Fan-shaped gear machining method

Abstract

The invention belongs to the field of metal processing technology, and relates to a sector gear processing method, which adopts an integral forging stock, removes allowance through rough machining, improves mechanical performance through heat treatment, and then enters a finish machining stage including fine machining, deburring and qualitative treatment to ensure processing precision and shape stability. The two half rings are accurately divided, further vertical machining is carried out, and then the positioning pins and the screw holes are used for accurate assembly, so that the matching accuracy is guaranteed. And after hole machining, aging treatment is conducted to remove stress, and the size, precision and tooth shape of a finished product are ensured in the final machining stage. In addition, corrosion resistance and attractiveness are improved through surface oxidation treatment. According to the method, the machining precision and the overall quality of the sector gear are remarkably improved, the reinstallation precision after disassembly and assembly is ensured, meanwhile, the corrosion resistance of the gear is enhanced, and the method is suitable for various precise transmission systems and has wide application prospects and important practical value.

Description

Technical Field

[0001] The invention belongs to the field of metal processing technology and relates to a sector gear processing method. Background Art

[0002] In the field of mechanical transmission, sector gears, as a special form of gear, are widely used in various precision transmission systems. Especially for sector gears designed to be detachable and composed of two half-circles (one half with teeth and the other half without teeth), their structural complexity and processing accuracy requirements are relatively high. However, in the actual processing process, this type of sector gear faces many technical challenges.

[0003] First, since the wall thickness of most of the sector gear is very thin, while the wall thickness of the tooth part is relatively thick, this uneven wall thickness distribution can easily lead to deformation during processing and use. Deformation not only affects the meshing accuracy of the gear, but may also cause the hole roundness to be unqualified, thus affecting the stability and reliability of the entire transmission system.

[0004] Secondly, since the sector gear is detachable, how to ensure the matching accuracy between the two half-circles and the installation accuracy after reinstallation during the disassembly and assembly process is an urgent problem to be solved. Traditional processing methods often make it difficult to effectively control the deformation after disassembly and assembly, resulting in a high scrap rate.

[0005] In addition, as the key part of the sector gear, the processing accuracy and shape accuracy of the tooth part directly affect the transmission performance and service life of the gear. However, during the processing, the tooth part is prone to defects such as burrs and cracks, which not only reduce the transmission efficiency of the gear, but also may cause failures and increase the maintenance cost during use.

[0006] In order to solve the above problems, technicians in this field have been exploring more effective processing methods and process means. Through research, it is found that adding qualitative treatment and aging treatment between key processes can effectively remove processing stress, improve processing quality, and reduce deformation. At the same time, adding a positioning pin between two gear parts can significantly improve the repeat positioning accuracy and avoid failure of the gear during use.

[0007] In summary, the existing technology has problems such as easy deformation, unqualified hole roundness, and size out-of-tolerance during the processing of sector gears. In particular, it is difficult to ensure the installation accuracy and processing accuracy of the teeth when reassembling after disassembly. Therefore, developing a sector gear processing method that can effectively control deformation, improve processing accuracy and processing quality, and reduce scrap rate is of great significance to improving the stability and reliability of the transmission system. Summary of the invention

[0008] In view of this, the object of the present invention is to provide a sector gear processing method, which reduces the scrap rate, controls the deformation amount, and effectively solves the deformation problem after disassembly and assembly.

[0009] To achieve the above object, the present invention provides the following technical solution: a sector gear processing method, comprising the following steps:

[0010] S1, material preparation stage: select integral forging billets to ensure the consistency and stability of materials and lay a solid foundation for subsequent processing;

[0011] S2, rough machining stage: preliminary turning of the forging blank to effectively remove most of the excess and facilitate subsequent processing;

[0012] S3, heat treatment stage: perform quenching and tempering heat treatment to make the overall hardness meet the requirements and significantly improve the mechanical properties of the material;

[0013] S4, finishing preparation stage: further turning to remove the remaining allowance, so that the shape gradually approaches the finished product size; smooth grinding of the surface to improve the surface finish and create good conditions for subsequent processing;

[0014] S5, fine processing stage: vertical processing is performed to complete some fine processing procedures to ensure processing accuracy; the groove is accurately cut in the middle position, but not cut off, to make full preparations for subsequent segmentation and strictly ensure cutting accuracy;

[0015] S6, deburring and qualitative treatment stage: remove burrs generated during the processing to ensure a smooth and flawless surface; perform qualitative treatment to stabilize the metal structure and effectively prevent deformation problems in subsequent processing.

[0016] S7, division and half-circle processing stage: the full circle is accurately divided into two half-circles along the original opening groove; the two half-circles are further processed vertically to ensure the accuracy of their respective sizes and shapes;

[0017] S7, assembly and grinding stage: Use positioning pins and screw holes to accurately assemble the two half circles together to ensure the matching accuracy; finely grind the assembled surface to strictly ensure flatness and parallelism;

[0018] S8, hole processing and aging treatment stage: preliminary processing of the hole to make full preparation for fine processing; aging treatment to effectively remove processing stress and stabilize size and shape;

[0019] S9, final processing and inspection stage: final processing of the holes to ensure that the finished product size and accuracy requirements are met; fine cutting processing to ensure the accuracy and shape of the teeth; removal of burrs on the teeth to ensure the smoothness of the teeth; surface oxidation treatment to improve corrosion resistance and aesthetics; finally, the finished product is inspected and put into storage.

[0020] Optionally, in the first step of online cutting, the groove is cut but not cut off to prepare for the subsequent precise segmentation and ensure the cutting accuracy.

[0021] Optionally, aging treatment is performed after semi-finishing to remove machining stress and stabilize size and shape.

[0022] Optionally, dowel pins are used during machining and assembly to ensure repeatability of the two half-turns.

[0023] Optionally, tighten the two half turns through the screw holes to ensure stability and precision after disassembly and assembly.

[0024] The beneficial effects of the present invention are:

[0025] 1) The present invention skillfully integrates qualitative treatment and aging treatment between key processes. The two major process steps work together to effectively remove the stress generated during the processing, thereby significantly reducing the deformation of the sector gear; this improvement not only ensures the dimensional stability of the gear during the processing, but also greatly improves its reliability during use;

[0026] 2) Through a carefully designed processing flow and strict process control, the present invention successfully improves the processing accuracy and overall quality of the sector gear; both the shape accuracy of the tooth and the roundness of the hole have reached a higher standard, thereby ensuring the precise meshing and efficient operation of the gear in the transmission system;

[0027] 3) Since the present invention effectively solves the deformation and size tolerance problems in the processing of sector gears, the scrap rate is significantly reduced; this achievement not only improves production efficiency, but also saves a lot of raw materials and processing costs for the enterprise;

[0028] 4) The present invention adopts the design of positioning pins and screw holes, so that the sector gear can maintain extremely high matching accuracy during the disassembly and assembly process. Even after multiple disassembly and assembly, the gear can still be easily restored to the original installation accuracy, thereby meeting the user's high requirements for maintainability and reusability of the transmission system.

[0029] 5) Since the sector gear processed by the present invention has higher processing accuracy and better dimensional stability, it can significantly improve the overall performance of the transmission system; both the transmission efficiency and the service life are significantly improved.

[0030] Other advantages, objectives and features of the present invention will be described in the following description to some extent, and to some extent, will be obvious to those skilled in the art based on the following examination and study, or can be taught from the practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below in conjunction with the accompanying drawings, wherein:

[0032] Figure 1 It is a schematic diagram of the sector gear structure of the present invention;

[0033] Figure 2 for Figure 1 Left view of . DETAILED DESCRIPTION

[0034] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments only illustrate the basic concept of the present invention in a schematic manner, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0035] Among them, the drawings are only used for illustrative explanations, and they only represent schematic diagrams rather than actual pictures, and should not be understood as limitations on the present invention. In order to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings may be omitted.

[0036] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if the terms "upper", "lower", "left", "right", "front", "rear", etc. indicate the orientation or position relationship, they are based on the orientation or position relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, the terms describing the position relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0037] See also Figure 1-2 , which is a sector gear processing method. For a sector gear assembled with an upper and lower half circle, it is fastened by screws and pins at the left and right ends. Due to the uneven thickness of the upper and lower walls, the part is very easy to deform. The inner hole size is large, which is Φ225H7. After processing, after the screws are tightened, the size and shape tolerances are unstable, resulting in the gear accuracy failing to meet the requirements;

[0038] In this embodiment, the specific processing method is:

[0039] 1. Material preparation stage

[0040] Select high-quality integral forging billets as raw materials to ensure the consistency and stability of the materials. The material of the forging billet should meet the design requirements and have good mechanical properties and machinability.

[0041] 2. Rough processing stage

[0042] Perform preliminary turning (rough turning) on ​​the forging blank. Use a large lathe to perform rough turning on the forging blank according to the preset machining allowance, effectively remove most of the allowance, and facilitate subsequent processing. During the rough turning process, the feed speed and cutting depth of the tool should be strictly controlled to avoid excessive cutting force and heat, which will affect the material performance and machining accuracy.

[0043] 3. Heat treatment stage

[0044] The forgings after rough turning are subjected to quenching and tempering heat treatment. The forgings are placed in a heat treatment furnace and heated and insulated according to the preset temperature and time to make the overall hardness meet the requirements and significantly improve the mechanical properties of the material. During the heat treatment process, the furnace temperature and insulation time should be strictly controlled to ensure the consistency and stability of the heat treatment effect.

[0045] 4. Finishing preparation stage

[0046] Further turning (finishing turning). After heat treatment, the forging blank is finished by finishing turning to remove the remaining allowance and gradually make the shape close to the finished product size. During the finishing turning process, high-precision lathes and tools should be used, and the processing parameters should be strictly controlled to ensure the processing accuracy and surface quality.

[0047] Flat grinding (flat grinding) of the surface. Use a surface grinder to flat grind the surface after fine turning to improve the surface finish and create good conditions for subsequent processing. During the grinding process, appropriate grinding parameters and abrasives should be selected to ensure the grinding effect and surface quality.

[0048] 5. Fine processing stage

[0049] Carry out vertical machining (vertical plus one). Use the vertical machining center to carry out some fine machining processes on the forging blank, such as milling, drilling, etc., to ensure the machining accuracy. During the machining process, high-precision tools and fixtures should be used, and the machining parameters and paths should be strictly controlled to ensure the machining accuracy and shape accuracy.

[0050] Cut the groove accurately in the middle position (wire cutting 1). Use the wire cutting machine to accurately cut the groove in the middle position of the forging blank, but do not cut it off, so as to make full preparation for the subsequent segmentation. During the cutting process, the cutting speed and path should be strictly controlled to ensure the cutting accuracy and the shape accuracy of the groove.

[0051] 6. Deburring and qualitative treatment stage

[0052] Remove burrs generated during processing (deburring with pliers). Use pliers to remove burrs on the surface of the forging blank and in the groove to ensure a smooth and flawless surface. During the deburring process, care should be taken to protect the surface and shape of the forging blank to avoid new damage or deformation.

[0053] Carry out qualitative treatment. Place the forging billet in the qualitative treatment furnace, heat and keep it warm according to the preset temperature and time to stabilize the metal structure and effectively prevent deformation problems in subsequent processing. During the qualitative treatment process, the furnace temperature and holding time should be strictly controlled to ensure the consistency and stability of the qualitative treatment effect.

[0054] 7. Segmentation and half-circle processing stage

[0055] The full circle is accurately divided into two half circles along the original opening groove (wire cutting 2). Using the wire cutting machine, the forging blank is accurately divided into two half circles along the previously cut groove. During the cutting process, the cutting speed and path should be strictly controlled to ensure the segmentation accuracy and the shape accuracy of the half circle.

[0056] The two half circles are further processed vertically (three vertical processing for each half circle). Using a vertical machining center, the two half circles are further processed vertically, such as milling, drilling, etc., to ensure the accuracy of their respective sizes and shapes. During the processing, high-precision tools and fixtures should be used, and the processing parameters and paths should be strictly controlled to ensure the processing accuracy and shape accuracy.

[0057] 8. Assembly and grinding stage

[0058] Use the locating pins and screw holes to accurately assemble the two half circles together (fitter assembly). According to the design drawings and process requirements, use the locating pins and screw holes to accurately assemble the two half circles together. During the assembly process, the assembly accuracy and fit tightness should be strictly controlled to ensure the accuracy and performance of the assembled sector gear.

[0059] Fine grinding (flat grinding) of the assembled plane. Use a surface grinder to finely grind the plane of the assembled sector gear, strictly ensuring flatness and parallelism. During the grinding process, appropriate grinding parameters and abrasives should be selected to ensure grinding effect and surface quality.

[0060] 9. Hole processing and aging treatment stage

[0061] Perform preliminary machining (semi-finishing) of the hole. Use a drilling machine or boring machine to perform preliminary machining (semi-finishing) of the hole of the sector gear to prepare for finishing. During the machining process, the machining parameters and paths should be strictly controlled to ensure the size and shape accuracy of the hole.

[0062] Perform aging treatment. Place the sector gear in an aging treatment furnace, heat and insulate it at the preset temperature and time to effectively remove processing stress and stabilize the size and shape. During the aging treatment, the furnace temperature and insulation time should be strictly controlled to ensure the consistency and stability of the aging treatment effect.

[0063] 10. Final processing and inspection stage

[0064] Perform final processing (finishing hole) on the hole. Use a high-precision drilling machine or boring machine to perform final processing (finishing hole) on the hole of the sector gear to ensure that the finished product size and accuracy requirements are met. During the processing, the processing parameters and paths should be strictly controlled, and high-precision measuring tools should be used for online detection to ensure the size and shape accuracy of the hole.

[0065] Perform fine cutting (wire cutting). Use wire cutting machine to perform fine cutting on the teeth of the sector gear to ensure the accuracy and shape of the teeth. During the cutting process, the cutting speed and path should be strictly controlled, and high-precision measuring tools should be used for online testing to ensure the size and shape accuracy of the teeth.

[0066] Remove burrs from the teeth (fitter deburring). Use fitter tools to deburr the teeth of the sector gear to ensure the smoothness of the teeth. During the deburring process, care should be taken to protect the shape and accuracy of the teeth to avoid new damage or deformation.

[0067] Perform surface oxidation treatment (oxidation). Place the sector gear in the oxidation treatment furnace, heat and keep it warm according to the preset temperature and time, so that a dense oxide film is formed on the surface to improve corrosion resistance and aesthetics. During the oxidation treatment process, the furnace temperature and insulation time should be strictly controlled to ensure the consistency and stability of the oxidation treatment effect.

[0068] The finished products are inspected and put into storage (components are put into the finished product warehouse). The dimensions and performance of the sector gears are inspected using high-precision measuring tools to ensure that they meet the design requirements and quality standards. After passing the inspection, the sector gears are placed in the finished product warehouse for safekeeping for subsequent use or sale.

[0069] Through the description of the above specific embodiments, the entire process and key steps of the sector gear processing can be clearly understood. In actual production, adjustments and optimizations should be made according to specific design requirements and process conditions to ensure processing quality and production efficiency.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution, which should be included in the scope of the claims of the present invention.

Claims

1. A method for processing a sector gear, characterized in that: The following steps are involved: S1, material preparation stage: select integral forging billets to ensure the consistency and stability of the materials and lay a solid foundation for subsequent processing; S2, rough machining stage: preliminary turning of the forging blank to effectively remove most of the excess and facilitate subsequent processing; S3, heat treatment stage: perform quenching and tempering heat treatment to make the overall hardness meet the requirements and significantly improve the mechanical properties of the material; S4, finishing preparation stage: further turning to remove the remaining allowance, so that the shape gradually approaches the finished product size; Grind the surface evenly to improve the surface finish and create good conditions for subsequent processing; S5, fine processing stage: vertical processing is performed to complete some fine processing procedures to ensure processing accuracy; the groove is accurately cut in the middle position, but not cut off, to make full preparations for subsequent segmentation and strictly ensure cutting accuracy; S6, deburring and qualitative treatment stage: remove burrs generated during the processing to ensure a smooth and flawless surface; perform qualitative treatment to stabilize the metal structure and effectively prevent deformation problems in subsequent processing. S7, division and half-circle processing stage: the full circle is accurately divided into two half-circles along the original opening groove; the two half-circles are further processed vertically to ensure the accuracy of their respective sizes and shapes; S7, assembly and grinding stage: Use positioning pins and screw holes to accurately assemble the two half circles together to ensure the matching accuracy; finely grind the assembled surface to strictly ensure flatness and parallelism; S8, hole processing and aging treatment stage: preliminary processing of the hole to make full preparation for fine processing; aging treatment to effectively remove processing stress and stabilize size and shape; S9, final processing and inspection stage: final processing of the holes to ensure that the finished product size and accuracy requirements are met; fine cutting processing to ensure the accuracy and shape of the teeth; removal of burrs on the teeth to ensure the smoothness of the teeth; surface oxidation treatment to improve corrosion resistance and aesthetics; finally, the finished product is inspected and put into storage.

2. A sector gear processing method according to claim 1, characterized in that: In the first step of online cutting, the groove is cut but not cut off, which prepares for the subsequent precise segmentation and ensures the cutting accuracy.

3. A sector gear processing method according to claim 1, characterized in that: Aging treatment is carried out after semi-finishing to remove machining stress and stabilize size and shape.

4. A sector gear processing method according to claim 1, characterized in that: Dowel pins are used during machining and assembly to ensure repeat positioning accuracy of the two half turns.

5. A sector gear processing method according to claim 1, characterized in that: Tighten the two half turns through the screw holes to ensure stability and precision after disassembly and assembly.

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