采用新材料、新结构、新工艺技术,攻克零件变形关

某变速箱产品主减速齿轮因最终热处理后变形大而只能采用加工效率低、制造成本高的磨齿工艺.通过综合分析,认为其变形大的原因在于:一是零件形状结构较特殊,二是钢材的综合质量性能欠稳定,三是坯件预先热处理质量及渗碳/碳氮共渗、淬火相关参数的搭配欠佳.为此,提出了采用新材料、新结构、新工艺对此进行攻关,以期将磨齿工艺改为剃齿工艺.结果表明:零件的结构改进、材料选择、工艺流程等基本合理,可以生产出变形满足技术、装配和使用寿命要求的产品.剃齿工艺替代磨齿工艺投入生产应用后,大幅度提高了生产效率、降低了制造成本,且有利于提高零件使用寿命.

Using new Material, new Structure and new Process Technology to Overcome the Difficulty of Part Deformation

because the final drive gear of some transmission is deformed too much after the final heat treatment and can only be machined by grinding process with low efficiency and high cost,the compositive analysis thinks: A,the form and the structure of the part is special;B,the general quality performance of the steel(isn't) steady;C,the relative data settings for pre-heat treatment quality of the blanks and carburizing / carbonitriding and quenching isn't suitable.So we put forward to use new material,new structure and new process technology to capture the technology difficulty and to change from grinding process to shaving process.The result shows: the improvementon part structure;the material choice and the process flow are basically reasonable and the products that the deformation met the technical,assembly and durability requirement can be manufactured by them.Using the shaving process to replace the grinding process the production efficiency can be increased and the manufacturing cost can be reduced greatly and the part durability was increased also.