1. Feed machinery equipment accessories tooth shaft product introduction
In feed machinery and equipment, the gear shaft is a very critical transmission component, its main role is to transfer power from one part to another part, and through the mesh with the gear to change the speed and torque to meet the needs of different production links. The performance of the gear shaft is directly related to the overall operation efficiency, stability and product quality of the feed production equipment.
2. Structural characteristics
Shaft body
The shaft body of the gear shaft is its main part, usually cylindrical, with sufficient length and diameter to ensure good strength and stiffness when transmitting torque. Shaft surface roughness requirements are low to reduce friction resistance when fitting with other components. On the shaft, according to different design requirements, keyways, splines or other connecting structures may be machined to connect with gear, pulley, coupling and other components to achieve effective power transmission. For example, in some feed shredders, the shaft of the tooth shaft is connected with the grinding tool through the keyway, and the power from the motor is transmitted to the tool, so that it can rotate at high speed to crush the feed raw materials.
tooth
The tooth is the key feature of the tooth shaft which is different from the ordinary shaft parts. The tooth shape of the gear shaft is usually an involute tooth shape, which has good transmission performance and can ensure smooth transmission of power during meshing, reducing vibration and noise. The parameters of tooth number, modulus, tooth width and so on are designed according to the specific transmission requirements of feed machinery and equipment. The number of teeth affects the transmission ratio of the gear shaft, the modulus determines the size and load bearing capacity of the tooth, and the tooth width is related to the contact strength of the tooth. For example, in the drive system of a feed pelletizer, the tooth parameters of the pinion shaft need to be precisely designed to ensure that, when paired with other gears, the power can be transferred stably to the ring die and press roller, so that the feed material can be evenly extruded into pellets. The tooth and shaft body are usually connected with transitional rounded corners to reduce stress concentration and improve the fatigue life of the tooth shaft.
End structure
The end structure of the pinion varies according to its installation and connection requirements in the equipment. Common end structures are shoulder, thread, center hole and so on. The shaft shoulder is used for axial positioning of the components installed on the shaft to prevent them from moving in the axial direction; The threaded structure can be used to install nuts, locking devices, etc., to further fix the position of the parts; The center hole is generally used for the positioning of the gear shaft during processing and installation, and it is also convenient to disassemble and install the gear shaft during maintenance. In some large feed machinery equipment, the end of the shaft may also be designed with a special connection structure, such as a flange, in order to connect with other large components to ensure the reliability of power transmission.
3. Material characteristics
High quality alloy steel
Many feed machinery equipment gear shaft using high quality alloy steel material, such as 40Cr, 42CrMo and so on. These alloy steels have high strength, toughness and wear resistance. After the quenching treatment, the hardness of 40Cr alloy steel can reach HRC28-32, which can meet the strength requirements of general feed mechanical transmission, and its good comprehensive mechanical properties make the gear shaft stable when bearing a certain torque and impact load. 42CrMo alloy steel contains molybdenum, which further improves the hardenability and strength of the material. After tempering and surface quenching treatment, the surface hardness can be increased to HRC50-55, which is excellent in large and heavy duty feed machinery transmission systems, such as the main transmission shaft of the large feed mixer. It can effectively withstand huge mixing resistance and torque changes, reduce the deformation and wear of the gear shaft, and extend its service life.
Carburizing steel
For some cases where the hardness and wear resistance of the tooth surface are very high, carburized steel such as 20CrMnTi is widely used. Carburized steel through carburizing quenching treatment, can form a high hardness carburizing layer on the tooth surface, hardness is usually up to HRC58-62, while the heart still maintains a relatively low hardness and good toughness. This "hard on the surface and tough in the inside" characteristic makes the pinion excellent when subjected to high surface contact stresses and impact loads. In the high-speed transmission gear shaft of the feed crusher, the carburized steel material can effectively resist the tooth surface wear, fatigue spalling and other failure forms, ensure the long-term stable operation of the equipment, reduce maintenance costs and downtime.
Stainless steel
In the feed production environment, if there is wet, corrosive media or high health requirements, stainless steel tooth shaft is a suitable choice. For example, 304 stainless steel has good corrosion resistance and oxidation resistance, which can resist the water, acid and alkali components and microbial erosion in the feed to a certain extent, and ensure the normal operation and service life of the gear shaft. In aquatic feed processing equipment or food grade feed production equipment, stainless steel gear shaft can effectively prevent the deterioration of gear shaft performance and pollution caused by corrosion, and ensure the quality and safety of feed products.
4. Manufacturing process
Forged blank
The blank of the gear shaft is usually prepared by forging process. Forging can refine the grain of the metal material and make the organization more dense, thereby improving the strength and toughness of the material, and eliminating the internal defects caused by the metal in the smelting process. The blank after forging needs to be normalized or annealed to eliminate the forging stress, improve the cutting performance of the material, and lay a good foundation for the subsequent machining process. For example, for 40Cr alloy steel tooth shaft blanks, normalizing treatment after forging can homogenize the organization, moderate hardness, and facilitate subsequent turning, milling and other processing operations.
machining
Machining is the key link of gear shaft manufacturing, including turning, milling, gear hobbing, gear shaper and other processes. First, through the turning process, the shaft body outer circle, shaft shoulder, end and other parts of the blank are processed to the design size, and the features of the keyway and the center hole are processed. In the process of turning, it is necessary to strictly control the precision indexes such as the cylindricity of the shaft body and the perpendicularity of the shaft shoulder. Then the milling process is used to process some special shapes or structures on the gear shaft, such as the positioning plane. For the processing of tooth shape, the hobbing process is one of the most commonly used methods, which uses the spread motion between the hobbing cutter and the workpiece to gradually cut out the gear teeth. The hobbing process can ensure higher tooth shape accuracy and production efficiency, and is suitable for processing various modulus and tooth number of cylindrical gear shaft. The gear shaper process is often used for machining internal gear, double gear or some tooth shaft parts with special tooth shape requirements, which is completed by matching the up and down reciprocating motion of the gear shaper cutter with the rotating motion of the workpiece. In the machining process, it is necessary to strictly control the processing accuracy of each process, and adopt high-precision machine tools and tools to ensure that the dimensional accuracy, shape accuracy and tooth surface roughness of the gear shaft meet the design requirements.
Heat treatment
Heat treatment is a key step to improve the performance of the gear shaft. For the gear shaft of alloy steel material, the general use of tempering treatment, that is, quenching after high temperature tempering, so that the gear shaft to obtain good comprehensive mechanical properties, improve its strength and toughness matching degree. For the tooth shaft made of carburized steel, it is necessary to carburize, quench and low temperature tempering. Carburizing treatment makes the tooth surface rich in high concentration of carbon elements, forming a high hardness carburizing layer after quenching, low temperature tempering further eliminates the quenching stress, stabilizes the structure and size, and improves the wear resistance and fatigue strength of the tooth surface. In the heat treatment process, it is very important to accurately control the heating temperature, holding time, cooling speed and other process parameters, otherwise it will easily lead to defects such as tooth shaft deformation, cracking or uneven hardness. For example, when the 42CrMo alloy steel gear shaft is tempered, the quenching temperature needs to be precisely controlled between 850-900 ° C and the tempering temperature between 550-650 ° C to obtain the ideal combination of hardness and toughness.
5. Performance characteristics
High precision drive
With precision manufacturing and strict quality control, the pinion has excellent dimensional accuracy and profile accuracy, and can achieve accurate meshing with the matching gear. This high-precision transmission characteristic can effectively reduce the pitch error and tooth profile error in the transmission process, so as to reduce vibration and noise, and improve the stability and reliability of the feed machinery transmission system. In the metering device transmission of feed dosing system, the high-precision gear shaft can ensure the precise proportion of ingredients, avoid the feed formula deviation caused by transmission error, and ensure the consistency of feed product quality.
High carrying capacity
With high-quality material selection, reasonable structural design and advanced manufacturing process, the gear shaft has a strong load capacity. Whether it is the impact of high torque at the start moment, or under the continuous load during stable operation, the gear shaft can transmit power reliably, and it is not easy to occur fatigue wear of the tooth surface, root fracture or plastic deformation. In the mixing shaft drive system of a large feed mixer, the gear shaft needs to bear huge mixing resistance and dynamic load, and its high bearing capacity ensures that the mixer can run stably for a long time, improving production efficiency and equipment utilization.
Good wear resistance and durability
By using appropriate materials (such as carburizing steel, alloy steel, etc.) and combined with effective heat treatment processes (such as carburizing quenching, tempering, etc.), the tooth surface of the gear shaft has high hardness and wear resistance, which can effectively resist the common failure forms such as tooth surface wear, fatigue pitting, and gluing during long-term and high-strength operation. At the same time, good material toughness and structural design also ensure the durability of the gear shaft under impact load. In the feed pelleting production line, the wear resistance and durability of the gear shaft are directly related to the continuous running time and maintenance cycle of the production line, and high-quality gear shaft can significantly reduce the maintenance cost and downtime of the equipment, and improve the production efficiency.
Strong fit
The gear shaft can be customized according to the specific transmission needs of different feed machinery and equipment. Whether it is the module of the shaft, the number of teeth, the shape of the teeth, or the diameter, length, end structure and other parameters of the shaft body, it can be flexibly adjusted to achieve a perfect match with various motors, reducers and other transmission components. This high degree of adaptability enables the gear shaft to be widely used in all kinds of feed machinery, such as shredders, mixers, granulators, bulking machines, conveying equipment, etc., to build a diverse and efficient and reliable transmission system to meet the requirements of different feed production processes and equipment layout.
6. FAQ
Q: What is the main material of the gear shaft?
A: The gear shaft is usually made of high-strength steel or alloy steel to ensure that it has sufficient strength and wear resistance. These materials can withstand high loads and long periods of use.
Q: How to choose the right shaft size?
A: Choosing the right size of the gear shaft needs to consider the power, speed and load of the equipment. Ensure that the selected size can meet the design requirements and conditions of use of the equipment.
Q: What are the surface treatment processes of the gear shaft?
A: The common surface treatment processes of the gear shaft include quenching, carburizing and nitriding. These processes can improve the hardness and wear resistance of the surface and extend the service life.
Q: How to ensure the transmission efficiency of the gear shaft?
A: In order to ensure the transmission efficiency of the gear shaft, the coordination accuracy between the shaft and the gear should be ensured, the lubrication system should be checked and maintained regularly, and the lubricating oil should be kept clean and appropriate.
Q: How long is the replacement cycle of the gear shaft?
A: The replacement cycle of the gear shaft depends on the frequency of use, the working environment and the operating condition of the equipment. In general, when significant wear, deformation or inability to effectively drive is found, a new gear shaft should be considered.
Q: What are the heat treatment processes of the gear shaft?
A: The heat treatment process of the gear shaft includes quenching, tempering and normalizing. These processes can improve the mechanical properties of the material, increase its hardness and wear resistance, and thus extend the service life of the gear shaft.
