ZLY160-11.2-II is a two-stage hard tooth surface helical gear reducer (center distance 160mm, transmission ratio 11.2, assembly type II), gear accuracy GB/T 10095 level 6, tooth surface carburizing and quenching (HRC58-62), and the core is adapted to the CNC gear grinding closed-loop compensation adjustment method (matched with hobbing pre-adjustment + Tooth surface modification), its scope of application is clearly defined around the four dimensions of process, accuracy, working conditions, and batch size .
1. Process adaptation range
1. Adaptation to the whole process of gear processing: covering the entire process of gear blank reference processing → gear hobbing pre-machining → carburizing and quenching → CNC gear grinding → meshing assembly. It is especially suitable for the hard tooth surface processing link of 'hobbing grinding + gear grinding finishing + closed-loop compensation', which can accurately compensate for heat treatment deformation and processing accumulated errors.
2. Tool and machine tool adaptation: adapted to AA-level high-precision hobs (gear hobbing stage), white corundum/cubic boron nitride grinding wheels (gear grinding stage); adapted to CNC gear grinding machines with on-site measurement or offline detection linkage capabilities (such as Reishauer, Liebherr, Qinchuan and other models), supporting real-time correction of grinding wheel dressing parameters and closed-loop compensation of the motion axis.
3. Modification adaptation: It can simultaneously realize drum modification and tooth end modification, adapt to the precise control requirements of helical gear tooth direction/tooth shape, compensate for shafting deformation and installation errors, and improve meshing stability.
2. Precision control range
1. Accuracy level adaptation: Stably achieves GB/T 10095 level 6 accuracy, which can meet the requirements of tooth profile deviation ≤0.012mm, tooth direction deviation ≤0.010mm, cumulative tooth pitch error ≤0.020mm, contact spot tooth height ≥40%/tooth width ≥50%, and adapt to the high-precision meshing requirements of hard tooth surfaces.
2. Error compensation range: It can effectively compensate for tooth bending and tooth shape distortion caused by carburizing and quenching (typical deformation amount 0.02-0.05mm), as well as tooth pitch deviation and helix angle deviation in the gear hobbing stage. Through closed-loop iteration, the total error is controlled within the 6-level accuracy range.
3. Surface quality adaptation: After fine grinding, the tooth surface roughness Ra≤0.8μm, combined with magnetic particle inspection, can ensure that there are no grinding cracks, and it meets the fatigue and wear resistance requirements of the tooth surface under heavy load conditions.
3. Working conditions and application scenario range
1. Adaptation to rated working conditions: It is suitable for industrial working conditions with high-speed shaft speed ≤1500r/min, gear peripheral speed ≤20m/s, and working environment temperature - 40℃~45℃ (low temperature startup requires preheating lubricating oil), and complies with the requirements of JB/T 8853-2001 standard.
2. Industry adaptation: widely used in metallurgy, mining, hoisting and transportation, cement and building materials, chemicals, textiles, printing and dyeing, etc., suitable for equipment with heavy load, continuous operation, and high requirements for transmission stability and noise control (such as conveyors, mixers, cranes, fans, etc.).
3. Assembly and operation adaptation: It adapts to the shafting layout of assembly type II. It can optimize the axial position and contact state through meshing adjustment, adapt to the requirements of forward and reverse two-way operation, and improve the reliability of equipment operation.
