【正文】 何形狀；切削刃必須鋒利；刀具的金相結(jié)構(gòu)絕不可因磨削過熱而受破壞。因而在刃磨硬質(zhì)合金滾刀時應(yīng)采用一種油基冷卻液，它對氯和硫不起反應(yīng)。對于刮削滾刀，刃磨后的重新涂層并不象用于實體毛坯硬滾的滾刀那樣重要。硬質(zhì)合金滾刀刃磨后涂層前，建議對其刃口進行預(yù)處理。 滾刀的重新刃磨將會除去切削表面的原有涂層，這會減少刀具壽命。刀具是可以重涂的。通常對于TiN涂層，可涂3～4次；對于TiCN和TiALN涂層而言，由于涂層本身有很大的內(nèi)應(yīng)力，所以在切削刃上難以再重新涂層。通過幾次涂覆TiN涂層后，會產(chǎn)生高低不均勻的狀況，并有分層脫落的傾向，所以原有涂層必須去除。 目前有兩種方法可去除刀具涂層：化學(xué)退涂和物理退涂。用化學(xué)退涂去除硬質(zhì)合金刀具上的涂層是一種精細工藝，要求操作者有相當(dāng)?shù)氖炀毘潭?。過度的化學(xué)退涂不僅將涂層去掉，而且還將溶洗鈷結(jié)合劑，損壞硬質(zhì)合金材料的微觀結(jié)構(gòu)。切削刃的微觀損壞將產(chǎn)生鋸齒狀表面。此外，在退涂時必須對滾刀軸臺、內(nèi)孔及標(biāo)志進行保護，以免損壞。而物理去涂，則必須由原刀具制造廠來進行，它涉及到整把滾刀齒形的重新磨削。雖然比化學(xué)退涂要貴得多，但得到的是一把新滾刀，質(zhì)量和壽命都能得到保證。 對滾齒機的要求 為了充分發(fā)揮硬質(zhì)合金和涂層工藝的優(yōu)點，滾齒機應(yīng)作相應(yīng)地改進。目前所有先進的滾齒機都按高速滾齒進行設(shè)計，其滾齒機的滾刀轉(zhuǎn)速超過3000r/min，通常為5000r/min，工件主軸轉(zhuǎn)速與滾刀轉(zhuǎn)速相匹配。此外，機床具有很高的動剛度和熱剛度。先進滾齒機的一些主要設(shè)計特點為：采用復(fù)合環(huán)氧樹脂床身，以改進機床的動態(tài)和靜態(tài)特性；帶有恒溫裝置的高速滾刀主軸箱；高速工件主軸；可采用干、濕二種滾削工藝；帶光電傳感器的數(shù)字驅(qū)動系統(tǒng)；直線滾動導(dǎo)軌系統(tǒng)；高速自動上料(2～3秒)；占地緊湊；按人機工程學(xué)設(shè)計；維修方便。 采用刮削工藝 無論是機械式的還是CNC的滾齒機都能進行刮削，但條件是機床必須裝備有工件到刀具的自動同步傳動系統(tǒng)。這可使刮削工藝更為經(jīng)濟，對帶有自動上下料系統(tǒng)的機床也很重要。電子非接觸系統(tǒng)靠一個模擬量傳感器發(fā)出脈沖來測量刀具主軸、工件主軸和齒輪的位置。機床CNC控制器對這些脈沖進行處理，然后對工件主軸相對于刀具的位置進行調(diào)整，使工件輪齒和滾刀刀齒的相對位置關(guān)系正確。 在刮削工藝中用冷卻液有很多優(yōu)點：在刮削過程中，冷卻液提供了潤滑性；由于刮削產(chǎn)生的不是正常的切屑，溫度控制極其重要。刮下的切屑較小較薄，不象正常刀屑那樣可帶走許多熱量，所以刮削時采用冷卻液可控制刀具、工件及機床系統(tǒng)的溫度；冷卻液可將切屑從刀具和工件上沖走；改善了工件表面精糙度；提高了刀具壽命。 在“綠色滾削”工藝中，正確選擇齒厚余量是很重要的。推薦選擇順銑滾齒，因為它可得到最厚的切屑，這有助于控制切削過程的動態(tài)狀況，提高刀具壽命。經(jīng)驗證明，切削速度可以超過200m/min，進給量的選擇取決于所要達到的表面光潔度?！５毒咭莆?竄刀)的方法也很重要，因為刮削時只有粗加工截面的部分切削刃才經(jīng)受磨損。相反，在“綠色切削”過程中，刀具的精加工部分承擔(dān)了主要加工量。這意味著在刮削時竄刀量應(yīng)更大，如齒輪為12～48DP時，～。 刮削滾刀的選取 刮削硬質(zhì)合金滾刀分為兩大類：用于10DP或更大模數(shù)的滾刀，通常都設(shè)計有一個負前角的切削前面，當(dāng)切削刃接觸到淬硬齒面時，減小了對硬質(zhì)合金材料的沖擊；對于較小模數(shù)的齒輪，就不需要有負前角。負前角的滾刀的缺點是刃磨困難。滾刀刃磨后外徑減小，為了得到正確的負前角就應(yīng)改變砂輪的偏置量。 當(dāng)刮削中、大模數(shù)齒輪時，其齒頂、外圓直徑和齒根部位通常都不被滾削，并要求輪齒到齒根有一個平滑的過渡。為得到沉切和完整的過渡圓弧半徑，提高齒根的抗彎強度，用于大模數(shù)齒輪的理想刮削滾刀應(yīng)帶有凸緣。 對于小模數(shù)齒輪的加工，應(yīng)采用標(biāo)準(zhǔn)滾刀。采用標(biāo)準(zhǔn)的徑向前角硬質(zhì)合金滾刀加工稱為“硬質(zhì)合金滾刀的再滾切”，而不是“刮削”，后者指的是采用了一個負前角滾刀。 硬滾削的技術(shù)要求和硬刮削、或硬質(zhì)合金滾刀再滾削的技術(shù)要求幾乎相同，不同之處是采用的竄刀移位的策略不同。在硬滾時，切屑的切除需花費大量能量。該能量最終變?yōu)闊崃?。設(shè)法把這些熱量散發(fā)帶走至關(guān)重要。建議每加工一個工件后，滾刀竄位一個全齒距。當(dāng)滾刀從頭到尾竄位過后，應(yīng)將滾刀移到離原始位置有一個偏置量的部位。該偏置量取決于滾刀的設(shè)計和應(yīng)用，其目的是為了有助于滾刀的均勻磨損。另一不同之處是所采用的裝夾系統(tǒng)。由于極大的切削力，夾具必須安全夾緊工件。加工結(jié)果表明，同一斜齒輪用硬質(zhì)合金滾刀再硬滾時，其齒輪質(zhì)量很高，齒形接近AGMA10級，齒向和齒距超過AGMA12級；全淬硬毛坯硬滾切加工的斜齒輪，其齒輪精度也非常高，齒形精度可達AGMA10級，齒向和齒距可達到AGMA12級。 結(jié)論 已探索出許多經(jīng)濟的方法來加工淬硬齒輪，包括材料的選擇、軟加工方法、熱處理工藝和硬精加工，使淬硬齒輪得到普及，滿足了高質(zhì)量傳動裝置對淬硬齒輪的要求。 個實體全淬硬工件毛坯進行淬硬滾切加工是一種新的加工工藝。由于有剛性更好的機床和優(yōu)質(zhì)的硬質(zhì)合金刀具材料并加以涂層處理，使淬硬滾切成為一種行之有效的加工方法。從工廠的實際應(yīng)用結(jié)果表明，淬硬齒輪滾切(硬滾)工藝具有廣闊的應(yīng)用前景。英文原文Hard gear processing[abstract ]uses in the power drive gear and the gear box, its size request smaller, the gear drive noise is lower, thus causes to the hard gear demand, also gave the gear manufacturer to propose explored the gear to process the new method the requestOutline Uses in the power drive gear and the gear box, its size request smaller, the gear drive noise is lower, thus causes to the hard gear demand, also gave the gear manufacturer to propose explored the gear to process the new method the request. The gear in the hard heat treatment process, its material organization and the stress change, usually can cause the gear to have the distortion, namely tooth profile, tooth to and tooth pitch error. This this error will cause the tooth profile not correctly to mesh in the transmission time, thus has enlarged the load, will have the gear noise. Therefore, the hard gear after the heat treatment, should increase together the precision work working procedure generally. The hard gear precision work craft may divide into two kinds: A kind is uses non formed the cutting edge, like the gear rubs truncates the processing。 Another kind then is has formed the cutting edge like hard gear (HRC48 ~ 53) to roll truncates the processing. This article strongly will discuss will use in hardly rolling the hard alloy tools forming cutting edge precision work process which the tooth will process. The now hard alloy material, the cutting tool coating and the gearhobbing machine technology development, has caused the hard gear to roll cuts the processing technology to have the remarkable enhancement, specially is smaller than in the processing or was equal to when 12DP center small modulus gear, may withstand the enormous cutting force which in the hard cutting process produces. Hard alloy hob selection The hard alloy hob has the very big progress in the material variety specification. Superfine, is thin, medium or the big pellet hard alloy now all has the product. In addition, the hard alloy hob semifinished materials formed craft technology also had the remarkable enhancement, like uses static pressure and so on heat (HIP) the craft, this craft under the highpressured high temperature, increased the hard alloy semifinished materials intrinsic binding force, enhanced the hard alloy anti curved intensity. According to the ISO stipulation, the entity hard alloy material may differently divide into certain kinds according to the application situation: The gear cutting tool divides into K kind and P kind, K kind of hard alloy has a higher resistance to wear, P kind then has the better high temperature red hardness. In the K trademark and in the P trademark hard alloy, each kind of trademark hard alloy granular structure is different, from medium pellet to superfine pellet. Each kind of trademark all has its application situation, this is and the granular structure is connected. Generally speaking, regarding softly rolls truncates, the K analogy P kind of performance is friends with, K kind of hard alloy can obtain a micron level the granular structure (granularity to be smaller than mu m), but P kind then is not good. In abrasion aspect, K kind of toughness better, the life is longer. The hob resharpens and renovates After the hob processing certain quantity work piece, its cutting edge failure, this time must resharpen. Sharpens the after hob to have to maintain the original geometry shape。 The cutting edge must be sharp。 The cutting tool golden phase structure cannot because rub truncates the heat but to destroy. Thus when sharpens the hard alloy hob should use one kind of oil base refrigerant, it does not get up to the chlorine and the sulfur the response. Regarding scrap