齒輪
- 聯系人：陳先生
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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(lun)(lun)軸(zhou)工(gong)(gong)(gong)藝設計(ji)說明書(shu) 一、分析零(ling)件(jian)(jian)(jian)圖(tu)(tu)（如圖(tu)(tu)） 1、零(ling)件(jian)(jian)(jian)名(ming)稱：齒(chi)輪(lun)(lun)軸(zhou)； 2、材料：40Cr； 3、質量(liang)：17.38kg； 4、產(chan)量(liang)：100件(jian)(jian)(jian)； 5、技術要求(qiu)： 1）調(diao)質處理28-32HRC。 6、齒(chi)輪(lun)(lun)基本參數： 1）m=4; β=9°22′（左旋）; 2）z=33, 精度等(deng)級887FH； 3）α=20°。 二、鍛(duan)(duan)(duan)造(zao)工(gong)(gong)(gong)藝性(xing)(xing)分析 1、加(jia)工(gong)(gong)(gong)目(mu)的(de)(de)、環境及鍛(duan)(duan)(duan)后(hou)現象分析 零(ling)件(jian)(jian)(jian)為(wei)軸(zhou)類零(ling)件(jian)(jian)(jian)，因(yin)此(ci)鍛(duan)(duan)(duan)造(zao)的(de)(de)目(mu)的(de)(de)不是(shi)側(ce)(ce)重于成形、減少加(jia)工(gong)(gong)(gong)余量(liang)，而是(shi)側(ce)(ce)重于提高鍛(duan)(duan)(duan)件(jian)(jian)(jian)的(de)(de)力學性(xing)(xing)能(neng)(neng)(neng)。結合現代(dai)工(gong)(gong)(gong)廠(chang)設備、技術力量(liang)和加(jia)工(gong)(gong)(gong)能(neng)(neng)(neng)力，選用(yong)自(zi)由(you)手工(gong)(gong)(gong)鍛(duan)(duan)(duan)造(zao)。鍛(duan)(duan)(duan)后(hou)零(ling)件(jian)(jian)(jian)性(xing)(xing)能(neng)(neng)(neng)可能(neng)(neng)(neng)變化的(de)(de)趨勢有坯(pi)料端部(bu)彎(wan)曲并帶毛刺和脫碳等(deng)。 2、零(ling)件(jian)(jian)(jian)結構(gou)(gou)形狀對鍛(duan)(duan)(duan)造(zao)適應性(xing)(xing)的(de)(de)分析 即鍛(duan)(duan)(duan)件(jian)(jian)(jian)結構(gou)(gou)工(gong)(gong)(gong)藝性(xing)(xing)分析。該零(ling)件(jian)(jian)(jian)為(wei)簡單(dan)的(de)(de)階梯軸(zhou)類零(ling)件(jian)(jian)(jian)，可通(tong)過手工(gong)(gong)(gong)自(zi)由(you)鍛(duan)(duan)(duan)造(zao)來(lai)完成初步成型(xing)。因(yin)鍛(duan)(duan)(duan)造(zao)而產(chan)生的(de)(de)缺陷可以通(tong)過鍛(duan)(duan)(duan)造(zao)后(hou)的(de)(de)熱處理和切削加(jia)工(gong)(gong)(gong)來(lai)改善(shan)。 三、繪(hui)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)根據零(ling)件(jian)(jian)(jian)圖(tu)(tu)繪(hui)制(zhi)的(de)(de)。自(zi)由(you)鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu)是(shi)在(zai)零(ling)件(jian)(jian)(jian)圖(tu)(tu)的(de)(de)基礎上(shang)(shang)考慮了加(jia)工(gong)(gong)(gong)余量(liang)、鍛(duan)(duan)(duan)造(zao)公(gong)差、工(gong)(gong)(gong)藝余塊等(deng)參數后(hou)繪(hui)制(zhi)而成的(de)(de)。根據以下(xia)步驟(zou)繪(hui)制(zhi)鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu)（如下(xia)頁(ye)圖(tu)(tu)）： （1）確定鍛(duan)(duan)(duan)件(jian)(jian)(jian)形狀。 （2）用(yong)紅線繪(hui)出鍛(duan)(duan)(duan)件(jian)(jian)(jian)圖(tu)(tu)。 （3）計(ji)算尺寸，查公(gong)差并注于圖(tu)(tu)上(shang)(shang)。
四(si)(si)、參數(shu)選(xuan)擇(ze) 1、工(gong)(gong)(gong)藝(yi)參數(shu) 首先選(xuan)擇(ze)工(gong)(gong)(gong)藝(yi)余(yu)塊以簡化(hua)(hua)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)外形(xing)(xing)(xing)，然后(hou)確(que)定(ding)加工(gong)(gong)(gong)余(yu)量(liang)(liang)(liang)(liang)和(he)(he)公(gong)(gong)差。 2、選(xuan)擇(ze)依據(ju) 選(xuan)擇(ze)參數(shu)應(ying)考慮鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)材(cai)料(liao)(liao)(liao)(liao)、形(xing)(xing)(xing)狀(zhuang)尺(chi)(chi)(chi)寸、現有設備、生產(chan)批量(liang)(liang)(liang)(liang)等(deng)因素(su)。 3、確(que)定(ding)方法 查(cha)有關(guan)標準進行(xing)分(fen)析，并與同類件(jian)(jian)(jian)(jian)(jian)比較，選(xuan)擇(ze)的(de)(de)(de)(de)(de)(de)公(gong)(gong)差余(yu)量(liang)(liang)(liang)(liang)可依下(xia)列條件(jian)(jian)(jian)(jian)(jian)確(que)定(ding)： （1）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)數(shu)量(liang)(liang)(liang)(liang)。數(shu)量(liang)(liang)(liang)(liang)多(duo)，其(qi)(qi)值(zhi)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)小(xiao)(xiao)(xiao)些(xie)(xie)(xie)(xie)，否(fou)則(ze)(ze)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)大(da)些(xie)(xie)(xie)(xie)。 （2）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)材(cai)料(liao)(liao)(liao)(liao)。一(yi)(yi)般材(cai)料(liao)(liao)(liao)(liao)其(qi)(qi)值(zhi)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)小(xiao)(xiao)(xiao)些(xie)(xie)(xie)(xie)，特殊鋼(gang)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)大(da)些(xie)(xie)(xie)(xie)。 （3）表(biao)面質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)。原材(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)(de)(de)(de)表(biao)面質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)好，其(qi)(qi)值(zhi)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)小(xiao)(xiao)(xiao)些(xie)(xie)(xie)(xie)，否(fou)則(ze)(ze)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)大(da)些(xie)(xie)(xie)(xie)。 （4）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)形(xing)(xing)(xing)狀(zhuang)尺(chi)(chi)(chi)寸。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)形(xing)(xing)(xing)狀(zhuang)簡單，長度短，其(qi)(qi)值(zhi)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)小(xiao)(xiao)(xiao)些(xie)(xie)(xie)(xie)，否(fou)則(ze)(ze)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)大(da)些(xie)(xie)(xie)(xie)。 （5）鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)(gong)(gong)技術水平。鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)工(gong)(gong)(gong)技術水平高，其(qi)(qi)值(zhi)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)小(xiao)(xiao)(xiao)些(xie)(xie)(xie)(xie)，否(fou)則(ze)(ze)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)大(da)些(xie)(xie)(xie)(xie)。 （6）工(gong)(gong)(gong)具(ju)和(he)(he)設備情況、企業(ye)工(gong)(gong)(gong)藝(yi)習慣(guan)等(deng)其(qi)(qi)它(ta)因素(su)。 4、數(shu)據(ju)處(chu)理 對于(yu)大(da)型鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)尾數(shu)圓整為(wei)5或0；中(zhong)(zhong)小(xiao)(xiao)(xiao)型鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)按(an)四(si)(si)舍五(wu)入原則(ze)(ze)處(chu)理成整數(shu)。最(zui)后(hou)確(que)定(ding)的(de)(de)(de)(de)(de)(de)工(gong)(gong)(gong)藝(yi)參數(shu)如鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)圖所(suo)示。 五(wu)、確(que)定(ding)坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)和(he)(he)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)尺(chi)(chi)(chi)寸 1、確(que)定(ding)坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)包(bao)括鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)本身的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)、加熱時(shi)氧化(hua)(hua)燒(shao)(shao)損(sun)、切(qie)(qie)(qie)頭(tou)時(shi)的(de)(de)(de)(de)(de)(de)損(sun)失及(ji)沖(chong)(chong)孔(kong)(kong)時(shi)的(de)(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)(liao)損(sun)失等(deng)。 (1) 計(ji)(ji)(ji)算鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang) 根據(ju)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)形(xing)(xing)(xing)狀(zhuang)和(he)(he)基(ji)本尺(chi)(chi)(chi)寸，可計(ji)(ji)(ji)算出鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)： m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV 式中(zhong)(zhong) m鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)； p—鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)材(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)(de)(de)(de)密度（ kg/dm3 ）取(qu)(qu)(qu)(qu)(qu)(qu)(qu)7.85kg /dm3 ； V —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)體積（ dm3 ）； 由此(ci)計(ji)(ji)(ji)算得：m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝ pV = 7.85 kg /dm3×3.498 dm3 = 27.46 kg (2) 計(ji)(ji)(ji)算坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang) 坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)包(bao)括鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)本身的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)、加熱時(shi)氧化(hua)(hua)燒(shao)(shao)損(sun)、切(qie)(qie)(qie)頭(tou)時(shi)的(de)(de)(de)(de)(de)(de)損(sun)失及(ji)沖(chong)(chong)孔(kong)(kong)時(shi)的(de)(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)(liao)損(sun)失等(deng)。其(qi)(qi)計(ji)(ji)(ji)算公(gong)(gong)式為(wei)： m 坯(pi)(pi)(pi)(pi) ＝ m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) ＋ m 燒(shao)(shao) ＋ m 切(qie)(qie)(qie) ＋ m 芯(xin) 式中(zhong)(zhong) m 坯(pi)(pi)(pi)(pi) —坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)（ kg ）； m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) —鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)（ kg ）； m 燒(shao)(shao)—氧化(hua)(hua)燒(shao)(shao)損(sun)的(de)(de)(de)(de)(de)(de)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)（ kg ）， m 切(qie)(qie)(qie)—表(biao)示對拔(ba)長工(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)切(qie)(qie)(qie)頭(tou)損(sun)失（ kg ）； m 芯(xin)—沖(chong)(chong)孔(kong)(kong)時(shi)沖(chong)(chong)掉的(de)(de)(de)(de)(de)(de)芯(xin)料(liao)(liao)(liao)(liao)損(sun)失（ kg ）； m 燒(shao)(shao)一(yi)(yi)般按(an)火(huo)次進行(xing)估(gu)算，如第一(yi)(yi)火(huo)取(qu)(qu)(qu)(qu)(qu)(qu)(qu)鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)質(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)(zhi)量(liang)(liang)(liang)(liang)的(de)(de)(de)(de)(de)(de) 2.0% ～ 3.0% ，以后(hou)各火(huo)一(yi)(yi)般取(qu)(qu)(qu)(qu)(qu)(qu)(qu) 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)(jian)(jian)質(zhi)(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)(qie)一(yi)(yi)般按(an)下(xia)面經驗公(gong)(gong)式估(gu)算：對于(yu)該零(ling)(ling)件(jian)(jian)(jian)(jian)(jian)圓形(xing)(xing)(xing)截(jie)面 m 切(qie)(qie)(qie)＝1.81 ，其(qi)(qi)中(zhong)(zhong)D 為(wei)切(qie)(qie)(qie)頭(tou)部分(fen)直徑（ dm ）；零(ling)(ling)件(jian)(jian)(jian)(jian)(jian)沒有沖(chong)(chong)孔(kong)(kong)，故， m 芯(xin)= 0kg。 所(suo)以，m 坯(pi)(pi)(pi)(pi) ＝ m 鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan) ＋ m 燒(shao)(shao) ＋ m 切(qie)(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)(pi)料(liao)(liao)(liao)(liao)尺(chi)(chi)(chi)寸 坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)尺(chi)(chi)(chi)寸的(de)(de)(de)(de)(de)(de)確(que)定(ding)與所(suo)采(cai)用(yong)的(de)(de)(de)(de)(de)(de)第一(yi)(yi)道基(ji)本工(gong)(gong)(gong)序(xu)（鐓(dui)粗(cu)或拔(ba)長）有關(guan)，所(suo)采(cai)用(yong)的(de)(de)(de)(de)(de)(de)工(gong)(gong)(gong)序(xu)不同，確(que)定(ding)的(de)(de)(de)(de)(de)(de)方法也不一(yi)(yi)樣。 此(ci)零(ling)(ling)件(jian)(jian)(jian)(jian)(jian)中(zhong)(zhong)間部分(fen)采(cai)用(yong)鐓(dui)粗(cu)法鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)制，對于(yu)鋼(gang)坯(pi)(pi)(pi)(pi)，為(wei)避免(mian)鐓(dui)粗(cu)時(shi)坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)產(chan)生 彎(wan)曲，坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)高度H與其(qi)(qi)直徑D之比應(ying)滿(man)足鐓(dui)粗(cu)規則(ze)(ze)，即 1.25≤H/D≤2.5 對于(yu)此(ci)零(ling)(ling)件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)圓坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao) ,D坯(pi)(pi)(pi)(pi)＝（0.8～1）D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan),取(qu)(qu)(qu)(qu)(qu)(qu)(qu)D坯(pi)(pi)(pi)(pi)＝0.8 D鍛(duan)(duan)(duan)(duan)(duan)(duan)(duan)(duan)＝0.8*150mm＝120mm 由此(ci)，可求出坯(pi)(pi)(pi)(pi)料(liao)(liao)(liao)(liao)高度H坯(pi)(pi)(pi)(pi)。
