Gears ne Bearing Sets: Ɔhyew-Ayaresa Distortion Ne Ɔtamfo Ankasa a Ɔyɛ Pɛpɛɛpɛ

Atwerɛ

June 15, 2009

Tolerances a ɛwɔ gear drawing so no yɛ finished-state tolerances: profile, kɔbere, bore cylindricity, anim runout. Nea ɛkyerɛ sɛ ebia wobetumi adi ho dwuma ne nneɛma dodow a wogyaw ma wɔyam bere a wɔde ɔhyew ayɛ akyi — na wontumi nhu nea wɔakyinkyim no ansa na fononoo no aba.

Gear Pɛpɛɛpɛyɛ Yɛ Pɛpɛɛpɛ wɔ Ɔhyew a Wɔde Yɛ Adwuma Akyi

Wɔakyerɛ abodwokyɛre wɔ gears ne bearing nkongua so wɔ tebea a wɔawie no mu: profile abodwokyɛre, kɔbere abodwokyɛre, bore cylindricity, anim runout. Nea ɛkyerɛ ankasa sɛ ebia wobetumi akura saa nneɛma no ne sika dodow a wɔde ma a ɛma wonya nkwa wɔ ɔhyew a wɔde yam no mu. Wɔ carburising ne quenching mu no, ɔfã bi fa structure transformation ne thermal stress mu bere koro no ara mu: afasu a ɛyɛ tratraa nyin, afã horow a ɛyɛ den no twetwe, afã horow a ɛnyɛ pɛpɛɛpɛ no kotow. Wɔn mu biara nni hɔ a wotumi hu wɔ fononoo no anim.

Ɛnyɛ grinder a eye sen biara na ɛyɛ tolerance bore a ɛkorɔn; ɛnam adeyɛ bi a na enim baabi a bore no bɛkɔ ansa na wɔayam no so na ɛba. Enti nhyehyɛe a wɔyɛ ma gears no yɛ distortion prediction plus allowance allocation. Sotɔɔ ahorow a wɔn ho akokwaw kyekye distortion database denam nneɛma, ɔfasu-thickness ratio ne loading pattern so, afei wotua pre-heat-treatment dimensions no ka wɔ akyi. Sotɔɔ ahorow a enni saa data no betumi agyaw allowance pii nkutoo na wɔagye grinding passes foforo. Ɛka kɔ soro, na allowance dodow no ara fa carburised case no mu na ɛma ɛyɛ den no so tew.

Nneɛma Abiɛsa a Ɛma Nkyinkyim: Nneɛma, Geometry, Loading

Nea edi kan ne honam fam nneɛma. Ɔhyew abien a ɛyɛ 20CrMnTi grade koro no ara betumi ayɛ soronko wɔ hardenability band trɛw mu a ɛbɛsakra distortion ɔha biara mu aduasa. Adeyɛ a ɛyɛ dɛ ne sɛ wɔbɛhwehwɛ sɛ wɔde hardenability band amanneɛbɔ fi owiyammo no mu na wɔpaw kɔ band no ase-mfinimfini.

Nea ɛto so abien ne geometry: ɔfasu no mu duru a ɛnyɛ pɛpɛɛpɛ, offset keyway, asymmetric tokuru a ɛwɔ web no mu nyinaa ma onwini a ɛnyɛ pɛpɛɛpɛ bere a wɔredum no. Ɛsɛ sɛ wɔma eyinom so wɔ mfoniniyɛ fã no — nhyehyɛe a wɔde yɛ nneɛma a wɔyɛ no mu nhwehwɛmu taa tumi dannan ade a ɛnyɛ pɛpɛɛpɛ ma ɛyɛ nea ɛne ne ho hyia anaasɛ ɛde adeyɛ mpampam ka ho. Nea ɛto so abiɛsa ne adesoa: fixture no na ɛkyerɛ quenchant flow field, cooling rate yɛ soronko wɔ basket mfinimfini ne ano, na afã horow a ɛwɔ adesoa koro no ara mu no betumi akyinkyim wɔ akwan horow a ɛne ne ho bɔ abira so.

Wɔabu Grinding Allowance, Ɛnyɛ Nea Wɔasusuw

Wontumi nsiesie allowance ne distortion kakraa bi dodo, na ɛma honam ani yɛ tuntum bere a wɔayam awie no. Dodow na grinding bere ne ɛka kɔ soro bere a carburised case no asiane wɔ hɔ sɛ wobetwa mu. Allowance a ɛteɛ no yɛ pɛpɛɛpɛ distortion a wɔhwɛ kwan a wɔde stock removal a wɔde aka ahobammɔ factor ho, na ɛsɛ sɛ distortion a wɔhwɛ kwan no fi susuw mu, na ɛnyɛ handbook mu.

Ɔkwan a mfaso wɔ so no yɛ adeyɛ validation run: load afã du wɔ cycle biako mu, susuw kɛse nkyekyɛmu ansa na ne akyi, nya mean shift ne standard deviation, afei hyehyɛ allowance. Wɔ production mu no, sample by batch na plot nkyekyɛmu no wɔ control chart so; nsakrae a ɛba wɔ mfinimfini no kyerɛ sɛ fononoo anaa ade no asesa. Eyi mu biara nyɛ foforo, nanso sotɔɔ kakraa bi na wɔyɛ no yiye — a ɛyɛ mfiri a wɔde yɛ adwuma a wɔayɛ no sɛnea wɔpɛ a ɛyɛ den sen biara sɛ wɔbɛsesa no fã pɛpɛɛpɛ.

Batch Consistency: Ɔfã Pa Baako Nkyerɛ Biribiara

Su a ɛyɛ huammɔdi wɔ gears so no nyɛ ɔfã biako a ɛnyɛ tolerance na mmom batch dispersion. Ɔfã bi susuw wɔ mfinimfini abodwokyɛre, nanso wɔ batch bi so no awiei biako drifts fi — mpɛn pii no dodow a ɔhyew nyin, adwinnade wear ne fixture wear. Bere a wɔde nnɔnhwerew anan akɔ so de mfiri ayɛ adwuma akyi no, spindle hyew a enyin no betumi adu micron du du, a ɛdɔɔso sɛ ɛbɛwe abodwokyɛre kuw no nyinaa.

Control wɔ layers abiɛsa: asɛm a edi kan a wosi so dua, in-process sampling, asɛm a etwa to mu nokwaredi; nea ɛka ho ne ɔhyew a wɔde yɛ hyew ansa na wɔayɛ ne adwinnade nkwa nna a wɔhwɛ so denam ne tenten a wobetwitwa so sen sɛ wɔbɛbubu so. Wɔ bearing nkongua a wɔde kura IT6 mu no, ɛsɛ sɛ wɔkan susuw a wontumi nsi pi no ankasa: nsonsonoe a ɛyɛ digrii abien a ɛda gauge ne workpiece ntam no dɔɔso sɛ ɛbɛkenkan mfomso a ɛyɛ micron biako wɔ bore a ɛyɛ milimita aduonum so.

Gear ne Bearing Fit: Afã Abien, Ɔhaw Baako

Wɔbom si sɛnea gear shaft ne ne bearing ntam hyia ho gyinae: shaft tolerance, bearing inner-ring tolerance, ne abien no nyinaa kurukuruwa. Mfomso a ɛtaa ba ne sɛ wobɛhwɛ shaft no kɛse nkutoo na woabu wɔn ani agu kurukuruwa ne soro a ɛyɛ mmerɛw so. Wɔ saa ntwitwiridii koro no ara mu no, shaft a ɛnyɛ kurukuruwa no sesa emu ring no ma ɛbɛyɛ ellipse, bearing clearance sesa, na dede ne ɔhyew a ɛkɔ soro di akyi.

Enti afã horow te sɛ eyinom yɛ nea eye sen biara sɛ obiako na ɔde mfiri yɛ, anaasɛ anyɛ yiye koraa no, wɔ datum nhyehyɛe biako mu. Esiane sɛ wɔakyekyɛ mu wɔ sotɔɔ abien ntam nti, ɛtaa ba sɛ emu biara bɛtwam wɔ nhwehwɛmu mu na nhyiam no adi nkogu. Asɛmmisa tẽẽ yɛ adwuma yiye wɔ supplier evaluation mu: so wɔde mfiri ayɛ gear ne bearing seat no wɔ clamping koro mu wɔ afiri koro no ara so?

Nhwehwɛmu: CMM Ntumi Nsusuw Nsõ Nsusuwii

Gear pɛpɛɛpɛyɛ ntumi nkɔ CMM nkutoo so. CMM susuw bore kɛse, anim runout ne keyway gyinabea, nanso profile ne lead tolerances hwehwɛ sɛ wɔkɔ so hwehwɛ involute no ho, a ɛkyerɛ sɛ gear susuw beae anaasɛ involute tester a wɔatu wɔn ho ama. Nsɛm pii a wɔafa aka no hyɛ bɔ sɛ wɔbɛyɛ CMM nhwehwɛmu a edi mũ bere a wɔankyerɛ sɛ sẽ kratasin no yɛ nokware ankasa da no.

Ɛno yɛ akasakasa a ɛfa gye a wogye tom ho a wonim no yiye: ɔfã no de CMM data kɔ na ɛda so ara si apini bere a ɛkɔ adan no mu no. Nea ɛde ba no betumi ayɛ profile crowning, helix angle deviation anaasɛ accumulated pitch error, na wɔn mu biara ntena CMM nhyehyɛe a wɔahyɛ da ayɛ mu.

Wɔde nhyehyɛe a wɔde gye tom a ɛyɛ adwuma ayɛ layered. Asɛm a edi kan no nya amanneɛbɔ a edi mũ fi gear susuw mfinimfini a ɛkata profile, lead, pitch ne radial runout so. Production runs de double-flank composite inspection di dwuma sɛ fast screen, a bere ne bere mu sampling san kɔ susudua no. Mfiri a ɛwɔ afã abien no bo nyɛ den na ɛyɛ ntɛmntɛm sɛnea ɛbɛyɛ a wobetumi ahwɛ mu ɔha biara mu ɔha, nanso ɛda mfomso a wɔabom ayɛ nkutoo adi na entumi nka element bɛn na apue, enti ɛsɛ sɛ akwan abien no bom yɛ adwuma.

Kɔkɔbɔ baako fa susudua no ankasa ho: gear susudua beaeɛ te nka kɛseɛ wɔ calibration ne temperature ho sene CMM, na digrii aduonu a wɔde ka ho anaa wɔayi baako afiri mu ne mfitiaseɛ. Sɛ wohwɛ metrology dan no mu hyew ho kyerɛwtohɔ bere a woreyɛ akontaabu a, ɛkyerɛ wo pii sen afiri no din krataa.

Nsɛmmisa Anan a Wɔde Ma Ɔdetɔfo

Nea edi kan no, so wɔyɛ carburising ne quenching wɔ fie anaasɛ wɔde ma afoforo, na sɛ wɔde ma afoforo a, so heat treater no kura CQI-9? Nea ɛto so abien no, so wobetumi de distortion data a wɔasusuw ama, a wɔde mean ne standard deviation a wɔahyehyɛ no akuwakuw sɛnea nneɛma ne ɔfasu no mu duru te? Nea ɛto so abiɛsa, ɔkwan bɛn so na wɔde grinding allowance si hɔ, na so wɔayɛ validation run? Nea ɛto so anan, ɔkwan bɛn so na wɔma batch consistency awerɛhyem — so SPC ne adwinnade-asetra sohwɛ wɔ hɔ?

Wɔn a wɔde nneɛma ma no mu kakraa bi na wobua anan no nyinaa yiye, nanso wɔn a wobua no taa fa nsɛm ka ankasa, efisɛ wonim sɛ wɔrenhwere sika no wɔ nneɛma a wɔabubu ho. Sɛ worekyerɛw China precision machining adwumayɛbea anaa China CNC afã horow yɛfo din tiawa a, fa ɔhyew-aduru tumi di dwuma sɛ nea edi kan a wɔde yiyi mu; ɛka pii kyerɛ wo sen nnwinnade a wɔahyehyɛ.