle and tooth-shaped anti-fatigue manufacturing design methods of the bowl-shaped conical gear with the internal spline, is suitable for batch production, and can effectively solve the problems in the background art.
In order to achieve the above purpose, the present invention provides the following technical solutions: the anti-fatigue manufacturing method of the bowl-shaped conical gear with the internal spline comprises the following steps of:
(1) Rough turning of the outer contour: processing a blank forging, including rough turning of an outer circle, an end face, drilling and a center hole of the blank;
(2) Grinding an outer circle, an end face and an addendum circle: machining an outer circle of the shaft and an end face and a top circle of the shaft by taking a central hole formed by rough turning of an outer contour as a positioning and tightening surface;
(3) Turning conical surfaces: the method comprises the steps of turning a rear conical surface, a front conical surface and an inner conical surface, wherein the rear conical surface is processed to a designed size, and the front conical surface and the inner conical surface leave a margin;
(4) Rough machining of tooth shapes: the method comprises rough milling, rough planing and finish planing, wherein after finish planing, the tooth thickness needs to be single-side allowance, and the tooth bottom is processed to the designed size;
(5) Tip edge rounding and polishing: rounding sharp edges along tooth length by adopting a assorted cotton file, polishing the bottom of the tooth, keeping the root fillet, and polishing the end face of the large and small modulus tooth;
(6) And (3) heat treatment: including carburizing and high temperature tempering;
wherein the carburization depth is 0.8-1mm; after high-temperature tempering, the hardness HRC of the part is less than or equal to 38, and fine sand is blown to remove surface oxide skin;
(7) And (3) reference repair: comprises repairing a central hole, grinding an outer circle and grinding an end surface;
(8) Vehicle inner cavity, boring and center hole: the center hole is subjected to coloring inspection, so that the area of the center hole is ensured to be at least 75%, and the center hole is uninterrupted along the circumference; machining the top circle of the internal spline to a designed size by boring an inner hole;
(9) Processing an internal spline: the internal spline is processed by adopting a mode of pulling the spline or inserting the spline, and the positioning surface is positioned by adopting a large end surface;
(10) Drilling and rounding: drilling two holes on the end face, and rounding and polishing the sharp edges;
(11) Cyaniding: selecting the surface of a carburization area for cyaniding, blowing fine sand to remove oxide skin;
(12) Magnetic flaw detection I: checking whether the part has defects such as cracks and the like;
(13) Grinding the internal spline and polishing: removing scale remaining on the internal spline during the cyanation process;
(14) Grinding two outer circles and end faces thereof: the positioning tool is matched with the internal spline to position the bowl-shaped conical gear, so that the references of two bearing surfaces are unified, the central axis of the bowl-shaped grinding wheel, the central axis of the positioning tool and the central axis of the part are in the same plane state during processing, and the bowl-shaped grinding wheel rotates to grind and shape two outer circles and the end faces of the two outer circles simultaneously;
(15) Tooth profile finish machining: comprises grinding teeth, tempering at low temperature, detecting burn, detecting engagement, rounding and polishing sharp edges again;
wherein, during grinding, the relevant size and technical conditions of the tooth form are processed to design requirements;
(16) Magnetic flaw detection II: detecting whether fatigue defects exist after tooth grinding.
Further, in the finish machining process of grinding two outer circles, the end faces and the tooth shapes, the low-temperature tempering time is controlled to be 2.5-3H, and the temperature is 145+/-10 ℃.
Further, when the outer contour, the ground outer circle, the end face and the tooth tip circle are roughly turned, the center hole and the end face are inspected by coloring, the coloring area is at least 75%, and the coloring area is uninterrupted along the circumference.
Further, the process of rounding and polishing the sharp edge is as follows:
(1) rounding the sharp edge R0.4-0.6 mm along the tooth length by using a cotton assorted file;
(2) polishing the tooth bottom with 301 polishing paste and maintaining the root fillet: the R1.8 of the large end is +/-0.3 mm, the minimum R1.2 mm of the small end is smoothly connected;
(3) and grinding and polishing the end faces of the large and small modulus teeth.
Further, the reference repair process is as follows:
(1) repairing the reference hole by scraping or grinding on an internal grinding machine, wherein the area of the center hole to be inspected by coloring is not less than 75%, and the center hole is uninterrupted along the circumference;
(2) the outer circle grinding and the end face adopt the repaired center hole for positioning and clamping, the runout of the outer circle to the two center holes after grinding is not more than 0.008mm, and the runout to the end face is not more than 0.01mm, wherein the end face is a process face for positioning a key-drawing.
Furthermore, when the positioning tool is matched with the internal spline, the central axis of the bowl-shaped grinding wheel, the central axis of the positioning tool and the central axis of the part are in the same plane state during processing, and the internal excircle and the end face are processed by adopting the rotary bowl-shaped grinding wheel.
Furthermore, the positioning tool is a cone spline core rod, which is provided with a spline shaft, and spline teeth are arranged on the spline shaft along the axial direction of the spline shaft.
Furthermore, the bowl-shaped grinding wheel is bowl-shaped as a whole, the center is provided with a mounting hole, and the outer side is provided with a grinding conical surface correspondingly adapted to the outer circle and the end face of the outer circle.
Further, the method for grinding and polishing the internal spline comprises the following steps:
(1) uniformly coating the prepared grinding paste on a positioning tool;
(2) the positioning tool is matched with the internal spline of the part;
(3) reciprocating grinding along the axial direction of the spline, finding out teeth matched with the teeth tightly, and increasing the grinding strength moderately in the radial direction so that the spline pair can freely move in the axial direction;
(4) exchanging tooth coordination is carried out according to the steps (1) to (3).
Further, the specific steps of bearing surface processing are as follows:
step 1: before the part is machined, after the positioning tool is meshed with the internal spline without a side gap, the position of the conical gear is fixed; firstly processing a bearing surface and an end surface of one end of the bearing, and ensuring that runout of an outer circle of the bearing and the end surface of the outer circle of the bearing against an internal spline is not more than 0.01mm; ensuring the size of the outer circle; ensuring the surface roughness; coloring the inspection end surface to ensure that the area is at least 80 percent and the circumference is uninterrupted;
and 2, a step of: and on the premise of not taking down the positioning tool, the bearing surface and the end face of the other end are processed, and after the size, the runout and the roughness are inspected, the positioning tool is taken down.
Further, the tip edge rounding and polishing comprises rounding along the tooth length direction, polishing the end face edge of the tooth and polishing the oxide skin at the bottom of the tooth, and the polishing is carried out on a polishing machine by adopting polishing paste.
Compared with the prior art, the invention has the beneficial effects that: the anti-fatigue manufacturing method of the bowl-shaped conical gear with the internal spline has the following advantages:
1. the processing technology of the bowl-shaped conical gear is designed mainly aiming at the fact that the dimensional accuracy, the form and position tolerance and the surface roughness of the bowl-shaped conical gear are difficult to meet the use requirements with high efficiency and high quality, and the processing technology of the bowl-shaped conical gear can meet the requirements of high accuracy, stable state and good fatigue resistance and is suitable for the fatigue resistance manufacturing technology of the conical gears in batch production through reasonable planning of technological routes;
2. adopting a positioning tool to unify the references of the two outer circles and the tooth form;
3. the outer circle and the end face of the bowl-shaped conical gear are machined by adopting the bowl-shaped positioning grinding wheel after the shaping, and the outer circle and the end face of the bowl-shaped conical gear are machined by adopting a common outer circle grinding mode, so that the two outer circles and the end face of the bowl-shaped conical gear are clamped and machined at one time;
4. the fatigue resistance of the gear can be improved;
5. the process flow is simple, the arrangement is clear, the portable working efficiency can be realized, and the technical requirements on operators are not high.
Drawings
FIG. 1 is a schematic view of a bowl-shaped bevel gear of the present invention;
FIG. 2 is a schematic diagram of a positioning tool according to the present invention;
FIG. 3 is a schematic view of the bowl-shaped grinding wheel of the present invention after modification;
FIG. 4 is a schematic view of the bowl-shaped wheel and parts processing after modification of the present invention;
FIG. 5 is a schematic illustration of a special tooling and parts of the present invention assembled without backlash engagement;
FIG. 6 is a schematic illustration of a blank forging of the present invention;
FIG. 7 is a schematic view of the turning circle, end face and tip circle of the present invention;
FIG. 8 is a schematic view of the grinding outer circle, the end face and the top circle of the present invention;
FIG. 9 is a schematic view of the various tapered surfaces of the cart of the present invention;
FIG. 10 is a schematic view of the tooth form roughing of the invention;
FIG. 11 is a schematic view of the present invention with rounded and polished sharp edges;
FIG. 12 is a schematic diagram of a repair fiducial of the present invention;
FIG. 13 is a schematic view of the interior cavity, bore, center hole of the vehicle of the present invention;
FIG. 14 is a schematic illustration of the spline machining of the present invention;
FIG. 15 is a schematic view of the present invention for drilling two holes and rounding;
FIG. 16 is a schematic view of the two outer circles and the end face thereof of the mill of the present invention;
fig. 17 is a schematic view of the tooth coloring area of the tooth form finishing of the present invention.
In the figure: 1 inner excircle, 2 inner end face, 3 outer excircle, 4 outer end face, 5 conical gear teeth, 6 internal spline, 7 spline shaft, 8 external spline and 9 bowl-shaped grinding wheel.
Description of the embodiments
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1-17, the present embodiment provides a technical solution: the method comprises the following steps:
(1) Rough turning of the outer contour: processing a blank forging, including rough turning a blank excircle, an end face, drilling and a center hole (shown in fig. 7), wherein the processing thickness of the bearing excircle is 2mm, the processing thickness of the addendum circle is 3mm, the processing thickness of the end face is 3.8mm, the center hole and the end face are inspected by coloring, the coloring area is at least 75%, and the bearing is uninterrupted along the circumference; the blank forging (shown in figure 6) is a class III forging, the heat treatment is normalizing and quenching and tempering, and the blank forging is inspected according to ultrasonic flaw detection, so that the cutting performance and fatigue resistance of the part are improved;
(2) Grinding an outer circle, an end face and an addendum circle: with the central hole formed by rough turning of the outer contour as the locationAddingThe clamping surface is used for processing the outer circle of the shaft, the end surface and the top circle of the shaft, (see figure 8), the processing thickness of the outer circle of the middle bearing is 0.3mm, the processing thickness of the top circle is 0.4mm, and the end isThe surface processing thickness is 1.5mm, so that the runout of the outer circle and the end face to the center hole is not more than 0.01;
coloring the inspection center hole and the end face, wherein the coloring area is at least 75%, and the coloring area is uninterrupted along the circumference;
(3) Turning conical surfaces: the method comprises the steps of turning a rear conical surface, a front conical surface and an inner conical surface, wherein the rear conical surface is processed to a designed size, and the front conical surface and the inner conical surface leave a margin; (see fig. 9) to prevent deformation of the parts after the subsequent heat treatment process;
(4) Rough machining of tooth shapes: the method comprises rough milling, rough planing and finish planing, wherein after finish planing, the tooth thickness needs to leave 0.17mm allowance on one side, and the tooth bottom is processed to the designed size; the round angle R1.8+/-0.3 mm of the large end tooth root and the round angle R1.2min of the small end tooth root are used for testing the coloring engagement of the tooth surface and the standard gear, and the contact area is as required by the figure 10 and is kept symmetrical;
(5) Tip edge rounding and polishing: the polishing method comprises the following steps of rounding along the tooth length direction, polishing the end face edge of the tooth and polishing the oxide skin at the bottom of the tooth, wherein polishing is carried out on a polishing machine by adopting polishing paste, and the specific steps are as follows:
(1) rounding the sharp edge R0.4-0.6 mm along the tooth length by using a cotton assorted file;
(2) polishing the tooth bottom with 301 polishing paste and maintaining the root fillet: the R1.8 of the large end is +/-0.3 mm, the minimum R1.2 mm of the small end is smoothly connected;
(3) and grinding and polishing the end faces of the large and small modulus teeth. (see FIG. 11)
(6) And (3) heat treatment: including carburizing and high temperature tempering;
wherein the carburization depth is 0.8-1mm; after high-temperature tempering, the hardness HRC of the part is less than or equal to 38, and fine sand is blown to remove surface oxide skin; the method can increase the surface residual compressive stress under the condition of not affecting the size of the part, and is beneficial to improving the fatigue resistance;
(7) And (3) reference repair: comprises repairing a central hole, grinding an outer circle and grinding an end face:
(1) repairing the reference hole by scraping or grinding on an internal grinding machine, wherein the area of the center hole to be inspected by coloring is not less than 75%, and the center hole is uninterrupted along the circumference;
(2) the outer circle grinding and the end face adopt the repaired center hole to position and clamp, the runout of the outer circle on the two center holes after grinding is not more than 0.008mm, the allowance of 0.15mm is reserved in the diameter direction of the outer circle after cyaniding, the runout on the end face is not more than 0.01mm, and the end face is a process face for positioning a key. (see fig. 12);
(8) Vehicle inner cavity, boring and center hole: (see fig. 13), the center hole is subjected to coloring inspection, and the tip circle of the internal spline is processed to the designed size by boring the inner hole;
coloring the inspection center hole and the end face, wherein the coloring area is at least 75%, and the coloring area is uninterrupted along the circumference;
(9) Processing an internal spline: the internal spline is processed by adopting a mode of pulling the spline or inserting the spline, and the positioning surface is positioned by adopting a large end surface; wherein the angular position of the spline to the tooth part is arbitrary; because the spline is longer, in order to prevent the spline from being inserted or pulled out due to larger processing stress, the positioning surface needs to be positioned by a large end surface (as shown in fig. 14);
(10) Drilling and rounding: drilling two holes (for bearing disassembly) on the end face; and rounding and polishing the sharp edge; the two holes are polished to R0.3-0.5mm round corners (see figure 15) at the end faces of the two holes at any angular positions of the tooth parts and the internal spline, and the end faces of the two holes are polished to R1.6, so that when the end faces of the two holes are in the cyanidation process, if sharp edges exist, stress concentration is easily caused, defects such as delayed cracks and the like can occur, and the part is invalid;
(11) Cyaniding: selecting the surface of a carburization area for cyaniding, blowing fine sand to remove oxide skin;
the cyanidation process requires that the surface hardness HRC=59-62 of a carburized region, the cyanidation layer depth is 0.1-0.3mm, the core hardness d=3.4-3.1, and oxide skin is removed by blowing fine sand, and the method can increase the surface residual compressive stress under the condition of not affecting the size of a part, thereby being beneficial to improving the fatigue resistance;
(12) Magnetic flaw detection I: checking whether the part has crack defects;
(13) Grinding the internal spline and polishing: removing scale remaining on the internal spline during the cyanation process;
the grinding and polishing method of the internal spline comprises the following steps:
(1) uniformly coating the prepared grinding paste on a positioning tool;
(2) the positioning tool is matched with the internal spline of the part;
(3) reciprocating grinding along the axial direction of the spline, finding out teeth matched with the teeth tightly, and increasing the grinding strength moderately in the radial direction so that the spline pair can freely move in the axial direction;
(4) exchanging tooth coordination, and performing according to the steps (1) to (3);
(14) Grinding two outer circles and end faces thereof: the positioning tool is matched with the internal spline to position the bowl-shaped conical gear, so that the references of two bearing surfaces are unified, the central axis of the bowl-shaped grinding wheel, the central axis of the positioning tool and the central axis of the part are in the same plane state during processing, and the two outer circles and the end faces of the two outer circles are simultaneously ground and formed by adopting the rotating bowl-shaped grinding wheel (see figure 16);
the positioning tool is a cone spline core rod and is provided with a spline shaft, and spline teeth are arranged on the spline shaft along the axial direction of the spline shaft; the positioning tool is used as a comprehensive gauge, so that the comprehensive performance of the internal spline can be detected in advance, whether the assembly requirement with a spline shaft is met or not can be met, and the coaxiality requirement of two excircles after machining can be met;
the bowl-shaped grinding wheel is integrally bowl-shaped, a mounting hole is formed in the center of the bowl-shaped grinding wheel, and a grinding conical surface correspondingly adapted to the outer circle and the end face of the outer circle is formed on the outer side of the bowl-shaped grinding wheel;
bowl-shaped positioning grinding wheel plays a role in: (1) the processing of bowl-shaped inner and outer circles is solved, and the linear speed is difficult to meet the requirement when a conventional cylindrical grinder or an internal grinder is adopted for processing, so that the surface defects such as grinding cracks and the like are easy to generate; (2) the two outer circles and the end faces of the two outer circles are synchronously processed, so that the difficulty in processing the outer circles in the bowl-shaped part is solved, the installation of the bearing is ensured, and deviation of shape and position errors caused by reference conversion is avoided;
the specific process steps of bearing surface machining are as follows:
step 1: before the part is machined, after the positioning tool is meshed with the internal spline without a side gap, the position of the conical gear is fixed; firstly processing a bearing surface and an end surface of one end of the bearing, and ensuring that runout of an outer circle of the bearing and the end surface of the outer circle of the bearing against an internal spline is not more than 0.01mm; ensuring the size of the outer circle; ensuring the surface roughness; coloring the inspection end surface to ensure that the area is at least 80 percent and the circumference is uninterrupted;
and 2, a step of: and on the premise of not taking down the positioning tool, the bearing surface and the end face of the other end are processed, and after the size, the runout and the roughness are inspected, the positioning tool is taken down.
(15) Tooth profile finish machining: comprises grinding teeth, tempering at low temperature, detecting burn, detecting engagement, rounding and polishing sharp edges again;
wherein, during grinding, the relevant size and technical conditions of the tooth form are processed to design requirements; the low-temperature tempering time is controlled to be 2.5-3H, the temperature is 145+/-10 ℃, and the residual tensile stress generated by grinding teeth is reduced;
the burn detection is to check whether the tooth surface has grinding burn or not, detect whether the tooth surface has oxidized due to instant grinding heat, whether the tooth surface changes color, if the grinding burn occurs, the meshed gear will wear out prematurely, and the service life of the gear is shortened;
engagement detection tooth coloring areas (see fig. 17); the sharp edge rounding and polishing are used for avoiding concave-convex points on the tooth profile and improving the surface roughness.
(16) Magnetic flaw detection II: the magnetic flaw detection process is required to be carried out at least 7 days after tooth grinding, so as to detect whether the fatigue defect of delayed cracks exists after tooth grinding.
The foregoing description is only illustrative of the present invention and is not intended to limit the scope of the invention, and all equivalent structures or equivalent processes or direct or indirect application in other related technical fields are included in the scope of the present invention.
Claims (10)
1. The anti-fatigue manufacturing method of the bowl-shaped conical gear with the internal spline is characterized by comprising the following steps of:
(1) Rough turning of the outer contour: processing a blank forging, including rough turning of an outer circle, an end face, drilling and a center hole of the blank;
(2) Grinding an outer circle, an end face and an addendum circle: processing an external excircle and an end surface and a tooth top circle by taking a central hole formed by rough turning of the outer contour as a positioning clamping surface;
(3) Turning conical surfaces: the method comprises the steps of turning a rear conical surface, a front conical surface and an inner conical surface, wherein the rear conical surface is processed to a designed size, and the front conical surface and the inner conical surface leave a margin;
(4) Rough machining of tooth shapes: the method comprises rough milling, rough planing and finish planing, wherein after finish planing, the tooth thickness needs to leave allowance on a single side, and the tooth bottom is processed to the designed size;
(5) Tip edge rounding and polishing: rounding the sharp edge along the tooth length, polishing the tooth bottom, maintaining the root fillet, and polishing the end face of the large and small module tooth;
(6) And (3) heat treatment: including carburizing and high temperature tempering;
wherein the carburization depth is 0.8-1mm; after high-temperature tempering, the hardness HRC of the part is less than or equal to 38, and fine sand is blown to remove surface oxide skin;
(7) And (3) reference repair: comprises repairing a central hole, grinding an outer circle and grinding an end surface;
(8) Vehicle inner cavity, boring and center hole: performing coloring inspection on the central hole, and processing the top circle of the internal spline to the designed size by boring the inner hole;
(9) Processing an internal spline: the internal spline is processed by adopting a mode of pulling the spline or inserting the spline, and the positioning surface is positioned by adopting a large end surface;
(10) Drilling and rounding: drilling two holes on the end face; and rounding and polishing the sharp edge;
(11) Cyaniding: selecting the surface of a carburization area for cyaniding, blowing fine sand to remove oxide skin;
(12) Magnetic flaw detection I: checking whether the part has crack defects;
(13) Grinding the internal spline and polishing: removing scale remaining on the internal spline during the cyanation process;
(14) Grinding two outer circles and end faces thereof: the positioning tool is matched with the internal spline to position the bowl-shaped conical gear, so that the references of two bearing surfaces are unified, the central axis of the bowl-shaped grinding wheel, the central axis of the positioning tool and the central axis of the part are in the same plane state during processing, and the bowl-shaped grinding wheel rotates to grind and shape two outer circles and the end faces of the two outer circles simultaneously;
(15) Tooth profile finish machining: comprises grinding teeth, tempering at low temperature, detecting burn, detecting engagement, rounding and polishing sharp edges again;
wherein, during grinding, the relevant size and technical conditions of the tooth form are processed to design requirements;
(16) Magnetic flaw detection II: detecting whether fatigue defects exist after tooth grinding.
2. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: in the tooth form finish machining process, the low-temperature tempering time is controlled to be 2.5-3H, and the temperature is 145+/-10 ℃.
3. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: when the outer contour, the outer circle and the end face are roughly turned, the top circle is ground, the inner cavity is turned, the boring and the center hole are turned, the center hole and the end face are inspected by coloring, the coloring area is 75% at least, and the coloring area is uninterrupted along the circumference.
4. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: the sharp edge rounding and polishing processes are as follows:
(1) rounding the sharp edge R0.4-0.6 mm along the tooth length by using a cotton assorted file;
(2) polishing the tooth bottom with 301 polishing paste and maintaining the root fillet: the R1.8 of the large end is +/-0.3 mm, the minimum R1.2 mm of the small end is smoothly connected;
(3) and grinding and polishing the end faces of the large and small modulus teeth.
5. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: the reference repair process is as follows:
(1) the repair reference hole can be scraped or polished on an inner circle grinding machine, the area of the center hole to be inspected by coloring is not less than 75%, and the center hole is uninterrupted along the circumference;
(2) the outer circle grinding and the end face adopt the repaired center hole for positioning and clamping, the runout of the outer circle to the two center holes after grinding is not more than 0.008mm, and the runout to the end face is not more than 0.01mm, wherein the end face is a process face for positioning a key-drawing.
6. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: the positioning tool is a cone spline core rod, and is provided with a spline shaft, and spline teeth are arranged on the spline shaft along the axial direction of the spline shaft.
7. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: the bowl-shaped grinding wheel is integrally bowl-shaped, the center of the bowl-shaped grinding wheel is provided with a mounting hole, and the outer side of the bowl-shaped grinding wheel is provided with a grinding conical surface correspondingly adapted to the outer circle and the end face of the outer circle.
8. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 6, wherein the method comprises the following steps: the grinding and polishing method of the internal spline comprises the following steps:
(1) uniformly coating the prepared grinding paste on a positioning tool;
(2) the positioning tool is matched with the internal spline of the part;
(3) reciprocating grinding along the axial direction of the spline, finding out teeth matched with the teeth tightly, and increasing the grinding strength moderately in the radial direction so that the spline pair can freely move in the axial direction;
(4) exchanging tooth coordination is carried out according to the steps (1) to (3).
9. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: the specific process steps of bearing surface machining are as follows:
step 1: before the part is machined, after the positioning tool is meshed with the internal spline without a side gap, the position of the conical gear is fixed; firstly processing a bearing surface and an end surface of one end of the bearing, and ensuring that runout of an outer circle of the bearing and the end surface of the outer circle of the bearing against an internal spline is not more than 0.01mm; ensuring the size of the outer circle; ensuring the surface roughness; coloring the inspection end surface to ensure that the area is at least 80 percent and the circumference is uninterrupted;
and 2, a step of: and on the premise of not taking down the positioning tool, the bearing surface and the end face of the other end are processed, and after the size, the runout and the roughness are inspected, the positioning tool is taken down.
10. The method for manufacturing the bowl-shaped conical gear with the internal spline for resisting fatigue according to claim 1, wherein the method comprises the following steps: the sharp edge rounding and polishing comprises rounding along the tooth length direction, polishing the end face edge of the tooth and polishing the oxide skin at the bottom of the tooth, wherein polishing is carried out on the polishing machine by adopting polishing paste.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311689490.6A CN117506348A (en) | 2023-12-11 | 2023-12-11 | Anti-fatigue manufacturing method of bowl-shaped conical gear with internal spline |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311689490.6A CN117506348A (en) | 2023-12-11 | 2023-12-11 | Anti-fatigue manufacturing method of bowl-shaped conical gear with internal spline |
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| CN202311689490.6A Pending CN117506348A (en) | 2023-12-11 | 2023-12-11 | Anti-fatigue manufacturing method of bowl-shaped conical gear with internal spline |
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| CN (1) | CN117506348A (en) |
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