小(xiao)齒輪件的(de)成形工藝及模(mo)具(ju)設(she)計

1引(yin)言冷(leng)擠(ji)(ji)壓(ya)(ya)技(ji)術是一(yi)種高(gao)(gao)精(jing)(jing)(jing)、、低耗(hao)的(de)(de)(de)(de)(de)生產工藝技(ji)術，是零(ling)件(jian)成(cheng)形(xing)(xing)(xing)(xing)加(jia)工的(de)(de)(de)(de)(de)主(zhu)要(yao)方(fang)法之一(yi)。而齒(chi)(chi)(chi)輪和(he)(he)花鍵(jian)形(xing)(xing)(xing)(xing)狀(zhuang)(zhuang)(zhuang)復雜(za)，尺寸精(jing)(jing)(jing)度(du)(du)、表面質量及綜(zong)合機械(xie)性能(neng)(neng)等要(yao)求均很高(gao)(gao)，而且常(chang)溫下(xia)金屬(shu)的(de)(de)(de)(de)(de)變(bian)(bian)(bian)形(xing)(xing)(xing)(xing)能(neng)(neng)力(li)低、流動性差，這(zhe)些原因導(dao)致(zhi)鍛造(zao)載荷陡(dou)增、齒(chi)(chi)(chi)形(xing)(xing)(xing)(xing)型腔角隅(yu)充(chong)填(tian)能(neng)(neng)力(li)銳減(jian)，模(mo)具(ju)處(chu)(chu)(chu)于極限加(jia)工狀(zhuang)(zhuang)(zhuang)態，帶來易磨損、彈性變(bian)(bian)(bian)形(xing)(xing)(xing)(xing)嚴重、壽命低等弊病(bing)。如果采用流線(xian)型的(de)(de)(de)(de)(de)擠(ji)(ji)壓(ya)(ya)過渡型腔，能(neng)(neng)改(gai)善(shan)金屬(shu)流動的(de)(de)(de)(de)(de)均勻性，降(jiang)低成(cheng)形(xing)(xing)(xing)(xing)壓(ya)(ya)力(li)，提(ti)高(gao)(gao)齒(chi)(chi)(chi)輪和(he)(he)花鍵(jian)擠(ji)(ji)壓(ya)(ya)成(cheng)形(xing)(xing)(xing)(xing)的(de)(de)(de)(de)(de)精(jing)(jing)(jing)度(du)(du)。2工藝分析2．1成(cheng)形(xing)(xing)(xing)(xing)工藝設(she)計圖1為(wei)(wei)小(xiao)齒(chi)(chi)(chi)輪件(jian)的(de)(de)(de)(de)(de)零(ling)件(jian)圖，材料(liao)為(wei)(wei)40Cr，高(gao)(gao)精(jing)(jing)(jing)度(du)(du)磨齒(chi)(chi)(chi)機廠家，零(ling)件(jian)一(yi)端為(wei)(wei)齒(chi)(chi)(chi)輪，另(ling)一(yi)端為(wei)(wei)花鍵(jian)。齒(chi)(chi)(chi)輪參(can)數為(wei)(wei)：齒(chi)(chi)(chi)數Z=8，模(mo)數m=1．5，高(gao)(gao)精(jing)(jing)(jing)度(du)(du)磨齒(chi)(chi)(chi)加(jia)工工序(xu)，齒(chi)(chi)(chi)形(xing)(xing)(xing)(xing)為(wei)(wei)漸開線(xian)，壓(ya)(ya)力(li)角口=20°，齒(chi)(chi)(chi)頂圓直徑(jing)da=13ram，齒(chi)(chi)(chi)根(gen)圓直徑(jing)df=11 mm，精(jing)(jing)(jing)度(du)(du)等級為(wei)(wei)IT6～IT7。根(gen)據對(dui)零(ling)件(jian)的(de)(de)(de)(de)(de)分析得出(chu)小(xiao)齒(chi)(chi)(chi)輪件(jian)的(de)(de)(de)(de)(de)成(cheng)形(xing)(xing)(xing)(xing)工藝方(fang)案為(wei)(wei)：精(jing)(jing)(jing)剪(jian)下(xia)料(liao)一(yi)擠(ji)(ji)壓(ya)(ya)小(xiao)端一(yi)正擠(ji)(ji)花鍵(jian)-鐓(dui)粗一(yi)反擠(ji)(ji)齒(chi)(chi)(chi)輪、齒(chi)(chi)(chi)輪孔(kong)成(cheng)形(xing)(xing)(xing)(xing)一(yi)擠(ji)(ji)臺階(jie)一(yi)齒(chi)(chi)(chi)輪部分精(jing)(jing)(jing)整(zheng)成(cheng)形(xing)(xing)(xing)(xing)，如圖2所(suo)示。2．2坯(pi)(pi)(pi)(pi)料(liao)形(xing)(xing)(xing)(xing)狀(zhuang)(zhuang)(zhuang)和(he)(he)尺寸的(de)(de)(de)(de)(de)確定(ding)坯(pi)(pi)(pi)(pi)料(liao)形(xing)(xing)(xing)(xing)狀(zhuang)(zhuang)(zhuang)和(he)(he)尺寸對(dui)冷(leng)擠(ji)(ji)壓(ya)(ya)件(jian)的(de)(de)(de)(de)(de)充(chong)填(tian)性能(neng)(neng)和(he)(he)模(mo)具(ju)壽命影響(xiang)很大。根(gen)據小(xiao)齒(chi)(chi)(chi)輪件(jian)的(de)(de)(de)(de)(de)形(xing)(xing)(xing)(xing)狀(zhuang)(zhuang)(zhuang)特點，同時為(wei)(wei)了便于送(song)料(liao)以及有利于坯(pi)(pi)(pi)(pi)料(liao)的(de)(de)(de)(de)(de)定(ding)位，故選用圓柱形(xing)(xing)(xing)(xing)坯(pi)(pi)(pi)(pi)料(liao)。毛(mao)坯(pi)(pi)(pi)(pi)的(de)(de)(de)(de)(de)體(ti)積(ji)是根(gen)據變(bian)(bian)(bian)形(xing)(xing)(xing)(xing)前(qian)(qian)后的(de)(de)(de)(de)(de)體(ti)積(ji)不變(bian)(bian)(bian)定(ding)律計算(suan)(suan)，經(jing)計算(suan)(suan)確定(ding)毛(mao)坯(pi)(pi)(pi)(pi)直徑(jing)為(wei)(wei)12 mm，長度(du)(du)為(wei)(wei)27mm。2．3坯(pi)(pi)(pi)(pi)料(liao)的(de)(de)(de)(de)(de)軟化處(chu)(chu)(chu)理小(xiao)齒(chi)(chi)(chi)輪件(jian)的(de)(de)(de)(de)(de)材料(liao)為(wei)(wei)40Cr，其(qi)供(gong)應狀(zhuang)(zhuang)(zhuang)態強度(du)(du)高(gao)(gao)、變(bian)(bian)(bian)形(xing)(xing)(xing)(xing)抗力(li)大、塑性較差且有加(jia)工硬化存在。加(jia)工前(qian)(qian)要(yao)對(dui)坯(pi)(pi)(pi)(pi)料(liao)進行(xing)充(chong)分的(de)(de)(de)(de)(de)軟化處(chu)(chu)(chu)理，降(jiang)低變(bian)(bian)(bian)形(xing)(xing)(xing)(xing)抗力(li)，提(ti)高(gao)(gao)塑性，以滿(man)足冷(leng)擠(ji)(ji)壓(ya)(ya)成(cheng)形(xing)(xing)(xing)(xing)工藝。退火處(chu)(chu)(chu)理過程如圖3所(suo)示。經(jing)退火處(chu)(chu)(chu)理后，材料(liao)硬度(du)(du)達到(dao)150～163HBS。

同步帶輪的優勢

同(tong)步(bu)帶(dai)(dai)(dai)輪傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)是由一(yi)根內周表(biao)面(mian)設有等間(jian)距齒(chi)的封閉(bi)環(huan)形膠(jiao)(jiao)帶(dai)(dai)(dai)和相應的帶(dai)(dai)(dai)輪所組成。運(yun)動(dong)(dong)(dong)時，帶(dai)(dai)(dai)齒(chi)與帶(dai)(dai)(dai)輪的齒(chi)槽相嚙合傳(chuan)(chuan)(chuan)(chuan)遞(di)運(yun)動(dong)(dong)(dong)和動(dong)(dong)(dong)力，是一(yi)種嚙合傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)，因(yin)而(er)具(ju)有齒(chi)輪傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)、鏈傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)和平(ping)(ping)帶(dai)(dai)(dai)傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)的各種優(you)點(dian) 。　　同(tong)步(bu)帶(dai)(dai)(dai)按材質(zhi)可(ke)(ke)(ke)分為(wei)氯丁(ding)橡(xiang)膠(jiao)(jiao)加纖維繩同(tong)步(bu)帶(dai)(dai)(dai)，聚氨酯加鋼絲同(tong)步(bu)帶(dai)(dai)(dai)，按齒(chi)的形目前(qian)主要分為(wei)梯形齒(chi)和圓弧齒(chi)兩大(da)類，按帶(dai)(dai)(dai)齒(chi)的排布面(mian)又可(ke)(ke)(ke)分為(wei)單面(mian)齒(chi)同(tong)步(bu)帶(dai)(dai)(dai)和雙面(mian)齒(chi)同(tong)步(bu)帶(dai)(dai)(dai)。同(tong)步(bu)帶(dai)(dai)(dai)傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)具(ju)有準確的傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)比，無滑(hua)差，可(ke)(ke)(ke)獲得恒定的速(su)比，可(ke)(ke)(ke)精密(mi)傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)，傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)平(ping)(ping)穩，能吸震(zhen)，噪音小，傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)速(su)比范圍大(da)，一(yi)般可(ke)(ke)(ke)達1∶10，允許線速(su)度可(ke)(ke)(ke)達50m/s，傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)，一(yi)般可(ke)(ke)(ke)達98℅―99℅。傳(chuan)(chuan)(chuan)(chuan)遞(di)功率從幾瓦(wa)到數百千瓦(wa)。結構緊湊(cou)還適用多軸傳(chuan)(chuan)(chuan)(chuan)動(dong)(dong)(dong)，張(zhang)緊力小，不需潤滑(hua)，無污染(ran)，蘇州高精度磨齒(chi)，因(yin)而(er)可(ke)(ke)(ke)在不允許有污染(ran)和工作環(huan)境較為(wei)惡劣的場(chang)合下正常工作。

蘇州(zhou)奧本馬精(jing)密機械(xie)(xie)有限公(gong)司于(yu)2013年6月在中國蘇州(zhou)注冊成立，高精(jing)度磨齒(chi)(chi)(chi)性能，主要從(cong)事(shi)中小模數傳動機械(xie)(xie)齒(chi)(chi)(chi)輪(lun)(lun)(lun)，渦輪(lun)(lun)(lun)，蝸(gua)桿，傘齒(chi)(chi)(chi)輪(lun)(lun)(lun)，螺旋錐齒(chi)(chi)(chi)輪(lun)(lun)(lun)，軸齒(chi)(chi)(chi)輪(lun)(lun)(lun)，齒(chi)(chi)(chi)輪(lun)(lun)(lun)箱等，零(ling)部件生(sheng)產和研發，服(fu)務于(yu)汽車制造行業(ye)，紡織機械(xie)(xie)，航空航天，工(gong)業(ye)零(ling)件行業(ye)，電(dian)子行業(ye)，家用電(dian)器等領域。

齒輪主要特點

在各種機器上所用(yong)的機械(xie)傳(chuan)動方法很多(duo)，主(zhu)要(yao)的有皮帶傳(chuan)動、鏈條傳(chuan)動、摩擦輪(lun)(lun)傳(chuan)動、齒輪(lun)(lun)傳(chuan)動及(ji)絳杠螺母傳(chuan)動等。

其(qi)中齒輪傳動，一般說來，也就(jiu)是使得一個(ge)軸在旋(xuan)轉(zhuan)時(shi)能夠帶動另一個(ge)軸旋(xuan)轉(zhuan)；或者是把(ba)一個(ge)軸的旋(xuan)轉(zhuan)運動變為直線運動。