How to improve the machining accuracy of RXF97-7.5-358 hard tooth surface gear reducer

To improve the machining accuracy of the RXF97-7.5-358 hard-tooth gear reducer, you can start from the following aspects:

• Optimized material selection and heat treatment

• Select high-quality materials : According to the working conditions and performance requirements of the reducer, select high-strength and wear-resistant materials, such as carburized steel, alloy steel, etc., such as 40Cr, 45Mn, etc. At the same time, factors such as material processability, cost, fatigue strength, hardness and toughness should be considered.

• Optimize heat treatment process : improve the microstructure of the material through normalization process, improve toughness and plasticity; use tempering treatment (quenching + low-temperature tempering) to achieve the best matching of material strength and toughness. For gears with high surface hardness requirements, surface treatments such as carburizing and nitriding can be carried out to form a hard and wear-resistant seepage layer on the surface of the gear to improve wear resistance and fatigue resistance.

• Precisely controlled cutting processing

• Optimized cutting parameters : Cutting speed, feed quantity and back-feeding tool quantity are key parameters that affect processing accuracy. We must comprehensively consider factors such as material characteristics, tool performance and machine tool rigidity, and determine the best combination of cutting parameters through a combination of experiments and numerical simulation to avoid over-processing or under-processing.

• Ensure tool quality : The purchased gear tools must be inspected to meet the AA requirements. After the tool is sharpened, the radiality of the cutting edge surface of the tool and the adjacent peripheral differences of the chip receptacle groove should be checked to ensure the tool accuracy. At the same time, the installation accuracy of the tool is strictly controlled, and the radial jump of the tool is controlled below 0.003mm and the end face jump is below 0.004mm.

• Improve the accuracy of the tooth blank : The dimensional accuracy of the gear hole requires distribution between the left and right differences in the deviation value of the hole. The end face jump and radial jump of the tooth blank are controlled within a small range. For example, the end face jump and radial jump are 6 levels, which are set in the range of 0.01-0.02mm.

• Improve processing technology : Choose appropriate processing technology according to the gear accuracy requirements. For example, gear processing below level seven mainly adopts tooth insertion or hobbing production process. Gears above level seven will increase the grinding and shaving processes based on the preliminary process. During the processing process, we should focus on the periodic changes of tooth thickness and tooth pitch, and strictly control geometric eccentricity and motion eccentricity, etc.

• Improve machine tool accuracy

• Ensure the accuracy of machine tool parts : The accuracy of the machine tool has a direct impact on the gear machining accuracy. It is necessary to ensure the reasonable coordination of all parts of the machine tool, improve the level of equipment refinement and automation, ensure the precision of the operation of each component, and do a good job in intelligent upgrades and transformations.

• Regular adjustment of machine tools : When conditions permit, periodic adjustment of the indexing worm gear pair of the machine tool should be made to reduce the installation eccentricity of the indexing worm gear of the machine tool, the axial series and radial oscillation of the worm gear, thereby reducing the tangential error and tooth shape error caused by motion eccentricity.

• Optimized installation and assembly

• Strict installation of tooth blanks : The installation of tooth blanks must be carried out strictly in accordance with the reference surface specified in the process, and the correcting error should be as small as possible to prevent geometric eccentricity. For example, for the gear tooth blank with holes, the process should be specified in a single loading card, the inner hole outer circle and the end face are cut by one cut, and the end face is used as the installation reference for cutting teeth.

• Control installation error : During the assembly process of reducer, the installation accuracy of each component must be strictly controlled, such as the bearing installation clearance, gear meshing clearance, etc., to ensure the stability and accuracy of gear transmission.

• Improve measurement and detection

• Use high-precision measurement instruments : use advanced measurement instruments, such as three-coordinate measuring instruments, etc. to accurately measure the gear tooth shape, tooth pitch, tooth direction and other parameters, and promptly discover processing errors and adjust them.

• Establish a quality inspection system : Establish a complete quality inspection system, conduct strict quality inspections in all aspects of gear processing, and deal with unqualified products in a timely manner to avoid flowing into the next process.