| WANG Qingzhi,CHEN Yiming,WU Jizhan,ZHANG Xiuhua,LIU Huaiju.Experimental Study on Surface Integrity Characteristics of High-performance Carburized Gears[J],54(5):233-244 |
| Experimental Study on Surface Integrity Characteristics of High-performance Carburized Gears |
| Received:June 16, 2024 Revised:August 09, 2024 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.05.018 |
| KeyWord:carburized gears surface integrity residual stress surface roughness hardness gradient |
| Author | Institution |
| WANG Qingzhi |
State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing , China |
| CHEN Yiming |
Taihang Laboratory, Chengdu , China |
| WU Jizhan |
State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing , China |
| ZHANG Xiuhua |
State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing , China |
| LIU Huaiju |
State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing , China |
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| Abstract: |
| 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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