What does the process analysis of parts include?

1) forging blank: hot die forging is still a widely used blank forging process for automobile gear parts. In recent years, cross wedge rolling technology has been widely used in shaft machining. This technology is especially suitable for the manufacture of complex stepped shaft blanks, which not only has high precision, small post-processing allowance, but also has high production efficiency. Since 2002, the company has cooperated with Shandong Laiwu Wedge Cross Rolling Plant, and has achieved mass production in recent years. Now the shaft parts produced are all made by this technology. (2) Normalization: The purpose of this process is to obtain the hardness suitable for subsequent tooth cutting and prepare for the final heat treatment, thus effectively reducing the heat treatment deformation. The gear steel material used by the company is usually 20CrMnTi. Due to the great influence of personnel, equipment and environment, the cooling speed and cooling uniformity of the workpiece are difficult to control, resulting in large hardness dispersion and uneven metallographic structure, which directly affects the processing and final heat treatment. The thermal deformation is large and irregular, and the quality of parts cannot be controlled. Therefore, the isothermal normalizing process is adopted. Practice has proved that this isothermal normalization has effectively changed the disadvantages of general normalization, and the product quality is stable and reliable. (3) Turning: In order to meet the positioning requirements of high-precision gear machining, all gear blanks are machined by CNC lathe, and mechanical clamping and non-grinding turning tools are adopted, so that the machining of aperture, end face and outer diameter can be completed at the same time under one clamping, which not only ensures the verticality requirements of inner hole and end face, but also ensures the small size dispersion of gear blanks in batch production. So as to improve that precision of the gear blank and ensure the proces quality of subsequent gears. In addition, the high efficiency of CNC lathe processing also greatly reduces the number of equipment, which is economical. (4) Gear hobbing machine/gear shaper: Ordinary gear hobbing machines and gear shapers are still widely used for machining teeth. Although the adjustment and maintenance are convenient, the production efficiency is low. If large capacity is realized, multiple machines need to be produced at the same time. With the development of coating technology, the grinded hob and gear shaper cutter can be easily recoated, and the durability of coated cutter can be obviously improved, generally by more than 90%, which effectively reduces the number of tool changes and sharpening time, with remarkable benefits. At present, this technology has been promoted in the company. (5) Gear shaving: Radial gear shaving technology is widely used in mass production of automobile gears because of its high efficiency and easy to meet the requirements of tooth profile and tooth direction modification. Since 1995, the company purchased the special radial gear shaving machine for Italian company, the technology application is mature and the processing quality is stable and reliable. (6) Heat treatment: The automobile gear requires carburizing and quenching to ensure the good mechanical properties required by its design. For products that are not ground after heating, stable and reliable heat treatment equipment is essential. The company introduced the continuous carburizing and quenching production line of Lloyd's of Germany, and obtained satisfactory heat treatment effect. (7) Grinding: It is mainly to finish the inner hole, end face and outer diameter of the shaft after heat treatment, so as to improve the dimensional accuracy and shape and position accuracy. Using pitch circle fixture to position and clamp gears can effectively ensure the machining accuracy and installation benchmark of teeth and obtain satisfactory product quality. (8) Dressing: This is to check and clean the dent before assembling the transaxle gear, so as to eliminate the noise and abnormal sound generated after assembly. By listening to the sound of single and double meshing or observing the meshing deviation on the comprehensive tester. The transmission intermediate housing parts produced by the manufacturing company include clutch housing, transmission housing and differential housing. Clutch housing and transmission housing are load-bearing parts. Generally, it is made of die-casting aluminum alloy through special mold, and its shape is irregular and complicated. The general process flow is milling the joint surface → machining the process hole and connecting hole → rough boring the bearing hole → fine boring the bearing hole and locating pin hole → cleaning → leakage test. At present, two rigid production lines composed of modular machine tools and special planes and two flexible production lines mainly based on machining centers are used. The annual production capacity of these four production lines reaches 220,000 pieces. The production capacity of two rigid production lines reaches 6.5438+0.2 million pieces, but only two kinds of shells can be processed. The differential housing is a moving part, and the material used is generally ductile iron, which looks like a ball, and both the inner and outer surfaces need to be machined. The general process flow is semi-finish machining at one end → finish machining at the other end → finish machining at one end → process hole and connecting hole → process inner spherical surface → cleaning → inspection.