王庆志,陈易明,吴吉展,张秀华,刘怀举.高性能渗碳齿轮表面完整性特征的试验研究[J].表面技术,2025,54(5):233-244.
WANG Qingzhi,CHEN Yiming,WU Jizhan,ZHANG Xiuhua,LIU Huaiju.Experimental Study on Surface Integrity Characteristics of High-performance Carburized Gears[J].Surface Technology,2025,54(5):233-244 |
| 高性能渗碳齿轮表面完整性特征的试验研究 |
| Experimental Study on Surface Integrity Characteristics of High-performance Carburized Gears |
| 投稿时间：2024-06-16 修订日期：2024-08-09 |
| DOI：10.16490/j.cnki.issn.1001-3660.2025.05.018 |
| 中文关键词: 渗碳齿轮 表面完整性 残余应力 表面粗糙度 硬度梯度 |
| 英文关键词:carburized gears surface integrity residual stress surface roughness hardness gradient |
| 基金项目:国家自然科学基金(52322504);四川省自然科学基金(24NSFSC7353) |
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| Author | Institution |
| WANG Qingzhi | State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing 400044, China |
| CHEN Yiming | Taihang Laboratory, Chengdu 610000, China |
| WU Jizhan | State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing 400044, China |
| ZHANG Xiuhua | State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing 400044, China |
| LIU Huaiju | State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing 400044, China |
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| 中文摘要: |
| 目的 针对材料牌号、加工工艺、几何结构与渗碳齿轮表面完整性关联规律不明的问题，探究不同材料、工艺、结构对表面完整性的影响。方法 对18CrNiMo7-6、9310、20Cr2Ni4A、20CrMnTi几种常用渗碳齿轮的渗碳磨削、喷丸强化、二次喷丸、滚磨光整、喷丸光整等工艺状态进行表面粗糙度、残余应力、硬度梯度等表面完整性表征，讨论材料、工艺、结构对表面完整性特征的影响规律。结果 在渗碳磨削、喷丸强化工艺状态下，几种常用渗碳钢的表面残余压应力、表面硬度等参数基本一致。经喷丸强化、二次喷丸、滚磨光整处理后，最大残余压应力幅值范围为1 100~1 400 MPa，表面硬度为660HV~720HV。通过滚磨光整改善表面微观形貌的效果最显著，能够使表面粗糙度Sa降至0.25 μm以下。通过二次喷丸提升次表面最大残余压应力的效果明显，能够使齿轮次表面最大残余压应力提升至1 200 MPa。滚子和齿轮2种几何结构的试件在渗碳磨削、喷丸强化、喷丸光整等工艺状态下，其表面完整性参数基本一致。结论 揭示了不同材料牌号、加工工艺、几何结构对渗碳齿轮表面完整性的影响规律，可为齿轮加工工艺优化和高表面完整性创成提供理论支撑和数据参考。 |
| 英文摘要: |
| Surface integrity is a crucial factor affecting the machining quality and operational performance of gears. It is also a prerequisite for achieving fatigue resistance of gears. However, the current research on the surface integrity of carburized gears involves few types of materials and process states, lacking a comprehensive exploration of the relationship between different materials, process states, structures, and gear surface integrity. This has affected the quality of gear manufacturing and anti-fatigue design. In response to the unclear correlation between different materials, surface treatments, structures, and surface integrity of carburized gears, the work aims to characterize the surface roughness, residual stress and hardness gradient of 18CrNiMo7-6, 9310, 20Cr2Ni4A, and 20CrMnTi gears under various process conditions, such as carburizing and grinding, shot peening, dual shot peening, and barrel finishing after shot peening. The impact of materials, structures, and processes states on surface integrity characteristics was investigated. It was found that the surface residual stress and surface hardness parameters of carburized steel were relatively consistent under the conditions of carburized grinding and shot peening. However, there was a significant difference in surface roughness Sa, with a maximum difference of 0.6 μm. Additionally, shot peening process showed a similar degree of alteration in the surface integrity of gear steels with different materials. After carburizing and grinding treatment, the surface residual compressive stress amplitude of gears ranged from 500 to 600 MPa, with a surface hardness of 640HV to 690HV. After shot peening treatment, the maximum residual compressive stress amplitude ranged from 1 100 to 1 300 MPa. For the surface integrity under different process states, the maximum residual compressive stress amplitude ranged from 1 100 to 1 400 MPa, and the surface hardness ranged from 660HV to 720HV under shot peening, dual shot peening, and barrel finishing treatment. Barrel finishing significantly improved the surface microstructure, reducing the surface roughness Sa to below 0.25 μm. The dual shot peening treatment had a noticeable effect on enhancing the maximum residual compressive stress in the subsurface, raising it to 1 200 MPa. After composite surface strengthening processes such as barrel finishing after shot peening, the maximum surface residual compressive stress amplitude exceeded 1 400 MPa. Additionally, the surface hardness value reached 720HV, representing a 60HV increase compared to that in the carburizing and grinding state. For the surface integrity under different structures, the surface integrity parameters of rollers and gears are relatively consistent under the processing conditions of carburizing and grinding, shot peening, and barrel finishing after shot peening. Among these, under the same process states, the difference in surface roughness Sa between the roller and the gear is within 0.4 μm. The difference in surface residual compressive stress and subsurface maximum residual compressive stress is within 200 MPa, and the maximum difference in surface hardness is within 50HV. Under permissible conditions, rollers can be effectively used as substitutes for gears in surface integrity and load-carrying capacity studies. In this work, the effect patterns of different materials, surface treatments, and structures on the surface integrity of carburized gears are clarified. This provides theoretical support and empirical evidence for the optimization of gear machining processes and the achievement of high surface integrity. |
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