Powder preparation:
choose suitable metal powders, such as iron powder, copper powder, nickel powder and other pure metal powders, or choose alloy powders according to demand. The particle size, shape and surface characteristics of the powder will affect the performance of the final gear. Metal raw materials can be made into powder by atomization, reduction, mechanical grinding or chemical methods.
Powder mixing:
According to the design requirements of the gear, the powder of different components is mixed in a certain proportion. In order to improve the fluidity and pressing performance of the powder, lubricants, binders and other auxiliary materials may be added, and sometimes reinforcements may be added to improve the mechanical properties of the final product.
Pressing:
The mixed powder is filled into the mold, and the pressure is applied with a press to form the powder in the mold to form a blank with a certain strength and shape. During the pressing process, parameters such as pressure, temperature and time need to be precisely controlled to ensure that the density, shape and size of the gear meet the design requirements.
Sintering:
Put the pressed blank into the sintering furnace and sinter it under high temperature and a specific atmosphere (such as a protective atmosphere). In this process, the binding force between the powder particles is enhanced to form a dense metal body, thus improving the density, hardness and wear resistance of the gear. Sintering temperature, time and atmosphere are the key parameters.
Post-processing:
Heat treatment:
Through quenching, tempering and other heat treatment processes, the hardness and toughness of the gears are improved to meet the requirements of use.
Surface treatment:
Carburization, nitriding, coating, spraying and other surface treatment methods are used to improve the wear resistance, corrosion resistance and surface hardness of gears.
Finishing:
According to the accuracy requirements of the gear, turning, grinding, milling and other finishing operations are carried out to improve the accuracy and surface quality of the gear, remove excess materials, and make the dimensional accuracy and surface finish of the gear reach the prescribed standards.
Quality inspection:
Strict quality inspection of gears is carried out throughout the production process, including dimensional accuracy, surface roughness, material properties (such as hardness, density, etc.) and meshing properties of gears, to ensure that the products meet the design requirements. Qualified gears are packaged after cleaning and anti-rust treatment, and ready to be shipped.
