WO2011122315A1 - 波動歯車用基材の製造方法 - Google Patents
波動歯車用基材の製造方法 Download PDFInfo
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- WO2011122315A1 WO2011122315A1 PCT/JP2011/055894 JP2011055894W WO2011122315A1 WO 2011122315 A1 WO2011122315 A1 WO 2011122315A1 JP 2011055894 W JP2011055894 W JP 2011055894W WO 2011122315 A1 WO2011122315 A1 WO 2011122315A1
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/26—Methods of annealing
- C21D1/32—Soft annealing, e.g. spheroidising
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
- C21D1/19—Hardening; Quenching with or without subsequent tempering by interrupted quenching
- C21D1/20—Isothermal quenching, e.g. bainitic hardening
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
- C21D1/19—Hardening; Quenching with or without subsequent tempering by interrupted quenching
- C21D1/22—Martempering
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/32—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for gear wheels, worm wheels, or the like
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/22—Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/02—Pretreatment of the material to be coated
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/20—Carburising
- C23C8/22—Carburising of ferrous surfaces
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/28—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases more than one element being applied in one step
- C23C8/30—Carbo-nitriding
- C23C8/32—Carbo-nitriding of ferrous surfaces
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/80—After-treatment
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2211/00—Microstructure comprising significant phases
- C21D2211/002—Bainite
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
- F16H49/00—Other gearings
- F16H49/001—Wave gearings, e.g. harmonic drive transmissions
- F16H2049/003—Features of the flexsplines therefor
Definitions
- the present invention includes an annular and rigid internal gear, an annular and flexible external gear disposed on the inner side of the internal gear, and a flexible external gear that is fitted on the inner side and flexes the flexible external gear in the radial direction.
- the number of teeth of the internal and external teeth is obtained by meshing a part of the external teeth formed on the external external gear with the internal teeth formed on the rigid internal gear and moving the meshing position in the circumferential direction. More particularly, the present invention relates to a method of manufacturing an external gear that is forced to undergo elastic deformation in a cross-sectional shape, among wave gear devices having a wave generator that generates relative rotation according to a difference between an internal gear and an external gear.
- the object of the present invention is to provide the desired strength and elastic deformation characteristics particularly necessary as an external gear among the wave gear devices, and also to work.
- An object of the present invention is to provide a production method capable of effectively suppressing man-hours and production costs.
- the first characteristic configuration of the method for manufacturing a wave gear substrate according to the present invention is as follows: A steel having a carbon content of 0.5% or less is primarily formed into the shape of an external gear of a wave gear by cold working, This primary molded product is heated to a temperature range in which the main phase of the metal structure becomes an austenite structure, While rapidly cooling to a predetermined temperature higher than the martensitic transformation start temperature, By maintaining the temperature for a predetermined time, a metal structure having bainite as the main phase, Then, it is in the point which cools to normal temperature.
- a plate-like material is formed into a desired shape of the final external gear by cold working such as drawing or thickening.
- cold working such as drawing or thickening.
- the base material for external gears can be obtained in a short time without producing a large amount of chips by cutting.
- steel having a carbon content of 0.5% or less is used as a raw material. Therefore, defects such as cracks and cracks are unlikely to occur even when cold worked.
- the primary molded product is heated to a temperature range where the main phase of the metal structure becomes an austenite structure. This eliminates residual stress that occurs in the substrate during cold working and can cause cracking during use.
- the second characteristic configuration of the wave gear base material manufacturing method according to the present invention is as follows: A steel having a carbon content of 0.5% or less is primarily formed into the shape of an external gear of a wave gear by cold working, This primary molded product is heated to a temperature range in which the main phase of the metal structure becomes an austenite structure, After quenching to the martensite region and then tempering, it has a metal structure with sorbite as the main phase, Then, it is in the point which cools to normal temperature.
- a plate-like material is formed into a final shape of a desired external gear by cold working such as drawing or thickening.
- cold working such as drawing or thickening.
- the base material for external gears can be obtained in a short time without producing a large amount of chips by cutting.
- the steel having a carbon content of 0.5% or less is used as a raw material, the structure is hardly deteriorated even if it is cold worked.
- the primary molded product is heated to a temperature range where the main phase of the metal structure becomes an austenite structure. This eliminates residual stress that occurs in the substrate during cold working and can cause cracking during use.
- Another feature of the production method according to the present invention is that a chromium molybdenum steel having a carbon content of 0.4% or less is used as the steel.
- Another characteristic configuration of the manufacturing method according to the present invention can be finally obtained by holding for a predetermined time in a carburizing or carbonitriding gas atmosphere in the temperature range where the austenite structure of the primary molded product is formed.
- the hardness of the metal structure is set to Hv 300 to 500.
- the carbon concentration in the surface and inside of the wave gear base material can be increased to 0.3 to 1.0% by such carburizing or carburizing and nitriding.
- the surface and internal hardness of the wave gear base material is increased to Hv 300 to 500, good spring characteristics are obtained, and wear resistance is improved.
- the atmosphere and time of the carburizing process or the carburizing and nitriding process it is possible to control an arbitrary steel material having a carbon concentration of 0.5% or less to a desired hardness.
- Another feature of the production method according to the present invention is that the primary molded article is maintained in a temperature region that becomes the austenite structure in a carburizing or carburizing and nitrogening gas atmosphere for a predetermined time, so that The difference is that the difference between the maximum hardness and the minimum hardness of the metal structure in the range up to 2 mm depth is set within Hv130.
- the base material for wave gears with still less hardness difference between the surface of the raw material of heat processing, and the inside is obtained. For this reason, even higher hardness can be obtained for the root portion formed by cutting in the next step. Also, if there is a difference in hardness between the surface and the inside of the heat-treated material, if the originally circular material is distorted by the heat treatment, it is finally formed after being cut into a circle in the next process Although the hardness of the teeth may vary along the circumferential direction, with this configuration, the strength of each tooth in the finished external gear is uniformized to a sufficient level.
- Another feature of the production method according to the present invention is that the cooling from the temperature range that forms the austenite structure is performed by gas cooling using an inert gas.
- Gas cooling using an inert gas such as nitrogen or helium generally has a lower cooling capacity than oil cooling, so it is difficult to achieve the desired cooling rate, and it is easy to generate ferrite and pearlite. There's a problem.
- a wave gear base material with a large specific surface area is used as a heat treatment target, it is difficult to precipitate ferrite or pearlite even by gas cooling as in this configuration, and it is a primary molded product with a hard and homogeneous structure. Is obtained.
- the gas is cooled using an inert gas such as nitrogen or helium, the oxidation of the steel can be prevented.
- the environmental load is greatly reduced, and post-process cleaning can be made unnecessary.
- Another feature of the manufacturing method according to the present invention is that the primary molded product is held in a carburizing or carbonitriding gas atmosphere for a predetermined time, and then the primary molded product is removed from the low carbon potential for a predetermined period. It is in the point of exposure to a charcoal atmosphere.
- FIG. 1 is a schematic view illustrating a method for manufacturing a wave gear substrate according to the present invention. It is a conceptual diagram which shows the temperature sequence used at the heat processing process of this invention. It is a conceptual diagram which supplements the temperature sequence of FIG. It is a conceptual diagram which shows the temperature sequence used at the heat processing process of another embodiment. It is a conceptual diagram which supplements the temperature sequence of FIG. It is a graph which shows distribution of the hardness of the raw material after heat processing. It is a graph which shows distribution of the carbon concentration in the raw material after heat processing.
- the manufacturing method according to the present invention is directed to a wave gear base material capable of transmitting rotational torque with a very large reduction ratio.
- an inner portion is formed through elastic deformation from a circular shape to an elliptic shape. It is intended for a base material for an external gear (flex spline) that meshes with a gear (circular spline).
- the raw material used as the starting material of the present invention is a steel material having a carbon content of about 0.5% or less.
- a cold-rolled steel plate, a hot-rolled steel plate, a high-tensile steel plate, a carbon steel plate, a low alloy steel plate, a stainless steel plate and the like can be used.
- carbon steel plates such as S40C material, S45C material, and S48C material, and low alloy steel plates such as SCM420 material and SNCM220 material can be used.
- component standard values (JIS) of SCM420 material and S45C material which are representative examples of materials that can be used in the present invention, are listed in Table 1 below.
- the plate material 2 that meets the above conditions is subjected to pressing, drawing, thickening, cold forging, rotary drawing, rotary swaging, etc.
- Primary molding is performed at room temperature to a shape close to the shape. Prior to this cold working, it is preferable to perform the spheroidizing annealing on the plate material so that the cold working can be easily performed.
- the primary molded workpiece 3 approximates the final finished shape of the external gear constituting the wave gear, and has a small-diameter output portion 4A and a flange extending radially outward from the other end of the output portion 4A.
- a portion 4B and a large-diameter cylindrical body portion 4C extending along the axis X from the flange portion 4B.
- the heat treatment method applied to the primary molded workpiece 3 is any of carburized austemper, carburized quenching and tempering, austempering without carburizing, and quenching and tempering without carburizing, depending on the type of steel used. Is applicable.
- the purpose of the heat treatment is to give the workpiece 3 the necessary spring property as an external gear constituting the wave gear, and to suppress the distortion that is an impediment to durability.
- FIG. 2 is an explanatory view showing a temperature sequence of carburizing austempering treatment together with a constant temperature transformation diagram of eutectoid carbon steel.
- the workpiece 3 such as by electrical heating A 3 higher than the transformation temperature or the A 1 transformation temperature
- the region of the predetermined temperature T 1 of the main phase of the metal structure is substantially austenite (e.g. 930 ° C.) until heated (S1), then held at the same temperature T 1 of the predetermined time (S2).
- Stable austenitic structure is formed by a temperature hold at temperature T 1 of the S2 process.
- internal strain generated during cold working is effectively released.
- the workpiece 3 which is heated by the A 1 transformation temperature higher than temperature T 1 of less temperature T 2 than (e.g. 870 ° C.) decreased to (S3), held at the same temperature T 2 a predetermined time (S4) .
- S3 the workpiece 3 which is heated by the A 1 transformation temperature higher than temperature T 1 of less temperature T 2 than (e.g. 870 ° C.) decreased to (S3), held at the same temperature T 2 a predetermined time (S4) .
- S3 the occurrence of distortion associated with the heat treatment is suppressed.
- the final distortion of the external gear manufactured as a result of the distortion suppression effect can be kept small. It is also possible to reduce the amount of subsequent cutting.
- the carburizing as austempering a step of holding a predetermined time the material at a temperature of austenite region (S2), a step of decreasing the temperature to temperature T 2 (S3), the temperature T 2 (S4) is performed in a carburizing gas atmosphere (carburizing treatment).
- a carburizing and nitriding treatment may be adopted instead of the carburizing treatment (vacuum carburizing treatment).
- the step (S2) held at T 1, to equalize the temperature in the material is first for about 0.5 hours (S2- 1) Next, carburizing with a high carbon concentration (CP value: about 1.15) for about 4.5 hours, and finally a slightly lower carbon concentration (CP value: about 0 for about 3 hours) .75) Carburize. Next, the carbon concentration (CP value: about 0.75) while maintaining, performing a cooling step to a temperature T 2 (S3), and a holding step at a temperature T 2 (S4).
- quenching is performed by gas cooling or salt (salt bath) cooling to a predetermined temperature T 3 (for example, 400 ° C.) higher than the martensitic transformation start temperature (S5).
- T 3 for example, 400 ° C.
- S5 martensitic transformation start temperature
- this rapid cooling in order to avoid the precipitation of pearlite and ferrite, it takes a short time (1 to 10 seconds) so as not to be applied to the nose of the transformation start line (generally around 550 ° C.) in the isothermal transformation diagram entered in FIG. Cool quickly.
- lower bainite precipitates in the period from the vicinity of the intersection (Bs) with the transformation start line to the vicinity of the intersection (Bf) with the transformation end line.
- the lower bainite has a needle-like structure and has sufficient hardness and high toughness that are not too hard like martensite.
- the finally obtained wave gear base material has a metal structure with lower bainite as the main phase, so that it has adequate workability, while ensuring hardness and having good spring characteristics and sufficient toughness. It becomes a base material for use.
- the obtained wave gear base material has both dimensional accuracy, durability, and spring properties by having the outer shape cut by a hobbing machine after the outer shape is further precisely adjusted by subsequent cutting. An external gear is obtained.
- a series of steps from S1 to S4 and a series of steps from S6 to S7 may have to be performed in separate equipment separated from each other.
- the process of S4 is completed in the first equipment, as a process of S5, for example, the material temperature is kept from falling below T 3 (such as 400 ° C.) to the second equipment while exposing the material to the air.
- steps S6 and S7 can be performed.
- this method is referred to as a process division method.
- Carburizing, quenching and tempering In carburizing and quenching and tempering, the primary molded product is heated to a temperature range in which the main phase of the metal structure becomes an austenite structure. Next, by quenching to the martensite region and then tempering, the main phase of the metal structure of the wave gear base material finally obtained becomes a sorbite structure. As a result, the spring property and sufficient hardness required for the external gear constituting the wave gear can be obtained.
- FIG. 4 is an explanatory diagram showing a temperature sequence for carburizing, quenching, and tempering processing. As shown in the temperature sequence of FIG. 4, the steps S ⁇ b> 1 to S ⁇ b> 4 related to the heat treatment of the workpiece 3 are the same as the heat treatment steps shown in FIGS. 2 and 3.
- the temperature sequence of the carburizing and quenching tempering process shown in FIG. 4 is different from the carburizing austempering process of FIG. 2 in that it is rapidly cooled by gas cooling or the like from the predetermined temperature (T 2 ) to the temperature in the martensite region (S5). (S6) and tempering to a temperature at which sorbite is likely to precipitate (about 550 ° C.) (S7, S8), so that the main phase of the metal structure becomes a sorbite structure, and then rapidly cooled to room temperature (S9).
- the sorbite structure consists of a structure in which a large amount of cementite (fine particles) is precipitated in the ferrite fabric, and has sufficient hardness and high toughness that is not too hard like martensite.
- the tempering treatment of steel gears is generally performed at around 150 ° C., but here, tempering at a high temperature of about 550 ° C. is performed in order to impart desirable characteristics as a wave gear base material.
- carburizing and nitriding treatment may be employed instead of carburizing treatment (vacuum carburizing treatment).
- carburization is not performed in the tempering process (S8), but is performed in a carbon-enriched N 2 gas atmosphere.
- N 2 gas is used to prevent oxidation of the material surface, and carbon enrichment by butane gas or the like is performed in order to prevent carbon that has entered through the carburizing process in the previous step from escaping out of the metal structure.
- Oil cooling with oil at about 120 ° C. or the like is used for the final rapid cooling (S9) to room temperature after the tempering step (S8).
- Table 2 shown above shows material costs, press formability, characteristics obtained by various heat treatments, and the like for a plurality of steel types selected as raw material candidates for manufacturing a wave gear base material.
- the steel types considered were SCM420 (chromium molybdenum steel with a carbon content of about 0.2%), S45C (carbon steel with a carbon content of about 0.45%), SNCM220 (carbon content of about 0.2%).
- Nickel chromium molybdenum steel), SNCM439 nickel chromium molybdenum steel having a carbon content of about 0.39%
- SPH440 high tensile rolled steel having a carbon content of about 0.15%).
- SNCM439 is a material used as a solid material in the above-described bulk cutting method, and serves as a reference material for demonstrating the performance of the wave gear base material according to the present invention. Note that SNCM439 is not subjected to heat treatment including carburizing treatment because it is predicted that a significant excess of hardness, lack of toughness, and machinability will be reduced due to the carburizing treatment.
- the press formability was evaluated by the roundness after deep drawing into a cup shape, and materials with a roundness of less than 0.1 were evaluated as good.
- Strain in heat treatment refers to dimensional strain caused by heat treatment.
- the hardness was evaluated by a Vickers hardness tester, and the range of HV 330 to 400 was considered good.
- the carburized austempered SCM420 (hereinafter referred to as A1) satisfies all the standard values of material cost, press formability, hardness, structure state, and strain.
- SCM420 subjected to carburizing, quenching and tempering treatment (hereinafter referred to as A2) also satisfies all the reference values although the strain is slightly larger than A1.
- S45C quenched and tempered (without carburizing) (hereinafter referred to as A3) satisfies all the standard values except that the hardness slightly did not reach the standard value, and in terms of material cost The determination is good considering the advantages over SCM420.
- SNCM220 and SNCM439 the properties after heat treatment were generally good. However, SNCM220 did not satisfy the standard value with roundness exceeding 0.1 in press molding, and SNCM439 was cracked in press molding. The evaluation result was acceptable. About these materials, it is possible to improve press formability by using warm forming, a servo press, or the like.
- the SNCM439 that has been austempered is referred to as a reference material R1
- the SNCM439 that has been quenched and tempered is referred to as a reference material R2.
- SPH440 has good press formability and is superior to S45C in material cost, but does not satisfy the hardness standard value, and ferrite precipitation was observed in the structure after heat treatment.
- Table 3 relates to three materials (A1, A2, A3) determined to be most suitable for the base material for wave gears based on the evaluation results shown in Table 2, and two materials (R1, R2) as reference materials. Further, detailed measurement results of physical property values (hardness, fatigue limit, tensile test) are shown. The hardness is measured at two locations, the sample surface (position 0.75 mm from the sample surface) and the vicinity of the center (position 1.5 mm from the sample surface).
- Hardened and tempered S45C (A3) has lower hardness measurement values than other materials (A1, A2, R1, R2), but there are significant differences in fatigue limit and tensile test results. Since it is not recognized, it seems that there is a possibility that it can be improved to a physical property level that can be adopted by fine adjustment of heat treatment conditions or the like, or depending on the application area of the wave gear.
- FIG. 6 shows a hardness distribution obtained by measuring the hardness at each depth from the surface of the sample for two materials (A1, A2) determined to be most suitable as a wave gear base material based on the evaluation results shown in Table 3. Indicates. In addition, about A1, it heat-processed with the said process division
- the carburized austempered product (A1) of SCM420 shows the maximum hardness (420HV) at a depth of 0.5 mm from the surface, and the hardness decreases as it approaches the surface from the same position.
- the hardness tends to decrease as the distance from the center decreases, and the overall range is from 420 HV (maximum value) to 365 HV (minimum value) (the difference between the maximum value and the minimum value is 55 HV).
- the hardness (455 HV) at a depth of 0.2 mm from the surface shows the maximum value, and the hardness decreases with increasing distance from the surface on the basis of the same position.
- the range is from 455 HV (maximum value) to 330 HV (minimum value) (the difference between the maximum value and the minimum value is about 130 HV).
- FIG. 7 shows carbon concentration distributions obtained by measuring the carbon concentration by EPMA for two materials (A1 and A2) that were judged to be most suitable as a wave gear base material.
- the carbon concentration inside the sample 0.5 to 1.5 mm
- It shows a general tendency of increasing linearly, and the carbon concentration values themselves are substantially equal, indicating that the carburization process has proceeded well.
- the carburized quenching and tempering product (A2) shows a general tendency that the carbon concentration increases as it approaches the surface, but the carburized austempered product.
- the carbon concentration generally tends to decrease as the surface is approached.
- the tendency of the carbon concentration of the carburized austempered product (A1) to decrease in the vicinity of the surface seems to support the phenomenon of surface hardness reduction seen for the carburized austempered product (A1) in FIG.
- the heat treatment process based on the process division method based on FIG. 3 it is presumed that decarburization from the surface of the material occurred when it was allowed to cool in air to a suitable temperature in the transfer process after step S ⁇ b> 4.
- the surface layer portion having a thickness of about 0.5 mm of the wave gear substrate after completion of the heat treatment is removed in the next cutting step anyway. For this reason, it is possible to reduce the hardness of the surface layer part of a specific thickness by decarburizing the surface of the material intentionally during the heat treatment for the purpose of extending the blade life in the cutting process. It is.
- a method for decarburization a method of exposing the material to air (an example of a decarburizing atmosphere with a low carbon potential) for a certain period of time in the step S5 can be adopted as performed by the process division method.
- a method of controlling to a potential decarburizing atmosphere can be adopted.
- the low hardness surface layer formed in the intentional decarburization process is all removed in the subsequent cutting process, and the desired high hardness is secured on the surface of the product after the removal.
- the surface depth of the decarburized region can be appropriately set by appropriately selecting the exposure period to the decarburizing atmosphere having a low carbon potential, the carbon potential, the holding temperature, and the like.
- the cylindrical body 4C that requires high spring properties and tooth durability is made to have a higher carbon concentration than the other output parts 4A and flange parts 4B. Partial carburizing / nitriding control may be performed.
- It can be used as a method for manufacturing a wave gear base material that can effectively reduce work man-hours and manufacturing costs while having strength and elastic deformation characteristics necessary for an external gear of a wave gear.
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Abstract
Description
炭素含有量が0.5%以下の鋼を、冷間加工によって波動歯車の外歯車の形状に一次成形し、
この一次成形品を金属組織の主相がオーステナイト組織となる温度域まで加熱し、
マルテンサイト変態開始温度よりも高い所定の温度まで急冷すると共に、
当該温度を所定の時間に亘って維持することで、ベイナイトを主相とする金属組織とし、
その後、常温まで冷却する点にある。
炭素含有量が0.5%以下の鋼を、冷間加工によって波動歯車の外歯車の形状に一次成形し、
この一次成形品を金属組織の主相がオーステナイト組織となる温度域まで加熱し、
マルテンサイト領域まで急冷したのち焼き戻すことでソルバイトを主相とする金属組織とし、
その後、常温まで冷却する点にある。
また、熱処理の素材の表面と内部との間での硬度差があると、もしも熱処理によって元々円形の素材に歪みが生じた場合、次工程で円形に切削された後に、最終的に形成される歯の硬度が周方向に沿って異なる虞があるが、本構成であれば、外歯車完成品における各歯の強度が十分なレベルまで均一化される。
本発明による製造方法は、非常に大きな減速比で回転トルクを伝えることの可能な波動歯車用基材を対象としており、特に波動歯車のうちでも、円形から楕円状への弾性変形を介して内歯車(サーキュラースプライン)と噛合する外歯車(フレックススプライン)のための基材を対象としている。
本発明の出発材料として用いる素材は、炭素含有量が約0.5%以下の鋼材である。例えば、冷延鋼板・熱延鋼板・高張力鋼板・炭素鋼板・低合金鋼板・ステンレス鋼板などを使用できる。特に、S40C材、S45C材、S48C材などの炭素鋼板、SCM420材、SNCM220材などの低合金鋼板が使用可能である。
参考として、本発明で使用可能な素材の代表例であるSCM420材及びS45C材の成分規格値(JIS)を下記の表1に記載する。
図1に示すように、上記の条件に適合する板材2を、プレス加工、絞り加工、増肉加工、冷間鍛造、回転絞り加工、ロータリースウェージングなどにより、目的とする最終的な外歯車の形状に近い形状まで室温で一次成形する。尚、この冷間加工に先立って、板材に対して球状化焼鈍処理を行うと冷間加工を実施し易く好適である。
一次成形された加工物3に対して施す熱処理方法としては、用いる鋼種に応じて、浸炭オーステンパと、浸炭焼入焼戻と、浸炭なしのオーステンパと、浸炭なしの焼入焼戻とのいずれかを適用可能である。熱処理の目的は、加工物3に対して波動歯車を構成する外歯車として必要なバネ性を与えること、耐久性の阻害要因となる歪みを低く抑えることである。熱処理は厳密な温度制御、特に、急冷が可能な熱処理設備を用いるのがよい。
図2は、浸炭オーステンパ処理の温度シーケンスを、共析炭素鋼の恒温変態線図と共に示す説明図である。
図2の温度シーケンスに示すように、先ず通電加熱などによって加工物3をA3変態温度若しくはA1変態温度より高い、金属組織の主相がほぼオーステナイトとなる領域の所定温度T1(例えば930℃)まで加熱(S1)し、次に、同温度T1で所定時間保持する(S2)。S2工程における温度T1での温度保持によって安定なオーステナイト組織が形成される。また、同時に、冷間加工時に生じた内部歪みが効果的に解放される。
浸炭焼入焼戻では、一次成形品を金属組織の主相がオーステナイト組織となる温度域まで加熱する。次に、マルテンサイト領域まで急冷したのち焼き戻すことで、最終的に得られる波動歯車用基材の金属組織の主相がソルバイト組織となる。この結果、波動歯車を構成する外歯車として必要なバネ性と十分な硬度が得られる。
上に示す表2は、波動歯車用基材を製造するための素材の候補として選択した複数の鋼種について、材料コスト、プレス成形性、種々の熱処理によって得られた特性等を示す。検討対象とした鋼種には、SCM420(炭素含有量約0.2%のクロムモリブデン鋼)、S45C(炭素含有量約0.45%の炭素鋼)、SNCM220(炭素含有量約0.2%のニッケルクロムモリブデン鋼)、SNCM439(炭素含有量約0.39%のニッケルクロムモリブデン鋼)、SPH440(炭素含有量約0.15%の高張力圧延鋼)が含まれる。
尚、浸炭オーステンパ処理及びオーステンパ処理(浸炭なし)では、設備の都合から前記工程分割法を用いた。
S45Cを焼入焼戻処理(浸炭なし)したもの(以下でA3と称する)は、硬度が僅かに基準値に及ばなかった点を除いて全ての基準値を満たしており、且つ、材料コストにおいてSCM420に比べて優位な点を考慮して判定を良としている。
SPH440は、プレス成形性は良好で、材料コストにおいてはS45Cよりも優位だが、硬度の基準値を満たさず、熱処理後の組織内にフェライトの析出が観察されたため、評価結果を不可とした。
表3は、表2に示す評価結果に基づいて波動歯車用基材に最も適合すると判断された3つの材料(A1、A2、A3)、及び、参照材料としての2材料(R1、R2)に関するさらに詳細な物性値(硬度、疲労限、引張試験)の測定結果を示す。硬度は試料表面(試料表面から0.75mmの位置)及び中心付近(試料表面から1.5mmの位置)の2箇所を測定している。
表3から理解されるように、硬度、疲労限、引張試験の結果のいずれを見ても、SCM420は浸炭オーステンパ処理したもの(A1)と、浸炭焼入焼戻処理したもの(A2)とのいずれも、同等の熱処理(但し浸炭なし)を加えた参照材料としてのSNCM439(R1、R2)と遜色のない物性値を示すことがわかった。
図6は、表3に示す評価結果に基づいて波動歯車用基材として最も適合すると判断された2つの材料(A1、A2)について、試料の表面からの深さ毎に硬度を測定した硬度分布を示す。尚、A1については、図3を基本とした前記工程分割法にて熱処理した。
図6から理解されるように、試料の表面からの深さと無関係に2つの材料(A1、A2)のいずれも、300~500HVの比較的狭い範囲に収まる、良好な結果を示している。2つの材料(A1、A2)を比較すると、最も表面に近い部位(0.1~0.8mm)の硬度に関しては、SCM420の浸炭焼入焼戻処理品(A2)がSCM420の浸炭オーステンパ処理品(A1)よりも高い硬度を示す。試料の内部側(0.8~2.0mm)の硬度に関しては、逆に、浸炭オーステンパ処理品(A1)が(A2)浸炭焼入焼戻処理品よりも高い硬度を示している。
図7から理解されるように、2つの材料(A1、A2)を比較すると、試料の内部(0.5~1.5mm)の炭素濃度は、いずれの熱処理方法でも表面に近付くほど炭素濃度が直線的に高くなる一般的な傾向を示し、炭素濃度の値自体も略等しく、浸炭処理が良好に進められたことを示している。
3 加工物
4A 出力部
4B フランジ部
4C 円筒状胴部
Claims (7)
- 炭素含有量が0.5%以下の鋼を、冷間加工によって波動歯車の外歯車の形状に一次成形し、
この一次成形品を金属組織の主相がオーステナイト組織となる温度域まで加熱し、
マルテンサイト変態開始温度よりも高い所定の温度まで急冷すると共に、
当該温度を所定の時間に亘って維持することで、金属組織の主相をベイナイトとし、
その後、常温まで冷却する波動歯車用基材の製造方法。 - 炭素含有量が0.5%以下の鋼を、冷間加工によって波動歯車の外歯車の形状に一次成形し、
この一次成形品を金属組織の主相がオーステナイト組織となる温度域まで加熱し、
マルテンサイト領域まで急冷したのち焼き戻すことで、金属組織の主相をソルバイトとし、
その後、常温まで冷却する波動歯車用基材の製造方法。 - 前記鋼として炭素含有量が0.4%以下のクロムモリブデン鋼を用いる請求項1または2に記載の波動歯車用基材の製造方法。
- 前記一次成形品の前記オーステナイト組織となる温度領域で、浸炭性あるいは浸炭浸窒性のガス雰囲気中で所定時間保持することで、金属組織の硬度をHv300~500に設定する請求項1から3のいずれか一項に記載の波動歯車用基材の製造方法。
- 前記一次成形品の前記オーステナイト組織となる温度領域で、浸炭性あるいは浸炭浸窒性のガス雰囲気中で所定時間保持することで、基材の表面から2mm深さまでの範囲における金属組織の最大硬度と最小硬度の差をHv130以内に設定する請求項4に記載の波動歯車用基材の製造方法。
- 前記オーステナイト組織となる温度域からの冷却を、不活性ガスを用いたガス冷却により行なう請求項1から5のいずれか一項に記載の波動歯車用基材の製造方法。
- 前記一次成形品を浸炭性あるいは浸炭浸窒性のガス雰囲気中で所定時間保持した後に、前記一次成形品を所定期間に亘って低カーボンポテンシャルの脱炭性雰囲気に暴露する請求項1から6のいずれか一項に記載の波動歯車用基材の製造方法。
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EP2554686B1 (en) | 2018-07-25 |
EP2554686A1 (en) | 2013-02-06 |
US8940109B2 (en) | 2015-01-27 |
EP2554686A4 (en) | 2017-10-18 |
US20130000788A1 (en) | 2013-01-03 |
JP5709025B2 (ja) | 2015-04-30 |
CN102803522A (zh) | 2012-11-28 |
CN102803522B (zh) | 2013-12-04 |
JPWO2011122315A1 (ja) | 2013-07-08 |
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