Study for Hybrid Finishing Apparatus for Manufacturing High Quality Gear

制造高质量齿轮的混合精加工设备研究

基本信息

批准号：
11650154
负责人：
HOYASHITA Shigeru
金额：
$ 2.24万
依托单位：
Saga University
依托单位国家：
日本
项目类别：
Grant-in-Aid for Scientific Research (C)
财政年份：
1999
资助国家：
日本
起止时间：
1999 至 2000
项目状态：
已结题

来源：
https://kaken.nii.ac.jp/grant/KAKENHI-PROJECT-11650154/
关键词：
Gear Surface Durability Tribology Shot Peening Process Barreling Process Surface Roughness

项目摘要

The new method of the tooth surface improvement in order to manufacture a high quality gear is developed when a shot peening process and a barreling process are continuously applied to tooth surfaces of a hardened and ground gear or a sheaved and hardened gear. The compressive residual stress induced on/below the gear tooth surface by the shot peening process increases the bending fatigue strength of the tooth root and the improvement of the surface roughness by the barreling process increases the surface durability (resistance for pitting, scoring and wear, etc.).In this study, the hybrid apparatus for finishing the ground tooth surface is designed and manufactured. This apparatus is a prototype one in order to investigate a performance of the tooth surface improvement. However, by some modification of design, one can easily design the apparatus established in a gear manufacturing process line for an automobile transmission, in which the processes of shot peening and barreling are con … More ducted at the same time, and many gears are barreled together. The cost will scantly increase by an addition of the processes of shot peening and barreling.Furthermore, a running test of high quality gears was conducted investigating the tooth profile, the surface roughness and the condition of the oil film formed between meshing gears. The processes of shot peening and barreling don't only restrict the gear with an involute curve, but also can be applied to all gears with an arbitrary tooth profile. A p* of Hypoid gears is ordinarily lapped after cutting and heat-treating. Since the time for lapping process is shortly a few to over ten minutes, the surface roughness is comparatively rough, for example as 5〜10 μmRy (≒1〜2 μmRa). Recently, the friction heat produced by the surface roughness becomes a question. For the sake of solving this problem the barreling process is effective.If the barreling process will be utilized as a last machining, the surface of the gear is not only smooth like a mirror, but also it can remove a burr and a protrusion around a scratch produced during machining. As a result, it will contribute to the quality control of the gear. The shot peening and barreling processes can decrease the friction coefficient by improvement of the surface roughness. If the load carrying capacity of gears will increase, the automobile transmission can be designed to a small size, and ultimately it will contribute to the saving of energy as an ecological gear. Less

当对淬火磨削齿轮或滑轮淬火齿轮的齿面连续进行喷丸处理和滚磨处理时，开发了一种改进齿面的新方法，以制造高质量齿轮。通过喷丸工艺在齿轮齿表面上/下方引起的冲击增加了齿根的弯曲疲劳强度，并且通过滚磨工艺改善了表面粗糙度，从而提高了表面耐用性（抗点蚀、划痕和磨损，等）。在这项研究中，设计和制造了用于精加工齿面的混合装置。该装置是一个原型装置，旨在研究齿面改善的性能，但是，通过对设计进行一些修改，可以实现。轻松设计汽车变速器齿轮制造生产线中的设备，其中喷丸和滚磨工序同时进行，并且许多齿轮一起滚磨，增加的成本不会增加。喷丸处理过程和此外，还对高质量齿轮进行了运行试验，研究了齿形、表面粗糙度以及啮合齿轮之间形成的油膜状况。喷丸和滚磨工艺不仅限于渐开线齿轮。曲线，但也适用于所有具有任意齿形的齿轮，由于研磨过程的时间很短，因此通常在切削和热处理后进行研磨。分钟，表面粗糙度比较粗糙，例如5~10μmRy（≒1~2μmRa）。近来，表面粗糙度产生的摩擦热成为一个问题，为了解决这个问题，滚磨工艺是有效的。如果将滚磨工艺作为最后的加工，齿轮的表面不仅光滑如镜，而且可以去除加工过程中产生的毛刺和划痕周围的突出物。结果，这将有助于齿轮的质量控制。喷丸和滚磨工艺可以通过改善表面粗糙度来降低摩擦系数，如果齿轮的承载能力增加，则汽车变速器可以设计得较小。尺寸，最终将作为一种生态齿轮为节省能源做出贡献。