齒輪加工
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- 產品描述：常州茂通機械是機械零部件加工制造的經營實體，主要業務包括數控車床加工，CNC加工中心，內外圓磨床加工，龍門銑床加工，鏜孔（鉆孔）加工。已獲得ISO9001:2008質量體系認證。本廠現年產值1600多萬元，員工30余名，廠房2000㎡。擁有獨立的數控車間、焊接車間、普通金加工車間，并以加工產品質量上乘，工作進程迅速而常年與三一重工、江蘇南方機電股份有限公司、、博雷（中國）控制系統有限公司、蘇州昆侖
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齒(chi)輪軸工(gong)藝(yi)設計說明(ming)書 一、分(fen)析(xi)零(ling)(ling)件圖(tu)（如圖(tu)） 1、零(ling)(ling)件名稱(cheng)：齒(chi)輪軸； 2、材料(liao)：40Cr； 3、質(zhi)量：17.38kg； 4、產量：100件； 5、技術要求： 1）調質(zhi)處理(li)28-32HRC。 6、齒(chi)輪基本參數(shu)： 1）m=4; β=9°22′（左旋）; 2）z=33, 精度等級887FH； 3）α=20°。 二(er)、鍛(duan)(duan)(duan)造(zao)(zao)工(gong)藝(yi)性分(fen)析(xi) 1、加(jia)工(gong)目(mu)的(de)、環境及鍛(duan)(duan)(duan)后現(xian)象分(fen)析(xi) 零(ling)(ling)件為(wei)軸類(lei)零(ling)(ling)件，因(yin)此鍛(duan)(duan)(duan)造(zao)(zao)的(de)目(mu)的(de)不是側重于(yu)成(cheng)形、減少加(jia)工(gong)余(yu)量，而(er)(er)是側重于(yu)提高(gao)鍛(duan)(duan)(duan)件的(de)力(li)學性能(neng)。結(jie)合現(xian)代工(gong)廠設備(bei)、技術力(li)量和加(jia)工(gong)能(neng)力(li)，選用自由手(shou)工(gong)鍛(duan)(duan)(duan)造(zao)(zao)。鍛(duan)(duan)(duan)后零(ling)(ling)件性能(neng)可(ke)能(neng)變化的(de)趨勢有坯(pi)料(liao)端部彎曲并帶毛刺和脫碳等。 2、零(ling)(ling)件結(jie)構形狀(zhuang)(zhuang)對鍛(duan)(duan)(duan)造(zao)(zao)適(shi)應(ying)性的(de)分(fen)析(xi) 即鍛(duan)(duan)(duan)件結(jie)構工(gong)藝(yi)性分(fen)析(xi)。該零(ling)(ling)件為(wei)簡單的(de)階梯軸類(lei)零(ling)(ling)件，可(ke)通(tong)過(guo)手(shou)工(gong)自由鍛(duan)(duan)(duan)造(zao)(zao)來完成(cheng)初步(bu)成(cheng)型(xing)。因(yin)鍛(duan)(duan)(duan)造(zao)(zao)而(er)(er)產生的(de)缺(que)陷可(ke)以通(tong)過(guo)鍛(duan)(duan)(duan)造(zao)(zao)后的(de)熱(re)處理(li)和切削(xue)加(jia)工(gong)來改善(shan)。 三、繪(hui)(hui)制鍛(duan)(duan)(duan)件圖(tu) 鍛(duan)(duan)(duan)件圖(tu)是根據零(ling)(ling)件圖(tu)繪(hui)(hui)制的(de)。自由鍛(duan)(duan)(duan)件圖(tu)是在(zai)零(ling)(ling)件圖(tu)的(de)基礎上(shang)(shang)考慮了加(jia)工(gong)余(yu)量、鍛(duan)(duan)(duan)造(zao)(zao)公(gong)差、工(gong)藝(yi)余(yu)塊等參數(shu)后繪(hui)(hui)制而(er)(er)成(cheng)的(de)。根據以下步(bu)驟繪(hui)(hui)制鍛(duan)(duan)(duan)件圖(tu)（如下頁圖(tu)）： （1）確定鍛(duan)(duan)(duan)件形狀(zhuang)(zhuang)。 （2）用紅線繪(hui)(hui)出鍛(duan)(duan)(duan)件圖(tu)。 （3）計算尺寸，查公(gong)差并注于(yu)圖(tu)上(shang)(shang)。
四、參數(shu)選(xuan)擇(ze) 1、工(gong)藝參數(shu) 首先選(xuan)擇(ze)工(gong)藝余塊以簡(jian)化鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)外形(xing)(xing)，然后確(que)(que)(que)(que)(que)定(ding)加工(gong)余量(liang)(liang)(liang)(liang)和公(gong)差(cha)。 2、選(xuan)擇(ze)依(yi)據(ju) 選(xuan)擇(ze)參數(shu)應考慮鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)材(cai)料(liao)(liao)(liao)、形(xing)(xing)狀尺(chi)寸、現有(you)設(she)備、生產批量(liang)(liang)(liang)(liang)等因(yin)素(su)。 3、確(que)(que)(que)(que)(que)定(ding)方法 查有(you)關(guan)標準(zhun)進行分析，并與(yu)同類件(jian)(jian)(jian)比較，選(xuan)擇(ze)的(de)(de)(de)(de)(de)(de)公(gong)差(cha)余量(liang)(liang)(liang)(liang)可(ke)依(yi)下(xia)列(lie)條件(jian)(jian)(jian)確(que)(que)(que)(que)(que)定(ding)： （1）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)數(shu)量(liang)(liang)(liang)(liang)。數(shu)量(liang)(liang)(liang)(liang)多，其值(zhi)(zhi)(zhi)取(qu)小(xiao)些(xie)，否則(ze)(ze)取(qu)大(da)些(xie)。 （2）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)材(cai)料(liao)(liao)(liao)。一(yi)(yi)(yi)般(ban)材(cai)料(liao)(liao)(liao)其值(zhi)(zhi)(zhi)取(qu)小(xiao)些(xie)，特殊鋼(gang)取(qu)大(da)些(xie)。 （3）表(biao)面(mian)(mian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)。原材(cai)料(liao)(liao)(liao)的(de)(de)(de)(de)(de)(de)表(biao)面(mian)(mian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)好，其值(zhi)(zhi)(zhi)取(qu)小(xiao)些(xie)，否則(ze)(ze)取(qu)大(da)些(xie)。 （4）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)形(xing)(xing)狀尺(chi)寸。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)形(xing)(xing)狀簡(jian)單，長(chang)度短(duan)，其值(zhi)(zhi)(zhi)取(qu)小(xiao)些(xie)，否則(ze)(ze)取(qu)大(da)些(xie)。 （5）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)技術水平。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)技術水平高，其值(zhi)(zhi)(zhi)取(qu)小(xiao)些(xie)，否則(ze)(ze)取(qu)大(da)些(xie)。 （6）工(gong)具和設(she)備情況、企業工(gong)藝習慣等其它因(yin)素(su)。 4、數(shu)據(ju)處理 對(dui)(dui)于(yu)大(da)型(xing)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)尾(wei)數(shu)圓整(zheng)為(wei)(wei)(wei)5或0；中(zhong)小(xiao)型(xing)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)按四舍(she)五入原則(ze)(ze)處理成整(zheng)數(shu)。最后確(que)(que)(que)(que)(que)定(ding)的(de)(de)(de)(de)(de)(de)工(gong)藝參數(shu)如(ru)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)圖所(suo)示。 五、確(que)(que)(que)(que)(que)定(ding)坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)和鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)尺(chi)寸 1、確(que)(que)(que)(que)(que)定(ding)坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)包(bao)括(kuo)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)本(ben)身的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)、加熱(re)時(shi)(shi)(shi)氧化燒(shao)損(sun)(sun)、切(qie)(qie)頭時(shi)(shi)(shi)的(de)(de)(de)(de)(de)(de)損(sun)(sun)失及沖(chong)孔(kong)時(shi)(shi)(shi)的(de)(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)損(sun)(sun)失等。 (1) 計(ji)算(suan)(suan)(suan)(suan)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang) 根據(ju)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)形(xing)(xing)狀和基本(ben)尺(chi)寸，可(ke)計(ji)算(suan)(suan)(suan)(suan)出(chu)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)： m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV 式(shi)中(zhong) m鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)； p—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)材(cai)料(liao)(liao)(liao)的(de)(de)(de)(de)(de)(de)密度（ kg/dm3 ）取(qu)7.85kg /dm3 ； V —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)體積(ji)（ dm3 ）； 由(you)此計(ji)算(suan)(suan)(suan)(suan)得：m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV = 7.85 kg /dm3×3.498 dm3 = 27.46 kg (2) 計(ji)算(suan)(suan)(suan)(suan)坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang) 坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)包(bao)括(kuo)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)本(ben)身的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)、加熱(re)時(shi)(shi)(shi)氧化燒(shao)損(sun)(sun)、切(qie)(qie)頭時(shi)(shi)(shi)的(de)(de)(de)(de)(de)(de)損(sun)(sun)失及沖(chong)孔(kong)時(shi)(shi)(shi)的(de)(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)損(sun)(sun)失等。其計(ji)算(suan)(suan)(suan)(suan)公(gong)式(shi)為(wei)(wei)(wei)： m 坯(pi)(pi)(pi)(pi)(pi) ＝ m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan) ＋ m 燒(shao) ＋ m 切(qie)(qie) ＋ m 芯(xin) 式(shi)中(zhong) m 坯(pi)(pi)(pi)(pi)(pi) —坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)（ kg ）； m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan) —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)（ kg ）； m 燒(shao)—氧化燒(shao)損(sun)(sun)的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)（ kg ）， m 切(qie)(qie)—表(biao)示對(dui)(dui)拔長(chang)工(gong)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)切(qie)(qie)頭損(sun)(sun)失（ kg ）； m 芯(xin)—沖(chong)孔(kong)時(shi)(shi)(shi)沖(chong)掉的(de)(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)損(sun)(sun)失（ kg ）； m 燒(shao)一(yi)(yi)(yi)般(ban)按火次進行估算(suan)(suan)(suan)(suan)，如(ru)第一(yi)(yi)(yi)火取(qu)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)的(de)(de)(de)(de)(de)(de) 2.0% ～ 3.0% ，以后各火一(yi)(yi)(yi)般(ban)取(qu) 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)的(de)(de)(de)(de)(de)(de) 1.5% ～ 2.0% ；m 切(qie)(qie)一(yi)(yi)(yi)般(ban)按下(xia)面(mian)(mian)經驗(yan)公(gong)式(shi)估算(suan)(suan)(suan)(suan)：對(dui)(dui)于(yu)該零(ling)件(jian)(jian)(jian)圓形(xing)(xing)截面(mian)(mian) m 切(qie)(qie)＝1.81 ，其中(zhong)D 為(wei)(wei)(wei)切(qie)(qie)頭部(bu)分直徑（ dm ）；零(ling)件(jian)(jian)(jian)沒(mei)有(you)沖(chong)孔(kong)，故， m 芯(xin)= 0kg。 所(suo)以，m 坯(pi)(pi)(pi)(pi)(pi) ＝ m 鍛(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)(que)(que)(que)(que)定(ding)坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)尺(chi)寸 坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)尺(chi)寸的(de)(de)(de)(de)(de)(de)確(que)(que)(que)(que)(que)定(ding)與(yu)所(suo)采用的(de)(de)(de)(de)(de)(de)第一(yi)(yi)(yi)道基本(ben)工(gong)序(xu)（鐓粗或拔長(chang)）有(you)關(guan)，所(suo)采用的(de)(de)(de)(de)(de)(de)工(gong)序(xu)不同，確(que)(que)(que)(que)(que)定(ding)的(de)(de)(de)(de)(de)(de)方法也不一(yi)(yi)(yi)樣。 此零(ling)件(jian)(jian)(jian)中(zhong)間部(bu)分采用鐓粗法鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)制，對(dui)(dui)于(yu)鋼(gang)坯(pi)(pi)(pi)(pi)(pi)，為(wei)(wei)(wei)避免鐓粗時(shi)(shi)(shi)坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)產生 彎曲，坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)高度H與(yu)其直徑D之(zhi)比應滿足鐓粗規則(ze)(ze)，即 1.25≤H/D≤2.5 對(dui)(dui)于(yu)此零(ling)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)圓坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao) ,D坯(pi)(pi)(pi)(pi)(pi)＝（0.8～1）D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan),取(qu)D坯(pi)(pi)(pi)(pi)(pi)＝0.8 D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝0.8*150mm＝120mm 由(you)此，可(ke)求(qiu)出(chu)坯(pi)(pi)(pi)(pi)(pi)料(liao)(liao)(liao)高度H坯(pi)(pi)(pi)(pi)(pi)。
