Ilimi- Kintai

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Gear nika tsari ne na kammala kayan aiki daidai. Yana amfani da keken niƙa mai sauri mai jujjuyawa azaman kayan aikin yankan don yin niƙa mai kyau akan saman haƙora na kayan aikin da aka yi aikin farko kamar hobbing ko aski kuma an yi musu maganin zafi. Wannan tsari yana gyara nakasar da maganin zafi ke haifarwa kuma yana haɓaka daidaiton girman girman, daidaiton bayanin haƙori, da ingancin saman gears. Siffofin sa na asali sune madaidaicin madaidaici kuma babban ingancin ƙasa, yana sa ana amfani da shi sosai a cikin dogaro mai ƙarfi, manyan filayen masana'anta. A ƙasa, za mu gabatar da shi daga fannoni kamar ƙa'idar aiki, halayen tsari, kayan aiki, da iyakokin aikace-aikace.

I. Makasudai da Ka'idojin Niƙa

1) Manufofin Niƙa Gear

Haɓaka daidaito: Haɓaka ƙimar daidaiton gear daga IT7-IT8 a farkon aiki zuwa IT6-IT4 (ko ma mafi girma) don biyan buƙatun ingantaccen watsawa (kamar a cikin jirgin sama da madaidaicin watsa robot).

Rage Taushin Sama: Niƙa na iya rage ƙaƙƙarfan haƙori daga Ra1.6-3.2μm zuwa Ra0.4-0.8μm, yana rage gogayya da lalacewa a lokacin meshing.

Gyaran Maganin Zafi Mai Kyau: Gears suna da saurin nakasu kamar bayanin martabar haƙori warping da karkatar da haƙori bayan jiyya na zafi kamar carburizing da quenching ko nitriding. Gear niƙa yadda ya kamata yana rama waɗannan kurakurai.

Haɓaka Ayyukan Meshing: Ta sarrafa matsayin wurin lamba akan saman haƙori (kamar gyaran rawani da gyaran gyare-gyaren haƙori), yana rage ƙarar watsawa kuma yana tsawaita rayuwar sabis na kayan aikin biyu.

2) Nikawar kaya

Mahimmancin niƙan kaya shine yanke juzu'i mai sarrafawa tsakanin injin niƙa (kayan aiki) da kayan aiki (aiki), kuma ana sarrafa saman haƙori ta hanyar haɗin motsi biyu:

Babban motsi: babban saurin juyawa na injin niƙa (gudun linzamin yawanci yawanci 30 zuwa 80 m / s, kuma yana iya kaiwa 100 zuwa 200 m / s a ​​cikin niƙa mai sauri);

Motsin ciyarwa: gami da ciyarwar axial na dabaran niƙa tare da jagorar nisa haƙori, motsin nuni na kayan aiki (aiki na haƙori-haƙori ko ci gaba da sarrafawa), da motsin haɓakawa (yana kwaikwayi jujjuyawar dangi na meshing gear, wanda aka yi amfani da shi wajen samar da hanyar niƙa na gears).

II. Rarraba Gear Nika

Dangane da dangantakar motsi tsakanin dabaran niƙa da kayan aikin, kayan niƙa galibi sun kasu kashi biyu: nau'in niƙa da samar da niƙa.

1) Form Nika

- Ƙa'ida: Ana sanye da dabaran niƙa a cikin bayanin martaba wanda ya dace daidai da ramin haƙorin kayan aiki (kamar ƙafafun niƙa mai siffar diski ko ƙafafun niƙa mai siffar kwano). A haƙori tsagi an kasa daya bayan daya ta axial feed na nika dabaran da indexing motsi na workpiece.

- Halaye: Kayan aiki yana da sauƙi (kamar injin niƙa), amma suturar ƙafafun niƙa yana da rikitarwa; daidaito yana iyakance ta daidaitaccen suturar dabaran niƙa (yawanci IT6-IT5); ingancin samarwa yana da ƙasa kaɗan (kamar yadda ake niƙa haƙori ta haƙori ko tare da ayyukan ƙididdigewa da yawa); ya dace da ƙananan nau'i-nau'i, nau'i-nau'i daban-daban na sarrafa kayan aiki (kamar samfurin samfurin, kayan aiki don injunan manufa na musamman, da kayan aiki, da dai sauransu).

- Kewayon sarrafawa: Gears na cylindrical na waje (madaidaici da helical): diamita daga 10mm zuwa 2m; kayan ciki na ciki.

- Hanyar clamping: The workpiece yawanci saka a kan cibiyoyi, kuma zane dole ne ba da damar domin motsi sarari a duka iyakar nika dabaran.

2. Form nika na gears

- Ƙa'ida: Ƙaƙwalwar niƙa da kayan aiki suna yin kwaikwayon motsin motsi na gears guda biyu (samfurin samar da motsi). Ta hanyar jujjuyawar injin niƙa da jujjuyawar kayan aikin, saman haƙori yana ƙasa gabaɗaya ko hakori ta haƙori. Dangane da siffar dabaran niƙa, ana iya ƙara shi kamar:

(1) Nika tare da ƙafafun niƙa mai siffar diski:

- A "Virtual tara" da aka kafa ta karshen fuskoki na daya ko biyu disc-dimbin yawa nika ƙafafun, wanda meshes da workpiece kaya (form samar motsi), da kuma hakori surface ne kasa hakori da hakori (da workpiece ne indexed sau daya bayan kowane hakori ne kasa).

- Halayen: Madaidaicin madaidaici (IT3 zuwa IT5), amma ƙarancin inganci (aiki haƙori-da-haƙori), wanda ya dace da madaidaicin madaidaicin gears (kamar kayan aikin sandar injin, gears aerospace).

(2) Nika da ƙafafun niƙa mai siffar kwano:

- The m cylindrical surface na kwano-dimbin yawa nika dabaran da ake amfani da matsayin nika surface, wanda meshes da workpiece gear (form samar da motsi), da hakori surface ne kasa hakori da hakori.

- Halayen: Babban madaidaicin (IT4 zuwa IT5), ingantaccen ƙarfin injin niƙa, wanda ya dace da daidaitaccen aiki na manyan gears (module m> 5mm) (kamar gears don injunan nauyi).

(3) Nika tare da ƙafafun niƙa mai siffar tsutsa (hanyar niƙa):

- The nika dabaran da aka yi a cikin siffar tsutsotsi (forming tsutsotsi-gear meshing tare da workpiece gear), da kuma ta hanyar juyawa na nika dabaran (babban motsi) da kuma synchronous mirgina na workpiece (form samar motsi), da hakori surface ne kasa ci gaba (kama da gear hobbing, amma ta amfani da nika dabaran maimakon hob).

- Halaye: Babban inganci (ci gaba da sarrafawa), babban madaidaici (IT4 zuwa IT6), kawai dace da sarrafa kayan aiki na waje; dace da madaidaicin sarrafa kayan aiki a cikin manyan batches (kamar kayan aikin watsa motoci, kayan injin jirgin sama).

 

 

III. Tsarin Niƙa Guda

Yin niƙa na buƙatun yana buƙatar kulawa mai ƙarfi na kowane mataki don tabbatar da daidaito. Tsarin al'ada shine kamar haka:

1) Pre-aiki: Gear blank yana jujjuyawa / simintin gyare-gyare → m machining (juyawa) → Semi-finish machining (mirgina / yankan), samun ɓangarorin gear wanda ya dace da buƙatun haƙuri da matsayi, tare da izini don niƙa.

2) Maganin zafi: Yi carburizing da quenching, nitriding, da dai sauransu, bisa ga buƙatun aiki (misali, kayan aikin mota suna buƙatar carburized da kashe su zuwa HRC58-62).

3) Niƙa abin tunani: A niƙa ramin ciki da ƙarshen fuska da kyau don samar da madaidaicin matsayi don niƙa haƙora.

4) Pre-nika shirye-shirye: Tsaftace workpiece → matsa da matsayi (ta yin amfani da wani mandrel ko gyarawa don tabbatar da coaxiality) → miya da nika dabaran (daidai dress manufa haƙori profile da hakori profile gyara, da kuma hakori shugabanci gyara aka samu ta hanyar canza radial yankan zurfin na nika dabaran).

5) sarrafa nika:

 - Saitin kayan aiki: Daidaita matsayi na dangi na dabaran niƙa da kayan aiki don tabbatar da daidaiton wurin farawa;

 - Niƙa: Niƙa saman haƙori bisa ga saitin samar da motsi ko ƙirƙirar yanayin (abinci da yawa na hakori ɗaya ko ci gaba da ƙididdigewa);

 - Gyara (na zaɓi): Ta hanyar daidaita yanayin dabaran niƙa ko amfani da ƙarin na'urori, yin gyare-gyaren kambi, chamfering a ƙarshen haƙori, da dai sauransu, don haɓaka yankin lamba.

6) Dubawa da ramuwa: Yi amfani da cibiyar aunawa gear (CMM) don bincika kuskuren bayanin martabar haƙori, kuskuren shugabanci na haƙori, kuskuren farar tarawa, da dai sauransu. Idan ba tare da haƙuri ba, daidaita sigogin tsari (kamar saurin niƙa, ƙimar ciyarwa) ko yin sutura dabaran niƙa.

7) Deburring da tsaftacewa: Cire burrs daga saman hakori, mai tsabta, da kunshin don ajiya.

IV. Maɓalli na Kayan aiki don Niƙa Gear

Injin niƙa Gear sune ainihin kayan aiki don tafiyar matakai na niƙa, kuma aikin su yana ƙayyade daidaiton sarrafa kayan aiki kai tsaye. Dangane da tsari da aikace-aikacen, an rarraba su galibi kamar haka:

1. Injin niƙa na tsutsa (irin su KAPP NILES daga Jamus, Liebherr daga Jamus, da Qinchuan Machine Tool daga China): Suna iya samun saurin niƙa na haƙora 10-20 a cikin minti ɗaya (ci gaba da ƙididdigewa) kuma ana amfani da su sosai a cikin kayan aikin mota.

2. Na'urorin niƙa na Conical (kamar Gleason daga Amurka da Reishauer daga Switzerland): Suna amfani da ƙafafun niƙa biyu ko guda ɗaya kuma sun dace da manyan nau'i, kayan aiki masu mahimmanci (kamar gears don injunan jirgin sama).

3. Form injin niƙa (kamar Mitsubishi daga Japan da Harbin Tool & Die Group daga China): Suna da tsari mai sauƙi da ƙananan farashi, kuma sun dace da ƙananan ƙananan ƙananan ƙananan ƙwayoyin cuta (irin su kayan aiki na kayan aiki da mita).

4. Na'urori masu niƙa guda biyar (samfuran masu tsayi): Suna haɗa tsarin CNC masu yawa, suna ba da izinin gyare-gyaren gyare-gyaren ƙafar ƙafar ƙafar ƙafa da ƙwanƙwalwar haƙora mai rikitarwa (kamar gears masu siffa da gears marasa madauwari), wakiltar matsayi mafi girma na yanzu (irin su Tornos daga Switzerland da DMG MORI daga Jamus).

V. Yanayin aikace-aikace

Saboda girman madaidaicin su da ingancin saman su, ana amfani da hanyoyin niƙa gear a cikin filayen tare da ƙaƙƙarfan buƙatu don aikin watsawa:

- Aerospace: Gears don masu rage injin jirgin sama (kamar kayan aikin injin turbofan), kayan aikin jigilar rotor mai saukar ungulu (yana buƙatar ingantaccen aminci da tsawon rayuwa).

- Robotics: Babban kayan aikin duniya don masana'antar robot RV masu ragewa da masu rage jituwa (ana buƙatar ƙarancin koma baya da daidaiton watsawa).

- Motoci: Gears don sabbin akwatunan abin hawa makamashi, kayan aikin daidaitawa don watsawa ta atomatik (AT/DCT), da manyan kayan ragewa (yana buƙatar babban nauyi da juriya).

- Injin Madaidaici: Madaidaicin nau'ikan nau'ikan kayan aiki don tsarin ciyarwar injin CNC (kamar gears don ƙwanƙwasa ƙwallon ƙwallon ƙafa), akwatunan gear ɗin igiya mai sauri.

- Kayayyakin Makamashi: Gears don akwatunan injin turbine na iska (na buƙatar juriya ga gajiya da juriya mai tasiri), kayan aikin injin dizal na ruwa (yana buƙatar tsawon rayuwa), kayan injin ga manyan akwatunan gear a cikin injin injin injin turbin gas, da kayan aiki masu sauri, da sauransu.

 

Idan kuna da wata tambaya ko kuna buƙatar haɓaka shafts na spline da gears, da fatan za ku iya tuntuɓar mu a info@castings-froging.com