CN110757112A - Machining process of large welded gear - Google Patents
Machining process of large welded gear Download PDFInfo
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- CN110757112A CN110757112A CN201911280300.9A CN201911280300A CN110757112A CN 110757112 A CN110757112 A CN 110757112A CN 201911280300 A CN201911280300 A CN 201911280300A CN 110757112 A CN110757112 A CN 110757112A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
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Abstract
The invention discloses a processing technology of a large-scale welded gear, which specifically comprises the following steps: step 1: gear blank primary machining, step 2: blank preliminary heat treatment, step 3: preliminary machining of gear tooth shapes, and step 4: turning the gear tooth shape, and step 5: welding of various parts of the gear, and step 6: gear shaving and hobbing finish machining are carried out, and step 7: the invention discloses secondary heat treatment of a gear, and relates to the technical field of gears. This processing technology of large-scale welded gear, through the setting of step 5 for the gear preheats and keeps warm to the welding position when the welding, after preheating, the wholeness ability of gear is more lively than the normal atmospheric temperature state, the solder joint can heat completely and fuse during the welding, reach best welding state, and adopt carbon dioxide to carry out welding protection during the welding, effectively avoid the air to carry out the oxidation to the solder joint, further improved the reliability of solder joint when the welding, improved the qualification rate of welding back product.
Description
Technical Field
The invention relates to the technical field of gears, in particular to a machining process of a large-scale welded gear.
Background
Gear refers to a mechanical element on a rim with gears continuously engaged to transmit motion and power. The use of gears in transmissions has long emerged. The principle of generating the cutting method and the successive appearance of the special machine tool and the cutter for cutting teeth by using the principle pay attention to the running stability of the gear along with the development of production. Gears can be classified by tooth profile, gear profile, tooth trace shape, surface on which the teeth are located, and manufacturing method, etc. The tooth profile of the gear includes profile curve, pressure angle, tooth height and profile variation. Involute gears are relatively easy to manufacture, so that in the gears used in modern times, involute gears are the absolute majority, while cycloid gears and circular arc gears are less used. In the aspect of pressure angle, the bearing capacity of the small pressure angle gear is smaller; however, the large pressure angle gear is used only in special cases because the load of the bearing increases when the transmission torque is the same, although the load capacity is high. The tooth height of the gear is standardized and generally adopts the standard tooth height. The advantages of the modified gears are more, and the modified gears are distributed in various mechanical equipment.
Traditional large gear often can cause the service life of gear to be shorter because of the welding flaw of gear after the welding, is unfavorable for large-scale welded gear to use for a long time steadily, and some advanced enterprises adopt advanced welding method to weld, but because welding requirement is not up to standard and the gear is in man-hour to its thermal treatment untimely, often can lead to welding the gear to stabilize operating time shorter.
Disclosure of Invention
Technical problem to be solved
Aiming at the defects of the prior art, the invention provides a processing technology of a large-scale welded gear, which solves the problems that the service life of the gear is short and the large-scale welded gear is not beneficial to long-time stable use of the large-scale welded gear because the welding flaw of the gear often causes after the traditional large-scale gear is welded, some advanced enterprises adopt the modern advanced welding method to weld, but the stable working time of the welded gear is often short because the welding requirement does not reach the standard and the heat treatment of the gear is not timely during processing.
(II) technical scheme
In order to achieve the purpose, the invention is realized by the following technical scheme: a machining process of a large welded gear specifically comprises the following steps:
step 1: primary machining of a gear blank: clamping a blank of the gear on a vertical turning machine, additionally arranging an auxiliary stabilizing device on the other side of the main shaft, and then performing primary processing on the precision of an inner hole and an end face of a gear blank through mechanical processing equipment;
step 2: blank preliminary heat treatment: annealing carbon steel and alloy steel with carbon content of 0.5-1.5%, namely slowly heating the metal to a specified temperature, preserving heat for 30-50 minutes, and then cooling along with the furnace;
and step 3: preliminary machining of gear tooth shapes: carrying out secondary mechanical processing on the inner hole and the end face of the gear subjected to heat treatment;
and 4, step 4: turning the gear tooth shape: fixing the gear blank by using a numerical control machine tool, and processing an inner hole and an end face of the gear blank by using the numerical control machine tool;
and 5: welding of each part of the gear: preheating the parts to be welded, aligning all the parts of the gear to welding points when the heating temperature reaches 180-220 ℃, protecting the welding points by using carbon dioxide gas at the temperature of 300-350 ℃, and then welding one by one, wherein once the welding is started, the welding cannot be stopped in the midway;
step 6: gear shaving and hobbing finish machining: a plurality of gear blanks are arranged on the same central shaft in series, and the method for cutting the gear blanks into the hob during gear hobbing is radial cutting;
and 7: secondary heat treatment of the gear: putting the workpiece into an active carburizing medium, heating the workpiece to a single-phase austenite region with the temperature of 900-950 ℃, and after preserving heat for enough time, enabling active carbon atoms decomposed from the carburizing medium to permeate into the surface layer of the steel part, thereby obtaining high carbon on the surface layer, wherein the core part still keeps the original components;
and 8: grinding and flaw detection of the gear: the gear is polished after heat treatment and cooling, the gear is placed in a spacious place and cannot shield the flaw detection surface, any part needing to be detected can be conveniently touched, the illumination of the place is up to 500 lux, and oil stains and black skin cannot be formed on the surface of the gear.
Preferably, in the step 2, if the carbon content of the blank is 0.5% -1.5%, the metal is annealed in a spherical mode.
Preferably, in the step 2, the heat treatment of the gear is carried out and then the gear is electrically heated and kept warm.
Preferably, in step 3, the gear is further processed by generating method, the machine tool makes the hob and the workpiece rotate strictly according to the transmission ratio relation of meshing of a pair of helical cylindrical gears, and the hob cuts teeth on the workpiece.
Preferably, in the step 4, the gear inner hole with the axis central symmetry is processed by using a numerical control machine.
Preferably, in the step 5, the gear is welded by using a hardfacing electrode.
Preferably, in the step 6, the tooth blank is stably fixed during the string assembly.
Preferably, in the step 7, the heat treatment of the gear is performed and then the gear is electrically heated and kept warm.
(III) advantageous effects
The invention provides a processing technology of a large-scale welded gear. Compared with the prior art, the method has the following beneficial effects:
(1) the machining process of the large welded gear comprises the following steps of: welding of each part of the gear: the method comprises the steps of preheating positions needing to be welded, aligning all the positions of a gear to welding points when the heating temperature reaches 180-220 ℃, protecting the welding points by using carbon dioxide gas, enabling the temperature to reach 300-350 ℃, then welding one by one, once welding starts, stopping in the midway, preheating the welding positions and preserving heat of the gear during welding through the setting of the step 5, wherein after preheating, the overall performance of the gear is more active than the normal temperature state, the welding points can be completely heated and fused during welding to reach the optimal welding state, and welding protection is carried out by using carbon dioxide during welding, so that the welding points are effectively prevented from being oxidized by air, the reliability of the welding points during welding is further improved, and the qualified rate of products after welding is improved.
(2) The machining process of the large welded gear comprises the following steps of 1: primary machining of a gear blank: clamping a blank of the gear on a vertical turning machine, additionally arranging an auxiliary stabilizing device on the other side of the main shaft, and then performing primary processing on the precision of an inner hole and an end face of a gear blank through mechanical processing equipment; step 2: blank preliminary heat treatment: carbon steel and alloy steel with the carbon content of 0.5% -1.5% are annealed, namely metal is slowly heated to a specified temperature, heat preservation is carried out for 30-50 minutes, then cooling along with a furnace is carried out, and effective heat treatment is carried out on a gear blank after primary machining is carried out through the combined setting of the step 1 and the step 2, so that the hardness and the toughness of the gear can be greatly improved, various subsequent operations on the gear are facilitated, the comprehensive performance and the product percent of pass of the gear are improved, the integral operation is simpler, and the rapid operation of workers is facilitated.
(3) The machining process of the large welded gear comprises the following steps of: gear shaving and hobbing finish machining: a plurality of gear blanks are arranged on the same central shaft in series, and the method for cutting the gear blanks into the hob during gear hobbing is radial cutting; and 7: secondary heat treatment of the gear: the method comprises the following steps of putting a workpiece into an active carburizing medium, heating the workpiece to a single-phase austenite region with the temperature of 900-950 ℃, keeping the temperature for enough time, and enabling active carbon atoms decomposed from the carburizing medium to permeate into the surface layer of the steel part, so that high carbon on the surface layer is obtained, the core part still keeps the original components, and through the combined arrangement of the step 6 and the step 7, after the gear is stably and finely processed, the self accuracy of the gear can be further improved, and through secondary heat treatment, the indexes of the gear, such as the hardness, can be further improved, and the reliability of the gear in use is effectively improved.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The embodiment of the invention provides three technical schemes: a machining process of a large-scale welded gear specifically comprises the following embodiments:
example 1
Step 1: primary machining of a gear blank: clamping a blank of the gear on a vertical turning machine, additionally arranging an auxiliary stabilizing device on the other side of the main shaft, and then performing primary processing on the precision of an inner hole and an end face of a gear blank through mechanical processing equipment;
step 2: blank preliminary heat treatment: annealing carbon steel and alloy steel with carbon content of 0.5%, namely slowly heating the metal to a specified temperature, heating the steel to a temperature of more than 30 ℃ of a critical temperature, preserving heat for 30 minutes, and then cooling along with the furnace;
and step 3: preliminary machining of gear tooth shapes: carrying out secondary mechanical processing on the inner hole and the end face of the gear subjected to heat treatment;
and 4, step 4: turning the gear tooth shape: fixing the gear blank by using a numerical control machine tool, and processing an inner hole and an end face of the gear blank by using the numerical control machine tool;
and 5: welding of each part of the gear: preheating parts needing to be welded, aligning all parts of the gear to welding points when the heating temperature reaches 180 ℃, protecting the welding points by using carbon dioxide gas, and then welding one by one, wherein once welding is started, the welding cannot be stopped in the midway;
step 6: gear shaving and hobbing finish machining: a plurality of gear blanks are arranged on the same central shaft in series, and the method for cutting the gear blanks into the hob during gear hobbing is radial cutting;
and 7: secondary heat treatment of the gear: putting the workpiece into an active carburizing medium, heating the workpiece to a single-phase austenite region at 900 ℃, and after the workpiece is kept warm for enough time, enabling activated carbon atoms decomposed from the carburizing medium to permeate into the surface layer of the steel part, thereby obtaining high carbon on the surface layer, and keeping the original components in the core part;
and 8: grinding and flaw detection of the gear: the gear is polished after heat treatment and cooling, the gear is placed in a spacious place and cannot shield the flaw detection surface, any part needing to be detected can be conveniently touched, the illumination of the place is up to 500 lux, and oil stains and black skin cannot be formed on the surface of the gear.
Example 2
Step 1: primary machining of a gear blank: clamping a blank of the gear on a vertical turning machine, additionally arranging an auxiliary stabilizing device on the other side of the main shaft, and then performing primary processing on the precision of an inner hole and an end face of a gear blank through mechanical processing equipment;
step 2: blank preliminary heat treatment: annealing carbon steel and alloy steel with carbon content of 1%, namely slowly heating the metal to a specified temperature, heating the steel to 40 ℃ above the critical temperature, preserving heat for 40 minutes, and then cooling along with the furnace;
and step 3: preliminary machining of gear tooth shapes: carrying out secondary mechanical processing on the inner hole and the end face of the gear subjected to heat treatment;
and 4, step 4: turning the gear tooth shape: fixing the gear blank by using a numerical control machine tool, and processing an inner hole and an end face of the gear blank by using the numerical control machine tool;
and 5: welding of each part of the gear: preheating parts needing to be welded, aligning all parts of the gear to welding points when the heating temperature reaches 200 ℃, protecting the welding points by using carbon dioxide gas, and welding the parts one by one when the temperature reaches 330 ℃, wherein once the welding is started, the welding cannot be stopped in the midway;
step 6: gear shaving and hobbing finish machining: a plurality of gear blanks are arranged on the same central shaft in series, and the method for cutting the gear blanks into the hob during gear hobbing is radial cutting;
and 7: secondary heat treatment of the gear: putting the workpiece into an active carburizing medium, heating the workpiece to a single-phase austenite region at 925 ℃, and after keeping the temperature for enough time, enabling activated carbon atoms decomposed from the carburizing medium to permeate into the surface layer of the steel part, thereby obtaining high carbon on the surface layer, wherein the core part still keeps the original components;
and 8: grinding and flaw detection of the gear: the gear is polished after heat treatment and cooling, the gear is placed in a spacious place and cannot shield the flaw detection surface, any part needing to be detected can be conveniently touched, the illumination of the place is up to 500 lux, and oil stains and black skin cannot be formed on the surface of the gear.
Example 3
Step 1: primary machining of a gear blank: clamping a blank of the gear on a vertical turning machine, additionally arranging an auxiliary stabilizing device on the other side of the main shaft, and then performing primary processing on the precision of an inner hole and an end face of a gear blank through mechanical processing equipment;
step 2: blank preliminary heat treatment: annealing carbon steel and alloy steel with carbon content of 1.5%, namely slowly heating the metal to a specified temperature, heating the steel to a temperature 50 ℃ above the critical temperature, preserving heat for 50 minutes, and then cooling along with the furnace;
and step 3: preliminary machining of gear tooth shapes: carrying out secondary mechanical processing on the inner hole and the end face of the gear subjected to heat treatment;
and 4, step 4: turning the gear tooth shape: fixing the gear blank by using a numerical control machine tool, and processing an inner hole and an end face of the gear blank by using the numerical control machine tool;
and 5: welding of each part of the gear: preheating parts needing to be welded, aligning all parts of the gear to welding points when the heating temperature reaches 220 ℃, protecting the welding points by using carbon dioxide gas, and then welding one by one, wherein once welding is started, the welding cannot be stopped in the midway;
step 6: gear shaving and hobbing finish machining: a plurality of gear blanks are arranged on the same central shaft in series, and the method for cutting the gear blanks into the hob during gear hobbing is radial cutting;
and 7: secondary heat treatment of the gear: putting the workpiece into an active carburizing medium, heating the workpiece to a single-phase austenite region at 950 ℃, and after keeping the temperature for enough time, enabling activated carbon atoms decomposed from the carburizing medium to permeate into the surface layer of the steel part, thereby obtaining high carbon on the surface layer, wherein the core part still keeps the original components;
and 8: grinding and flaw detection of the gear: the gear is polished after heat treatment and cooling, the gear is placed in a spacious place and cannot shield the flaw detection surface, any part needing to be detected can be conveniently touched, the illumination of the place is up to 500 lux, and oil stains and black skin cannot be formed on the surface of the gear.
Through the arrangement of the step 5, the welding part of the gear is preheated and heat is preserved during welding, after preheating, the overall performance of the gear is more active than the normal temperature state, the welding spot can be completely heated and fused during welding to reach the optimal welding state, and carbon dioxide is adopted for welding protection during welding, so that the welding spot is effectively prevented from being oxidized by air, the reliability of the welding spot during welding is further improved, and the qualification rate of a welded product is improved; through the combined arrangement of the step 1 and the step 2, the gear blank is subjected to effective heat treatment after being subjected to primary machining, so that the hardness and toughness of the gear can be greatly improved, various subsequent operations on the gear are facilitated, the comprehensive performance and the product percent of pass of the gear are improved, the overall operation is simpler, and the quick operation of workers is facilitated; through the combined arrangement of the step 6 and the step 7, after the gear is stably and finely processed, the self accuracy of the gear can be further improved, through secondary heat treatment, indexes such as the hardness of the gear can be further improved, the reliability of the gear in use is effectively improved, the end face is subjected to secondary mechanical processing in the step 2, if the carbon content of a blank is 0.5-1.5%, the metal adopts a spherical annealing mode, the carbon steel with the structure has moderate hardness, good machinability and large cold deformation capability, in the step 2, the gear is subjected to electric heating and heat preservation after heat treatment, the end face is subjected to secondary mechanical processing in the step 3, the gear is further processed by adopting a generating method, a machine tool enables a hob and the workpiece to strictly rotate according to the transmission ratio relation of meshing of a pair of helical cylindrical gears, the hob cuts teeth on the workpiece, and the gear is operated by the hob of the machine tool, the operation of staff has been simplified, make things convenient for the management and control, the terminal surface carries out secondary machinery and adds in step 4, axis centrosymmetric's gear hole uses the digit control machine tool to process, the digit control machine tool is fast to the equipment process velocity of symmetry, the terminal surface carries out secondary machinery and adds in step 5, the welding of gear is welded with the hardfacing electrode, the electrode model is WEWELDING777, the terminal surface carries out secondary machinery and adds in step 6, stable fixed when the tooth base cluster dress, the tooth base cluster dress is stable, the terminal surface carries out secondary machinery and adds in step 7, adopt electrical heating heat preservation after the gear thermal treatment, above-mentioned electrical heating heat preservation mode is the environmental protection mode.
Comparative experiment
According to the three embodiments, the conventional manufacturer can produce three large-scale welded gears, after the three large-scale welded gears are subjected to comprehensive post-treatment, the product yield and the durability time of the three large-scale welded gears and the common large-scale welded gear are compared, and as shown in a table, the lowest yield of the three embodiments is 92, the yield is improved by 7.2% compared with the comparative example, the shortest durability time is 28.2 months, and the yield is increased by 5.2 months compared with the comparative example.
Table 1: comparison table of gear percent of pass and gear durability time with comparative example
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (8)
1. A machining process of a large-scale welded gear is characterized by comprising the following steps: the method specifically comprises the following steps:
step 1: primary machining of a gear blank: clamping a blank of the gear on a vertical turning machine, additionally arranging an auxiliary stabilizing device on the other side of the main shaft, and then performing primary processing on the precision of an inner hole and an end face of a gear blank through mechanical processing equipment;
step 2: blank preliminary heat treatment: annealing carbon steel and alloy steel with carbon content of 0.5-1.5%, namely slowly heating the metal to a specified temperature, preserving heat for 30-50 minutes, and then cooling along with the furnace;
and step 3: preliminary machining of gear tooth shapes: carrying out secondary mechanical processing on the inner hole and the end face of the gear subjected to heat treatment;
and 4, step 4: turning the gear tooth shape: fixing the gear blank by using a numerical control machine tool, and processing an inner hole and an end face of the gear blank by using the numerical control machine tool;
and 5: welding of each part of the gear: preheating the parts to be welded, aligning all the parts of the gear to welding points when the heating temperature reaches 180-220 ℃, protecting the welding points by using carbon dioxide gas at the temperature of 300-350 ℃, and then welding one by one, wherein once the welding is started, the welding cannot be stopped in the midway;
step 6: gear shaving and hobbing finish machining: a plurality of gear blanks are arranged on the same central shaft in series, and the method for cutting the gear blanks into the hob during gear hobbing is radial cutting;
and 7: secondary heat treatment of the gear: putting the workpiece into an active carburizing medium, heating the workpiece to a single-phase austenite region with the temperature of 900-950 ℃, and after preserving heat for enough time, enabling active carbon atoms decomposed from the carburizing medium to permeate into the surface layer of the steel part, thereby obtaining high carbon on the surface layer, wherein the core part still keeps the original components;
and 8: grinding and flaw detection of the gear: the gear is polished after heat treatment and cooling, the gear is placed in a spacious place and cannot shield the flaw detection surface, any part needing to be detected can be conveniently touched, the illumination of the place is up to 500 lux, and oil stains and black skin cannot be formed on the surface of the gear.
2. The machining process of the large welded gear according to claim 1, characterized in that: in the step 2, if the carbon content of the blank is 0.5% -1.5%, the metal adopts a spherical annealing mode.
3. The machining process of the large welded gear according to claim 1, characterized in that: in the step 2, the heat treatment of the gear is carried out, and then electric heating heat preservation is adopted.
4. The machining process of the large welded gear according to claim 1, characterized in that: in the step 3, the gear is further processed by adopting a generating method, the machine tool enables the hob and the workpiece to do rotary motion strictly according to the transmission ratio relation of meshing of the pair of helical cylindrical gears, and the hob cuts teeth on the workpiece.
5. The machining process of the large welded gear according to claim 1, characterized in that: and in the step 4, machining the inner hole of the gear with the axis central symmetry by using a numerical control machine.
6. The machining process of the large welded gear according to claim 1, characterized in that: and in the step 5, welding the gear by using a wear-resistant surfacing electrode.
7. The machining process of the large welded gear according to claim 1, characterized in that: and in the step 6, the gear blanks are stably fixed during serial assembly.
8. The machining process of the large welded gear according to claim 1, characterized in that: in the step 7, the gears are subjected to heat treatment and then are subjected to electric heating and heat preservation.
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