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High Quality Raw Materials Are A Prerequisite For The Production Of High Quality Products

In order to avoid the reducer can not pass the factory test, one of the reasons is the existence of intermittent high noise reducer; ND6-type precision sound level meter test, low noise reducer 72.3Db (A), to the factory requirements; and high noise reduction Machine is 82.5dB (A), can not meet the factory requirements. After repeated testing, analysis and improvement of the test, the conclusion is that the production of all aspects of the comprehensive management, in order to effectively reduce the gear transmission noise.

1, the accuracy of the control gear: the basic requirements of gear accuracy: the practice of verification, gear accuracy must be controlled in the GB10995-887 ~ 8, the line speed is higher than 20m / s gear, pitch deviation, Tooth tolerance must be stable to 7 level accuracy. In the case of 7 precision gears, the teeth to reverse the shuttle, to prevent the tooth root boss.

2, control the quality of raw materials: high-quality raw materials is the prerequisite for the production of high-quality products, the company's largest use of materials 40Cr and 45 steel gears. No matter what way, raw materials to the factory after a rigorous chemical composition testing, grain size determination, purity assessment. Its purpose is to timely adjust the heat treatment deformation, improve the quality of tooth processing.

3, to prevent heat treatment deformation: tooth blanking in the rough after the forging, the normalizing or quenching and tempering to achieve:

(1) softening the steel for cutting;

(2) elimination of residual stress;

(3) refine the grain, improve the organization to improve the mechanical properties of steel;

(4) for the final treatment can be prepared for the organization. It should be noted that in normalizing or quenching and tempering treatment, be sure to keep the furnace temperature uniform, and the use of station equipment, so that the workpiece evenly heated and cooled, is strictly stacked together. Need to drill to reduce the weight of the gear, the drilling sequence should be arranged after the heat treatment. The final heat treatment of the gears uses high-frequency quenching of the tooth surface with small deformation of the parts. The tooth surface obtained by high frequency quenching has high strength, hardness, wear resistance and fatigue limit, while the heart still maintains sufficient plasticity and toughness. To reduce deformation. Toothed high frequency quenching should be used with lower quenching temperature and shorter heating time, uniform heating, slow cooling.

4, to ensure the accuracy of the blanket: the accuracy of the size of the gear hole in the deviation of the hole in the middle of the deviation of the distribution, set at ± 0.003 ~ ± 0.005mm; if the tolerance and the hole in the design requirements, must be classified , Respectively, into the cutting process. The bevel side of the blank and radial runout is 6, set in the range of 0.01 ~ 0.02mm.

5, cutting teeth processing measures: the outsourcing of gear cutting tools must be tested, must meet the AA level requirements. After cutting the gears, the tool should be tested for the radial direction of the cutting edge of the tool, the adjacent circumferential difference of the chip flute, the maximum cumulative error of the chip trough and the parallelism of the front and the inner bore. Without affecting the strength of the gear under the premise of raising the high coefficient of the tooth, an increase of 0.05 ~ 0.1m ,, to improve the tool tooth top high coefficient, to avoid gear transmission tooth root interference. M = 1 ~ 2 gears with tooth top round hob, rounded rounds R = 0.1 ~ 0.15m. Eliminate the burr of the tooth and improve the tooth tip interference when gearing. Cutting equipment to carry out a precision check every year, fail to meet the requirements must be repaired. Operators should also conduct self-test, especially in the machine tool spindle radial control in the 0.01mm below the knife shaft diameter jump 0.005mm below the knife shaft movement 0.008mm below. Tool installation accuracy: tool radial runout control in 0.003mm below the end of the runout 0.004mm below. Cutting tooling precision, spindle diameter and the gap between the workpiece hole to ensure that within 0.001 ~ 0.004mm. The thread on the mandrel must be grounded by the thread bed in the top of the top of the crest: vertical ≦ 0.003mm, diameter jump ≦ 0.005mm. Nuts must ensure that the internal thread and the base surface of a fixture, the parallelism of the gasket ≦ 0.003mm.

6, civilized production: gear transmission noise more than 30% of the reasons from the burr, bumps. Some factories in the gear box before assembly, remove the burr and bumps, is a passive approach. (1) gear shaft parts, hobbing teeth immediately after the cover with a dedicated plastic protective cover into the next process, and with a dedicated plastic protective cover and delivery. (2) the honing process, reduce the tooth surface roughness, remove the burr, and prevent bumps, can effectively reduce the gear transmission noise.

7, to take other materials and heat treatment, surface treatment: (1) can use powder metallurgy molding technology, gear forming after tooth high frequency quenching. (2) the use of cast iron, gear cutting, and then soft nitriding. (3) the use of 40Cr material, gear cutting work, the use of soft nitriding or tooth copper treatment. In summary, to cure gear transmission noise, gear materials and heat treatment is to be the case, tooth blank precision is guaranteed, the gear accuracy is the key, civilized production is the foundation.

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