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Tool materials and tool surface coatings directly affect heavy machining cutting efficiency and machining costs. At present, the hob materials used in China are mainly high-speed steel materials such as W6Mo5Cr4V2 and W9Mo3Cr4V. Most of the foreign countries use new tool materials such as M35 and M42. The cutting performance of new material tools such as M35 and M42 is much better than that of W6Mo5Cr4V2 and W9Mo3Cr4V. Coating the surface of the tool with super-hard coatings such as TiN, TiC, TiCN, etc. can also greatly improve the cutting performance of the tool. The durability of the coated tool is more than double that of the uncoated tool. For the Fujitsu, the hob is used in our factory.
The name of the workpiece to be machined: one gear gear workpiece parameters: mn=2.5mm, Z=37, n=20,=2528, workpiece width B=15mm. It can be seen that the use of the multi-headed hob saves the man-hours and improves labor. Productivity, the number of workpieces processed by the hob sharpening is greatly increased, saving machine tool change and adjustment time, product quality is stable, and product cost is reduced.
Rolling tool rolling tools are widely used in the automotive industry, and the processing efficiency of small modulus involute splines, oil grooves, threads, etc. is high. The surface of the rolled spline has small grain size, reasonable metal flow direction, high bending strength of the key teeth, and the rolling spline strength is more than 5 times higher than the hobbing and pinion. The surface roughness of the rolled spline key can reach Ra16m. Above, the quality is stable. The rolling tool of Japan Fujitsu Company has been widely used in the input shaft spline and output shaft spline machining of our automobile transmission.
Take the input shaft spline processing of our light-duty transmission as an example, the spline parameters m=1.275mm, =30, Z=21, the spline length L=65mm, the use of the rolling knife EXL-5507 rolling processing, single-piece processing At time 30, the efficiency is more than 10 times that of hobbing. A new set of rolling knives can process more than 30,000 workpieces. The new knives can be repaired after being scrapped. The durability of the tool after grinding is basically the same as that of the new knives. . In the case of the machine tool, the design of the rolling knife should be as long as possible, which can reduce the load per tooth of the rolling knife and improve the service life of the tool.
The gear shaping tool is a widely used gear processing method. The material of the gear shaping tool and the super hard film coating of the tool play an important role in tool durability and product quality. The light-speed transmission of the five-speed gear hub material of our factory is 40Cr (tempering and tempering), and the heat treatment hardness is 2328HRC. When using the self-made toothed cutter, the sharpening can only process 60 pieces at a time, which cannot meet the needs of mass production. Now using the shaper cutter made by Fujitsu, the durability of the tool is greatly improved and the product quality is stable. It is the comparison table between the Fujitsu tool and the domestic homemade gear cutter.
Workpiece parameters: m=2.18mm, Z=33,=30, workpiece tooth width B=25mm, workpiece material 40Cr (tempering and tempering), 2328HRC. As can be seen from the table, the Japanese Fujitsu teeth are made of new materials. Knife, its tool durability can reach more than 23 times of our own domestic shaper cutter, the surface roughness of the workpiece is Ra32m, the effect is very good, and the economic benefit is very remarkable.
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