A bevel gear forging

Abstract

The utility model discloses a kind of spiral bevel gear forgings, it is related to the technical field of precision transmission parts, it includes tooth portion, core part and the connecting portion of the integral setting with core part, the tooth portion includes metallurgical combination's super wear-resistant surface layer, fatigue resistance intermediate layer and strong tough bottom layer, and the inside of super wear-resistant surface layer is contacted with the outside of fatigue resistance intermediate layer, the inside of fatigue resistance intermediate layer is contacted with the outside of strong tough bottom layer, and the inside of strong tough bottom layer is provided with gradient transition layer, the core part includes metallurgical combination's high-strength support inner layer, damping intermediate layer and plastic cushion outer layer, and the outside of plastic cushion outer layer is contacted with the inside of gradient transition layer, the outside of damping intermediate layer is contacted with the inside of plastic cushion outer layer, and the inside of damping intermediate layer is contacted with the outside of high-strength support inner layer. The spiral bevel gear forging realizes the synergistic working performance of high wear resistance, fatigue resistance, impact resistance and low vibration noise by its multilayer gradient composite structure.

Description

Technical Field

[0001] This utility model relates to the field of precision transmission parts technology, specifically a spiral bevel gear forging. Background Technology

[0002] Currently, spiral bevel gears are generally manufactured using a single homogeneous material or surface modification process. While carburized and quenched gears possess high surface hardness, the hardened layer thickness is typically small, making them prone to surface spalling and fatigue crack propagation into the core under heavy-load impact conditions. Meanwhile, integrally quenched gears suffer from insufficient core strength and toughness, significantly increasing the risk of tooth breakage. Cast iron gears, while exhibiting superior wear resistance, lack sufficient fatigue strength and struggle to meet the dynamic balance requirements of high-speed transmissions. None of the aforementioned material systems can simultaneously achieve the synergistic requirements of extreme wear resistance on the tooth surface, deep fatigue resistance, and high strength and toughness in the core.

[0003] To address the performance contradictions, some studies have attempted to employ a bimetallic composite process, where a wear-resistant alloy layer is laminated onto the gear teeth while the structural steel matrix is ​​retained in the core. However, existing composite processes suffer from weakened interlayer bonding, meaning that stress concentration easily occurs at the mechanical interface, leading to delamination failure under cyclic loading. Furthermore, there is a lack of performance gradient, as there is no transition layer between the wear-resistant layer and the matrix, resulting in a sharp drop in hardness and preventing the gradual dissipation of contact stress. Finally, vibration control is lacking, as existing structures do not incorporate a damping dissipation layer, leading to generally high vibration acceleration levels in gear systems, excessive noise, and poor performance.

[0004] Therefore, in order to address the above problems, the applicant needs to design a spiral bevel gear forging to solve the problem. Utility Model Content

[0005] The purpose of this utility model is to provide a spiral bevel gear 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 spiral bevel gear forging, comprising a tooth portion, a core portion, and a connecting portion integrally formed with the core portion. The tooth portion includes an ultra-wear-resistant surface layer, an anti-fatigue intermediate layer, and a strong and tough bottom layer. The inner side of the ultra-wear-resistant surface layer contacts the outer side of the anti-fatigue intermediate layer, the inner side of the anti-fatigue intermediate layer contacts the outer side of the strong and tough bottom layer, and a gradient transition layer is provided on the inner side of the strong and tough bottom layer. The core portion includes a high-strength support inner layer, a damping intermediate layer, and a plastic buffer outer layer. The outer side of the plastic buffer outer layer contacts the inner side of the gradient transition layer, the outer side of the damping intermediate layer contacts the inner side of the plastic buffer outer layer, and the inner side of the damping intermediate layer contacts the outer side of the high-strength support inner layer.

[0007] Furthermore, the material of the ultra-wear-resistant surface layer is high-chromium vanadium alloy wear-resistant cast iron.

[0008] Furthermore, the material of the fatigue-resistant intermediate layer is chromium-molybdenum alloy structural steel.

[0009] Furthermore, the material of the tough bottom layer is nickel-chromium low-carbon martensitic steel.

[0010] Furthermore, the material of the plastic buffer outer layer is low-alloy high-strength structural steel.

[0011] Furthermore, the material of the damping intermediate layer is a copper-aluminum sintered porous iron-based alloy.

[0012] Furthermore, the material of the high-strength support inner layer is an ultra-low temperature high-strength tough non-magnetic special composite.

[0013] Furthermore, a metallurgical bonding interface is formed between the gradient transition layer, the tough bottom layer, and the plastic buffer outer layer.

[0014] Compared with the prior art, the beneficial effects of this utility model are: the spiral bevel gear forging achieves efficient synergy of load transfer, stress dispersion and vibration dissipation through its multi-layer gradient composite structure, thereby achieving synergistic performance of high wear resistance, fatigue resistance, impact resistance and low vibration noise. The specific details are as follows:

[0015] The working principle of this spiral bevel gear forging is to achieve efficient synergy of load transfer, stress dispersion, and vibration dissipation through its multi-layered gradient composite structure: When the teeth are working, the ultra-wear-resistant surface layer bears the meshing friction and contact stress, and its high hardness resists surface wear; the contact stress is dispersed and transferred through the fatigue-resistant intermediate layer, and its high cyclic strength inhibits the initiation of fatigue cracks; the strong and tough bottom layer supports the upper structure through the high-toughness base, preventing cracks from propagating inward; the tooth load is transferred to the core through the gentle stress gradient of the gradient transition layer, and the plastic buffer outer layer absorbs local stress peaks through micro-plastic deformation; the porous structure and interface friction of the damping intermediate layer convert vibration energy into heat energy dissipation; finally, the high-strength support inner layer provides a rigid core skeleton to stably bear the overall torque, thereby achieving synergistic working performance of high wear resistance, fatigue resistance, impact resistance, and low vibration noise. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention;

[0017] Figure 2 This is a schematic diagram of the toothed layered structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the core layer structure of this utility model;

[0019] Figure 4 This is a layered block diagram of the present invention.

[0020] In the diagram: 1. Tooth; 2. Core; 3. Connecting part; 4. Ultra-wear resistant surface layer; 5. Fatigue-resistant intermediate layer; 6. Strong and tough bottom layer; 7. High-strength support inner layer; 8. Damping intermediate layer; 9. Plastic buffer outer layer; 10. Gradient transition layer. Detailed Implementation

[0021] 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.

[0022] like Figures 1-4 As shown, a spiral bevel gear forging of this utility model includes a tooth portion 1, a core portion 2, and a connecting portion 3 integrally formed with the core portion 2. The tooth portion 1 includes an ultra-wear-resistant surface layer 4, an anti-fatigue intermediate layer 5, and a tough bottom layer 6. The inner side of the ultra-wear-resistant surface layer 4 contacts the outer side of the anti-fatigue intermediate layer 5, and the inner side of the anti-fatigue intermediate layer 5 contacts the outer side of the tough bottom layer 6. A gradient transition layer 10 is provided on the inner side of the tough bottom layer 6. The core portion 2 includes a high-strength support inner layer 7, a damping intermediate layer 8, and a plastic buffer outer layer 9. The outer side of the plastic buffer outer layer 9 contacts the inner side of the gradient transition layer 10, the outer side of the damping intermediate layer 8 contacts the inner side of the plastic buffer outer layer 9, and the inner side of the damping intermediate layer 8 contacts the outer side of the high-strength support inner layer 7. The connecting portion 3 includes a load-bearing section of the same material as the high-strength support inner layer 7 and a vibration-damping section of the same material as the damping intermediate layer 8. The two are integrally formed by hot forging deformation to avoid stress concentration caused by bolt connection.

[0023] The material of the ultra-wear-resistant surface layer 4 is high-chromium vanadium alloy wear-resistant cast iron. The high-hardness carbides and wear-resistant matrix structure of the ultra-wear-resistant surface layer 4 can improve the tooth surface's resistance to abrasive wear and adhesive wear. Especially under high-speed and heavy-load conditions, it can reduce pitting and scratches on the tooth surface and extend the service life of the gear.

[0024] The fatigue-resistant intermediate layer 5 is made of chromium-molybdenum alloy structural steel. Molybdenum enhances hardenability and high-temperature strength, while chromium enhances oxidation resistance, giving the layer both high cyclic strength and crack propagation resistance. This effectively inhibits the initiation of fatigue cracks at the tooth root and improves the bending fatigue life of the gear.

[0025] The tough bottom layer 6 is made of nickel-chromium low-carbon martensitic steel. Nickel improves low-temperature toughness, and low-carbon martensite provides a combination of high yield strength and fracture toughness. Under impact load, it can prevent the crack in tooth 1 from propagating to the core 2, thus ensuring the overall structural integrity of the gear.

[0026] The outer plastic buffer layer 9 is made of low-alloy high-strength structural steel. Its moderate plasticity and work hardening characteristics can absorb the local stress peak transmitted by the tooth 1, buffer vibration and impact through micro-plastic deformation, prevent brittle fracture in high-stress areas, and protect the structure of the core 2.

[0027] The damping intermediate layer 8 is made of copper-aluminum sintered porous iron-based alloy. Its porous structure and copper-aluminum interface can effectively dissipate vibration energy. The copper component improves thermal conductivity to reduce thermal stress concentration, suppress the resonance noise of the gear system and delay fatigue damage.

[0028] The high-strength inner layer 7 is made of ultra-low temperature high-strength toughness non-magnetic special alloy. It maintains high strength and toughness at extreme temperatures, and its non-magnetic nature avoids electromagnetic interference, providing a stable core load-bearing skeleton for the gear. It is suitable for the complex working conditions of special equipment.

[0029] The gradient transition layer 10 forms a metallurgical bonding interface with the tough bottom layer 6 and the plastic buffer outer layer 9. The gradient transition layer 10 and the adjacent layers are also metallurgical bonding interfaces. Through atomic diffusion, a continuous transition of composition / performance is formed, eliminating interlayer stress abrupt changes and interface defects, and ensuring the coordinated deformation capability and long-term bonding reliability of the multilayer structure under alternating loads.

[0030] 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 spiral bevel gear forging, comprising a toothed portion (1), a core portion (2), and a connecting portion (3) integrally formed with the core portion (2), characterized in that, The tooth (1) comprises a metallurgically bonded ultra-wear resistant surface layer (4), an anti-fatigue intermediate layer (5), and a tough bottom layer (6), with the inner side of the ultra-wear resistant surface layer (4) in contact with the outer side of the anti-fatigue intermediate layer (5), the inner side of the anti-fatigue intermediate layer (5) in contact with the outer side of the tough bottom layer (6), and a gradient transition layer (10) provided on the inner side of the tough bottom layer (6). The core (2) comprises a metallurgically bonded high-strength support inner layer (7), a damping intermediate layer (8), and a plastic buffer outer layer (9), with the outer side of the plastic buffer outer layer (9) in contact with the inner side of the gradient transition layer (10), the outer side of the damping intermediate layer (8) in contact with the inner side of the plastic buffer outer layer (9), and the inner side of the damping intermediate layer (8) in contact with the outer side of the high-strength support inner layer (7).

2. A spiral bevel gear forging according to claim 1, characterized in that: The material of the ultra-wear-resistant surface layer (4) is high-chromium vanadium alloy wear-resistant cast iron.

3. A spiral bevel gear forging according to claim 1, characterized in that: The material of the fatigue-resistant intermediate layer (5) is chromium-molybdenum alloy structural steel.

4. A spiral bevel gear forging according to claim 1, characterized in that: The tough bottom layer (6) is made of nickel-chromium low-carbon martensitic steel.

5. A spiral bevel gear forging according to claim 1, characterized in that: The material of the plastic buffer outer layer (9) is low alloy high strength structural steel.

6. A spiral bevel gear forging according to claim 1, characterized in that: The material of the damping intermediate layer (8) is a copper-aluminum sintered porous iron-based alloy.

7. A spiral bevel gear forging according to claim 1, characterized in that: The high-strength inner support layer (7) is made of ultra-low temperature high-strength tough non-magnetic special composite material.

8. A spiral bevel gear forging according to claim 1, characterized in that: The gradient transition layer (10) forms a metallurgical bonding interface with the tough bottom layer (6) and the plastic buffer outer layer (9).

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