民营企业高效滚齿应用实践

    作为一家处在激烈竟争的齿轮精加工企业，作为本田、铃木、雅马哈等日系企业摩托车高速齿的加工协作企业，作为年产2千万件齿轮的企业。高精度和高效率的设备和刀具成了我们的首选。我公司在添置KLINGELNBERG-HOFLER P40测量仪、SU RSB18CNC剃刀磨、KG251L滚刀磨等一批高精度设备以提高产品精度的同时，为了打破滚齿效率低、品质不稳定的瓶颈。在高效滚齿机与M35材料、S390和ASP2060粉末冶金材料滚刀、刀具涂层方面也大量投入，并收到了显著的降本成绩。

    为了使刀具、设备、涂层等的性能综合最大化发挥我们在以下几方面做了大量实验：

    1、刀具寿命的确定：

    一齿距切削工件长度综合考虑，为了能对加工不同参数的齿轮的刀具寿命进行比较；必须明确：1齿距移位时间内可加工的切削齿槽长度（m），这当然也必须在刀具磨损Vb≤0.2mm内的切削长度；否则将导致刀具寿命的极大浪费。

    Tf=（B/cosβ）ZN

    B齿宽

    β螺旋角

    Z工件齿数

    N切削工件数量

    2.粉末冶金材料滚刀S390、ASP2060结合TiAlN和M35的滚刀结合TiN切削参数的正确选定；当然我们都知道粉末冶金和TiAlN都能满足V切=130～180mm/min和较大进给量，但实际使用过程中将的受机床的性能的极大制约。目前国产的四轴数控滚齿机主轴转速只有600rpm、工作台转速50rpm；而六轴高速滚虽然具有100-1500 rpm的主轴转速和150rpm的工作台转速，但却同四轴滚一样只有1.5～3.5Mpa的工件夹紧力；导致切削性能严重受限。但由于其相对低廉的机床价格，在民营企业使用此种规格机床要充分扬长避短，仍然可以达到较低的单件成本。

    切削实验一：

    M1.5  Z44  a20°β28°右旋 材料:40Cr  硬度HRC14-18

    65*120*32   N3  Z12刀具材料：S390涂层：TiAlN

    当V切≥112m/min时，只能选择f≤1.5mm/rev，否则fHα、fHβ、M值都将改变且不稳定；

    切削实验二：

    M1.5  Z44  a20°β28°右旋 材料:40Cr   HRC14-18

    65*120*32   N3  Z12刀具材料：S390涂层：TiAlN

    当2mm/rev ≥f≥1.5mm/rev时，只能选择V切≤112m/min，否则fHα、fHβ、M值都将改变且不稳定；

    3.我公司在除Y5120B这种性能及其低下的插床外，其于滚、插机床均有应用刀具每次修磨后做TiN、TiAlN涂层的工艺，所有滚齿加工实现一次切削，从而提升滚齿机近一倍的生产率，并且使刀具寿命延长3倍以上。但在一部分机床主轴转速≤300rpm时，涂层的效率与耐磨性无法充分发挥，使工件制造成本反而偏高。此类机床不论应用何种刀具都将成为产品高成本、低Cpk值的源头。成为公司的“小煤窑”，大量浪费资源。

    4.为了改善滚齿质量（齿槽径跳、累计齿距）一般倡导单件装夹，但在工件齿宽小于20mm时浪费加工效率100%，故齿宽小于20mm时二到四件的装夹方式并非不可取。通过车坯的质量控制其Fp基本可以控制在DIN6-7级。
除了上述内容以外，窜刀量、切削液、逆/顺滚切削等的选择也有不可忽略；通过大量的不同材料、硬度、参数工件的切削实验，选择最优的切削参数，高品质、高效率、低成本的生产一定可以实现。

    下述两例切削案例基本体现了上述切削方法仅供参考：

    相关参数：                         

normal style="MARGIN: 0cm 0cm 0pt">产品产数

normal style="MARGIN: 0cm 0cm 0pt">M1.5  Zvalue="44" UnitName="a">44  a20°β28°右旋

normal style="MARGIN: 0cm 0cm 0pt">材料:40Cr   HRC14-18

normal style="MARGIN: 0cm 0cm 0pt">产品厚度：value="10.9" UnitName="mm">10.9mm

normal style="MARGIN: 0cm 0cm 0pt; TEXT-ALIGN: center" align=center>刀具参数

normal style="MARGIN: 0cm 0cm 0pt">规格：65*120*32   N3  Z12

normal style="MARGIN: 0cm 0cm 0pt">刀具材料：S390

normal style="MARGIN: 0cm 0cm 0pt">涂层：TiAlN（苏州巴尔查斯）

normal style="MARGIN: 0cm 0cm 0pt">刀具生产商：汉江工具厂

normal style="MARGIN: 0cm 0cm 0pt; TEXT-ALIGN: center" align=center>修磨设备

normal style="MARGIN: 0cm 0cm 0pt">KGvalue="251" UnitName="l">251L滚刀磨

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">切削设备：

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">YS3112CNC高速滚齿机

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">产地：

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">南京第二机床厂

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">主轴转速：650rpm

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">V切value="132.6" UnitName="m">132.6m/min  

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">走刀量：value="1.5" UnitName="mm">1.5mm/rev

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">窜刀量value="5.12" UnitName="mm">5.12mm/次

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">切削量：一刀切 

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">切削时间：60秒

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">装夹件数：4件（装卸时间15秒）

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">切削液：纳克2020

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">次修磨涂层加工数量：5944件

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">一齿距切削工件齿槽长度：value="169.3" UnitName="m">169.3m

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">平均单件加工时间：20秒

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly"> 

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">刀具磨损量≤value=".2" UnitName="mm">0.20mm

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly">刀具磨损情况见图一:

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 3.35pt; mso-height-rule: exactly" align=center>

  相关参数：              

normal style="MARGIN: 0cm 0cm 0pt; TEXT-ALIGN: center" align=center>产品产数

normal style="MARGIN: 0cm 0cm 0pt">M1.5  Zvalue="44" UnitName="a">44  a20°β28°右旋

normal style="MARGIN: 0cm 0cm 0pt">材料:40Cr   HRC14-18

normal style="MARGIN: 0cm 0cm 0pt">产品厚度：value="10.9" UnitName="mm">10.9mm

normal style="MARGIN: 0cm 0cm 0pt; TEXT-ALIGN: center" align=center>刀具参数

normal style="MARGIN: 0cm 0cm 0pt">规格：65*120*32   N3  Z12

normal style="MARGIN: 0cm 0cm 0pt">刀具材料：M35

normal style="MARGIN: 0cm 0cm 0pt">涂层：TiN（苏州巴尔查斯）

normal style="MARGIN: 0cm 0cm 0pt">刀具生产商：汉江工具厂

normal style="MARGIN: 0cm 0cm 0pt; TEXT-ALIGN: center" align=center>修磨设备

normal style="MARGIN: 0cm 0cm 0pt">KGvalue="251" UnitName="l">251L滚刀磨

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">切削设备：

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">Y3116CNC数控滚齿机

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">产地：

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">南京第二机床厂

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">主轴转速：500rpm

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">V切value="102.05" UnitName="m">102.05m/min  

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">走刀量：value="2" UnitName="mm">2mm/rev

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">窜刀量value="4.71" UnitName="mm">4.71mm/次

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">切削量：一刀切 

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">切削时间：37秒

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">装夹件数：1件（装卸时间10秒）

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">切削液：纳克2020

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">次修磨涂层加工数量：3500件

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">一齿距切削工件齿槽长度：value="99.6" UnitName="m">99.6m

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">平均单件加工时间：47秒

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly"> 

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">刀具磨损量≤value=".2" UnitName="mm">0.20mm

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly">刀具磨损情况见图二:

normal style="MARGIN: 0cm 0cm 0pt; mso-element: frame; mso-element-frame-hspace: 9.0pt; mso-element-wrap: around; mso-element-anchor-vertical: paragraph; mso-element-anchor-horizontal: margin; mso-element-top: 20.8pt; mso-height-rule: exactly" align=center>