航空齿轮钢强化工艺与表面完整性关联规律研究

目的 探究不同加工工艺与表面完整性的关联规律。方法 对渗碳航空齿轮钢AISI9310 进行常规喷丸、二次喷丸、微粒喷丸、滚磨光整、喷丸光整等齿轮高表面完整性强化加工工艺处理，使用白光干涉仪、X射线衍射应力仪和显微硬度计对不同工艺状态下的试件进行表面形貌、表面粗糙度、残余应力和显微硬度等表面完整性表征。结果 喷丸能使得航空齿轮钢的表面粗糙度Sa值由磨削状态的0.68 μm增加到0.96 μm，而光整处理后，Sa下降到0.2 μm以下;微粒喷丸使表面残余压应力提升到–1 300 MPa，相比于常规喷丸和磨削状态，其幅值分别增加了450、800 MPa;滚磨光整使得表面残余压应力幅值进一步增加到1 400 MPa以上;二次喷丸及喷丸光整能显著提升表面硬度，相比磨削状态的645HV分别提升到718HV、721HV。 结论 二次喷丸、微粒喷丸、光整等工艺通过影响齿轮表面粗糙度、残余应力、硬度梯度等表面完整性参数，从而影响润滑状态、受力状态、应力集中、失效风险等，直接影响齿轮的服役性能。

Correlation between Strengthening Process and Surface Integrity of Aviation Gear Steel

High surface integrity plays a key role in determining the service performance of basic components such as gears. How to obtain components with high surface integrity has become a focus of engineering and academic research. In this study, the carburizing aviation gear steel AISI9310 was treated by conventional shot peening, dual shot peening, fine particle peening, barrel finishing, barrel finishing after shot peening and other gear high surface integrity strengthening processes. For the conventional shot peening, a total of 3 groups of shot peening process were subject to different peening intensity, which were set to 0.2, 0.35, 0.5 mmA. Dual shot peening equipment was adopted for conventional shot peening atshot diameter of 0.6 mm, shot peening coverage of 200%, shot peening intensity of 0.35 mmA, and thendual shot peening at shot diameter 0.4 mm, shot peening coverage of 200%, shot peening intensity of 0.2 mmA. In addition, for the fine particle peening, the material of the shot was cast steel with an average shot diameter of 0.05 mm. Shot peening intensity was 0.1 mmN, shot peening coverage was 200%. As for the barrel finishing, the XL 400 vertical swirl finishing machine was used to carry out the finishing process test. The spindle speed was 147 r/min and the drum speed was 47 r/min. The positive and negative rotation time of the spindle was the same for 30 min in the whole process, and the embedded depth of the parts was 150 mm. The abrasive was made of TP3×3 white corundum, the loading amount of the barrel grinding block was 80%, and the grinding agent was HA-PC (3% concentration). The grinding agent was mainly used for black metal finishing, which could prevent the generation of sludge and had good dispersion function. The pH value was 8.3, which played a role in corrosion prevention and cleaning. And it was expected to give an active anti fatigue design method. White light interferometer, X-ray diffraction stress meter and micro-hardness tester were used to characterize the surface integrity such as surface morphology, surface roughness, residual stress and micro-hardness of specimens under different processing conditions, and to explore the relationship between different processing parameters and surface integrity. The results showed that conventional shot peening increased the surface roughness Sa value from 0.68 μm to 0.96 μm in the grinding state, while it decreased to below 0.2 μm after barrel finishing, which would effectively avoid micro pitting, near surface peeling, scuffing and other failures. The residual compressive stress on the surface of particle shot peening was –1 300 MPa, which was 450 MPa and 800 MPa higher than that of conventional shot peening and grinding, respectively. Barrel finishing further increased the surface residual compressive stress amplitude to above -1 400 MPa. Dual shot peening and conventional shot peening could significantly improve the surface hardness, compared with the grinding state of 645HV increased to 718HV, 721HV. Double shot peening, fine particle shot peening, barrel finishing and other processes affect the service performance such as lubrication state, stress state, stress concentration, and failure risk through surface integrity, thus directly affecting the service performance of gears.