Thin-wall gear ring machining process
Through the large margin cutting and low-temperature tempering treatment in the thin-wall ring processing technology, combined with the disk adsorption and the use of pig iron ring flat fixtures, the problem of difficult deformation and accuracy of thin-wall ring gears in traditional processing is solved, and the problem of difficulty in controlling the deformation and accuracy of thin-wall ring gears in traditional processing is realized. Stress control and accuracy improvement during processing.
Patent Information
- Application Number
- CN202411505939.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-28
- Publication Date
- 2024-12-06
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
Thin-walled ring gears are prone to deformation in traditional processing technology, resulting in scrapping, mainly due to the difficulty in controlling the clamping force during turning and grinding, resulting in component size deformation and accuracy problems.
A thin-wall ring processing technology is adopted, including low-temperature tempering treatment after large margin cutting, and the internal stress is released. The disk adsorption and pig iron ring flat fixture are used for finishing to ensure the stability of clamping stress, and step-by-step rough grinding to control Accuracy.
Effectively control the deformation during thin-wall ring gear processing to ensure that the parts do not cause excessive stress during turning and grinding, improve product accuracy and stability, extend processing cycle and reduce costs.
Smart Images
Figure CN119077306A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to a thin-wall gear ring processing technology, belonging to the technical field of gear ring processing. Background Art
[0002] Thin-walled gear rings have the characteristics of thin wall thickness, light weight, and saving raw materials. They are widely used in the transmission devices of heavy-duty equipment in the fields of lifting and transportation, metallurgy, mining, petrochemicals, and shipping, and play the role of bearing, load balancing, and transmission.
[0003] Thin-walled gear rings are prone to large deformation when produced using traditional processing technology, which leads to the scrapping of thin-walled gear rings. The main difficulties are as follows: 1. Difficulties in turning 1.1. Clamping The small difference in diameter between the inner and outer rings of thin-walled gear rings results in poor strength of the parts themselves, which makes the machining and clamping process more difficult; If the clamping force is too small, the parts will become loose during processing, resulting in changes in part size or scrapping of the parts. If the clamping force is too large, it will increase the clamping stress of the parts. After the processing is completed, the size of the parts will be deformed, resulting in the scrapping of the parts. 1.2 Turning The thin-walled gear ring needs to have a large amount of turning allowance during turning, which will also lead to a series of problems; If the turning allowance is too large, turning stress will be generated inside the part. After the part is processed, the turning stress will be released, which will cause the part to deform and thus lead to the scrapping of the part. The turning allowance is too small, the processing cycle becomes longer, and the processing cost increases; 2. Difficulties in grinding 2.1. Clamping Since the precision grade of the internal gear ring is required to reach Grade 5, the internal stress caused by clamping can only be avoided as much as possible during the grinding process. Once the flatness of the two contact surfaces of the part and the tooling body does not meet the requirements, the product will inevitably warp during the locking process, thereby increasing the generation of internal stress; 2.2 Grinding The control of the grinding allowance of thin-walled gear rings will greatly affect the generation of internal stress; If the grinding allowance is too small, the product may not be ground clean due to early deformation problems, resulting in product scrapping; If the grinding allowance is too large, the grinding stress will be released after grinding, which will cause the product accuracy to exceed the tolerance.
[0004] Therefore, a thin-walled gear ring processing technology is needed to ensure that the deformation amount during the thin-walled gear ring processing is controllable. Summary of the invention
[0005] The technical problem to be solved by the present invention is: in order to overcome the deficiencies of the prior art, a thin-walled gear ring processing technology is provided to ensure that the deformation amount during the processing of the thin-walled gear ring is controllable.
[0006] The technical solution adopted by the present invention to solve the above problem is: a thin-walled gear ring processing process, comprising the following steps: Step S1, preparing materials; Step S2, one-time turning; Step S3, one-time marking; Step S4, flaw detection; Step S5, conditioning; Step S6, secondary turning; Step S7, three times turning; Step S8, secondary marking; Step S9, flat grinding; Step S10, copper plating; Step S11, gear shaping; Step S12, fitter; Step S13, carburizing and quenching; Step S14, removing copper; Step S15, primary composite grinding; Step S16, four times turning; Step S17, five times of turning; Step S18, secondary composite grinding; Step S19, three-time composite grinding; Step S20, drilling; Step S2, step S6, step S7, step S16 and step S17 all belong to turning processing; During turning, the part is first cut with a large allowance and a certain allowance is left; Within 2 hours after the large allowance cutting is completed, the parts are subjected to low-temperature tempering treatment using tempering equipment to release the internal stress generated during the processing; After tempering, the upper suction cup is flat-ground on both ends to control the parallelism of both ends to 0.01mm, thus establishing a good clamping benchmark for subsequent finishing. Use magnetic disk to absorb parts, and clamp the magnetic disk with lathe claws, so as to prevent deformation caused by directly clamping parts, and then perform small margin cutting to control the generation of turning stress; Step S9, step S15, step S18 and step S19 all belong to grinding processing; During the grinding process, the main body fixture uses a cast iron ring flat plate and performs a scraping process. The flatness of the supporting plane is required to be controlled within 0.002mm to ensure the stability of the tooling; The product is ground in steps, first rough grinding and then fine grinding, and the fine grinding allowance is controlled to be 0.08mm on a single side, so that after the rough grinding teeth are deformed, there is enough allowance for the fine teeth to ensure size and accuracy.
[0007] Preferably, the tempering temperature is controlled at 140°C±5°C.
[0008] Preferably, the tempering time is 4 hours.
[0009] Preferably, the small margin cutting speed is 60 r / min and the feed rate is 0.5 mm.
[0010] Preferably, the tempering device comprises a box body, a box door and a central control device are arranged on the box body, a cavity is arranged in the box body, a heating system is arranged in the box body, the heating system is used to heat the cavity in the box body, a plurality of placement plates are arranged in the cavity, the plurality of placement plates are spaced apart from top to bottom, and an auxiliary mechanism is arranged in the cavity; The auxiliary mechanism includes an upper air box and a lower air box, the upper air box is arranged above the placing plate, and the lower air box is arranged below the placing plate, the upper air box and the lower air box are both fixedly arranged in the cavity, the bottom of the upper air box is provided with an air hole, the top of the lower air box is provided with a rotating tube, the rotating tube is vertically inserted into the lower air box, the top of the rotating tube is sealed, the rotating tube is rotatably connected to the lower air box, a driving assembly is connected to the rotating tube, the driving assembly is used to drive the rotating tube to rotate and drive the air in the lower air box to be transported to the rotating tube, a branch pipe is fixedly arranged on the outer peripheral wall of the rotating tube, one end of the branch pipe is arranged on the rotating tube, the distance between the exhaust end of the branch pipe and the axis of the rotating tube is greater than the radius of the air hole, the air hole is arranged opposite to the rotating tube, the upper air box and the lower air box are connected through two groups of air pipes, and the upper air box and the lower air box are both located between the two groups of air pipes.
[0011] Preferably, each group of tracheas is provided with a plurality of tracheas, and the plurality of tracheas in the same group are spaced apart from front to back.
[0012] Preferably, the driving assembly includes a driving shaft, which is coaxially arranged with the rotating tube, the top end of the driving shaft is inserted into the bottom end of the rotating tube, the diameter of the driving shaft is smaller than the inner diameter of the rotating tube, the bottom end of the driving shaft is connected to a motor, the motor is located in the lower air box, the motor is fixed on the lower air box, fan blades are installed on the driving shaft, the fan blades are located in the rotating tube, and the fan blades are located below the branch pipe.
[0013] Preferably, the placement plate is provided with a plurality of through holes, and the plurality of through holes are distributed in a matrix.
[0014] Preferably, a plurality of groups of support bars are arranged in the cavity, the plurality of groups of support bars correspond one-to-one to the plurality of placement plates, each group of support bars is provided with two support bars, and the two support bars in the same group are respectively located on the left and right sides of the placement plate, the support bars are fixedly arranged in the box, a slide groove is arranged on one side of the support bar close to the placement plate, the slide groove is parallel to the front and rear direction, the placement plate is inserted into the slide groove, and the placement plate is slidably connected to the slide groove.
[0015] Preferably, two support bars in the same group correspond to two groups of air pipes one by one, and the air pipes are fixedly passed through the support bars.
[0016] Compared with the prior art, the advantages of the present invention are: The present invention discloses a thin-wall gear ring processing technology. During turning processing, the parts are firstly cut with a large allowance and a certain allowance is reserved. Then, the internal stress is released through tempering treatment. Then, the parts are cut with a small allowance. Before the small allowance cutting, a clamping reference is flat-ground. A magnetic disk is used to absorb the parts. The magnetic disk is clamped by lathe jaws to avoid deformation of the parts and control the generation of turning processing stress. During grinding processing, a main body fixture adopts a cast iron ring flat plate and a scraping process is performed to ensure the stability of the tooling, so that the clamping stress meets the product precision requirement, thereby ensuring that the deformation amount during the processing of the thin-wall gear ring is controllable. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Figure 1 It is a three-dimensional diagram of the tempering equipment; Figure 2 It is a schematic diagram of the internal structure of the tempering equipment; Figure 3 is a first structural schematic diagram of the auxiliary mechanism; Figure 4 is a second structural schematic diagram of the auxiliary mechanism; Figure 5 It is a schematic diagram of the connection structure between the rotating tube and the driving assembly; Figure 6 is a schematic diagram of the structure of the drive component; Figure 7 It is a schematic diagram of the connection structure between the placement plate and the support bar; Figure 8 Schematic diagram of the structure of the support bar.
[0018] in: Box body 1, box door 2, central control device 3, placement plate 4, auxiliary mechanism 5, through hole 6, support bar 7, slide groove 8; An upper air box 51, a lower air box 52, an air hole 53, a rotating tube 54, a driving assembly 55, a branch pipe 56, and an air pipe 57; Driving shaft 551 , motor 552 , and fan blades 553 . DETAILED DESCRIPTION
[0019] like Figure 1-8 As shown, a thin-walled gear ring processing process in this embodiment includes the following steps: Step S1, preparing materials; Step S2, one-time turning; Use ordinary lathe to turn the raw materials; Step S3, one-time marking; Print, mark or stick various information on the surface of parts to facilitate identification, tracking and management; Step S4, flaw detection; Use ultrasonic flaw detectors to perform nondestructive testing on parts to detect potential defects or damage; Step S5, conditioning; Improve the physical and mechanical properties of materials through quenching and tempering; Step S6, secondary turning; Step S7, three times turning; Step S8, secondary marking; Step S9, flat grinding; Step S10, copper plating; Step S11, gear shaping; Step S12, fitter; Step S13, carburizing and quenching; Improve the hardness, wear resistance and fatigue strength of parts; Step S14, removing copper; Step S15, primary composite grinding; Step S16, four times turning; Step S17, five times of turning; Step S18, secondary composite grinding; Step S19, three-time composite grinding; Step S20, drilling; Step S2, step S6, step S7, step S16 and step S17 all belong to turning processing; During turning, the parts are first cut with large allowance. This processing method will cause large clamping deformation of the parts. During this process, a certain allowance is left for the parts. For example, for a thin-walled gear ring with an outer diameter of about Φ150, a 3mm finishing allowance is left; After large-residue cutting, in order to better control the deformation of the gear ring, within 2 hours after the large-residue cutting, the parts are subjected to low-temperature tempering treatment using tempering equipment to release the internal stress generated during the processing. The tempering temperature is controlled at 140℃±5℃, which is lower than the tempering temperature during hot carburizing and quenching of the parts. The tempering time is 4 hours. After tempering, the upper suction cup is flat-ground on both ends to control the parallelism of both ends to 0.01mm, thus establishing a good clamping benchmark for subsequent finishing. The parts are adsorbed by magnetic disks and clamped by lathe claws, which can prevent deformation caused by direct clamping of parts. Then, low-speed and small-residue cutting is performed at a speed of 60r / min and a feed amount of 0.5mm to control the generation of turning stress. Step S9, step S15, step S18 and step S19 all belong to grinding processing; During the grinding process, the main body fixture uses a cast iron ring flat plate and performs a scraping process. The flatness of the supporting plane is required to be controlled within 0.002mm to ensure the stability of the tooling.
[0020] The grinding process of the product support end surface is to ensure that the coloring of the standard plate reaches more than 98% after grinding, and the flatness detection reaches within 0.002mm. After the two supports are pressed tightly, the clamping stress meets the product precision requirements; Grind the product in steps, first rough grinding and then fine grinding. For example, the fine grinding allowance is controlled to be 0.08mm on a single side, so that after the rough grinding teeth are deformed, there is enough allowance for the fine teeth to ensure the size and accuracy; The tempering device comprises a box body 1, on which a box door 2 and a central control device 3 are arranged, a cavity is arranged in the box body 1, and a heating system is arranged in the box body 1, and the heating system is used to heat the cavity in the box body 1; A placement plate 4 is provided in the cavity, and a plurality of the placement plates 4 are provided, and the plurality of placement plates 4 are spaced apart and distributed from top to bottom; An auxiliary mechanism 5 is provided in the cavity, and the auxiliary mechanism 5 is used to realize the circulation of air in the cavity; The auxiliary mechanism 5 includes an upper air box 51 and a lower air box 52, wherein the upper air box 51 is arranged above the placement plate 4, and the lower air box 52 is arranged below the placement plate 4. The upper air box 51 and the lower air box 52 are both fixedly arranged in the cavity, and an air hole 53 is arranged at the bottom of the upper air box 51. A rotating tube 54 is arranged at the top of the lower air box 52, and the rotating tube 54 is vertically inserted into the lower air box 52. The top end of the rotating tube 54 is sealed, and the rotating tube 54 is rotatably connected to the lower air box 52. A driving component 55 is connected to the rotating tube 54, and the driving component 55 is used to drive The rotating tube 54 is driven to rotate and drive the air in the lower air box 52 to be transported into the rotating tube 54. A plurality of branch pipes 56 are fixedly arranged on the outer peripheral wall of the rotating tube 54. The plurality of branch pipes 56 are evenly distributed circumferentially with the rotating tube 54 as the center. One end of the branch pipe 56 is arranged on the rotating tube 54. The distance between the exhaust end of the branch pipe 56 and the axis of the rotating tube 54 is greater than the radius of the air hole 53. The air hole 53 is arranged opposite to the rotating tube 54. The upper air box 51 and the lower air box 52 are connected through two groups of air pipes 57. The upper air box 51 and the lower air box 52 are both located between the two groups of air pipes 57. Each group of air pipes 57 is provided with a plurality of air pipes, and the plurality of air pipes 57 in the same group are spaced from front to back; The driving assembly 55 includes a driving shaft 551, which is coaxially arranged with the rotating tube 54. The top end of the driving shaft 551 is inserted into the bottom end of the rotating tube 54. The diameter of the driving shaft 551 is smaller than the inner diameter of the rotating tube 54. The bottom end of the driving shaft 551 is connected to a motor 552, which is located in the lower air box 52 and fixedly arranged on the lower air box 52. The driving shaft 551 is equipped with a fan blade 553, which is located in the rotating tube 54 and below the branch pipe 56. The placement plate 4 is provided with a plurality of through holes 6, and the plurality of through holes 6 are distributed in a matrix; Multiple groups of support bars 7 are arranged in the cavity, and the multiple groups of support bars 7 correspond to the multiple placement plates 4 one by one. Each group of support bars 7 is provided with two, and the two support bars 7 in the same group are respectively located on the left and right sides of the placement plate 4. The support bars 7 are fixedly arranged in the box body 1, and a slide groove 8 is arranged on one side of the support bar 7 close to the placement plate 4. The slide groove 8 is parallel to the front and rear direction, and the placement plate 4 is inserted into the slide groove 8, and the placement plate 4 is slidably connected with the slide groove 8; The two support bars 7 in the same group correspond to the two groups of air pipes 57 one by one, and the air pipes 57 are fixedly passed through the support bars 7; During the tempering of the parts, the box door 2 is opened, and the parts are placed on the placement plate 4 and then the box door 2 is closed. During the placement of the parts, the placement plate 4 can be pulled forward to cause relative sliding between the placement plate 4 and the slide groove 8. When the placement plate 4 moves to the outside of the cavity, the parts are placed on the placement plate 4 again. After the placement is completed, the placement plate 4 can be pushed to reset. Subsequently, the heating system works to increase the temperature in the cavity, and the temperature is transferred to the parts to achieve the tempering treatment of the parts. At the same time, the motor 552 is started, so that the driving shaft 551 drives the fan blades 553 and the rotating tube 54 to rotate. Through the rotation of the fan blades 553, the air in the rotating tube 54 is transported from the branch pipe 56 to the cavity. After passing through the placement plate 4, the air in the cavity enters the lower air box 52 from the air hole 53. The air in the lower air box 52 is then transported to the lower air box 52 from the air pipe 57. The air in the lower air box 52 is transported to the rotating tube 54, and the cycle continues. The rotation of the rotating tube 54 drives the branch pipe 56 to rotate synchronously. Since the distance between the exhaust end of the branch pipe 56 and the axis of the rotating tube 54 is greater than the radius of the air hole 53, the air moves upward in the air cavity, which is convenient for the air to act on the side of the part, improve the uniformity of the heating of the part, and thus improve the tempering effect. In addition, through the rotation of the branch pipe 56, the air is evenly distributed in the cavity, thereby further improving the uniformity of the heating of the part. To summarize, during the turning process, the parts are first cut with a large allowance and a certain allowance is left, and then the internal stress is released through tempering, and then the parts are cut with a small allowance. Before cutting with a small allowance, the clamping reference is flat ground, and a magnetic disk is used to adsorb the parts. The lathe jaws clamp the magnetic disk to avoid deformation of the parts and control the generation of turning stress. During the grinding process, the main body fixture uses a cast iron ring flat plate and a scraping process is performed to ensure the stability of the tooling, so that the clamping stress meets the product precision requirements, thereby ensuring that the deformation of the thin-walled gear ring is controllable during processing.
[0021] In addition to the above embodiments, the present invention also includes other implementation modes. Any technical solutions formed by equivalent transformation or equivalent replacement should fall within the protection scope of the claims of the present invention.
Claims
1. A thin-wall gear ring processing technology, Features: The steps include: Step S1, preparing materials; Step S2, one-time turning; Step S3, one-time marking; Step S4, flaw detection; Step S5, conditioning; Step S6, secondary turning; Step S7, three times turning; Step S8, secondary marking; Step S9, flat grinding; Step S10, copper plating; Step S11, gear shaping; Step S12, fitter; Step S13, carburizing and quenching; Step S14, removing copper; Step S15, primary composite grinding; Step S16, four times turning; Step S17, five times of turning; Step S18, secondary composite grinding; Step S19, three-time composite grinding; Step S20, drilling; Step S2, step S6, step S7, step S16 and step S17 all belong to turning processing; During turning, the part is first cut with a large allowance and a certain allowance is left; Within 2 hours after the large allowance cutting is completed, the parts are subjected to low-temperature tempering treatment using tempering equipment to release the internal stress generated during the processing; After tempering, the upper suction cup is flat-ground on both ends to control the parallelism of both ends to 0.01mm, thus establishing a good clamping benchmark for subsequent finishing. Use magnetic disk to absorb parts, and clamp the magnetic disk with lathe claws, so as to prevent deformation caused by directly clamping parts, and then perform small margin cutting to control the generation of turning stress; Step S9, step S15, step S18 and step S19 all belong to grinding processing; During the grinding process, the main body fixture uses a cast iron ring flat plate and performs a scraping process. The flatness of the supporting plane is required to be controlled within 0.002mm to ensure the stability of the tooling; The product is ground in steps, first rough grinding and then fine grinding, and the fine grinding allowance is controlled to be 0.08mm on a single side, so that after the rough grinding teeth are deformed, there is enough allowance for the fine teeth to ensure size and accuracy.
2. A thin-walled gear ring processing process according to claim 1, Features: The tempering temperature is controlled at 140°C ± 5°C.
3. A thin-walled gear ring processing process according to claim 1, Features: The tempering time is 4 hours.
4. A thin-walled gear ring processing process according to claim 1, Features: The small margin cutting speed is 60r / min, and the feed amount is 0.5mm.
5. A thin-walled gear ring processing process according to claim 1, Features: The tempering device comprises a box (1), the box (1) is provided with a box door (2) and a central control device (3), the box (1) is provided with a cavity, the box (1) is provided with a heating system, the heating system is used to heat the cavity in the box (1), a plurality of placement plates (4) are provided in the cavity, the plurality of placement plates (4) are spaced apart from top to bottom, and an auxiliary mechanism (5) is provided in the cavity; The auxiliary mechanism (5) comprises an upper air box (51) and a lower air box (52), wherein the upper air box (51) is arranged above the placement plate (4), and the lower air box (52) is arranged below the placement plate (4). The upper air box (51) and the lower air box (52) are both fixedly arranged in the cavity, and an air hole (53) is arranged at the bottom of the upper air box (51). A rotating tube (54) is arranged at the top of the lower air box (52). The rotating tube (54) is vertically inserted into the lower air box (52), and the top end of the rotating tube (54) is sealed. The rotating tube (54) is rotatably connected to the lower air box (52), and a driving component (55) is connected to the rotating tube (54). ), the driving assembly (55) is used to drive the rotating tube (54) to rotate and drive the air in the lower air box (52) to be transported into the rotating tube (54); a branch pipe (56) is fixedly arranged on the outer peripheral wall of the rotating tube (54); one end of the branch pipe (56) is arranged on the rotating tube (54); the distance between the exhaust end of the branch pipe (56) and the axis of the rotating tube (54) is greater than the radius of the air hole (53); the air hole (53) and the rotating tube (54) are arranged opposite each other; the upper air box (51) and the lower air box (52) are connected through two groups of air pipes (57); the upper air box (51) and the lower air box (52) are both located between the two groups of air pipes (57).
6. A thin-walled gear ring processing process according to claim 5, Features: Each group of tracheas (57) is provided with a plurality of tracheas, and the plurality of tracheas (57) in the same group are spaced apart from front to back.
7. A thin-walled gear ring processing process according to claim 5, Features: The driving assembly (55) comprises a driving shaft (551), the driving shaft (551) being coaxially arranged with the rotating tube (54), the top end of the driving shaft (551) being inserted into the bottom end of the rotating tube (54), the diameter of the driving shaft (551) being smaller than the inner diameter of the rotating tube (54), the bottom end of the driving shaft (551) being connected to a motor (552), the motor (552) being located in the lower air box (52), the motor (552) being fixedly arranged on the lower air box (52), the driving shaft (551) being mounted with a fan blade (553), the fan blade (553) being located in the rotating tube (54), and the fan blade (553) being located below the branch pipe (56).
8. A thin-walled gear ring processing process according to claim 5, Features: The placement plate (4) is provided with a plurality of through holes (6), and the plurality of through holes (6) are distributed in a matrix.
9. A thin-walled gear ring processing process according to claim 5, Features: A plurality of groups of support bars (7) are arranged in the cavity, and the plurality of groups of support bars (7) correspond one to one with the plurality of placement plates (4). Each group of support bars (7) is provided with two support bars, and the two support bars (7) in the same group are respectively located on the left and right sides of the placement plate (4). The support bars (7) are fixedly arranged in the box body (1), and a slide groove (8) is arranged on one side of the support bar (7) close to the placement plate (4). The slide groove (8) is parallel to the front-rear direction, and the placement plate (4) is inserted into the slide groove (8), and the placement plate (4) is slidably connected to the slide groove (8).
10. A thin-walled gear ring processing process according to claim 9, Features: The two support bars (7) in the same group correspond one to one with the two groups of air pipes (57), and the air pipes (57) are fixedly passed through the support bars (7).