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齒輪軸加工
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齒(chi)輪軸(zhou)工(gong)(gong)(gong)(gong)藝(yi)設計說(shuo)明書 一、分(fen)析(xi)(xi)零(ling)(ling)件(jian)(jian)(jian)圖(tu)(tu)（如圖(tu)(tu)） 1、零(ling)(ling)件(jian)(jian)(jian)名稱(cheng)：齒(chi)輪軸(zhou)； 2、材料(liao)：40Cr； 3、質量(liang)：17.38kg； 4、產量(liang)：100件(jian)(jian)(jian)； 5、技術要求： 1）調質處理28-32HRC。 6、齒(chi)輪基本(ben)參數： 1）m=4; β=9°22′（左旋）; 2）z=33, 精度等級887FH； 3）α=20°。 二、鍛(duan)(duan)(duan)造工(gong)(gong)(gong)(gong)藝(yi)性(xing)分(fen)析(xi)(xi) 1、加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)目的(de)(de)(de)(de)、環(huan)境及鍛(duan)(duan)(duan)后(hou)(hou)現象分(fen)析(xi)(xi) 零(ling)(ling)件(jian)(jian)(jian)為軸(zhou)類零(ling)(ling)件(jian)(jian)(jian)，因此鍛(duan)(duan)(duan)造的(de)(de)(de)(de)目的(de)(de)(de)(de)不是(shi)側重于(yu)成形(xing)、減(jian)少加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)余(yu)量(liang)，而是(shi)側重于(yu)提高鍛(duan)(duan)(duan)件(jian)(jian)(jian)的(de)(de)(de)(de)力(li)學性(xing)能(neng)。結(jie)合(he)現代工(gong)(gong)(gong)(gong)廠設備、技術力(li)量(liang)和加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)能(neng)力(li)，選用自由(you)手工(gong)(gong)(gong)(gong)鍛(duan)(duan)(duan)造。鍛(duan)(duan)(duan)后(hou)(hou)零(ling)(ling)件(jian)(jian)(jian)性(xing)能(neng)可能(neng)變化的(de)(de)(de)(de)趨勢(shi)有坯料(liao)端部彎曲并(bing)帶毛刺和脫碳等。 2、零(ling)(ling)件(jian)(jian)(jian)結(jie)構形(xing)狀(zhuang)對(dui)鍛(duan)(duan)(duan)造適應性(xing)的(de)(de)(de)(de)分(fen)析(xi)(xi) 即鍛(duan)(duan)(duan)件(jian)(jian)(jian)結(jie)構工(gong)(gong)(gong)(gong)藝(yi)性(xing)分(fen)析(xi)(xi)。該零(ling)(ling)件(jian)(jian)(jian)為簡(jian)單的(de)(de)(de)(de)階梯軸(zhou)類零(ling)(ling)件(jian)(jian)(jian)，可通過手工(gong)(gong)(gong)(gong)自由(you)鍛(duan)(duan)(duan)造來完成初步成型。因鍛(duan)(duan)(duan)造而產生的(de)(de)(de)(de)缺陷可以通過鍛(duan)(duan)(duan)造后(hou)(hou)的(de)(de)(de)(de)熱(re)處理和切削加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)來改善。 三、繪制(zhi)鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu) 鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu)是(shi)根(gen)據零(ling)(ling)件(jian)(jian)(jian)圖(tu)(tu)繪制(zhi)的(de)(de)(de)(de)。自由(you)鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu)是(shi)在(zai)零(ling)(ling)件(jian)(jian)(jian)圖(tu)(tu)的(de)(de)(de)(de)基礎上考慮了加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)余(yu)量(liang)、鍛(duan)(duan)(duan)造公差、工(gong)(gong)(gong)(gong)藝(yi)余(yu)塊等參數后(hou)(hou)繪制(zhi)而成的(de)(de)(de)(de)。根(gen)據以下(xia)(xia)步驟(zou)繪制(zhi)鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu)（如下(xia)(xia)頁圖(tu)(tu)）： （1）確定鍛(duan)(duan)(duan)件(jian)(jian)(jian)形(xing)狀(zhuang)。 （2）用紅線繪出鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu)。 （3）計算(suan)尺寸(cun)，查公差并(bing)注于(yu)圖(tu)(tu)上。
四、參(can)(can)數選擇(ze) 1、工(gong)(gong)(gong)(gong)(gong)藝參(can)(can)數 首(shou)先選擇(ze)工(gong)(gong)(gong)(gong)(gong)藝余(yu)塊以簡化(hua)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)外形，然后確(que)定(ding)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)余(yu)量(liang)(liang)(liang)(liang)(liang)和(he)公差。 2、選擇(ze)依據(ju) 選擇(ze)參(can)(can)數應考慮(lv)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)的(de)(de)(de)(de)(de)材(cai)料(liao)(liao)(liao)(liao)、形狀(zhuang)尺寸、現有(you)(you)設備、生產批量(liang)(liang)(liang)(liang)(liang)等(deng)因素(su)。 3、確(que)定(ding)方法(fa) 查有(you)(you)關(guan)標準進行分(fen)(fen)析，并與同類件(jian)(jian)比(bi)較(jiao)，選擇(ze)的(de)(de)(de)(de)(de)公差余(yu)量(liang)(liang)(liang)(liang)(liang)可依下列條件(jian)(jian)確(que)定(ding)： （1）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)數量(liang)(liang)(liang)(liang)(liang)。數量(liang)(liang)(liang)(liang)(liang)多，其(qi)(qi)值取(qu)(qu)(qu)小些(xie)，否則(ze)取(qu)(qu)(qu)大(da)(da)(da)些(xie)。 （2）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)材(cai)料(liao)(liao)(liao)(liao)。一般材(cai)料(liao)(liao)(liao)(liao)其(qi)(qi)值取(qu)(qu)(qu)小些(xie)，特殊鋼取(qu)(qu)(qu)大(da)(da)(da)些(xie)。 （3）表面質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)。原材(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)(de)(de)表面質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)好，其(qi)(qi)值取(qu)(qu)(qu)小些(xie)，否則(ze)取(qu)(qu)(qu)大(da)(da)(da)些(xie)。 （4）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)形狀(zhuang)尺寸。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)形狀(zhuang)簡單，長度(du)短，其(qi)(qi)值取(qu)(qu)(qu)小些(xie)，否則(ze)取(qu)(qu)(qu)大(da)(da)(da)些(xie)。 （5）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)(gong)(gong)(gong)(gong)技術水平。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)(gong)(gong)(gong)(gong)技術水平高，其(qi)(qi)值取(qu)(qu)(qu)小些(xie)，否則(ze)取(qu)(qu)(qu)大(da)(da)(da)些(xie)。 （6）工(gong)(gong)(gong)(gong)(gong)具和(he)設備情況、企業工(gong)(gong)(gong)(gong)(gong)藝習(xi)慣等(deng)其(qi)(qi)它因素(su)。 4、數據(ju)處(chu)(chu)理(li) 對于大(da)(da)(da)型鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)尾數圓(yuan)(yuan)整為(wei)5或0；中小型鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)按四舍五入(ru)原則(ze)處(chu)(chu)理(li)成整數。最(zui)后確(que)定(ding)的(de)(de)(de)(de)(de)工(gong)(gong)(gong)(gong)(gong)藝參(can)(can)數如鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)圖(tu)所(suo)(suo)示。 五、確(que)定(ding)坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)和(he)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)尺寸 1、確(que)定(ding)坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)包括鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)本(ben)身的(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)、加(jia)(jia)熱(re)時(shi)(shi)氧(yang)化(hua)燒(shao)損(sun)(sun)(sun)(sun)、切(qie)(qie)頭(tou)時(shi)(shi)的(de)(de)(de)(de)(de)損(sun)(sun)(sun)(sun)失(shi)及(ji)沖(chong)(chong)(chong)孔(kong)時(shi)(shi)的(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)(liao)損(sun)(sun)(sun)(sun)失(shi)等(deng)。 (1) 計算鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang) 根據(ju)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)的(de)(de)(de)(de)(de)形狀(zhuang)和(he)基本(ben)尺寸，可計算出鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)的(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)： m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV 式(shi)中 m鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)； p—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)材(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)(de)(de)密度(du)（ kg/dm3 ）取(qu)(qu)(qu)7.85kg /dm3 ； V —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)的(de)(de)(de)(de)(de)體積（ dm3 ）； 由此(ci)(ci)計算得(de)：m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV = 7.85 kg /dm3×3.498 dm3 = 27.46 kg (2) 計算坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang) 坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)的(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)包括鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)本(ben)身的(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)、加(jia)(jia)熱(re)時(shi)(shi)氧(yang)化(hua)燒(shao)損(sun)(sun)(sun)(sun)、切(qie)(qie)頭(tou)時(shi)(shi)的(de)(de)(de)(de)(de)損(sun)(sun)(sun)(sun)失(shi)及(ji)沖(chong)(chong)(chong)孔(kong)時(shi)(shi)的(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)(liao)損(sun)(sun)(sun)(sun)失(shi)等(deng)。其(qi)(qi)計算公式(shi)為(wei)： m 坯(pi)(pi)(pi) ＝ m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) ＋ m 燒(shao) ＋ m 切(qie)(qie) ＋ m 芯(xin) 式(shi)中 m 坯(pi)(pi)(pi) —坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)（ kg ）； m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)（ kg ）； m 燒(shao)—氧(yang)化(hua)燒(shao)損(sun)(sun)(sun)(sun)的(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)（ kg ）， m 切(qie)(qie)—表示對拔(ba)長工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)的(de)(de)(de)(de)(de)切(qie)(qie)頭(tou)損(sun)(sun)(sun)(sun)失(shi)（ kg ）； m 芯(xin)—沖(chong)(chong)(chong)孔(kong)時(shi)(shi)沖(chong)(chong)(chong)掉的(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)(liao)損(sun)(sun)(sun)(sun)失(shi)（ kg ）； m 燒(shao)一般按火次進行估算，如第(di)一火取(qu)(qu)(qu)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)的(de)(de)(de)(de)(de) 2.0% ～ 3.0% ，以后各火一般取(qu)(qu)(qu) 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)質(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)(liang)的(de)(de)(de)(de)(de) 1.5% ～ 2.0% ；m 切(qie)(qie)一般按下面經(jing)驗公式(shi)估算：對于該零(ling)件(jian)(jian)圓(yuan)(yuan)形截面 m 切(qie)(qie)＝1.81 ，其(qi)(qi)中D 為(wei)切(qie)(qie)頭(tou)部分(fen)(fen)直徑（ dm ）；零(ling)件(jian)(jian)沒有(you)(you)沖(chong)(chong)(chong)孔(kong)，故， m 芯(xin)= 0kg。 所(suo)(suo)以，m 坯(pi)(pi)(pi) ＝ m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) ＋ m 燒(shao) ＋ m 切(qie)(qie) ＋ m 芯(xin)＝27.46×（1+1.5%）+1.81×0.873 ＝28.60(kg) 2、確(que)定(ding)坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)尺寸 坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)尺寸的(de)(de)(de)(de)(de)確(que)定(ding)與所(suo)(suo)采(cai)用(yong)的(de)(de)(de)(de)(de)第(di)一道基本(ben)工(gong)(gong)(gong)(gong)(gong)序(xu)(xu)（鐓粗或拔(ba)長）有(you)(you)關(guan)，所(suo)(suo)采(cai)用(yong)的(de)(de)(de)(de)(de)工(gong)(gong)(gong)(gong)(gong)序(xu)(xu)不(bu)同，確(que)定(ding)的(de)(de)(de)(de)(de)方法(fa)也不(bu)一樣。 此(ci)(ci)零(ling)件(jian)(jian)中間部分(fen)(fen)采(cai)用(yong)鐓粗法(fa)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)制，對于鋼坯(pi)(pi)(pi)，為(wei)避(bi)免鐓粗時(shi)(shi)坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)產生 彎曲，坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)高度(du)H與其(qi)(qi)直徑D之比(bi)應滿足鐓粗規則(ze)，即 1.25≤H/D≤2.5 對于此(ci)(ci)零(ling)件(jian)(jian)的(de)(de)(de)(de)(de)圓(yuan)(yuan)坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao) ,D坯(pi)(pi)(pi)＝（0.8～1）D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan),取(qu)(qu)(qu)D坯(pi)(pi)(pi)＝0.8 D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝0.8*150mm＝120mm 由此(ci)(ci)，可求出坯(pi)(pi)(pi)料(liao)(liao)(liao)(liao)高度(du)H坯(pi)(pi)(pi)，
