外文翻译--淬硬齿轮的加工

附录1淬硬齿轮的加工【摘要】用于动力传动的齿轮和齿轮箱，其尺寸要求更小，齿轮传动的噪音更低，从而导致对淬硬齿轮的需求，也给齿轮制造厂家提出了探索齿轮加工新方法的要求.概述 用于动力传动的齿轮和齿轮箱，其尺寸要求更小，齿轮传动的噪音更低，从而导致对淬硬齿轮的需求，也给齿轮制造厂家提出了探索齿轮加工新方法的要求。 齿轮在淬硬热处理过程中，其材料组织及应力的改变，通常会使齿轮产生变形，即齿形、齿向及齿距误差。这此误差将引起齿廓在传动时的不正确啮合，从而加大了载荷，产生齿轮噪音。因此，淬硬齿轮在热处理后，一般应添加一道精加工工序。 淬硬齿轮精加工工艺可分为两类：一类是采用非成形的切削刃，如齿轮磨削加工；另一类则是具有成形的切削刃如淬硬齿轮(HRC4853)滚削加工。 本 将 中 用于硬滚齿加工的硬 合 具成形切削刃的精加工过程。的硬 合 材料、 具 和滚齿 的 ， 使淬硬齿轮滚切加工 有了 的提 ， 是在加工小于 于12DP的中小 齿轮时，可 硬切削过程中 产生的 大的切削力。 硬 合 滚 的 硬 合 滚 在材料的 有大 。currency1、currency1、中 大“的硬合 在有产 。此，硬 合 滚 fifl的成形工艺 也有了 提 如采用热 (HIP)工艺，工艺在 ， 加了硬 合 fifl的在合力，提 了硬 合 的”。ISO的 ， 硬 合 材料可应用合的不分为类：齿轮切削 具分为K类和P类，K类硬 合 有更 的磨，P类则有更的 硬。在K 和P 硬 合 中， 硬 合 的“ 是不的，从中 “currency1“。 有其应用合，这是和“ 的。一般 ，对于 滚削，K类 P类的要，K类硬 合 的“ (“小于0.5m)，而P类则不。在磨 方 ，K类 更， 更 。 滚 的新刃磨和 新 滚 加工一 的工 后，其切削刃变 ，此时 新刃磨。刃磨后的滚 有的 形 ；切削刃 ； 具的 不可因磨削过热而 。因而在刃磨硬 合 滚 时应采用一 ，对和不起应。对于 削滚 ，刃磨后的新 不 用于 fifl硬滚的滚 样要。硬 合 滚 刃磨后 前，建议对其刃口 预处理。 滚 的新刃磨将会除去切削表 的有 ，这会减少 具 。 具是可以 的。通常对于TiN ，可 34次；对于TiCN和TiALN 而言，由于 本身有大的应力， 以在切削刃难以再新 。通过次 覆TiN 后，会产生 低不均匀的 况， 有分 脱落的倾向， 以有 去除。 目前有两方法可去除 具 ：化学退 和物理退 。用化学退 去除硬合 具的 是一精currency1工艺，要求操作者有 的熟练程。过的化学退 不仅将 去掉，而且还将溶洗钴合剂，损 硬 合 材料的 观。切削刃的 观损 将产生锯齿 表 。此，在退 时 对滚 轴台、孔及标志 护，以免损 。而物理去 ，则 由 具制造厂 ，涉及整把滚 齿形的新磨削。虽然 化学退 要贵 多，但 的是一把新滚， 和 证。 对滚齿 的要求 为了充分 挥硬 合 和 工艺的优点，滚齿 应作应地改。目前 有先的滚齿 速滚齿 设计，其滚齿 的滚 转速过3000r/min，通常为5000r/min，工 主轴转速与滚 转速匹配。此， 床具有 的动刚和热刚。先滚齿 的一些主要设计 点为：采用复合环氧树脂床身，以改 床的动态和 态 ；带有恒装置的 速滚 主轴箱； 速工 主轴；可采用、湿二滚削工艺；带光电传感器的 字驱动系统；直线滚动导轨系统速自动料(23秒)；占地紧凑；人 工程学设计；维修方便。 采用 削工艺 无 是 械式的还是CNC的滚齿 削，但条 是 床 装备有工 具的自动步传动系统。这可使 削工艺更为经济，对带有自动料系统的 床也要。电子非接触系统靠一个 拟传感器 出脉冲 具主轴、工 主轴和齿轮的 置。 床CNC 制器对这些脉冲 处理，然后对工 主轴对于 具的 置 整，使工 轮齿和滚 齿的对 置系正确。 在 削工艺中用 有多优点：在 削过程中， 提 了 ；由于 削产生的不是正常的切 ， 制 其要。 的切 小 ，不正常 样可带 多热， 以 削时采用 可 制 具、工 及 床系统的； 可将切 从 具和工 冲 ；改 了工 表 精 ；提 了 具 。 在 滚削 工艺中，正确 齿 是要的。 滚齿因为可 的切 ，这有 于 制切削过程的动态 况，提 具 。经 证 ，切削速可以过200m/min，给的 于 要 的表 光 。 给为0.51.25mm/r。 具 ( )的方法也要，因为削时有加工currency1 的分切削刃“经 磨损。，在 切削 过程中具的精加工分 了主要加工。这fi在 削时 应更大，如齿轮为1248DP时，次 为0.30.4mm。 削滚 的 削硬 合 滚 分为两大类：用于10DP 更大 的滚 ，通常设计有一个fl前 的切削前 ， 切削刃接触淬硬齿 时，减小了对硬 合 材料的冲；对于 小 的齿轮，不需要有fl前 。fl前 的滚 的点是刃磨难。滚 刃磨后 减小，为了 正确的fl前 应改变轮的置 削中、大 齿轮时，其齿、直 和齿” 通常不滚削，要求轮齿齿”有一个 的过。为 切和整的过 ，提 齿”的”，用于大 齿轮的理 削滚 应带有。 对于小 齿轮的加工，应采用标滚 。采用标的 向前 硬 合 滚加工为 硬 合 滚 的再滚切 ，而不是 削 ，后者的是采用了一个fl前 滚 。 硬滚削的 要求和硬 削、 硬 合 滚 再滚削的 要求，不 处是采用的 的不。在硬滚时，切 的切除需 大 变为热。设法把这些热 带 要。建议加工一个工 后，滚 一个 齿距。 滚 从 过后，应将滚 置有一个置的 。置 于滚 的设计和应用，其目的是为了有 于滚 的均匀磨损。另一不 处是 采用的装 系统。由于 大的切削力， 具紧工 。加工 表 ，一 齿轮用硬 合 滚 再硬滚时，其齿轮 ，齿形接 AGMA10 ，齿向和齿距过AGMA12 ； 淬硬fifl硬滚切加工的 齿轮，其齿轮精也非常 ，齿形精可 AGMA10 ，齿向和齿距可 AGMA12 。 探索出 多经济的方法 加工淬硬齿轮， 材料的 、 加工方法、热处理工艺和硬精加工，使淬硬齿轮 及， 了 传动装置对淬硬齿轮的要求。 个 淬硬工 fifl 淬硬滚切加工是一新的加工工艺。由于有刚更的 床和优 的硬 合 具材料 加以 处理，使淬硬滚切成为一有 的加工方法。从工厂的应用 表 ，淬硬齿轮滚切(硬滚)工艺具有 的应用前 。 Hard gear processingabstract uses in the power drive gear and the gear box, its size request smaller, the gear drive noise is lower, thus causes to the hard gear demand, also gave the gear manufacturer to propose explored the gear to process the new method the requestOutline Uses in the power drive gear and the gear box, its size request smaller, the gear drive noise is lower, thus causes to the hard gear demand, also gave the gear manufacturer to propose explored the gear to process the new method the request. The gear in the hard heat treatment process, its material organization and the stress change, usually can cause the gear to have the distortion, namely tooth profile, tooth to and tooth pitch error. This this error will cause the tooth profile not correctly to mesh in the transmission time, thus has enlarged the load, will have the gear noise. Therefore, the hard gear after the heat treatment, should increase together the precision work working procedure generally. The hard gear precision work craft may divide into two kinds: A kind is uses non- formed the cutting edge, like the gear rubs truncates the processing； Another kind then is has formed the cutting edge like hard gear (HRC48 53) to roll truncates the processing. This article strongly will discuss will use in hardly rolling the hard alloy tools forming cutting edge precision work process which the tooth will process. The now hard alloy material, the cutting tool coating and the gear-hobbing machine technology development, has caused the hard gear to roll cuts the processing technology to have the remarkable enhancement, specially is smaller than in the processing or was equal to when 12DP center small modulus gear, may withstand the enormous cutting force which in the hard cutting process produces. Hard alloy hob selection The hard alloy hob has the very big progress in the material variety specification. Superfine, is thin, medium or the big pellet hard alloy now all has the product. In addition, the hard alloy hob semifinished materials formed craft technology also had the remarkable enhancement, like uses static pressure and so on heat (HIP) the craft, this craft under the high-pressured high temperature, increased the hard alloy semifinished materials intrinsic binding force, enhanced the hard alloy anti- curved intensity. According to the ISO stipulation, the entity hard alloy material may differently divide into certain kinds according to the application situation: The gear cutting tool divides into K kind and P kind, K kind of hard alloy has a higher resistance to wear, P kind then has the better high temperature red hardness. In the K trademark and in the P trademark hard alloy, each kind of trademark hard alloy granular structure is different, from medium pellet to superfine pellet. Each kind of trademark all has its application situation, this is and the granular structure is connected. Generally speaking, regarding softly rolls truncates, the K analogy P kind of performance is friends with, K kind of hard alloy can obtain a micron level the granular structure (granularity to be smaller than 0.5 mu m), but P kind then is not good. In abrasion aspect, K kind of toughness better, the life is longer. The hob resharpens and renovates After the hob processing certain quantity work piece, its cutting edge failure, this time must resharpen. Sharpens the after hob to have to maintain the original geometry shape； The cutting edge must be sharp； The cutting tool golden phase structure cannot because rub truncates the heat but to destroy. Thus when sharpens the hard alloy hob should use one kind of oil base refrigerant, it does not get up to the chlorine and the sulfur the response. Regarding scrapes the hob, sharpens after the coating not likely to use in hob such which the entity semifinished materials hardly rolls being important again. After the hard alloy hob sharpens in front of the coating, suggested carries on the pretreatment to its cutting edge. The hob rewill sharpen can except the cutting surface original coating, this will be able to reduce the cutting tool life. The cutting tool is may again spread. Usually regarding the TiN coating, may spread 3 4； Says regarding TiCN and the TiALN coating, because coating itself has the very big internal stress, therefore on cutting edge with difficulty again again coating. After several spreading TiN coating, can have the height non-uniformity condition, and influentials the tendency which the level falls off, therefore the original coating must remove. At present has two methods to be possible to remove the cutting tool coating: Chemistry draws back spreads draws back with physics spreads. Draws back with chemistry spreads removes on the hard alloy tools the coating is one kind of fine craft, requests the operator to have the suitable level of expertise. The excessively chemistry draws back spreads not only removes the coating, moreover also will dissolve washes the cobalt cement, the damage hard alloy material microscopic structure. The cutting edge microscopic damage will produce the zigzag surface. In addition, when draws back spreads must to the hob pillow block, in the hole and the sign carries on the protection, in order to avoid damages. But physics spreads, then must carry on by the original cutting tool factory, it involves to puts in order rerubs the hob tooth profile truncates. Although draws back chemistry spreads must be much more expensive than, but obtains is a new hob, the quality and the life all can obtain the guarantee. To gear-hobbing machine request In order to fully displays the hard alloy and the coating craft merit, the gear-hobbing machine should do correspondingly improves. At present all advanced gear-hobbing machines all press high speed roll the tooth to carry on the design, its gear-hobbing machine hob rotational speed surpasses 3000r/Min, usually is 5000r/Min, the work piece main axle rotational speed and the hob rotational speed match. In addition, the engine bed has very high moves the rigidity and the hot rigidity. The advanced gear-hobbing machine some main design characteristics are: Uses the compound epoxy resin lathe bed, by improves the engine bed the tendency and the static characteristic； Has the constant temperature installment the high speed hob headstock； High speed work piece main axle； May use does, the wet two kinds rolls truncates the craft； Belt electro-optical sensor digital actuation system； The straight line rolls the guide rail system； High speed automatic high-quality goods (2 3 seconds)； The occupying a land area of is compact； According to man-machine engineering design； Services conveniently. Uses scrapes the craft Regardless of is the mechanical type the CNC gear-hobbing machine all can carry on scrapes, but the condition is the engine bed must equip has the work piece to the cutting tool selsyn train system. This may cause to scrape the craft economically, to has on the automatic yummy treats system the engine bed very to be also important. The electronic non- contact system depends on a simulation quantity sensor to send out the pulse to survey the cutting tool main axle, the work piece main axle and the gear position. The engine bed CNC controller carries on processing to these pulses, then is opposite to the work piece main axle in the cutting tool position carries on the adjustment, causes a work piece turn of tooth and the hob knife tooth relative position relations is correct. In scrapes in the craft to have very many merits with the refrigerant: In scrapes in the process, the refrigerant has provided the lubricating ability； Because scrapes produces is not the normal scrap, the temperature control is extremely important. Blows the scrap small is thin, does not look like normal knife filings such to be possible to carry off many quantity of heats, therefore scrapes time uses the refrigerant to be possible to control the cutting tool, the work piece and the engine bed system temperature； The refrigerant may washes away the scrap from the cutting tool and the work piece； Improved the work piece surface fine roughness； Enhanced the cutting tool life. Rolls in the green truncates in the craft, correctly chooses the tooth thick remainder is very important. The recommendation choice down milling rolls the tooth, because it may obtain the thickest scrap, this is helpful to the control cutting process dynamic condition, enhances the cutting tool life. The experience proved that, the cutting speed may surpass 200m/Min, enters for the quantity choice is decided by the superficially attractive fineness which must achieve. The model enters for the scope is 0.5 1.25mm/R. The cutting tool shifts (flees knife) the method very to be also important, because scrapes time only then the rough machining section partial cutting edges only then undergo the attrition. On the contrary, in the green cutting in the process, the cutting tool precision work has partially undertaken the main process load. This meant when scraping flees the knife quantity to be supposed to be bigger, when like the gear is 12 48DP, each time flees the knife quantity is 0.3 0.4mm. Scrapes the hob the selection Scrapes the hard alloy hob to divide into two big kinds: Uses in 10DP or the bigger modulus hob, usually all designs has a negative rake front the cutting, when the cutting edge contacts to the hard tooth face, reduced to the hard alloy material impact； Regarding the small modulus gear, does not need to have the negative rake. The negative rake hob shortcoming is sharpens the difficulty. After the hob sharpens the outer diameter to reduce, in order to obtain the correct negative rake to be supposed to change the grinding wheel the bias quantity. When scrapes, the big modulus gear, its addendum, the outer annulus diameter and the tooth root spot all are usually not rolled truncates, and has a smooth transition a request turn of tooth to the tooth root. In order to obtain sinks cuts with the integrity transition circular arc radius, enhances the tooth root the anti- curved intensity, uses in the big modulus gear ideal scraping the hob to be supposed to have the flange. Regarding the small modulus gear processing, should use the standard hob. Uses the standard in front of the radial direction the angle hard alloy hob processing to be called the hard alloy hob to roll again cuts, but is not scrapes, latter referred has used a negative rake hob. Hardly rolls the specification which truncates and hardly scrapes the specification which, or the hard alloy hob rolls again truncates nearly same, similarity is uses the strategy which flees the knife to shift to be different. When hardly rolls, the scrap excision must spend the massive energies. This energy finally becomes the quantity of heat. Tries to carry off very important these thermal sending out. After the suggestion processes a work piece every time, the hob flees a position entire tooth pitch. When the hob will flee from beginning to end the position from now on, will be supposed to transfer to the hob to the initial position has a bias quantity the spot. This bias quantity is decided by the hob d