Gear and method of manufacturing and mechanical device

Abstract

The present application relates to the field of mechanical equipment manufacturing, and provides a gear, a manufacturing method of the gear and a mechanical equipment.The gear comprises a wheel base and a tooth surface structure, the wheel base has a mounting surface, and the tooth surface structure is arranged on the mounting surface; the mounting surface is provided with a first meshing tooth structure, one side of the tooth surface structure is provided with a second meshing tooth structure which is mutually meshed with the first meshing tooth structure, and the other side of the tooth surface structure is provided with a meshing tooth structure which is used for meshing with another gear; the material of the wheel base is an aluminum alloy material, and the material of the tooth surface structure is gear steel.The manufacturing method of the gear comprises the following steps: gear steel material is selected to manufacture the tooth surface structure; the tooth surface structure is placed in a mold of a spray deposition device, molten aluminum alloy liquid is sprayed on one side of the tooth surface structure where the second meshing tooth structure is located, and the aluminum alloy is deposited.The mechanical equipment comprises the above gear.The gear provided by the present application realizes weight reduction, and reduces the noise of a gear reduction system relative to the existing gear.

Description

Technical Field

[0001] This invention relates to the field of mechanical equipment manufacturing technology, and more specifically, to a gear, its manufacturing method, and mechanical equipment. Background Technology

[0002] As the trend of lightweighting of transportation mechanisms becomes more and more obvious, the weight of the transmission system is becoming more prominent in terms of weight reduction. In electric vehicles and even flying cars and helicopters with rotors, the transmission system has always used high-hardness and high-strength gear steel due to its harsh working environment, large transmission torque and high speed.

[0003] Due to the requirements for wear resistance, temperature resistance and strength of the tooth surface, the gear materials of the transmission system have not been able to be improved in terms of lightweighting. As a result, the work on lightweighting the transmission system has been stagnant. In the work on lightweighting of transportation mechanisms, it is basically an area that is not valued and is difficult to break through.

[0004] Therefore, this application is hereby submitted. Summary of the Invention

[0005] The object of the present invention includes, for example, providing a gear, a method for manufacturing the same, and a mechanical device thereof, aimed at improving at least one of the problems mentioned in the background art.

[0006] The embodiments of the present invention can be implemented as follows:

[0007] In a first aspect, the present invention provides a gear, including a gear base and a tooth surface structure, wherein the gear base has a mounting surface and the tooth surface structure is disposed on the mounting surface;

[0008] The mounting surface is provided with a first fitting tooth structure, one side of the tooth surface structure is provided with a second fitting tooth structure that fits into the first fitting tooth structure, and the other side of the tooth surface structure is provided with a meshing tooth structure for meshing with another gear.

[0009] The wheel base is made of aluminum alloy, and the tooth surface structure is made of gear steel.

[0010] In an alternative implementation, the gear is a cylindrical gear or a bevel gear.

[0011] In an optional embodiment, each tooth of the first interlocking tooth structure has a head size larger than a tail size, and each tooth of the second interlocking tooth structure also has a head size larger than a tail size.

[0012] Each tooth of the first interlocking tooth structure is precisely inserted between two adjacent teeth of the second interlocking tooth structure, and each tooth of the second interlocking tooth structure is precisely inserted between two adjacent teeth of the first interlocking tooth structure.

[0013] Preferably, the number of teeth in the second interlocking tooth structure is less than or equal to the number of teeth in the meshing tooth structure.

[0014] In an optional embodiment, the aluminum alloy material is a high-strength aluminum alloy;

[0015] Preferably, the aluminum alloy material is a spray-deposited 7000 series or 2000 series aluminum alloy material;

[0016] Preferably, the aluminum alloy is an alloy containing 0.05 to 0.3 wt% rare earth elements, wherein the rare earth elements are at least one of erbium and scandium;

[0017] Preferably, the gear steel is 40Cr, 42CrMo, or 35CrMo.

[0018] In optional embodiments, at least one of features (1) to (4) is also included;

[0019] (1) The aluminum alloy material is a 7075 series spray-deposited aluminum alloy material, and contains at least one of Ni and Zr in a mass ratio of 0.8 to 1.2%;

[0020] (2) The aluminum alloy material contains 0.03-10% Fe by mass;

[0021] (4) The aluminum alloy material contains 0.5% to 3% Li by mass;

[0022] (4) The aluminum alloy material contains 10-30% SiC by mass.

[0023] Secondly, the present invention provides a method for manufacturing a gear as described in any of the foregoing embodiments, comprising:

[0024] A tooth surface structure blank with a second interlocking tooth structure is obtained by selecting gear steel material;

[0025] The tooth surface structure blank is placed in the mold of the jet deposition equipment, and the molten aluminum alloy liquid is deposited on one side of the second interlocking tooth structure of the tooth surface structure to obtain the gear blank;

[0026] The gear blank is machined to form a meshing tooth structure on the side of the tooth surface blank that is opposite to the second meshing tooth structure.

[0027] In an optional implementation, aluminum alloy is deposited on the side of the second mating tooth structure of the tooth surface structure by means of pressurized or high-speed inert gas side nozzle injection.

[0028] In an optional embodiment, before machining the gear blank, the aluminum alloy portion of the gear blank is forged by die forging, wherein the gear blank is heated to 400-500°C for die forging.

[0029] Thirdly, the present invention provides a mechanical device comprising a gear as described in any of the foregoing embodiments or a gear manufactured by any of the foregoing embodiments.

[0030] The beneficial effects of the embodiments of the present invention include, for example:

[0031] The gear provided by this invention consists of an aluminum alloy wheel base and a gear steel tooth surface structure. The tooth surface structure is made of gear steel, which possesses high hardness, high strength, and high wear resistance to ensure it can withstand the impact of meshing and torque transmission during gear transmission. The wheel base is made of aluminum alloy, which is lightweight, allowing for a weight reduction of 50% or more. Furthermore, because the damping coefficient of aluminum alloy is greater than that of high-hardness steel used in gears, it effectively reduces vibration and impact during transmission, lowering noise and improving smoothness. In addition, the interlocking design of the first and second interlocking tooth structures prevents the tooth surface structure and wheel base from disengaging during gear operation, improving the strength of their connection. Attached Figure Description

[0032] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the cylindrical gear provided in the first embodiment of this application;

[0034] Figure 2 for Figure 1 Enlarged view of region A in the middle;

[0035] Figure 3 This is a schematic diagram of the gear blank obtained during the manufacturing process of the manufacturing method provided in the first embodiment;

[0036] Figure 4 This is a schematic diagram of the bevel gear provided in the second embodiment of this application.

[0037] Icons: 100-Gear; 100a-Gear blank; 110-Gear base; 111-First mating tooth structure; 112-Gear head; 113-Gear tail; 130-Gear surface structure; 131-Second mating tooth structure; 132-Meshing tooth structure; 140-Gear surface structure blank. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0039] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0040] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0041] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0042] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0043] It should be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.

[0044] First Embodiment

[0045] Please refer to Figure 1 This embodiment provides a gear 100, including a gear base 110 and a tooth surface structure 130. The gear base 110 has a mounting surface, and the tooth surface structure 130 is disposed on the mounting surface.

[0046] The mounting surface is provided with a first engaging tooth structure 111, one side of the tooth surface structure 130 is provided with a second engaging tooth structure 131 that engages with the first engaging tooth structure 111, and the other side of the tooth surface structure 130 is provided with a meshing tooth structure 132 for meshing with another gear 100.

[0047] The wheel base 110 is made of aluminum alloy, and the tooth surface structure 130 is made of gear 100 steel.

[0048] The gear 100 provided in this embodiment primarily serves a supporting function in its base 110, while the tooth surface structure 130 primarily provides impact protection for meshing with another gear 100 and transmitting torque. Since the tooth surface structure 130 is still made of gear steel, it possesses high hardness, high strength, and high wear resistance, ensuring the performance of the gear 100. Because the base 110 is made of aluminum alloy, a lightweight material, the gear 100 can be reduced in weight by 50% or more. Furthermore, since the damping coefficient of aluminum alloy is greater than that of the high-hardness steel used in gear 100, it effectively reduces shock and impact during the entire transmission process, lowering the noise of the transmission system and improving operational smoothness. In addition, the interlocking design of the first meshing tooth structure 111 and the second meshing tooth structure 131 prevents the tooth surface structure 130 and the base 110 from disengaging during gear 100 operation, improving the robustness of their connection.

[0049] Preferably, such as Figure 2 As shown in the figure, the specific structure of the first interlocking tooth structure 111 is indicated. Each tooth of the first interlocking tooth structure 111 has a tooth head 112 with a size larger than the tooth tail 113. Each tooth of the second interlocking tooth structure 131 also has a tooth head with a size larger than the tooth tail.

[0050] Each tooth of the first interlocking tooth structure 111 is precisely inserted between two adjacent teeth of the second interlocking tooth structure 131, and each tooth of the second interlocking tooth structure 131 is precisely inserted between two adjacent teeth of the first interlocking tooth structure 111.

[0051] The shape design of the tooth head 112 being larger than the tooth tail 113 makes the first interlocking tooth structure 111 and the second interlocking tooth structure 131 appear in an inverted state after they are interlocked. During the transmission of the gear 100, the tooth surface structure 130 and the wheel base 110 are less likely to separate from each other.

[0052] Preferably, the number of teeth in the second interlocking tooth structure 131 is less than or equal to the number of teeth in the meshing tooth structure 132.

[0053] The number of teeth in the undercut (the number of teeth in the first or second meshing tooth structure 131) can be designed according to the size of the gear 100, its working condition, and stress distribution. The optimal structure is the denser the better, and the more teeth the better. However, considering the difficulty of the process and the production cost, as well as the fact that the undercut itself needs to withstand a certain strength, the number of teeth in the undercut is less than or equal to the number of teeth in the meshing tooth structure 132.

[0054] Preferably, the gear 100 steel is conventional 40Cr, 42CrMo or 35CrMo.

[0055] Preferably, the aluminum alloy material is a high-strength aluminum alloy material, such as spray-deposited 7000 series or 2000 series aluminum alloy materials; or, the aluminum alloy material contains 0.05 to 0.3 wt% of rare earth elements, which are at least one of erbium and scandium.

[0056] Furthermore, to give the wheel base 110 higher strength, the aluminum alloy material is a 7075 series spray-deposited aluminum alloy material, and contains at least one of Ni and Zr in a mass ratio of 0.8 to 1.2%.

[0057] Furthermore, to give the wheel base 110 better high-temperature durability, the aluminum alloy material contains 0.03-10% Fe by mass.

[0058] Furthermore, to achieve a lower density in the wheel base 110, the aluminum alloy material contains 0.5% to 3% Li by mass.

[0059] Furthermore, to give the wheel base 110 higher strength, the aluminum alloy material contains 10-30% SiC by mass.

[0060] Furthermore, the gear 100 provided in this embodiment is a cylindrical gear 100. The structure of the cylindrical gear 100 can be, for example, as follows: the gear base 110 is cylindrical or disc-shaped, the mounting surface is the outer peripheral surface of the gear base 110, the first mating tooth structure 111 is disposed on the outer peripheral surface of the gear base 110, the tooth surface structure 130 is annular, the second mating tooth structure 131 is disposed on the inner peripheral surface of the tooth surface structure 130, and the meshing tooth structure 132 is disposed on the outer peripheral surface of the tooth surface structure 130.

[0061] This embodiment also provides a method for manufacturing a gear 100, including:

[0062] A tooth surface structure blank 140 with a second interlocking tooth structure 131 is obtained by selecting gear steel material;

[0063] The tooth surface structure blank 140 is placed in the mold of the spray deposition equipment, and the molten aluminum alloy liquid is deposited on the side of the second mating tooth structure 131 of the tooth surface structure 130 to obtain the gear blank 100a.

[0064] The gear blank 100a is machined to form the tooth surface structure 130 by machining the meshing tooth structure 132 on the side of the tooth surface structure blank 140 opposite to the second meshing tooth structure 131 (in this embodiment, it is its circumferential surface).

[0065] Specifically:

[0066] a. First, the tooth surface structure blank 140 is produced. Based on the transmission load requirements, the corresponding gear steel material is selected, and rolling or forging processes are employed, followed by heat treatment. Since the required tooth surface structure 130 is a thin-walled ring (cylindrical gear 100) or disc (bevel gear 100), it is easier to achieve hardenability in the machining process, reducing the tempering section and making it easier to produce gear 100 tooth surfaces with stable performance and grain refinement.

[0067] The tooth surface structure blank 140 is a ring structure with only the second interlocking tooth structure 131 and no meshing tooth structure 132. The reason why the meshing tooth structure 132 is not pre-processed is that subsequent processes such as deformation and heat treatment of the aluminum alloy part are required. If the meshing tooth structure 132 is pre-processed, it may cause structural deformation during subsequent processing.

[0068] b. Place the produced tooth surface structure blank 140 into the mold of the spray deposition equipment. The mold has a coolant flow channel inside, which can cool the tooth surface parts and make the aluminum alloy spray droplets or mist deposited on it form a cooling effect, thereby further improving the performance of the obtained spray deposited cooled aluminum alloy.

[0069] c. The jet deposition equipment atomizes molten aluminum alloy liquid (700-900℃) through pressurized or high-speed inert gas side nozzles and sprays it onto the side of the tooth structure 130 where the second interlocking tooth structure 131 is provided, so as to deposit it as shown in the image. Figure 3 The gear blank shown is 100a.

[0070] d. After the gear blank 100a is fully formed, it is taken out and heated to 400-500℃ to perform die forging on the aluminum alloy part, so that the aluminum alloy part is deformed and compacted, thereby further improving the toughness of the aluminum alloy and refining the grain.

[0071] e. The forged gear 100 blank is machined to form the meshing tooth structure 132 on the tooth surface structure blank 140, and the spokes are machined on the aluminum alloy part to obtain the desired shape. Figure 1 The tooth surface structure 130 shown can be further surface treated as needed.

[0072] Second Embodiment

[0073] This embodiment is basically the same as the first embodiment in terms of structure and implementation principle, with the only difference being: Figure 4 As shown, this embodiment provides a bevel gear 100, the specific structure of which can be, for example:

[0074] The wheel base 110 is a disc with a conical surface. The mounting surface is the conical surface of the wheel base 110. The first meshing tooth structure 111 is disposed on the conical surface of the wheel base 110. The tooth surface structure 130 is conical and has an inner conical surface and an outer conical surface. The second meshing tooth structure 131 is disposed on the inner conical surface, and the meshing tooth structure 132 is disposed on the outer conical surface.

[0075] It should be noted that although only two gear structures (cylindrical gear and bevel gear) are illustrated in the embodiments of this application, it does not mean that the gear structures provided in this application are only applicable to these two types of gears. The gear structures provided in this application are applicable to all types of gears.

[0076] The following provides a weight comparison between existing technologies for gears of the same size and the technical solution of this application.

[0077]

[0078] In summary, the gear 100 provided in this embodiment is composed of an aluminum alloy wheel base 110 and a gear tooth surface structure 130 made of gear steel. The gear tooth surface structure 130 is still made of gear steel, which has high hardness, high strength, and high wear resistance to ensure that it can withstand the impact of meshing and torque transmission during the gear 100's transmission process. The wheel base 110 is made of aluminum alloy, which is lightweight, allowing for a weight reduction of 50% or more in the gear 100. Furthermore, since the damping coefficient of aluminum alloy is greater than that of the high-hardness steel used in the gear 100, it plays a role in shock absorption and impact reduction during the entire transmission process, reducing the noise of the transmission system and improving the smoothness of operation. In addition, the mutual interlocking design of the first interlocking tooth structure 111 and the second interlocking tooth structure 131 can prevent the gear tooth surface structure 130 and the wheel base 110 from disengaging during the operation of the gear 100, improving the firmness of their connection.

[0079] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for manufacturing a gear, characterized in that, The gear includes a gear base and a tooth surface structure, the gear base has a mounting surface, and the tooth surface structure is disposed on the mounting surface; The mounting surface is provided with a first fitting tooth structure, one side of the tooth surface structure is provided with a second fitting tooth structure that fits into the first fitting tooth structure, and the other side of the tooth surface structure is provided with a meshing tooth structure for meshing with another gear. The wheel base is made of aluminum alloy, and the tooth surface structure is made of gear steel; Manufacturing methods include: A tooth surface structure blank with a second interlocking tooth structure is obtained by selecting gear steel material; The tooth surface structure blank is placed in the mold of the spray deposition equipment, and the molten aluminum alloy liquid is sprayed by pressurization or high-speed inert gas side nozzle to atomize and deposit on the side of the second mating tooth structure of the tooth surface structure blank to obtain the gear blank. The aluminum alloy portion of the gear blank is heated to 400~500℃ for die forging. After die forging, the gear blank is machined to form the meshing tooth structure on the side of the tooth surface structure blank opposite to the second mating tooth structure.

2. The manufacturing method according to claim 1, characterized in that, The gear is a cylindrical gear or a bevel gear.

3. The manufacturing method according to claim 1, characterized in that, Each tooth of the first interlocking tooth structure has a head size larger than a tail size, and each tooth of the second interlocking tooth structure also has a head size larger than a tail size. Each tooth of the first interlocking tooth structure is precisely embedded between two adjacent teeth of the second interlocking tooth structure, and each tooth of the second interlocking tooth structure is precisely embedded between two adjacent teeth of the first interlocking tooth structure.

4. The manufacturing method according to claim 1, characterized in that, The number of teeth in the second interlocking tooth structure is less than or equal to the number of teeth in the meshing tooth structure.

5. The manufacturing method according to claim 1, characterized in that, The aluminum alloy is a high-strength aluminum alloy.

6. The manufacturing method according to claim 1, characterized in that, The aluminum alloy material is a 7000 series or 2000 series aluminum alloy material that has been spray-deposited.

7. The manufacturing method according to claim 1, characterized in that, The aluminum alloy is an alloy containing 0.05~0.3wt% rare earth elements, wherein the rare earth elements are at least one of erbium and scandium.

8. The manufacturing method according to claim 1, characterized in that, The gear steel is 40Cr, 42CrMo, or 35CrMo.

9. The manufacturing method according to claim 1, characterized in that, It also includes at least one of features (1) to (4); (1) The aluminum alloy material is a 7075 series spray-deposited aluminum alloy material, and contains at least one of Ni and Zr with a mass ratio of 0.8~1.2%; (2) The aluminum alloy material contains 0.03-10% Fe by mass; (3) The aluminum alloy material contains 0.5-3% Li by mass; (4) The aluminum alloy material contains 10-30% SiC by mass.

10. The manufacturing method according to claim 1, characterized in that, Machining also includes machining spokes into the aluminum alloy material to form the wheel base.

11. A mechanical device, characterized in that, This includes gears manufactured by the manufacturing method as described in any one of claims 1 to 10.

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