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In response to the key technology of high-frequency induction hardening of Santana (three/fourth gear in the manual transmission of the car), the innovative design and development of the "shield guiding technology" has broken through the difficulties of high-frequency induction heating of complex and special-shaped gears. The surface hardness and depth of the workpiece are achieved by the technical requirements of the curing curve of the West German Volkswagen. Advanced technology, stable performance, quality ability to reach A grade.
Shanghai University of Technology Jiading General Machinery Co., Ltd. Zhu Huiwen
In order to cooperate with the localization of the Santana sedan, the company I worked for was established in 1993. The company was mainly engaged in the induction heat treatment of the parts inside the transmission.
At that time, we used the early domestic induction heat treatment equipment, the energy level is not high. From the 19 parts of the Santana car transmission parts that require induction heat treatment, we chose the three- or four-speed synchronizer hub with the most difficult key parts to tackle the problem. If it is not successful, the company can only introduce huge inductive heat treatment equipment from abroad.
1. Development and application of shielding and diversion technology
The three- or four-speed synchronizer hub of the Santana car manual transmission is subjected to local induction heating and quenching after the overall gas nitrocarburizing. The three- or four-speed synchronizer hub has a slider groove every 120° in the circumferential direction. The pattern specifies that the surface of the circumferential tooth is inductively heated and quenched, and the slider groove and the two half teeth on both sides are not allowed to be heated and quenched and hardened. When planning the localization of the heat treatment of the manual transmission parts of the Santana car, it was learned that when the German Volkswagen began to produce the Santana sedan in 1982, the circumferential induction heating quenching method along the circumferential direction of the tooth hub was used to process the third/fourth gear synchronizer hub, which was later improved. For the circumferential segmentation simultaneous induction heating quenching, FAW-Volkswagen introduced a circumferential segmentation simultaneous induction heating quenching device from abroad. Although the above two methods can achieve the slider groove and the half teeth on both sides thereof are not hardened by heating and quenching, it is time consuming and consumes electricity. If the induction heating quenching is not carried out in stages, it is necessary to solve the problem that the slider groove and the two half teeth on both sides are not hardened by heating and quenching. In this regard, based on the principle of induction heating, according to the characteristics of the toothed parts, we applied the shielding and guiding technology, designed the three- or four-speed synchronizer hub circumferential non-segmented simultaneous induction heating quenching process, and successfully applied produce.
The evaluation opinion of the expert group headed by Professor Pan Jiansheng of Shanghai Jiaotong University is: "Shanghai University of Technology Jiading General Machinery Factory has overcome the advantages of the school's scientific and technological strength and has overcome the synchronization gear of Santana (three/fourth gear in the manual transmission of the car) The key technology of high-frequency induction hardening of the hub, the innovative design and development of the "shield diversion technology", broke through the difficulties of high-frequency induction heating of complex and special-shaped gears, so that the surface hardness and depth of the workpiece reached the hardening characteristic curve of West Germany Volkswagen The technical requirements are advanced, stable performance, and the quality capability reaches Grade A. The Shanghai Automotive Gear Factory, which uses this product, has been approved by Shanghai Volkswagen Automotive Co., Ltd., and has made positive contributions to the key supporting products of Santana car localization products. The information was retrieved and the project reached the international leading level."
The application of shielded diversion technology has doubled the induction and quenching efficiency of the three- or four-speed synchronizer hub, and saved more than RMB 3 million for imported induction heating equipment.
Since the shielded diversion technology was applied to induction heating and quenching in 1993, the three/four-speed synchronizer hub has been assembled with more than 1.5 million Santana cars, and the total output value has reached more than 15 million yuan.
The shielded diversion technology is applied for in the name of “a gear tooth profile high frequency induction hardening device†and has obtained one invention and utility model patent granted by the Intellectual Property Office of the People's Republic of China.
Now this technology has been successfully applied to the high frequency induction heating quenching of the ring gear of Shanghai Automotive Gear No.3 Factory. The pattern stipulates that the root of the ring gear cannot be hardened, and the hardened area of ​​the tooth is from the top of the tooth to the vicinity of the pitch circle. Also in the domestic induction heat treatment equipment, the shielding and guiding technology makes the physical quality of the ring gear completely meet the technical requirements of the pattern.
My company has developed rapidly with the development of China's car industry. The business has expanded from single car transmission parts to induction heat treatment of transmissions, brakes, steering gears and parts in electric tools for passenger cars and light passenger vehicles. Shanghai GM, Shanghai Volkswagen, Shenyang Jinbei, Dongfeng Motor, Japan Makita and other products. The company's induction heat treatment equipment was also replaced by the original tube power supply and hydraulic quenching machine for CNC or PLC controlled transistor power supply plus full mechanical quenching machine. By 2005, the company's accumulated profits and taxes were 11 times that of the company when it was built.
2. Problems and countermeasures of induction heat treatment technology
Induction heat treatment is an advanced heat treatment process that changes the surface texture and properties of parts. It is also a low-energy, pollution-free heat treatment process. According to the statistics of our company, to achieve the same output value, the electricity cost for induction heat treatment is half of that of chemical heat treatment. Under the background of China's current scientific development concept, the development of advanced manufacturing industry and the construction of a resource-saving society, it is particularly important for China's machinery manufacturing industry to further expand the application range of low-energy and pollution-free induction heat treatment.
However, from the production practice of my company, the rate of carburizing and carbonitriding production has increased 2.1 times faster than induction heat treatment over the years. Many parts that can be replaced by carburizing or carbonitriding by induction heat treatment are still carburized. Or carbonitriding for treatment. There are two reasons for this:
(1) The diversity of induction heating power supply is not enough, and the degree of automation of quenching machine tools is not high, which is one of the reasons that restrict the development of induction heat treatment in China. A US-owned company near my company has a small modulus gear that requires profile induction heating and quenching, and our existing induction heating power supply cannot meet the technical requirements. We have been looking for a number of domestic induction heat treatment equipment manufacturers, have been told that "can not do", and finally we chose to give up. "If a worker wants to do something good, he must first sharpen his weapon." In the case of a device that is not working, we usually try to make up for it by work, but the practice proves that ten compensations are not enough.
(2) The research on the induction heating quenching process is at a standstill. I remember many years ago, the Fujian Provincial Machinery Research Institute cooperated with the Sanming Gear Factory of Fujian Province and the Nanping Handheld Tractor Factory of Fujian Province to carry out the induction hardening of gears and sprockets by induction heating and quenching to obtain a continuous hardened layer along the contour surface of the gear. Research has done a very useful job in expanding the application range of induction heat treatment in China. Nowadays, many research institutions have been restructured from business to enterprises, and there is no funding for vertical projects. There are no production companies paying for horizontal projects.
To change the situation that China's induction heat treatment has developed but the pace is not fast, I think "Mechanical Workers", "Metal Heat Treatment" and China Heat Treatment Industry Association, China Society of Mechanical Engineering Heat Treatment Society can jointly organize a research in this area to relevant government agencies. Reflecting the situation and striving for support policies; at the same time, whether "Mechanical Workers" and "Metal Heat Treatment" can be bridged to form a project team with induction heat treatment equipment manufacturing plant, induction heat treatment equipment use factory and relevant experts. The funds are manufactured by induction heat treatment equipment. The factory and the induction heat treatment equipment use factory undertake, use the method of “introduction, digestion, absorption, innovation†to share the results according to the principle of who will invest and who will benefit.
This article was issued by the "Mechanical Workers" (Hot Processing), the 11th issue of 2006, so stay tuned!
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