Heat treatment process of gear

Abstract

The invention discloses a heat treatment process of a gear, which relates to the technical field of automobile gear heat treatment, and comprises the following steps: S1, blanking, S2, forging, S3, normalizing: preheating the gear in a preheating furnace by adopting a heating mode of combining infrared radiation and hot air circulation, S4, rough machining, S5, carburizing and quenching: carburizing and quenching, s6, induction heat quenching: performing induction heat quenching on an induction coil; S7, nitriding treatment; S8, low-temperature tempering; S9, finish machining; normalizing is combined with infrared radiation, hot air circulation preheating and induction heating, the effects of reducing energy consumption and machining cost and improving production efficiency are achieved, the forging force is reduced through isothermal forging, the energy consumption of equipment is greatly reduced, pulse type vacuum carburizing, high-pressure gas quenching and induction heat quenching are adopted to introduce a self-adaptive induction heating technology, and the energy consumption of equipment is greatly reduced. And a plasma nitriding technology and a composite nitriding technology are adopted, so that the surface hardness, wear resistance and fatigue strength are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive gear heat treatment, and particularly to a heat treatment process for gears. Background Art

[0002] With the rapid development of the automotive industry, the performance requirements for gears are increasing day by day, especially the demands for high strength, high wear resistance, and long service life. As a key process in gear manufacturing, heat treatment directly affects the final performance of gears. Gear heat treatment technologies mainly include normalizing, carburizing and quenching, induction heating quenching, nitriding treatment, etc. The main purpose of gear normalizing heat treatment is to eliminate the internal stress generated after the cold working process. In this process, the gear workpiece is heated to 30 - 50°C higher than its upper critical temperature and cooled in the air. Gear normalizing heat treatment is a heat treatment process carried out to restore the normal state of the structure, improving the performance, machinability, and tensile strength of the gear workpiece. Gear carburizing and quenching usually involves heating the gear in a carburizing medium to absorb carbon elements on its surface and then performing quenching treatment to improve the surface hardness and wear resistance of the gear. Induction heating quenching uses the principle of electromagnetic induction to rapidly heat and quench the gear surface, increasing the service life and strength of the gear. Nitriding treatment involves heating the gear in a nitrogen environment to form a nitrided layer on its surface, thereby improving the hardness and wear resistance.

[0003] The existing gear heat treatment process has high energy consumption, cannot meet the requirements of energy conservation and environmental protection, and is also complex in process and difficult to operate, increasing the production cost. It is difficult to balance the strength, wear resistance, and service life of gears. There is a need to design a gear heat treatment process to solve the above-mentioned problems. Summary of the Invention

[0004] The purpose of the present invention is to solve the deficiencies existing in the prior art and propose a heat treatment process for gears to solve the problems of high energy consumption, low efficiency, and difficulty in balancing the strength, wear resistance, and service life of gears in the above-mentioned technical solutions.

[0005] To achieve the above purpose, the present invention is realized through the following technical solutions: A heat treatment process for gears includes the following treatment processes: S1. Blanking: If the automotive gear is a gear that can be cut into shape, a high-power density laser cutting method is adopted. According to the gear blanking size specifications, the cutting path and parameters are accurately set in the control system in advance. After starting the equipment, the laser beam quickly focuses on the surface of the metal raw material to perform efficient cutting of the gear. S2. Forging: If the automotive gear is a gear whose shape cannot be obtained by machining, the forging method is adopted. The blank is placed in an isothermal forging die with precise temperature control function. Using an advanced temperature control system, the die and the blank are heated together to the required forging temperature, and during the entire forging process, the temperature fluctuation is ensured to be controlled within ±5°C. During forging, with the help of a high-precision pressure sensor and speed control system, the forging pressure and speed are strictly regulated to make the metal deform uniformly at a constant temperature; S3. Normalizing: The gear obtained in step S1 or S2 is placed in a preheating furnace and preheated by a heating method combining infrared radiation and hot air circulation. The preheated gear is quickly transferred into the induction coil of the induction heating equipment. After the equipment is powered on, the alternating magnetic field quickly penetrates the gear, generating a strong induced current inside the gear, thereby quickly heating up and cooling naturally in the air to eliminate the stress of the gear; S4. Rough machining: For the normalized gear in step S3, according to the specific material characteristics and complex shape of the gear, professional cutting simulation software is used to comprehensively simulate the machining process under different cutting parameters, accurately determine the optimal cutting speed, feed rate, and cutting depth. At the same time, a tool with a high-performance coating is selected to perform gear cutting operations according to the optimized cutting parameters; S5. Carburizing and quenching: The rough-machined gear in step S4 is carburized by using a pulsed vacuum carburizing combined with high-pressure gas quenching process. After carburizing is completed, it is immediately transferred into a high-pressure gas quenching equipment, and high-pressure nitrogen and other inert gases are used as quenching media to quench the gear; S6. Induction heat quenching: The carburized and quenched gear in step S5 is introduced into the induction heating equipment again. By setting multiple modules with adjustable magnetic field intensity in the induction coil and combining an intelligent temperature monitoring and feedback system, the magnetic field distribution of induction heating is adjusted in real time according to the shape and size of the gear. At the same time, a modular induction heating design is adopted; S7. Nitriding treatment: The induction heat quenched gear in step S6 is nitrided by using plasma nitriding technology. In a low-pressure environment, glow discharge is used to accelerate the bombardment of the gear surface by nitrogen ions under the action of an electric field to achieve rapid nitriding; S8. Low-temperature tempering: The nitrided gear in step S7 is placed on a special heat-resistant bracket in a resistance tempering furnace. At the same time, the infrared auxiliary heating device is turned on. The resistance furnace provides stable basic heating, and the infrared heating device quickly increases the surface temperature of the gear, making the inside and outside of the gear evenly heated. With the help of an intelligent temperature control system, the tempering temperature and time are accurately set; S9, Finish Machining: For the gear after low-temperature tempering in step S8, use an advanced CNC gear grinding machine. Input the precise machining parameters of the gear into the equipment control system in advance, and through a high-precision on-line detection system, monitor the machining accuracy of the gear in real time. Once a deviation is found, the system will immediately automatically compensate and adjust. S10, Benefit Evaluation: Conduct data detection on the heat-treated gear, and evaluate the energy consumption, efficiency, and cost through data. S11, Equipment Maintenance: Regularly maintain the equipment in steps S1 - S9 to ensure the stable operation of the equipment.

[0006] Furthermore, the following implementation steps are also included in steps S1 and S2: T1, Cleaning: Remove grease, dust, impurities, etc. on the surface of the gear after laser cutting through a cleaning agent. At the same time, check whether the size and shape of the gear meet the requirements, and carry out necessary trimming and machining. T2, Removal of Surface Impurities: Remove scale, rust, dirt, etc. on the surface of the gear by pickling or polishing.

[0007] Furthermore, in the normalizing step S3, hot air circulation is used for preheating to make the temperature in the furnace evenly distributed, control the temperature difference between the inside and outside of the gear within a very small range, and through an intelligent temperature control system, heat the gear to a certain preheating temperature at a relatively slow and stable rate. The preheating rate is controlled at 5 - 10 °C / min; for induction heating, through an intelligent temperature control system, according to the material and size of the gear, accurately set the heating speed, target temperature, and holding time.

[0008] Furthermore, in step S5, in the vacuum carburizing link, after pumping to the specified vacuum degree, periodically introduce carburizing gas into the furnace, and use an advanced gas flow and pressure control system to accurately control the amount, pressure, and duration of each pulse of carburizing gas introduced; in the high-pressure gas quenching link, accurately control the cooling rate of the gas by precisely adjusting the pressure and flow of the gas, and use a high-speed camera and temperature field monitoring system to monitor the cooling state and temperature distribution of the gear in real time.

[0009] Furthermore, in step S7, simulate the gas composition and ratio of nitriding treatment according to gears of different materials, and adjust the ratio according to the influence on the nitriding effect, and appropriately add hydrogen to assist the nitriding process; combine the plasma nitriding and gas soft nitriding methods to develop a composite nitriding process. First, carry out ion nitriding for a period of time to initially form a nitriding layer on the surface of the gear, and then carry out gas soft nitriding.

[0010] Further, in step S8, a gas circulation assistance technology is introduced, and a gas circulation device is installed in the resistance tempering furnace to form a stable circulating air flow of the protective gas in the furnace; the tempering process is optimized by data analysis. After each tempering treatment is completed, performance data such as the hardness, toughness, and residual stress of the gear are collected, and a tempering process database is established in combination with parameters such as temperature and time during the tempering process.

[0011] Further, in step S10, it specifically includes the following implementation steps: T3. Energy consumption assessment: Install high-precision energy meters for electricity, gas, oil, etc. on the equipment, and record the energy consumption data of each heat treatment process when processing a certain number of gears in real time, and calculate the data of electricity, gas, oil, etc. consumed and the data consumed by the traditional process; T4. Efficiency assessment: Record the processing time of each heat treatment process and the entire production process through the production management system, including the time from raw material input to finished product output, and at the same time count the number of gears processed per unit time; T5. Cost assessment: Calculate the energy cost and material cost.

[0012] In summary, the present invention provides a heat treatment process for gears, which has the following beneficial effects: 1. Through steps S1-S9, in the heat treatment process of gears, while making the gears have both strength, wear resistance and service life, uniform heating, shortened cycle and reduced energy consumption are realized.

[0013] 2. By combining normalizing with infrared radiation, hot air circulation preheating and induction heating, the effects of reducing energy consumption and processing cost and improving production efficiency are achieved. Laser cutting has no mechanical stress, and isothermal forging reduces the forging force and greatly reduces the equipment energy consumption.

[0014] 3. By using pulse vacuum carburizing and high-pressure gas quenching for carburizing and quenching, introducing adaptive induction heating technology for induction heat quenching, and using plasma nitriding technology and composite nitriding process for nitriding treatment, the effects of improving product quality and reducing the scrap rate are achieved, the heating, carburizing and nitriding processes are optimized, quenching deformation and cracking are reduced, uniform heating is realized, surface hardness, wear resistance and fatigue strength are improved, and at the same time the processing speed is fast and the energy consumption is reduced.

[0015] 4. By introducing gas circulation assistance technology and optimizing the process by using data analysis for low-temperature tempering, using a CNC gear grinding machine combined with an on-line detection system for finish machining, and accurately calculating energy consumption, efficiency and cost for benefit assessment, the effects of continuously improving the process, ensuring product accuracy and stable production are achieved, which can not only improve the performance stability of gears, but also timely discover process problems and optimize them. Description of the Drawings

[0016] Figure 1Schematic diagram of the process architecture of a heat treatment process for a gear of the present invention. Detailed implementation mode

[0017] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present invention.

[0018] Embodiment: Please refer to Figure 1 As shown, the present invention provides a technical solution: a heat treatment process for a gear, including the following treatment processes: S1. Blanking: If the automotive gear is a gear that can be cut into shape, a high-power density laser cutting method is adopted. According to the gear blanking size specifications, the cutting path and parameters are accurately set in the control system in advance. After starting the equipment, the laser beam quickly focuses on the surface of the metal raw material to perform efficient cutting of the gear. The cutting process is fast, the cutting accuracy is high, it can effectively reduce the subsequent processing allowance, and no mechanical stress is generated during cutting, so there is no need to perform a stress relief process, which not only shortens the processing time but also avoids material waste, increasing the material utilization rate compared to traditional mechanical cutting; S2. Forging: If the automotive gear is a gear that cannot be cut into shape, a forging method is adopted. The blank is placed in an isothermal forging die with a precise temperature control function. Using an advanced temperature control system, the die and the blank are heated to a specific forging temperature together, and the temperature fluctuation is ensured to be controlled within ±5°C during the entire forging process. During forging, with the help of a high-precision pressure sensor and speed control system, the forging pressure and speed are strictly regulated to make the metal deform uniformly at a constant temperature. Compared with the traditional forging process, the forging force required for isothermal forging is reduced. Not only can a forging equipment with a smaller tonnage be selected, significantly reducing the equipment energy consumption, but also the dimensional accuracy and internal quality of the forgings can be effectively improved, reducing the subsequent processing allowance and lowering the processing cost; S3. Normalizing: The gear obtained in step S1 or S2 is placed in a preheating furnace and preheated by a heating method combining infrared radiation and hot air circulation. The preheated gear is quickly transferred into the induction coil of the induction heating equipment. After the equipment is powered on, the alternating magnetic field quickly penetrates the gear, generating a strong induced current inside the gear, thereby quickly heating up and cooling naturally in the air to eliminate the stress of the gear. Through the specific processes of preheating and induction heating, the gear performance is improved, the energy consumption is shortened, and the time for normalizing the gear is reduced, ensuring the uniformity of the internal structure of the gear; S4. Rough machining: For the normalized gear in step S3, according to the specific material properties and complex shape of the gear, use professional cutting simulation software to comprehensively simulate the machining process under different cutting parameters, accurately determine the optimal cutting speed, feed rate, and cutting depth. At the same time, select a tool with a high-performance coating and perform gear cutting operations according to the optimized cutting parameters, which not only improves the cutting efficiency and machining time but also reduces the cost of tool wear; S5. Carburizing and quenching: For the gear after rough machining in step S4, adopt the pulse vacuum carburizing combined with high-pressure gas quenching process to carry out carburizing treatment on the gear. After carburizing is completed, immediately transfer it to a high-pressure gas quenching device and use inert gases such as high-pressure nitrogen as the quenching medium to quench the gear, which not only reduces the energy consumption during the carburizing and quenching process but also reduces problems such as quenching deformation and cracking, effectively reducing the rejection rate; S6. Induction hardening: For the gear after carburizing and quenching in step S5, introduce it into the induction heating device again. By setting multiple modules with adjustable magnetic field strength in the induction coil and combining an intelligent temperature monitoring and feedback system, adjust the magnetic field distribution of induction heating in real time according to the shape and size of the gear to achieve uniform heating. At the same time, adopt a modular induction heating design to reduce the equipment cost; S7. Nitriding treatment: For the gear after induction hardening in step S6, adopt plasma nitriding technology. In a low-pressure environment, use glow discharge to accelerate nitrogen ions to bombard the gear surface under the action of an electric field to achieve rapid nitriding. By precisely controlling parameters such as discharge voltage, current, and gas flow rate, the nitriding cycle can be effectively shortened. In addition, plasma nitriding has stronger adaptability to materials, can process various gear materials with different compositions, reduces the special requirements for materials, and improves the versatility of the process; S8. Low-temperature tempering: Place the gear after nitriding treatment in step S7 on a special heat-resistant bracket in a resistance tempering furnace, and at the same time turn on the infrared auxiliary heating device. The resistance furnace provides stable basic heating, and the infrared heating device quickly raises the surface temperature of the gear to make the inside and outside of the gear evenly heated. With the help of an intelligent temperature control system, accurately set the tempering temperature and time. While the tempering time can be shortened and the energy consumption reduced, the production efficiency is greatly improved; S9. Finish machining: For the gear after low-temperature tempering in step S8, use an advanced CNC gear grinding machine. Input the precise machining parameters of the gear into the equipment control system in advance, and through a high-precision on-line detection system, monitor the machining accuracy of the gear in real time. Once a deviation is found, the system immediately automatically compensates and adjusts. This machining method not only improves the machining accuracy grade, effectively reduces the rejection rate, but also improves the machining efficiency, significantly reducing the manual inspection time and rework cost; S10. Benefit evaluation: Conduct data detection on the heat-treated gears, evaluate the data of energy consumption, efficiency, and cost. If the comprehensive energy consumption, efficiency, and cost are reduced by more than 20%, it indicates that the new process has achieved good results in control. S11. Equipment maintenance: Regularly maintain the equipment in steps S1 - S9 to ensure the stable operation of the equipment.

[0019] Steps S1 and S2 also include the following implementation steps: T1. Cleaning: Remove grease, dust, impurities, etc. on the surface of the gears after laser cutting through a cleaning agent to ensure the quality and effect of subsequent processing. At the same time, check whether the dimensions and shapes of the gears meet the requirements, and perform necessary trimming and processing to ensure the geometric shape and dimensional accuracy of the gears. T2. Removal of surface impurities: Remove scale, rust, dirt, etc. on the surface of the gears through pickling or polishing to ensure the uniformity and stability of the subsequent heating process.

[0020] In the normalizing step S3, when hot air circulation is used for preheating, the temperature in the furnace is evenly distributed, the temperature difference between the inside and outside of the gears is controlled within a very small range, and through an intelligent temperature control system, the gears are heated to a certain preheating temperature at a relatively slow and stable rate. The preheating rate is controlled at 5 - 10 °C / min to ensure that the structure of the gears changes evenly during the preheating process. The preheating time is shorter compared to the traditional heating method, and at the same time, the energy consumption is reduced. Induction heating, through an intelligent temperature control system, accurately sets the heating speed, target temperature, and holding time according to the material and size of the gears. The heating speed in the induction heating stage is higher than that of the traditional box furnace, the heating time is shorter, the energy consumption is reduced, and at the same time, the internal structure uniformity of the gears is ensured to be good.

[0021] In step S5, in the vacuum carburizing link, after pumping to the specified vacuum degree, carburizing gas is periodically introduced into the furnace, and an advanced gas flow and pressure control system is used to accurately control the amount, pressure, and duration of the carburizing gas pulsed each time, accelerating the carburizing speed and shortening the carburizing time; in the high-pressure gas quenching link, by precisely adjusting the pressure and flow of the gas, the cooling speed of the gas is accurately controlled, and a high-speed camera and temperature field monitoring system are used to monitor the cooling state and temperature distribution of the gears in real time to ensure uniform cooling.

[0022] In step S7, according to gears of different materials, simulate the gas components and ratios for nitriding treatment, adjust the ratios based on the influence on nitriding effect, and appropriately add hydrogen to assist the nitriding process. This can not only precisely control the nitrogen addition amount, but also further improve the activity of nitrogen atoms, accelerate the nitriding reaction process, and help improve the organizational structure of the nitrided layer, enhancing its toughness and corrosion resistance. Compared with nitriding using only pure nitrogen, the nitriding treatment with optimized gas components can increase the surface hardness and wear resistance of the gears; combine plasma nitriding with gas soft nitriding methods to develop a composite nitriding process. First, perform ion nitriding for a period of time to initially form a nitrided layer on the gear surface, and then perform gas soft nitriding. This can give full play to the advantages of the two nitriding methods. Ion nitriding can achieve rapid nitriding, while gas soft nitriding can further optimize the surface properties on the basis of the already formed nitrided layer, making the nitrided layer more uniform and dense. The fatigue strength of the gears treated by the composite nitriding process is higher than that of single plasma nitriding, and at the same time, the nitriding cycle is shorter than that of the traditional single nitriding process, further improving production efficiency and product quality.

[0023] In step S8, introduce gas circulation assistance technology. Install a gas circulation device in the resistance tempering furnace to make the protective gas in the furnace form a stable circulating gas flow. The circulating gas can quickly take away the heat generated on the gear surface, making the temperature of each part of the gear more uniform, avoiding local overheating or overcooling, effectively reducing the performance differences caused by uneven tempering, and further improving the dimensional stability and mechanical property consistency of the gears; use data analysis to optimize the tempering process. After each tempering treatment is completed, collect performance data such as the hardness, toughness, and residual stress of the gears, and combine parameters such as temperature and time during the tempering process to establish a tempering process database. Through in-depth analysis of a large amount of data, explore the internal relationship between different parameters and gear performance, and then continuously optimize the tempering process parameters to achieve refined control of the tempering process and continuously improve product quality and production efficiency.

[0024] In step S10, it specifically includes the following implementation steps: T3. Energy consumption assessment: Install high-precision energy meters for electricity, gas, oil, etc. on the equipment to record in real time the energy consumption data of each heat treatment process when processing a certain number of gears, and calculate the data of electricity, gas, oil, etc. consumed and the data consumed by the traditional process; Calculation method: Energy consumption reduction rate = (unit energy consumption of traditional process - unit energy consumption of new process) ÷ unit energy consumption of traditional process × 100%; Unit energy consumption = energy consumption reduction rate ÷ number of gears processed at one time; T4. Efficiency Evaluation: Record the processing time of each heat treatment process and the entire production process through the production management system, including the time from raw material input to finished product output, and at the same time count the number of gears processed per unit time; Production cycle shortening rate = (Traditional process production cycle - New process production cycle) ÷ Traditional process production cycle × 100%; Production efficiency improvement rate = (New process output per unit time - Traditional process output per unit time) ÷ Traditional process output per unit time × 100%; T5. Cost Evaluation: Calculate the energy cost and material cost; Production cost = (Total energy cost and material cost) ÷ Number of gears processed in one operation.

[0025] The above are only the preferred embodiments of the present invention, and are not intended to limit the present invention in other forms. Any person skilled in the art may use the technical content disclosed above to make changes or modifications into equivalent embodiments with equivalent changes and apply them to other fields. However, as long as it does not depart from the technical solution content of the present invention, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention still fall within the protection scope of the technical solution of the present invention.

Claims

1. A heat treatment process for a gear, characterized in that: It includes the following processing techniques: S1. Blanking: If the automotive gear is a gear that can be cut into shape, a high-power density laser cutting method is adopted. According to the blanking size specifications of the gear, the cutting path and parameters are accurately set in the control system in advance. After starting the equipment, the laser beam quickly focuses on the surface of the metal raw material to perform efficient cutting of the gear; S2. Forging: If the automotive gear is a gear that cannot be cut into shape, a forging method is adopted. The blank is placed in an isothermal forging die with precise temperature control function. Using an advanced temperature control system, the die and the blank are heated to the required forging temperature together, and during the entire forging process, the temperature fluctuation is ensured to be controlled within ±5°C. During forging, with the help of a high-precision pressure sensor and speed control system, the forging pressure and speed are strictly regulated to make the metal deform uniformly at a constant temperature; S3. Normalizing: The gear obtained in step S1 or S2 is placed in a preheating furnace and preheated by a heating method combining infrared radiation and hot air circulation. The preheated gear is quickly transferred into the induction coil of the induction heating equipment. After the equipment is powered on, the alternating magnetic field quickly penetrates the gear, generating a strong induced current inside the gear, thereby quickly heating up and cooling naturally in the air to eliminate the stress of the gear; S4. Rough machining: For the gear normalized in step S3, according to the specific material characteristics and complex shape of the gear, professional cutting simulation software is used to comprehensively simulate the machining process under different cutting parameters, accurately determine the optimal cutting speed, feed rate, and cutting depth. At the same time, a tool with a high-performance coating is selected to perform gear cutting operations according to the optimized cutting parameters; S5. Carburizing and quenching: The gear rough machined in step S4 is carburized by a pulsed vacuum carburizing combined with high-pressure gas quenching process. After carburizing is completed, it is immediately transferred into a high-pressure gas quenching equipment, and high-pressure nitrogen and other inert gases are used as the quenching medium to quench the gear; S6. Induction heat quenching: The gear carburized and quenched in step S5 is introduced into the induction heating equipment again. By setting multiple modules with adjustable magnetic field strength in the induction coil and combining an intelligent temperature monitoring and feedback system, the magnetic field distribution of induction heating is adjusted in real time according to the shape and size of the gear. At the same time, a modular induction heating design is adopted; S7. Nitriding treatment: The gear induction heat quenched in step S6 is nitrided by plasma nitriding technology. In a low-pressure environment, glow discharge is used to accelerate the bombardment of the gear surface by nitrogen ions under the action of an electric field to achieve rapid nitriding; S8. Low-temperature tempering: The gear nitrided in step S7 is placed on a special heat-resistant bracket in a resistance tempering furnace. At the same time, the infrared auxiliary heating device is turned on. The resistance furnace provides stable basic heating, and the infrared heating device quickly raises the surface temperature of the gear to make the inside and outside of the gear uniformly heated. With the help of an intelligent temperature control system, the tempering temperature and time are accurately set; S9. Finish machining: For the gear after low-temperature tempering in step S8, use an advanced CNC gear grinding machine. Input the precise machining parameters of the gear into the equipment control system in advance, and through a high-precision on-line detection system, monitor the machining accuracy of the gear in real time. Once a deviation is found, the system immediately makes automatic compensation adjustments; S10. Benefit evaluation: Conduct data detection on the heat-treated gear, and evaluate the data of energy consumption, efficiency, and cost; S11. Equipment maintenance: Regularly maintain the equipment in steps S1 - S9 to ensure the stable operation of the equipment.

2. The heat treatment process of a gear according to claim 1, characterized in that: The following implementation steps are also included in steps S1 and S2: T1. Cleaning: Remove the grease, dust, impurities, etc. on the surface of the gear after laser cutting through a cleaning agent. At the same time, check whether the size and shape of the gear meet the requirements, and perform necessary trimming and machining; T2. Removal of surface impurities: Remove the scale, rust, dirt, etc. on the surface of the gear by pickling or polishing.

3. The heat treatment process of a gear according to claim 1, characterized in that: In the normalizing step S3, when preheating with hot air circulation, the temperature in the furnace is evenly distributed, and the temperature difference between the inside and outside of the gear is controlled within a very small range. Through an intelligent temperature control system, the gear is heated to a certain preheating temperature at a relatively slow and stable rate, and the preheating rate is controlled at 5 - 10 °C / min; For induction heating, through an intelligent temperature control system, according to the material and size of the gear, the heating speed, target temperature, and holding time are accurately set.

4. A heat treatment process for a gear according to claim 1, characterized in that: In step S5, in the vacuum carburizing process, after pumping to the specified vacuum degree, periodically introduce carburizing gas into the furnace, and use an advanced gas flow and pressure control system to accurately control the amount, pressure, and duration of each pulse of carburizing gas introduced; In the high-pressure gas quenching process, accurately control the cooling rate of the gas by precisely adjusting the pressure and flow of the gas, and use a high-speed camera and temperature field monitoring system to monitor the cooling state and temperature distribution of the gear in real time.

5. A heat treatment process for a gear according to claim 1, characterized in that: In step S7, simulate the gas composition and ratio of nitriding treatment according to different materials of the gear, and adjust the ratio according to the influence on the nitriding effect, and appropriately add hydrogen to assist the nitriding process; Combine the plasma nitriding and gas soft nitriding methods to develop a composite nitriding process. First, perform ion nitriding for a period of time to initially form a nitriding layer on the surface of the gear, and then perform gas soft nitriding.

6. The heat treatment process of a gear according to claim 1, characterized in that: In step S8, introduce a gas circulation assistance technology. Install a gas circulation device in the resistance tempering furnace to make the protective gas in the furnace form a stable circulating air flow; Optimize the tempering process using data analysis. After each tempering treatment is completed, collect the performance data of the gear such as hardness, toughness, and residual stress, and establish a tempering process database in combination with parameters such as temperature and time during the tempering process.

7. The heat treatment process of a gear according to claim 1, characterized in that: In step S10, the following implementation steps are specifically included: T3. Energy consumption evaluation: Install high-precision energy meters for electricity, gas, oil, etc. on the equipment to record the energy consumption data of each heat treatment process when processing a certain number of gears in real time, and calculate the data of electricity, gas, oil, etc. consumed and the data consumed by the traditional process; T4. Efficiency evaluation: Record the processing time of each heat treatment process and the entire production process through the production management system, including the time from raw material input to finished product output, and at the same time count the number of gears processed per unit time; T5. Cost evaluation: Calculate the energy cost and material cost.

Images