High-meshing precision gear set forge piece

Abstract

The utility model discloses a high-meshing precision gear set forge piece, which relates to the technical field of precision part castings, and comprises an ultra-precision wear-resistant layer, a gradient transition layer, a damping shock absorption layer and an inner core layer which are sequentially arranged from outside to inside, and the inner core layer is made of boron microalloyed forged steel. The outer surface of the boron microalloying forged steel is in contact with the inner surface of the damping shock absorption layer, the damping shock absorption layer is made of copper-based shape memory alloy, the outer surface of the copper-based shape memory alloy is in contact with the inner surface of the gradient transition layer, the gradient transition layer is made of iron-chromium-nickel component gradient functional alloy, and the outer surface of the gradient transition layer is in contact with the inner surface of the boron microalloying forged steel. And the outer surface of the iron-chromium-nickel component gradient functional alloy is in contact with the inner surface of the ultra-precision wear-resistant layer. According to the high-meshing-precision gear set forge piece, through the super-precision wear-resisting layer, the gradient transition layer, the damping shock absorption layer and the inner core layer, under the common synergistic effect, the meshing precision retentivity, the fatigue life and the transmission stability of a gear set are improved.

Description

Technical Field

[0001] This utility model relates to the field of precision parts casting technology, specifically a high-meshing precision gear set forging. Background Technology

[0002] As the core power coupling unit of a mechanical transmission system, gear sets operate under conditions of high speed, heavy load, frequent reversing, and vibration and impact for extended periods. Their tooth surfaces simultaneously endure combined friction from high-stress rolling and sliding, contact fatigue, and impact loads, while the tooth root region is continuously subjected to alternating bending stress and torsional loads. This multi-axis composite load environment requires gear sets to simultaneously meet mutually constraining performance requirements: extreme wear resistance of the tooth surface, ultra-high toughness and fatigue resistance of the core, efficient transmission of interlaminar stress, and dissipation of impact energy.

[0003] Existing gear set technology suffers from three fundamental defects: First, the performance of single-material gears is limited. For example, carburized and quenched alloy steel has low surface hardness and a high coefficient of friction; insufficient depth of the wear-resistant layer on the tooth surface and abrupt changes in the subsurface hardness gradient lead to deep spalling; and insufficient overall toughness results in a high risk of tooth breakage under high impact loads. Second, composite structure interfaces are prone to failure. The surface strengthening layer has low bonding strength and high interface porosity; the mismatch between the coating and the substrate's thermal expansion coefficients leads to high interfacial thermal stress; and large interlayer hardness jumps cause stress concentration. Third, dynamic performance is also lacking. Forged steel substrates have low damping ratios and low meshing impact energy conversion rates, resulting in large vibration acceleration amplitudes and high noise levels. Furthermore, existing vibration damping structures experience significant damping performance degradation after high-temperature aging, thus reducing tooth profile accuracy and transmission smoothness.

[0004] Therefore, in order to address the above problems, the applicant needs to design a high-meshing precision gear set forging to solve the problem. Utility Model Content

[0005] The purpose of this invention is to provide a high-meshing precision gear set forging to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a high-meshing precision gear forging, comprising, sequentially from the surface to the inside, an ultra-precision wear-resistant layer, a gradient transition layer, a damping and shock-absorbing layer, and an inner core layer. The inner core layer is made of boron microalloyed forged steel, and the outer surface of the boron microalloyed forged steel is in contact with the inner surface of the damping and shock-absorbing layer. The damping and shock-absorbing layer is made of copper-based shape memory alloy, and the outer surface of the copper-based shape memory alloy is in contact with the inner surface of the gradient transition layer. The gradient transition layer is made of iron-chromium-nickel gradient functional alloy, and the outer surface of the iron-chromium-nickel gradient functional alloy is in contact with the inner surface of the ultra-precision wear-resistant layer.

[0007] Furthermore, the ultra-precision wear-resistant layer is configured from the outside to the inside as a nano-diamond layer, an amorphous carbon layer, and a microcrystalline cemented carbide layer.

[0008] Furthermore, the nanodiamond layer and the amorphous carbon layer are connected by covalent bonds through ion beam activation bonding.

[0009] Furthermore, the microcrystalline hard alloy layer and the gradient transition layer are mechanically interlocked through laser texturing and supersonic particle bombardment.

[0010] Furthermore, the damping and shock-absorbing layer and the inner core layer are metallurgically bonded together by pulsed magnetic field-assisted diffusion welding.

[0011] Furthermore, the gradient transition layer and the damping layer are metallurgically bonded together by pulsed magnetic field-assisted diffusion welding.

[0012] Furthermore, the supersonic particle bombardment uses silicon nitride particles.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows: the high-meshing precision gear set forging achieves extreme wear resistance and low friction through an ultra-precision wear-resistant layer, a gradient transition layer buffers stress abrupt changes, a damping and shock-absorbing layer efficiently dissipates impact kinetic energy, and a high-strength and tough inner core layer supports the whole. Under the synergistic effect, the meshing accuracy retention, fatigue life, and transmission stability of the gear set are improved. The specific details are as follows:

[0014] This gear set forging achieves high-precision transmission through the synergistic effect of multiple functional structures during meshing: the ultra-fine wear-resistant layer provides extreme wear resistance and low-friction lubrication on the surface, reducing tooth surface wear and energy loss; the gradient transition layer buffers thermal and mechanical stress through continuous gradient changes in iron-chromium-nickel composition, avoiding delamination between layers due to differences in expansion coefficients; the damping and shock-absorbing layer utilizes the phase transformation hysteresis characteristics of copper-based shape memory alloys to convert meshing impact kinetic energy into heat dissipation, suppressing vibration and noise; the boron microalloyed forged steel inner core provides a high-strength and tough matrix to support the overall structure. Seamless connections between layers are achieved through technologies such as ion bonding, mechanical interlocking, and pulsed magnetic field-assisted metallurgical bonding, ensuring efficient load transmission and dynamic stability, ultimately maintaining tooth profile accuracy and transmission smoothness under high-speed and high-load conditions. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall layered structure of this utility model;

[0016] Figure 2 This is a schematic diagram of the separation structure of the ultra-precision wear-resistant layer of this utility model;

[0017] Figure 3 This is a layered block diagram of the present utility model.

[0018] In the diagram: 1. Ultra-fine wear-resistant layer; 2. Gradient transition layer; 3. Damping and vibration reduction layer; 4. Inner core layer; 5. Nano diamond layer; 6. Amorphous carbon layer; 7. Microcrystalline hard alloy layer. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] like Figures 1-3 As shown, a high-meshing precision gear forging of this utility model includes an ultra-precision wear-resistant layer 1, a gradient transition layer 2, a damping and shock-absorbing layer 3, and an inner core layer 4 arranged sequentially from the outside to the inside. The inner core layer 4 is made of boron microalloyed forged steel, and the outer surface of the boron microalloyed forged steel is in contact with the inner surface of the damping and shock-absorbing layer 3. The damping and shock-absorbing layer 3 is made of copper-based shape memory alloy, and the outer surface of the copper-based shape memory alloy is in contact with the inner surface of the gradient transition layer 2. The gradient transition layer 2 is made of iron-chromium-nickel gradient functional alloy, and the outer surface of the iron-chromium-nickel gradient functional alloy is in contact with the inner surface of the ultra-precision wear-resistant layer 1.

[0021] The ultra-precision wear-resistant layer 1 is composed of a nano-diamond layer 5, an amorphous carbon layer 6, and a microcrystalline cemented carbide layer 7, arranged sequentially from the outside to the inside. By subdividing the ultra-precision wear-resistant layer 1 into the nano-diamond layer 5, the amorphous carbon layer 6, and the microcrystalline cemented carbide layer 7 arranged sequentially from the outside to the inside, the surface wear resistance performance is optimized in a gradient manner. The nano-diamond layer 5 provides extremely high hardness and wear resistance, making it suitable for high-load meshing conditions. The amorphous carbon layer 6 provides low friction coefficient and self-lubricating properties, effectively reducing energy loss during gear operation. The microcrystalline cemented carbide layer 7 serves as a transition substrate, giving the overall wear-resistant layer excellent impact toughness and thermal stability, improving the service life and reliability of gears in precision transmission, while avoiding premature failure caused by stress concentration in a single material.

[0022] The nanodiamond layer 5 and the amorphous carbon layer 6 are connected by covalent bonds through ion beam activation bonding. This ion beam activation bonding technology enhances the interfacial bonding strength and chemical stability. The covalent bond connection eliminates the weak points of traditional physical bonding, effectively resisting the risk of interlayer delamination under high shear stress and thermal cycling. This ensures that the wear-resistant layer maintains its overall integrity during high-speed meshing, while also optimizing the interfacial energy transfer efficiency, reducing the generation of microcracks, and further improving the fatigue resistance and durability of the gear surface.

[0023] The microcrystalline cemented carbide layer 7 and the gradient transition layer 2 are mechanically interlocked through laser texturing and supersonic particle bombardment. The supersonic particle bombardment uses silicon nitride particles. The mechanical interlocking structure formed between the microcrystalline cemented carbide layer 7 and the gradient transition layer 2 by laser texturing and supersonic particle bombardment improves the interfacial bonding force. Laser texturing creates a micro-rough surface to increase the contact area, while the supersonic bombardment of silicon nitride particles induces surface plastic deformation and embedding effect, producing a strong and tough mechanical anchoring effect, effectively dispersing the meshing stress, preventing the interface from slipping or cracking under impact load, thereby enhancing the overall vibration resistance and dimensional stability of the gear.

[0024] The damping layer 3 and the inner core layer 4 are metallurgically bonded together by pulsed magnetic field-assisted diffusion welding. This ensures atomic-level fusion and continuity at the interface. The metallurgical bonding eliminates porosity and inclusion defects in traditional welding, providing a high-strength and low-impedance connection. This allows the damping properties of the damping layer to be efficiently transferred to the inner core layer 4, improving the gear's impact resistance and noise control under dynamic loads. At the same time, it reduces the risk of stress concentration and ensures the long-term operational reliability of the gear set.

[0025] The gradient transition layer 2 and the damping layer 3 are metallurgically bonded by pulsed magnetic field assisted diffusion welding. This method optimizes the thermodynamic matching and mechanical properties of the interlayer interface. The metallurgical bonding ensures a seamless connection between the composition gradient alloy and the shape memory alloy, avoiding interface failure caused by differences in thermal expansion coefficients. This efficiently transmits the damping function and maintains the integrity of the structure, improving the stability and fatigue life of the gear in high-frequency vibration environments. At the same time, it simplifies the manufacturing process and reduces the risk of delamination.

[0026] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A high-meshing precision gear set forging, characterized in that, The material includes an ultra-precision wear-resistant layer (1), a gradient transition layer (2), a damping and shock-absorbing layer (3), and an inner core layer (4) arranged sequentially from the surface to the inside. The inner core layer (4) is made of boron microalloyed forged steel, and the outer surface of the boron microalloyed forged steel is in contact with the inner surface of the damping and shock-absorbing layer (3). The damping and shock-absorbing layer (3) is made of copper-based shape memory alloy, and the outer surface of the copper-based shape memory alloy is in contact with the inner surface of the gradient transition layer (2). The gradient transition layer (2) is made of iron-chromium-nickel gradient functional alloy, and the outer surface of the iron-chromium-nickel gradient functional alloy is in contact with the inner surface of the ultra-precision wear-resistant layer (1).

2. The high-meshing precision gear set forging according to claim 1, characterized in that: The ultra-precision wear-resistant layer (1) is composed of a nano-diamond layer (5), an amorphous carbon layer (6), and a microcrystalline hard alloy layer (7) from the outside to the inside.

3. The high-meshing precision gear set forging according to claim 2, characterized in that: The nanodiamond layer (5) and the amorphous carbon layer (6) are connected by covalent bonds through ion beam activation bonding.

4. A high-meshing precision gear set forging according to claim 2, characterized in that: The microcrystalline hard alloy layer (7) and the gradient transition layer (2) are mechanically interlocked through laser texturing and supersonic particle bombardment.

5. A high-meshing precision gear set forging according to claim 1, characterized in that: The damping and shock-absorbing layer (3) and the inner core layer (4) are metallurgically bonded by pulsed magnetic field-assisted diffusion welding.

6. A high-meshing precision gear set forging according to claim 1, characterized in that: The gradient transition layer (2) and the damping and shock absorption layer (3) are metallurgically bonded by pulse magnetic field-assisted diffusion welding.

7. A high-meshing precision gear set forging according to claim 4, characterized in that: Supersonic particle bombardment uses silicon nitride particles.

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