Finish forging bevel gear trimming-free process

Abstract

The invention relates to the technical field of gear machining, and discloses a finish forging bevel gear trimming-free process which at least comprises the following steps: S1, cutting raw materials into required sizes; s2, grinding treatment is carried out, and surface black skin is removed; s3, chamfering treatment; s4, phosphating treatment; and S5, pressing. S6, machining is conducted; s7, spline machining; s8, heat treatment; and S9, finish machining to obtain a finished product. According to the technology, edge and corner burrs at the tooth surface and the back cone generated after finish turning of the back cone and the large outer circle of the tooth surface of a traditional precisely-forged gear are eliminated for S6, the manufacturing cost is greatly reduced, the production efficiency and the economic benefits are improved, flash is eliminated by adopting the technology, no burr is generated, the edge and corner positions are smooth and round, and the product quality is improved. Hard damage in the product circulation process is reduced, and the product quality is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of gear processing, and in particular to a precision forged bevel gear free trimming process. Background Art

[0002] When manufacturing the existing precision forged bevel gears, the large outer circle and back cone of the precision forged bevel gears are first turned, which will produce edges and burrs on the large outer circle and back cone (see Appendix Figure 1 ), affecting gear meshing. The traditional old processing technology uses cutting or trimming methods. There are cumbersome processes, rough and uneven gear edges (attached Figure 3 ), low production efficiency, high processing cost, and difficult quality control. Summary of the invention

[0003] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a process for precision forging bevel gears without cutting or trimming.

[0004] In order to achieve the above object, the present invention adopts the following technical solution: a precision forging bevel gear free trimming process, comprising at least the following steps:

[0005] S1 cuts the steel raw materials into required sizes through machine tools;

[0006] S2 grinds the material cut by S1 to remove the black skin on the surface of the material.

[0007] S3 performs chamfering on the material ground by S2 and smoothes the edges of the material;

[0008] S4 puts the material which has been chamfered in S3 into a phosphating tank for phosphating treatment;

[0009] S5 puts the material treated by phosphating in S4 into a precision pressing tooth-shaped die, so as to press it into the required gear at one time;

[0010] S6 processes the gear obtained in S5 into the required part geometry by machining (machining includes: back cone, journal, plane, spherical surface, inner hole, and chamfering in one step);

[0011] S7 performs spline processing on S6 axle gear;

[0012] S8 heat treats the half-shaft gears that have been splined and the planetary gears that have been fine-turned in S7;

[0013] S9 performs fine machining on the half-shaft gears and planetary gears that have been heat treated in S8 until they are finished products;

[0014] In S3, chamfering is performed using a double-head chamfering machine, saving time in chamfering.

[0015] In S5, the precision embossing tooth-shaped die is pressed by cold shaping, in which an R surface is added to the precision embossing die (attached Figure 4 ) so that the cold shaping and pressing process of the tooth blank can ensure one-time forming.

[0016] After chamfering, it is best to perform phosphate saponification treatment to increase the corrosion resistance of the gear.

[0017] The present invention has the following beneficial effects:

[0018] The precision pressing die ensures one-time forming and eliminates the need for trimming die precision pressing die technology. It is suitable for all types of gears and is not restricted by product materials, shapes and burr locations. It greatly reduces manufacturing costs and improves production efficiency and economic benefits.

[0019] This process eliminates burrs, does not produce any burrs, and makes the edges and corners smooth and round, reducing damage during product circulation and greatly improving product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 The effect picture after the back cone is finely turned using traditional old craftsmanship;

[0021] Figure 2 This is a process flow chart of a precision forging bevel gear without trimming according to the present invention;

[0022] Figure 3 This is a comparison chart of the new and old processes;

[0023] Figure 4 It is a schematic diagram of a precision pressing die for a precision forging bevel gear without trimming process of the present invention;

[0024] Figure 5 This is a product rendering of a precision forged bevel gear trimming-free process of the present invention. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] The present invention adopts the following technical solution: a precision forging bevel gear free trimming process, comprising at least the following steps:

[0027] S1 cuts the steel raw materials into required sizes through machine tools;

[0028] S2 grinds the material cut by S1 to remove the black skin on the surface of the material;

[0029] S3 performs chamfering on the material ground by S2 and smoothes the edges of the material;

[0030] S4 puts the material which has been chamfered in S3 into a phosphating tank for phosphating treatment;

[0031] S5 puts the material treated by S4 phosphating into a precision pressing tooth-shaped mold, so as to press it into the required gear at one time.

[0032] S6 processes the gear obtained in S5 into the required part geometry by machining (machining includes: back cone, journal, plane, spherical surface, inner hole, and chamfering in one step);

[0033] S7 performs spline processing on S6 axle gear;

[0034] S8 heat treats the half-shaft gears that have been splined in S7 and the planetary gears that have been fine-turned;

[0035] S9 heat treats the half-shaft gears and planetary gears that have been heat treated in S8 and then finishes them into finished products.

[0036] In S3, chamfering is performed using a double-head chamfering machine, saving time in chamfering.

[0037] In S5, the coining die is processed by cold shaping, in which an R surface is added to the coining die (attached Figure 4 ) so that the cold shaping and pressing process of the tooth blank can ensure one-time forming.

[0038] After chamfering, it is best to perform phosphate saponification treatment to increase the corrosion resistance of the gear.

[0039] The present invention and its embodiments are described above, and such description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if ordinary technicians in the field are inspired by it, without departing from the purpose of the invention, they can design a structure and embodiment similar to the technical solution without creativity, which should belong to the protection scope of the present invention.

Claims

1. A precision forging bevel gear trimming-free process, comprising at least the following steps: S1 cuts the steel raw materials into required sizes through machine tools; S2 grinds the material cut by S1 to remove the black skin on the surface of the material; S3 performs chamfering on the material ground by S2 and smoothes the edges of the material; S4 puts the material which has been chamfered in S3 into a phosphating tank for phosphating treatment; S5 puts the material treated by phosphating in S4 into a precision pressing tooth-shaped die, so as to press it into the required gear at one time; S6 processes the gear obtained in S5 into the required part geometry by machining; (machining includes: back cone, journal, plane, spherical surface, inner hole, chamfering and one-step forming); S7 performs spline processing on S6 axle gear; S8 heat treats the half-shaft gears that have been splined and the planetary gears that have been fine-turned in S7; S9 heat treats the half-shaft gears and planetary gears that have been heat treated in S8 and then finishes them into finished products.

2. The process for precision forging bevel gears without trimming according to claim 1, characterized in that: In S3, chamfering is performed using a double-head chamfering machine, saving time in chamfering.

3. The process for precision forging bevel gears without trimming according to claim 1, characterized in that: In S5, the coining die is pressed by cold shaping, wherein an R surface is added to the coining tooth profile die to ensure one-time forming in the cold shaping pressing process of the tooth blank.

4. The process for precision forging bevel gears without trimming according to claim 1, characterized in that: After chamfering, phosphorus saponification treatment is required to increase the corrosion resistance of the gear.

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