变速箱齿轮热处理的变形与控制研究
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摘要
变速箱是汽车的重要组成部件之一,而齿轮则是变速箱的关键零件。因成本和精度要求,变速箱齿轮一般不要求热处理后磨齿加工,所以热处理后的齿部尺寸就是成品尺寸,这就对热处理变形有了较高的要求。目前,国内外经过多年研究对影响热处理变形的因素主要归结为以下几种:零件的形状(对称性)、原材料、锻造、预热处理、加工应力、热处理工艺和设备等。
本论文从实际工作需要的角度出发,结合现有设备和条件对我公司主要产品的变形做了设计形状、预热处理等方面的对比试验,对热处理工艺和设备采用正交试验方法进行了试验优化设计,为我公司变速箱齿轮的热前加工提供了指导数据,保证了产品的顺利投产。
论文首先对变速箱主轴齿轮内花键的变形进行了对比试验,通过数据分析讨论了零件的设计形状对变形的影响、预先热处理对变形的影响;其次通过正交试验的方法对热处理工艺进行了试验优化设计,找到变形趋势和热处理指标都较好的工艺方案;最后采用该工艺进行不同热处理设备的热处理变形对比试验,分析不同热处理设备对热处理变形的影响。通过试验分析提出了合理选择预先热处理工艺方式,热处理工艺参数和设备等手段来达到改善热处理变形的目的,为我公司变速箱齿轮的热处理生产提供了理论和试验依据。
Heat treatment is an important working procedure in transmission gear process, it is a key process to increase gear hardness, strength, rubbing fastness. At one time, heat treatment makes deformation and accuracy reduce. The precision reduction of gear induces serious noise and abnormal sound in gear power transmission , and even lead to early failure of gear. The deformation control in heat treatment is a important issues in automotive industry, it needs a long-term to research..
The factor of deformation in heat treatment on the micro factors that can be summed up: stress, plastic and time. The stress which lead to deformation include forging stress、pre-heat treatment stress、machining stress、thermal stress in carburizing and quenching、organizational stress..
There are more factors of deformation in heat treatment .Such as design of gear、pre-heat treatment、machining methods and tools、heat treatment and Equipment、and so on. Qualified material、Precision forging、Preheating specification、effective with machining and heat treatment are important factor of reduce and steady deformation in heat treatment.
the quality of raw materials not only affects heat treatment control, but also related to the fatigue life of gears. The basic features of meterials like: hardenability、Purity、Grain size are also important factors of deformation in heat treatment. Hardenability of the material is higher ,the deformation will be greater, Grain size is Finer, the deformation will be better.
The purpose of preheating is to get a good organization, grain refinement, elimination of residual stress. Isothermal annealing process has been increasingly common applications.
A stable machining process is an important factors to control the deformation in heat treatment. There are several key parameters on the deformation in carburizing process such as clamping method, carburizing temperature, heating rate, quenching temperature, quenching medium. In addition, the characteristics of heat treatment equipment, is a important factor of. deformation in heat treatment.
Although there are a number of factors of deformation in heat treatment, but the deformation is concentrated arises in the heat treatment process. This requires strict control to every aspect of the gear processing, then can control the deformation, improve product quality, increase market competitiveness.
My company also used carburizing and quenching heat treatment process of transmission gear. The purpose of carburizing is to increase the surface of carburized carbon content, improve the surface strength. The core of gear maintains a lower carbon content , lower carbon content can maintains good toughness. This is a common heat treatment for metal. Carburizing and quenching process is basic heat treatment process in domestic and foreign for heavy transmission gears.
In carburizing and quenching process, carburizing temperature、quenching temperature、carburizing time、oil temperature etc. that are the main parameters which affect the distortion. Firstly, this subject tested the factors of distortion in carburizing and quenching process by using the method of test optimization design. Test Optimization method using the principle of mathematical statistics, in virtue of normalization "orthogonal form" Selected representative and typical experimental points from a number of experimental points arrange test reasonable. Test Optimization method can greatly reduce the number of tests. It makes to selected a reasonable parameters carburizing process by testing. After Authentication by several batches of gear testing, carburizing process works well, deformation is stable, product quality can be Guaranteed.
Followed this subject tested the heat treatment deformation in different heat treatment equipment, that find the Differences in heat treatment deformation on different equipment. It provides data to support for products produced in different heat treatment equipment Currently at this time that all the company is moved to a new place, The test provides experimental support for the production produced in different heat treatment equipment.
At the same time, I analyze the data by scientific method with the chance of graduation design, which data I has tested and collated in recent years. The analyzed data provides basis and beginning for my future work.
本论文从实际工作需要的角度出发,结合现有设备和条件对我公司主要产品的变形做了设计形状、预热处理等方面的对比试验,对热处理工艺和设备采用正交试验方法进行了试验优化设计,为我公司变速箱齿轮的热前加工提供了指导数据,保证了产品的顺利投产。
论文首先对变速箱主轴齿轮内花键的变形进行了对比试验,通过数据分析讨论了零件的设计形状对变形的影响、预先热处理对变形的影响;其次通过正交试验的方法对热处理工艺进行了试验优化设计,找到变形趋势和热处理指标都较好的工艺方案;最后采用该工艺进行不同热处理设备的热处理变形对比试验,分析不同热处理设备对热处理变形的影响。通过试验分析提出了合理选择预先热处理工艺方式,热处理工艺参数和设备等手段来达到改善热处理变形的目的,为我公司变速箱齿轮的热处理生产提供了理论和试验依据。
Heat treatment is an important working procedure in transmission gear process, it is a key process to increase gear hardness, strength, rubbing fastness. At one time, heat treatment makes deformation and accuracy reduce. The precision reduction of gear induces serious noise and abnormal sound in gear power transmission , and even lead to early failure of gear. The deformation control in heat treatment is a important issues in automotive industry, it needs a long-term to research..
The factor of deformation in heat treatment on the micro factors that can be summed up: stress, plastic and time. The stress which lead to deformation include forging stress、pre-heat treatment stress、machining stress、thermal stress in carburizing and quenching、organizational stress..
There are more factors of deformation in heat treatment .Such as design of gear、pre-heat treatment、machining methods and tools、heat treatment and Equipment、and so on. Qualified material、Precision forging、Preheating specification、effective with machining and heat treatment are important factor of reduce and steady deformation in heat treatment.
the quality of raw materials not only affects heat treatment control, but also related to the fatigue life of gears. The basic features of meterials like: hardenability、Purity、Grain size are also important factors of deformation in heat treatment. Hardenability of the material is higher ,the deformation will be greater, Grain size is Finer, the deformation will be better.
The purpose of preheating is to get a good organization, grain refinement, elimination of residual stress. Isothermal annealing process has been increasingly common applications.
A stable machining process is an important factors to control the deformation in heat treatment. There are several key parameters on the deformation in carburizing process such as clamping method, carburizing temperature, heating rate, quenching temperature, quenching medium. In addition, the characteristics of heat treatment equipment, is a important factor of. deformation in heat treatment.
Although there are a number of factors of deformation in heat treatment, but the deformation is concentrated arises in the heat treatment process. This requires strict control to every aspect of the gear processing, then can control the deformation, improve product quality, increase market competitiveness.
My company also used carburizing and quenching heat treatment process of transmission gear. The purpose of carburizing is to increase the surface of carburized carbon content, improve the surface strength. The core of gear maintains a lower carbon content , lower carbon content can maintains good toughness. This is a common heat treatment for metal. Carburizing and quenching process is basic heat treatment process in domestic and foreign for heavy transmission gears.
In carburizing and quenching process, carburizing temperature、quenching temperature、carburizing time、oil temperature etc. that are the main parameters which affect the distortion. Firstly, this subject tested the factors of distortion in carburizing and quenching process by using the method of test optimization design. Test Optimization method using the principle of mathematical statistics, in virtue of normalization "orthogonal form" Selected representative and typical experimental points from a number of experimental points arrange test reasonable. Test Optimization method can greatly reduce the number of tests. It makes to selected a reasonable parameters carburizing process by testing. After Authentication by several batches of gear testing, carburizing process works well, deformation is stable, product quality can be Guaranteed.
Followed this subject tested the heat treatment deformation in different heat treatment equipment, that find the Differences in heat treatment deformation on different equipment. It provides data to support for products produced in different heat treatment equipment Currently at this time that all the company is moved to a new place, The test provides experimental support for the production produced in different heat treatment equipment.
At the same time, I analyze the data by scientific method with the chance of graduation design, which data I has tested and collated in recent years. The analyzed data provides basis and beginning for my future work.
引文
[1]廖正中,渗碳齿轮钢的冲击-弯曲性能与应用[J].重型汽车,1996.
[2]史美堂主编,金属材料与热处理[J].上海:科技出版社,1987
[3]潘一凡等,齿轮热处理变形控制[J],机械设计与制造工程,2002.
[4]文源康,国外齿轮渗碳淬硬工艺的研究与应用[J],国外金属热处理,1990
[5]陈锐,罗新民,钢件的淬火热处理变形与控制[J].北京:热处理技术与装备,2006.
[6] Hoffmann F, KesslerO,Luebben Th,Mayr P.”Distortion Engineering”-Distortion control during the production process[J].金属热处理,2004,29(8):61
[7]程善述,汽车渗碳齿轮的疲劳强度与工艺最佳选择。国外金属热处理
[8]李宝奎,王爱香,顾敏,渗碳淬火齿轮畸变控制技术的研究现状[J],金属热处理2006
[9]孙铭炎,华公平,渗碳齿轮的热处理畸变及其控制技术[J],热处理,2008
[10]孙抗美,影响齿轮热处理变形的主要因素[J]机械设计与制造工程,1999
[11]马宝丽,齿轮热处理变形控制对策[J],机械工程师,2007
[12]龚冰,重型汽车齿轮材料及热处理工艺的研究[J].北京:重型汽车,1998.
[13]姚贵升,国外汽车用合金结构钢[J].北京:国外金属热处理,1996
[14]谢浪,浅析渗碳淬火齿轮的变形与控制[J],机械工人,2002
[15]刘云旭主编,金属材料与热处理[J],机械工业出版社1981
[16]安运铮,热处理工艺学[M].北京:机械工业出版社,1986.
[17]林锋,汽车锻造和冷挤压坯料的热处理[J],,国外金属热处理,1996
[18]吕永顺,锻造对齿轮热处理变形的影响[J],,机械工人,2000
[19]雷声,齿轮热处理变形的控制[J],机械工程师,2008
[20]刘云旭等,正火—影响渗碳齿轮热处理畸变的一个重要因素[J],金属热处理,2005
[21]陈国民,对我国齿轮渗碳淬火技术的评述[J],金属热处理,2008
[22]李先强编译,可行的渗碳工艺[J],国外金属热处理,
[23] Kllaus-Dieter Thoben,Dieter Klein“Distortion Engineering”:A system-oriented view on the distortion of component parts[J],金属热处理,2004
[24]金荣植,我国中重型载货汽车齿轮材料与热处理的发展概况[J],国外金属与热处理,2005
[25]陆载厚主编,可控气氛热处理[J],机械工业出版社,1982
[26]阎承沛,我国齿轮热处理技术概况及发展趋势[J],热处理,2002
[27]彭俊等,汽车渗碳齿轮用钢及热处理工艺的现状和发展趋势[J],热处理技术与装备,2007
[28]钢的形变热处理[J],机械工业出版社,1979
[29]ЛНВАГОУК,齿轮渗碳厚的冷却速度对变形和强度的影响,,国外金属热处理,1989
[30]洪福生,汽车齿轮热处理变形的机理与控制[J],材料与工艺,1995
[31]牛万斌,齿轮的淬火冷却和变形控制[J],热加工工艺,2000
[32] Kessler O等,Influence of the Heating Parameters on the Distortion of Quench Hardened AISI52100 Steel Bearing Rings[j],Surface and Coating Technology,2004
[33]戴凤梅,正交试验法在热处理工艺上的应用[J],机械设计与制造,1999
[34]刘晔东,热处理变形浅析,机械工人,2007
[35]王承槐,渗碳齿轮与花键内孔的热处理变形规律[J],金属热处理,1989
[36]李朝霞,渗碳钢的淬透性对机械性能和变形的影响[J],金属热处理,1986
[37] Sharma V K,Walter G H,Breen D H.Stress and strength in tersection analysis to optimize case in carburzeoled gears[J].ASM Technical Report System[C].A.S.M Metals Park,Ohio:1976,76-40:44-73.
[38] ATLAS.Hardenability of carburized steels[M].USA:Climax Molybdenum company.1975:114
[39] Sagaradze U S Effect of carbon content on the strength of carburized steel [J].Trans of ASM,1958,50:227-241.
[40] Geoffrey parrish.The Influence of Microstructure on the Properties of Case-carburized Components[M].ASM,Metals Paek Ohio,1980:35
[41] By Daniel W.Mocurdy.Desktop computer simulation of at-mosphere carburizing[J],Heat treating July 1990:26-29.
[42]热处理手册,机械工业出版社,1992
[43]涂小龙,20CrMnTiH钢热处理变形试验研究[J],国外金属热处理,2005
[44]涂小龙,等温退火工艺优化[J],机械工人,2001
[45]董秦铮,齿轮热处理变形的讨论[J],汽车工艺与材料,1996
[46]刘建明,汽车齿轮渗碳淬火热处理异常变形的研究[J],机械工人,2005
[47]孙捷,汽车后桥齿轮热处理翘曲变形的分析及控制[J],现代机械,1997
[48]陈振,渗碳钢齿轮热处理变形及预防[J],现代制造工程,2003
[49]程健康,渗碳齿轮畸变控制与修正措施[J],金属热处理,2002
[50]任凤章,解决渗碳齿轮热处理变形方法的试验[C],全国齿轮热处理变形控制技术研讨会论文集,1994.11
[51]孙美英,影响热处理变形的主要因素[J],机械设计与制造工程,1999
[2]史美堂主编,金属材料与热处理[J].上海:科技出版社,1987
[3]潘一凡等,齿轮热处理变形控制[J],机械设计与制造工程,2002.
[4]文源康,国外齿轮渗碳淬硬工艺的研究与应用[J],国外金属热处理,1990
[5]陈锐,罗新民,钢件的淬火热处理变形与控制[J].北京:热处理技术与装备,2006.
[6] Hoffmann F, KesslerO,Luebben Th,Mayr P.”Distortion Engineering”-Distortion control during the production process[J].金属热处理,2004,29(8):61
[7]程善述,汽车渗碳齿轮的疲劳强度与工艺最佳选择。国外金属热处理
[8]李宝奎,王爱香,顾敏,渗碳淬火齿轮畸变控制技术的研究现状[J],金属热处理2006
[9]孙铭炎,华公平,渗碳齿轮的热处理畸变及其控制技术[J],热处理,2008
[10]孙抗美,影响齿轮热处理变形的主要因素[J]机械设计与制造工程,1999
[11]马宝丽,齿轮热处理变形控制对策[J],机械工程师,2007
[12]龚冰,重型汽车齿轮材料及热处理工艺的研究[J].北京:重型汽车,1998.
[13]姚贵升,国外汽车用合金结构钢[J].北京:国外金属热处理,1996
[14]谢浪,浅析渗碳淬火齿轮的变形与控制[J],机械工人,2002
[15]刘云旭主编,金属材料与热处理[J],机械工业出版社1981
[16]安运铮,热处理工艺学[M].北京:机械工业出版社,1986.
[17]林锋,汽车锻造和冷挤压坯料的热处理[J],,国外金属热处理,1996
[18]吕永顺,锻造对齿轮热处理变形的影响[J],,机械工人,2000
[19]雷声,齿轮热处理变形的控制[J],机械工程师,2008
[20]刘云旭等,正火—影响渗碳齿轮热处理畸变的一个重要因素[J],金属热处理,2005
[21]陈国民,对我国齿轮渗碳淬火技术的评述[J],金属热处理,2008
[22]李先强编译,可行的渗碳工艺[J],国外金属热处理,
[23] Kllaus-Dieter Thoben,Dieter Klein“Distortion Engineering”:A system-oriented view on the distortion of component parts[J],金属热处理,2004
[24]金荣植,我国中重型载货汽车齿轮材料与热处理的发展概况[J],国外金属与热处理,2005
[25]陆载厚主编,可控气氛热处理[J],机械工业出版社,1982
[26]阎承沛,我国齿轮热处理技术概况及发展趋势[J],热处理,2002
[27]彭俊等,汽车渗碳齿轮用钢及热处理工艺的现状和发展趋势[J],热处理技术与装备,2007
[28]钢的形变热处理[J],机械工业出版社,1979
[29]ЛНВАГОУК,齿轮渗碳厚的冷却速度对变形和强度的影响,,国外金属热处理,1989
[30]洪福生,汽车齿轮热处理变形的机理与控制[J],材料与工艺,1995
[31]牛万斌,齿轮的淬火冷却和变形控制[J],热加工工艺,2000
[32] Kessler O等,Influence of the Heating Parameters on the Distortion of Quench Hardened AISI52100 Steel Bearing Rings[j],Surface and Coating Technology,2004
[33]戴凤梅,正交试验法在热处理工艺上的应用[J],机械设计与制造,1999
[34]刘晔东,热处理变形浅析,机械工人,2007
[35]王承槐,渗碳齿轮与花键内孔的热处理变形规律[J],金属热处理,1989
[36]李朝霞,渗碳钢的淬透性对机械性能和变形的影响[J],金属热处理,1986
[37] Sharma V K,Walter G H,Breen D H.Stress and strength in tersection analysis to optimize case in carburzeoled gears[J].ASM Technical Report System[C].A.S.M Metals Park,Ohio:1976,76-40:44-73.
[38] ATLAS.Hardenability of carburized steels[M].USA:Climax Molybdenum company.1975:114
[39] Sagaradze U S Effect of carbon content on the strength of carburized steel [J].Trans of ASM,1958,50:227-241.
[40] Geoffrey parrish.The Influence of Microstructure on the Properties of Case-carburized Components[M].ASM,Metals Paek Ohio,1980:35
[41] By Daniel W.Mocurdy.Desktop computer simulation of at-mosphere carburizing[J],Heat treating July 1990:26-29.
[42]热处理手册,机械工业出版社,1992
[43]涂小龙,20CrMnTiH钢热处理变形试验研究[J],国外金属热处理,2005
[44]涂小龙,等温退火工艺优化[J],机械工人,2001
[45]董秦铮,齿轮热处理变形的讨论[J],汽车工艺与材料,1996
[46]刘建明,汽车齿轮渗碳淬火热处理异常变形的研究[J],机械工人,2005
[47]孙捷,汽车后桥齿轮热处理翘曲变形的分析及控制[J],现代机械,1997
[48]陈振,渗碳钢齿轮热处理变形及预防[J],现代制造工程,2003
[49]程健康,渗碳齿轮畸变控制与修正措施[J],金属热处理,2002
[50]任凤章,解决渗碳齿轮热处理变形方法的试验[C],全国齿轮热处理变形控制技术研讨会论文集,1994.11
[51]孙美英,影响热处理变形的主要因素[J],机械设计与制造工程,1999