A processing technology for high-precision gear ring

Abstract

The present invention discloses a high-precision ring gear machining process. This process utilizes a warm extrusion process to complete the machining of the ring gear's end face, outer diameter, and inner bore in a single step. The specific steps include: 1) manufacturing the machined part; 2) warm extrusion; 3) normalizing; 4) finishing; 5) high-frequency quenching; and 6) roundness testing. This method provides a high-precision ring gear machining process that utilizes extrusion instead of traditional methods. This process requires only a single finishing step, significantly improving the ring gear's surface quality, significantly saving materials, and increasing production efficiency, thereby reducing product production costs.

Description

Technical Field

[0001] The present invention relates to the field of automobile parts, and in particular to a processing technology for high-precision gear rings. Background Art

[0002] Diesel vehicles and some hybrid vehicles have long suffered from vibration issues during use. To address this, the dual-mass flywheel was invented. It significantly reduces and isolates vibrations within the vehicle's powertrain. The ring gear, as the most critical component within the dual-mass flywheel, plays a crucial role in the entire vehicle.

[0003] In the processing of existing gear rings, such as the gear ring steel and gear ring production process of application number 201210564860.9, a rolling method is used to directly roll out the gear ring steel with a tooth shape, and then the gear ring steel ring is directly welded into a crusher gear ring product according to the size requirements. The processing steps are complicated, and irregular shapes and sudden deformation after stress release are easily generated during rounding and welding. It is difficult to guarantee all dimensions, flatness and roundness of the inner hole. Summary of the Invention

[0004] The main technical problem solved by the present invention is to provide a high-precision gear ring processing technology, which can improve the surface quality of the gear ring.

[0005] To solve the above technical problems, the present invention adopts a technical solution: a high-precision gear ring processing process, characterized in that the gear ring is processed by a warm extrusion process, and the end face, outer circle and inner hole of the gear ring can be processed in one step. The specific steps include:

[0006] 1) Manufacturing and processing parts: the raw materials are drawn and then rolled, the rolled raw materials are sawed, welded and shavings are carried out to obtain processed parts;

[0007] 2) Warm extrusion process: heating and shaping the processed part obtained in step 1), placing the processed part in the intermediate frequency inductor of the intermediate frequency furnace for heating, using a manipulator to grab the processed part to the lower die of the installed extrusion die, extruding the processed part and then taking it out;

[0008] 3) Normalizing: The parts processed after extrusion in step 2) are hoisted into a pit furnace for heating, and then hoisted into a cooling furnace for cooling after heating;

[0009] 4) Finishing: Finish turning the outer circle, total length, chamfering and deburring the processed part after cooling in step 3), then performing gear hobbing, and finally performing gear chamfering on the processed part after the gear hobbing operation, thereby obtaining a gear ring;

[0010] 5) High-frequency quenching: quenching the gear ring obtained in step 4);

[0011] 6) Roundness detection: the gear ring after quenching in step 5) is calibrated by a hydraulic press, and finally subjected to magnetic particle inspection.

[0012] In a preferred embodiment of the present invention, the raw material is drawn in step 1) to a right-angled trapezoidal shape, and the surface of the drawn product is clean and smooth, without defects such as rust, cracks, folds, scars, inclusions and oxide scale.

[0013] In a preferred embodiment of the present invention, when sawing the material in step 1), it is necessary to ensure that the perpendicularity between the cut and the end face is 90°±2°.

[0014] In a preferred embodiment of the present invention, in step 2), when the processed part is placed in the intermediate frequency inductor of the intermediate frequency furnace for heating, it is required to first stand for 4 seconds and then be post-heated to 800°C.

[0015] In a preferred embodiment of the present invention, in step 3), the plurality of processed parts need to be neatly placed in a material frame, and then sequentially hoisted into the pit furnace and the cooling furnace through the material frame.

[0016] In a preferred embodiment of the present invention, during step 4) gear hobbing, the gear wheel needs to be calculated and replaced according to the gear parameter requirements. During clamping, after confirming that the processed parts are free of burrs, clean, and dirt, the inner hole is manually tightened first, and then the end face is pressed. After confirming that there are no abnormalities, the inner hole tension is released and the program is restarted. The program should be set to tighten the inner hole first and then press the end face.

[0017] In a preferred embodiment of the present invention, the hardness of the gear ring after quenching in step 5) satisfies HRC53-58.

[0018] In a preferred embodiment of the present invention, during step 6) roundness calibration, the hydraulic press column and the roundness calibration die are first lubricated. The upper and lower dies of the roundness calibration die are then positioned and height adjusted, and the part is pressed downward along the lower punch of the roundness calibration die, thereby calibrating the roundness of the gear ring.

[0019] In a preferred embodiment of the present invention, in step 6), the concentration and flow rate of the magnetic suspension are checked during magnetic particle inspection. The inner hole of the gear ring is expanded in the fixture so that the end face of the gear ring is in close contact with the end face of the fixture. The equipment is then turned on, the gear ring is rotated, and the magnetic suspension is sprayed. After 20 seconds, the spraying of the magnetic suspension is stopped. After the gear ring is stationary, the gear ring is observed under a fluorescent light to determine whether there is magnetic powder adsorption.

[0020] In a preferred embodiment of the present invention, after the roundness calibration test in step 6) is completed, the gear ring is cleaned by air intake, packaged, and then put into storage.

[0021] The beneficial effects of the present invention are: the present invention provides a high-precision gear ring processing process, which uses extrusion instead of traditional methods. When processing the gear ring, only one fine processing is required to complete it, which can significantly improve the surface quality of the gear ring, greatly save materials, and improve production efficiency, thereby achieving the purpose of reducing product production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 The figure is a flow chart of the machining process of a high-precision gear ring.

[0023] Figure 2 The front view of a gear ring manufactured using a high-precision gear ring processing technology. DETAILED DESCRIPTION

[0024] The preferred embodiments of the present invention are described in detail below so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more precise definition of the protection scope of the present invention.

[0025] according to Figure 1 and Figure 2 A high-precision gear ring processing process is characterized in that the gear ring is processed by a warm extrusion process, and the end face, outer circle and inner hole of the gear ring can be processed in one step. The specific steps include:

[0026] 1) Manufacturing and processing parts: The raw material C35 is drawn to a right-angled trapezoidal shape with dimensions of 10+0.1+0.2mm for the upper base, 10.9+0.1+0.2mm for the lower base, and 15.9+0.1+0.2mm for the height. The tensile strength requirement is ≥550Mpa, the yield strength requirement is ≥300Mpa, the material elongation is ≥12%, and the total length of the raw material is 5415 +2 mm, the surface of the drawn product is clean and smooth, and no defects such as rust, cracks, folds, scars, inclusions and oxide scale are allowed.

[0027] After drawing, roll it, correctly select the required roller specifications, adjust the size and distance between the three rollers on the coiling machine as required, select 10×10.9×15.9×5415 material, and ensure that the upper bottom is facing up when feeding. After adjusting to the working state, start the machine, feed, pre-roll, press the head and roll. The roll size is outer diameter φ291mm×inner diameter φ259.5mm.

[0028] After rolling is completed, the material is sawed. Select the correct saw blade and install it on the cutting machine. Place the rolled raw material on the tooling, expand the outer diameter to φ298mm, clamp it, and then saw the material. Ensure that the verticality of the cut and the end face is 90°±2°.

[0029] After sawing, welding and slag removal are carried out, welding parameters are checked, and the raw materials are placed on the welding fixture. After the end faces of the workpieces are aligned, the foot switch is pressed to press the raw materials to prevent welding dislocation. After welding is completed, the weld joint is polished and all welding slag 10mm away from the welding area is removed to obtain the processed parts.

[0030] Before each welding shift, the upper and lower electrode working surfaces must be polished smooth with sandpaper, and the welded joints and nearby oil, rust, and oxide scale must be cleaned.

[0031] 2) Warm extrusion process: heat and shape the processed parts obtained in step 1), check the power setting of the medium frequency furnace, check whether the medium frequency sensor is abnormal, install the extrusion die, adjust the size of the ejector, adjust the height limit, lubricate the hydraulic press column and the automatic upper and lower dies, adjust the pressure of the hydraulic press to 30-35MPa, check whether the upper and lower die positions and heights of the extrusion die are correct before processing, start processing after everything is normal, place the processed parts in the medium frequency sensor of the medium frequency furnace for heating, let it stand for 4 seconds and then heat to 800℃, use a robot to grab the processed parts to the lower die of the installed extrusion die, extrude the processed parts and take them out.

[0032] The lower die will have oxide scale, which should be cleaned frequently to avoid affecting the size of the parts.

[0033] 3) Normalizing: The several processed parts extruded in step 2) are hoisted into a pit furnace for heating. After heating, they are hoisted into a cooling furnace for cooling. First, check whether the instruments of the normalizing pit furnace are intact and whether the cooling circulating water is unobstructed. The several processed parts need to be neatly placed in the material frame, with 340 to 360 parts per furnace. Then, the material frame containing the processed parts is hoisted into the pit furnace, and the temperature is evenly raised to 860±5°C. After the processed parts are kept at this temperature for 100±5 minutes, the material frame is hoisted into a cooling furnace for cooling. After the processed parts are cooled in the cooling furnace for 45 minutes, they reach 30 to 60°C and are taken out of the furnace.

[0034] 4) Finishing: The processed part after cooling in step 3) is subjected to finish turning of the outer diameter, total length, chamfering, and deburring. The inner hole of the fixture is aligned, and the positioning plane runout is ≤0.02 mm. The chuck clamping force is set to 0.3-0.6 MPa and the system pressure is set to 2.5-3.0 MPa. The processed connection is clamped so that the end face of the processed part is in close contact with the end face of the fixture. The outer diameter, total length, chamfering, and deburring are then performed.

[0035] Then, the deburred processed parts are hobbed, and the end face and outer circle runout of the alignment fixture are ≤0.015mm, and the hob shoulder and end face runout are ≤0.015mm. The gear parameters need to be calculated and replaced according to the gear parameter requirements. When clamping, confirm that the processed parts should be free of burrs, clean and dirt. First, manually tighten the inner hole, then press the end face to confirm that there is no abnormality, then release the inner hole tension, and then start the program. The program should be set to tighten the inner hole first and then press the end face.

[0036] Finally, the tooth chamfers of the processed parts after the gear hobbing operation are processed, the positioning end face of the fixture is aligned, the positioning outer circle runout is ≤0.02mm, the chuck clamping force is set to 0.3~0.6Mpa, the system pressure is 2.5~3.0Mpa, the processed parts are clamped so that the end face of the processed parts is close to the end face of the fixture, and the tooth chamfers are processed to obtain the gear ring. After the processing is completed, the gear ring is degreased.

[0037] 5) High-frequency quenching: The gear ring obtained in step 4) is quenched. First, the gear ring is inspected to ensure it is clean and free of oil. The power supply of the equipment and the cooling water of the quenching equipment are checked to see if the pressure is between 0.1 and 0.5 MPa. The quenching pump is started and the distance between the sensor and the gear ring is adjusted to make the gap between the gear ring and the sensor consistent. The temperature of the cooling medium is controlled to be 10°C to 40°C. The gear ring is quenched and, after completion, the hardness of the gear ring is checked to meet HRC53 to 58. Finally, the gear ring is placed in a cleaning solution for cleaning.

[0038] Roundness calibration: The gear ring after quenching in step 5) is calibrated through a hydraulic press. First, the roundness calibration die is installed, the size of the ejector rod is adjusted, the height limit is adjusted, the hydraulic press column and the roundness calibration die are lubricated, and the hydraulic press pressure is adjusted to 20-25MPa. The upper and lower die positions and heights of the roundness calibration die are adjusted, and the part is squeezed downward along the lower die punch of the roundness calibration die to complete the roundness calibration of the gear ring.

[0039] Finally, magnetic particle inspection is performed to check the concentration and flow rate of the magnetic suspension. The inner hole of the gear ring is expanded in the fixture so that the end face of the gear ring is close to the end face of the fixture. Then the equipment is turned on, the gear ring rotates, and the magnetic suspension is sprayed. After 20 seconds, the magnetic suspension spraying is stopped. After the gear ring is stationary, the gear ring is observed under a fluorescent light to see if there is any magnetic powder adsorption.

[0040] After the roundness calibration is completed, the gear ring is cleaned and packed before being put into storage.

[0041] Compared with the existing technology, the present invention provides a high-precision gear ring processing technology, which uses extrusion instead of traditional methods. When processing the gear ring, only one finishing process is required, which can significantly improve the surface quality of the gear ring, greatly save materials, and improve production efficiency, thereby achieving the purpose of reducing product production costs.

[0042] The production cost of this process is 15% to 25% lower than that of similar products. It replaces the cumbersome domestic process, improves processing efficiency, increases competitiveness with foreign countries, has high production capacity, and can meet domestic supply needs in a short time.

[0043] In the description of the present invention, it should be noted that the components are all universal standard parts or components known to those skilled in the art, and their structures and principles are known to those skilled in the art through technical manuals or conventional test methods. The directions or positional relationships indicated by the terms "upper", "lower", "left", "right", "inside", "outside", etc. are based on the directions or positional relationships shown in the accompanying drawings, or are the directions or positional relationships in which the inventive product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention.

[0044] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention's description and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A high-precision gear ring processing technology, characterized in that: The gear ring is processed by the warm extrusion process, and the end face, outer circle and inner hole of the gear ring can be processed in one step. The specific steps include: 1) Manufacturing and processing parts: the raw materials are drawn and then rolled, the rolled raw materials are sawed, welded and shavings are carried out to obtain processed parts; 2) Warm extrusion process: heating and shaping the processed parts obtained in step 1), placing the processed parts in the intermediate frequency inductor of the intermediate frequency furnace for heating, using a manipulator to grab the processed parts to the lower die of the installed extrusion die, extruding the processed parts and then taking them out, placing the processed parts in the intermediate frequency inductor of the intermediate frequency furnace for heating, first standing for 4 seconds, and then heating to 800°C; 3) Normalizing: the parts processed after extrusion in step 2) are hoisted into a pit furnace for heating, and after heating is completed, are hoisted into a cooling furnace for cooling; 4) Finishing: The processed part after cooling in step 3) is subjected to finish turning of the outer circle, total length, chamfering and burr removal, and then gear hobbing is performed. Finally, the processed part after gear hobbing is subjected to gear chamfering to obtain a gear ring. During gear hobbing, the gear wheel needs to be calculated and replaced according to the gear parameter requirements. During clamping, after confirming that the processed part is free of burrs, clean, and dirt, the inner hole is first manually tightened, and then the end face is pressed to confirm that there is no abnormality. After that, the inner hole tightening is released and the program is restarted. The program should be set to tighten the inner hole first and then press the end face; 5) High-frequency quenching: quenching the gear ring obtained in step 4); 6) Roundness detection: the gear ring after quenching in step 5) is calibrated by a hydraulic press, and finally subjected to magnetic particle inspection.

2. A high-precision gear ring processing process according to claim 1, characterized in that: In the step 1), the raw material is drawn until it is in the shape of a right-angled trapezoid. The surface of the drawn product is clean and smooth, and no defects such as rust, cracks, folds, scars, inclusions and oxide scale are allowed.

3. A high-precision gear ring processing process according to claim 1, characterized in that: When sawing the material in step 1), it is necessary to ensure that the perpendicularity between the cut and the end face is 90°±2°.

4. A high-precision gear ring processing process according to claim 1, characterized in that: In step 3), the plurality of processed parts need to be neatly placed in a material frame, and then sequentially hoisted into the pit furnace and the cooling furnace through the material frame.

5. The high-precision gear ring processing process according to claim 1, characterized in that: The hardness of the gear ring after quenching treatment in step 5) meets HRC53-58.

6. A high-precision gear ring processing process according to claim 1, characterized in that: During the roundness calibration in step 6), the hydraulic press column and the roundness calibration die are first lubricated. Then, the upper and lower die positions and heights of the roundness calibration die are adjusted, and the part is pressed downward along the lower die punch of the roundness calibration die, thereby completing the roundness calibration of the gear ring.

7. The high-precision gear ring processing process according to claim 1, characterized in that: During the step 6) magnetic particle inspection, the concentration and flow rate of the magnetic suspension are checked. The inner hole of the gear ring is expanded in the fixture so that the end face of the gear ring is in close contact with the end face of the fixture. The equipment is then turned on, the gear ring is rotated, and the magnetic suspension is sprayed. After 20 seconds, the magnetic suspension spraying is stopped. After the gear ring is stationary, the gear ring is observed under a fluorescent light to see whether there is magnetic powder adsorption.

8. The high-precision gear ring processing process according to claim 1, characterized in that: After the roundness test is completed in step 6), the gear ring is cleaned and packed before being put into storage.

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