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1、,Janne Vuola,Konecranes Standard Lifting Oy Gear Training 齿轮知识培训,Gear Training,Agenda: 课程 Piece of theory 齿 轮 理 论 知 识 Manufacturing technology 齿 轮 制 造 技 术 ,Gear Training Gear types,Bevel gears 锥齿轮（伞齿轮） Spur gear (Ext., Int.) 圆柱齿轮 Worm gears 蜗轮 Rack and pinion 齿轮齿条 ,description of teeth 齿部名称描述 tooth
2、trace root line tip surface flank 啮合线 齿根线 齿顶面 齿腹 tip trace 顶棱 齿顶圆 Tip circle Addendum flank 上（顶）腹 dedendum flank 下(根) 腹 Root surface Bottom surface Root circle Reference circle 齿根面 齿底面 齿根圆 分度圆,Gear Training Terminology,Gear Training Terminology,module m = reference diameter d / number of teeth z 模数=
3、分度圆直径/齿数 Or 或 m = pitch P / 模数=齿距/圆周率 pitch P = d/z 齿距=圆周率X分度圆直径/齿数,Gear Training Terminology,Anglo-American countries uses DP (diametral pitch) 英制单位 DP (法向齿距) 换算: DP = 25,4/P = 25,4 / m,Gear Training Involute gear,Involute curve,most popular gear type 最常用的齿形 Gear flank surface is involute shaped 齿腹
4、为渐开线齿形 渐开线 Basic circle 基 圆 ,Pressure angle 压力角 Normally 20 deg. In Konecranes gears 科尼齿轮通常为20度。,Gear Training Terminology,protuberance (pp) used when work allowance (p) needed,Gear Training Terminology,Gear Training Terminology,Addendum modification 齿顶高变位 =xm, in mm =变位系数乘以模数 单位 mm Used to avoid un
5、dercut with small Z gears 变位用来避免由于最少齿数产生的根切现象 Can also be used to adjust center distance of gear pair 也可以用于调整齿轮副中心距 da will increase with small z, therefore big counter gear da need to be decreased to keep the center distance same 变位还可以减少由于大质数齿数产生的齿顶高增加 现象，从而保证中心距。,Manufacturing methods for cylindri
6、cal gears 圆柱齿轮加工方法,Gear Training Manufacturing technology,Soft machining 软齿面加工,cutting with geometrically determined tools 展成法加工,forming methods 仿形法,Hobbing 滚齿,Gear shaping插齿,Shaving 剃齿,Forging精锻,Pressing,Rolling 热轧齿,Broaching 拉齿,Profile cutting齿,Form shaping 挤齿,Casting铸齿,Sintering 粉末烧结,Precision cu
7、tting 铣齿,Heat treatment 热处理,Hard finishing 硬齿面加工,cutting with geometrically determined tools,cutting with geom. undetermined tools,Skiving (hard hobbing) 硬质合金滚刮加工,Geargrinding 磨齿,Honing 珩磨齿,Profile grinding,Lapping 对滚,Hard broaching 拉刮齿,Quality classes used for different purpose 各类机械传动所应用的齿轮精度等级,Gea
8、r Training Manufacturing technology,Usage 应用场合,Quality class,1,2,3,4,5,6,7,8,9,10,11,12,Measuring devices 测量仪器用齿轮,Automotive 汽车传动齿轮,Machine tools 机床及工具齿轮,Aircrafts 航 空 齿 轮,Precisio instruments 精密仪器用齿轮,Marine, pumps, buses, trucks 船用，泵阀用，载重汽车类齿轮,Locomotives, other rail vehicles 火车，轨道列车用齿轮,Printing ma
9、chines, paper machines, rubber industrial machines, rolling mills 打印机，造纸机，橡胶设备，磨粉机齿轮,Machines in Chemical industry, tractors, construction machines 化工机械，拖拉机，建筑机械用齿轮,Textile industry machines 纺织机械用齿轮,Lifting and transporting devices 起重及传送机械用齿轮,Cement industry machines, wood and pulp industry 水泥工业机械，木
10、材及纸浆机械齿轮,Achievable quality classes by different methods for typical cylindrical gears used by KC 圆柱齿轮不同加工工艺所能达到的精度等级 Hobbing, finished without hardening 7-8 滚齿作为齿轮终加工 7-8 级 Hobbing, hardened, no finishing after heat treatment 8-10滚齿后通过热处理使齿面硬化 后 达到810级。 Hobbed and shaved, hardened 8-9 滚齿，剃齿后表面硬化 达到
11、89级 Hobbed, hardened, skived (hard hobbing) 7 滚齿，齿面硬化，滚刮加工后 达到7级 Hobbed, hardened, ground or honed 3-6 滚齿，齿面硬化，磨齿或珩磨齿后可达到36级 滚 齿 刀 和 插 齿 刀 剃 齿 刀 珩 磨 轮,Gear Training Manufacturing technology,Gear Training Manufacturing technology 齿 轮 加 工 技 术,Gearwheel blank turning 盘类齿轮坯车削加工 Important issues 重要问题 Mac
12、hine all around - two clamping required 全部加工需要两次装夹。 Other side and bore are finished in OP20 另一面和镗孔加工一次完成。 This side must be known in later phases! 此面在下道工序中必须能被识别。 Bore diameter is affecting to runout of teeth 孔公差将影响齿轮的跳动。 Gearshaft blank turning 齿轮轴毛坯车削加工 Important issues 重要问题 Quality and position
13、for centerholes are critical for gear characteristics 轴两端中心孔将对齿轮特性产生重大影响。 Shaft lenght and end straightness are important because of clamping in later phases 轴的长度和直线度将影响后道工序的装夹。 Neither one of these have specification in drawings 上述两项图纸中一般不做特别说明。,Gear Training Manufacturing technology,Gearwheel hobb
14、ing盘类齿轮滚齿 Clamping for the ”known” side (bore perpendicular for side) towards work-piece spindle 与孔一次加工的齿坯面在装夹时朝下穿过工装心轴与滚齿工装基准面贴合。 Runout of tool and work-piece fixture important 滚刀的旋转跳动以及工件装夹非常重要 Quality of tool 滚刀质量,Gear Training Manufacturing technology,Gearshaft hobbing齿轮轴滚削加工 Small gearshafts (
15、typically in STD) are clamped between centers. Rotation generated by facedriver 小齿轮轴靠机床两顶尖顶紧并带动旋转。 If end is not straight clamping force will bend the shaft affectingt to quality 如果轴不直，则顶紧时会使轴弯曲从而影响齿部质量。 If center bores are not ok extensive runout will occur 如果轴两端中心孔不再同一轴线上，则会产生很大的跳动。 Quality for fr
16、ee-end center point is also critical - often reason for runout problems 浮动顶尖质量非常重要，这也是跳动产生的原因。 Quality of tool 滚刀质量。,Hardening,Case hardening is applicable for low carbon steel and alloy steel. Surface hardness can be 58-62 HRC. Typically depth of the hardening is 0.2 - 3.0mm. High surface hardness
17、gives a good wearing resistance and together with tough interior it gives excellent fatigue resistance. Normally used with gearwheel and pinions. 表面硬化适用于低碳钢及低碳合金钢。表面硬度能够达到HRC 58-62 。硬化层深度一般0.2 - 3.0mm，齿面的高硬度提高了抗磨损能力，心部良好的韧性非常有利于抗疲劳。 Induction hardening is a local hardening method. Work piece surface
18、 is heated up fast with high-frequency electric. Locally hardness depth can be 0.1 - 4.0mm. Mostly used with tool steels. 感应淬硬 是一种局部硬化方法。工件表面在高频感应下迅速被加热。局部硬化层深度可达到0.1 - 4.0mm， 通常此方法用于工具钢材料。 Nitroc hardening is normally used for non-alloy and tempering steel. Nitroc process gives a hard and wearing r
19、esistance surface. Compound layer is normally 5-20m and the diffusion layer is 0.1-0.6mm. 表面渗氮 通常用于非合金结构钢及回火钢. 表面渗氮工艺硬化齿面提高耐磨性能.氮化层通常5-20m,氮化扩散层可达到0.10.6mm.,Case hardening,Hardening process flow in STD 硬化工艺流程 Washing 清洗 Preheating 2 hours in 300C 预热 Hardening process carborizing on hardening furnace
20、 quenching to oil and cooling 硬化工艺 表面渗碳 油淬后空冷 Washing 清洗 Tempering 2 hours in 200C 低温回火,Case hardening, hardening process,1. Loading the batch 1，产品装炉 2. Heating up to 920C 2，加热到920C 3. Rising the carbon potential 0.95 3，提高炉内碳离子密度0.95 4. The carbon potential laying to 0.82 4，工件表面碳含量达到0.82 5. Temperat
21、ure drop to 850C 5，温度降到850C 6. Quenching to oil (60C) and cooling 6，油淬（油温60C）冷却。,1,2,3,4,5,6,Case hardening,Gear Training Manufacturing technology,Gearwheel bore finishing 齿轮基准孔修整 Can be done by hardturning or bore grinding 孔精加工可以通过硬化刀具镗削（如金刚镗)或磨削完成。 Again clamping for the ”known” side (bore perpend
22、icular for side) towards work-piece spindle 与上道工序中和孔一次加工的端面为装夹基准。 Runout work-piece important 工件跳动很重要 Can be used pitch-line clamping or OD-clamping 使用相同齿距的工装装夹或用分度圆定心装夹. Pitch-line clamping gives better quality but hig tooling costs 齿距工装装夹可得到好的质量但也意味着高成本。 OD-clamping means cheaper tooling and norma
23、lly ok for KC purposes. 对于科尼齿轮使用分度圆定心来装夹成本低而且也能达到要求。 Gearshaft external finishing (cylindrical) 齿轮轴外圆精加工 Can be done by hardturning or cylindrical grinding 外圆精加工可以通过硬化刀具车削或外圆磨磨削。 Clamping between the centers 两顶针孔定位装夹。,Gear Training Manufacturing technology,Gear grinding 磨齿 Continious grinding normal
24、ly used 通常使用连续磨齿（如蜗杆砂轮磨齿） Profile grinding also possible but not economic for small parts or/and high z 渐开线靠模磨齿法可以磨出齿形但对于小件或是大齿数齿轮 则不经济。 Gearwheel clamping once more for the ”known” side (bore perpendicular for side) towards work-piece spindle 再一次使用与孔同一次加工的面来装夹定位。 Gearshafts clamped between centers and friction taper in KHT 齿轮轴利用两端的中心孔来装夹定位，依靠顶尖与中心孔锥面摩擦带动齿轮轴旋转。 Other clamping methods also possible 其他装夹方法也可以。,