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齒(chi)輪(lun)軸(zhou)(zhou)工(gong)(gong)(gong)(gong)藝(yi)設計說明書 一、分析零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)圖(tu)（如圖(tu)） 1、零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)名稱(cheng)：齒(chi)輪(lun)軸(zhou)(zhou)； 2、材料：40Cr； 3、質量(liang)：17.38kg； 4、產量(liang)：100件(jian)(jian)(jian)(jian)； 5、技(ji)術要求(qiu)： 1）調質處理28-32HRC。 6、齒(chi)輪(lun)基本參數(shu)： 1）m=4; β=9°22′（左(zuo)旋）; 2）z=33, 精(jing)度(du)等(deng)級887FH； 3）α=20°。 二、鍛(duan)(duan)(duan)(duan)造(zao)工(gong)(gong)(gong)(gong)藝(yi)性(xing)(xing)分析 1、加(jia)工(gong)(gong)(gong)(gong)目的(de)(de)(de)、環境及鍛(duan)(duan)(duan)(duan)后現象分析 零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)為(wei)軸(zhou)(zhou)類零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)，因此鍛(duan)(duan)(duan)(duan)造(zao)的(de)(de)(de)目的(de)(de)(de)不是(shi)側重于成(cheng)形(xing)、減少加(jia)工(gong)(gong)(gong)(gong)余量(liang)，而是(shi)側重于提高鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)的(de)(de)(de)力(li)學性(xing)(xing)能。結(jie)合現代工(gong)(gong)(gong)(gong)廠設備、技(ji)術力(li)量(liang)和加(jia)工(gong)(gong)(gong)(gong)能力(li)，選(xuan)用自(zi)由(you)手(shou)工(gong)(gong)(gong)(gong)鍛(duan)(duan)(duan)(duan)造(zao)。鍛(duan)(duan)(duan)(duan)后零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)性(xing)(xing)能可能變化的(de)(de)(de)趨勢有坯料端部彎(wan)曲并帶毛刺和脫碳等(deng)。 2、零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)結(jie)構形(xing)狀(zhuang)對鍛(duan)(duan)(duan)(duan)造(zao)適應(ying)性(xing)(xing)的(de)(de)(de)分析 即鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)結(jie)構工(gong)(gong)(gong)(gong)藝(yi)性(xing)(xing)分析。該零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)為(wei)簡單的(de)(de)(de)階梯軸(zhou)(zhou)類零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)，可通過手(shou)工(gong)(gong)(gong)(gong)自(zi)由(you)鍛(duan)(duan)(duan)(duan)造(zao)來完成(cheng)初步成(cheng)型。因鍛(duan)(duan)(duan)(duan)造(zao)而產生的(de)(de)(de)缺(que)陷可以通過鍛(duan)(duan)(duan)(duan)造(zao)后的(de)(de)(de)熱處理和切(qie)削加(jia)工(gong)(gong)(gong)(gong)來改善。 三、繪(hui)制(zhi)(zhi)鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)圖(tu) ;鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)圖(tu)是(shi)根(gen)據零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)圖(tu)繪(hui)制(zhi)(zhi)的(de)(de)(de)。自(zi)由(you)鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)圖(tu)是(shi)在(zai)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)圖(tu)的(de)(de)(de)基礎(chu)上考慮了加(jia)工(gong)(gong)(gong)(gong)余量(liang)、鍛(duan)(duan)(duan)(duan)造(zao)公(gong)差、工(gong)(gong)(gong)(gong)藝(yi)余塊等(deng)參數(shu)后繪(hui)制(zhi)(zhi)而成(cheng)的(de)(de)(de)。根(gen)據以下(xia)步驟繪(hui)制(zhi)(zhi)鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)圖(tu)（如下(xia)頁圖(tu)）： （1）確定鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)形(xing)狀(zhuang)。 （2）用紅(hong)線(xian)繪(hui)出(chu)鍛(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)圖(tu)。 （3）計算尺寸，查公(gong)差并注于圖(tu)上。
四(si)、參(can)(can)數(shu)選(xuan)(xuan)擇(ze) 1、工(gong)(gong)藝(yi)參(can)(can)數(shu) 首先選(xuan)(xuan)擇(ze)工(gong)(gong)藝(yi)余塊以簡(jian)(jian)化(hua)(hua)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)外形(xing)，然后(hou)確(que)(que)定(ding)(ding)(ding)加工(gong)(gong)余量(liang)(liang)(liang)和(he)公(gong)(gong)差。 2、選(xuan)(xuan)擇(ze)依據(ju) 選(xuan)(xuan)擇(ze)參(can)(can)數(shu)應考(kao)慮鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)材料(liao)、形(xing)狀(zhuang)尺(chi)(chi)寸(cun)(cun)、現有設(she)備(bei)、生產批量(liang)(liang)(liang)等(deng)因素(su)。 3、確(que)(que)定(ding)(ding)(ding)方(fang)法(fa)(fa) 查有關(guan)(guan)標準進行(xing)分(fen)析，并與(yu)(yu)同(tong)類件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)比較，選(xuan)(xuan)擇(ze)的(de)(de)(de)公(gong)(gong)差余量(liang)(liang)(liang)可(ke)(ke)依下(xia)列條件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)確(que)(que)定(ding)(ding)(ding)： （1）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)數(shu)量(liang)(liang)(liang)。數(shu)量(liang)(liang)(liang)多，其(qi)值(zhi)(zhi)取(qu)(qu)小(xiao)(xiao)(xiao)(xiao)些，否(fou)則取(qu)(qu)大(da)(da)些。 （2）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)材料(liao)。一(yi)般材料(liao)其(qi)值(zhi)(zhi)取(qu)(qu)小(xiao)(xiao)(xiao)(xiao)些，特(te)殊鋼(gang)取(qu)(qu)大(da)(da)些。 （3）表(biao)(biao)(biao)面質(zhi)(zhi)量(liang)(liang)(liang)。原(yuan)材料(liao)的(de)(de)(de)表(biao)(biao)(biao)面質(zhi)(zhi)量(liang)(liang)(liang)好，其(qi)值(zhi)(zhi)取(qu)(qu)小(xiao)(xiao)(xiao)(xiao)些，否(fou)則取(qu)(qu)大(da)(da)些。 （4）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)形(xing)狀(zhuang)尺(chi)(chi)寸(cun)(cun)。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)形(xing)狀(zhuang)簡(jian)(jian)單，長(chang)度短，其(qi)值(zhi)(zhi)取(qu)(qu)小(xiao)(xiao)(xiao)(xiao)些，否(fou)則取(qu)(qu)大(da)(da)些。 （5）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)(gong)技(ji)術水平。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)(gong)技(ji)術水平高，其(qi)值(zhi)(zhi)取(qu)(qu)小(xiao)(xiao)(xiao)(xiao)些，否(fou)則取(qu)(qu)大(da)(da)些。 （6）工(gong)(gong)具和(he)設(she)備(bei)情況、企業工(gong)(gong)藝(yi)習慣等(deng)其(qi)它因素(su)。 4、數(shu)據(ju)處理 對(dui)于大(da)(da)型鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)尾數(shu)圓(yuan)整為5或0；中(zhong)小(xiao)(xiao)(xiao)(xiao)型鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)按四(si)舍五入(ru)原(yuan)則處理成整數(shu)。最后(hou)確(que)(que)定(ding)(ding)(ding)的(de)(de)(de)工(gong)(gong)藝(yi)參(can)(can)數(shu)如(ru)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)圖所(suo)(suo)示。 五、確(que)(que)定(ding)(ding)(ding)坯(pi)(pi)(pi)(pi)料(liao)質(zhi)(zhi)量(liang)(liang)(liang)和(he)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)尺(chi)(chi)寸(cun)(cun) 1、確(que)(que)定(ding)(ding)(ding)坯(pi)(pi)(pi)(pi)料(liao)質(zhi)(zhi)量(liang)(liang)(liang)坯(pi)(pi)(pi)(pi)料(liao)質(zhi)(zhi)量(liang)(liang)(liang)包括鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)本(ben)身(shen)的(de)(de)(de)質(zhi)(zhi)量(liang)(liang)(liang)、加熱時氧化(hua)(hua)燒(shao)損(sun)、切(qie)頭(tou)時的(de)(de)(de)損(sun)失(shi)(shi)(shi)及(ji)沖(chong)孔時的(de)(de)(de)芯(xin)(xin)料(liao)損(sun)失(shi)(shi)(shi)等(deng)。 (1) 計(ji)算鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)量(liang)(liang)(liang) 根據(ju)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)形(xing)狀(zhuang)和(he)基本(ben)尺(chi)(chi)寸(cun)(cun)，可(ke)(ke)計(ji)算出(chu)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)質(zhi)(zhi)量(liang)(liang)(liang)： m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV 式中(zhong) m鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)量(liang)(liang)(liang)； p—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)材料(liao)的(de)(de)(de)密度（ kg/dm3 ）取(qu)(qu)7.85kg /dm3 ； V —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)體(ti)積（ dm3 ）； 由此計(ji)算得：m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV = 7.85 kg /dm3×3.498 dm3 = 27.46 kg (2) 計(ji)算坯(pi)(pi)(pi)(pi)料(liao)質(zhi)(zhi)量(liang)(liang)(liang) 坯(pi)(pi)(pi)(pi)料(liao)的(de)(de)(de)質(zhi)(zhi)量(liang)(liang)(liang)包括鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)本(ben)身(shen)的(de)(de)(de)質(zhi)(zhi)量(liang)(liang)(liang)、加熱時氧化(hua)(hua)燒(shao)損(sun)、切(qie)頭(tou)時的(de)(de)(de)損(sun)失(shi)(shi)(shi)及(ji)沖(chong)孔時的(de)(de)(de)芯(xin)(xin)料(liao)損(sun)失(shi)(shi)(shi)等(deng)。其(qi)計(ji)算公(gong)(gong)式為： m 坯(pi)(pi)(pi)(pi) ＝ m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) ＋ m 燒(shao) ＋ m 切(qie) ＋ m 芯(xin)(xin) 式中(zhong) m 坯(pi)(pi)(pi)(pi) —坯(pi)(pi)(pi)(pi)料(liao)質(zhi)(zhi)量(liang)(liang)(liang)（ kg ）； m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)量(liang)(liang)(liang)（ kg ）； m 燒(shao)—氧化(hua)(hua)燒(shao)損(sun)的(de)(de)(de)質(zhi)(zhi)量(liang)(liang)(liang)（ kg ）， m 切(qie)—表(biao)(biao)(biao)示對(dui)拔長(chang)工(gong)(gong)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)切(qie)頭(tou)損(sun)失(shi)(shi)(shi)（ kg ）； m 芯(xin)(xin)—沖(chong)孔時沖(chong)掉的(de)(de)(de)芯(xin)(xin)料(liao)損(sun)失(shi)(shi)(shi)（ kg ）； m 燒(shao)一(yi)般按火(huo)次進行(xing)估算，如(ru)第一(yi)火(huo)取(qu)(qu)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)量(liang)(liang)(liang)的(de)(de)(de) 2.0% ～ 3.0% ，以后(hou)各火(huo)一(yi)般取(qu)(qu) 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)量(liang)(liang)(liang)的(de)(de)(de) 1.5% ～ 2.0% ；m 切(qie)一(yi)般按下(xia)面經(jing)驗公(gong)(gong)式估算：對(dui)于該零件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)圓(yuan)形(xing)截面 m 切(qie)＝1.81 ，其(qi)中(zhong)D 為切(qie)頭(tou)部分(fen)直徑(jing)（ dm ）；零件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)沒有沖(chong)孔，故， m 芯(xin)(xin)= 0kg。 所(suo)(suo)以，m 坯(pi)(pi)(pi)(pi) ＝ m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) ＋ m 燒(shao) ＋ m 切(qie) ＋ m 芯(xin)(xin)＝27.46×（1+1.5%）+1.81×0.873 ＝28.60(kg) 2、確(que)(que)定(ding)(ding)(ding)坯(pi)(pi)(pi)(pi)料(liao)尺(chi)(chi)寸(cun)(cun) 坯(pi)(pi)(pi)(pi)料(liao)尺(chi)(chi)寸(cun)(cun)的(de)(de)(de)確(que)(que)定(ding)(ding)(ding)與(yu)(yu)所(suo)(suo)采用(yong)(yong)的(de)(de)(de)第一(yi)道基本(ben)工(gong)(gong)序(xu)（鐓(dui)粗(cu)(cu)或拔長(chang)）有關(guan)(guan)，所(suo)(suo)采用(yong)(yong)的(de)(de)(de)工(gong)(gong)序(xu)不(bu)同(tong)，確(que)(que)定(ding)(ding)(ding)的(de)(de)(de)方(fang)法(fa)(fa)也不(bu)一(yi)樣。 此零件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)中(zhong)間(jian)部分(fen)采用(yong)(yong)鐓(dui)粗(cu)(cu)法(fa)(fa)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)制，對(dui)于鋼(gang)坯(pi)(pi)(pi)(pi)，為避免鐓(dui)粗(cu)(cu)時坯(pi)(pi)(pi)(pi)料(liao)產生 彎曲，坯(pi)(pi)(pi)(pi)料(liao)高度H與(yu)(yu)其(qi)直徑(jing)D之比應滿足鐓(dui)粗(cu)(cu)規則，即(ji) 1.25≤H/D≤2.5 對(dui)于此零件(jian)(jian)(jian)(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)圓(yuan)坯(pi)(pi)(pi)(pi)料(liao) ,D坯(pi)(pi)(pi)(pi)＝（0.8～1）D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan),取(qu)(qu)D坯(pi)(pi)(pi)(pi)＝0.8 D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝0.8*150mm＝120mm 由此，可(ke)(ke)求出(chu)坯(pi)(pi)(pi)(pi)料(liao)高度H坯(pi)(pi)(pi)(pi)，
