AGMA 99FTM6-1999 Submerged Induction Hardening of Gears《齿轮的浸没感应硬化》.pdf
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1、99FTM6 The Submerged Induction Hardening of Gears by: D.W. Ingham, David Brown Special Products American Gear Manufacturers Association TECHNICAL PAPER COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesThe Submerged Induction Hardening of Gears - David W
2、. Ingham, David Brown Special Products The statements and opinions contained herein are those of the author and should not be construed as an official action or opinion of the American Gear Manufacturers Association. Abstract With examples of field failures directly attributable to Tooth by Tooth In
3、duction Hardening, there has been a negative feeling against the use of this process. This paper shows successes of this process founded on Process Development and Quality Control. A case for and against Tooth by Tooth Induction Hardening is layed out for the reader to draw their own conclusion. Cop
4、yright O 1999 American Gear Manufacturers Association 1500 King Street, Suite 201 Alexandria, Virginia, 22314 October. 1999 ISBN: 1-55589-744-4 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesThe Submerged Induction Hardening of Gears Authors D.W Ingha
5、m (David Brown Special Products Ltd) and G Parrich (Consultant) Viewing the Gearing Industry from our base in the UK we feel the Passion built up against the Tooth by Tooth induction Hardening Process for Gears. This Passion is particularly strong in the USA. We would like to strike a blow against t
6、his Passion and this paper is intended for this purpose. In staking our Claim for the Process we do understand the anti-feelings - which are based on numerous examples of field failures directly attributable to the Process. Our Claim is founded on Process Development and Quality Control, features wh
7、ich are absolutely essential to the integrity of Gears manufactured using the Tooth by Tooth Induction Hardening Process We would seek to encourage Engineers to embrace this impressive tool and thereby achieve notable Gear Rating Enhancements. By attainment of an in-depth understanding of the Proces
8、s, together with rigorous Quality Control these Enhancements are worthy of the effort. This paper lays out the case for and against Tooth by Tooth Induction Hardening for the impartial. and partial observers to draw their own conclusions. INTRODUCTION The tooth bv tooth submerged Induction Hardening
9、 Process for gear tooth surface hardening has been successfully carried out at David Brown, for weil over thirty years During that time Process experience, backed up by in depth Research and Development, has given David Brown Engineers a much greater understanding of, and confidence in, the results
10、obtainable from the Process Also, field experience and the refinement in gear design and manufacturing procedures specifically to accommodate the Induction Hardening Process now ensures that gears so treated are of guaranteed quality lhe purpose of the process is to produce a continuous hardened lay
11、er which extends along the entire length of the tooth, and from the tip of one tooth, down the flank, around the fillet and root area and up the opposite flank to the tip of the next tooth (Fig 1) and to ensure that the depth of the hardened zone is sufficient so that in service the subsurface high
12、tooth stresses are contained within the high strength regions In the submerged, tooth by tooth process, the inductor (Fig 2). which has essentially the same shape as the space between two adjacent gear teeth, is energised and traversed along the tooth space heating and austenitising the neighbouring
13、 tooth surfaces, including the root-fillets, as it goes. The heating operation, which is of a short duration, takes place beneath the surface of the quenchant so that as soon as the inductor has moved on it is replaced by the surrounding quenchant; thus, heating and quenching are very localised. pro
14、gressive, and of short duration. The zone being heated and quenched during this process is CO localised that the distortion and growth problems, which tend to plague carburize case hardening, are essentially avoided. By virtue of a high surface hardness and the presence of the surface compressive re
15、sidual stresses, imparted by the process, the contact and bending fatigue strengths are dramatically improved. This article deals with many aspects of the process itself, describes problem areas, considers applications. and discusses the properties and the quality of the product Fig i. Typical Harde
16、ning Pattern Fig 2. The Inductoi COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Services- The Submerged Induction Hardening of Gears - Fig 3. Schematic diagram of the gear handling machine for tooth-by-tooth submerged induction hardening - THE INDUCTION HARDE
17、NING PROCESS At David Brown the frequency used for Gear Induction Hardening is 9.6kHz. and the range of tooth sizes processed is 8 to 38 module. The Facility is shown schematically in Fig 3. Adjacent to this is a generator, water cooling tank, oil circulation tank and control console. The Gear Handl
18、ing Machine rigidly supports the gear, accurately rotates aligns and indexes it during processing On this plant the water-cooled inductor is secured to a workhead transformer which itself IS mounted onto a carriage within the gear handling machine ( Fig 4 ) The workhead transformer can be set to tra
19、verse a distance of over 1 metre on linear bearing tracks The actual length of inductor travel is controlled by pre-set limit switches Because the plant is intended for the submerged version of the process with the inductor at the bottom centre position, much of the handling equipment is contained i
20、n an open tank which is filled with quenchant during processing, and drained for loading and setting up. The generator which provides up to 75 Kw of energy for the process, converts the mains power supply of 380volts. 50Hz to a medium frequency (9.6kHz.1 supply at a nominal voltage of 500v. This is
21、transformed to a supply of 50v. energy by the 14:l workhead transformer in the gear handling machine. The water cooling tank supplies three recirculatory lines: a 1 To the inductor, which is capable of some heating via its own resistance, and by radiation from the workpiece during processing. b To t
22、he quenchants heat exchanger. c )To the generator and the workhead transformer. COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesD.W. Ingham and G. Parrish The control console manages the induction hardening process by control of the inductor traverse s
23、peed, inductor energising and de-energising, quenchant flow, cooling water supplies etc. Over many years David Brown have performed Research Projects on the Process in addition to Production Hardening. O Consequently relationships between hardening parameters and hardened depth/pattern have been est
24、ablished. As a result the need to establish parameters on separate test pieces has been eliminated. The Process is controlled by several significant parameters. these being: 1) The inductor Workpiece Gap This is the space between the inductor and the gear tooth and is quite critical. The surface to
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