Transmission system gear part and surface quality improving process method
By optimizing the gear manufacturing process, introducing liquid sandblasting, steam cleaning, and strictly controlling the interval between processes, the problems of contaminant embedding and corrosion on the gear surface were solved, achieving stability and consistency in surface quality.
Patent Information
- Application Number
- CN202511726023.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-24
- Publication Date
- 2026-01-23
AI Technical Summary
In traditional gear manufacturing processes, incomplete cleaning leads to contaminant embedding, and inadequate time control between processes results in corrosion, affecting the surface quality and stability of the gears.
The process involves liquid sandblasting, saturated steam cleaning, enhanced shot blasting, applying rust-preventive oil, and packaging. The intervals between each process are strictly controlled to ensure surface cleanliness and rust prevention.
It significantly improves the cleanliness and stability of gear surfaces, reduces rework rates, and enhances product reliability and market competitiveness.
Smart Images
Figure CN121374058A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of gear processing technology for transmission systems, and specifically to a transmission system gear part and a process method for improving its surface quality. Background Technology
[0002] Gears are key components in transmission systems, and their surface quality directly affects the reliability, service life, and overall quality of the system. Currently, the typical production process for transmission gears in the industry is: pre-heat processing → carburizing, quenching, shot blasting → post-heat grinding → cleaning → enhanced shot blasting → warehousing (see [reference]). Figure 1 ).
[0003] However, this traditional process has the following inherent defects, leading to unstable surface quality of the finished gears: First, the single cleaning performed between hot post-grinding and shot blasting is insufficient to completely remove the complex oil and metal dust generated during grinding. These residual contaminants are easily embedded or "rolled" into the surface of the parts by the impact of the shot during subsequent shot blasting, forming permanent stains that are difficult to remove and may become the origin of stress corrosion.
[0004] Secondly, and more critically, but often overlooked, is the lack of clear and strict time interval control between different processes. For example, if ground gear parts are exposed in the workshop for too long before cleaning, initial rust will begin to appear on their surface; the chemically active "shot blasting dust" produced after shot blasting, if not cleaned in time, will quickly cause surface rust; and if the finally cleaned parts are not promptly packaged with rust-proof materials, they will quickly rust again in the storage environment. This problem of "process rust" and "secondary contamination" caused by loose process connections is the main issue affecting the final surface appearance quality and long-term storage stability of gears. Summary of the Invention
[0005] In view of the shortcomings of the existing technology, the technical problem to be solved by the present invention is to provide a transmission system gear parts and a surface quality improvement process, which can effectively improve the surface appearance quality of gear parts and improve the performance of the product.
[0006] To achieve the above objectives, the present invention provides a method for improving the surface quality of gear parts in a transmission system, comprising: After carburizing, quenching and shot blasting, the parts undergo a liquid sandblasting process to remove burrs and excess material. After the parts are hot-ground, use a saturated steam cleaner to clean the dust and oil stains on the surface of the parts; The parts are subjected to shot blasting for reinforcement. After shot blasting is completed, a cleaning process is performed to remove the shot blasting dust generated during the process, and the cleanliness of the parts is checked with a white paper towel. After cleaning, a rust-preventive oil coating process is carried out, and an oiling machine is used to automatically coat the parts with rust-preventive oil. After applying rust-preventive oil, the packaging process is carried out. Each part is sealed and packaged with oil paper before being put into storage. The interval between each process, including gear grinding, cleaning, shot blasting, cleaning, applying rust-preventive oil, and packaging, shall not exceed 7 days.
[0007] Furthermore, the liquid sandblasting process is performed after carburizing, quenching, and shot blasting, and before hot grinding.
[0008] Furthermore, in the saturated steam cleaning step, the cleaning temperature is 80℃~120℃, and the cleaning time is 5~15 minutes.
[0009] Furthermore, the shot blasting medium used in the enhanced shot blasting process is cast steel shot with a particle size range of 0.3 mm to 0.8 mm.
[0010] Furthermore, in the process of applying anti-rust oil, the oiling machine is an automatic spraying device, and the oil thickness is 5μm to 20μm.
[0011] Furthermore, in the packaging process, the oil paper is rust-proof oil paper, and its rust-proof effectiveness period is not less than 12 months.
[0012] Furthermore, the standard for checking the cleanliness of the white paper towel is: there are no obvious stains after wiping with the paper towel.
[0013] Furthermore, the interval between each process shall not exceed 5 days.
[0014] Furthermore, the abrasive used in the liquid sandblasting process is alumina or glass microspheres with a particle size range of 80 mesh to 150 mesh.
[0015] A gear-type part for a transmission system, the part being prepared by the above-described process.
[0016] The beneficial effects of this invention are: The aforementioned transmission system gear parts and surface quality improvement process methods produce transmission system gear parts with at least the following advantages: 1. Through a series of interconnected steps—"pre-purification with liquid sandblasting, deep cleaning with saturated steam, thorough dust removal after enhanced shot blasting, automatic oiling and sealing packaging"—a complete quality assurance chain is constructed from intermediate processes to the final product. In particular, the introduction of the liquid sandblasting process effectively removes microscopic burrs and adhering substances that are difficult to handle with traditional dry shot blasting after heat treatment and before finishing, providing a clean reference surface for all subsequent processes.
[0017] 2. In this process, "the interval between each process shall not exceed 7 days." This avoids surface quality deterioration caused by process delays, effectively prevents problems such as oil residue after gear grinding, active corrosion from shot blasting ash, and rusting of clean parts before they are put into storage, thus ensuring the consistency and stability of the final product's surface quality.
[0018] 3. By using the intuitive and verifiable standard of "checking cleanliness with white paper towels," the traditional method of relying on subjective human judgment has been replaced, making the cleanliness assessment standard quantifiable and unified, and greatly improving the reliability and traceability of quality control. Attached Figure Description
[0019] To more clearly illustrate the specific embodiments of the present invention, the accompanying drawings used in the specific embodiments will be briefly described below. In all the drawings, the elements or parts are not necessarily drawn to scale.
[0020] Figure 1 To use the traditional process flow diagram; Figure 2 for Figure 1 The process flow diagram of the present invention. Detailed Implementation
[0021] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the invention; therefore, the invention is not limited to the specific embodiments disclosed below.
[0022] This invention provides a process method for improving the surface quality of gear parts in transmission systems. This method optimizes the traditional process route, adds key processes, and strictly controls the turnaround time between processes, effectively solving problems such as surface corrosion, incomplete removal of foreign matter, and inadequate cleaning of gear parts.
[0023] This embodiment uses a certain type of gearbox transmission gear as an example to describe the process method of the present invention in detail. See also... Figure 2The process flow of the present invention includes the following steps: (1) Liquid sandblasting process: After the parts undergo the traditional pre-heat processing ("pre-heating → carburizing, quenching, shot blasting"), they enter the liquid sandblasting process. This process further removes any burrs, oxide scale, and small impurities that may remain after carburizing, quenching, and initial shot blasting, while also giving the parts a more uniform and delicate matte finish, enhancing their appearance. Following the liquid sandblasting process, post-heat grinding can then be performed.
[0024] Implementation parameters: Place the parts in a liquid sandblasting machine, using 100-mesh alumina abrasive, mixed with water and a small amount of rust inhibitor to form a sandblasting fluid. Control the spray gun pressure at 0.4–0.6 MPa, maintain the nozzle distance from the part surface at 150–250 mm, and process for 3–5 minutes per part.
[0025] (2) Grinding and cleaning after heating: After liquid sandblasting, the parts undergo hot post-grinding for precision machining. Once grinding is complete, the parts must be transferred to a cleaning process within four days. The saturated steam cleaning step involves a cleaning temperature of 80℃~120℃ and a cleaning time of 5~15 minutes.
[0026] Objective: To promptly remove cutting oil, metal powder, and adhering dust generated during gear grinding, providing a clean surface for subsequent shot blasting and preventing contaminants from being embedded into the surface of the parts by the impact force of shot blasting.
[0027] Specific implementation parameters: Use a saturated steam cleaner. Set the cleaning temperature to 95℃ and the steam pressure to 0.8MPa, and perform all-around steam cleaning on all surfaces of the parts for 10 minutes. After cleaning, the surfaces of the parts should be free of visible oil and water stains.
[0028] (3) Strengthen the shot blasting process: The cleaned parts are then subjected to shot blasting to enhance their fatigue strength. The shot blasting medium used in the enhanced shot blasting process is cast steel shot with a particle size range of 0.3 mm to 0.8 mm.
[0029] Specific implementation parameters: Cast steel shot with a particle size of 0.5mm is used as the shot blasting medium, and the shot blasting intensity is set to 0.35mmA.
[0030] (4) Cleaning and cleanliness inspection after shot blasting: After shot blasting is completed, cleaning must be carried out within 48 hours.
[0031] Objective: To completely remove shot blasting dust (fine metal dust and abrasive debris) generated during enhanced shot blasting.
[0032] Implementation parameters: Use a saturated steam cleaner of the same type and parameters as in step (2) for cleaning. After cleaning, wipe the main working surfaces of the parts (such as tooth surfaces) with a clean white paper towel.
[0033] Inspection standard: The paper towel should be free of obvious black or gray stains after wiping to be considered qualified.
[0034] (5) Applying rust-preventive oil: After the cleanliness inspection is passed, the rust-preventive oil application process is immediately carried out. During the rust-preventive oil application process, the oiling machine is an automatic spraying device, and the oil thickness is 5μm to 20μm.
[0035] Purpose: To form a uniform and dense anti-rust oil film on the surface of parts, isolate them from air, and prevent rust from occurring during inter-process transfer and storage.
[0036] Specific implementation parameters: An automatic oiling machine is used to spray the parts. A thin-film lubricating oil is selected as the rust-preventive oil. By controlling the spraying pressure and time, the oil film thickness is maintained at approximately 10μm to ensure complete coverage and prevent oil droplet accumulation.
[0037] (6) Packaging process: After applying the oil, package it immediately.
[0038] Purpose: To provide final sealing protection for parts, preventing them from coming into contact with air or being contaminated by external sources during storage and transportation.
[0039] Implementation parameters: Wrap each part individually with rust-proof paper conforming to GB / T22812 standard, ensuring complete coverage, and then place them in a dedicated rust-proof packaging box for storage. This rust-proof paper provides effective rust protection for at least 12 months.
[0040] (7) Process interval time control: A key aspect of this process is the strict control of the time intervals between all steps. From gear grinding to subsequent cleaning, shot blasting, cleaning, applying rust-preventive oil, and packaging, the interval between each step and the next must not exceed 7 days, preferably no more than 5 days. This regulation minimizes the exposure time of parts after processes that are prone to corrosion and contamination, ensuring the stability and consistency of appearance quality through process management.
[0041] In addition, the present invention also discloses a gear-type part for a transmission system, which is prepared by any of the above-described processes.
[0042] Gear parts processed using the method of this invention, compared to those processed using traditional methods (see process flow diagram) Figure 1Compared to parts treated with [specific treatment], the surface cleanliness is significantly improved, with no rust or stains, and the appearance quality is consistently stable. Tests show that the cleanliness index of the product before assembly is improved by over 60%, and the rework rate due to appearance issues is reduced by over 95%, greatly enhancing product reliability and market competitiveness.
[0043] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.
Claims
1. A process for improving the surface quality of gear parts in a transmission system, characterized in that, include: After carburizing, quenching and shot blasting, the parts undergo a liquid sandblasting process to remove burrs and excess material. After the parts are hot-ground, use a saturated steam cleaner to clean the dust and oil stains on the surface of the parts; The parts are subjected to shot blasting for reinforcement. After shot blasting is completed, a cleaning process is performed to remove the shot blasting dust generated during the process, and the cleanliness of the parts is checked with a white paper towel. After cleaning, a rust-preventive oil coating process is carried out, and an oiling machine is used to automatically coat the parts with rust-preventive oil. After applying rust-preventive oil, the packaging process is carried out. Each part is sealed and packaged with oil paper before being put into storage. The interval between each process, including gear grinding, cleaning, shot blasting, cleaning, applying rust-preventive oil, and packaging, shall not exceed 7 days.
2. The process method according to claim 1, characterized in that, The liquid sandblasting process is performed after carburizing, quenching, and shot blasting, and before hot grinding.
3. The process method according to claim 1, characterized in that, In the cleaning process of the saturated steam cleaner, the cleaning temperature is 80℃~120℃ and the cleaning time is 5~15 minutes.
4. The process method according to claim 1, characterized in that, The shot blasting medium used in the enhanced shot blasting process is cast steel shot with a particle size range of 0.3 mm to 0.8 mm.
5. The process method according to claim 1, characterized in that, In the process of applying rust-preventive oil, the oiling machine is an automatic spraying device, and the oil thickness is 5μm to 20μm.
6. The process method according to claim 1, characterized in that, In the packaging process, the oil paper is rust-proof oil paper, and its rust-proof effectiveness period is not less than 12 months.
7. The process method according to claim 1, characterized in that, The standard for checking the cleanliness of the white paper towel is: there are no obvious stains after wiping with the paper towel.
8. The process method according to claim 1, characterized in that, The interval between each process shall not exceed 5 days.
9. The process method according to claim 1, characterized in that, The abrasive used in the liquid sandblasting process is alumina or glass microspheres with a particle size range of 80 mesh to 150 mesh.
10. A gear-type part for a transmission system, characterized in that, The part is prepared by the process method described in any one of claims 1 to 9.