How to improve the manufacturing process level of SF37-DRE90M4-1.1KW gear reducer

Forging blanks : Adopt advanced forging technology to ensure that the internal structure of raw materials is dense during forging, improve the strength and toughness of the materials, and provide a good foundation for subsequent processing. Strictly control the forging ratio to ensure the dimensional accuracy and performance uniformity of the blank.

Heat treatment : For gears, carburizing and quenching can be used to improve the hardness and wear resistance of the tooth surface while maintaining the toughness of the core. Accurately control parameters such as carburizing temperature, time and quenching cooling speed, such as carburizing temperature rise to 720℃ for carburizing, and keep it for 2 hours, carburizing temperature falls to 620℃ and air-cooling, and quenching heat to 650℃ for quenching and heating treatment. For other key components, reasonable heat treatment processes should also be formulated based on their materials and usage requirements to eliminate internal stress and improve material performance.

Cutting machining : Improve the accuracy and efficiency of cutting machining, adopting high-precision CNC machine tools and advanced cutting tools. In gear processing, the gear hobbing, tooth insertion and other processes must ensure the tooth shape accuracy and tooth separation accuracy, while the tooth grinding process further improves the accuracy and surface quality of the tooth surface and reduces the tooth shape error and surface roughness. Rationally select cutting parameters, optimize cutting paths, and reduce machining allowance and machining stress.

Improve machine tool accuracy : Regularly conduct accuracy detection and calibration of machining machine tools, timely repair or replace worn parts, and ensure that the machine tool's spindle rotation accuracy, guide rail guidance accuracy and transmission chain transmission accuracy and other indicators meet the requirements. For machine tools with key processes, high-precision imported machine tools can be considered or upgraded and modified.

Upgraded testing equipment : Equipped with advanced testing equipment, such as three-coordinate measuring instruments, gear measurement centers, etc., to accurately measure the gear tooth shape, tooth direction, tooth spacing and other parameters, and timely discover processing errors and adjust them. At the same time, non-destructive testing equipment is used to detect and detect parts such as gears to ensure that there are no internal defects.

Establish a complete quality management system : Establish a quality management system strictly in accordance with relevant standards such as ISO, and strictly control every link of the manufacturing process. From the procurement of raw materials to the delivery of the finished product, strict inspection and testing must be carried out.

Process quality monitoring : During the production process, we will strengthen the quality monitoring of key processes, adopt statistical process control (SPC) and other methods to collect and analyze data in real time, promptly detect quality fluctuations and take measures to correct them to ensure the stability of product quality.

Part cleaning : thoroughly clean all parts to remove residual oil, iron filings and other impurities during processing, ensure the cleanliness of the assembly environment, prevent impurities from entering the reducer, affecting their performance and life.

Assembly accuracy control : Strictly control the assembly accuracy of each component, such as the installation position of the gear, the assembly clearance of the bearing, the coaxiality of the shaft, etc. Use appropriate assembly tools and processes, such as using a press for bearing assembly, to ensure assembly quality. At the same time, during the assembly process, some key assembly parameters are recorded and traced.