With the emergence of new technologies, the processing technology of parts requires higher efficiency, higher quality and higher accuracy. Therefore, it is difficult for typical mechanical processing technology to meet the new process requirements, especially for the emergence of new energy machinery and equipment to bring new challenges to mechanical processing, which requires the research of some new high-precision processing technology to improve the quality of mechanical processing to a new level.
Hard tooth surface processing technology
The processing technology proposed by this technology is mainly aimed at gears with high requirements for gear processing. Generally, it refers to the gear with large tooth surface hardness obtained after the first heat treatment, that is, the gear with hardness value exceeding 45HRC and high accuracy requirements. It is mainly used in gear shaving, gear grinding, gear honing and other finishing processes. This technology can obtain gears with better performance, but it also has high requirements for the equipment, tools and fixtures used. In the era of continuous technological innovation, new materials and equipment gradually appear in mechanical processing, especially in the enhancement of tool performance, processing efficiency and processing accuracy, making the hard tooth surface processing technology more widely used. This technology uses a new type of tool coated with protective coating in the process of gear hobbing, which reduces the wear and replacement of the tool and reduces the processing cost; In the process of gear grinding, CBN grinding wheel with good performance is selected as the grinding tool, which has a significant effect on improving the surface roughness and precision of the gear. CBN grinding wheel grinding process: the grinding tool reduces the processing procedures and improves the processing efficiency by combining the rough and finish grinding tools. Gear hobbing with hard tooth surface processing technology keeps the gear accuracy at the level of IT5. The gear shaving process with superhard cutter not only reduces the surface roughness, but also improves the gear accuracy by 2 levels, and the processing efficiency reaches 10 times of the original increase. It can be seen that the machining quality of gears has been greatly improved by hard tooth surface machining technology, which can meet the high requirements for the quality of parts in the future.
Powerful honing technology
In the process of gear finishing, it is often necessary to achieve high accuracy, while the typical gear hobbing and shaving can not meet the requirements of high-precision machining, so a new process technology is needed to process the gear. The powerful honing technology is a process of fine machining the tooth surface after grinding. Compared with the ordinary honing process, it can reduce the processing cost and improve the honing efficiency. From the actual processing situation, when the processing cost is about the same as that of ordinary honing, in order to obtain high-precision, high-efficiency and high-quality processed products, the powerful honing technology can be used for processing, further increasing economic benefits. Generally, the tooth profile and direction correction of the gear machined by powerful honing is greater than 0.05mm, which can well correct the heat treatment deformation and micro defects, and the surface roughness can reach Ra0.2 μ m。 The advantages of powerful honing technology mainly include:
(1) It can well deal with the grain defects generated after gear grinding, and reduce the vibration and noise of the gear in the transmission process.
(2) In the process of material removal, the cutting speed is not as fast as gear grinding, and there will be no surface burn caused by high-speed cutting.
(3) The strong honing process will produce large residual compressive stress on the gear surface, further improving the hardness, corrosion resistance and wear resistance of the gear, and comprehensively improving the mechanical properties.
(4) Powerful honing technology can process some gears with special structure, such as gears with shoulder, which has a wide range of processing for gear grinding.
(5) The gear precision obtained by powerful honing is equivalent to that of gear grinding, but it can greatly reduce the manufacturing cost and improve the machining efficiency. The powerful honing technology is most suitable for the machining of high-precision gears. At the same time, it can further improve the stability of gear power transmission and increase the service life of gear, which is a new and high technology worth promoting.
The processing technology of gears is the key to mechanical manufacturing, because good technology can always produce high-quality products. In terms of ensuring the quality of gears, relevant personnel should strictly control every detail of the processing and improve the qualification rate of gear processing. In addition, according to the new requirements of the development of the manufacturing industry in the new era, we should continue to innovate, introduce advanced processes and technologies into the processing and manufacturing, and constantly optimize and improve the process technology of the manufacturing industry, so as to upgrade the gear machining process to a new level. Finally, we should not abandon the traditional process technology, but combine the traditional typical process with the new technology technology to produce a higher quality gear without increasing the processing cost.