In the gearbox processed by our factory, the transmission power of a pair of gears is, the speed ratio is, the modulus machine, the helix angle of the helix and the large gear, and the input speed is cold. According to the original design material, gear tooth surface hardness, core hardness, tooth surface requirement, carburizing, boring, carburizing layer depth and original process problems. When the machining process is programmed, the following difficulties are encountered: Carbon quenching, the blank of the big gear can only be the whole forging, the forging is heavy, the gear is finished, the net weight is only mechanically processed, the material waste is serious, the machining volume is large, and the manufacturing cost is high.
The magic tooth surface needs to be ground after carburizing and quenching. The tooth surface of the tooth surface is deep and the gear is large. After the two heat treatment processes of carburizing and quenching, the tooth deformation is very large, and the tooth surface must be left on each side. Skillful grinding of the amount of teeth. After hobbing, the carburizing depth is required, the gear is large, the carburized layer is deep, and the heat treatment is very demanding. The factory cannot handle the tooth surface roughness requirements of the large gear, and the gear must be ground after the carburizing After processing, the drawing requirements can be met. The grinding teeth must be processed on the large-scale grinding machine. In the case of no large plough grinding machine, if the machining is to be externally processed, the grinding cost is very expensive.
Since the large gear needs multiple external processing in the processing, it cannot be grasped in terms of processing progress and time. In order to meet the requirements of the drawings, the process is as follows: forging blanks, normalizing roughing, ultrasonic testing, semi-finishing hobbing, carburizing, car to carburizing, drilling, tooth surface, quenching, core, quenching and finishing, grinding, external grinding The tooth is inserted into the key Li Qi. The improved process is in response to the above situation. Consult the relevant manual and conduct extensive research and discussion. It is decided to change the carburizing quenching of the original gear to the quenching and tempering medium frequency quenching, and the gear teeth are changed to the insert structure. For the ring gear.
Forgings, steel castings for wheel cores. The strength of the improved gear is checked, the contact strength safety factor of the tooth surface, and the bending strength safety factor of the gear teeth completely meet the original design requirements in terms of strength. From the same strength, it is more reasonable than the original design. The improved gear process is as follows: forging ring gear, normalizing, roughing, ultrasonic testing, quenching and tempering, semi-guessing, casting, wheel core, annealing, car, ring gear, overlaid on the wheel core, finishing car, rolling tooth. Medium frequency quenching, grinding teeth, and keyway.
Improved advantages The new gear machining process is much simpler than the original gear machining process.
Compared with the original design of the gear, the material cost is reduced. The original design uses the overall forging weight, and now uses the ring gear, the ring gear forging weight and the wheel core weight. Each piece of material saves 10,000 yuan.
The structure is more reasonable, which not only ensures the strength requirement of the original design for the gear, but also satisfies the requirements of use. The ring gear and the wheel core adopt an interference fit, and the tooth surface adopts quenching and tempering intermediate frequency quenching to make the tooth surface have large contact strength in the wheel core. The lower part of the intestine steel castings with lower strength is more suitable for the strength distribution of each part of the gear. Save a lot of processing costs.
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