Japanese railway vehicle gear introduction
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System, using a certain quality control system to manufacture high-quality gears. Sumitomo Gear, which is manufactured with rich experience and advanced technology, began to be used in Shinkansen railway vehicles, and later gradually applied to ships, construction industry, machining and other industries. Its good performance has won wide acclaim. 1 Main products Sumitomo Corporation's main products for railway vehicles are shown in Table 1. The processing size range sees that gears are important mechanical elements for transmitting power, in order to make full use of their excellent performance. In design and manufacture, high-quality materials and precise processing methods must be used.
Sumitomo Metal Co., Ltd. is the most representative metal manufacturer in Japan and a manufacturer of vehicle parts with a long history. The processes of material smelting, forging, processing and heat treatment can be controlled: 2000-09-11 1963-), male, senior engineer.
The relative torsional deformation between the two is borne by the air spring, and the four air springs will produce large longitudinal displacement and torsional deformation. Therefore, the air spring is required to have good torsional characteristics and torsional durability. According to the technical conditions of the air spring for the railway vehicle (for trial), the air spring is subjected to the rotary fatigue test. The air spring is placed at the standard working height and charged at 0.5 MPa. After the air pressure, simulate the load applied by the vehicle through the small radius curve, and apply the alternating load in the horizontal direction of the air spring. After 2×105 weeks of test operation, no cracks and other abnormal phenomena were found on the surface of the capsule. 2.3 Air Spring Composition Swing Fatigue Characteristic test Because the bolster is eliminated, when the vehicle passes the curve, the body and the frame 3 conclude that the air spring has a small vertical and lateral stiffness, which is beneficial to improve the vertical and lateral running performance of the vehicle; The small longitudinal stiffness is beneficial to the torsion and deflection of the car body around the bogie when the vehicle passes the curve, which is beneficial to improve the curve passing ability; the air tightness and fatigue test indicate that the air spring meets the design requirements. All. Design and Experimental Study of Air Springs for Test Type Articulated High Speed ​​Passenger Car Bogies R1.1999. (Editor: He Fang) Table 1 Main Product Uses of Sumitomo Corporation for Railway Vehicles - Heat Treatment and Surface Hardness (Shore Hardness) Large gear pinion large gear small pinion parallel universal joint type drive device gear vertical universal joint type drive gear helical gear, spiral bevel gear right angle staggered axis hypoid gear high frequency quenching 65-75 carburizing quenching 75- Carburizing and quenching 75-85 electric locomotive and tram with elastic gear spur gear high frequency quenching> carburizing quenching 75-85 electric locomotive hollow shaft gear spur gear high frequency quenching> carburizing quenching 75-85 suburban tram and tram hoist Hanging gear spur gear, helical gear induction hardening > carburizing bonfire>65 electric locomotive spiral elastic gear spur gear induction hardening> carburizing bonfire>65 cast steel large gear spur gear ordinary quenching> tooth coupling Spur gear inner sleeve (external gear) S45C 2 gear design gear design general requirements are: root and tooth surface must have sufficient strength; low noise and good running characteristics; low temperature rise; gear size, tooth shape, number of teeth,
Load, peripheral speed, tooth width, gear tooth stiffness, machining accuracy and dynamic load will cause breaking stress on the gear teeth. Therefore, it is necessary to fully consider the elastic coefficient of the lubricating oil and the matching gear material in addition to the above dynamic load. Both have an influence on the strength of the tooth surface. It must also be considered that the tooth profile of the 2.2 toothed selection gear is determined by the following factors: standard tooth, short tooth; tooth tip clearance and fillet radius; pressure angle; displacement and displacement ; helix angle; modulus, number of teeth and tooth width; tooth shape trimming, drum tooth gear displacement, tip trimming and backlash. In addition, the root, tooth surface strength and running performance have an effect on the tooth profile.
In addition, due to the bearing clearance of the supporting gear shaft and the deflection of the wear shaft box due to power transmission and vibration load, assembly error, tooth shape error, etc. are all causes of single and full tooth defects, noise and early damage of the gear teeth, Sumitomo According to these factors, the company determines the tooth shape. In order to reduce the noise, improve the running performance, reduce the tooth shape error and the flexural deformation caused by the power transmission, the tooth shape trimming and the drum teeth are performed on the basis of satisfying the accuracy and the use conditions. The example is shown in the figure. i Gear processing range 3 Gear heat treatment Sumitomo Corporation uses the equipment that can be automatically controlled, such as induction hardening, carburizing and quenching, ordinary quenching, etc., according to the gear material and the use conditions, to perform the most appropriate heat treatment on the gear surface. To ensure a uniform and good performance.
3.1 High-frequency quenching The high-frequency quenching adopts the gear as a whole to simultaneously heat and quench the way, quenching along the entire profile of the tooth shape to the root of the tooth, and simultaneously quenching the gear with the whole tooth, so that the surface of the whole tooth is hardened and hardened, and the surface layer constitutes a fine and uniform martensite structure, so that the whole The wear resistance of the mating surface is improved.
The hardened layer formed on the surface of the tooth along the entire tooth shape and the surrounding surface layer are very strong. This quenching method is characterized in that the hardened surface gear core is formed into a Soxite-like pearl by quenching and tempering before induction hardening. Body structure, has very good toughness, therefore, it shows excellent wear resistance, high fatigue strength and impact resistance. Casting 3.2 carburizing and quenching carburizing and quenching using gas carburizing furnace, and then tempering, using the most advanced Equipment and technology to prevent harmful excess carbides in the carburized part, so that the hardness is uniform, the toughness and wear resistance is improved. 3.3 High-frequency single-tooth quenching can not be the whole high-frequency quenching of large gears, using special high-frequency induction ring to the tooth surface Single-tooth quenching 3.4 Normal quenching Gears that have no special requirements on the hardness of the tooth surface can be properly quenched and tempered in order to obtain proper hardness and toughness.
4 Gear processing Sumitomo gears are designed to ensure performance requirements, strict precision control in manufacturing and the use of advanced mechanical equipment and effective tools, thus maintaining a high level.
In order to prevent the influence of temperature changes, the high-precision large gears are subjected to tooth cutting and grinding in a thermostatic chamber of 20 ° C. In order to meet the requirements of the application, drum teeth machining and tooth shaping are performed during the cutting or tooth surface grinding. More perfect performance 4.1 Cutting tooth processing Sumitomo has more than 20 cutting gear processing equipment, especially the most advanced high-precision cutting equipment in the field. In addition to the above, for large gears, the maximum modulus of 100, the maximum outer diameter of 12000mm gear can also be processed, and many other special tooth shapes can also be achieved with 4.2 tooth cutting tools in order to get the correct tooth shape, use special Grinding tools and related tools for gear cutting 4.3 tooth surface grinding heat treatment gears or high-speed precision gears use the most advanced grinding machine for tooth surface grinding.
4.4 Combined gears Combined gears are classified into three types according to their use: (1) cushioning for impact on the gear teeth for cushioning; (2) hot-loading gear ring for considering the overall economy of the gear; (3) mounting for the shaft It is convenient to divide the gear into two bodies.
Table 2 lists the combined gears that the company mainly manufactures.
Table 2: Combination gears manufactured by Sumitomo Corporation Type of cushioning rubber combined electric locomotive large gear buffer spring combined type railway vehicle - gear ring type high speed electric vehicle large gear cushion rubber combined road electric vehicle large gear cushion rubber combined split type Marine large gear buffer spring combined split type Other industrial large gear gear ring type cushion rubber combination type 5 Quality management and inspection Sumitomo Corporation in the production process, the process from blank to finished product is carried out according to certain quality regulations.
The chemical composition and mechanical properties of various steels are strictly tested.
All products are subjected to surface magnetic particle inspection and, if necessary, inspection of ultrasonic internal defects.
After heat treatment of all products, the hardness of the tooth surface is checked. In particular, the hardness of the root surface of the high frequency hardened gear must be checked.
All products must be inspected for shape and size, and gear accuracy, gear tolerances, etc. should be checked on the gear tester.
6 Drives Sumitomo Corporation has become a manufacturer of railway vehicle bogies and axles and gears. It has a production experience of about 60a. It has developed a high-speed parallel universal joint and a vertical universal joint drive. The high-speed electric train drive is on the axle. New method of installation. All of Japan's state-owned railway lines and tram associations have been widely adopted, and the Shinkansen tram has also adopted Sumitomo products.
Parallel gears used in parallel universal joint drive mode, hypoid gears or spiral bevel gears used in vertical universal joint drive, including gears, gearboxes, bearings, etc. All parts are high-quality products, and the coupling of the drive gear unit There are flexible couplings, toothed couplings, flexible plate couplings, crisscross couplings, CG couplings, etc. These products are specially designed and manufactured by Sumitomo. Couplings, which have many advantages such as large deflection, large transmission, large torque, and easy maintenance. In practice, parallel universal joint drives are used. For the application, see Table 3, Table 3, Sumitomo Corporation's vehicle drive. Device vehicle motor power maximum speed coupling mode gear ratio gear division modulus material heat treatment tooth surface hardness (HS) tooth surface processing national railway new trunk gear coupling large wheel small wheel high frequency quenching carburizing hardening grinding, tooth Shape grinding, drum shaping, national railway, old trunk, flexible plate, coupling, big wheel, small wheel, high-frequency quenching, carburizing, quenching, grinding, drum shaping, private railway gear coupling, flexible plate Shaft section big wheel small wheel ordinary quenching high frequency quenching carburizing and quenching grinding, tooth shape dressing grinding, drum shaping, metro gear coupling large wheel small wheel ordinary quenching high frequency quenching carburizing quenching grinding, tooth shape trimming Grinding, drum shaping 7 Conclusion The above is the entire forming process of the production of gears by Sumitomo Metal Industries Co., Ltd., which provides a certain degree for the production of gears for subway vehicles in the future, and creates conditions for entering the international market.
(Editor: Peng Yingxi)