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【夹具技术讲堂】第三讲:珩齿夹持技术

发布时间 : 2019-09-05

【夹具技术讲堂】第三讲:珩齿夹持技术

讲堂25


齿轮的承载能力、运动平稳性以及使用寿命主要取决于实际工况下啮合齿面的接触状况,齿面的微观几何形貌对齿轮振动噪音、使用寿命影响巨大。珩齿因可以获得理想的齿面微观几何形貌,尤其是独特的齿面纹路,对传动装置的振动噪音有非常明显的抑制作用,因此珩齿工艺在汽车齿轮精密加工中一直得到应用发展。


珩齿原理


珩齿原理与剃齿相似,珩轮与工件类似于一对螺旋齿轮呈无侧隙啮合,利用啮合处的相对滑动,并在齿面间施加一定的压力来进行珩齿。

珩齿时的运动和剃齿相同。即珩轮带动工件高速正、反向转动,工件沿轴向往复运动及工件径向进给运动。与剃齿不同的是开车后一次径向进给到预定位置,故开始时齿面压力较大,随后逐渐减小,直到压力消失时珩齿便结束。

珩齿工艺的发展

珩齿加工工艺先后经历了软珩齿、CBN砂轮硬珩齿以及强力珩齿技术。

1.软珩齿:传统珩齿加工应用齿轮形或蜗杆形珩磨轮与被珩齿轮做自由啮合运动,相当于一对交错轴斜齿轮传动,利用啮合齿面间的相对滑动和压力来进行珩削,珩磨轮采用具有一定弹性的合成树脂或人造橡胶制成,在自由啮合状态下,珩磨轮主要起到光整作用,去除余量有限,对齿轮精度的修正能力有限,误差复映现象难以克制,齿轮的精度主要取决于前道切齿及热处理精度。

2.CBN砂轮硬珩齿:硬珩轮珩齿技术是用中碳钢做成齿轮状的珩轮基体,用电镀沉积法将超硬磨料涂在钢基体的齿面上,依靠珩磨齿轮面上的超硬磨料来珩磨工件,材料去除能力强,且珩磨轮刚性提高,除了能光整,还能纠正齿轮齿形、基节、齿向误差,并能将齿轮精度显著提高。

3.强力珩齿:随着齿轮精度及齿面质量要求不断提高,以及电子齿轮箱、自动上下料、在机检测、误差修正、直接驱动、CAM等先进技术的引入,开了各具特色的强力珩齿机,珩磨轮与工件强制啮合,对齿轮精度具有很强的纠正能力,可显著提高齿轮精度,强力珩齿精度可达到DIN5级,表面粗糙度Ra<0.2um

珩齿技术不再仅仅是一项光整辅助工序,可以作为一种独立的精加工方式,和磨齿工艺形成优势互补。


强力珩齿的优势

1.齿面纹路有利于降低齿轮的振动噪声;

2.形成较高残余压应力(1000~1600N/mm2),有效提高齿轮强度、耐磨性以及抗点蚀性能;

3.齿面无磨削烧伤、无热应力、无材料微观结构改变、无磨削烧伤,有效提高齿轮寿命;

4.可获得较高齿面粗糙度,表面粗糙度Ra<0.2um;

5.可加工带台肩的齿轮,无需沿工件轴向进刀,相比磨齿加工需要一定出头量,更适合加工带台肩的紧凑齿轮工件;

6.很经济的精加工工艺——尤其在大批量生产中,采用的陶瓷烧结的珩磨轮寿命很长,刀具成本低。




珩齿夹具案例

01

液胀式夹具

讲堂30
讲堂27

02

机械式夹具


讲堂28

讲堂29



03

液压转机械式夹具

讲堂31

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