Gear machining tsari, yankan sigogi da kayan aiki da bukatun idan kayan aiki yana da wuya a juya kuma ana buƙatar inganta aikin injin.

Gear shine babban jigon watsawa a cikin masana'antar mota. Yawancin lokaci, kowace mota tana da hakora 18 ~ 30. Ingancin kayan aiki kai tsaye yana shafar amo, kwanciyar hankali da rayuwar sabis na mota. Kayan aikin injin sarrafa Gear shine tsarin kayan aikin injin hadaddun da kayan aiki mai mahimmanci a cikin masana'antar kera motoci. Kamfanonin kera motoci na duniya irinsu Amurka da Jamus da Japan suma suna da karfin kera kayan aikin injin. Bisa kididdigar da aka yi, sama da kashi 80 cikin 100 na na'urorin kera motoci a kasar Sin ana sarrafa su ne ta na'urorin kera na'urorin cikin gida. A lokaci guda kuma, masana'antar kera motoci suna cinye fiye da kashi 60% na kayan aikin sarrafa kayan aiki, kuma masana'antar kera motoci za ta kasance babban jigon amfani da na'ura koyaushe.

Fasaha sarrafa Gear

1. Yin simintin gyare-gyare da yin komai

Hoton mutuƙar ƙirƙira har yanzu tsarin simintin simintin faifai ne da ake amfani da shi sosai don sassan kayan aikin mota. A cikin 'yan shekarun nan, fasahar birgima ta giciye ta sami ɗaukaka ko'ina a cikin injin injuna. Wannan fasaha ta dace musamman don yin billet don sarƙaƙƙun ramukan ƙofa. Ba wai kawai yana da madaidaicin madaidaici ba, ƙaramin izinin injin injin na gaba, amma kuma yana da ingantaccen samarwa.

2. daidaitawa

Manufar wannan tsari shine don samun taurin da ya dace da yankan kayan aiki na gaba da kuma shirya microstructure don maganin zafi na ƙarshe, ta yadda za a iya rage lalacewar maganin zafi. Kayan karfen gear da ake amfani da shi yawanci 20CrMnTi ne. Saboda da babban tasiri na ma'aikata, kayan aiki da muhalli, da sanyaya gudun da kuma sanyaya uniformity na workpiece da wuya a sarrafa, sakamakon babban taurin watsawa da m metallographic tsarin, wanda kai tsaye rinjayar da karfe yankan da kuma matuƙar zafi magani, sakamakon a manyan. da nakasar thermal mara kyau da ingancin sashin da ba a iya sarrafawa. Don haka, ana aiwatar da tsarin daidaita yanayin isothermal. Aiki ya tabbatar da cewa isothermal normalizing iya yadda ya kamata canza disadvantages na general normalizing, da samfurin ingancin ne barga da kuma abin dogara.

3. juyawa

Domin saduwa da buƙatun sakawa na sarrafa kayan aiki masu ma'ana, kayan kwalliyar gear duk ana sarrafa su ta hanyar lathes CNC, waɗanda ke danne da injina ba tare da sake jujjuya kayan aikin ba. Ana yin aiki na diamita na rami, ƙarshen fuska da diamita na waje tare da haɗin gwiwa tare da haɗin gwiwa na lokaci ɗaya, wanda ba wai kawai yana tabbatar da buƙatun madaidaiciyar rami na ciki da ƙarshen fuska ba, amma kuma yana tabbatar da ƙaramin tarwatsawar ɓangarorin taro. Don haka, ana inganta daidaiton babu komai kuma ana tabbatar da ingancin injin ɗin na gaba. Bugu da kari, babban inganci na NC lathe machining shima yana rage yawan kayan aiki sosai kuma yana da tattalin arziki mai kyau.

4. hobbing da tsara kayan aiki

Injunan hobbing na yau da kullun da na'urar siffar kayan aiki har yanzu ana amfani da su don sarrafa kayan aiki. Ko da yake yana da dacewa don daidaitawa da kiyayewa, ƙimar samar da ƙananan ƙananan. Idan an kammala babban ƙarfin aiki, ana buƙatar samar da injuna da yawa a lokaci guda. Tare da haɓaka fasahar sutura, yana da matukar dacewa don sake suturar hobs da plungers bayan niƙa. Rayuwar sabis na kayan aikin da aka rufa za a iya inganta sosai, gabaɗaya ta fiye da 90%, yadda ya kamata rage yawan canjin kayan aiki da lokacin niƙa, tare da fa'idodi masu mahimmanci.

5. aski

Ana amfani da fasahar aski na Radial gear a ko'ina a cikin samar da kayan aikin mota na jama'a saboda babban ingancinsa da sauƙin fahimtar buƙatun gyare-gyare na bayanin martabar haƙori da aka ƙera da jagorar haƙori. Tun lokacin da kamfanin ya sayi na'urar aski na musamman na radial gear na kamfanin Italiya don sauye-sauyen fasaha a cikin 1995, ya kasance balagagge a cikin aikace-aikacen wannan fasaha, kuma ingancin sarrafawa yana da karko da dogaro.

6. maganin zafi

Gears na mota suna buƙatar carburizing da quenching don tabbatar da kyawawan abubuwan injin su. Barga da abin dogara kayan aikin kula da zafi yana da mahimmanci ga samfuran da ba su da batun niƙa kayan aiki bayan maganin zafi. Kamfanin ya gabatar da ci gaba da aikin carburizing da quenching samar da layin Lloyd na Jamusanci, wanda ya sami sakamako mai gamsarwa na maganin zafi.

7. nika

Ana amfani da shi ne musamman don gama ramin ciki na kayan zafi da aka yi wa zafi, ƙarshen fuska, diamita na waje da sauran sassa don haɓaka daidaiton girman da rage juriya na geometric.

Kayan sarrafa kayan aiki yana ɗaukar na'urar da'irar firam don sakawa da matsawa, wanda zai iya tabbatar da ingancin mashin ɗin hakori da bayanin shigarwa, da samun ingantaccen ingancin samfur.

8. gamawa

Wannan shi ne don dubawa da tsaftace kullun da burs a kan sassan gear na watsawa da kuma fitar da axle kafin taro, don kawar da hayaniya da rashin jin daɗi da suka haifar da su bayan taro. Saurari sauti ta hanyar haɗin gwiwa guda biyu ko lura da karkacewar haɗin gwiwa akan cikakkiyar ma'aikaci. Sassan gidaje na watsawa da kamfanin kera ya samar sun hada da gidaje masu kama, gidajen watsawa da gidaje daban-daban. Gidajen kamawa da gidajen watsawa sassa ne masu ɗaukar nauyi, waɗanda gabaɗaya ana yin su da gawa na almuran da ke kashe-kashe ta hanyar simintin mutuwa na musamman. Siffar ba ta dace ba kuma mai rikitarwa. Tsarin gabaɗaya yana niƙa saman haɗin gwiwa → machining tsari ramuka da haɗa ramuka → m m hali ramuka → lafiya m hali ramuka da gano fil ramukan → tsaftacewa → leakage gwajin da ganewa.

Ma'auni da buƙatun kayan aikin yankan kaya

Gears suna da rauni sosai bayan carburizing da quenching. Musamman ga manyan gears, girman nakasar carburized da kashe da'irar waje da rami na ciki gabaɗaya babba ne. Koyaya, don jujjuyawar da'irar da'ira ta waje, babu wani kayan aiki da ya dace. Kayan aikin bn-h20 wanda "Valin superhard" ya ƙera don jujjuyawar ƙarfe mai ƙarfi na ɗan lokaci ya gyara nakasar carburized da kashe gear waje ramin da'irar ciki da ƙarshen fuska, kuma ya sami ingantaccen kayan aikin yankan tsaka-tsaki, Ya yi babban ci gaba a duniya filin yankan tsaka-tsaki tare da manyan kayan aiki.

Gear carburizing da quenching nakasawa: gear carburizing da quenching nakasawa ne yafi lalacewa ta hanyar hade mataki na saura danniya samar a lokacin machining, thermal danniya da tsarin danniya generated a lokacin zafi magani, da kai nauyi nakasawa na workpiece. Musamman ga manyan zoben gears da gears, manyan zoben gear suma za su ƙara nakasu bayan carburizing da quenching saboda babban ma'aunin su, zurfin carburizing Layer, dogon lokacin carburizing da nauyin kai. Ka'idar nakasawa na babban shingen kaya: diamita na waje na da'irar addendum yana nuna yanayin ƙanƙancewa a fili, amma a cikin hanyar nisa na haƙori na shingen gear, tsakiyar yana raguwa, kuma ƙarshen biyu ya ɗan faɗaɗa. Dokokin nakasa na zoben kaya: Bayan Carburizing da quenching, diamita na waje na babban zoben kaya zai kumbura. Lokacin da fadin hakori ya bambanta, shugabanci na fadin haƙori zai zama conical ko kugu.

Gear juya bayan carburizing da quenching: da carburizing da quenching nakasawa na gear zobe za a iya sarrafawa da kuma rage zuwa wani iyaka, amma shi ba za a iya gaba daya kauce masa Domin nakasawa gyara bayan carburizing da quenching, da wadannan shi ne taƙaitaccen magana a kan yiwuwa. na juyawa da yankan kayan aikin bayan carburizing da quenching.

Juya da'irar waje, rami na ciki da ƙarshen fuska bayan carburizing da quenching: juyawa ita ce hanya mafi sauƙi don gyara nakasar da'irar waje da rami na ciki na carburized da quenched zobe kaya. A baya can, duk wani kayan aiki, gami da manyan kayan aikin waje, ba zai iya magance matsalar yanke da'irar da aka kashe ba. An gayyaci Valin superhard don gudanar da bincike da haɓaka kayan aiki, “Yanke taurin ƙarfe na wucin gadi koyaushe ya kasance matsala mai wuyar gaske, ba tare da ambaton ƙarfe mai taurin kamar HRC60 ba, kuma alawus ɗin nakasa yana da yawa. Lokacin juya taurin karfe a babban saurin, idan kayan aikin yana da yankan tsaka-tsaki, kayan aikin zai kammala aikin injin tare da girgiza sama da 100 a cikin minti daya yayin yanke taurin karfe, wanda babban kalubale ne ga juriya na kayan aikin. ” Masana kungiyar wuka ta kasar Sin sun ce haka. Bayan shekara guda na maimaita gwaje-gwaje, Valin superhard ya gabatar da nau'in kayan aiki mai ƙarfi don Juya Hardened Karfe tare da katsewa mai ƙarfi; Ana yin gwajin jujjuyawar a kan da'irar waje na gear bayan carburizing da quenching.

Gwaji kan juyar da kayan aikin siliki bayan carburizing da quenching

Babban kayan (gear ɗin zobe) an ɓata da gaske bayan da aka yi carburizing da quenching. Nakasar da'irar waje na kayan zobe na gear ya kai mm 2, kuma taurin bayan quenching shine hrc60-65. A lokacin, da wuya abokin ciniki ya sami babban injin niƙa, kuma alawus ɗin injin ɗin yana da yawa, kuma aikin niƙa ya yi ƙasa sosai. A ƙarshe, an kunna carburized da kuma kashe kayan aikin.

Yanke saurin layi: 50-70m / min, zurfin yanke: 1.5-2mm, yanke nisa: 0.15-0.2mm / Juyin juya hali (daidaita bisa ga buƙatun rashin ƙarfi)

Lokacin jujjuya kayan aikin da aka kashe, ana kammala aikin a lokaci ɗaya. Kayan aikin yumbu da aka shigo da shi na asali ana iya sarrafa shi sau da yawa don yanke nakasar. Bugu da ƙari, rushewar gefen yana da tsanani, kuma farashin amfani da kayan aiki yana da yawa.

Sakamakon gwajin kayan aiki: yana da tasiri mai juriya fiye da kayan aikin yumbu na siliki nitride na asali da aka shigo da shi, kuma rayuwar sabis ɗin sa shine sau 6 na kayan aikin yumbu na silicon nitride lokacin da zurfin yankan ya ƙaru sau uku! Ana haɓaka ingancin yankan da sau 3 (a da ya kasance sau uku na yankan, amma yanzu an kammala shi sau ɗaya). Har ila yau, ƙaƙƙarfan yanayin aikin aikin ya dace da buƙatun mai amfani. Abu mafi mahimmanci shi ne cewa nau'in gazawar ƙarshe na kayan aiki ba shine abin damuwa da ɓarna ba, amma yanayin baya na al'ada. Wannan gwajin jujjuyawar gear excircle na ɗan lokaci ya karya tatsuniya cewa ba za a iya amfani da manyan kayan aikin masana'antu don juyar da ƙarfe mai ƙarfi na ɗan lokaci ba! Ya haifar da babban abin mamaki a cikin da'irar ilimi na kayan aikin yanke!

Ƙarshen saman ƙasa mai wuyar jujjuya rami na ciki na kaya bayan quenching

Ɗaukar yanke tsaka-tsalle na rami na ciki tare da tsagi mai a matsayin misali: rayuwar sabis na kayan aikin gwaji ya kai fiye da mita 8000, kuma ƙare yana cikin Ra0.8; Idan an yi amfani da kayan aiki mai ƙarfi tare da gefen gogewa, ƙarshen jujjuyawar ƙarfe mai taurin zai iya kaiwa kusan Ra0.4. Kuma ana iya samun rayuwar kayan aiki mai kyau

Machining karshen fuskar kaya bayan carburizing da quenching

A matsayin al'ada aikace-aikace na "juyawa maimakon nika", cubic boron nitride ruwa an yi amfani da ko'ina a cikin samar da al'adar juyar da kaya karshen fuska bayan zafi. Idan aka kwatanta da niƙa, jujjuyawar juzu'i yana inganta ingantaccen aiki sosai.

Don carburized da kayan aikin da aka kashe, abubuwan da ake buƙata don masu yankan suna da girma sosai. Na farko, yankan tsaka-tsaki yana buƙatar babban taurin, juriya mai tasiri, tauri, juriya, juriya, rashin ƙarfi da sauran kaddarorin kayan aiki.

bayyani:

Don juyawa bayan carburizing da quenching da kuma ƙarshen juyawa fuska, an haɓaka kayan aikin welded composite cubic boron nitride kayan aikin. Duk da haka, don girman nakasar da'irar waje da rami na ciki na carburized da quenched manyan zobe na kaya, yana da wuyar matsala don kashe nakasar tare da adadi mai yawa. Juya juzu'i na ƙarewar karfe tare da kayan aiki na Valin superhard bn-h20 cubic boron nitride kayan aiki babban ci gaba ne a cikin masana'antar kayan aiki, wanda ke ba da fa'ida ga haɓaka aikin "juyawa maimakon niƙa" a cikin masana'antar kayan aiki, kuma ya sami ci gaba. amsa matsalar tauraruwar kayan aikin juyi cylindrical da aka ruɗe shekaru da yawa. Har ila yau, yana da mahimmanci don rage girman ƙirar ƙirar zobe da rage farashin samarwa; Bn-h20 jerin yankan da aka sani da duniya model na mai karfi tsaka tsaki juya quenched karfe a cikin masana'antu.